BTN Agitators Installation, Operation Maintenance Manual: Equipment Reference
BTN Agitators Installation, Operation Maintenance Manual: Equipment Reference
BTN Agitators
Installation, Operation
Maintenance Manual
Equipment Reference:
BTN Style Agitator
MODEL:
UNIT SERIAL #:
EQUIPMENT TAG #:
P.O. #:
TABLE OF CONTENTS
Page
Initial Inspection 1
Chemineer Assistance 1
Storage 2
Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lubrication 10
Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lubricated Mechanical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation 14
Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance 16
Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Agitator Drive Removal and Mechanical Seal Maintenance . . . . . 17
Mechanical Seal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Vendor Data
Gear Drive
TABLE OF CONTENTS
Page
Tables
Figures
INITIAL INSPECTION
Step 1: Inspect crates. Upon receipt, inspect all crates and equipment for shipping damage. Report
shipping damage to your local Chemineer office or to the factory in Dayton, Ohio. A claim should be
filed immediately with the carrier involved.
Step 2: Uncrate. Check the contents. Do not uncrate the unit until you have read the Mounting &
Installation section of this manual and looked at the assembly drawing shipped with the unit. Be
careful in uncrating and handling. Do not discard the crating without making sure that all agitator parts
have been removed. Correct assembly of this unit requires referring to both the unit assembly drawing
and this manual.
Step 3: Questions? Call Chemineer. If the shipment is not complete or you do not understand what
you have received, please contact your local Chemineer office immediately.
CHEMINEER ASSISTANCE
Chemineer maintains a fully staffed Parts and Field Service Department ready to help you with any
service requirement. Simply contact your local Chemineer office, or contact Parts/Field Service at the
Chemineer Factory in Dayton, Ohio:
Chemineer, Inc.
P.O. Box 1123
Dayton, Ohio 45401
Phone: (937) 454-3200
FAX: (937) 454-3375
STORAGE
Do not remove protective packaging, desiccant, or any protective coverings applied to the wetted parts
until the agitator is to be put into service. If the equipment is to be stored, do not stack crates. Store
in a clean dry indoor location which is free from wide variations in temperature. The storage area
should be free from vibration and excessive heat.
Inspect for external rust at six-month intervals. Apply rust preventative as required. If the unit has been
in storage for more than six months or subjected to adverse moisture conditions, the motor windings
may have to be dried prior to operation.
Agitators should be stored indoors in areas with no vibration and relatively constant temperatures and
humidity. The factory storage preparations should be acceptable for up to six months storage.
Rotate the motor and gear drive shafts 10 to 15 revolutions at least once per month to reduce the
possibility of brinelling of the bearings and to redistribute bearing grease.
AGITATOR INSTALLATION
Bolt unit securely to mounting nozzle. Mounting fasteners and flange-to-vessel seal are not supplied
with agitator. Total weight is shown on assembly drawing. Support structure must be rigid enough to
prevent deflection and vibration. If required, install impellers as shown on assembly drawings.
Impellers should be installed with the flat or concave side of the blades away from the gear reducer.
Special Case, Angle Mounted Units: The BTN agitator may be angle mounted. Position unit as
shown in Figure 1 to properly provide optimum mixing results. CAUTION: Angle mounted units
must be supported vertically during shaft, seal and bearing installation.
AGITATOR INSTALLATION
Correct installation requires the unit assembly drawing, seal assembly drawing and this manual. Also
refer to Figure 2, page 5. Completely read and understand all of the following instructions before
attempting to install or service this equipment.
1. The agitator unit is usually shipped fully assembled. Occasionally units are not shipped from the
factory assembled. In these instances, refer directly to Agitator Drive Assembly and
Mechanical Seal Installation, page 6 for full assembly/mounting instructions.
Agitator installation consists of mounting the unit onto the vessel and making the necessary coolant-
lubricant connections, if required. Locate all contents before discarding crating materials.
NOTE: In order to properly align and mount the unit, the unit must be oriented so that
the shaft is vertical. Do not attempt to support the shaft using the setscrews in the
bearing or seal rotary part.
2. Remove all shipping constraints and any protective covering on the mounting flange face.
A lifting mechanism for the agitator may be helpful. Please note the approximate net weight of
the unit as shown on the assembly drawing and use caution when moving or lifting these items.
Special care should be exercised in mounting the unit to avoid damage to the seal
components. Any type of shock or impact should be avoided as the carbon seal element
is easily damaged. NEVER lift the agitator using the extension shaft as a lift point.
3. Set the proper mounting flange seal (gasket or o-ring supplied by customer unless specially
noted) on the vessel flange and protect it from damage.
4. Carefully lower the agitator assembly into the vessel. Properly align the agitator flange to vessel
flange and install the flange to vessel hardware (customer supplied). Torque bolts to the value
shown in Table 1, page 8.
5. This step only applicable if mechanical seal is lubricated -- dry-running seals never
require lubrication. Connect seal fluid lines and fill the seal lubricator and seal housing with
seal fluid. Pressurize the seal lubricator to 20 psi (138 kPa) above the maximum vessel
operating pressure. Refer to unit assembly drawing for operating pressures. Refer to
Lubrication, Lubricated Mechanical Seals for specific lubrication information.
CAUTION! Never pressurize the vessel without first pressurizing the seal cavity (seal
lubricator).
AGITATOR INSTALLATION
This section applies to any unit not fully assembled from the factory.
NOTE: In order to properly align the unit, it must be oriented so that the shaft is vertical.
Do not attempt to support the shaft using the setscrews in the bearing or seal rotary part.
1. Remove all shipping constraints and any protective covering on the mounting flange face.
A lifting mechanism for the agitator may be helpful. Please note the approximate net weight of the
unit as shown on the assembly drawing and use caution when moving or lifting these items.
Special care should be exercised in mounting the unit to avoid damage to the seal
components or shaft. Any type of shock or impact should be avoided as the carbon seal
element is easily damaged. NEVER lift the agitator using the extension shaft as a lift point.
2. Lower shaft through vessel nozzle into tank and support with approximately 8 inches of shaft
extending above the vessel flange.
3. Clean the exposed surface of the extension shaft. Verify that the upper seat and o-ring are in the
seal housing and the lower seat is in the agitator mounting flange. Refer to the unit mechanical seal
assembly drawing or Figure 3, page 18.
Special care should be exercised in mounting the unit to avoid damage to the seal
components. Any type of shock or impact should be avoided as the carbon seal element is
easily damaged.
4. Set the proper mounting flange seal (gasket or o-ring supplied by customer unless specially noted)
on the vessel flange and protect it from damage.
5. Carefully lower the agitator assembly into the vessel. Properly align the agitator flange to vessel
flange and install the flange to vessel hardware (customer supplied). If angle mounted, make sure
the unit is properly oriented as shown in Figure 1 on Page 3. Torque bolts to the value shown
in Table 1, page 8.
6. Properly orient the seal heads and slide them over the shaft end and against the lower seal seat.
Carefully place the seal housing over the exposed seal heads. Do not bolt the housing to flange.
7. Install the snap ring over the shaft. Carefully raise the shaft enough to insert it into the sleeve
coupling and install the snap ring into the top of the groove above the seal housing.
9. Move the snap ring toward the top of the shaft and raise the seal housing to access and adjust the
seal heads.
10. Set the inboard seal head at the dimension shown on the unit mechanical seal assembly drawing.
Place the outboard seal head “back to back” with the inboard seal head.
11. Lower the seal housing and carefully cross-tighten the bolts that secure the housing to the mounting
flange. Torque to the value shown in Table 1, page 8.
12. Tighten the set screws on the seal bearing and install the snap ring.
13. This step only applicable if mechanical seal is lubricated -- dry-running seals never require
lubrication. Connect seal fluid lines and fill the seal lubricator and seal housing with seal fluid.
Pressurize the seal lubricator to 20 psi (138 kPa) above the maximum vessel operating pressure.
Refer to unit assembly drawing for operating pressures. Refer to Lubrication, Lubricated
Mechanical Seals for specific lubrication information.
CAUTION! Never pressurize the vessel without first pressurizing the seal cavity (seal lubricator).
AGITATOR
3/8 - 16 15 20 23 31 15 20
1/2 - 13 38 51 56 76 38 51
Tighten all fasteners to values shown unless specifically instructed to do otherwise. Lubricate all
fasteners at assembly with grease, oil or an anti-seize material. Bolt threads and contact surfaces of
bolt heads and nuts should be lubricated.
(1)
If fasteners cannot be lubricated, multiply table values by 1.33.
(2)
If fasteners cannot be lubricated, multiply table values by 1.25.
MOTOR
1. Check the nameplate data on the motor to assure that the available power supply agrees with
the motor requirements. Protective devices should be of the proper size and rating to safely
carry the load and interrupt the circuit on overloads.
2. If motor has been stored in a damp location, the windings may require drying.
NOTE: Do not obstruct the normal flow of ventilating air through or over the motor.
3. Connect the motor in accordance with the National Electric Code and local requirements, but
do not make the connections permanent until the motor rotation has been checked.
Identify motor auxiliary devices such as space heaters or temperature sensors. Connect them in
proper circuits and insulate them from motor power cables.
4. Jog the motor to check for correct rotation prior to securing wiring. Refer to unit assembly
drawing for unit rotation direction.
LUBRICATION
This section defines the proper oils and greases that must be used with this equipment.
GEAR DRIVE
The gear drive on this agitator has been charged at the factory with a special lubricant which need not
be changed for the life of the unit. If grease is ever added, use Mobilux® EP023 or equivalent. Refer
to Vendor Data at the end of this manual for specific gear drive information.
MOTOR
The motor bearings have been properly greased by the manufacturer. Motor bearings should be
regreased at 12-month intervals when installed in clean, dry environments, or every six months for
heavy duty and dusty locations. Any good quality general purpose grease consisting of a refined base
oil stock and a lithium or calcium-complex based soap, with an NLGI No. 2 classification, will work
satisfactorily. Most major oil companies offer such products, usually with extreme pressure (EP)
additives for additional protection. Table 3, page 11 lists some commonly available greases.
When regreasing, stop the motor, remove the outlet plug and add grease according to Table 2 with a
hand lever gun only. Run the motor for about ten minutes before replacing the outlet plug. Certain
TEFC motors have a spring relief outlet fitting on the fan end. If the outlet plug is not accessible at the
surface of the hood, it is the spring relief type and need not be removed when regreasing.
56C sealed for life sealed for life sealed for life
MOTOR
Amoco Oil Co. Amolith grease: Grade 2 Amolith grease: Grade 2EP
EP Lithium #2
Alvania grease EP LF 2
MOTOR
The following table may be used as a guide in determining frequency of lubrication. The periods listed
assume a clean, dry environment with a temperature not exceeding 150oF (66oC). If conditions are less
desirable than this, adjust the frequency accordingly. (Table 4 is for motor speeds 1800 RPM or
slower).
Intermittent 36
8-16 Hours/Day 30
Continuous 24
This section DOES NOT apply to dry-running mechanical seals. Do not lubricate the seal faces
of dry-running seals.
Double mechanical seals must be supplied with adequate lubricant in order to operate properly. The
lubricant can be any low viscosity fluid with reasonable lubricity, compatible with the process fluid, and
stable over the full range of pressures and temperatures at which the mechanical seal will be operated.
Common liquid lubricants (barrier fluids) include glycerine, ethylene glycol, mineral oil and water.
Operating temperature limits for these lubricants are listed in Table 5 below. Refer to unit assembly
drawings for specific agitator/seal pressure and temperature operating limits. Consult Chemineer Field
Service for other lubricants.
o o
F C
The specific gravity of any liquid lubricant should never be less than .63 at a reference temperature
50oF or 28oC above the maximum vessel temperature. The boiling (flash) point of a lubricant should
never be less than 25oF or 14oC above maximum vessel operating temperature. The standard seal
housing operating pressure is 20 psi (138 kPa) above the maximum vessel operating pressure.
The BTN mechanical seal housing includes an integral bearing which maintains proper seal alignment.
This bearing is grease lubricated. The bearing should be regreased at one month intervals. Add new
grease slowly at the grease fitting until new grease is evident around the bearing. Typical greases are as
shown in Table 3, page 11.
AGITATOR
Your Chemineer agitator has been designed for your specific application. Proper operating procedures
will allow maximum performance. The following list will aid in the safe operation of your unit.
! Do not operate the unit before reading and following the instructions on all tags and nameplates
attached to the unit.
! Do not operate the unit with less than one impeller’s diameter liquid coverage above the lowest
impeller. Increased side loading caused by operations at liquid level will decrease unit life.
! Do not operate the unit in a fluid with a specific gravity or viscosity higher than that for which
the unit was designed.
! Do not attempt to start a unit with the mixing impeller buried in solids or a "set up" fluid.
! Do not operate mechanical shaft seals at temperatures or pressures higher than those for which
the unit was designed. Refer to unit assembly drawing.
! Do not locate large pump discharges, other agitators, down comers, coils, baffles, or other
vessel internals close to the agitator impellers and extension shaft.
! Do not make any changes in the field (i.e. motor horsepower, agitator speed, shaft length,
impeller diameter, impeller blade width, etc.) without reviewing the change with your local
Chemineer office or Chemineer Field Service.
For variable speed units, the liquid level may be allowed to pass through the impeller zone on filling or
draining by operating at a reduced speed. Prolonged operation with the liquid level at the impeller
location should be avoided at any operating speed as the side forces on the impeller will decrease
machine life.
CAUTION: There may be a speed range where the unit cannot be operated because of shaft resonant
frequency. This range must be avoided or passed through quickly or destructive forces can be
generated. Refer to main unit assembly drawing for speed range information or consult the Chemineer
Factory.
Should there be problems operating the unit, confirm that the installation is correct. If you are unable to
resolve the problem, contact your local Chemineer office.
MOTOR
Electric motors furnished on Chemineer BTN agitators are designed to deliver their rated output
when properly installed and maintained.
Air circulation is very important to get full performance and long life from an electric motor. Do not
block the suction inlets on fan cooled motors. Life of the motor will be decreased if its temperature
exceeds its thermal rating. The allowable temperature is stamped on the motor nameplate.
! Check nameplate data on motor to assure that the available power supply agrees with the
motor requirements. Protective devices should be the proper size and rating to safely carry the
load and to interrupt the circuit on overloads.
! Check motor leads with connection diagrams on motor nameplate and/or conduit box so that
the proper connections are made. All motors should be installed in accordance with the
National Electric Code and local requirements.
! Check the gear drive output shaft rotation against the proper rotation indicated on the assembly
drawing. BTN units may run in reverse unless otherwise noted on the assembly drawing. For
standard three-phase electric motors, the rotation is reversed by switching any two power
leads.
The motor should start quickly and run smoothly. If the motor should fail to start or make abnormal
noise, immediately shut motor off, disconnect it from the power supply, and investigate the cause. If the
problem cannot be corrected, contact your local Chemineer office for assistance.
GEAR DRIVE
The gear drive on this agitator has been charged at the factory with a special lubricant which need not
be changed for the life of the unit. Should any problem arise involving damage to the gear drive,
replace the reducer in its entirety.
Tighten the bolts at the motor to the gear drive and the gear drive to the pedestal. Torque to the values
shown in Table 1, page 8.
The motor shaft fits into a quill in the gear drive. There is no flexible coupling. There is a key to
transmit the motor torque.
The output shaft on the gear drive is fitted with a split rigid sleeve coupling and is positioned so that the
shaft end is flush with the coupling horizontal split line. This positioning creates approximately 1/8"
(3.18mm) gap between the gear drive output shaft and the agitator shaft.
Refer to both the main unit assembly drawing and the mechanical seal assembly drawing for this section.
3. Lock out and disconnect all power to the gear drive motor and optional devices.
NOTE: The unit must be oriented with the shaft vertical in order to change the seal.
DO NOT attempt to support the shaft using the setscrews in the bearing or shaft seal rotary
part.
4. Depressurize and ventilate the vessel. Disconnect seal fluid lines and cap to exclude dirt and
moisture. (Dry-running seals will not have fluid lines.)
6. Remove bolts holding agitator mounting flange to vessel nozzle. Lift unit away from the nozzle
sufficiently to allow the extension shaft to be blocked in place. Block extension shaft securely
under mounting flange face (without damaging flange face). Lower unit until shaft blocking rests
on vessel nozzle.
7. Remove bolts anchoring agitator pedestal to mounting flange. Loosen clamping bolts in lower
half of shaft sleeve coupling. The drive/pedestal assembly may now be removed from mounting
flange to a suitable service area. Ensure clamping bolts in lower half of sleeve coupling remain
with coupling.
8. The mounting flange, seal housing, and shaft should be remaining on top of vessel. Reference
Figure 3, page 18.
9. Remove snap ring above bearing. Loosen set screws in bearing inner race. Remove seal
housing to flange bolts. Clean shaft above the bearing with a crocus cloth and slide the seal
housing assembly off end of shaft. At this point, the upper seat and o-ring will remain inside the
seal housing, while the lower seat and both seal heads will remain on the shaft.
It is recommended that whenever the mechanical seal components are maintained, that the
flange is removed and the flange gasket replaced.
11. Refer to the above instructions in reverse order to re-assemble the mechanical seal and agitator
drive.