SPECIFICATION NO.

TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10

FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

TECHNICAL SPECIFICATION
FOR
AGITATORS

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

CONTENTS

1 SCOPE

2 VENDOR'S QUALIFICATION

3 APPLICABLE DOCUMENTS

4 DESIGN CRITERIA

5 INSPECTION

6 TESTING

7 PREPARATION FOR SHIPMENT

8 HANDLING

9 VENDOR’S DATA

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

1.0 SCOPE

1.1 This specification covers the minimum requirements for rotating agitators
designed and manufactured to Vendor’s standard design.

1.2 Compliance with this specification does not relieve the Vendor or his sub-
Vendors of their responsibility to provide equipment of correct design,
construction and materials entirely suitable for continuous, safe and reliable
operation under the specified process and environmental operating conditions.

2.0 VENDOR'S QUALIFICATION

Equipment offered by Vendor shall satisfy the following minimum service and
manufacturing experience requirements:

2.1 Equipment shall be identical or validly similar in power rating, speed, capacity,
service and application, mechanical design, materials and rotor dynamics as
compared with at least two units produced by the Vendor at the proposed
manufacturing plant one of which must have had at least one year's satisfactory
operation at the time of enquiry issue.

2.2 Equipment manufactured under licence, in addition to satisfying the above

requirements shall also have the licensor's written guarantee.

Relevant reference list shall be submitted with Vendor’s quotation detailing the
application, power rating, rotational speed, year of installation, client contact
person details, mechanical configuration and materials of construction etc.

3.0 APPLICABLE DOCUMENTS

3.1 Statutory Requirements The Vendor shall ensure that all equipment in his scope
of supply complies with all applicable statutory requirements, standards, codes,
local rules and regulations.

4.0 DESIGN CRITERIA

4.1 General

4.1.1 The equipment ( including auxiliaries ) covered by this specification shall be

designed and constructed for a minimum service life of 20 years and at least 3
years of uninterrupted operation. Vendor shall recognize that this is a design
criterion.

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

4.1.2 The Vendor shall assume unit responsibility for all equipment and all auxiliary
systems included in the scope of the order. He shall assure that all sub-Vendors
comply with the requirements of this specification and all reference documents.

4.1.3 All electrical components, enclosures and installations shall be in accordance

with ‘’Electrical Requirements for Package Supply Equipment Units’’ and suitable
for the area classification and environmental conditions specified in the material
requisition.

4.1.4 The Vendor shall provide all the information necessary for the correct design of
all electrical, instrumentation, civil and mechanical interfaces. Agitator
components shall be designed to fit the vessel opening specified in the Material
Requisition.

4.1.5 All special tools and fixtures required to dismantle, re-assemble and maintain the
agitator and its components shall be provided by the Vendor with the equipment.

4.1.6 The motor, transmission system and shaft shall be rated adequately to cover the
most arduous of the following operating conditions:
a. In water
b. With solids in suspension (particularly if suspension is not homogenous).
c. In the process liquid specified.
d. Operation in multi-phase layers and in the transition between liquid and
vapour phases.
e. In air (outside the liquid).
f. During speed changes.
g. For the vessel design, e.g. whether baffles, heaters etc are fitted.
h. During vessel filling and emptying, including passing through the liquid
surface.

4.1.7 The agitator, including drive and seal unit, shall be designed for 3 years of
continuous operation.

4.2 Pressure Containment Pressure containing components including mounting

flanges shall be suitable for the design pressure and temperature, of the mixing
vessel, specified in the Material Requisition.

4.3 Agitator Shafts

4.3.1 Solid constant diameter, one piece shafts of cantilever design are preferred.

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

4.3.2 The shaft’s first critical speed shall not be less than 30% above the maximum
shaft speed under all operating conditions, including operation in air and when
partially submerged in the process liquid.

4.3.3 When specified the Vendor shall conduct a lateral/torsional analysis of the
rotating system and submit the calculated critical speeds to the IOCL for review
declaring the allowances made for support stiffness and damping.

4.3.4 Torsional modes of the complete drive systems shall be at least 10% away from
any operating speed under all operating conditions.

4.3.5 If mechanical seal is not specified, packed glands may be offered. The shaft, in
the region of packed glands shall be surface hardened with a hardness in the
range of 360/465 Brinell unless otherwise specified.

4.3.6 Impeller hubs shall be keyed and located with set screws to the shaft. Hubs shall
be fabricated with full penetration welds.

4.3.7 Impeller vanes shall be bolted to hubs by at least four (4) bolts, located by two (2)
dowels at two bolts and two close fitted bolts.

4.3.8 The shaft shall be designed for an operating life of 200,000 hours minimum

4.3.9 All changes in shaft section shall be radiused, polished and shot peened.

4.4 Balancing Impellers, hubs and couplings shall be individually statically balanced
and complete shaft assemblies shall be check balanced. High speed agitator
assemblies, running at over 200 RPM, shall be dynamically balanced.

Vendor shall submit full details of the balance procedure for IOCL’s review.

4.5 Shaft Seals

4.5.1 Shaft seals shall be provided to prevent leakage from or into the mixing vessel
over the range of specified operating conditions and during periods of idleness.
Shaft seals shall be designed for safety and suitability for the intended service
taking into account all normal, abnormal and emergency conditions as specified,
including start-up and shutdown.

4.5.2 Where mechanical seals are used, the same shall comply with technical
specification for Mechanical Seals (IOC/M&I/MECH/E/R/06 Revision-00) and the
following:

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

a. The shaft mechanical seal assembly shall be of the cartridge type,

designed for ease of maintenance and shall be positioned close to a
bearing. The shaft and shaft support system shall be designed to
minimize shaft deflections in the seal area. Maintenance and replacement
of the seal shall be possible without draining the vessel, removing the
agitator from the vessel or, for large agitator units, removing the drive
unit. The agitators shall have provision for the support of the agitator shaft
during servicing of the mechanical seals.

b. Mechanical seals of the single type are preferred. When leakage cannot
be tolerated, double seals, tandem seals or auxiliary shaft sealing devices
shall be provided. The Vendor shall furnish all mechanical seal piping and
appurtenances. Seal pots, when required, shall be designed to ASME
VIII, fully tested and code stamped.

c. A fully detailed mechanical seal schedule shall be submitted.

d. Mechanical seals shall be designed for continuous operation of at least

120% of the maximum pressure expected.

e. Vendor shall submit seal details with his quotation.

f. All parts of seal housing in contact with the process fluid shall be
constructed in a material providing similar or better mechanical and
chemical properties to the vessel material.

4.5.3 Where gland packing is used:

a. Stuffing boxes for packings shall include a seal cage with connections for
introducing cooling medium or lubricant directly into the packing.

b. A spare set of gland packing shall be supplied with each agitator.

4.6 Bearings and Lubrication

4.6.1 The use of steady bearings is discouraged, however where they are used, they
shall comply with the following:

a. Unless otherwise specified, bearings shall be of the replaceable design

and lubricated by the liquid in the vessel.

b. Bearings shall be capable of running 'dry', for short periods during tank
filling and emptying, and while totally immersed in the tank fluids. The

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

Vendor shall consider carefully the selection of shaft, bush materials and
running clearances.

c. The Vendor shall be responsible for the design of the fixing of any
proposed steady bearing. The Vendor shall state in his quotation the
proposed method of securing the steady bearing support to the vessel.

d. Bearing inserts shall be readily replaceable without removing the agitator

or the impeller.

e. Provision shall be made to permit steady bearing alignment in the field.

f. The shaft shall be engaged in the steady bearing at all times including
when the mechanical seal unit is removed or serviced.

g. All locating points on steady bearings shall have at least two (2) dowels or
fitted bolts per plane of location.

h. Fixed joints on steady bearing supports shall have two (2) dowels or fitted
bolts.

4.6.2 Vendor shall state the L-10 rating of the proposed bearings.

4.6.3 The lubrication system shall be Vendor's standard unless otherwise specified in
the material requisition. Bearing housings for oil bath lubrication shall be
equipped with constant level oilers or an oil level indicating gauge, a fill
connection with a plug, a drain connection with a plug, a breather-type vent with
a dust filter and a means of locking constant oil level oilers in the correct position.

4.6.4 Main bearings shall be rated to take loads 50% greater than those predicted for
the equipment. The effect of reverse thrust shall be taken into consideration.

4.7 Agitator Mounting Flanges

4.7.1 Mounting flanges shall be in accordance with ANSI B16.5 unless otherwise
specified and shall be designed as a pressure part of the vessel in accordance
with the vessel design code.

4.7.2 Agitator Vendor shall include the gasket, nuts and bolts for the vessel mounting
flange in his scope of supply. Gasket type to be as specified in the material
requisition.

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

4.7.3 The Vendor shall advise the magnitude of the static and dynamic loads imposed
on the vessel nozzle by the agitator. The Vendor shall also advise the details of
the required mounting flange flatness required to which the nozzle should be
machined.

4.8 Auxiliary Piping

4.8.1 All auxiliary piping including all accessories such as gauges and valves, shall be
furnished by the agitator Vendor, fully assembled and installed.

4.8.2 Flanged connections shall conform to ANSI B16.5.

4.8.3 Pipe nipples shall be seamless Schedule 160 and shall be 20mm (3/4") minimum
size.

4.9 Materials

4.9.1 Materials for agitator parts shall be suitable for the service specified. Materials
shall be identified in the proposal with the applicable International Standard
numbers, including material grade listed on requisition data sheet. Where
International standards are not available, internationally recognized national or
other equivalent standards may be used.

4.9.2 Asbestos shall not be used in any form.

4.9.3 The Vendor shall furnish bolt torque values with his installation instructions.

4.10 Drivers

4.10.1 Electric motor drivers shall be in accordance with the material requisition and
shall have the nameplate power rating at least equal to the following percentage
of the maximum absorbed power (including transmission losses), required for
any of the specified operating conditions.

Motor Nameplate Power Percentage of Max Abs Power

18.5 kw and less 125%

22 kw - 74 kw 115%
75 kw and more 110%

4.10.2 Electric motors to be supplied to Specification ‘’Induction Motors’’. Vendor to

complete and return the relevant motor data sheets.

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

4.11 Gears

4.11.1 All gear ratings and service factors shall preferably conform to AGMA 420 or
AGMA 421. Gear service factor should not be less than 2.0 based on motor
installed power.

4.11.2 Gears shall be designed for direct-on-line starting of electric motor and starting
torque of agitator.

4.11.3 A positive lubrication system shall be used to ensure a continuous supply of oil to
the meshed surfaces of the gears and to the bearings (pumped or splash
lubrication). Pumped systems shall be fitted with strainer and/or filter, a pressure
gauge and low pressure trip to safeguard against pump failure. The oil reservoir
shall be positioned such that the oil level can be adjusted while the agitator is
running. An oil cooler shall be included where necessary.

4.11.4 The Vendor shall provide full details of the lubrication system in his proposal.

4.11.5 A ready means of checking the gear box oil level shall be provided.

4.11.6 Gear box design shall be such that oil will not leak down the shaft in the event of
a failure of the gear box rotary oil seal. 4.12 V-Belt Direct or gearbox drives are
preferred, however V-belt drives may be acceptable for agitators with a power
rating of 75kW or less. V-belts shall be furnished by the agitator Vendor.

V-belt drives shall be selected with a minimum service factor of 1.4. All belts shall
be oil resistant. Belt guards shall be supplied along with the equipment.

4.13 Couplings and Guards

4.13.1 Agitator to gearbox coupling shall be of the rigid spacer type. For motor to
gearbox connection a flexible coupling, belt drive or geared motor unit is
acceptable. Gear type couplings are not acceptable. Flexible couplings shall be
adequately rated for all operating and transient conditions.

4.13.2 The flexible coupling between the driver and gear shall be supplied and installed
by the agitator Vendor. Unless otherwise specified, installation and alignment of
the driver and gear box shall be the responsibility of the agitator Vendor.

4.13.3 Couplings shall be keyed in place. Cylindrical interference fits shall be light to
permit removal in the field without heat.

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

4.13.4 A spacer type coupling shall be provided for units using solid shaft drive units
equipped with mechanical seals. Sufficient length of spacer shall be allowed to
permit replacement of the seal assembly without removing the driver.

4.13.5 Limited end float couplings shall be used with sleeve bearing motors to prevent
the motor rotor from rubbing the ends of either bearing. The maximum rotor
thrust that can be developed shall be stated by the motor Vendor and must be
taken care of by the gear unit, if used or by the agitator if a gear unit is not used.

4.13.6 The agitator Vendor shall be responsible for the finished boring of the motor half
coupling.

4.13.7 Coupling guards shall be provided along with equipment.

4.14 Instrumentation and Control In addition to any instrumentation specified in the

Material Requisition, the Vendor shall specify all the necessary instrumentation,
control, alarms and shut-down devices to ensure safe and reliable operation.

4.15 Jacking screws shall be provided to assist in parting joints.

4.16 Parting surfaces shall be spigotted or provided with fitted bolts or dowels to
ensure correct alignment (spigots are preferred).

4.16.1 Means for removal of seal cartridges and supporting the shaft during this
operation shall be provided.

5.0 INSPECTION

5.1 Inspection shall be carried out in accordance with the material requisition.

5.2 The Vendor shall provide a quality control plan showing the proposed
programme of inspection and testing and which items are to be witnessed or
observed. This plan will be reviewed by IOCL who will advise any required
amendments. When requested, the Vendor shall provide a copy of his quality
control procedures for IOCL's review.

5.3 The scope of IOCL’s inspection shall include as a minimum, suborders,

materials, welding, heat treatment, non-destructive testing of materials and
welds, repairs, rotor balancing, dimensional checks, hydrostatic and running
tests, internal check after testing and final inspection prior to shipment.

5.4 IOCL's inspector shall be informed of any defects noticed during manufacture.
Vendor shall also inform IOCL and obtain his permission before proceeding with

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

any repairs which may affect equipment operation, integrity or interchangeability.

Repair procedures shall be approved by IOCL before rectification. Rejections
made by IOCL shall be final.

6.0 TESTING

6.1 The number of working days for advance notice shall be as specified in the
Purchase order.

6.2 IOCL or his representatives shall observe all testing, dismantling, inspection and
re-assembly of equipment, as specified in the data sheet.

6.3 Mechanical Seals Tests

All mechanical seal assemblies shall be hydrostatically works tested to a
minimum test pressure of 1.5 times the normal seal lubricant pressure. A works
running test of the seal at this pressure is also required.

6.4 Mechanical Running Test

The Vendor shall conduct a standard running test on all agitators to ensure
satisfactory operation at the specified operating speed. Such tests should consist
of the following:

- Operation of the assembled mixer under "no load".

- Running test of shaft seal with the seal under pressure.
- Actuation of the tank shut-off device with the test tank at maximum operating
pressure.

6.5 Test Procedures

Vendor shall issue test procedures for the mechanical seal and running tests for
IOCL’s approval.

6.6 Certified copies of test data shall be submitted to IOCL immediately following the
test.

7.0 PREPARATION FOR SHIPMENT

7.1 The preparation for shipment, storage type and period, and the type and mode of
shipment shall be in accordance with the purchase order.

7.2 The paint for all exterior surfaces shall be suitable for the environment specified.
The paint, preparation and painting procedures shall be approved by IOCL.

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

7.3 Unless otherwise stated in the purchase order, all on package pipe-work shall be
fully fitted and assembled prior to dispatch. Pipe-work between main packages
and off-package auxiliaries, if supplied by Vendor, shall have sufficient spare
lengths for final field welding.

7.4 All openings, disconnected for shipping purposes, shall be closed. These shall be
identified with a securely attached tag indicating the type of connection, the
instrument or the line description of the connecting piping.

8.0 HANDLING

8.1 The equipment shall have sufficient rigidity and strength to permit normal
handling.

8.2 The equipment shall be provided with sufficient bracing and lifting lugs to permit
handling at the construction site with conventional slings or hooks without
damage to the equipment.

9.0 VENDOR'S DATA

9.1 Proposals

The Vendor's proposals shall include the information listed below:

1. Completed copies of the material requisition data sheet(s) with all required
information entered thereon.
2. Certified outline arrangement drawing and weights.
3. Typical cross-sectional drawings, schematic drawings and literature to
describe fully all details of the offer including specific drawings of the gear
and variable speed system (if applicable).
4. Power absorbed by the agitator assembly.
5. The diameter, type and position of the impeller, together with its speed and
direction of rotation.
6. The size, type and location of any baffles that may be considered necessary
to ensure adequate mixing.
7. The critical speeds.
8. Type of shaft seal where necessary. Seals and glands shall be readily
renewable without dismantling other components of the mixer. A seal change
procedure shall be provided.
9. Flange thickness calculations, agitator calculations and all loadings imposed
on the vessels by the agitator.

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 SPECIFICATION NO.
TECHNICAL SPECIFICATION IOCL/M&I/MECH/E/R/10
FOR AGITATORS REVISION-00
 
        Refineries Division DATED: 19.01.2012
 

10. A Specific statement that the system and all components are in strict
accordance with the material requisition and specifications. If they are not in
strict accordance, the Vendor shall include a definitive list detailing every
deviation and exception.

11. Evidence of manufacturing and service experience, stating the name of the
user, plant, location, service and date of commissioning.

9.2 The Vendor shall quote in his proposal separate itemised prices for spare parts.
a. for commissioning
b. for 2 year operation

9.3 Vendor to provide a statement of guaranteed noise emission data and confirm
compliance to material requisition requirements.

9.4 Contract Data

1. After receipt of the purchase order, the Vendor shall supply certified
dimensional drawings as agreed prior to the purchase order. The
Vendor’s certified drawings shall show identification data, rotation, weight,
applied loads and adequate dimension data to permit the design of
supporting vessel or structure, piping and wiring connections. All auxiliary
piping connections shall be identified with terminations located and sizes
indicated. The drawings shall show the disassembly clearances required.
2. Vendor's drawings shall be reviewed by IOCL; such review shall not
constitute permission to deviate from any requirements in the order
unless specifically agreed upon in writing. After the drawings have been
reviewed, the Vendor shall furnish certified copies in the quantity
specified in the purchase order.
3. In addition the information listed below shall be submitted at dates agreed
prior to order placement.

1. Analyses as required by para 4.3.3.

2. Major repair procedures (if applicable).
3. Test schedule.
4. Quality control plan.
5. Surface preparation and painting procedure.
6. A drawing showing mechanical seal installation and setting
dimensions.
7. Certified test data.
8. Installation, operation and maintenance manuals.
9. Production data book with all required material and electrical
certification data. 

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