IChE QUIPMENT TESTING PROCEDURE \ | EQUIPMENT - "(Impeller Type) oh {CAN INSTITUTE OF CHEMICAL ENGINEERS AST 47 STREET * NEW YORK, NEW YORK 10017CAN INSTITUTE OF CHEMICAL ENGINEERS EQUIPHENT TESTING PROCEDURES COMMITTEE Chairman: R.L. Neary Monsanto Company t Vice Chairman: 8.D. Fegan ‘Lawrence Pump and Engine Co. : Past Chairman: R.E. Hcliarg 1 |" UOP (Retired) ' WIXING EQUIPHENT - IMPELLER TYPE PROCEDURE REVISION SUBCOMMITTEE ReAs Coble and D.S. Dickey Union Carbide Corp. (Retired) Patterson-Kelley Co Meabers C.N. Carpenter ¥.D. Ramsey Monsanto Company Chenineer, Inc. C.K, Coyle R.N. Salzman Hixing Equipment Co. Mixing Equipment Co. J.B. Fasano W.D.R. Short Chemineer, Inc. E.L. du Pont de Newour Co. CN. Garrison J.A. Von Essen Procter & Gamble Co. Philadelphia Mixers Corp. J.B. Gray Beechwood Consultants Meabers Participating in First Edition Bates C.H. Nelson Canham, Jr. HLF. Nolting Connolly SLY, Oldshue Gray: R.B. Olney, Jebens T. Vermeulen Lopata ; 8.8. Keidenbaun Lyons vy ‘Second Edition ‘officially approved by AIChE Council on November 24, 1987 {u\/ for publication, supersedes all earlier versions published. ij} Mipteat paition officially approved by AICHE Council in 1959 for puttication. i. ah { Edition revised, January, 1965 ye api rane ‘AICHE anid members ‘of ‘the various committees involved make no representation, warranties or lquarantecd ji expressed or implied, az to the application or fitness of the testing procedures miggested’ herein iforj‘any, specific purpose or Company affiliations are shown for infor- ifaation oniy aid dd) not; imply ‘procedure approval by the companies listed.AIChE Equipment Testing Procedure HIXING EQUIPMENT) IMPELLER TYPE A Guide to Performance Evaluation Second Edition Prepared by the Equipment Testing Procedures Committee Copyright 1967 . American Institute of Chemical Engineers 345 East 47 Street, New York, NY 10017TABLE OF CONTENTS PSE 100.0 PURPOSE AND SCOPE . {01.0 Purpo: 102.0 Scope 103.0 Liability 200,0 DEFINITION AND DESCRIPTION OF TERNS 201.0 Introduction... ees ees 202.0 Nixing Equipment... s,s 202.1 Equipment Configurations . . 202.2 Impellers... +++ ss i207: S Veaselateees eee 203.0 Basic Nomenclature... . 203.1 Equipment Variables... ; 203.2 Agitation Related Groups. . 203.3 Process Related Groups... 204.0 Operating Conditions... . . . 205.0 Types of Tests... 1... 205.1 Operating Performance... . 205.2 Mechanical Conditions... - 205-3 Mechanical Operation . - . - 205-4 Process Conditions .... . 206.0 Performance Criteria... .. - 300,0 TEST PLANNING 6 oe ee ee 301.0 Preliminary Considerations . . - 301.1 Safety... ee ee 301.2 Environmental... 301.3 Performance Criteria 301-4 Test Objectives . . . 301.5 Multiple Applications 302.0 ‘Plans for Operating Performance Tete eee ere 302.1 Speed. . 302-2 Power... 302.3 Torque . . 303.0 ‘Plans for Hechanicai Condition Tests 303.1 303.2 Equipment Verification < . ° Algment Ove: 303.3 Runout 5 303-4 Gear Tooth Contact 303.5 Seals... ...- 303.6 Auxillary Equipaent 303.7 Vibration... . . 303.8 Noise... se : 304.0 ‘Plans for MechanJcal Operation Tests 305.0 Plans for Process Condition Tests 308.1 * 305.2 308.3 305.4 305.5 Miscible Liquid Blending . . Heat Transfer»... Inniscible Liquid Dispersion Solids Suspension in Liquid . Gas-Liquié Dispersion... « 305.6 Variable Conditions... 305.7 Other Heasurable Results|. - 306.0 Performance Criteria... ... 400.0 MEASUREMENT HETHODS & INSTRUMENTS . 401.0 Introduction... 402.0 Operating Performance Heasurenents WOR. Speed ose cee ee ee oil 6 oouodcod00d 402.3 Torque . 403.0 ‘Hechanical Condition Heasur 403.1" Alignment and Adjustment. 403.2 Runout . Fi 403.3 Gear Tooth Contact Pattern’ Rov) (igen umee os 403.5 Auxiliary Equipment . . 403.6 Vibration... + 403.7 Noises. sss. ttt 403.8 Temperature... 404.0 “Mechanical Operation Measurements 404.1 Natural Frequency... . 404.2 Shaft Strain... ss 404.3 Deflection... . 404.4 Spectral Analysis 405.0. "Process Condition Heasurenents ‘05.1 Density or Specific Gravity - 405.2 Viscosity... : Physical state Chemical Composition... 405.5 Other Physical /Chemical Properties»... a 406.0 Syste Operating Conditions | 06.1 Temperatures... ss ss 406.2 Pressure i 06:3 Fluid Level, Volune, and Fiow 406-4 Phase Ratios 406.5 Blend Time 406.6 Sampling»... 5. ss 300,0 TEST PROCEDURES... 2... 501.0 General Test Procedures 502.0 Preliminary Operation and Safety 502.1 Instruction Manuals 502.2 Check for Debris in Vessel” 302.3 Check for Obstructions 502.4 Pre-Operational Check . - 502.5 Hand Turning 302.6 Joge sess esses 502.7 Hydrostatic Pressure Tes! 502.8 502.9 Systen Water Test . ‘i 503.0. Operating Performance Tests. . i503, Wi spesd eee ee 503.2 Power... ss Com) ite ood noob bG : 504.0 Mechanical Condition Tests . . . 504.1 Alignment and Adjustments . | 504.2 Runout ss. ss. 504.3 Gear Tooth Contact Pate BOHM Seals. ee eew a 504.5 Auxiliary Equipment... .. 18 703.1 Alignment and Adjustments . . 26 300.6 Vibration... se eee 19 703.2 Runout seve es 26 504.7 Noise. ss ee ees 19 03.3 Gear Tooth Contact Patterns » 26 504.8 Temperature... . 5. 19 03:4 Seals esse ree es 505.0 Mechanical Operation Tests... 19 703.5 Auxiliary Equipment»... + 26 505.1 Natural Frequency... . + 19 703.6 Vibration... ese 6 505.2 Deflections of Structure .. 19 uchd ehig@insachocdoo f 506.0 ‘Process Condition Tests... . 19 703.8 Temperature»... 1% 506.1 Blending... ss Dil 49 703.9 Water Power and Corrections . 27 506.2 Heat Transfer... 0. 19 704.0 ‘Interpretation of Hechanical 506.3 Imniscible Liquids Dispersion 20 Operation. eee ee ee ee 2 306.4 Ligquid-Solid Contacting . . . 20 704.1 Natural Frequency Vibrations 27 50615 Liquid-Gas Contacting... . 20 104.2 Deflection»... ++. + 27 506.6 Liquid-Gas-Solid Tests... 21 705.0 Interpretation of Process 506.7 Other Tests... ee es OL Conditions s+ esse ee ee OT 705.1 Blending sss... 0. 0s 27 600.0 COMPUTATIONS OF RESULTS... 4. . 20 705.2 Heat Transfers... 1. 28 601.0 Data Requirements... 2... 2 705.3 Inaiscible-Liguid Contacting 28 601.1. Dimensional Heasurements . . 21 705.4 Liguid-Solid Contacting... 28 601.2: Operating Conditions... . 21 705.5 Liquid-Gas Contacting... . 29 001.3. Process Properties... .. 21 705.6 Other Tests... +s... 29 602.0 ‘Fundamental Calculations»... 21 706.0 ‘Sources of Error. sss...) 29 603.0 Operating Performance Calculations 22 OUST. Power eee ee ee ee + 22 800.0 APPENDIX sv vee se ee 29 603.2, Torque ss 8 801.0 Trouble Shooting Checklist . . 29 604.0 ‘Mechanical Condition Calculations 24 802.0 Glossary. sss sees ees 28 603.0. Mechanical Operation Calculations 24 803.0 Notation) see ee ee OL 605.1. Natural Frequency)... + 24 003.1 Greek Letters v0... 31 605.2. Deflection Beir 024 803.2 Dimenstonle: tae. 32 600.0 Process Condition Calculations . 24 804.0 ‘Equations and Related Groups » . 32 605.1. Blending. se eee ee 2H 805.0 Calculation Examples... .. + 32 608.2. Heat Transfer. 25 805.1 Power. ee eee es 32 606.3. Inniscible Liquid Dispersion 25 805.2 Mechanical ss... 36 606.4. Liquid-Solid Contacting . . 25 805.3 Liquid-Solid ©... 5.43 37 606.5. Liquid-Gas Contacting... 25 806.0 “Semple Log Sheet... 0... 37 606.6. Other Tests... 1. se. 25 806.1 System Test Logs vs... 37 806-2 Physical Description Sketch . 37 700.0 INTERPRETATION OF RESULTS... .. 25 807.0 ‘Scale-Up/Scale-Domn ss +. 37 701.0 Introduction. vv ee es 5 807.1 Geometric Similarity»... 37 702.0 Interpretation of Operating 807.2 General Process Log... ++ 38 Performance ses ev ee ees 6 07:3 Scale Parameter... 1. 39 WORL Speeds. sere eens 6 807-4 Correlating Process Paraneters 39 702.2 Powers vee eee 26 807.5 Correlating Conditions ... 39 702.3 Torque. + 1h. 26 807.6 Mixing Correlation... + 39 703.0 Interpretation of Mechanicel 808.0 References sees ee ees 39 Conditions oe ee 6 Authorization to photocopy itens for internal or personal use, or the internal or personal use of specific clients, is granted by AIChE for libraries and other users registered with the Copyright Clearance Center (CCC) Transactional Reporting Service, provided that the $1.00 fee per copy is pnid directly to CCC, 21 Congress St., Salem, HA 01970. ‘This consent does not extend to copying for general distribution, for advertising of promotional purposes, for inclusion in a publication, or for resale. Articles published before 1978 are subject to the same copyright conditions and the fee is $1.00 per page. AIChE Equipment Testing Procedures fee code: 0569-5473/87-$1.00. ISBN 0-6169-0439-1100.0 PURPOSE AND SCOPE 101-0 Purpose This procedures cffers methods of conducting and interpreting performance tests on impeller= type mixing equipment. These tests may be conducted to determine process performance, mechanical reliability, or suitability of equipment for the intended use Since the correct identification of the "real problen can be the most difficult part of the tests conducted on mixing equipment, several of the procedures tend to follow trouble-shooting tactics. fests may be conducted to determine scale-up or scale-down criteria and to develop other equip- nent sizing. The reasons for conducting performance tests can be varied, but the methods presented should ve generally applicable to most situations. Care should be taken to set testing priorities and to select the most suitable methods for a given situation. 12.0 Scope Rather than specific instructions, a collection of techniques is presented to guide the user. Enphasis is placed on practical methods which are likely to produce reliable results. This procedure includes widely accepted nomen- clature and definitions to assist in the col lection and communication of results. General methods are provided for collecting and analyz- ing process results, but because of the enor- mous variety of possible applications for impeller-type mixing equipment, little detail is included. Manv of the useful indirect measures of process conditions involve mechanically related obser- vations. Because mechanically sound equipment is necessary for successful process operation, many aspects of the testing are mechanical. Observations of mechanical operation are also essential for long equipment Life and personnel safety. 103.0 Liability AIChE and members of the various committees in- volved make no representation, warranties or guarantees, expressed or implied, as to the aplication or fitness of the testing Mixing Equipment - Impeller Type procedures suggested herein for any specific purpose or use. Company affiliations are shown for information only and do not imply procedure approval ty the companies listed. The user ultimately must make his own judgement as to which testing procedures to utilize for a specific application. 200.0 DEFINITION AND DESCRIPTION OF TERMS 201.0 Introduction Inpeller-type mixing equipment encompasses wide variety of specific equipaent used for fluid ‘processing. No single description can provide complete information about all types of equipment. In. general, impel ler-type mixing equipment includes both the rotating mixing equipment and the tank in which it is used. The fluid in the tank is also an important con sideration in any testing procedure. | — dette rie [E=. Fig. 201.1 Impeller Mixing EquipmentThe terms mixing and agitation are used almost interchangeably. However, mixing may be used to refer more specifically to the blending of liquids, and agitation may be used to refer sore generally to the motion of fluids for ‘purposes other_than”blénding, such as” suspend- ‘solids in a slurry. Mixing equipment and ,, ation equipaent are ~indistinguishable, ess their application has specific meaning. 202.0 Mixing Bqvipment An impeller-type mixer or agitator can be de- fined as equipment for blending and agitation nf liquids and liquids, liquids and solids, or liquids and gases or combinations, such that a liquid phase is continuous, A rotating im- veller provides ¢ thrusting or shearing action an the fluid in a vessel. The @yuipment takes any forms, but conmon to each is a device (impeller) attached to a rotating shaft. 202.1 Equipment Configurations In general, the system includes the impel- lev-type mixer, the vessel, and all inter- nal accessories, and sometimes auxiliary equipment. The impeller mixer usually consists of five (5) basic components: a prime mover (typically a motor), an agitator drive which reduces speed and increases torque (not alvays required), a shaft seal (used only with closed tanks), a shaft and impeller(s). See Fig. 201-1 202.1.1 The most common impeller mixer configuration is the center-mounted, top- entering agitator. The shaft is vertical Cat the centertine of on upright cylindri- cal tank. Various types of impellers may be used, and baffles at the tank walls are usually necessary to prevent swirling of the contents. Such equipment is extremely versatile, and the tank volume may be less than a few hundred gallons \ Fig. 202.1 Center Mount Impeller Mixer Fig, 202.3 Side-entering Propeller Mixer AIChE Equipment Testing Procedure& Fig. 202.4 Close Clearance Impeller Mixer {one cubic meter) to over a hundred thousand. gallons (five hundred cubic meters). 202.1.2 Top-entering, angle-mounted mixers and side-entering mixers are sone fof the more common configurations using higher shaft speeds and propeller-stvle impellers. 202.1.3 Close clearance impeller systens are a special case of the center-nounted mixers, which are typically used in special applications with unusual fluids. 202.1.4 Additional impeller mixer con- figurations include botton-entering kK? in (O}) LI / ty Fig. 202.6 Pitched-blade Turbine mixers, and tanks with multiple top or side-entering mixers. Most of the test methods still apply, even to the more unusual mounting arrangements. 202.1.5 For additional testing proce- dures for mixing equipment used with dry solids, paste and dough, see Ref. 608.1. 202.2 Impellers An impeller is defined by a set of physical and geometric’ ‘factors which include diane- ter, number of blades, contour of blades (blade shape), width of blades, angle of blades, and thickness of blades. Typical impeller types include radial-flow impellers, tangential-flow impellers, axial ele I t Fig. 202.5 Straight-blade Turbine Mixing Equipment - Impeller Type Fig. 202.7. Dise-style Turbinep = theoretical helical pitch Fig. 202.8 Marine Propeller flow impellers, anchors, augers (screws), and helixes. The term “turbine” is fre- quently used when referring to impellers with flat plate-style blades. Examples of —@o—t [ Fig. 202.9 Anchor Impeller Fig. 202.10 Double Flight Helix impellers are shown in Figs. 202.5 throu, 202.11. ‘These examples are far from all-inclusic but do reflect sone of the commonly use impeller configurations. Many other impe! lers are similar in construction and funr tion, but different in detail. Other impe lers incorporate features from more than o! of the types shown. For additional informa tion see Ref. 808.10 and 608,13.3. 202.3 Vessels An impeller mixer is normally operated in vertical cylindrical tank. The cylindrica tank is used because of ease of fabricatic fron metals and the convenience in use Tanks with square or rectangular cros sections are used when the material o construction is concrete. All length dimen sions can be chosen to define a wide variet, of both sizes and shapes. In addition to the vessel itself, baffles at the wall, impeller locations, and sany other AIChE Equipaent Testing ProcedureFig. 202.11 Single Flight Auger or Screw devices, such as: dip pipes, sparge rings, cooling coils, plate coils, feed points, draw-off points, and recirculation points are all part of the equipment. 202.4 Auxiliary equipment such as compres~ sors for gas sparging, pumps for liquid recirculation, external heat exchangers, and similar devices associeted with the agitated process must be considered. Such equipment may contribute substantially to the perfor- mance and/or behavior of the agitation equi paent . 203.0 Basic Nomenclature 203.1 Equipment Variables Numerous dimensions and parameters are necessary to completely describe agitation equipment, but some are so commonly used that their symbols are used throughout the description of the testing procedures. For @ complete list of the nomenclature, see Sec. 803.0 203.1.1 Impeller Diameter, D. Diameter is normally measured as the maximum diameter swept about the axis of rota~ tion. Impeller diameter is the most important dimension for mixer testing and should be accurately measured. 203.1.2 Rotational Speed, N. Speed is normally measured in revolutions per unit time, such as revolutions per minute. 203.1.3 Tank Diameter, T. Since most agitated tanks are cylindrical, diaceter Aixing Equipment - Impeller Type is an appropriate measure of tank size, especially inside dianeter. 203.1.4 Liquid Level, 2." Liquid level is usually measured at the deepest point, such as the bottom of a dished head. 203.1.5 Power, P. Inpeller pover is the ost ‘commonly used measure of agitator performance. Pover requirements depend on all of the impeller dimensions and to some degree the tank dimensions and in- peller location. The prinary variables affecting power are inpeller dioneter and rotational speed, which must be measured accurately. Hotor power may be used to describe equipment, but does not neces sarily reflect the operating performance of an impeller. 203.1.6 Torque, t. Torque is related to Power” and speed by the relationship, = P/(2nN). Although torque is an important measure of equipment perfor- mance, it is even more important in determining mechanical strength require- ments. ’ 203.1.7 Pumping “Capacity, Q. Pumping capacity, while not consistently defined, is often used to characterize the fluid notion resulting from impeller rotation. Prinary pumping capacity normally descri- bes the direct discharge from the inpel- ler, Total pumping capacity may include sone portion of the entrained flow, but definition must be provided. 203.1.68 Fluid Density, p. Density usually has a direct effect on inpeller power, so while vater-like liquids may have ‘little effect, hydrocarbon liquids ‘and heavy solutions or slurries aust be appropriately characterized. Density is often handled as specific gravity (3.6.) relative to water. 203.1.9 Viscosity, yl. Viscosity is a measure of the resistance of a fluid to shear or flow. Consequently 1t is one of the most descriptive variables available to characterize liquids relative to how they may behave when agitated. 203.1.10 Baffle Width, B. Baffles are vertical plates attached to the wall of « tank to prevent uncontrolled swirling of the fluid. 203.1-11 Impeller Clearance, ¢. The clearence between an impeller and the dotton of the tank is an important vari able in determining impeller position. Clearance is usually measured to the cen- terline of a simple impeller for posi- tioning purposes. Clearance between the bottom edge of the impeller and the bottom of the tank may also be used, but either dimension must be checked for echnical interference, especially in dished bottom tanks. 203.112 Shaft Length, L. | The shaft length is directly related to inpeller clearance and location, as well as being