STANDARD SPECIFICATION STANDARD SPECIFICATION No. ‘SGHfetzre ams ENGINEERS FOR 6-26-0001 Rev. 3 Sage eS NOAIMTED yecHaNicaL AGITATORS Page ata user ar ame fatrést STANDARD SPECIFICATION FOR MECHANICAL AGITATORS Wool fie ne 3 22.03.10 REVISED AND REISSUED AS STD. SPEC. TK RKT ol piv eee ee ease Toe iiss aaouce eee Soetcan eta Felon eect eee se sea —tas tee ee Ppeet comes Somer amy ‘Approved by ‘Format No. €-00-0001-F1 Rev. 0 (Copyright Ell — Al Aights reservedSRLS fly ENGINEERS. STANDARD SPECIFICATION STANDARD SPECIFICATION No. eat OND FOR 6-26-0001 Rev. 3 TSG mona eterinate MECHANICAL AGITATORS Page 2 of 12 ASME = American Society of Mechanical Engineers ASTM : American Society for Testing and Materials BKW : Brake Kilowatts BS: _ British Standards Is Indian Standards KW Kilowatts NB : Nominal Bore PTFE : Poly Tetra Flouro Ethylene RPM : Revolutions Per Minute AGMA ‘American Gear Manufacturer's Association GPpc : General Purchase Conditions dBA Decibels. Static Equipment Standards Committee Convenor: Mr. A.K. Malik Member Mr. RK. Trivedi Mr. K. Anjaneyulu Mr. Tarun Kumar Mr. Chandra Kant (Inspection) Mr. G.K. Iyer (Construction) Mr. Ratan Lal (Project) Format No. 6-00-0001-F1 Rev. 0 ‘Copyright EIL— Allvighis resened‘STANDARD SPECIFICATION No. SERGI (ly ENGINEERS, STANDARD SPECIFICATION Gets @NIATTED FOR 6-26-0001 Rev. 3 OES nan aeerbennee MECHANICAL AGITATORS Page 3of 12 CONTENTS 1.0 SCOPE. 2.0 BASIC DESIGN.. 3.0 MATERIALS.... 4.0 INSPECTION & TESTING 5.0 PREPARATION FOR SHIPMENT. 6.0 VENDOR DATA. 7.0 GUARANTEES. Format No. -00-0001-F1 Rev. 0 ‘Copyright EIL— Allvighis reservedSERIE fly ENGINEERS. STANDARD SPECIFICATION STANDARD SPECIFICATION No. ESR UMITED Tams ey nae MECHANICAL AGITATORS 1.0 1d 1.2 13 1.4 2.0 21 24d 24.2 FOR 6-26-0001 Rev. 3 Page 4 of 12 SCOPE ‘This specification covers minimum requirements for design, supply, inspection and testing of mechanical agitators, their auxiliaries and accessories. No deviation or exception from this specification shall be permitted without the written approval of the purchaser. Intended deviations shall be separately listed by the vendor and supported by reasons for consideration of the Purchaser. Compliance with this specification shall not relieve the vendor of the responsibility of furnishing equipment and accessories of proper design, materials and workmanship to meet the specified operating conditions. This general specification supplements the specific requirements contained in the job specifications, if any, and the equipment data sheets. In the event of any contradiction. between the information contained in various attached documents, the following order of precedence shall govern : i) Data sheets. Job Specification. This Specification. iv) Various reference specifications. BASIC DESIGN General Agitators, gears and auxiliary equipment shall be designed and constructed for operation at continuous full load duty. Units shall be of a proven design for the intended service. The agitator vendor shall be wholly responsible for satisfactory hydraulic, mechanical and overall performance of the equipment and all connected subassemblies. Unless otherwise specified elsewhere, the following equipment qualification criteria shall be applied for acceptance of the offered agitator model. i) The vendor shall be an established agitator manufacturer having adequate engineering, manufacturing and testing facilities. ii) Agitator offered shall be from the existing regular manufacturing range of the vendor. iii) Proposed agitator shall be identical or similar in terms of power rating, shaft diameter, speed, impeller type, number of impellers, bearing size, overall shaft length, mechanical seal/vapor seal, mounting arrangement and mechanical design to at least two units of same model designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have successfully been operated in the field for at least 8000 hours without any major overhaul as on due date of bid submission. As an alternative, vendor may show to the satisfaction of the purchaser that the equipment offered is comprised of standard subassemblies which individually satisfy the above requirements. Format No, 6:00-0007-F1 Rev. 0 ‘Copyright EIL — Al ighis reservedSIGE > ENGNERS STANDARD SPECIFICATION —_ STANDARD SPECIFICATION No. san fetes SS NDIA LIMITED FOR 6-26-0001 Rev. 3 See niente! MECHANICAL AGITATORS i Page 5.0f 12 2.1.3 2.15 247 218 219 2.1.10 2.1L 2112 2.2 221 iv) The above acceptance criteria shall also be applicable for auxiliaries like Gearbox etc, v) Vendor shall furnish record of his past experience to justify the proven-ness of the offered equipment. In case where the impeller geometry, power number, horsepower and input speed are specified by the Purchaser, the vendor shall be responsible for maintaining the same. ‘The agitator shall be suitably designed for mounting and operation in purchaser's vessel/tank ‘whose drawing is annexed with the enquiry specification. ‘The agitator vendor shall review and comment on the Purchaser's vessel drawing for number and size of baffles, sparger locations, mounting nozzle details etc. Unless otherwise specified, for small diameter impeller, it shall be possible to remove the complete Agitator assembly without dismantling through the opening provided on the vessel/tank and for large diameter impeller, blades shall be of removable construction for cease of removal. Vendor shall also furnish the headroom required for taking out the agitator as above. All equipment furnished by the vendor shall be suitable for the area clas in the data sheets. ation specified The noise level of unit when measured at 1 meter distance, shall not exceed 85 dBA (slow response). ‘The supplier shall submit noise emission data for the proposed unit. Pressure containing parts and mounting flanges shall be designed, fabricated, tested and inspected in accordance with the ASME codes, unless specified otherwise on the data sheets, Pressure containing parts of carbon steel shall have a minimum corrosion allowance of 3mm, unless otherwise specified on the data sheets. Carbon steel shaft shall have corrosion allowance of 6 mm on its diameter unless otherwise specified. On other non pressure carbon steel parts a corrosion of 3 mm shall be considered on each surface Lifting eye bolts. shall be provided for driver, gear box etc. for ease of lifting and shall be located at the centre of gravity of the part. Vendor shall provide proper dowelling between motor and base plate, gear box and ‘mounting stool/base plate for ease of assembly of the agitator unit. Tapered dowels shall be provided. ‘Vendor shall provide suitable arrangement for supporting the agitator shaft with impellers during removal of gear box for maintenance and details of such arrangement shall be furnished. Electric Drives Unless stated otherwise, the driver shall be in the scope of agitator vendor. The driver shall conform to the corresponding specifications listed in the enquiry document, Format No, 6-00-0001-F1 Rev. 0 ‘Copyright EI — Al ighs reservedINDIA LIMITED FOR 6-26-0001 Rev. 3 ‘SGA zIe ly ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No. a) TE GmG ara gna MECHANICAL AGITATORS 2.2.2 2.3 2.3.1 23.2 2.3.3 2.3.4 2.3.5 24 241 Page 6of 12 Electric motors shall have a minimum power rating in accordance with the following table: Agitator BKW at input shaft of gear box Motor rating (% of (including Gear &Transmission losses) Agitator Rated BKW) Less than 22 KW 125% 22-55 KW 115% (But not less than 27KW) Higher than 55 KW 110% (But not less than 64KW) The electric motor shall be suitable for the electrical area classification indicated in the motor specification/data sheets. Gear Units In case where speed reduction is required, the vendor shall incorporate helical ot worm gear reduction unit. Use of V-belt/Chain drive (antistatic type ) is permitted for swivel type side entry agitators. Use of V-belt / Chain drive for any other agitator configuration ( i.e. top/oottom entry or fixed type side entry) shall require purchaser's approval, unless otherwise specified in data sheet. Minimum design life of V-belt shall be 25000 hrs. ‘The gear box rating shall be selected based on minimum gear service factor of 1.5 over the driver's name plate rating, The gear box shall be of heavy duty type and the bearings shall be capable of withstanding maximum radial cum thrust loading which may occur during operation. The reduction unit shall be procured from a reputed manufacturer and shall conform to BS:721 (latest edition)/AGMA. or equivalent specification. The accuracy shall be to class A limits of the above specification. In case where shut off and retracting arrangements are requ gear reduction unit having a hollow output shaft sd, the vendor shall provide a ‘The gear reduction unit shall always be provided with an oil drain, a breather and oil level gauge. The lubrication must be designed keeping in view that temperature within bearings should not exceed 85°C. Couplings The vendor shall use the following nomenclature. i) High Speed Coupling Coupling used between the motor and gear reducer. It shall be of flexible type and shall be provided with a non-sparking guard. ii) Low Speed Coupling: Coupling used between the output shaft of the gear reducer or driver, and the agitator shaft. It shall be of the flexible or rigid type with spacer. iii) Auxiliary coupling : Coupling provided to sectionlise the agitator shaft inside the tank/vessel. Format No, 6:00-0007-F1 Rev. 0 ‘Copyight EL Alighis reseedSTANDARD SPECIFICATION _ STANDARD SPECIFICATION No. sae ENGINEERS sear INDIA UMITE FOR 6-26-0001 Rev. 3 Soe ATMS MECHANICAL AGITATORS Page 7of 12 2.4.2 Flexible couplings shall be selected with a minimum service factor of 2 over the driver ‘nameplate rating and shall be capable of continuous operation at the maximum anticipated misalignment. 2.4.3 Rigid couplings wherever used, shall have tapered bores with key and nut arrangement. All rigid couplings shall be manufactured from cast steel as per IS: 1030 Gr. Il or forged steel as per IS : 2004 Cl. 3 of cast iron as per IS : 210 Cl. 30. Rigid couplings in forged steel may be welded to the shaft for atmospheric tanks. 2.4.4. All necessary instructions for assembly of coupling shall be furnished by the Vendor. 2.5 Mounting Stool & Flanges 2.5.1 Wherever required, the vendor shall provide a mounting stool for the agitator unit, It shall house the shaft coupling, the bearing housing, the seal and the auxiliary coupling as applicable. 2.5.2 The lantern stool shall be designed to provide adequate accessibility for ease of erection and maintenance. The stool shall be either in standard ERW pipe construction as per IS: 1978 or shall be fabricated from IS :2062 E250 Grade B plate. Plugged holes shall be provided at proper locations to drain the oil which may get collected in the stool due to improper functioning of gear box, oil seal, etc. 2.5.3 Mounting flange dimenisions shall be as per ASME B16.5 upto 600 NB, ASME B16.47 Series B for more than 600 NB or as specified in the data sheets. Material of construction shall be as specified in the data sheet. 2.6 Agitator Shaft 2.6.1 Unless otherwise specified in the enquiry, the bottom shaft of top mounted agitators shall be fone piece. Constant diameter solid/hollow shaft of cantilever design suitable for 20 yrs. of service life shall be furnished. Larger lengths shaft may be divided. 2.6.2 The selection of the shaft diameter shall be done to satisfy the following criteria : a) Shaft shall be suitable for transmitting full rated (pull out) torque as mentioned in driver's name plate. b) Shaft shall be suitable for jamming conditions considering that impeller is jammed at a point 0.75R from the centre (R=radius of impeller). Unless otherwise specified a safety factor of 1.5 shall be taken on motor rating to work out pull out torque for calculating the stresses as per maximum shear strain energy theory. The maximum stress thus calculated shall be limited to yield stress of the shaft material at vessel design temperature. ce) Shaft runout shall be limited to a maximum value of 0.05 mm at the face of the stuffing box/seal 4) Dynamic shaft deflection at the mechanical seal (cartridge) face shall be limited to the value specified by mechanical seal manufacturer or 0.07mm whichever is less. ) Shaft diameter shall also take into account factors of straightness and runout at shaft end. In the assembled condition, the maximum shaft runout at the free end shall be Format No, &-00-0001-F1 Rev. 0 ‘Copyright EIL— Al ighs reservedSTANDARD SPECIFICATION —_ STANDARD SPECIFICATION No. $5Gte BQN INDIA LIMITED FOR 6-26-0001 Rev. 3 sear eles SNOAUMTED MECHANICAL AGITATORS Page Bot 12 27 241 272 2.73 214 2.8 2.8.1 2.8.2 2.8.3 2.8.4 2.8.5 2.8.6 2.8.7 limited to 1.0 mm per meter of overhung length of shaft (measured from nearest bearing/seal face end). f) There shall be a separation margin of minimum 20% between the critical speed (ary/wet) and any operating speed. Impellers Impellers with small diameter shall be of one piece construction. Impellers with large diameter blades shall be of bolted construction. Discs and stabilizers may be split to permit removal through manhole openings Wherever possible the impellers shall be mounted on the taper bore of the shaft by means of key. Care shall be taken that both tapers match each other. A lock nut with cotter pin shall be provided to safeguard against loosening during operation. All impellers shall be dynamically balanced. Seals ‘The type of seal required shall be as. specified in the data sheets. Seals, when specified shall be of standard manufacturing range and shall be procured. from a reputed manufacturer In case mechanical seal is specified, it shall be of Flowserve / John crane/ Eagle Burgmann Poonawala (EBPIL) or any other EIL approved make only. Gland packings, if specified, shall be designed for ease of maintenance and shall not require auxiliary coupling for the same. ‘The design shall incorporate : a) Gland in two halves. ») _ individual packing rings of PTFE or PTFE impregnated asbestos. ©) Spacer ring in two halves between two packing rings. 4) Lantern ring in two halves, if lubrication is required. Equipment necessary for lubrication of packing shall be supplied by the vendor and a detailed drawing for the same shall be submitted as per vendor data requirement. Mechanical seal assemblies shall be of cartridge type and shall be removable without dismantling the agitator drive unit. The seal model/type/material code etc. shall be suitable for the specified operating media and shall be as per the seal manufacturer's recommendations. ‘The seal design pressure shall be more than the vessel design pressure. The equipment for lubrication/flushing/quenching, if specified shall be in the agitator vendor's scope of supply. Sufficient information about the system shall be supplied at the time of bid so as to facilitate technical evaluation of the same. Format No. 6-00-0001-F1 Rev. 0 ‘Copyright EIL— Al ighis reservedSTANDARD SPECIFICATION — STANDARD SPECIFICATION No. SoG @ NONEERS sar SRR UMITED FOR 6-26-0001 Rev. 3 Ree more anaren MECHANICAL AGITATORS Page 9of 12 29 2.9.1 2.9.2 2.10 2.10.1 2.10.2 2.10.3 211 2AM 211.2 212 3.0 31 3.2 33 Bearing Housing and Bearings thrust loadings used for the design of the shaft. The housing shall be bolted to the mounting stool and be provided with a precision machined step facing to make a corresponding facing ‘on the stool for the purpose of maintaining alignment and interchangeability All bearings shall be designed for the maximum radial cum thrust loadings and any shock loadings expected during operation. The bearings shall have a trouble free operating life of 30,000 hours minimum. Steady Bearings & Baffles Unless otherwise agreed upon, the design of the agitator shall not incorporate the use of a steady bearing at the shaft end. However, if the use of such a bearing is imperative, the design shall be such that the bearing is of self alligning type and is product lubricated. The steady bearing and its support arrangement including its pad (welded to tank bottom) for top mounted agitator shall be in the scope of agitator vendor. The vendor shall supply necessary drawings/specifications to purchaser for making arrangement in the vessel/tank for mounting the steady bearing and its support. If antivortex-baffles are required, vendor shall design and furnish the complete details (in terms of dimensions, nuimber, location, orientation) including its supports. Piping Connections ‘Threaded and plugged connections for seal flushing, vents and lubrication shall be ¥ inch NB minimum size. Flanged connections shall be used for sizes 1 inch NB and above and shall conform to ASME B 16.5. Special Tools and Tackles If required, Vendor shall supply a set of special tools and tackles required either for erection or operation or maintenance of the agitator units. A list of such tools shall be submitted alongwith the offer. MATERIALS Vendor shall indicate the materials of construction for the various parts on the data sheet. However the vendor shall adhere to the materials as specified by the purchaser in the data sheets or elsewhere in specification and shall quote accordingly. IS, BS, ASTM or other international standards shall be used to specify exact material designations. Castings used for any part of agitator assembly ordered under these specifications shall be sound and free of shrink or blow holes, scale, blisters and other similar casting defects Unless otherwise specified in the data sheets, material test certificates (chemical analysis and ‘mechanical properties) shall be supplied for impeller, shaft, mounting flange and coupling Format No. 6:00-0001-F1 Rev. 0 ‘Copyright EIL— All ighis reservedENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No, Bese QNA ined FOR 6-26-0001 Rev. 3 Tareereasen Mant steasrra MECHANICAL AGITATORS Page tot 12 4.0 INSPECTION & TESTING 4.1 General 4.1.1 Unless otherwise specified all agitator units shall be tested at vendor's shop in accordance with Clause 4.2 to 4.4 of this specification. 4.1.2 The tests to be witnessed by the Purchaser shall be as indicated in the data sheets / approved vendor quality assurance plan. 4.1.3 The vendor shall notify the purchaser not less than 10 days prior to the date of inspection or test 4.1.4 Acceptance of shop tests shall neither be considered a waiver of requirements to meet field tests under specified operating conditions nor does inspection relieve the manufacturer of his responsibilities in any way whatsoever. 4.1.5 The inspector representing the purchaser shall have entry to the plants including sub-vendor plants where work or testing of the equipment is being performed. 4.1.6 Vendor shall furnish the inspector with all necessary material certificates, shop test data for verifying the vendor's compliance with the specifications on the agitator and all auxiliaries furnished by subvendors 4.1.7 No surfaces or parts are'to be painted until the inspection is completed. 4.2 Hydrostatic Test Each pressure part like stuffing box jacket or seal reservoir of a unpressurized/ pressurized sealing lubrication system, etc., shall be hydrostatically tested with water at a pressure not Jess than one and a half time the maximum operating pressure. The duration of the test shall be 30 minutes, Criteria of acceptance shall be no leaks. 4.3 Mechanical Run Test (in air) Each agitator unit shall be given a 4 hour mechanical run test in air at vendor’s shop Agitator unit shall be mounted in the same manner as it will operate in the field. During this test, the record shall be made of : a) Shaft run out at the free end. b) _ Dynamic shaft deflection adjacent to the mechanical seal/packing/vapor seal. ©) Gear box oil temperature and temperature of bearing housing in stool. The temperature of gear box oil shall not exceed ambient plus 40°C and that of bearing housing shall not exceed room temperature plus 20°C after the temperatures have stabilized. 4) Bearing housing vibration check shall be carried out. The maximum acceptable vibration velocity shall be 6 mm/sec. ©) Noise levels shall be checked and shall be as per clause 2.1.7 Format No. 6-00-0001-F1 Rev. 0 ‘Copyright EL AllighisresenedOx STANDARD SPECIFICATION STANDARD SPECIFICATION No. eee RR LUMITED FOR 6-26-0001 Rev. 3 sar elses © NOAUMITEL MECHANICAL AGITATORS Page 11 of = f) Agitator shaft RPM and motor RPM. 2) Check of satisfactory operation of shut off and retracting arrangement. 4.4 Mechanical Run Test (in water) If specified in the data sheets, the agitator unit shall be given a load test in water at the vendor's shop. The duration of this test shall be 4 hours unless agreed otherwise between the Purchaser and the vendor. ‘The following parameters shall be recorded during the test: a) Dynamic shaft deflection adjacent to the mechanical seal/packing/vapor seal. b) Gear box bearing oil temperature and temperature of bearing housing in stool. ‘The temperature of gear box oil shall not exceed ambient plus 40°C and that of bearing housing shall not exceed room temperature plus 20°C after the temperatures have stabilized. ©) Bearing housing vibrations. Maximum acceptable vibration velocity is 6 mm/sec. d) Noise levels shall be checked and shall be as per clause, 2.1.7 °) Electrical power input to the motor. f) Agitator shaft RPM and motor RPM. 2) Check of satisfactory operation of shut off and retracting arrangement. 4.5 Acceptance Test At Site (if specified) After the agitator has been installed at site and is ready for test, vendor shall depute his representative to supervise the site acceptance test. All measurements and record of readings shall be done in accordance with para 4.4 above. 5.0 PREPARATION FOR SHIPMENT 5.1 After completion of inspection and tests all exposed machined surfaces and all internal parts shall be thoroughly coated with a rust preventive. All exterior parts of the unit, except. machined surfaces, shall receive one coat of primer and one coat of synthetic enamel of approved make. 5.2 All untapped openings shall be provided with 4mm thick metal closures with full rubber gaskets and bolted with not less than 4 bolts. ‘Tapped openings not otherwise closed shall be plugged. The end of small piping may be closed with tape. 5.3 The agitator shall be supplied with a name plate containing the following information : - Manufacturer's Name - Type and Serial Number of Unit - Rotational Speed - Direction of Rotation - KW Rating - Tag number of equipment - P.O. Number Format No, 6-00-0007-F1 Rev. 0 ‘Copyight ELA ighis reservedENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No. eae OR UMITED aa 6-26-0001 Rev. 3 54 6.0 6.1 1.0 TA 12 ES resenoonen MECHANICAL AGITATORS Page 120f 12 ‘The name plate shall be of stainless steel and relevant information shall be punched onto the same, ‘The equipment and spare parts shall be suitably packed, fastened to avoid damage during transit and crated for shipment and outdoor storage for a period of 6 months. Lifting, unpacking and handling instructions shall be securely attached to the exterior of the largest packing in a well marked weather proof container. The upright position, lifting points, gross weight and dimensions shall be clearly marked on each package. Each package shall clearly identify the equipment contained therein. VENDOR DATA The Vendor shall submit the mechanical calculations for EIL review. EIL's review of calculation shall not relieve the Vendor of his responsibility in any manner. The fabrication drawings and other documents shall also be submitted in accordance with the requisition/bid document. GUARANTEES Unless otherwise specified in General Purchase Conditions (GPC) regarding guarantee, the following shall govern, Vendor shall guarantee the equipment for design, materials, workmanship and specified performance for a period as specified in GPC. Defects/short falls, if any, shall be rectified by the Vendor at his cost by repair and/or replacement without any delay. Review of design/drawing by EIL or release of equipment for shipping shall in no way release or relieve the vendor of any responsibility for making the supplies in accordance with all provisions of this specification. Format No, -00-0001-F1 Rev. 0 ‘Copyright EL Allvighisresened