Installation of Glass Lined Equipment Information given herein is for guidance only and may not be complete. It is important that only trained and competent personnel are permitted to handle glass lined equipment. 1.0 Inspection before installation a) Carry out installation only after confirming by visual observation that there is no damage to the glass lined surface. b) Keep the equipment with manhole opening on the ground in a horizontal position. Remove shoes before entering the equipment, and ensure that belt buckles etc do not damage flange portion of manhole. c) Do not wear clothes with buttons made of metal and similar accessories. Use portable light. d) Ensure that foreign materials do not fall into the equipment. Perform installation carefully with nozzles covered properly and manhole in closed position. 1.1 Cover the glass lined surface with thick rubber sheet, etc., so that spatter or spark created at the time of welding, cutting, and grinding works does not hit the glass lined surface directly. 1.2 Welding: Arc-welding should not be done on glass lined surface as this would lead to thermal shock causing chipping of glass lining. 2.0 Installation Prior to installation, note the weight of the equipment, and select a strong enough hook, rope, etc. Use a suitable crane or hoist. 3.0 Lifting of equipment 3.1 For lifting, it is advisable to wind the rope double around the equipment as illustrated in the diagram given below. In case of using hooks welded on the reactor, use all the hooks. Avoid lifting the equipment by using hooks installed on the reactor cover of flanged equipment or reducer base.
3.2 Do not use wire ropes around nozzle/manhole neck since it would cause damage to the glass lining. Use rubber sheets or wooden pieces to cover the surface coming in contact with the wire ropes to avoid scratches on the painted surface. 4.0 Leveling of the equipment Leveling of vertical storage tank, etc., (except columns) in which agitator is not installed. Use a plumb bob at two places (at right angles to each other) on the circumference of a circle to check the verticality of equipment. Adjust the verticality by inserting suitable rigid packing material below the brackets/legs to keep the verticality below 2 mm / M. Installation of reactors in which agitator is assembled. Use a plumb bob at two places (at right angles to each other) on the circumference of a circle to examine the verticality of the equipment. Adjust the verticality to keep it below 1 mm / M. After installing the equipment at the designated place, check and tighten all bolts and clamps. Before and after assembling, perform visual inspection of glass lined surface. 5.0 Precautions to be taken while entering the equipment a) When entering the equipment, use a ladder made of wood or aluminum. Use rubber sheets or blankets to cover the bottom of the equipment and portions of glass lined surface coming in contact with the ladder to avoid scratches. b) Spread soft materials such as rubber sheet (more than 5mm thick) or blanket inside the equipment at the bottom. c) Remove shoes before entering the equipment. d) Fasten tools such as spanners to the clothing to ensure that they do not fall on the glass lined surface. e) Use a portable light for illumination inside the equipment.
f) Do not use metal tools. It is advisable to use a wooden stick, hammer, etc., to remove the packing used as supports for the agitator/ baffle. If proper care is taken, a saw may also be used. g) After completion of work inside the equipment, confirm that no tools or packing materials are left inside. After adjusting the thickness of manhole gasket, make match marks on the outside diameter of flange and gasket. Close manhole after ensuring that the gasket is placed as per the marks. 6.0 Assembly of other components on glass lined equipment Reducer (gear box) and motor are delivered in separate packing. Install the reducer on the drive support. Locate it within the two guides provided for correct alignment. The output shaft of the reducer is connected with a flexible coupling to the agitator. Fix all the bushes to connect the reducer to the agitator. Motor is installed as per the drawing and is to be suitably aligned. Connect the motor to the reducer using belts /bushes provided. Confirm that anti-falling devices provided for the agitator inside the equipment have been removed. If Double Mechanical Seal is installed in the equipment, thermosyphon must be unpacked and installed. Fill thermosyphon or other fluid reservoir of mechanical seal with the selected fluids, ensuring that the fluid does not contaminate the product. Check the seal drawing or consult the seal manufacturer for more details. Install piping for cooling water on stuffing box or mechanical seal housing, and jacket of convection type lubricator. a) Inspection before starting operation Tighten bolts and nuts fixing the mechanical seal unit. Carefully clean pipes connecting the seal to the thermo siphon unit to remove dirt and dust. Dirt and scale are primary factors causing seal failure. Make pipe connections in accordance with the drawing, and leave the hole for detecting leakage open. Charge sealing liquid under pressure so that air pockets are not formed.
b) Lubricant - Bearing Grease: Bearings are installed on the same sleeve on which seal is mounted. Use Daphne Corronex EP No.2 grease or equivalent for lubricating the bearings. Excessive filling may generate heat. When temperature exceeds ambient by 40ºC, remove the grease charging nipple. After one or two hours of running, the surplus grease will come out. Fix the charging nipple and fill the housing with some grease. The charging of grease should be carried out after one month for the first time, and every three months thereafter. Sealing Liquid: Fill the thermosiphon pot with the sealing liquid that does not affect quality of the contents of vessel from deteriorating due to contamination (to be selected in consultation with the designer of the seal). Lubricant oils, water, glycerine or other solvents are typically used. Liquid in the thermosiphon should be filled to have pressure at least 1 Kg/cm2 above the operating pressure in the reactor. Pressure is built up with Nitrogen in the vapour space. Cooling water shall be circulated through the jacket of seal and the thermo siphon at a rate to have the temperature of water at the outlet not more than 70ºC. Before pressurizing the reactors, read carefully instruction manual of mechanical seal unit,as well as that of convection type lubricators and set the required parameters. Remove the blind flanges of nozzles on which Dip Pipe/Feed Pipe/Reducers /Instruments are to be fitted. Examine the glass lining and confirm that there are no damages. Fit the required fittings/gadgets and valve. Make sure again that nothing is left inside the equipment. Agitating nozzles are to be fitted to the nozzles in the jacket used for inlet of steam/cooling medium. If a baffle plate is provided, it gets corroded due to impingement over a period of time, and exposes the shell plate of the vessel to corrosion. If agitating nozzle is installed, it can be removed periodically for checking for reduction in the thickness of the tip and replaced, if required. This would result in increasing the life of the shell plate of the reactor. Fix all other valves, etc., in the jacket nozzles.
7.0 Test Run Preparation for test run 1) Fill reducer with oil. Use only the oil recommended by the manufacturer and the specified quantity. For details, refer to the component manufacturer s manual. 2) Grease nipples are provided in motor, bearing housing of the agitator assembly and mechanical seal. Apply grease at these points. 3) Re-confirm tightening of all of the bolts, nuts, and clamps. 4) After connecting the motor to the power supply, set the direction of rotation as indicated by the direction arrow marked on the reactor. 5) Fill the equipment with water, and carry out pressure test to check for leakages on each nozzle, manhole, shaft seal, etc. 7.1 Running trial Circulate cooling water through the stuffing box, mechanical seal or jacket of convection type lubricator. At start, inch the motor by switching on and off, and increase the speed of the agitator gradually. Confirm that the current drawn by the motor is within limits. Ensure the absence of: - Abnormal sound from the rotating parts - Abnormal vibration on the shaft and equipment. - Abnormal temperature on the reducer, and the top of shaft. Gland Seal Temperature of upper side of stuffing box must be measured (40ºC above ambient is permitted, but not to exceed 75ºC). If the temperature exceeds this limit, carry out adjustment of gland seal by loosening to some extent
Mechanical Seal: Refer to the instruction manual of mechanical seal supplier. If in doubt, contact the manufacturer of the seal. In case anything abnormal is noticed, stop the operation and get in touch with manufacturer. If you have to enter the equipment, for some reason, make sure to isolate the starter from the power source (keep the key, take the fuse of power supply), and hang a tag or indication working inside the equipment, for safety. Leak Test: Fill the inside of the jacket with water and pressurize to the test pressure to confirm that there are no leakages through the flange joints. Similarly test the flange joints of nozzles in the jacket and confirm that there is no leakage. Inject steam or heating medium (after draining the water) into the jacket. Heat the water in the vessel to 95 deg. Centigrade for two hours. Carry out visual inspection of glass-lined surface after washing the inside of the equipment with hot water and cooling to ambient temperature. In case anything abnormal is noticed, stop the operation and get in touch with NILE immediately. Now the equipment is ready for process use and attachments such as piping, insulation, etc., application of preventive coatings can be undertaken. Nameplate Nameplate gives information on identification of the equipment given by the manufacturer and design conditions. This information is required for future correspondence with the manufacturer regarding performance and spares. Hence ensure that nameplate is visible and is not covered by insulation. If you need assistance, please contact us