搅拌器说明书(直连)(1)

APMA泥浆搅拌器使用及维护说明书APMA mud agitator Operation & maintenance manual陕西艾潽机械制造有限公司Shaanxi Aipu Solids Control Co.,Ltd第一章导言总则本说明书介绍了钻井泥浆搅拌器的安装，使用和维护说明，.为了方便查阅相关信息，本说明书分成了几部分。

负责运输人员，安装人员，使用人员，以及技术服务人员，需要认真阅读并理解本说明书。

在设备使用现场需要备有一份说明书，便于使用人员阅读。

安全本说明书包含设备使用和维护过程中的安全信息。

这些信息需要告知所有人员，并确保其能理解。

在出现故障和其他问题时，严禁使用搅拌器。

设备用途搅拌器用于在开顶罐上的泥浆搅拌。

不允许设备用在其他用途。

使用设备要遵循本说明书中所列的使用，维护和安全说明。

说明和操作泥浆搅拌器是高效的泥浆搅拌器，配有多种定制化的尺寸和排列方式，适用各种罐体各种泥浆。

有立式和卧式两种类型，适用用各种尺寸的泥浆罐。

卧式搅拌器用于安装在顶部空间较小的泥浆罐上面。

立式搅拌器采用圆柱斜形齿轮传动，卧式搅拌器采用螺旋锥齿轮传动搅拌轴上的单层或者双层的直立式或者倾斜式叶轮。

搅拌器搅拌泥浆，使固体颗粒悬浮在泥浆里。

搅拌器安装在泥浆罐顶部，单层和双层叶轮沉入泥浆里。

搅拌轴跟电机直连，额定功率从2.2Kw到22Kw,频率50Hz或者60Hz。

每个泥浆搅拌器用于具体的泥浆罐，要考虑罐体尺寸，深度，以及泥浆参数。

AIPU公司提供立式和卧式搅拌器。

立式搅拌器采用圆柱斜形齿轮转动搅拌轴，卧式搅拌器采用螺旋锥齿轮传动搅拌轴。

两种类型的搅拌器都可以安装单层或者双层的直立式或者倾斜式叶轮。

叶轮通过螺栓或者焊接在轴上，安装在工作轮上的销轴防止叶轮的旋转。

叶轮安装在离罐底0.75倍叶轮直径的高度上。

例如，叶轮直径为1000mm，那叶轮需要安装在离罐底750mm 的高度上。

AIPU公司建议罐高度小于1500mm时使用直立式叶轮，较深时使用倾斜叶轮。

如果使用两个轮子，直立式叶轮安装在底部，倾斜式叶轮需要安装在罐底上2/3高度处。

电机和被动轴通过连接法兰盘连接。

轴长根据客户技术要求定做。

轴长超过2400mm需要在罐底安装稳定器，用于稳定轴。

主要组成部分尽管不同配置和尺寸的搅拌器组成是相同的，但是电机，叶轮，轴长，直径，减速机，转动方向取决与搅拌器型号。

图1－2中展示了搅拌器的标准配置。

相同功率的卧式搅拌器除了齿轮的传动形式，其他配置都是相同的。

在现场需要专业技术人员或经过培训的人员进行搅拌器的安装。

电机搅拌器由三相异步电机驱动。

功率范围是5-30马力(4-22Kw)，电制为230/460V，60hz，3-25马力((2.2-22Kw)，电制190/380V50HZ。

电制根据客户的要求配置。

客户提供电源，配套设备和防护设备。

减速机电机的转动通过直连齿轮传动到搅拌轴上。

驱动装置是减速机和电机相连，已在工厂组装好。

驱动装置的尺寸允许使用最大扭矩来实现搅拌轴转速达到60转/分。

立式搅拌器采用斜齿轮传动功率到搅拌轴，卧式搅拌器采用普通蜗轮蜗杆减速机或斜齿轮减速机传动功率到搅拌轴。

搅拌轴搅拌器叶轮直径从20''-52''(500-1320mm)，可以满足不同尺寸泥浆罐的要求。

叶轮直径由罐尺寸决定。

大罐或者深罐需要两层叶轮，第二层叶轮安装靠近泥浆表面。

用销轴把叶轮固定在轴上，防止旋转。

直立结构使泥浆水平运动，而倾斜式叶轮在搅拌过程增加了上下运动。

产品技术支持和服务AIPU公司对生产的产品提供全天候的技术支持。

这包括更换/订单，以及更换/修理和产品总成及维修配件的信息。

参见下表服务中心联系方式.第二章安全综述本章包含了在使用中的警告信息，同时有使用设备时材料安全信息参考表。

泥浆搅拌器用于在安全区域实现说明书所阐述的功能。

警告所有使用人员和设备维修人员在使用设备和维修设备前要学会和理解安全信息。

进行下列安全提醒是工作内容一部分。

声音影响警告！为了防止失聪，在工作期间或者设备附近是需要佩戴防护设备电力安全警告！为了防止在维修和调整前发生严重伤害，需要确认，设备已断电。

警告！电机需要在指定电压下工作。

警告！高压危险。

确定，摘开电源传输开关保险装置。

在维修或者调整期间要使设备处于闭锁，并固定预防签在电源处，防止偶然的电力传输。

第三章安装综述本章含有搅拌器设备安装时建议顺序的描述，根据图纸和设备型号。

设备可以分开以便于运输。

安全在搅拌器安装和工作前必须学习和理解所有列在本章中的和其他相关文件的信息。

参照第二章中关于本设备安装，使用和维修方面的警告。

安装前，学习在本章列出的拆卸和安装顺序。

设备起吊或者转移前，特别注意有关起吊点和摇臂使用的信息。

不遵守安装和拆卸顺讯可能会产生严重损伤或者损坏。

型号确定为了保证需要的搅拌器和固体颗粒悬浮，必须正确确定搅拌器规格和安装。

确定搅拌器规格需要以下：1、选择好类型―― 立式或者卧式2、电制――230/460V，60HZ，3相或者190/380V，60HZ，3相3、根据以下参数选择功率和叶轮：a、罐的类型――圆形或者方形b、罐的尺寸c、泥浆比重d、转速比以下是搅拌器使用方面的建议：1、罐体尺寸要一样，即，宽高比一样或者接近2、不要设置转动时间超过85秒，因为可能破坏固体颗粒悬浮3、不要设备转动时间低于40秒，因为可能产生漩涡，使空气进入。

安装顺序接下来进行搅拌器安装的连续步骤。

所列安装顺序是完成安装的指南，但是根据客户拥有的资源会有变化，比如以前使用设备和选择的设备的经验。

1、开始安装和设备工作前，要阅读和学习第二章中所有的有关安全信息。

2、开始起吊移动设备前，要阅读和学习本章中设备装卸顺序。

3、参照第八章搅拌器各组成部分的名称4、在罐上安装和焊接安装台和稳定器（如果需要）。

5、把轴放入罐中，安装叶轮，锥形套和联轴节6、安装联轴节到主动轴7、安装电机和减速机，搅拌轴联轴节和主动轴联轴节相连。

8、接电。

设备装卸AIPU搅拌器可以以多种形式运输，除了电机和减速机需要一体运输。

其他的部分，除了轴，包装一个硬质纸箱里。

轴单独并且固定在底座上。

每个包装带有标签标明重量等。

设备能用吊装设备以及叉车装卸水平调整为了减速机和联轴器长期稳定使用而不是非运用过程种的磨损，轴应该在绝对垂直方向上转动。

这就需要安装平台在绝对的水平方向。

使用扶正套时应确保其与安装台中心完全相对。

减速机底座安装位置需要预先确定。

选择安装位置要留出叶轮和罐壁的间隙。

利用水平尺保持安装台的绝对水平。

利用调整垫片保持水平，标出垫片位置，然后拆下安装台。

因为安装台需要在安装联轴器前安装在减速机上。

扶正套（轴长超过2400mm）如果轴长超过2400mm,需要安装扶正套，为确保同心度，有以下形式1、从安装台中心孔放下垂直线，保证同心度2、确定好正确位置后，焊接在底部电机和减速机组装1、把安装板安装到减速机上。

安装板中心要与主动轴保持同心，紧固垫片和螺栓（一个螺栓两个垫片）。

按顺序拧紧螺栓，对角线安装。

2、安装叶轮到主动轴上，通过法兰转向驱动方向。

放入搅拌轴，要与断面平齐，放入止口固定3、保持组装好的轴直立，利用起吊设备把电机和减速机部分连同安装板放到罐面。

4、缓慢放下减速机和安装台到罐面上（用垫片保持平衡）安装联轴节，如本章所述。

安装示意图第四章使用说明综述本章讲述开始和正常启动，停止顺序。

为了保证使用和停止设备过程中的安全。

首次启动首次启动，是在设备第一次使用时，或者长时间停机后重新使用时的启动。

检查电源线是否接好，减速机叶轮是否卡死，减速机是否加油或者油量是否到位，然后开启启动按钮，观察搅拌器运转情况，振动和声音是否有异常，如有异常应立刻停机检查正常启动和工作按照日常工作安排，对设备定时检查和保养，如有问题及时维修，保证设备正常运转正常停止停止前请关闭泥浆仓人口阀门，停止泥浆在流入该仓。

紧急停止如果在运转过程中出现异常情况，需要立即关停设备控制箱上紧急停止按钮。

第五章技术维护综述为了保证搅拌器能够更长时间使用和不发生故障，进行例行维护是非常重要的。

本节所列维护规则是很灵活的。

改造需要建立在使用该设备丰富经验的基础上。

在设备使用期内必须以书面形式建立例行维护，控制和管理设备的安排以方便监测并调整维护计划表。

在起草技术维护安排时，考虑以下内容：工作周期、环境温度、使用条件例行维护例行维护包含减速机润滑油油位，润滑油情况，轴承润滑脂减速机根据使用环境尽可能多的检查减速机油位和油量。

最长更换时间――10000工作小时或者每两年，先到为准。

工作负荷大的情况下，需要多次更换润滑油。

使用合成润滑油更换周期要断。

检查油位见第三章。

下表列出了油量和可用的润滑材料。

轴承加油和清洗周期同样。

清洗后，加油到剩余1/3量。

电机检查电机检查应在每500工作小时或者每3个月进行，先到为准。

包括以下几点：1、清理电机和风扇孔。

确保，在电机内部和外部没有杂物，油迹，水或者其他污物。

正常运转的风扇防止过热和过早的发动机故障2、定期检查绝缘电阻和绝缘电阻，导致绝缘电阻显著下降的原因。

3、检查所有电缆和电线连接I. ForewordGeneralThis manual provides installation, operation, and maintenance instructions for the APMA mud agitators. The manual is divided into several sections to assist the user inreadily accessing the information.Personnel responsible for transporting, installing, commissioning, operating, or performing maintenance on this equipment are required to read and understand the instructions provided in this manual. One copy of this manual should be available and accessible at the equipment location.SafetySection 2 of this manual contains relevant safety information relating to both operation and maintenance of this equipment. Be sure this information is read and understood by all personnel.DO NOT operate the equipment if defective or faulty mechanical or electrical components are detected.UseThe mud agitator is designed for stirring mud slurries in an open tank. Aipu does not authorize any other use of this equipment. Intended usage of the equipment includes compliance with the operating, maintenance, and safety instructions provided in this manualDescription & operationThe mud agitators are high-efficiency mud-mixing units offered in a wide array of custom sizes and configurations to accommodate virtually any mud tank. Both horizontal and vertical drive configurations are available for all sizes of mud agitators. The horizontal drive is designed for installations having limited space above the mud tank. The vertical drive agitator employs an all- helical gearing system, and the horizontal drive utilizes a helical-bevel system to drive the agitator shaft, which may have one or two straight or canted mixing impeller(s).The mud agitator stirs a mud slurry to maintain suspension of solids. The agitator is mounted on top of the mud tank and has one or two impeller(s) immersed in the mud slurry. The impeller shaft is directly coupled to an electric drive motor that is available in several horsepower ratings from 3 (50Hz only) to 30 (60Hz).Each mud agitator is designed for the specific application, taking into account parameters such as tank size, tank depth, and mud characteristics. Aipu offers mud agitators in both vertical and horizontal drive motor configurations. For vertical configurations, the drive motor rotates the impeller shaft through an all-helical gear drive. For horizontal designs, themotor is connected through a combination of helical and bevel gears. Both designs permit mounting one or two impellers having either straight or canted blades.The impeller is secured to the shaft by a tapered locking bushing and prevented from rotating by a key inserted into the impeller shaft. Its vertical location on the shaft is determined as a height from the tank bottom corresponding to the impeller diameter times 0.75. For example, a 20” impeller should be mounted 15” above the bottom. Aipu recommends straight impeller blades for tanks under 5’ deep and canted blades for deeper tanks. If dual impellers are desired, straight blades are mounted on the bottom and the canted blade impeller is installed at a point about two-thirds above the tank bottom.The keyed motor and driven impeller shafts are rigidly connected by a multi-piece coupling, which uses tapered locking bushings to secure the shafts together. Shaft lengths are customized to suit customer speci fications. For shafts longer than 8’, a stabilizer is mounted on the tank bottom to support the lower end of the shaft.Major componentsAlthough the arrangement mud agitator components is identical across the various sizes and configurations, the drive motor, impeller, shaft length and diameter, gear drive, and motor orientation vary between models. Figure 1-2 shows the typical components of a vertical mud agitator. The horizontal configuration for the same power rating is identical, except for the type of gear drive. The unit is shipped unassembled and requires assembly by a trained, qualified technician.MotorThe mud agitator is operated by a 3-phase induction motor. Drive motors range from 5 to30hp (4~22kw) for the 230/460Vac 60Hz power configuration and 3 to 25hp (2.2~18.5kw) for the 190/380 50Hz power configuration; the power requirements are specified on the customer order. Electric power, switching, and safety devices are provided by the customerGear boxRotation of the drive motor is transferred to the impeller shaft through the directly coupled gear drive. The drive is a reduction gearbox and is factory assembled to the drive motor. The drive is sized to apply the maximum torque required to produce the design impeller rotation speed of 60 rpm.For vertical configurations, helical reduction gears transfer power from the motor to the impeller shaft. Horizontal gear drives employ a combination of helical and bevel gearsI mpellers are available in diameters ranging from 20” to 52” to meet the needs of various size mud tanks. The impeller diameter is generally determined by the size of the tank. Larger or deeper tanks employ dual impeller units having a secondary impeller mounted closer to the mud surface. The impeller is mounted on the shaft using a tapered locking bushing. A key inserted in the impeller shaft locks the impeller to the shaft and prevents rotation.The straight blade configuration disperses mud laterally, while the canted impeller blades add a vertical component to the mixing process. Canted impeller blades are desirable near the bottom of tanks more than 5’ deep or where other forces of flow factor may be absent in the tank.II.SafetyGeneralThis section contains a summary of WARNINGS used in this manual and a list material safety data sheets (MSDSs) applicable to the equipment. The mud agitator has been designed to perform the stated functions safelyWarningAll persons responsible for operation and maintenance of this equipment must read and understand all safety information in this manual prior to operating and/or maintaining the equipment. The safety warnings listed below are included in applicable procedures throughout this manualElectrical HazardsWARNING! TO AVOID SERIOUS PERSONAL INJURY BE SURE EQUIPMENT IS LOCKED OUT, TAGGED OUT, AND DE-ENERGIZED PRIOR TO PERFORMING MAINTENANCEAND/OR ADJUSTMENTS.WARNING! MOTOR MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE.WARNING! HIGH VOLTAGE MAY BE PRESENT. BE SURE FUSED DISCONNECT SUPPLYING ELECTRICAL POWER TO THIS EQUIPMENT IS OPEN. LOCK-OUT ANDTAG-OUT POWER SUPPLY TO PREVENT ACCIDENTAL APPLICATION OF POWER WHILE MAINTENANCE AND/OR ADJUSTMENTS ARE IN PROGRESS.III. InstallationGeneralThis document describes the recommended installation procedure for the Aipu agitator defined by the model number and drawing number associated with your equipment. This equipment may be partially disassembled to comply with shipping restrictionsRead and understand ALL safety information presented in this and associated documents before installing and operating the mud agitator. Refer to Section 2 for a summary ofwarnings related to installation, operation, and maintenance of this equipment.Before beginning the installation, review the equipment handling procedures in this section.Pay particular attention to information concerning “lift points” and the use of spreader bars before lifting or moving the equipment.Failure to observe proper equipment handling procedures may result in serious personalinjury and/or damage to the equipmentSizingFor proper mixing and suspension of solids, the mud agitator must be properly sized and installed. To properly size a mud agitator, proceed as follows:1.Select desired style - horizontal or vertical 2.Determine available electric power - 230/460V/60Hz 3 phase or 190/380V/50Hz 3 phase3.Select horsepower and impeller(s) as determined by the following factors:a.Tank design - round or square b.Tank dimensions c.Maximum mud weight d. Desired turnover ratio (TOR) Following are operational recommendations for mud agitators:1.Maintain uniform tank dimensions, i.e. equal width-to-length ratio or as close as possible toequal. 2.Avoid TOR values greater than 85 seconds, as this may jeopardize solids suspension. 3.Avoid TOR values less than 40 seconds, as this may result in formation of a vortex andincrease air entrapment. Installation sequenceFollowing are the sequential steps of the mud agitator installation procedure. The sequence presented is a guideline and may vary depending on the user’s facilities, previous experience with this equipment, and optional equipment.1.Read and understand all safety information in Section 2 before installing and operating thisequipment. 2.Read and understand the equipment handling procedures later in this section before liftingand moving the equipment. 3.Refer to Section 8 to identify the mud agitator components. 4.Locate and weld mounting plate and stabilizer (if required) to tank structure. 5.Place shaft in tank, and assemble impeller(s), tapered bushings, and male coupling on shaft.6.Install female coupling on gearbox shaft. 7.Install motor and gearbox assembly, and attach shaft coupling to gearbox coupling. 8.Connect electric power supply to drive motor. HandlingAIPU mud agitators are shipped disassembled except for motor and gearbox, which are supplied as an assembly. All components except the shaft are packaged in a single palletized carton. The shaft is packaged separately and strapped to a skid. The delivered equipment should be transported on the ground using a forklift. Once removed from the shipping skid, an overhead lifting device may be used.LevelingTo prevent undue premature wear on the gearbox or coupling and ensure long-term reliability and efficiency of the mud agitator, the impeller shaft should rotate in a true vertical orientation. This vertical installation is achieved by ensuring that the mounting plate is absolutely horizontal. If a stabilizer is used, it must be directly aligned with the center of the mounting plate. The following paragraphs describe the correct methods for installing the mounting plate and stabilizer. Refer to Figure 3-2 for parts identification and assistance in the installationGearbox plateThe mounting location must be determined before the gearbox is installed. When selecting the mounting plate location, ensure that sufficient clearance is provided between the impeller blades and the tank wall. Use a level to ensure absolute, horizontal orientation of the mounting plate in two perpendicular directions. Select shims as needed to achieve level mounting, mark the position of shims, and then remove the plate from the tank as it must be placed onto the gearbox shaft before installing the female couplingStabilizer（shaft over 8'/2400mm）If impeller shaft is more than 8’ long, a stabilizer is required to support the lower end of the shaft. Install the stabilizer as follows:1.Drop a plumb line through the center of the mounting plate to locate the exact centerposition of the stabilizer on the tank floor. 2.After determining its proper location, weld the stabilizer to tank floor. Assembly & installation of motor and gearbox1.Slide the mounting plate onto the gearbox shaft. Align mounting holes with gearbox, and secure mounting plate to gearbox with cap screws, washers (two at each location), and locknuts. Tighten all screws using an alternating, star-pattern sequence. 2.Install female coupling on gearbox shaft with wide flange facing away from gearbox. Position coupling with its hub flush with top of shaft, and select and install tapered bushings to secure coupling to shaft (refer to Shaft Assembly procedure above). 3.While supporting the assembled shaft vertically, use an appropriate lifting device to hoist and position the motor and gearbox assembly into alignment with the mounting plate location on the tank. 4.Slowly lower gearbox and mounting plate onto the tank (with any shims required for leveling mounting plate). 5.Gearbox lubrication levelVerify that lubricant level in the gearbox reaches the bottom of the oil level plug. Please refer to gearbox manual for more detailElectrical connectionConnect the three motor leads to the incoming power source, Also, refer to the motor connection diagram inside the motor’s conduit box cover for assistance.Before making power connections, be sure that electrical source meets one of the following standards:1. AC power at rated frequency is within ±10 percent of rated voltage, or 2. AC power at rated voltage is within ±5 percent of rated frequency, or 3. Combined variation in voltage and frequency is ±10 percent of rated values, provided the frequency variation does not exceed ±5 percent of rated frequency. Refer to motor manufacturer’s literature for additional assistance in making electrical connections.Start mud agitatorPlease refer to following information as well as control cabinet instruction for additional reference.IV.OperationGeneralThis section contains initial and normal startup and shutdown procedures for the mud agitator. These procedures are designed to ensure safe operation and shutdown of the equipment.Initial startupThe Initial Startup procedure is to be used when the equipment is being started for the first time, or when equipment is returned to use after an extended period out of service. The initial startup is performed as follows:1.Verify that all operators and maintenance personnel have read and understand all operatingand safety information in Section 2. 2.Verify that equipment has been assembled and installed in accordance with Section3. 3. Check oil level in gearbox (see Section 3). If low, fill to bottom of level plug. 4. Jog drive motor to check that impeller rotates in the correct direction. If rotation is incorrect, shut down and lock out and tag out electric power, and reverse any two leads to switch direction of motor rotation. Normal startup and operationOperate and maintain equipment according to the instruction. Do repair work instantly for daily normal performanceNormal shutdownTo shut down the mud agitator for any reason, first shut off the mud feed and then turn off electric power to the agitator motorEmergency shutdownTo immediately stop the machine in case of emergency, open the fused disconnect supplying electric power to the machine.V.MaintenanceGeneralRoutine maintenance is critical to ensure maximum life and trouble-free operation of the mud agitator. While the recommended maintenance schedule in this section is flexible, modifications should be based on experience with operating the equipment at your facilities.A maintenance log should be kept to help establish a routine maintenance schedule, as well as to monitor and adjust the schedule as necessary throughout the equipment’s life. When determining a suitable maintenance schedule, consider duty cycle, ambient temperature, and operating environmentRoutine maintenanceRoutine maintenance consists of checking gearbox oil level and oil condition and greasing gearbox bearings at required intervals.GearboxThe gearbox oil level and condition should be checked frequently, as necessary, depending on operating environment. The maximum oil-change interval is every 10,000 operating hours or every 2 years, whichever comes first. However, a more frequent interval is recommended due to the mud agitator’s severe operating environment. If synthetic oil is used, the interval can be extended. To check oil level, refer to Section 3. Refer to the following tables for oil quantities and approved lubricants.Bearings should be cleaned and re-greased on the same schedule as oil changing. After cleaning, fill bearings to one-third of their free volume.Motor inspectionInspect motor approximately every 500 hours of operation or every 3 months, whichever comes first. Perform the following steps when inspecting the motor:1.Clean the motor and ventilation openings. Check that motor interior and exterior are free ofdirt, oil, grease, water, or other contaminant. Proper ventilation prevents overheating and premature failure. 2.Check insulation resistance periodically, and immediately investigate cause of anysignificant drop in insulation resistance. 3.Check that all electrical connections are secure. TroubleshootingIf mud disturbance in the tank becomes unsatisfactory, check the possibilities listed below and correct as described.。