REPAIRING REPLACING THE AGITATOR SHAFT OF REACTORS

1.0 PURPOSE:
    
    To    describe    a  standard   operating    procedure    for repairing/replacing of agitator/shaft of reactors.
    
2.0    SCOPE:
    
    The standard operating procedure describes in detail the method of repairing/replacing of agitator/shaft of reactors in the plant.
    
3.0    RESPONSIBILITY:
    
    The responsibility of repairing/replacing of agitator/shaft  of  reactors lies with the staff of rank not lower than  supervisor  of maintenance 
    
    The  responsibility of preparing, reviewing  and approving  the standard  operating  procedure lies with the  Manager  -  Maintenance,  Head of Production and Head of QAD respectively.
    
4.0    METHOD:
    
4.1    Ensure  that the reactor is clean and free of  chemicals and obtain the vessel entry permit from the production department.(Annexure-I)
    
4.2    Isolate the equipment electrically.
    
4.3    Remove  the motor, gear box, shaft coupling, bearing  unit  and gear box stand from the reactor.
    
    
    
    
4.4
Unlock  the mechanical seal  unit (if the reactor  is  provided  with  mechanical  seal) or loosen the stuffing box  bolts,  and  take   out  the mechanical seal/stuffing box from  the  reactor shaft.
    
4.5    Open the man hole cover by removing  all the bolts.
    
4.6    Arrange filtered air supply to the reactor with air hose. Enter  into the reactor wearing nose mask.
    
4.7    Remove agitator bolts and take out the  agitator.
    
4.8    Remove the shaft from the reactor.
    
4.9    If the shaft/agitator is to be repaired by outside agency, send the same as per the SOP SENDING  OUT  EQUIPMENT  FOR RECTIFICATION TO THE OUTSIDE AGENCY.If the shaft/agitator is to be replaced with new, get the same and replace.
    
4.10    Insert  the shaft  into  the reactor.
    
4.11    Fix the agitator to the shaft.
    
4.12    Fix  the stuffing box/mechanical seal, gear box stand,  bearing unit, shaft coupling, gear box and motor in that order.
    
4.13    Rotate  the  shaft  manually and ensure that  the  agitator  is  rotating freely.
    
4.14    Replace the gland packings as per the SOP replacement  of gland packing of pumps and reactors.
    
4.15    Check the manhole gasket.  If it is damaged replace the  gasket as per the SOP REPLACEMENT OF  GASKETS OF REACTORS MAIN FLANGE, PRESSURE FILTERS AND LEAF FILTERS..
    
4.16
Restore the power supply to the equipment.
    
4.17    Record the replacement/repairing data in the equipment history record.
    
5.0    RECORDING:
    
    The  responsibility  of recording the  repairing/replacing  the agitator/shaft   in the equipment history card  as per the SOP lies  with the staff of rank not lower than maintenance supervisor.
    

Reactors, repairing replacing, engineering