Mixing Mechanical Design Fundamentals

Mixer Mechanical
Design
Antonio Iñiguez
GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
November, 2010
COMPANY CONFIDENTIAL
Mechanical Design of Mixers
Summary of Session
Mixer Loads
Critical Speed
Problem Solving
Mounting Design Loads
AGMA Rating
L-10 Bearing Life
What We Need to Know
COMPANY CONFIDENTIAL 6/2/98 2

Why do we care about mechanical design?
• Ensure a safe dynamic system

• Optimizing design = minimizing cost
• Ensure conformance to customer
specifications
• Avoid warranty issues
Mixer Loads
Mixers generate dynamic loads.
• Torque
• Fluid Force/Bending
Moment
Torque • Thrust
Bending
Fluid Forces GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
Thrust
Torque
Understanding Torque
Impeller
Force applied to Rotation
Fluid by Impeller
Blade R
Fluid F
Resistance
Torque
Torque is generated by the Impeller Power Draw
TORQUE = F x R
How is Torque related to Horsepower?
HP  63025
Torque 
RPM
Torque
(in.-lbs.)
Torque
Where RPM is INFRASTRUCTURE
GLOBAL the Reducer Output Speed
X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
and 63,025 is the conversion factor to obtain Torque in “in-lb”
Rearranging the equation we have:
Torque  RPM
HP 
63025
As the speed decreases the torque increases to maintain
the same HP
But… What does it mean?
Torque
Low Speed Mixers require bigger gearboxes and bigger shafts than High Speed
Mixers!
Torque
Torque
What effect does torque have on the machine?
High speed
• Generates shear stress in the high coupling
speed coupling and mixer shaft
• Generates loads inside gear reducer
• Generates bending stress in the
impeller blades and ears
Fluid Forces
This pressure can be translated into Forces acting upon each blade
F3
F4
F2

F1

Fluid Forces
If the flow were completely stable and predictable, this forces should be equal in
Magnitude
F3
F4 F3
F4
F1 F2
F2

F1

Fluid Forces
Thus cancelling each other out
F4 F3F4 F3
F 0
F1 F2F1 F2

Fluid Forces
In reality, the discontinuities occurring during the mixing process, alter
the magnitude and direction of these forces
F3
F4
F2

F1

Fluid Forces
Generating an unbalanced force in order to close the “Force Polygon”
FF F3
F3
F4
F4
F2
F1 F2

F1

Fluid Forces
FF
F3
F4
F2
F1
This unbalanced force is called “Fluid Force”


Fluid Forces
FF
F3
F4
FF
FF FF
F2
F1
FF
And it is considered to act perpendicular to the Mixer Shaft, at the impeller centerline
in a random direction

Fluid Forces
The force magnitude is an empirical calculation for each Lightnin Impeller
based on experimental observation and actual mixing conditions

Fluid Force
What Parameters affect the magnitude of the Fluid Forces?
• Impeller Type
• Diameter of Impeller
• Fluid Force  Speed 
Rotating Speed exp onent
• Fluid Regime
• Process Conditions
• Proximity
• Flowing Streams
• Gas

Bending Moment
Fluid forces at the impeller Create a Bending Moment
M=LxF
• L – Shaft length from inboard support
bearing
• F – Fluid force
L
F
Bending
Bending Moment
Generates drive shaft deflection Reaction
• Results in low speed gear misalignment

• Affects seal performance Reaction
High
Stress
Generates Reaction Loads
• Higher reaction loads lower L10 bearing MS
life
Generates stress in the shafting shaft

deflection @
• Overhung – Greatest at inboard support seal
bearing
• Steady Bearing – Greatest at upper
Impeller GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
Bending Moment
Maximum
moment
Maximum
moment
Overhung Steady Bearing
Bending Moment
Things that affect the magnitude

• Shaft Length
• Fluid Force
 Impeller Type Y X
 Impeller Diameter
 RPM
• Orientation
 Off Center Mounting
 Angular Mounting
SL
• Fluid Regime
 Low Level Coverage
 Swirl
 Vortex GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
 Gas FF
Thrust
Reaction
(Thrust)
Mixer thrust load is a function of :
•Impeller type
•Impeller pumping direction
•Power
•Speed
•Tank pressure
•Shaft and Impeller(s) weight(s)
Weight
Pumping
Direction

Thrust
Upward Thrust
• Down pumping impeller
• Tank pressure Impeller
thrust
Impeller
thrust

tank
pressure
Thrust
Downward Thrust
• Up pumping impeller
• Shaft and impeller weight
Rotation
Weight
Pumping Direction
Down Thrust
Thrust
Output shaft bearings must handle the
magnitude and direction of the thrust Bearings
Thrust
Mixer Loads
Summarizing the Loads
• Torque
• Fluid Force/Bending
Moment
Torque • Thrust
Bending
Fluid Forces GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
Thrust
Critical Speed
When Shaft RPM approaches its natural
frequency it begins to whip
This can lead to shaft failure
High
Stress
Area
Critical Speed
Industry usually refers to the ratio of the
operating speed divided by the Critical
Speed to get the Critical Speed Ratio
Operating Speed N O
N CR  
Critical Speed NC
NCR must be at or below 0.80 for
heavies.
This is: The Mixer shall not operate

above 80% of its NaturalGLOBAL
Frequency
INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
Critical Speed
So…
What Happens if you operate at speeds
above 80% of the Natural Frequency?
The Dynamic Response of the

Mixer becomes unpredictable due
to its proximity to resonance
Click for video

Critical Speed
Completely
Allowable Unpredictable
Amplification Factor
Design Force Operating Region
90% over
allowable Mixer in Air
Mixer in
1.9 partially
viscous liquid
Mixer in high
viscosity liquid
80% 90%
GLOBAL INFRASTRUCTURE Ncr
X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
Ncr Ncr Mixer
Speed
Critical Speed
R2
Effect on Gear Reducer
R1
 Elevated bending loads

On Bearings
Bending
Critical Speed
Approximation Equation for a Straight, overhung shaft
(results in RPM)
0.388 10 (d Fm ) 6 2
NC 
L We L  a
Critical Speed
0.388  10 (d Fm ) 6 2
NC 
L We L  a
Critical Speed is directly proportional to:
• Shaft diameter (d)
• Material Properties factor (Fm)
Critical Speed is inversely proportional to:

• Shaft length (L)
• Bearing spacing (overhung) (a)
• Equivalent weight of shaft and impellers (We)
Critical Speed
In General
Stiffness
NC 
Mass
Solutions to Critical Speed Problems
Engineering note:
 Decreasing bearing spacing or increasing drive shaft diameter

increases the stiffness of the mixer shaft and therefore
INCREASES the Critical Speed (Nc)
 Decrease lower shaft length (Increase impeller off bottom)
 Step the shaft to decrease impeller weights & shaft weight
 Use a pipe shaft or pipe section
 Reduce Speed (Increase impeller diameter)
 Use a larger speed reducer
 Use a Steady Bearing
Problem Solving
How do we design Mixers?
Meet LIGHTNIN design criteria

Torque requirement
shaft
Bending moment requirement deflection
Able to handle thrust load @ seal
Torque
Keep shaft deflection under limit
Keep critical speed ratio under limit
Shaft Vibration
Meet customer Specifications
Any one Condition that fails allowable limits
kills the design
Bending
Thrust
Problem Solving- Shaft Design
 Rubber coverings add weight and then decrease the

Critical Speed (Nc) of a mixer.
 High temperatures degrade material properties, lowering
the rigidity of the shaft and strength of all metal in tank.
 80/880 series units have lower critical speeds (higher
Critical speed ratio) than same size 70/700 units due to
longer bearing spacing
 LIGHTNIN can design multi-stepped shafts or pipe shafts
to optimize critical speed
Problem Solving- Impeller Design
Standard impellers are designed to handle up to a maximum torque level
If standards don’t work, Impellers can be designed to:
 Lessen weight to help critical speed
 Optimize plate thickness for high alloys ($)
 Work in high temperature or Extreme Operating
Conditions
What are Design Loads?
 They are Loads used for Mixer Support Design
 They are based on Actual Mixer Loads
 Factors Applied Based on LIGHTNIN
Experience
Vertical Downward Load ~ VDL
 include weights, impeller

thrust, gas and pressure
effects with suitable safety
factor
Bending Moment
 Based on mixer bending

moment
 Can act in any direction
Torque
 Based on mixer torque

with a safety factor
applied
Steady Bearing Radial Load
 For supporting structure design

 Based on steady bearing reaction load
with a safety factor applied
 Can be any direction
• Published Design Loads – Sales Data

Book and E-sales
• Actual Design Loads – Consult Factory
• Mixer Mounting structures are the
customers responsibility
AGMA Rating
AGMA – American Gear Manufacturers Association
LIGHTNIN is a member of AGMA
AGMA has developed a series of calculations and

formulae which can be applied to any gearbox to arrive
at its AGMA Rated Mechanical Horsepower
AGMA also specify a thermal rating for each gearbox,
which is the horsepower you can get out of the box
without overheating
Current GLOBAL
standard - ANSI/AGMA
INFRASTRUCTURE X PROCESS 6010
EQUIPMENT X DIAGNOSTIC TOOLS
L-10 Bearing Life
Bearing Life and Rating
Bearing Life
The number of revolutions or the number of
hours at a given speed which the bearing is capable of
enduring before the first sign of fatigue failure occurs on
one of its rings or rolling elements.
Basic Dynamic Load Rating (C or C90)

The load at which 90% of a group of
bearings can survive 1 million revolutions, assuming
load is constant in magnitude and direction.
L-10 Bearing Life
L-10 Bearing Life
The life in millions of revolutions or hours where 90% of the group will complete
or exceed under certain load conditions.
p
C 
L10    Millions of Revolutions
P
C= Basic dynamic load rating
P= Equivalent dynamic bearing load
p= exponent of the life equation (3 for ball
bearings, 10/3 for roller bearings)
It can also be expressed in hours
p
C 
GLOBAL INFRASTRUCTURE 6 PROCESS EQUIPMENT X DIAGNOSTIC TOOLS
X
10
L10 h    Hours
 P  (60n) n = RPM
L-10 Bearing Life
LIGHTNIN Gearbox Bearing Life
Bearing Ratings
You need AGMA 5000 Hours HP Rating for the Gearbox
Bearing Life Calculation - w/o External Loads
P
 AGMA 5000 HP Rating 
Bearing Life     5000
 Actual HP 
What We Need To Know
PLEASE Tell US – Other than mixer selection
• Variable speed range • Operating and Design

• Maximum tank opening temperatures
• Liquid level(s) • Fluid Regime (swirl, vortex)
• Load (low level operation, • Off bottom, spacings,
settled solids) adjustment
• Continuous keyway?

More information is better than too little !!!
Thank You

Mixing Mechanical Design Fundamentals

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Mixer Mechanical

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 2

• Ensure a safe dynamic system

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

Fluid Forces GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

and 63,025 is the conversion factor to obtain Torque in “in-lb”

But… What does it mean?

What effect does torque have on the machine?

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 11

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 12

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 13

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 14

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 15

This unbalanced force is called “Fluid Force”

COMPANY CONFIDENTIAL 6/2/98 16

COMPANY CONFIDENTIAL 6/2/98 17

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 18

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

COMPANY CONFIDENTIAL 6/2/98 19

Fluid forces at the impeller Create a Bending Moment

• Results in low speed gear misalignment

Generates stress in the shafting shaft

Overhung Steady Bearing

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

Things that affect the magnitude

COMPANY CONFIDENTIAL 6/2/98 24

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

Fluid Forces GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

This can lead to shaft failure

This is: The Mixer shall not operate

The Dynamic Response of the

Click for video

 Elevated bending loads

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

Critical Speed is inversely proportional to:

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

 Decreasing bearing spacing or increasing drive shaft diameter

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

Meet LIGHTNIN design criteria

 Rubber coverings add weight and then decrease the

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

Vertical Downward Load ~ VDL

 include weights, impeller

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

 Based on mixer bending

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

 Based on mixer torque

GLOBAL INFRASTRUCTURE X PROCESS EQUIPMENT X DIAGNOSTIC TOOLS

Steady Bearing Radial Load

 For supporting structure design