Agitator Selection

May 1997

Process Industry Practices Machinery

PIP RESM001 Specification for Agitators

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

©Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3208 Red River Street, Suite 340, Austin, Texas 78705. PIP member companies may copy this practice for their internal use.

Not printed with state funds

May 1997

Process Industry Practices Machinery

PIP RESM001 Specification for Agitators Table of Contents 1. Introduction ..................................2

5. Inspection ................................... 11

1.1 Purpose ..............................................2 1.2 Scope .................................................2 1.3 Vendor’s Quotation .............................2

6. Testing ........................................ 11

2. References....................................2

6.1 Mechanical Test ............................... 11 6.2 Noise Level Measurement ................ 11 6.3 Optional Tests .................................. 12

2.1 Process Industry Practices ..................2 2.2 Industry Codes and Standards ............3

7. Preparation for Shipment.......... 12

3. Definitions.....................................3 4. Design and Manufacture..............3 4.1 General...............................................3 4.2 Materials .............................................4 4.3 Agitation Assemblies...........................4 4.4 Steady Bearing ...................................6 4.5 Shaft Sealing System..........................6 4.6 Agitator Support ..................................7 4.7 Shaft Couplings and Guards ...............8 4.8 Gear Reducer .....................................8 4.9 Drive Motor .......................................10 4.10 Auxiliary Piping ...............................11

Process Industry Practices

7.1 Preservation ..................................... 12 7.2 Cleaning and Painting....................... 12 7.3 Packing and Tagging ........................ 12

8. Vendor’s Data............................. 13 8.1 Proposal ........................................... 13 8.2 Approval Drawings............................ 14 8.3 Final Data......................................... 14

Data Sheets Agitator/Mixer Data Sheet

Page 1 of 14

PIP RESM001 Specification for Agitators

1.

May 1997

Introduction 1.1

Purpose The purpose of this Practice is to provide designers and vendors with mechanical requirements for design and manufacture of permanently mounted agitators for use in process facilities.

1.2

Scope This Practice covers the minimum requirements for design and manufacture of permanently mounted, top and bottom-entering agitators, both with and without mechanical seals. This Practice does not cover requirements for tank mixers, portable and clamp-on, light duty agitators, in-line and jet-type mixers, and high speed dispersers. This Practice also does not cover requirements for the installation of agitators. A typical agitation process data sheet, included with this Practice, may be used to communicate purchaser requirements, however, supplemental information may be necessary to fully define process requirements.

1.3

Vendor’s Quotation 1.3.1

Vendor’s quotation shall conform to this Practice and purchaser’s addenda. At the vendor’s option, an alternate quotation may be offered if the following two conditions are met: a. If there is significant process or delivery advantage, a superior, more reliable agitator design may be offered. Vendor shall provide the technical justification. b. Alternate quotation shall indicate deviations from the requirements in this Practice. Complete details of deviations shall be submitted to purchaser for review.

1.3.2

2.

If vendor’s quotation indicates no deviations from the requirements in this Practice, it shall be assumed by the purchaser that the agitator quoted complies fully with this Practice.

References Applicable requirements in the latest edition (or the edition indicated) of the following industry standards shall be considered an integral part of this Practice: 2.1

Process Industry Practices •

Process Industry Practices (PIP)/American Petroleum Institute (API) –

Page 2 of 14

PIP REIE 686/API RP686 - Guidelines for the Pre-Installation Design and the Installation of Machinery

Process Industry Practices

PIP RESM001 Specification for Agitators

May 1997

2.2

Industry Codes and Standards •

•

•

American Gear Manufacturers Association (AGMA) –

AGMA 2000 - Gear Classification and Inspection Handbook

–

AGMA 6010-E - Spur, Helical, Herringbone, and Bevel Enclosed Drives

American Society of Mechanical Engineers (ASME) –

ASME B1.1 - Unified Inch Screw Threads (UN and UNR Thread Form)

–

ASME B16.5 - Pipe Flanges and Flanged Fittings (Steel)

–

ASME B16.47 - Large Diameter Steel Flanges

American Society for Testing and Materials (ASTM) –

•

International Organization for Standardization (ISO) –

3.

ASTM A269 - Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service ISO 1940 Balance Quality of Rotating Rigid Bodies

Definitions For the purposes of this Practice the following definitions apply: Auxiliary Piping Systems: Piping supplied with the agitator for services such as: seal flush or buffer fluid, cooling water, gear reducer lubrication oil, and instrument air or nitrogen Bearing Speed Factor (ndm): An approximation of the speed at which the surfaces of a rolling element bearing roll together, and therefore also an indicator of bearing service severity. The bearing speed factor is determined by multiplying the rotational speed in revolutions per minute times the bearing pitch diameter in millimeters. For convenience, the pitch diameter is taken as one half the sum of the bearing bore and outside diameters. Shrink Disc: Clamping assembly used to secure mechanical shaft seals against rotation on shafts. A shrink disc utilizes a bolted wedge assembly to maintain a friction fit to the shaft. Comment: Use of a shrink disc imposes lower stresses on a shaft than key drives, and does not damage the shaft surface like setscrew drives.

4.

Design and Manufacture 4.1

General 4.1.1

Agitators shall be complete, including drive motor, gear reducer, forced lubrication system (if required) for gear reducer, mounting flange, coupling and guard, shaft, agitation elements, and shaft sealing system. Scope of supply shall conform to the data sheet.

4.1.2

When specified, agitator shall be shop assembled before shipment. Disassembly for shipment shall be limited to that required for shipment,

Process Industry Practices

Page 3 of 14

PIP RESM001 Specification for Agitators

May 1997

rigging, storage, or installation. Components disassembled for shipment shall be clearly matchmarked for reassembly. 4.1.3

Agitators shall be designed for rapid and economical maintenance.4.1.4 Agitators shall be designed so that maintenance and disassembly can be performed with standard shop tools. Any special tools or fixtures required shall be listed in the vendor’s proposal.

4.1.5

Oil fill openings, grease points, and mechanical seal reservoir fill port shall be extended for access without disassembly.

4.1.6

Rabbetted fits or dowels shall be used for alignment for all coupling, adapter housing, and gear casing joints.

4.1.7

Internal agitator components shall be designed to fit through the vessel manhole openings. Vendor shall state the minimum manhole opening required for assembly and maintenance of internal components.

4.1.8

Vendor shall review and comment on purchaser-supplied process performance data, including efficiency, performance, and baffle size and placement.

4.1.9

Vendor shall review and comment on the installation details with respect to agitator mounting and maintenance accessibility of the agitator.

4.1.10 Vendor’s proposal shall state expected sound pressure levels in dB for each octave band. Agitator noise level shall not be higher than specified on the purchaser’s noise data sheet. 4.1.11 Vendor shall state in the proposal if external cooling or forced lubrication is required for the gear reducer, shaft seal, or steady bearing. Cooling water requirements shall be stated in the proposal. 4.1.12 Cooling water passages in heat exchangers or cooling jackets shall be designed for 7.0 barg (100 psig) minimum working pressure. 4.2

4.3

Page 4 of 14

Materials 4.2.1

Material of minor parts (e.g. bolting, shaft keys, and other attachment hardware) in contact with the process shall have a corrosion resistance equal to or better than that of material of major parts in the same environment.

4.2.2

Material of pressure-containing parts in contact with the process shall have a corrosion resistance equal to that of the vessel.

4.2.3

Unless otherwise specified, components in contact with the mechanical seal flush or buffer fluid shall be AISI 300 series stainless steel.

Agitation Assemblies 4.3.1

Shaft shall be designed to resist torsional loads and bending moments for all specified operating conditions, including cold startup.

4.3.2

Unless otherwise specified, shaft shall have a removable coupling spacer so the shaft seal can be replaced without removing the drive or the agitator shaft.

Process Industry Practices

PIP RESM001 Specification for Agitators

May 1997

4.3.3

Shaft shall be equipped with a removable collar or sleeve that supports the entire shaft assembly when the coupling spacer is removed. Coupling and support sleeve design shall be such that when the coupling bolts are loosened, the support sleeve supports the shaft automatically.

4.3.4

A dynamic analysis of the shaft assembly shall be performed for both dry and wet conditions, and the results included as part of the vendor’s proposal. This analysis shall verify that any lateral or torsional resonances are separated from the operating speed range by at least 20% of the normal operating speed. Also, these resonances shall not be within 10% of any agitator vane pass frequencies, (including baffle effects), or electrical excitation frequencies, such as those caused by variable frequency drives.

4.3.5

Shaft assemblies that operate at more than 100 RPM and less than 300 RPM shall be statically balanced to the purchaser’s tolerance.

4.3.6

Shaft assemblies that operate at 300 RPM or higher speed shall be dynamically balanced to G40 tolerance in accordance with ISO 1940.

4.3.7

With the agitator drive input shaft turned by hand, runouts of the assembled shaft and agitation elements shall not exceed the following limits of total indicator runout (TIR): a. 0.05 mm (0.002 in.) at the gear reducer output shaft b. 0.13 mm (0.005 in.) above and below the mechanical seal housing c. 0.25 mm/m (0.003 in./ft.) of shaft length measured from the agitator mounting flange at the first in-vessel coupling, at the agitator hubs, and at the shaft end without the support of a steady bearing d. 0.025 mm (0.001 in.) perpendicular runout at the coupling face

4.3.8

When specified, the shaft shall have extended key seats for adjustment of the agitation elements.

4.3.9

For shafts with multiple agitation elements, the key seats shall be circumferentially staggered around the shaft.

4.3.10 Bolting of agitator blades shall conform to ASME B1.1. 4.3.11 Bolted connections of the agitation elements to the hub shall have a maximum diametral clearance of 0.8 mm (0.03 in.). 4.3.12 Blades shall be fastened to the hub with a minimum of three (3) bolts. Bolt threaded length in hub and blade joint shall be minimized. 4.3.13 Bolts shall be secured by lockwire or other positive locking method. 4.3.14 Unless otherwise specified, agitator hub-to-shaft attachments shall be key driven. 4.3.15 Total allowable variation in the radial sweep of the blade tips shall be 13 mm (0.5 in.). Radial sweep shall be measured without use of a steady bearing. 4.3.16 Maximum tolerance for axial location of blades and hubs shall be ±13 mm (0.5 in.).

Process Industry Practices

Page 5 of 14

PIP RESM001 Specification for Agitators

4.4

May 1997

Steady Bearing 4.4.1

Unless specifically approved by the purchaser, steady bearings shall not be used.

4.4.2

If the use of steady bearings is approved, then the steady bearing design shall conform to the following criteria: a. Proposals for agitators that have a steady bearing shall include sufficient detail for evaluation of the steady bearing design. b. Bearing design shall provide sufficient clearance for the differential radial and axial thermal expansion of the shaft and the bearing support. c. Bearing support shall have provisions for lateral and axial adjustment of the bearing assembly for alignment purposes. d. Agitator shaft shall have a replaceable sleeve at the bearing. Shaft sleeves for abrasive services shall be hard coated. e. Bearing shall have a replaceable liner. Unless otherwise specified, liner shall be made of glass-filled polytetrafluorethylene (PTFE). f.

4.5

Unless otherwise specified, bearing liner and shaft sleeve shall be fieldreplaceable without removing the agitator shaft or the bearing support.

Shaft Sealing System 4.5.1

When specified, a sealing system shall be supplied by the vendor.

4.5.2

For toxic fluids, and for flammable fluids with vapor pressure that exceeds atmospheric pressure at operating temperature or maximum ambient temperature, the shaft sealing system shall have pressurized dual mechanical seals.

4.5.3

When specified, the sealing system shall have a positive shut-off device that allows maintenance of the sealing system without clearing the vessel. Comment: Partial depressuring of the vessel is allowed for maintenance, therefore the positive shut-off device may have a lower pressure rating than the actual mechanical seal.

4.5.4

The shaft sealing system shall have the following features: a. Seals shall be hydraulically balanced design and of single cartridge construction. The inner seal of dual seals shall have a reverse balance feature designed and constructed to withstand reverse pressure differentials without opening. b. Seal cartridge shall be field-removable without removing the gear reducer or the shaft. c. Seal cartridge design shall be adequate for stand-alone static bench testing before installation. d. Seal cartridges shall be self-venting through the seal circulation return line. Centerline of the seal flush return port shall be a minimum of 3 mm (0.13 in.) above the seal faces.

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Process Industry Practices

PIP RESM001 Specification for Agitators

May 1997

e. Seal cartridges shall have leak detection port(s). Leak detection ports shall have a tapped connection and shall be permanently labeled by stamping. f.

The rotating seal element shall be setscrew driven. When specified, the rotating seal element shall be key or shrink disc driven. Comment: The use of setscrews to drive large or high pressure mechanical seals requires the use of a large number of setscrews, which creates the possibility of distortion or improper installation of the seal due to uneven tightening. Mechanical damage to the shaft and possibly the shaft O-rings can result from the setscrews upsetting the shaft metal when tightened. The use of key or shrink disc driven seal elements eliminates these possible problems.

g. Pressure joints in the seal cartridge housing shall be sealed with O-rings. Use of gaskets is prohibited. h. Unless otherwise specified, the seal cartridge shall not have cooling jackets. i.

Dual seals shall have a seal reservoir with a minimum capacity of 12 liters (3 gallons).

j.

Seal reservoir shall have a level gauge, a fill connection, and vent and drain connections. Level gauge shall be sized to indicate a range of ±50 mm (2 in.) of normal operating level.

k. Systems with dual seals shall have a device that provides positive circulation of buffer fluid from the seal reservoir to the seal. Circulation device can be a pumping ring or a separate circulation pump. Comment: When a dead-ended seal lubrication system is specified, a cooling jacket may be required, and a circulation device is not necessary. 4.5.5

An anti-friction bearing shall be mounted in or near the mechanical seal cartridge to minimize shaft motion at the seal. For continuous service, the bearing shall have a minimum L10 life of 40,000 hours. Calculation of bearing life shall be based on the specified operating conditions.

4.5.6

When specified, a separate lifting device for seal maintenance shall be included in the vendor’s proposal. Comment: A separate lifting device for mechanical seal maintenance (usually a small bolt on trolley and hoist assembly) is recommended if no permanent overhead lifting capacity is available and the weight of any item in the seal system exceeds 20 kg (45 lb.).

4.6

Agitator Support 4.6.1

Process Industry Practices

Unless otherwise specified on the data sheet, agitators shall be equipped with a through-bolted connection flange with dimensions, drilling, and pressure rating in accordance with ASME B16.5 or ASME B16.47, whichever applies. Connection flange bolt hole orientation shall match vessel flange.

Page 7 of 14

PIP RESM001 Specification for Agitators

4.6.2 4.7

May 1997

Agitators shall be supported on the vessel nozzle.

Shaft Couplings and Guards 4.7.1

The coupling between the motor and gear reducer shall be of non-lubricated flexible design.

4.7.2

Coupling service factor shall be a minimum of 2.0 based on the motor nameplate power.

4.7.3

Couplings for motors 35 kW (50 hp) and larger shall be flexible disk type.

4.7.4

Couplings for gear reducer output shaft and agitator shaft shall be of rigid design.

4.7.5

Unless otherwise specified, agitator shaft coupling hubs shall be keyed or welded in place and the arrangement indicated on the outline dimension drawing. Threaded coupling mounts are prohibited.

4.7.6

When specified, shaft ends for agitator shaft coupling hubs shall be tapered for ease of disassembly. Comment: Tapered coupling hubs are used at coupling joints where the coupling must be easily field removable and also have a moderate interference fit to transmit torque. The coupling located just above the mechanical seal is an example of this.

4.8

4.7.7

When interference fits are specified, cylindrical bore couplings shall be mounted using an interference fit of 0.0005 mm/mm (0.0005 in./in.) of shaft diameter.

4.7.8

A coupling guard shall be supplied for the motor driver coupling area. Coupling guard shall be removable and shall be mounted so that the rotating parts are covered to within 13 mm (0.5 in.) of the stationary housings. Guard shall be rigid enough so that contact of the guard with moving parts does not occur as a result of bodily contact with the guard.

Gear Reducer 4.8.1

Page 8 of 14

General 4.8.1.1

Gear reducer shall be specifically designed for agitator service.

4.8.1.2

Output shaft and bearings shall be designed to support the weight of the agitator assembly.

4.8.1.3

Gear reducer shall be designed to withstand all torsional, bending, and thrust loads so that significant deflections are not transmitted to the gears and bearings.

4.8.1.4

Gear reducer shall be furnished in accordance with AGMA 6010-E.

4.8.1.5

Gears shall be spiral bevel and/or helical. Use of worm gears, hypoid gears, double helical, or herringbone gears is prohibited.

Process Industry Practices

PIP RESM001 Specification for Agitators

May 1997

4.8.2

4.8.3

Process Industry Practices

4.8.1.6

Minimum gear reducer service factor shall be 1.4. For services in which polymerization or solidification is possible in the vessel, gear reducer service factor shall be 2.0, as a minimum.

4.8.1.7

Gears shall be finished to Quality Level 9, as a minimum, in accordance with AGMA 2000.

4.8.1.8

For continuous duty agitators, gear reducer anti-friction bearings shall be designed for an L10 life of 40,000 hours. Loads on bearings shall be based on nominal driver rating and agitator shaft loads transmitted to the gear reducer.

4.8.1.9

Thermal rating of the gear reducer shall be calculated in accordance with AGMA 6010-E using a factor of 0.75 for the ambient modifier, T4.

Cooling/Lubrication 4.8.2.1

When the driver nominal nameplate power exceeds the thermal rating of the gear reducer, an external cooling system shall be provided.

4.8.2.2

Preferred cooling system shall consist of ducting and a fan mounted on the input shaft. When fan cooling is insufficient, forced-oil circulation through an external cooler shall be provided.

4.8.2.3

Forced-oil circulation system components shall include: •

Replaceable element filter

•

Motor-driven oil pump

•

Cooler (water or air cooled)

•

Pump discharge pressure gauge

•

Low oil pressure alarm switch

•

Sump and cooler exit temperature gauges

•

Stainless steel piping.

4.8.2.4

Gear reducer lubrication system shall be designed to operate automatically without operator intervention.

4.8.2.5

All gears shall be lubricated with oil.

4.8.2.6

Low speed bearings with a speed factor (ndm) less than 150,000 may be grease-lubricated. Sealed-for-life bearings are unacceptable.

Gear Reducer Housing 4.8.3.1

Gear reducer housing shall have lifting lugs sized and located to lift the agitator assembly for installation and maintenance.

4.8.3.2

Housing shall have an oil level sight glass. Normal oil levels for static and operating conditions shall be plainly marked on the housing.

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PIP RESM001 Specification for Agitators

May 1997

4.8.3.3

Housing shall have a gear reducer nameplate securely attached on its exterior. Nameplate shall be made of 300 series stainless steel and shall be attached with corrosion resistant fasteners.

4.8.3.4

Nameplate shall have the following information permanently marked on it: a. Size and type or model b. Rated power c. Service factor d. Ratio e. Input and output RPM f. Manufacturer’s name g. Serial number h. Purchaser’s equipment number

4.8.3.5

4.9

Page 10 of 14

Housing shall have rotation arrows cast or attached with corrosion resistant fasteners. Arrows shall indicate direction of rotation of input and output shafts.

Drive Motor 4.9.1

Drive motor shall have a 1.15 service factor.

4.9.2

Motor nameplate power shall not be less than 115% of maximum agitator power requirements, including drive losses. Motor service factor shall not be used to meet this requirement.

4.9.3

Vertical motors shall have a rain shield.

4.9.4

Motor shall be mounted on a rigid bracket attached to the gear reducer.

4.9.5

Foot mounted motors shall have stainless steel shims with a minimum thickness of 3 mm (0.125 in.) to support the motor feet. The shim pack shall consist of no less than three and no more than five shim pieces.

4.9.6

The agitator motor mounting adapter runouts for flange mount motors shall not exceed 0.05 mm (0.002 in.) concentricity (radial runout) and 0.13 mm (0.005 in.) perpendicularity (face runout) as measured from the gear reducer input shaft.

4.9.7

When specified, positioning screws to aid in driver alignment shall be provided for both foot and flange mount motors. For foot mount motors, horizontal positioning screws for both transverse and longitudinal directions shall be provided. For flange mount motors, positioning screws to adjust motor alignment in two directions normal to the shaft axis shall be provided. Any part of the positioning screw assembly above the plane of the mounting surface shall be removable without cutting, burning, or grinding.

4.9.8

The motor shall be provided with a grounding lug on the frame.

Process Industry Practices

PIP RESM001 Specification for Agitators

May 1997

4.10

Auxiliary Piping 4.10.1 Piping connections to purchaser systems 3/4 NPS or larger shall be flanged. 4.10.2 Piping components in contact with the mechanical seal flush fluid shall be stainless steel. 4.10.3 Seal flush system shall be stainless steel tubing that conforms to ASTM A269. Minimum size of tubing shall be 1/2 in. Use of 3/4 in. tubing is preferred.

5.

6.

Inspection 5.1

Purchaser will specify the minimum requirements for inspection in the purchase order or a separate addendum to the data sheet.

5.2

When specified on the data sheet, inspection shall be conducted by the purchaser before the agitator is shipped.

5.3

Purchaser shall have access to inspect the agitator, or any of its auxiliary systems, at any time during their fabrication or testing.

5.4

Vendor shall notify the purchaser a minimum of five (5) days before any scheduled shop tests and before the equipment is to be ready for final inspection.

Testing 6.1

6.2

Mechanical Test 6.1.1

The purchased motor, gear drive, and mechanical seal assembly shall be given a mechanical run test at the vendor’s facility.

6.1.2

The motor, gear drive, and seal assembly shall be operated at full speed and partial or no load conditions for one hour after bearing temperatures have stabilized, or for a mutually agreed upon time period.

6.1.3

Dual seal systems shall be operated at normal operating pressure during the mechanical performance test.

6.1.4

Bearing temperatures and housing vibration shall be measured and recorded just prior to the end of the mechanical test.

6.1.5

Bearing temperatures shall not exceed 65°C (150°F). Vibration as measured at the top of the gear drive shall not exceed 5 mm/sec (0.2 in/sec) RMS.

6.1.6

Shaft runouts at the input shaft and mechanical seal area shall be measured and recorded on the test data sheets after the mechanical test.

Noise Level Measurement 6.2.1

Process Industry Practices

When specified, the vendor shall measure and record the noise level of the agitator during the mechanical test as stated in Section 6.2.1.1 through 6.2.1.4.

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PIP RESM001 Specification for Agitators

6.3

May 1997

6.2.1.1

Noise level shall be measured in the horizontal plane at a distance of 1 m (3 ft.) from the drive motor or gear reducer surface.

6.2.1.2

A survey of the operating agitator shall be made to determine the location with the highest noise level. Noise level at this location shall be recorded.

6.2.1.3

Overall noise level shall be measured and recorded using the “A” weight filter. Frequency analysis of the noise shall be performed using an octave band filter with center frequencies from 31.5 to 8 kHz. Noise levels for each of the octave filter bands shall be recorded.

6.2.1.4

Noise level measurements shall be taken with the sound level meter operating in the slow response mode and a visual average of the meter fluctuation shall be recorded. Meter shall also be observed operating in fast response mode with the “A” weight filter. If the meter deflection on fast response is greater than 5 dB, then maximum and minimum meter values shall be recorded for each measurement.

Optional Tests When specified, optional tests, such as part or full load tests or testing to validate agitation element design, shall be performed.

7.

Preparation for Shipment 7.1

Preservation Interior of the gear reducer shall be treated with corrosion inhibitors in accordance with PIP REIE 686/API RP686.

7.2

7.3

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Cleaning and Painting 7.2.1

Exterior surfaces shall be painted with the vendor’s standard paint.

7.2.2

Stainless steel surfaces shall not be painted unless covered by insulation.

7.2.3

Exposed machined surfaces shall be coated with an easily removable rust preventative.

Packing and Tagging 7.3.1

Agitator shall be braced and small piping shall be secured to prevent damage during shipment.

7.3.2

All flanged openings shall be sealed with gaskets and metal covers. Small piping shall be sealed with metal or plastic plugs.

7.3.3

Mounting flanges shall be protected with sheet steel covers. Wooden covers with a minimum thickness of 20 mm (3/4 in.) shall be placed over the steel covers and shall be secured with a minimum of four (4) bolts.

Process Industry Practices

PIP RESM001 Specification for Agitators

May 1997

8.

7.3.4

Special tools and small accessories shall be boxed and shipped with the agitator.

7.3.5

A complete set of installation and operation instructions and a certified outline dimension drawing enclosed in a waterproof envelope shall be attached to the agitator.

7.3.6

Material shipped separately shall be identified with the purchaser’s item number on a metal tag.

7.3.7

Each separate item, crate, bag, etc., shall be identified with purchaser’s order and requisition numbers and all special markings specified by the purchase order.

Vendor’s Data 8.1

Proposal Vendor shall submit as a minimum the following data with the proposal: a. Spare parts list with unit pricing for spare parts. Spare parts list shall include parts required for three years of normal operation and critical startup spare parts. b. Completed agitator data sheet c. Preliminary (or typical) outline drawings showing: •

Principal dimensions

•

Weights of principal components

•

Clearances required for installation and maintenance

•

Mounting flange dimensions

•

Drive motor support

•

Agitator blade-to-hub connection details

•

Seal reservoir mounting location

•

Direction of rotation when looking at the top of the agitator

d. Typical cross-sectional drawing of the gear reducer showing details of construction e. Cross-sectional drawing of the shaft seal, with details and specifications of all sealing system components f.

Cross-sectional drawing of the steady bearing (if required)

g. Agitator performance (mixing) calculations and curves h. Typical schematics for seal flush and lubrication systems i.

A detailed procedure for replacement of mechanical seals

j.

Drawings showing the forces and moments applied by the agitator assembly to the vessel mounting flange

Process Industry Practices

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PIP RESM001 Specification for Agitators

8.2

May 1997

Approval Drawings After receipt of the order, vendor shall furnish the following certified drawings: a. Outline drawing(s) of the complete assembled agitator. Drawing(s) shall include: •

Principal dimensions

•

Direction of rotation of the agitator

•

Size and location of connections to the agitator

•

Size and location of mounting flanges

•

Total weight and individual weights of principal maintenance items

b. Actual cross-sectional drawings of the gear reducer, shaft sealing system, and steady bearing c. Drawings of auxiliary equipment or piping d. Drawings showing the forces and moments applied by the agitator assembly to the vessel mounting flange e. Bill of materials f. 8.3

Drive motor data sheet

Final Data 8.3.1

After final inspection, the vendor shall furnish the following data: a. As-built data sheets and final drawings b. Operating and maintenance instructions, including lubrication requirements, and a detailed procedure for mechanical seal replacement c. Parts list with factory cross reference number d. Certified data from the shop tests that were performed. Data shall be provided for purchaser’s review and acceptance prior to shipment of the agitator. e. Purchaser specified ducumentation such as material certifications.

8.3.2

Page 14 of 14

The number of copies required will be specified in the purchase order.

Process Industry Practices

RESM001

Specification for Agitators

PAGE 1 OF 3

AGITATOR DATA SHEET JOB __________________________________________________________

NUMBER

ITEM NO _____________________________________________________________ SERVICE _____________________________________________________________

CLIENT____________________________________________________________

REQUISITION NUMBER _________________________________________________

PROJECT LOCATION ________________________________________________

_____________________________________________________________________

UNIT ______________________________________________________________ DESIGN, MANUFACTURE, INSPECTION, AND TESTING SHALL CONFORM TO SPECIFICATION NOTES: PURCHASER

¡ INDICATES INFORMATION COMPLETED BY PURCHASER

GENERAL o MODEL NUMBER ¡ DRIVER TYPE OPERATING CONDITIONS

MIXER MANUFACTURER DRIVER ITEM NUMBER

¡ PRESSURE ¡ MIXED VOLUME

¡ QUANTITY

¡ UP ¡ RADIAL PERFORMANCE RPM o MAX SHAFT POWER o NORMAL SHAFT POWER o o IMPELLER DIAMETER CONSTRUCTION FEATURES

¡ DOWN

GAL

o MANUFACTURER CODE x FLAT x PROPELLER

o QUANTITY x PITCHED x MULTIPLE o PITCH

¡ VESSEL MFR

IN

x AGITATOR HUBS x BLADES x MECHANICAL SEAL PARTS ¡ NOT REQUIRED o RATED TEMP

x MANUFACTURER

¡ AGITATOR MFR

x MANUFACTURER CODE

o BRG SPAN (IN)

¡ POSITIVE SEAL SHUTOFF FOR MANTENANCE

o CRITICAL SPEED (RPM)

¡ KEY-DRIVEN ROTATING ELEMENT

GEARBOX

¡ SHRINKING-DISC DRIVEN ROTATING ELEMENT

o MANUFACTURER

o MODEL NUMBER

x PARALLEL SHAFT

TYPE

o RATED POWER

HP

o AGMA S.F. BEARINGS

o EFFICIENCY LOW SPEED

o TYPE o LUBRICATION TYPE o AFBMA L-10 LIFE

MOTOR

o MANUFACTURER o TYPE o HORSEPOWER

x SEAL RESERVOIR SIZE %

x COOLING WATER

¡ FLUID x FORCED CIRCULATION o PSIG o SOURCE

PAINTING

¡ INTERFERENCE FIT

¡ MANUFACTURER STANDARD ¡ SPEC NUMBER ¡ ASSEMBLE COMPLETE BEFORE SHIPMENT ¡ INSPECTION REQUIREMENTS ¡ MECHANICAL TEST ¡ OPTIONAL TEST ¡ FINAL BEFORE SHIPMENT ¡ OTHER ¡OPTIONAL TESTING ¡ PART LOAD ¡ FULL LOAD ¡ NOISE LEVEL ¡ AGITATOR PERFORMANCE ¡ OTHER o MODEL o RPM o FRAME o FOOT MOUNT o FLANGE MOUNT REVISIONS

NUMBER

REVIEWED

DATE

APPROVED

ORIGINATOR

o FLOW

o COOLING JACKET SEAL FLUSH

x DEAD ENDED x PRESSURIZED

HS COUPLING

¡ INTERFERENCE FIT x MANUFACTURER x MODEL LS COUPLING ¡ TAPERED HUBS

¡ MAINTENANCE LIFTING DEVICE

x RIGHT ANGLE o AGMA QUALITY

HIGH SPEED

°F

MANUFACTURER/TYPE

x MECHANICAL SEAL TYPE

x BOTTOM STEADY BEARING

BRG SUPPORTED BY:

HP

x IMPELLER x SHAFT x MOUNTING FLANGE x GASKET SHAFT SEALS ¡ REQUIRED o RATED PRESSURE PSIG x PACKING x SIZE/NO RINGS

¡ EXTENDED KEY SEATS

o SHAFT DIA (IN)

HP

MATERIALS OF CONSTRUCTION

o NO BLADES o RECOMMENDED CLEARANCE FROM OBSTRUCTION IN o PROJECTED BLADE AREA (IN2) o THICKNESS (IN) ATTACHMENT o WELDED o BOLTED ¡ POSITIVE LOCK HUB o FABRICATED o CAST o KEY-DRIVEN o SHAFT o HOLLOW o SOLID o STEPPED o FLANGED x STABILIZERS

o SERIAL NUMBER ¡ DRIVER PROVIDED BY

GAL

o OPERATING SPEED o CALCULATED PRIMARY PUMPING CAPACITY 3 o ROTATION o CW

TYPE

x BY MANUFACTURER OR

DIRECTION OF FLUID MOVEMENT

PSIG MIN MAX

IMPELLER

o BY MANUFACTURER

o GPM

RESM001

Specification for Agitators

PAGE 2a OF 3

AGITATOR DATA SHEET JOB NUMBER __________________________________________________________

ITEM NO _______________________________________________________________

VESSEL DETAILS ¡ VESSEL ITEM NUMBER

VESSEL DETAILS

¡ SIZE:

D/L

¡ API 620

H

(W)

¡ ASME SECT VIII

TOP HEAD TYPE

FT

¡ OTHER

¡ INTERNALS

¡ FLAT

¡ ASME DISHED

¡ CONE

¡ OTHER

BOTTOM HEAD TYPE

¡ CAPACITY

GAL/BBL

x MOUNTING FLANGE SIZE

FACING

x SIZE OPENING FOR IMPELLER INSTALLATION

RATING IN

¡ FLAT

¡ ASME DISHED

¡ CONE

¡ OTHER

FT-LB

DESCRIPTION

A

NORMAL LIQUID LEVEL

B

MAXIMUM LIQUID LEVEL

C

IMPELLER DIAMETER

D

IMPELLER DEPTH

E

VESSEL REFERENCE DEPTH

F

VESSEL I.D.

INCHES

¡ 2:1 ELLIPTICAL

LOADS TORQUE

ID

¡ 2:1 ELLIPTICAL

STATIC MOMENT

FT-LB

REMARKS

DYNAMIC MOMENT

FT-LB

WEIGHT

LB

RESM001

Specification for Agitators

PAGE 2b OF 3

AGITATOR DATA SHEET JOB NUMBER __________________________________________________________

ITEM NO _______________________________________________________________

TANK DETAILS ¡ VESSEL ITEM NUMBER

VESSEL DETAILS

¡ SIZE:

D/L

¡ API 620

H

(W)

¡ ASME SECT VIII

TOP HEAD TYPE

FT

¡ OTHER

¡ INTERNALS

¡ FLAT

¡ ASME DISHED

¡ CONE

¡ OTHER

BOTTOM HEAD TYPE

¡ CAPACITY

GAL/BBL

x MOUNTING FLANGE SIZE

FACING

RATING

x SIZE OPENING FOR IMPELLER INSTALLATION

IN

¡ FLAT

¡ ASME DISHED

¡ CONE

¡ OTHER

FT-LB

DESCRIPTION

A

NORMAL LIQUID LEVEL

B

MAXIMUM LIQUID LEVEL

C

IMPELLER DIAMETER

D

IMPELLER DEPTH

E

VESSEL REFERENCE DEPTH

F

VESSEL I.D.

INCHES

¡ 2:1 ELLIPTICAL

LOADS TORQUE

ID

¡ 2:1 ELLIPTICAL

STATIC MOMENT

FT-LB

REMARKS

DYNAMIC MOMENT

FT-LB

WEIGHT

LB

Specification for Agitators

RESM001 PAGE 3 OF 3

AGITATOR DATA SHEET JOB NUMBER __________________________________________________________

ITEM NO _______________________________________________________________

AGITATOR PROCESS DEFINITION FLUID PROPERTIES, COMPOSITION AND CONDITIONS FEED

COMPONENT

RATE(GPM)

TEMP (°°F)

3

DENSITY (LB/FT )

VISCOSITY (cP)

REMARKS

1 2 PRODUCT OPERATING TEMPERATURE (°°F)

FOAMING TENDENCY

VISCOUS PROPERTY

MAX. VISCOSITY (cP)

¡ NORMAL

¡ NONE

¡ DILUENT

¡ STARTUP

¡ MINIMUM

¡ MODERATE

¡ NEWTONIAN

¡ INTERMDEDIATE BLEND

¡ MAXIMUM

¡ EXCESSIVE

¡ PSEUDOPLASTIC

¡ FINAL BLEND

¡ OTHER

¡ UPSET

¡ TOXICITY

¡ VAPOR PRESSURE AT OPERATING TEMP OPERATION (CONTINUOUS RETENTION TIME) MIXING DURING

¡ FILLING

¡ DRAWOFF

¡ EMPTYING

¡ REQUIRED

¡ (MIN.) ¡ BATCH

PRIMARY BULK FLUID VELOCITY (FT/SEC)

o QUOTED

¡ BLEND TIME (MIN) ¡ TURNOVERS PER HOUR

AVERAGE SHEAR RATE (1/SEC)

¡ REQUIRED

o QUOTED

o MAX

¡ RECIPE (VOLUME/SEQUENCE MIX TIME)

¡ SIZE (GAL)

NORMAL

¡ MINIMUM

MAXIMUM

PROCESS REQUIREMENTS (COMPLETE ALL THAT APPLY) ¡ BLENDING OF MISCIBLE LIQUIDS

¡DISSOLVING

¡ SOLIDS SUSPENSION

¡ SOLUBILITY

¡ PARTICLE SIZE

¡ EASY

¡ MODERATE

¡ DIFFICULT

¡ DISSOLVING SOLIDS MAY AGGLOMERATE

MICRON

¡ WEIGHT % SOLIDS

¡ HEAT TRANSFER

¡ DISTRIBUTION

¡ SERVICE

¡ HEAT

¡ COOL ¡ MAINTAIN TEMPERATURE

¡ HEAT TRANSFER FLUID

NATURE OF SOLIDS

¡ SOLUBLE

¡ INSOLUBLE

¡ ABRASIVE

¡ SPECIFIC HEAT

BTU/LB

¡ STICKY

¡ CRYSTALLINE

¡ FLUFFY

¡ CONDUCTIVITY

°F

¡ SETTLING VELOCITY (fpm)

¡ DUTY

BTU/HR

¡ RESUSPEND AFTER SETTLING REQUIRED

¡ EXTERNAL JACKETS

¡ SOLIDS FLOAT

¡ OTHER

¡ UNIFORM SUSPENSION

¡ COMPLETE SUSPENSION

¡ SUPERFICIAL GAS VELOCITY

¡ ALL SOLIDS IN MOTION

¡ REQUIRED RESULTS ¡ EASILY WETTED

¡ FINE BUBBLES o UNGASSED POWER INPUT (HP)

¡ REDUCE AGGLOMERATES TO

MICRONS MAX

¡ CRYSTALLIZATION

¡ TWO SPEED MOTOR ¡ GAS SOURCE

¡ IMPELLER TO SCRAPE SURFACE(S)

¡ SOLIDS FORMATION

¡ COARSE RADIAL DISPERSION

¡ SMOOTH

REQUIRED RESULTS

¡ POLYMERIZING

FT/SEC

¡ GASSED/UNGASSED VOLUME RATIO

¡ DISPERSION (NON-MISCIBLE)

CRYSTALS

¡ TUBE BAFFLES

¡ GAS DISPERSION

REQUIRE RESULTS

¡ RESISTS WETTING

¡ INTERNAL COIL

¡ INTERLOCK DRIVER TO GAS FLOW ¡ SPARGER RING

¡ INJECTION TUBE

¡ FROM EVOLUTION

¡ FRIABLE

¡ FORM SLURRY

¡ SETTLE OUT

¡ DEPOSIT ON SURFACE

¡ CHEMICAL REACTION REACTION RATE

¡ EXTRACTION

¡ RAPID

¡ MODERATE

¡ SLOW

¡ LIQUID-LIQUID

¡ LEACHING

¡ WASHING

¡ PARTIPATIVE EXTRACTION