Hayward Gordon Mixer Maintenance Training Presentation

1. Hayward Gordon Mixer Maintenance Training Presentation Project: ? Equipment: ?

2. STX Mixer Maintenance Equipment Supplied: i.e. Hayward Gordon Mixer Model STX-12 c/w 7.5 hp 1800 rpm motor, single 71” 3AL39 impeller. Mixer output speed of 56 rpm. Wetted parts are 316ss.

3. STX Mixer Maintenance Training Outline: • Introduction. • Mechanics of mixing - Equipment overview. • Gearbox overview • Maintenance – general • Maintenance – motor • Maintenance – gearbox lubrication • Maintenance – wet end • Trouble shooting • Equipment start-up.

4. Introduction Hayward Gordon Ltd. is both a manufacturer of hard metal solids handling centrifugal pumps as well as a full line of mixers. Hayward Gordon Ltd. has been supplying mixers for over 45 years acquiring considerable expertise in the field. Our industry focus is municipal, mining, chemical and petro-chemical. We offer a full range of top, side, and bottom entry mixers. For this project the mixers incorporate our ST series all helical gearboxes.

5. Mechanics of Mixing

6. Mechanics of Mixing • Mechanically mixers consist of the following components: • Drive end. • Speed reduction • Mounting • Shaft • Impeller system

7. Mechanics of Mixing • Drive end – typically an electric motor. • Speed reduction – gear reducer, V-belt drive or combination of the two (gear reducer is most common). • Mounting – either open tank or close tank. • a) open tank: base plate or pedestal • b) close tank: flange mounting requiring a sealing device (mech. seal, etc.) • Shaft – transmits torque to the area of application. • Impeller system – one or more impellers designed to “pump” fluid through the impeller/s and produce “turbulence” both of which are essential to mixing.

8. Mixer Mechanical Overview Motor Gearbox Shaft Impeller

9. Gearbox Overview

10. Gearbox Overview Low speed shaft cover Motor mounting pedestal Gearbox housing and base assembly

11. Gearbox Overview Low speed helical gear High speed helical gear

12. Gearbox Overview Upper low speed shaft bearing – Grease lubricated High speed shaft bearings – Oil lubricated Lower low speed shaft bearing – Oil lubricated

13. Gearbox Overview No leak drywell High speed coupling

14. Gearbox Overview Tapered bushing and keeper plate Quill assembly Additional low speed bearing – Grease lubricated

15. Gearbox Overview – Low speed shaft

16. Mixer Maintenance

17. Mixer Maintenance - General • Monitor agitator for excessive vibration – a large change in vibration levels may indicate a bent shaft or missing impeller blade. • Visually inspect gearbox for oil leaks. • After first week of operation check alignment of the mixer and tighten all external bolts and plugs where necessary. • All hardware should be checked 2-3 months after initial start-up and at each scheduled shut-down. • All hardware should be re-torqued to the values indicated in the manual.

18. Motor Maintenance • Follow manufacturers recommended maintenance times. • Grease bearings (if required) as per manual

19. Gearbox Maintenance - Lubrication

20. Gearbox Maintenance - Lubrication To ensure long gearbox life it is critically important to properly monitor lubricant quality and quantity and maintain lubricating schedule. All ST units are splash oil lubricated. The oil is picked up by the revolving elements and distributed to all bearings (except grease lubricated upper low speed and additional lower low speed shaft bearings) and gear meshes. Oil and grease lubrication is addressed separately in this training.

21. Gearbox Maintenance – Oil Lubrication After first month’s service: • Operate unit until old sump oil reaches normal operating temperature. Shut the unit down and drain immediately • Immediately flush unit with an oil of the same type and viscosity grade as the original charge. • Rapidly pour or pump a charge equal to 25-100% of the initial fill through the unit or until clean oil flows through the drain. • Close the drain and refill the unit to the correct level with new or reclaimed oil of the correct type and viscosity. • If determined to be in good condition by the supplier, reclaimed oil may be reused if it is filtered through a 40 micron or finer filter.

22. Gearbox Maintenance – Oil Lubrication Table 16: Approximate Oil Capacity -- Quarts • The recommended grade oil should be used based on ambient temperature. • Change oil a minimum of every 2500 hours of operation or 6 months, what ever occurs first

23. Gearbox Maintenance – Oil Lubrication • Test oil regularly. Inspect for high concentration of metal filings (this could indicate gear wear) • Check oil level weekly • Oil changes should be more frequent in hot, humid or dusty environments. • External oil pumps and filters can be installed in very harsh conditions.

24. Gearbox Maintenance – Oil Lubrication Table 11: Gear Oil Viscosity Recommendations LUBRICATION Lubricant Recommendations Lubricants listed in this manual are typical products ONLY and should not be construed as exclusive recommendations. Industrial type petroleum based rust and oxidation inhibited (R & O) gear lubricants or industrial type sulphur-phosphorus extreme pressure (EP) gear lubricants are the recommended lubricants for ambient temperatures of 15°F to 125°F (-9°C to 52°C). For units operating outside the above temperature range refer to the synthetic lubricants paragraph. Viscosity (Important) The proper viscosity grade for R & O and EP lubricants is found in Table 11. For cold climate conditions refer to Table 14: Polyalphaolefin Type Synthetic Lubricants1, page 26, and the "Synthetic Lubricant" paragraphs. Select a lubricant that has a pour point at least 10°F (5.5°C) below the expected minimum ambient starting temperature. Useable temperature ranges can sometimes be widened if specific application conditions are know. R & O Gear Lubricants (Table 12) Industrial type petroleum based rust and oxidation inhibited (R & 0) gear lubricants are the most common and readily available general-purpose gear lubricants.

25. Gearbox Maintenance – Oil Lubrication Table 12: Petroleum Based R & O Gear Oils (Maximum operating temperature of lubricants 200F (93C)

26. Gearbox Maintenance – Oil Lubrication Oil dipstick Oil Fill and breather assembly Oil Drain

27. Gearbox Maintenance – Grease Lubrication For an ST mixer design there are four (4) grease fittings. The upper LS (low speed) bearing is grease packed at the factory. The extra lower LS bearing requires grease addition until grease exits the purge port below the grease fitting.  Prior to operation of the unit apply a few shots of grease to each of the seal grease fittings.

28. Gearbox Overview Four grease fittings

29. Gearbox Maintenance – Grease Lubrication L.S. bearing grease fitting Grease purge port

30. Gearbox Maintenance – Grease Lubrication TABLE 15 - GREASES FOR GREASE LUBRICATED BEARINGS AND GREASE PURGED SEALS** 0F TO 200F (-18 TO 93C)

31. Wet End Maintenance

32. Wet End Maintenance – Rigid Couplings Rigid Couplings • Coupling have male/female spigots for accurate alignment (no match marking required) • Hex Head cap screws (minimum grade 5) clamp couplings together with lock washers and hex nuts.

33. Wet End Maintenance - Impeller Blade to Hub arrangement • Blades placed on front side of hub (Blade is ‘pushed’ through the water) • Hex Head cap screws with washers and double nutting ensure strong clamping result between blade and hub.

34. Impeller breakdown Impeller hub Impeller blade Impeller hub ear and bolting

35. Troubleshooting

36. Trouble Causes Action Gear Wear 1. Improper backlash If backlash is insufficient, adjust to specifications. Refer to factory. 2. Gear Misalignment Check contact pattern; should cover approximately 75% of face, preferable in center area. Check condition of bearings. 3. Twisted or distorted housing Check shimming and stiffness of foundation. 4. Unit overloaded Reduce the loading or replace with drive of sufficient capacity. 5. Improper oil level Check level indicator that oil level is accurately at level indicated on housing plus 1/4”, minus 1/4”. 6. Bearings out of adjustments Make sure all bearings are not pinched. All shafts should spin freely when disconnected form loads. Adjustable tapered bearings must be set at proper lateral clearance. 7. Wrong grade of oil Check that oil grade specified in lubrication instructions. If it is not, clean unit and refill with correct grade. 8. Contaminated oil Check that oil grade specified in lubrication instructions. If it is not, clean unit and refill with correct grade.

37. 9. Coupling misalignment Disconnect couplings and check alignment. Realign as required. 10. Excessive speed Reduce speed or replace with drive suitable for speed. 11. Torsional or lateral vibration These vibrations will occur thru a particular speed range. Reduce speed to at least 25% below critical speed. System mass elastic characteristics to be adjusted to control critical speed location. If necessary, adjust coupling weight and stiffness and shaft lengths and diameters. 12. Rust due to water or humidity Make necessary provisions to keep out water. Use lubricant with good rust inhibiting properties. Make sure bearings are covered with sufficient lubricant. 13. Bearing exposed to an abrasive substance Make necessary provision to keep out abrasive substance. Clean and flush drive thoroughly and add new oil. Replace worn bearings. Abrasive substance will cause excessive wear; evidenced by dulled balls, rollers, and raceways.

38. Bearing Failure 1.Unit Overloaded See Overheating Item 1. Abnormal loading results in bearing flaking, cracks and fractures. 2.Excessive overhung load Reduce overhung load, use outboard bearing, or replace with unit having sufficient capacity. 3.Excessive speed Reduce speed or replace with drive suitable for speed. 4.Coupling misalignment Disconnect couplings and check alignments. Realign as required. 5.Bearings out of adjustment See Overheating Item 3. If bearing is too free or not square with axis, erratic wear pattern appears in bearing race. 6.Insufficient bearing lubrication See Overheating Items 2,6,7,8. Improper lubrication causes excessive wear and discoloration of bearing. 7.Rust due to water or humidity Make necessary provisions to keep out water. Use lubricant with good rust inhibiting properties. Make sure bearings are covered with sufficient lubricant. 8.Bearing exposed to an abrasive substance Make necessary provision to keep out abrasive substance. Clean and flush drive thoroughly and add new oil. Replace worn bearings. Abrasive substance will cause excessive wear, evidenced by dulled balls, rollers, and raceways.

39. Overheating 4. Dry oil seals 1. Unit overloaded Oil seals should be lubricated. If provision has been made for greasing, apply grease; otherwise apply small quantity of oil externally until seal is broken in. Reduce the loading or replace wit drive of sufficient capacity. 2. Improper oil Level Check level indicator that oil level is accurately at level indicated on housing plus or minus 1/4”. 5. Clogged breather Breather should be open and clean. Clean breather regularly in a solvent. 3. Bearings out of adjustment Make sure bearings are not pinches. All shafts should spin freely when disconnected from load. Adjustable tapered bearings must be set at proper lateral clearance. 6. Wrong grade of oil Check that oil is grade specified in lubrication instructions. If it is not, clean unit and refill with correct grade. 7. Contaminated oil Check oil for oxidation, dirt, and high sludge content. Change oil. 8. Coupling misalignment Disconnect couplings and check alignment. Realign as required. 9. Excessive speed Reduce speed or replace with drive suitable for speed.

40. Shaft Failure 1.Coupling misalignment Realign equipment as required. 2.Excessive overhung load Reduce overhung load. Use outboard bearing or replace with unit having sufficient capacity. 3.Unit overloaded Reduce the loading or replace with drive of sufficient capacity. 4.High energy loads or extreme repetitive shocks Apply coupling capable of reducing shocks and if necessary, replace with drive of sufficient capacity to withstand shock loads. 5.Torsional or lateral vibration These vibrations will occur thru a particular speed range. Reduce speed to at least 25% below critical speed. System mass elastic characteristics to be adjusted to control critical speed location. If necessary, adjust coupling weight and stiffness and shaft lengths and diameters.

41. Mixer Start-up Form

44. Summary When requesting spare parts: Provide Unit Model number Provide Hayward Gordon Serial number. Item numbers of parts required Maintenance Manuals are accessible on our website at www.haywardgordon.com