Contents. 1 Description of the Cryo-Lock system 2 General notes and safety instructions

Transcription

1 Contents Operating Instructions 1 Description of the system 2 General notes and safety instructions 2.1 General instructions 2.2 Instructions for accessing reactors 2.3 Safety instructions concerning the handling of liquid nitrogen 2.4 Compressed air connection for the air cushion 3 Storing the agitator parts 4 Required assembly and disassembly materials 4.1 Assembly material from Pfaudler 4.2 Operator s assembly material 5 Assembly/disassembly of an agitator shaft 5.1 Introducing the agitator shaft through the manhole opening of DIN reactors using the outlet nozzle 5.2 Introducing the agitator shaft through the agitator nozzle 5.3 Introducing the agitator shaft through the assembly hole of reactors type CE and reactors to Pfaudler factory standard type E 5.4 Removing an agitator shaft 6 General instructions concerning the assembly and disassembly of turbines 6.1 Nitrogen connection 6.2 Notes on shrink-fitting of turbines 6.3 Extended shaft for residual amounts 7 Assembly of single-step turbines 7.1 Assembly of a single-piece turbine for a single-step agitator using an air cushion 7.2 Assembly of a single-piece turbine for a single-step agitator using hoisting equipment 7.3 Assembly of a single-piece turbine for a single-step agitator using a wooden block 7.4 Assembly of a two-piece turbine for a single-step agitator using hoisting equipment 7.5 Assembly of a two-piece turbine for a single-step agitator using a wooden block 7.6 Assembly of a two-piece turbine for a single-step agitator using an air cushion 7.7 Disassembling a single-step agitator 7.8 Disassembling a single-step turbine 8 Assembly of a multi-step Cryo-Lock agitator 8.1 Preliminary work / tools 8.2 Assembly of the upper step 8.3 Assembly of the middle step 8.4 Assembly of the lower step 8.5 Disassembling a multi-step agitator 9 Assembly of single-/multi-step Cryo- Lock agitators in reactors type BE with a capacity of liters 9.1 General 9.2 Safe assembly of Cryo-Lock agitator in small reactors type BE 9.3 Safe disassembly of Cryo-Lock agitator in small reactors type BE 9.4 Assembly of multi-step agitators 10 Testing and maintenance of parts 11 Electrostatic charge 12 Documents quoted that are also applicable 13 Warranty and liability Annex 1: Cryo-Lock assembly tools Annex 2: Drawing of Cryo-Lock assembly in small reactors type BE Annex 3: EC Certificate of Conformity for Agitators e

2 1 Description of the system The joining technique is a process by which a turbine glasslined on all sides is shrunk onto the agitator shaft, with is equally glasslined on all sides. These agitators are used in glasslined reactors together with VS or VSO agitator drives. The cold-shrink connection is made and released inside the reactor. The temperature difference between the agitator shaft and the turbine required for the shrink-on process is obtained by cooling the agitator shaft with liquid nitrogen. Table 1 Overview of turbines Turbine type CBT CBR ANC 1 Designation Curved-blade turbine, single piece CBT for residual amounts, single piece Anchor-type agitator, single piece The small tolerances of the hub bore and the shaft, which are required for the shrink-on connection, are achieved by honing the contacting glass surfaces. The shrink-on connection is capable of transmitting a multiple of the gear torque produced while agitating yet can be released whenever necessary. Identical nominal diameters of the honed surfaces result in easy replacement of turbines and agitator shafts. ANC 2 TBF RCI FBT Anchor-type agitator, two-piece Turbofoil, two-piece Impeller, two-piece Flat-blade turbine, two-piece Available types include single- and twopiece units as well as single- and multistep agitators. A two-piece agitator is defined as a turbine on one level that has been assembled from two pieces. By contrast, multi-step agitators have several turbines at different levels on a joint shaft. PBT MXT Pitched-blade turbine, two-piece Maxflow turbine, two-piece Pfaudler offers a comprehensive range of standard turbines for virtually all applications. Besides, with the technology you can also optimize your agitating system for the respective specific application (also refer to our brochure 619, Processes in motion: Agitating and mixing with Pfaudler ). GST FBR MSG Turbine for mixing gases and fluids, two-piece Agitator blade for residual amounts to be combined with turbines producing an axial flow, single-piece (the figure shows an example of an application) Multi-step countercurrent agitator, suitable for homogenization and suspension MFI Multi Flight Impeller, multistep agitator system comprising different agitators (individual, process-dependent combination) 2 Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 2

3 Figure 1 Assembly of a single-step turbine 2 General notes and safety instructions 2.1 General instructions The agitators have been built according to the recognized rules of safety technology and comply with the state of the art. They may only be used for their intended purpose. The intended purpose also includes the observation of all instructions given in the Operating Instructions, and the performance of all inspections. The transport, installation, commissioning, operation and inspection of the agitators requires properly trained and instructed personnel, especially as regards the handling of nitrogen. Any person performing these works has to be trained for the basic rules of health and safety at work and accident prevention. They must have read and understood the safety sections and warnings contained in the Operating Instructions. Employees (operator s assembly personnel) must be regularly instructed on the hazards present and on the protective measures to be taken in accordance with Section 20 of the Hazardous Materials Ordinance, Operating Instructions, Section 2. For details, please refer to the Hazardous Materials Ordinance. Extracts: [ ] Workers who are assigned the task of handling hazardous substances shall be instructed concerning the possible hazards and the protective measures through the operating instructions. Workers capable of bearing children shall be additionally informed about the possible hazards and employment restrictions relating to expectant mothers. These instructions have to be provided prior to taking up employment and thereafter at least once per year verbally and specifically for the respective workplace. The contents and time of the instructions shall be recorded in writing and confirmed by the persons receiving the instructions by signing the records. The evidence of the instruction shall be kept for two years. [ ] Please also note the guidelines contained in the Safety and Health at Work Act (ArbSchG 6)! 2.2 Instructions for accessing reactors The turbine is fitted to and removed from the agitator shaft inside the very reactor, therefore, the reactor has to be accessed. The following should be noted before accessing the reactor: n Disconnect the motor. n The reactor must be empty, and access approval must have been given. n The reactor must be ventilated. n Obtain access permission. n Protect the manhole cover against unintentional closing. n Protect tools against falling down. n Observe all internal safety regulations of your company. n In particular, the provisions of the Working Substances Regulation must be observed. In order to avoid damages to the glass or scratches in the glass, special precautions are to be taken when entering the reactor: n Use suitable non-skid overshoes. n Protect the manhole with a rubber sleeve or plastic film before entering the reactor. n Cover the reactor bottom with a rubber mat. If a ladder is used, those parts of the ladder that touch the glass must be so designed as to avoid damaging the glass. Pfaudler Werke GmbH BA 373-4e 3 Pfaudler Werke GmbH OI e 3

4 2.3 Safety instructions concerning the handling of liquid nitrogen m For your own safety, you should observe the following rules when handling liquid nitrogen: n Wear closed safety goggles and insulating working gloves made of leather or thick textile fabric. n Skin contact with liquid nitrogen or cold nitrogen gas causes injuries similar to burns due to undercooling. n Good ventilation of the environment is essential. Anybody working with liquid nitrogen in a closed room may suffocate. Therefore, it is of vital importance to ensure the necessary fresh air circulation when working with liquid nitrogen inside a reactor (e. g. by extracting the nitrogen). Another option is to wear a self-contained breathing apparatus. n Nitrogen is heavier than air and accumulates in bottom areas, especially inside the reactor. Therefore, the oxygen concentration in the lower parts of the reactor and at the workplace outside the reactor must be continuously measured and monitored (also refer to Sect. 9). n Note the internal safety regulations regarding the use of liquid nitrogen. n The screwed unions and fittings along the entire lines must be absolutely leakage-proof. Always perform a visual inspection for leaks before introducing nitrogen. If possible, health and safety risks to the persons staying in the environment of a possible leak should be prevented by the proper routing of the lines. Do not use any leaking screwed unions or lines. We recommend testing nitrogen reservoirs and pipelines regularly or have them tested by the nitrogen supplier. Figure 2 Pfaudler air cushion For more important information concerning the handling of liquid nitrogen, please refer to the information sheets and the safety data sheet of your nitrogen supplier. In any case, the operator s safety instructions concerning the handling of nitrogen and liquid nitrogen must be strictly adhered to. 2.4 Compressed air connection for the air cushion m Only the air cushion available from Pfaudler and the related pressure reducing /safety station are permitted! For safety reasons, the air pressure permitted for the air cushion is limited to bar. For this reason, a hose must be used to connect the cushion to the pressure reducing /safety station which is to be set up outside the reactor. The operator of the compressed air station must have line-of-sight contact with the fitters inside the reactor! For reason of stability, do not join more than two air cushions using the velcro tapes provided otherwise, there is a risk of tilting! 3 Storing the agitator parts Upon arrival in the factory and prior to unloading, the agitator parts must be carefully checked for transport damages. All transport damages, if any, shall be immediately notified to and confirmed by the shipping company. We recommend storing the agitators in their original packaging in a closed room or at least in a roofed location. In any case, it must be ensured that the bare metallic shaft end of the agitator shaft has been provided with a rust-proofing agent, and that plugs have been fitted to the openings at the end of the shaft. 4 Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 4

5 4 Required assembly and disassembly materials 4.1 Assembly material from Pfaudler The tools and aids required for the assembly and disassembly of the agitator are available from Pfaudler as a tool kit. For a list of parts contained in the kit, refer to Annex 1 of the present document. X Operator s assembly material The operator shall make hoisting equipment and a compressed air connection available. The procurement of liquid nitrogen shall be coordinated with the operator on a case-to-case basis, taking into account the local situation. n For single-step agitators, a liquid nitrogen reservoir with a minimum capacity of 100 l and a minimum pressure of 6 bar is required. n For multi-step agitators, you need a liquid nitrogen reservoir with a minimum capacity of 160 l and a minimum pressure of 10 bar. n Three-step agitators for reactors with a capacity of more than l require two liquid nitrogen reservoirs with a minimum capacity of 160 l and a minimum pressure of 10 bar each. A screwed fitting size 3/8 must be provided at the liquid nitrogen reservoir for connecting the pressure hose and the union nut. The Pfaudler pressure hose has a special connector for cryogenic applications. Figure Lifting lug 2 Hoisting winch X refer to Table 2, Dimensions for disassembly Introducing the agitator shaft through the manhole opening 1 1 CLO003_ Guide roller 2 Eye bolt 3 Hoisting winch CLO004_2 Figure 4 Details of hoisting winch Pfaudler Werke GmbH BA 373-4e 5 Pfaudler Werke GmbH OI e 5

6 5 Assembly/disassembly of an agitator shaft 5.1 Introducing the agitator shaft through the manhole opening of DIN reactors using the outlet nozzle The shaft can be introduced through the manhole opening with the help of the outlet nozzle of numerous reactors type BE and CE and tanks to factory standard as shown in Figure 3. Please refer to the assembly drawing for the reactor if you want to use this option. Figure 6 Lifting lug CL0025 CL0026 Figure 7 Retaining lug for installing the turbine In the event of uncertainties, please contact Pfaudler. We will be pleased to check whether or not the agitator can be assembled /disassembled using the outlet nozzle. Figure 5 Plastic sleeve CL0027 Table 2 Standard shaft lengths Nominal capacity Reactor diameter mm Total length of shaft mm Weight of shaft kg Dimension for disassembly X mm BE/CE BE/CE BE/CE BE/CE BE/CE BE/CE BE CE BE CE BE CE BE CE Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 6

7 Procedure for installing shaft through manhole: t Remove outlet valve. t Remove coupling and mechanical seal; for VSO drives in accordance with Operating Instructions 367/368/369, for VS drives in accordance with Operating Instructions 361/362/363, t Install guide roller between axial thrust washer and gear shaft and secure it with a socket pin. t Attach hoisting winch to drive support stool. t Screw eye bolt to DIN (refer to Annex 1) into the shaft end. t Guide the rope of the winch via the guide roller, agitator nozzle and manhole nozzle without tension through the reactor and suspend it in the eye bolt. t Insert the plastic sleeve into the outlet nozzle. t Attach lifting lug to the shaft s center of gravity. Hang up the hoisting winch. t Introduce shaft through the manhole as shown in Fig. 3, tilting it carefully manually. t Pull shaft with the hoisting winch vertically through the agitator nozzle up to installation level. [1] t Fix the shaft with the retaining lug made of molded laminated material (refer to Annex 1) from the VSO or VS tool kit, refer to Operating Instructions 363 for VS drives or 368 for VSO drives. t Remove hoisting winch and guide roller. t Install coupling and mechanical seal; for VSO drives in accordance with Operating Instructions 367/368/369, for VS drives in accordance with Operating Instructions 361/362/363 Please note the operating instructions of drives made by third-party manufacturers. When the shaft has been installed, the turbine(s) can be shrunk-on as described in Section 6 ff. 5.2 Introducing the agitator shaft through the agitator nozzle A agitator shaft can always be installed/removed through the agitator nozzle. For this purpose, the clearance above the reactor must be sufficiently high for installing the agitator shaft vertically. Whenever the shaft is replaced through the agitator nozzle, it will always be necessary to remove the mechanical seal and gear box! For the length of standard shafts, please refer to the assembly drawing of your reactor or Table 2. Procedure: t Remove agitator drive and mechanical seal; for VSO drives in accordance with Operating Instructions 367/368/369, for VS drives in accordance with Operating Instructions 361/362/363, t Screw eye bolt (refer to Annex 1) into the shaft end. Use the hoisting winch to insert the shaft into the reactor until installation level is reached. [1] t Fix the shaft with the retaining lug made of molded laminated material (refer to Annex 1) from the VSO or VS tool kit, refer to Operating Instructions 363 for VS drives or 368 for VSO drives. t Remove the winch and the eye bolt. t Reinstall the agitator drive, mechanical seal and coupling; for VSO drives in accordance with Operating Instructions 367/368/369, for VS drives in accordance with Operating Instructions 361/362/363, Please note the operating instructions of drives made by third-party manufacturers. When the drive has been installed, the turbine(s) can be shrunk-on as described in Section 6 ff. 5.3 Introducing the agitator shaft through the assembly hole of reactors type CE and reactors to Pfaudler factory standard type E In this case, it is sometimes possible to introduce the complete agitator assembly like a single-piece agitator once the assembly cover has been removed. If the assembly cover is not removed, the shaft must be introduced into the reactor as described in Section Removing an agitator shaft The agitator shaft is removed in analogy to its installation in reverse order. n through the manhole opening refer to section 5.1 n through the agitator nozzle refer to section 5.2 n through the assembly opening refer to section 5.3 [1] Optional procedure for the turbine shrink-on process: When the shaft is suspended on the winch vertically inside the reactor, it is possible to shrink-on the turbine of a single-step agitator by lowering the cooled shaft. Please contact our service department. Pfaudler Werke GmbH BA 373-4e 7 Pfaudler Werke GmbH OI e 7

8 6 General instructions concerning the assembly and disassembly of turbines 6.1 Nitrogen connection In order to avoid frictional losses, the liquid nitrogen reservoir should be set up as close as possible to the agitator drive. Ensure that there is a minimum pressure of 6 bar for single-step agitators or 10 bar for multi-step agitators in the nitrogen reservoir. Drain the cooling circuit of the mechanical seal before introducing nitrogen in order to avoid freezing. Note Section 2 in this context. Procedure t Connect the nitrogen supply hose to the upper bore hole marked IN (Rp 3/8 or Rp 1/2) of the agitator shaft for all VS and VSO drives. The supply bore of VSO drives with a Pfaudler mechanical seal is located right below the agitator coupling. In this case, it is not necessary to remove the agitator coupling, therefore, the shaft need not be supported. t The lower bore hole (Rp 3/8 or Rp 1/2) at the shaft end is designed as nitrogen outlet (marking OUT ). A pipe or an internally smooth hose with a brass or stainless steel sheath of the largest possible cross-section may be connected to discharge the nitrogen (to minimize the pressure loss). The end of the hose should be installed in a location where the nitrogen can escape without endangering the assembly personnel. The hose should be installed without any curves, if possible, in order to minimize pressure loss. m Caution Since nitrogen is heavier than air, please make sure that the emerging nitrogen cannot enter the reactor, any channels or drains. The assembly processes for the following agitator combinations are described in the sections below: n 7.1 Single-step agitators with single-piece turbine n 7.2 Single-step agitators with two-piece turbine n 8. Multi-step agitators with single/ two-piece turbines n 9. Single/two step reactors with small reactors type BE right richtig wrong falsch 1a_fh4 CL00024 CLO005_2 Figure 8 Connection of nitrogen lines Figure 9 Introducing an anchor into the reactor Figure 10 Positioning the ground surface 8 Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 8

9 6.2 Notes on shrink-fitting of turbines The following instructions are applicable to all works described in Sections 7-9. t Carefully clean the bored hole of the hub and the honed area on the shaft before the shrink-fitting process. Both honed surfaces must be dry; avoid or remove condensation. Clean and degrease the honed areas. t Mark the proper position of the top edge of the agitator hub on the shaft s honed area, refer to Figure 11. t Align turbine so that the hub bore is centric with respect to the shaft. t Cover the turbine hub with a piece of cardboard until the shaft s shrunk dimension has been reached. t Open the nitrogen supply valve. Check the diameter in the lowermost and uppermost location of the honed area using the proper snap gage from the tool kit (refer to Annex 1) after approx. 3 minutes. t When the diameter has been shrunk to the required size (snap gage can be easily pushed over the honed area), reduce the nitrogen supply. The test must be performed for several axes and at various levels of the honed area. The next steps should be performed as quickly as possible. t Remove cover from hub. Wipe off the honed areas of the shaft and turbine with a non-fluffy piece of cloth. t Lift turbine to the honed area using proper hoisting equipment, refer to corresponding assembly instructions. 6.3 Extended shaft for residual amounts When extended shafts are used, the clearance is not big enough for installing the turbine. For this reason, the shaft must be lifted by the length of the extension (max. 250 mm). For procedure, refer to section Assembly of single-step turbines 7.1 Assembly of a single-piece turbine for a single-step agitator using an air cushion Procedure t Place Pfaudler air cushion below the agitator shaft. For reason of stability, do not join more than two air cushions using the velcro tapes provided otherwise, there is a risk of tilting! Make sure to center the air cushion below the shaft in order to avoid damaging cushion during the cooling phase by getting in touch with the shaft! t Connect the air cushion to a compressed air supply. The air pressure permitted for the air cushion is limited to 0.5 bar, also refer to Section 2.4. t Insert the turbine through the manhole and place it on the air cushion. Make sure that the hub bore and the air cushion are centered with respect to the shaft. Please note the general instructions on the shrinking process in Section 6.2 t Carefully inflate the air cushion until the turbine has been lifted slightly below the end of the shaft. t Cool down the agitator shaft as described in Section 6.2. t Inflate the air cushion in order to lift the turbine beyond the end of the shaft up to the marked level. This is achieved more easily if you move the turbine slightly while lifting it (slight tilting and turning). m Caution If the turbine gets jammed while being lifted, immediately cut off the air supply to the cushion, deflate the cushion and realign the turbine. A jammed turbine may damage the glass. t Once the turbine has reached its proper position, shut off the nitrogen supply. t Hold the turbine on the inflated air cushion in the proper position until the joint has warmed up and the turbine sits firmly on the shaft. t Then you may slowly deflate the cushion in order to ensure a firm joint. t Remove all tools from the reactor Shaft end 2 Turbine 3 Rubber mat 4 Pfaudler air cushion CLO015_1 Figure 11 Pfaudler air cushion Figure 12 Assembly using air cushion Pfaudler Werke GmbH BA 373-4e 9 Pfaudler Werke GmbH OI e 9

10 Before the agitator can be started up, the complete agitator and the mechanical seal must have warmed up to room temperature. Note Operating Instructions 303, Thermal capacity of glasslined apparatuses in this context Assembly of a single-piece turbine for a single-step agitator using hoisting equipment Procedure t Align rubber mat below the shaft. t Align turbine below the shaft. t Attach lifting lug to the shaft at a suitable distance above the honed area. t Attach hoisting equipment to the lifting lug. t Fasten turbine with rope loops to the hoisting equipment. t Cool shaft to shrink-fitting dimension using nitrogen. t Lift turbine using hoisting equipment, note general guidelines in Section 7. t Wait until the joint has warmed up again and the turbine sits firmly on the shaft. t Remove tools. 4 1 Shaft end 2 Turbine 3 Rubber mat 4 Wooden block with bored hole CLO016_1 Figure 13 Assembly using wooden block 7.3 Assembly of a single-piece turbine for a single-step agitator using a wooden block Alternative recommendation for firsttime installation of shaft and turbine Procedure t Lift shaft. t Align rubber mat and wooden block below the shaft. t Place turbine on the (upholstered) wooden block and align it below the shaft. Protect turbine against tilting. t Cool shaft to shrink-fitting dimension using nitrogen. t Lower shaft into the hub. t Wait until the joint has warmed up again and the turbine sits firmly on the shaft. t Lift shaft together with the turbine and remove the wooden block. t Fix the shaft with the mechanical seal and the shaft coupling. Note information in the Operating Instructions in this context: for VSO drives in accordance with Operating Instructions 363/367/ 368/369, for VS drives in accordance with Operating Instructions 368/361/ 362/363 CLO017_1 Figure 14 Determining the gage for bore holes 7.4 Assembly of a two-piece turbine for a single-step agitator using hoisting equipment Procedure t Align rubber mat below the shaft. t Align turbine parts below the shaft. Use the spacer (Part no ) for this purpose. Protect turbines against tilting. t Attach lifting lug to the shaft at a suitable distance above the honed area. t Attach two hoists to the lifting lug. t Fasten turbine parts with rope loops to the hoisting equipment. t Cool shaft to shrink-fitting dimension using nitrogen. t Lift upper turbine using the first hoist. t Lift lower turbine using the second hoist. Use the spacer for this purpose. (Part no ) t Align turbines. t Wait until the joint has warmed up again and both turbine parts sit firmly on the shaft. t Remove tools. 10 Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 10

11 7.5 Assembly of a two-piece turbine for a single-step agitator using a wooden block Alternative recommendation for firsttime installation of shaft and turbine Procedure t Lift shaft. t Align rubber mat and wooden block below the shaft. t Place both turbines on the (upholstered) wooden block and align it below the shaft. Use the spacer (Part no ) for this purpose. Protect turbines against tilting. t Cool shaft to shrink-fitting dimension using nitrogen. t Lower shaft into the hubs. t Wait until the joint has warmed up again and the turbines sit firmly on the shaft. t Lift shaft together with the turbines and remove the wooden block. t Fix the shaft with the mechanical seal and the shaft coupling. Note information in the Operating Instructions in this context: for VSO drives in accordance with Operating Instructions 363/367/ 368/369, for VS drives in accordance with Operating Instructions 368/361/ 362/ Assembly of a two-piece turbine for a single-step agitator using an air cushion t Place Pfaudler air cushion below the agitator shaft. Connect the air cushion to a compressed air supply. The air pressure permitted for the air cushion is limited to 0.5 bar. t First assemble the upper part of the turbine as described for the singlepiece turbine. t Attach a lifting lug from the tool kit to the shaft above the turbine, tightening torque: 40 Nm. t Fasten upper part of the turbine with a rope to the lifting lug in order to prevent it from sliding down when fitting the lower half of the turbine. t Install the lower part of the turbine in the same manner as the upper part. There should be a distance of 10 mm between the two parts of the turbine. This can be achieved by inserting the two plastic spacers from the tool kit. The proper position of the turbine axes is fixed when installing the lower part of the turbine. By checking the gage for bore holes across the ends of the turbines you can ensure that the two turbine parts are at the prescribed angle (refer to Fig. 15). 7.7 Disassembling a single-step agitator Preparation of the work as described in Sections Connection and discharge of nitrogen as described in Section Disassembling a single-step turbine t Place rubber mat on the bottom of the reactor. Place Pfaudler air cushion below the turbine and center it below the shaft. The air cushion must not touch the cooled shaft! t Remove moisture or condensation from the agitator shaft and the hub. t Slightly inflate the air cushion (refer to section 7.1). t Open the nitrogen supply valve. Important: It is especially important to cool the assembly quickly in order to disassemble parts because the shaft has to shrink before the turbine hub becomes too cold. t Once the agitator shaft has been sufficiently cooled, the turbine will slide onto the air cushion. Check: Try to turn the turbine. t Fully deflate the cushion until the turbine lies on the ground. If necessary, push turbine down. t Close nitrogen supply. Suitable hosting equipment (rope winch) may also be used instead of the air cushion. m Before disassembling an agitator that has already been used in production, the shaft must at least be subjected to a visual inspection for possible damages. Leakage of nitrogen into the reactor should be avoided by all means. In the event of damages that indicate a breakthrough, please contact a Pfaudler fitter. Carefully remove all contamination in the area of the gap between the hub and the agitator shaft. Pfaudler Werke GmbH BA 373-4e 11 Pfaudler Werke GmbH OI e 11

12 8 Assembly of a multi-step Cryo-Lock agitator m Caution! Special assembly tools as well as practical experience are required for the assembly of multi-step Cryo- Lock agitators, therefore, it should be carried out by our specially trained fitters. Based on the space available on location, the customer-specific construction of the agitator shaft and the turbines and several different assembly options, the optimum assembly process must be defined individually on a case-to-case basis. Due to the multiple use of our Cryo-Lock system, it is not possible to describe all possible assembly processes at this point. We have chosen a three-step Cryo-Lock agitator as an example. Please also note the general instructions on the shrinking process in Section Preliminary work / tools In addition to the tools described in Section 4, the following is needed for the assembly of multi-step agitators: n 2 chain/rope hoists n 1 lifting lug n 2 retaining lugs 8.2 Assembly of the upper step Procedure t Attach 1 lifting lug with 4 eyelets above the upper honed area. Evenly tighten the fastening screws using a dynamometric key; torque: 55 Nm. t Attach an adhesive film to the turbine blade(s) at the transition to the hub to protect it / them against scratches. t Introduce the turbine into the reactor. Make sure that the hub bore is centered with respect to the shaft. t Hang the chain hoists into the lifting lug and connect them to the turbine. t Open nitrogen supply, refer to section (2) (2) Lifting lug for chain hoists 2 Lifting lug for chain hoists 3 Upper turbine, two-piece 4 Lifting lug for retaining the middle turbine 5 Middle turbine, two-piece 6 Agitator shaft with 3 ground surfaces 7 Lower turbine, single piece CLO008_1 Figure 15 Multi-step agitator t Pull up turbine to the upper honed area using the chain hoists. Operate the chain hoists in parallel for this purpose and move the turbine slightly in order to prevent it from getting jammed. m A jammed turbine may damage the glass. t Remove the chain hoists from the turbine. t Pull up the lower part of two-piece turbines in the same manner, support it from below with a retaining lug in order to keep it in position. Then remove the chain hoists from the lower piece. There should be a distance of 10 mm between the two parts of the turbine. This can be achieved by inserting the two plastic spacers from the tool kit. The proper position of the turbine axes is fixed when installing the lower part of the turbine. By checking the gage for bore holes across the ends of the turbines you can ensure that the two turbine parts are at the prescribed angle (refer to Fig. 15). 8.3 Assembly of the middle step t In order to support the turbine(s), install another retaining lug above the middle honed area, or use the first lifting lug (1) or the retaining lug (support for 3rd step) for attaching the hoists. t The assembly of the middle step is performed as described in 8.2. The chain hoists may remain attached to the lifting lug above the upper level. t After assembly support the turbine(s) from below using a retaining lug. 8.4 Assembly of the lower step The assembly of the lower step is performed as described in Section Disassembling a multi-step agitator m Caution! Special assembly tools as well as practical experience are required for disassembling multi-step Cryo- Lock agitators, therefore, this work should be carried out by our specially trained fitters. m Please note that all shrunkon turbines get detached from the honed areas practically at the same time when the shaft is shrunk. It is absolutely necessary to use the tools described in Annex 1. For disassembling, the two upper steps are supported by retaining lugs during shrinking. The lower step is removed using the Pfaudler air cushion. The upper levels are removed one by one using chain hoists, while supporting the turbine part that still remains on the shaft using a lifting lug and a rope. 12 Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 12

13 9 Assembly of single-/multi-step Cryo-Lock agitators in reactors type BE with a capacity of liters 9.1 General n Small reactors type BE include BE630, BE800 and BE1000. n Agitators may be designed with one or two steps. n With a d / D (reactor diameter / turbine diameter) ratio of 0.5 max., the step spacing must not exceed 400 m. 400 mm are optimal from the agitating point of view. m For safety reasons, accessing or entering the reactor should be avoided. Please also note the general instructions on the shrinking process in Section 6.2 m Rules for repairs In order to ensure safe working methods, we recommend removing the reactor from its support structure and putting it up firmly with the manhole pointing downward before performing glass repairs. The repair work should be carried out through the manhole while standing on the ground. Entering the reactor is not permitted. CLO021_1 Figure 16 Assembly of Cryo-Lock Figure 17 Disassembly of Cryo-Lock CLO022_1 9.2 Safe assembly of Cryo-Lock agitator in small reactors type BE n Position the agitator shaft and the agitator outside the reactor above the agitator nozzle n Introduce air cushion into the reactor and inflate it n Fill reactor with water until the air cushion floats close to the upper head n Position the agitator on the air cushion below the agitator nozzle n Cool down the agitator shaft n When the shrink-on temperature has been reached, insert the agitator shaft into the agitator n Once the connection has been made, drain the water from the reactor, deflate and remove the air cushion from the manhole 9.3 Safe disassembly of Cryo-Lock agitator in small reactors type BE n Pull agitator assembly out of the agitator nozzle n Introduce air cushion into the reactor n Fill reactor with water until the air cushion floats and the agitator lies safely on the air cushion n Cool down the agitator shaft. When the shrink-on temperature has been reached, the turbine will come off the shaft n Completely pull out the agitator shaft n Remove turbine through the manhole n Deflate and remove air cushion through the manhole n Drain the reactor Pfaudler Werke GmbH BA 373-4e 13 Pfaudler Werke GmbH OI e 13

14 9.4 Assembly of multi-step agitators The sequence of operations to be observed for multi-step agitators is shown in drawing (refer to Annex 2). A special air cushion is available for assembly works CLO018_1 CLO019_1 CLO020_1 Figure 18 Sequence of operations for multi-step agitators CLO023_1 14 Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 14

15 10 Testing and maintenance of parts The agitator must be checked for glass damages and glass erosion at certain intervals whose length depends on the chemical and mechanical stress of the agitator. This test should be carried out at least once per year. High-voltage tests of the turbine cannot be performed using the customary DC equipment because this type of voltage presupposes metallic grounding of the part to be tested. But as a turbine is fully glassed, high-voltage testing with DC voltage is not possible. Glass tests using AC voltage do not require metallic grounding, however, a stable test voltage normally is not guaranteed with this testing method and no reliable / meaningful test result is obtained. For this reason, Pfaudler developed the GlaSparker high-voltage tester for this very purpose (high-voltage testing of fully glassed components). With its pulsed voltage, a special DC voltage variety, highvoltage testing of fully glassed parts can be performed using capacitive grounding (special adhesive film is glued to glassed surface and grounded). Furthermore, the battery-operated GlaSparker is also suitable for safely testing shafts and manhole covers, etc. (for which metallic grounding is possible), as well as complete apparatuses. Please contact our service department for more information on our GlaSparker or assistance with the performance or evaluation of the test. m Caution: Do not fill the agitator shaft with nitrogen in the event of corrosion damages at the shaft s steel material! There is an imminent risk of nitrogen leaking from the shaft into the reactor danger of suffocation! In such a case, please contact Pfaudler to coordinate any further measures to be taken. 11 Electrostatic charge Depending on the product and operating conditions, agitators may be electrostatically charged during the agitating process. This is not dangerous if the following points are noted: n Do not introduce any conductive and grounded items (e.g. when introducing solids using a shovel) into the reactor if there is a risk of electrostatic charge. n Exclude the possibility of zone 0 inside the reactor, i.e. introduce inert gas into the gas zone, if necessary. n Wait for at least 1 hour before accessing a reactor that has been put out of operation. Reference is also made to the information concerning electrostatic discharge that is provided in our Operating Instructions Documents quoted that are also applicable n Safety data sheet for nitrogen n Ordinance on pressure vessels, pressurized gas containers and filling stations, Annex II of 12, item 21 n VGB 1.61, TRG n Operating instructions 363, 367, 368, 369 (VSO drives) n Operating instructions 368, 361, 362, 363, 362 (VS drives) n Operating Instructions 306 GlaSparker high-voltage tester n DIN High-voltage testing of glass n Publication 362 Electrostatic charges of glasslined reactors and pipelines n Guidelines of the Berufsgenossenschaft (Employers Third Party Liability Insurance Association) on working in enclosures n Hazardous Materials Ordinance 20 n Safety and Health at Work Act 6 13 Warranty and liability As a rule, our Conditions of sale and delivery are applicable, as amended. These conditions will be made available to the operator on or before contractmaking. No warranty and liability claims for personal injuries and /or damage to property will be accepted if they have arisen out of at least one of the following causes: n Use of the agitator or the assembly installations for purposes other than their intended use n Inappropriate mounting, start-up, operation, or inspection n Non-compliance with the information provided in the Operating Instructions concerning transport, storage, assembly, commissioning, and operation. Pfaudler Werke GmbH BA 373-4e 15 Pfaudler Werke GmbH OI e 15

16 Annex 1 Cryo-Lock assembly tools, as per Annex 1 Cryo-Lock assembly tools, as per Component Part no. Assembly box containing standard assembly kit, consisting of: Air cushion, 800 x 800 mm, 0.5 bar Pressure reducing station Compressed air hose with coupling, 10 m Nitrogen pressure hose, 3 m Nitrogen pressure hose, 6 m Nitrogen discharge tube Spacer, plastic material Snap gauge Snap gauge 48.2 mm Snap gauge 63.4 mm Snap gauge 88.9 mm Snap gauge mm Snap gauge mm Snap gauge mm Lifting lugs for Cryo-Lock assembly for shaft 48.3 mm A for shaft 65.0 mm A for shaft 88.9 mm A for shaft mm A for shaft mm A for shaft mm A for shaft mm A Retaining lugs for turbine assembly for pipe 43.0 mm A for pipe 58.2 mm A for pipe 83.6 mm A for pipe mm A for pipe mm A for pipe mm A Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 16

17 Annex 1 Cryo-Lock assembly tools, as per Component Part no. Plastic protection sleeves Plastic sleeve for outlet nozzle DN Plastic sleeve for outlet nozzle DN Retaining lugs made of molded laminated material (to support the shaft) Retaining lug made of molded laminated material, VSO Retaining lug made of molded laminated material, VSO Retaining lug made of molded laminated material, VSO Retaining lug made of molded laminated material, VSO Eye bolts fitting into the thread in the shaft head Eye bolt M16, for VSO Eye bolt M20, for BE / CE Eye bolt M24, for BE / CE > Fastening lug for VS drives Fastening lug for VS Fastening lug for VS Fastening lug for VS Fastening lug for VS Assembly material for installing the shaft through the manhole Hoist for parts inside the reactor (turbines) 0.5 t Guide roller for attachment to gear shaft, for all sizes Rope winch for attachment to VSO drive support stool Pfaudler Werke GmbH BA 373-4e 17 Pfaudler Werke GmbH OI e 17

18 ca. 50 ca. 50 ca. 50 Annex 2 Drawing of Cryo-Lock assembly in small reactors type BE Annex 2 Drawing of Cryo-Lock assembly in small reactors type BE BE 630 BE 800 BE 1000 max. 900 D=Ø 1000 D=Ø 480 max. 900 D=Ø 1000 D=Ø 480 max. 900 D=Ø 1200 D=Ø 540 Ground surface 900 ca ca ca b a d _ = 0.5 max. D a b max. BE BE BE Figure 19 Disassembly of Cryo-Lock 18 Pfaudler Werke GmbH BA 373-4e Pfaudler Werke GmbH OI e 18

19 Annex 3 EC Certificate of Conformity for Agitators EC Declaration of Conformity Explosion Protection Directive 94/9/EC Component: Agitator Type: refer to drawing Size: refer to drawing subject to the conditions and limits specified in the Information on Explosion Protection - Agitators - (see overleaf). We hereby confirm that the reference agitators are suitable for their intended use in potentially explosive atmospheres and comply with the essential safety and health requirements stipulated in Annex II of Directive 94/9/EC. The agitator is defined as a component (Article 4, 2nd paragraph) to be incorporated in equipment. Components do not receive a CE mark. Conformity assessment EC type-examination pursuant to Annex III procedures applied: No.: EX Production quality assurance pursuant to Annex IV Notified body no TÜV Product Service GmbH Gottlieb-Daimler-Straße 7 D Filderstadt Type of protection: II 1GD c Tx 1) Harmonized standards applied: EN , EN , EN Community Directives applied: Explosion protection Directive 94/9/EC Machinery Directive 2006/42/EC 1) For details concerning the temperature class, please refer to the Information on Explosion Protection - Agitators - sheet (see overleaf). The Certificate of Conformity shall no longer be applicable if the product is incorporated in equipment that does not comply with the requirements of Directives 94/9/EC and 2006/42/EC Pfaudler Werke GmbH Andrew C. Wills CEO Schwetzingen, 05/25/2012 KE005E A Unit of National Oilwell Varco (NOV) Pfaudler Werke GmbH Firmensitz: Schwetzingen Geschäftsführung: Andrew C. Wills J.P. Morgan AG, Frankfurt am Main Postfach 1780, Schwetzingen USt.IdNr.: DE HRB Amtsgericht Mannheim Bankleitzahl: Pfaudler Straße, Schwetzingen Steuer-Nr.: 43049/02539 EORI-Nr.: DE Konto Telefon: +49 (0)6202/85-0 Entity: 838 Finanzamt Schwetzingen BIC/SWIFT: CHASDEFX Telefax: +49 (0)6202/ sales@pfaudler.de IBAN: DE Information on Explosion Protection - Agitators - Version 02 09/25/03, MTG/TES Equipment group II, category 1 GD of Directive 94/9/EC (ATEX) compliant agitators for use in zones 0 and 20 inside reactors Conditions for the installation and operation of an agitator in potentially explosive atmospheres General The manufacturer s instructions concerning the installation, commissioning, maintenance, and repair of the agitator shall be adhered to at all times. Other applicable documents include the operating instructions for neighboring equipment, such as reactors, agitator drives, mechanical seals, monitoring devices, motors. The reactor must be suitable for the installation and operation of the agitator, and must be sufficiently rigid in the area in which the agitator is connected in order to keep vibration, and the resulting displacement of the agitator, to a minimum. The agitator shaft must be guided inside the reactor at least by predetermined static fixtures. All devices and components used for this purpose shall comply with Directive 94/9/EC. During installation, it must be ensured that there is sufficient distance between the agitators and the reactor walls as well as all internal parts, if any, in order to avoid hitting neighboring parts. The assembly of the agitator shall not be done in an explosive atmosphere. Modifications of the agitator or of the specified operating conditions shall require coordination with and the approval of the manufacturer. Spare parts shall comply with the manufacturer s specifications. The internal parts may not be subject to excessive vibration. The ratio between the excitation frequency and the natural frequency of internal parts shall not exceed 0.5. Agitating process The reactor shall not be covered by Directive 94/9/EC unless atmospheric conditions prevail inside the reactor. Atmospheric conditions are defined as follows: Temperatures of -20 to +60 C and pressure of 0.8 to 1.1 bar. It is not permitted to stir fluids belonging to explosion group IIC without taking additional measures. Efficient protection is usually provided by inerting inside the reactor. The agitator s temperature class is determined by the process temperature. T6 up to 80 C max, T5 up to 95 C max, T4 up to 130 C max, T3 up to 195 C max, T2 up to 295 C max. To be used for their intended purpose only, taking into account the conditions and limits specified in the technical documents and the operating instructions. The operator is responsible for the process. If active ignition sources resulting from the process cannot be safely avoided, inerting must be carried out. Ignition risks resulting from friction, impact or frictional energy in conjunction with solid matter contained in the product to be stirred shall be excluded. The operator shall safely avoid dangerous electrostatic charges when stirring fluids. This can be done, e.g., by taking into account the conductivity of the fluids being stirred. If the conductivity is above 1000 ps/m, no dangerous charges are normally to be expected. The agitator drive shall not be continuously operated in the critical speed range. This requirement is of special importance in connection with variable-speed drives. A suitable agitator control shall be provided to ensure that critical speed ranges (75% to 125% of the critical speed) are inhibited and continuous operation is not possible. If the drive is to be operated in the supercritical range, the critical speed range should be passed as quickly as possible. The materials used for the parts that are in contact with the product must be resistant against the substances processed inside the reactor. The interaction between materials and substances must not lead to the formation of an explosive atmosphere. The drive must not be switched on while the agitator shaft is stalled. If the agitator is stalled during operation, the drive must be immediately shut off. Operating the agitator without being covered with liquid shall not be permitted unless this mode was accounted for by the manufacturer during production. Maintenance Clean the agitator whenever necessary. Avoid major product encrustation. Re-tighten all screwed connections on the agitator annually with the prescribed torque. Check accessible welded joints on the agitator blades every 5 years for cracks. Bottom bearing Re-tighten fastening screws annually with the prescribed torque. Check wear and proper position of bearing bush annually, and replace bush if necessary. Clean the bottom bearing regularly. Make sure that the agitator shaft cannot stick to the bearing or be blocked by solids. Pfaudler Werke GmbH BA 373-4e 19 Pfaudler Werke GmbH OI e 19

20 The information provided in this documentation corresponds to the state of the art at the time of printing. It is published in good faith. However, we will accept no warranty claims based on the information provided in this documentation. We reserve the right to include improvements, amendments and new findings in this documentation without prior notice. The actual design of products may deviate from the information contained in the calatoge if technical alterations and product improvements so require. The proposal made by Pfaudler for a concrete application will be binding in such cases. The present documentation is made available free of charge to our customers and other interested parties. The right to print or copy this documentation, or any parts thereof, or to convert the same into electronic form shall be subject to our written permission. All rights reserved by us e xc Pfaudler Werke GmbH P.O. Box 1780 D Schwetzingen Pfaudlerstrasse D Schwetzingen Phone Telefax service@pfaudler.de