Plenty Mixer General Instructions

8/18/2019 Plenty Mixer General Instructions

http://slidepdf.com/reader/full/plenty-mixer-general-instructions 1/25

SPX Process EquipmentLIGHTNIN/PLENTY Side Entry Mixers

Issued: 03/21/05 IT-5309Revision F, 08/09/11 of 25

E PLENTY 2008

GENERAL INSTRUCTIONS FOR PLENTY® BELT DRIVESIDE ENTRY MIXERS

SECTION 1 – INTRODUCTION

This manual should be used to facilitate the installation, start-up, operation and maintenance of your PlentySide Entry Mixer.

A good knowledge of the mixer, together with a planned preventative maintenance program, will ensureoptimum performance of your mixer. Information required to operate and maintain your mixer can be foundin this manual.

Plenty Side Entry Mixers are designed for use in oil production, refining and distribution industries forblending, homogenizing, maintaining temperature uniformity, tank cleaning and minimizing sludge build-up.The mixer is bolted to a connection nozzle or flange located on the side of a storage or blending tank.

The Plenty Belt Drive Side Entry Mixer is driven by an electric motor, mounted to the main mixer body(frame) by means of a mounting plate which is hinged relative to the mixer body, allowing the drive belt to becorrectly tensioned.

Standard Plenty units are furnished with a toothed, synchronous timing belt. This belt will not supportcombustion and provided that it is properly aligned and tensioned, will not generate sufficient heat to selfignite. The motor (drive) pulley and the mixer (driven) pulley utilize taperlock bushings to lock them inposition on their relative shafts. The belt drive components are totally enclosed within a non-sparking guard.

The main mixer body is a rigid, one piece iron casting, which houses grease lubricated sealed for life radialand thrust bearings selected to have in excess of 50,000 hours operating life. The mixer body is connectedto a mounting flange/mechanical seal assembly through which a mixer shaft passes. The mating taperbetween the mixer shaft and the mounting flange provides a shut-off device which enables mechanical sealand/or bearing replacement without the need to completely drain the tank contents.

The mixer flange includes studs and nuts for direct connection to a standard ANSI 150lb rated flange. Unitsmay be fitted with a tank adapter to suit a specific nozzle or manway drilling pattern.

The mixer shaft is fitted with a three bladed high efficiency propeller, which is connected to the shaft bymeans of a locking bolt and key.

Mixer parts referred to in these instructions can be identified by referring to the appropriate AssemblyDrawing.

SECTION 2 – INITIAL INSPECTION, SHIPPING ARRANGEMENTS &STORAGE

Be sure to check your Plenty Side Entry Mixer for possible shipping damage, and report any damageimmediately to the carrier and our factory.

All units are shipped completely assembled whenever possible. If shipping restrictions limit overall size, unitsmay be shipped disassembled. If necessary, install the drive belts as outlined in Section 6 of theseinstructions.

The unit has been treated with corrosion inhibitors and preservatives at the factory. Store unit indoors ifpossible. In the event outdoor storage is necessary, the unit should be protected from the elements.Extreme temperature fluctuations should be avoided in storage; a normal temperature and dry ambientconditions will afford the best storage results.





E PLENTY 2008

All unpainted steel surfaces are coated with a rust preventative that is easily removed with a non-volatilesolvent. In addition, various locations on the unit may be wrapped with a water repellent paper. Do notremove wrappings until unit is ready to be put into operation.

When properly stored, this equipment is protected against corrosion due to water and water vapor for aperiod of SIX MONTHS. For storage periods longer than six months, consult our factory for method ofreapplying inhibitors and preservatives.

During the storage period, it is necessary that regular maintenance checks are carried out as follows:

The mixer shaft should be rotated 3 to 4 revolutions by hand, every 6 weeks to ensure mechanical sealand bearings are running free.

NOTE: If the grease in the bearings is allowed to settle to the lowest point, this will cause severe dryconditions upon start-up, resulting in premature bearing failure.

It is recommended that fresh lubricant is introduced into the mechanical seal to ensure no damage to theseal faces resulting from rotating the mixer shaft. To add fresh lubricant, remove the needle screw on theair release valve (54), add approximately ½ ounce of lubricating oil, and replace needle screw.

NOTE: Failure to replenish the seal face lubricant can result in seal face damage during shaft rotation.Damaged seal faces can cause excessive temperatures which would then present a potential ignitionhazard.

On Model STM Mixers, the opening around the swivel ball should be sealed with tape to prevent dust anddirt from entering the opening.

It is recommended to protect the propeller from damage, as this may affect both the mechanical and processperformance of the unit.

SECTION 3 – SAFETY CONSIDERATIONS

Plenty assumes that your Health and Safety Department will have established a suitable program of safeworking practices, based on a thorough analysis of all industrial hazards arising from the installation,operation and maintenance of side entry mixers. Prior to installing the equipment outlined in theseinstructions, this program should be reviewed. It is important that due consideration is given to thosehazards which arise from the presence of electrical power supplies, hot oil, high pressure steam, toxic

gases, flammable liquids and flammable gases as applicable.

In addition to the above, the following SAFETY CHECK LIST should be THOROUGHLY REVIEWED AND ADHERED TO before installing, operating or performing maintenance on the mixer. FAILURE TO FOLLOWTHESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY. Ensure the use of qualified, qualitytrained and safety conscious personnel at all times.

We strongly recommend that all hoist rings be of the safety swivel type with 360 degree rotationalcapability. Lift in accordance with the instructions in Section 4 of these instructions.

DO NOT connect the motor to the power source until all components are assembled, the mixer isinstalled, and all hardware is tightened to the proper torque specified in these instructions.

DO NOT operate shaft sealing devices at temperatures or pressures higher than those specified in theseinstructions or on the nameplate.

DO NOT service the mixer until you have followed your “Control of Hazardous Energy Sources” (lockout,tagout procedure) as required by OSHA 29 CFR Part 1910.

DO NOT touch rotating mixer parts or any part of the mixer that has the potential of having a hot surfaceincluding motor, housing, seal, shafting, flange and drive belts.

DO NOT operate the mixer for other than its intended use, that being fluid mixing with the mixer attachedto a rigid structure and connected to a power source appropriate to operate the drive motor.

DO NOT make any field changes or modifications (horsepower, seal component materials, output speed,shaft length, impeller, etc.) without reviewing the proposed changes with your Plenty Representative orthe LIGHTNIN/Plenty Customer Service Department.





E PLENTY 2008

DO NOT install an aftermarket Variable Frequency Drive without first consulting your PlentyRepresentative or the LIGHTNIN/Plenty Customer Service Department to determine the compatibility ofyour existing motor with the Variable Frequency Drive.

DO NOT operate the mixer until you have checked the following items:

Make sure the mixer is properly grounded.Ensure all protective guards and covers are installed. Guarding of the mixer shaft beyond the

mounting flange is the responsibility of the customer.Ensure all detachable components are securely coupled to the mixer.Thoroughly REVIEW and ADHERE TO the mixer operating instructions supplied by Plenty.Ensure the mixer output shaft rotates freely by hand.Ensure all personnel and equipment are clear of rotating parts.Ensure all external connections (electrical, hydraulic, pneumatic, etc.) have been completed inaccordance with all applicable codes and regulations.

DO NOT enter the mixing vessel UNLESS:

The mixer power supply is locked out in accordance with OSHA 29 CFR Part 1910 (lockout, tagoutprocedures).The mixer shaft is firmly attached to the mixer or securely supported by some other means.You have followed the applicable confined space regulations.

CE COMPLIANCE:

If the mixer nameplate has a CE marking on it, then the equipment furnished conforms to the followingdirectives:

98/37/EC Machinery Directive89/336/EEC Electro-Magnetic Compatibility73/23/EEC Low Voltage

Any CE marking and/or associated documentation applies to the mixer only. This has been supplied onthe basis that the mixer is a unique system. When the mixer is installed, it becomes an integral part of alarger system which is not within the scope of supply, and CE marking is the responsibility of others.

CAUTION: CE Compliance does not imply that the mixer satisfies PED (Pressure Equipment 97/23/EC)or ATEX (Potential Explosive Atmospheres 94/9/EC) unless marking is clearly shown on the mixer.

NOISE LEVEL: Sound Pressure Level is maximum 85 db(A) at 1 meter.

SECTION 4 – INSTALLATION

4.1 Refer to the General Arrangement Drawing for weight and dimensions of the mixer. Using appropriatelyrated equipment, sling the mixer as shown in Figure 1 for safe lifting and maneuvering duringinstallation.

Figure 1B - Slinging Style STM ModelsFigure 1A - Slinging Style TM Models





E PLENTY 2008

4.2 To install mixers when the nozzle is smaller in diameter than the propeller, it is often necessary tomanipulate the propeller through the nozzle. Slide flange gasket over propeller. Place the propeller inthe nozzle as shown in Figure 2. The mixer shaft must then be moved to the right, and rotating the shaftcounterclockwise, the second blade will enter the tank, followed by the third blade.

MOVESHAFT

ROTATE

PROPELLER

Figure 2 - Passing Propeller into Tank

NOTE: Care must be taken at all stages of installation to ensure damage does not occur to the shaft or

propeller blades. Shaft distortion and small propeller pitch distortions can induce heavy vibration duringmixer operation.

4.3 Plenty Mixers are supplied with a skid support frame for storage and transportation purposes only. Thisskid should be removed after the mixer is installed firmly on the tank. It is recommended that the skid beretained for possible future use.

4.4 On Model STM Mixers, an allowance MUST be made with regard to the electrical connection to themotor conduit box to allow for up to 30 degree left and right rotation of the mixer as shown in Figure 3.

30°

30°

Figure 3 - Swivel Angle

CAUTION: All electrical connections to the mixer must be undertaken by a qualified electrician, and allsite regulations and procedures must be adhered to.

4.5 Secondary Supports

Plenty Side Entry Mixers are mounted onto nozzles located on the side of the tank. In general, the45mm and smaller (up to 20 HP) 60mm shaft size units require no additional support. The 70mm and85mm shaft size units are supplied with a mixer support sling assembly as standard (the support sling isrecommended, but not required, for 60mm shaft size units 25 HP and greater). The support slingassembly serves to remove a portion of the load from the mounting nozzle and transfer it to a point





E PLENTY 2008

above the mixer on the outside tank wall. The sling assembly incorporates variable load springs whichprovide a flexible component to allow for tank wall movements during filling and emptying of the tank.

Check to be sure that the sling support bracket (furnished by customer) is mounted correctly in relationto the mixer shaft centerline and tank flange/manway face. Refer to the Support Sling drawing fordetails.

CAUTION: Incorrectly positioned sling support bracket will lead to incorrect spring loading and possibly

prevent mixer swivel movement on STM models. After the mixer has been bolted to the mounting flange, the sling support must be adjusted to remove aportion of the load from the mounting nozzle. The nuts on the support sling below the lower spring capshould be adjusted to compress the spring to the dimension shown on either the Machine Assemblydrawing or the Support Sling drawing. This procedure should be accomplished with the tank empty.

CAUTION: DO NOT overtighten the springs, as this will induce additional loads on the nozzle.

4.6 Pre-Run Checks

With the mixer securely fastened to the tank nozzle, and the tank filled to operating level:

Check that the mechanical seal chamber is flooded by opening the check valve on the seal cover until aconstant flow of liquid is seen. Close and retighten the check valve.

CAUTION: Running the mechanical seal without lubrication can result in excessive temperature, which

could present a potential ignition hazard.Rotate the mixer shaft by hand to ensure free running of all components, and then observe the rotationof the mixer shaft upon start-up. If incorrect rotation is observed, stop the mixer immediately and correctthe rotation by reversing any two leads on the motor.

Ensure all guards are in place and secured before starting the mixer for operation.

For model STM swivel angle mixers, the mixer should be checked to ensure its free movement of up to30 degrees either side of center. A single person should be able to move the mixer from side to side. Ifthe movement of the mixer is found to be difficult, refer to Section 10 of these instructions foradjustment procedure.

Ensure all mixer mounting hardware is tightened to the torque value specified in Section 12 of theseinstructions.

NOTE: The hardware securing the solosele gland plate (78) should only be tightened as outlined inSection 10. Overtightening this hardware will restrict free movement of the mixer and could result in

damage to the solosele.

4.7 Belt Tensioning

The drive and driven pulleys are aligned and the belt installed at the factory prior to shipment, andshould not require any further adjustment. If for any reason, the belt and pulleys need to be installed oradjusted, refer to Section 6 of these instructions for details.

4.8 Minimum Liquid Level

To avoid excessive splashing, and to prevent the mechanical seal from running dry, the mixer shouldNOT be operated if the tank liquid level is less than 2-1/2 times the propeller diameter above the mixershaft centerline. It is recommended that a low level switch be installed to shut down the mixer if theliquid level becomes too low.

CAUTION: Running the mechanical seal without lubrication can result in excessive temperature, which

could present a potential ignition hazard.

4.9 Floating Roof

Floating roofs should be designed and manufactured so as not to interfere with the mixer propellerwhen the roof is at its lowest position. The tank must be designed with either mechanical stops orelectrical cut-off to stop roof movement when the clearance between the inside of the roof and thepropeller tip is a minimum of 6 inches.

CAUTION: Impact of the roof on the propeller tip can cause damage to the propeller, mixer shaft,mechanical seal and bearings. Contact between the roof and the propeller must be avoided.





E PLENTY 2008

4.10 Steam Quench for Mechanical Seal (if equipped)

The steam quench should be no more than 250 degrees F or 5.0 PSI. Failure to maintain pressureand temperature below limits shown may result in damage to the mixer and/or mechanical seal.

SECTION 5 – OPERATION

Plenty Side Entry mixers are designed to operate continuously under all standard conditions. It is not goodpractice to operate the mixer when extreme vortexing or surging occurs, or if tank liquid level falls to lessthan 2-1/2 times the propeller diameter above the centerline of the mixer shaft.

CAUTION: Running the mechanical seal without lubrication can result in excessive temperature, whichcould present a potential ignition hazard.

12 hours after assembly, and at each scheduled shutdown thereafter, check all fasteners and mountinghardware for tightness. Refer to Section 12 of these instructions for recommended torque.

Dirt accumulation on the body of an electric motor acts as an insulator, preventing effective motor cooling. Always keep the motor clean. Refer to Section 11 of these instructions for details regarding electric motormaintenance.

5.1 Swivel Angle Mixers (Model STM)

Model STM mixers are normally used for the suspension of sludge, solids, etc., with the occasionalrequirement for blending. Where 2 or more swivel mixers are used in the same tank, all the mixers mustbe set to the same initial angle. With the unit turned off, the angle of the mixer is adjusted by unlockingthe clamp screw/tommy bar (94) and releasing the swivel adjustment bar (92). The mixer is then pushedsideways until the adjustment bar notch corresponding to the required mixer angle is reached. Theswivel adjustment bar is then securely locked in this position by the clamp screw/tommy bar. Restorepower to the mixer.

CAUTION: Care must be taken to ensure the clamp screw/tommy bar (94) is secure to prevent vibrationduring mixer operation.

For optimum mixing efficiency, Model STM mixers should be operated on one of the followingschedules:

Clean or New Tanks – Solids Suspension: 30 degrees left, 10 degrees right, 20 degrees left, 20

degrees right, 10 degrees left, 30 degrees right, 30 degrees left, etc. Angle changes should be madeevery 2-3 months maximum. The mixer(s) should be operated 8-12 hours before tank pump downand during pump down until the minimum tank liquid level is reached. There is no need to operatethe mixer(s) continuously.

Dirty Tanks – Solids Suspension: Schedule is the same as for clean tanks, but initially the mixershould operate for approximately 8 hours at one angle per batch (i.e.; first batch 30 degrees left,second batch 10 degrees right, etc.) until all deposits are reduced to a reasonable level. Then revertto change of angle every 2-3 months as outlined above.

Blending, Homogeneity, Temperature Uniformity: The mixer should be positioned at 10 degrees leftfor full top to bottom turnover.

If your Plenty mixer is equipped with an automatic swivel actuator, refer to the instructions providedelsewhere in this manual.

5.2 Fixed Angle Mixers (Model TM)

Normally used where process requirements are blending type applications (homogeneity, prevention ofstratification in blended products, prevention of skin formation at liquor surface, heat transfer, ortemperature uniformity). These applications require strong top to bottom turnover to break up interfaces,etc. To assist in this, the mixers are installed at an angle of 10 degrees to the left of the tank axis.

5.3 Tank Cleansing, Testing & Inspection

During the start-up of new tanks, and for scheduled testing and inspection, it may be necessary to usehot fresh water or salt water in the tank.





E PLENTY 2008

Because of the obvious corrosion related problems that will be created by this type of cleaning, it isimperative that the mixer parts in contact with the tank contents (mixer shaft, mechanical seal,mechanical seal housing, mounting flange, etc.) are protected by a suitable corrosion inhibiting oil. Thisshould be done immediately after the tank cleaning process has been completed to prevent corrosionfrom forming on the mixer components that have been exposed.

To apply corrosion inhibiting oil, make sure that the tank liquid level is below the mixer shaft, thenremove the Mechanical Seal air release valve (54). Using this connection, apply the rust inhibiting oil

into the mechanical seal and shut-off chamber, allowing the oil to flush forward along the shaft throughthe shut-off faces, and into the tank away from the mechanical seal. Remove the seal chamber drainplug (51) and apply a final flush of oil. Replace the air release valve (54) and drain plug (51), makingsure the air release valve is completely closed.

NOTE: If salt water was used during the tank cleaning, then a flush of fresh water should first be appliedthrough the air release valve (54) connection before applying corrosion inhibiting oil.

NOTE: It is advisable to run the mixer for 2 minutes after each flush, to achieve complete protection.

Recommended protective lubricants include:

ExxonMobil Mobilarma 247

Castrol Rustilo 4163

Shell Ensis 158

Other similar products can be recommended by a trusted lubricant supplier.

SECTION 6 – MIXER MAINTENANCE

Plenty Side Entry Mixers are designed for reliability and long service life. A good maintenance program canhelp ensure a long life.

A complete and effective maintenance program should include the following:

• Maintaining a safe work environment

• Regular inspections, in addition to a scheduled service plan

• Adherence to the installation instructions included in this manual

• Familiarity with the mixer

•

Mixer performance evaluation• Troubleshooting

6.1 Maintain A Safe Work Environment

ALWAYS DISCONNECT OR OTHERWISE LOCKOUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE ON THE MIXER.

Only properly trained personnel should perform maintenance on your Plenty mixer.

Wear proper clothing. NEVER wear neckties, loose sleeves, loose coats, etc. when working on or nearthe mixer. Gloves are recommended when handling the mechanical seal, drive belt, or any other mixercomponents that may be hot to the touch.

Keep the area around the mixer free of clutter, debris or any other obstruction. Maintain proper balanceat all times while performing any maintenance.

Ensure all drive guards are in place and secure before operating mixer (except when visual inspectionof drive belt under load is required – in those cases, DO NOT touch the belt while mixer is operating,and with the power turned off, replace and secure belt cover as soon as inspection is completed).

6.2 Routine Preventative Maintenance (does not require mixer shutdown)

Look and listen for any unusual vibration or noise. Plenty Side Entry Mixers are designed to operatesmoothly and quietly, typically no more than 85db(A) at 1 meter from the mixer. Excessive noise orvibration can be caused by any number of factors. Refer to the Troubleshooting Guide in Section 13 ofthese instructions.





E PLENTY 2008

Inspect the pulleys for damage or excessive wear. Measure the pulley diameter at several locations todetermine amount of wear. Inconsistent wear is an indication of misalignment or incorrect belt tension. Ifpulley is damaged or shows signs of excessive wear, it should be replaced.

If the pulleys are found to be in good condition, a new drive belt can be installed.

IMPORTANT: Never force the belt over the pulley, as this will damage both the drive belt and thepulley.

Seat the drive belt in the pulleys, and take up the slack by tightening the motor mounting plate adjustingnuts (28) evenly, until the correct operating pulley center distance is obtained.

Check the alignment of the drive and driven pulleys by placing a straightedge of the proper length onthe face of the both the drive and driven pulley. Any misalignment between the pulleys will show as agap between the straightedge and pulley face. Also check spacing between drive belt (104) and guardspacers (121) to be sure that there is no interference.

Check the belt tension. Too little tension can cause the belt to slip, while too much tension can result inmotor or bearing overheating. It is recommended that a belt tension tester be used to check belttension (tension tester is available from the belt manufacturer). Figure 5 and table below showrecommended deflection values. Values are based on 1800 RPM motor @ 60 Hz.

SPAN

Figure 5 - Belt Deflection

DEFLECTION

Mixer ShaftSize (mm)

MotorH.P.

Span(in.)

Belt Deflection(in.)

Belt DeflectionForce (lbs.)

45

3 11.85 0.178 20

5 11.85 0.178 207.5 11.85 0.178 20

10 11.85 0.178 20

15 11.85 0.178 20

60

15 20.54 0.308 22

20 20.54 0.308 22

25 20.54 0.308 22

30 20.54 0.308 22

70

30 32.80 0.492 34

40 23.82 0.357 37

50 24.04 0.361 37

8560 26.77 0.401 56

75 26.54 0.398 56

Once tension and alignment are correct, tighten the motor mounting plate adjusting nuts (28) to thevalue listed in Section 12 of these instructions.

Reinstall belt guard (117) baseplate. Check to make sure that there is a uniform gap between the motorshaft and the opening in the baseplate. Install cap screws (118) and washers (119) and tightensecurely.





E PLENTY 2008

Start the mixer and observe the belt. Look and listen for any unusual vibration or noise. Check forclearance between the belt (104) and the guard spacers (121). Stop the mixer and again check belttension. Also check the temperature of the motor bearing end cover. If the temperature seemsexcessive, the belt tension or pulley alignment may be incorrect. Re-check these measurements asnecessary.

Once any adjustments are completed, install the belt guard (117) cover by installing the nuts (122) andwashers (123) on the guard spacers (121).

Check the belt tension at least two times during the first day’s operation as there will normally be a rapiddecrease in belt tension until the belt has run in.

6.5 Bearings

All mixer bearings are rated for a minimum of 50,000 hours life. However, if it is suspected that thebearings have become worn or damaged prior to the replacement interval, they should be replaced andthe underlying cause of the failure or damage should be identified and corrected. Refer to theTroubleshooting guide in Section 13 of these instructions for possible causes. Replacement of thebearings is outlined in Section 8 of these instructions.

6.6 Mechanical Seal

The Mechanical Seal should be checked for wear every 10,000 hours. However, if it is suspected thatthe seal has become worn or damaged prior to this interval, it should be replaced and the underlying

cause of the failure or damage should be identified and corrected. Refer to the Troubleshooting guide inSection 13 of these instructions for possible causes. Replacement of the seal is outlined in Section 8 ofthese instructions.

SECTION 7 – OPERATION OF SHUT-OFF

7.1 Removal of Drive Assembly

Figure 6 - Drive Removal

122

123

28

1096

117

110

119 118104

ALWAYS DISCONNECT OR OTHERWISE LOCKOUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE ON THE MIXER.

Remove the belt guard (117) cover by removing the nuts (122) and washers (123) from the guardspacers (121). Loosen the belt guard baseplate by removing the cap screws (118) and washers (119).Loosen the motor mounting plate adjusting nuts (28) evenly in order to maintain the alignment of the





E PLENTY 2008

IMPORTANT: If product flow is observed, and continues for several minutes, the shut-off procedurewas not successfully completed. Reverse above steps to re-open taper, then repeat shut-off procedure.

When no flow of product is observed at the air release valve, tank shut-off has been completed, and thebearings and/or mechanical seal can be serviced.

SECTION 8 – BEARING AND MECHANICAL SEAL REMOVAL

8.1 Bearing Housing Removal

22

Figure 8b - Inboard Bearing Housing

20

21

1 1

148

7

926

Figure 8a - Outboard Bearing Housing

Remove locknut (7), which has a left handed thread, and cap screws (9 & 26), and remove the outboardbearing housing (8) from the mixer frame (1). NOTE: Cap screws (26) can be utilized as jacking screwsin the threaded holes provided in the bearing housing (8).

Remove shaft spacer (14), which is marked “A” on its outer diameter.

IMPORTANT: Retain shaft spacer (14) in a safe place for use when reassembling. The width of thisspacer is set at the factory to achieve the correct running clearance between the shut-off device tapers.

Do not use any other width spacer.

Remove cap screws (20) and washers (21) from the inboard bearing housing (22), and insert them inthe jacking holes provided on the rear of the bearing housing. Use these screws to separate the bearinghousing (22) from the mixer frame (1). Note that the bearing will travel a short distance to a step in theshaft. Once the bearing is beyond the step, it will be free to be removed.

8.2 Bearing Replacement

22

Figure 9b - Inboard BearingFigure 9a - Outboard Bearing

19 181312101110 8





E PLENTY 2008

The bearings can now be replaced. It is recommended that this procedure be carried out in a cleanwork area.

Remove cap screws (13) and bearing clamp ring (12) from the outboard bearing housing (8). Removethe bearing (10), bearing spacer ring (11, stamped “B” on its outer diameter) and second bearing (10).

IMPORTANT: Retain bearing spacer (11) in a safe place for use when reassembling. Do not confusethis spacer with the shaft spacer (14). This spacer is designed only for bearing spacing.

Remove the circlip (19) from the inboard bearing housing (22) and remove the bearing (18).

Using new bearings, reassemble the bearings into their respective housings by reversing the abovesteps.

IMPORTANT: Bearing spacer ring (11) MUST be replaced in its original position.

8.3 Mechanical Seal Removal

Figure 10 - Mechanical Seal

62636566

56555450

2

Make sure that the mixer shaft (2) is clean and free of burrs.

Remove O-ring (50) by CAREFULLY sliding along shaft.

Remove air release valve (54) from seal cover (65).

CAREFULLY remove hex head bolts (63). NOTE: The springs in the seal create an outward force, andtherefore, the seal cover (65) must be slowly released to avoid damaging seal components.

The seal cover (65) including the back-up seal (66), O-ring (55) and mechanical seal stationary sealingface can now be removed by sliding along mixer shaft.

Remove the mechanical seal (62).

8.4 Mechanical Seal Re-assembly

Preparation For Assembly:

Clean all parts thoroughly.

Inspect all parts for damage to mating faces and rabbets.

Inspect mixer shaft and housing bores for dents, gouges or scoring.

Repair or replace any defective parts. It is good practice to replace any O-ring that has beenremoved.





E PLENTY 2008

Precautions Prior to Installation of Mechanical Seal

It cannot be emphasized too strongly that the greatest care must be exercised in the installation of amechanical seal. The efficiency of the seal depends on the degree of surface finish of the lappedsurfaces and proper alignment. The slightest foreign matter or any scratches will create sufficientsurface irregularities to permit leakage. Sharp blows, tapping or other impacts on the sealing facesare to be avoided.

Select a clean work area for seal assembly. Place all of the parts on a piece of coated wrappingpaper or other clean smooth surface. NEVER place lapped surfaces face downward and keep themcovered at all times to prevent dust particles and other matter from contacting the surface.

Before replacing the seal assembly, polish any rough edges on the shaft (2) over which the sealassembly will slide. Lubricate the internal bore of the mechanical seal (62) with a light coat ofpetroleum grease.

6563

50

66

Figure 11 - Mechanical Seal Assembly

STATIONARYSEALING

FACE

PIN

62

56 59

53

52 54 55

Install new back-up ring (66) in the seal cover (65).

CAREFULLY slide the mechanical seal (62) along the shaft, taking care not to damage the lapped sealface. Line up the drive pins in the mechanical seal with the holes in the shaft collar (59). Make sure thedrive pins seat in these holes, and the mechanical seal (62) is flush with the seal collar (59).

Lubricate the bore of the seal cover (65) and install a new pin sleeve (53), which was supplied with themechanical seal, over the drive pin (52).

Thoroughly clean the stationary sealing face. Lubricate the O-ring and CAREFULLY press thestationary sealing face into the seal cover (65), lining up the drive pin (52) with the slot in the stationarysealing face. Make sure the stationary sealing face is square with the seal cover bore, and firmlyseated.

Install a new O-ring (55) in the outside of the seal cover (65), and apply a light coat of petroleum grease

to this O-ring.CAREFULLY slide the seal cover (65) along the mixer shaft until it seats in the bore of the seal housing(56). Bolt the cover in position using cap screws (63), making sure that the connection for the airrelease valve (54) is pointing upward. The correct working length of the seal will be set when thehardware is properly tightened. Refer to the table below for reference working length.

NOTE: Due to the spring pressure of the mechanical seal (62), the cap screws (63) may be too short tostart into the threaded holes of the seal housing (56). In this case, use longer screws to draw the sealcover to a point where the correct cap screws (63) can be installed.





E PLENTY 2008

Slide a new O-ring (50) over the shaft, and locate directly behind the seal cover (65). This O-ring actsas a slinger, forcing any potential product leakage away from the mixer bearings.

8.5 Bearing Housing Re-Assembly

18

19

Figure 12a - Outboard Bearing Housing

22

Figure 12b - Inboard Bearing Housing

20

21

148

926

12

13

11

10

Slide the inboard bearing housing assembly (18, 19 & 22) into position and secure with cap screws (20)and washers (21).

Slide the bearing spacer (14, marked with “A” on the outside diameter) onto the shaft until it seatsagainst the shaft shoulder.

CAUTION: Make sure that ONLY the spacer (14) is fitted at this point. This spacer width has been setat the factory to match the shaft and other major components. The use of any other spacer will result inincorrect mixer shut-off taper running clearance, and could present a significant ignition hazard.

Replace the outboard bearing housing assembly (8, 10, 11, 12 & 13) and secure with cap screws (9 &26).

8.6 Completing Re-Assembly

61 57a57b

61

Figure 13 - Mechanical Seal

57b615657

6157b57a

Loosen the two seal change jacking screws (57a) until only two or three threads remain engaged in thetapped holes.





E PLENTY 2008

Evenly tighten the cap screws (57b) ½ to 1 turn to slowly pull the seal housing (56) outboard, therebydisengaging the shut-off tapers. Continue to evenly tighten the cap screws until the face to the sealhousing (56) contacts the bottom of the shoulder screw (61) head. Check that there is no leakage fromthe seal assembly.

2

Figure 14 - Final Assembly

76

109110

1410

Apply a small quantity of Loctite 241 or equivalent to the threads of the locknut (7). Thread the locknut(7) onto the mixer shaft (2), using it to draw the shaft away from the tank, until the bearing spacer (14) isfirmly clamped between the bearing (10) and the shaft shoulder. Keep in mind that the locknut (7) has aleft handed thread.

Install the drive key (6) in the mixer shaft (2) keyway.

Insert the taper lock bushing (110) into the driven pulley (109), lining up the non-threaded holes in thebushing with the tapped holes in the pulley.

Slide the driven pulley onto the mixer shaft, making sure that the teeth on the pulley are facing the samedirection as the teeth on the drive pulley. Align the pulley faces with a suitable length straight edge asoutlined in Paragraph 6.4.

Install cap screws in the pulley tapped holes, and the set screw over the key. Tighten hardware totorque listed below.

Refer to Paragraph 6.4 for drive belt installation.

TAPERLOCK BUSHING (106 & 110) HARDWARE TORQUE

Bushing Type Cap Screw Torque (ft-lb) Set Screw Torque (in-lb)

H 8 ----

SK 15 87SF 30 165

E 60 290

F 75 290

J 135 290

M 225 290





E PLENTY 2008

SECTION 9 – MIXER SHAFT REPLACEMENT

The replacement of the mixer shaft is not regarded as a common requirement of maintenance, but it may benecessary to replace the shaft in the event of damage or severe corrosion.

It is absolutely essential that whenever a new mixer shaft (2) is installed, a new inboard bearing spacer (14,stamped “A” on its outer diameter) must also be installed. The width of the bearing spacer must be correctlycalculated to allow a minimum of 0.118” [3mm] axial running clearance between the shaft & mounting flange

shut-off tapers. The procedure for calculating this width follows below. The procedure assumes that themixer has been disassembled and the shaft placed in the shut-off position as outlined in Section 7 of theseinstructions.

9.1 Bearing Spacer Width Calculation Procedure

Figure 15b - Dimension "B"

1

"B"

"A"

STRAIGHTEDGE

2

10

8

Figure 15a - Dimension "A"

Using a straight edge held against the rear face of the mixer frame (1), measure the distance from thisface to the shaft shoulder as shown in Figure 15a. Record this dimension as “A”.

Using a straight edge held across the inner face of the outboard bearing (10), measure the distancefrom this face to the bolting face of the outboard bearing housing (8) as shown in Figure 15b. Recordthis dimension as “B”.

The required width (dimension “C”) of the bearing spacer (14) is determined by subtracting dimension“B” from dimension “A”, then subtracting an additional 0.118” [3mm]. This additional amount is required

to ensure that when the mixer is reassembled, and the mixer shaft is returned to its operating position,that there will be the required running clearance between the mating shut-off tapers.

Bearing spacer (14) width: C = A – B – 0.118”

"C"

148

Figure 16 - Dimension "C"





E PLENTY 2008

SECTION 10 – SOLOSELE REMOVAL & REPLACEMENT (MODEL STM)

With the mixer removed from the tank and safely supported on its skid channel or other suitably stable andsafe supporting structure:

SWIVEL ANGLE ADJUSTMENT SCREWS

95

SET TO ± 30° AT FACTORY

93 94

3

5

4

125

2

88

81

8584

90

86

89

74

92

8180

7978

83

86

8584

82

727371 75

80

87

91

150

Figure 17 - Swivel/Solosele Assembly





E PLENTY 2008

74

Al ternate Swivel Bal l Arrangement

75 GASKET

70 FLANGE

71 BEDPAN

72 SWIVEL BALL

Remove the propeller retaining screw (4), propeller cone (5), propeller (125) and key (3).

Loosen and remove the six Solosele gland fasteners (79, 80 & 81).

Remove the Solosele gland plate (78) and Solosele elastomer (83), allowing these to rest upon theneck of the swivel ball (72).

Completely disengage the swivel adjustment bar from the clamping bracket (93) by loosening theclamping screw/Tommy bar (94).

Remove the two hinge pin circlips (85) from the lower hinge pin (84), and remove the hinge pin.

Ensure that the manhole/nozzle adapter (99) is supported to prevent it from dropping away from theswivel pan (71), which could result in damage or personal injury. Remove the two hinge pin circlips (85)from the upper hinge pin (84), and remove the hinge pin.

Examine the condition of the thrust washers (82) and thrust bushings (86). Replace if necessary.

With the manway/nozzle removed, the Solosele can be removed.

Wipe the outside surface of the swivel ball clean, removing any grit, accumulated dirt and grease.Smear a film of light lubricating oil or grease around the inner bore of the Solosele, and slip it over theswivel ball (72) and rest it on the neck of the swivel ball.

Replace the manway/nozzle, and reassemble the Solosele and gland plate by reversing procedureoutlined above.

NOTE: The six Solosele gland fasteners (79, 80 & 81) should only be initially hand tightened.

Reinstall the key (3), propeller (125), propeller cone (5) and propeller retaining screw (4). Beforeinstalling propeller, make sure shaft taper and mating propeller bore taper are clean and free from burrs.Tighten propeller retaining screw to value listed in Section 12 of these instructions.





E PLENTY 2008

Lubrication – Prior to shipment, motor bearings are greased with the proper amount and grade oflubricant by the motor manufacturer. Motors equipped with sealed bearings require no additionallubrication. Motors equipped with open or shielded bearings require lubrication periodically. It isrecommended that the bearing lubricant be inspected at the end of every 2 – 3 months to determinethe necessity of adding grease. Frequency of re-lubrication will vary with the particular application, andcan be determined with periodic inspection. The following table offers suggested re-lubricationfrequency based on general operating conditions.

Type of Service General Conditions HP Range Re-Lubr ication Frequency

StandardEight hours per day, normal orlight loading, clean, 100degrees F ambient

3-7 ½

10-40

50-75

3 years

1 year

6 months

Severe

Twenty four hours per dayoperation or shock loading,vibration or in dirt or dust @100-120 degrees F ambient

3-7 ½

10-40

50-75

1 ½ years

6 months

3 months

Very SevereHeavy shock or vibration, dirtor dust, high ambienttemperature

3-7 ½

10-40

50-75

6 months

3 months

1 month

All motors over 1800 RPM should be checked for re-lubrication at three month intervals.

IMPORTANT: The greatest cause of bearing failure is over greasing rather than under greasing.

For best results, grease should be compounded from a lithium soap base and a good grade ofpetroleum oil. It should be of No. 2 consistency and stabilized against oxidation. Most leading oilcompanies have special bearing greases that are satisfactory.

Lubrication Procedure:

For motors equipped with grease fittings or plugs:

Motor should be warm and disconnected from power source.

Clean the exterior of the motor.

Remove all pipe plugs and relief plugs. For some TEFC motors, it may be necessary to removecaps on the fan cover and hexagonal rod through fan cover to gain access to grease plugs andrelief plugs.

Using a low pressure, hand operated grease gun, pump in clean grease until it appears at therelief hole or along the motor shaft.

Run the motor with the plugs removed for approximately two hours.

Stop the motor and wipe away grease at relief or along shaft and replace all plugs.

Motors not having pipe plugs or grease fittings in bearing housings can be re-lubricated by removingend shields from motor, cleaning grease cavities, and refilling cavities to capacity with new grease.

IMPORTANT: Bearings and grease must be kept free of dirt.

Oil lubricated (sleeve bearing equipped) motors should be re-lubricated after 3 years of normalservice or 1 year of heavy duty service. Electric Motor or SAE 20 oil should be used.

For more specific maintenance and lubrication instructions, contact your local motor manufacturers’representative.

11.3 Storage

Electric motors and other prime movers are not prepared by the factory for indoor storage beyond 12months in a dry ambient atmosphere with controlled temperatures, or 6 months in a dry ambientatmosphere without temperature control. OUTDOOR STORAGE OF ELECTRIC MOTORS IS NOTRECOMMENDED BY ANY MOTOR MANUFACTURER. For information on storage periods beyondthose listed, contact the motor manufacturer.





E PLENTY 2008

SECTION 12 – RECOMMENDED TIGHTENING TORQUES

Inadequately or improperly tightened hardware can loosen due to vibration or the load reactions imposed byfluid forces. This can result in reduced equipment service life, or damage and failure.

Recommended torques for tightening bolts and screws on Plenty Side Entry Mixers and their mountingstructures are listed below for your general reference. These average torque values should be consideredonly as guides and not as absolute values.

The amount of torque required to maintain a tight connection can vary considerably for bolts of the samesize under different operating conditions. Variations such as basic joint design, compression factors, typeand strength of base and hardware material, surface finish of mating parts and lubrication are only some ofthe factors that influence the tightness of bolted connections for given torque values.

UNLESS SPECIFICALLY LISTED ELSEWHERE IN THE DETAILED INSTRUCTIONS, TIGHTEN THEMIXER AND MOUNTING HARDWARE TO THE RECOMMENDED VALUES SHOWN.

For severe duty service, torques higher than listed, to tighten a bolt to maximum capacity, can often beused. However, due to the many variables previously mentioned, the only absolute method to determineoptimum torque is to deliberately yield a bolt under actual conditions. If a bolt does yield or shear, 75% of thetorque applied in yielding the bolt can be used to obtain a tight connection that is satisfactory.

ALL HARDWARE SHOULD BE RETIGHTENED 12 HOURS AFTER ASSEMBLY, AND AT EVERYSCHEDULED SHUT DOWN THEREAFTER.

RECOMMENDED TIGHTENING TORQUES

BOLT THREAD SIZE

HEX HEAD SCREWS

GRADE 8.8

SOCKET HEAD SET &CAP SCREWS

GRADE 12.9

FLANGE STUDS

GRADE 4.8

TIGHTENING TORQUE IN FT-LBS

M6 7 12 -----

M8 17 28 -----

M10 34 56 -----

M12 59 98 -----

M16 146 243 -----M20 284 473 181

M22 386 ----- 246

M24 491 818 -----

Plenty Mixer General Instructions

Documents

Transcript of Plenty Mixer General Instructions