TMX1000A

TurboMix™ - TMX1000A
Diana Joint Stock Corporation, PF U1085/07
Erection Work, Operating and Maintenance

Instructions
Machine: TurboMix™ TMX1000A
Equipment No.: 131659192
Year built: 2005
Order code: Diana Joint Stock Corporation
Order no.: PF U1085/07
Issued: PF Wang Sufang, 2008-05
Checked: PF Jiang Lijie, 2008-05
Rev. 0, 2008.05.21 TITLE PAGE

00-Title Page.FM
The operating manual is protected by copyright. All usual rights reserved. It must not
be wholly or partly reproduced without authorization by Andritz AG. Contraventions
shall entail damage claims and may have penal consequences. All rights shall also be
reserved for any patents granted, registration of trade marks and technical
modifications without prior notification.
© 2005 Andritz AG
Rev. 0, 2008.05.21 TITLE PAGE

00-Title Page.FM
TABLE OF CONTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 How to use the manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Warranty and guarantee . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Manufacturer's name and address . . . . . . . . . . . . . . . . . 4
1.6 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 1

2.2 Danger and warning signs . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 General remarks on machine/plant safety . . . . . . . . . . . 3
2.5 Hazardous applications . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 User's obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 General obligations of personnel . . . . . . . . . . . . . . . . . . 6
2.8 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.9 Personal protective apparel . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 Safety at the machine installation site . . . . . . . . . . . . . . 9
2.11 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.12 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.13 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.14 Fluids, (liquids, gases, vapour or smoke). . . . . . . . . . . 11
2.15 Oils and greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.16 Work in enclosed vessels and in confined spaces . . . 12
2.17 Permit for work in enclosed / confined spaces . . . . . . 15
3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . 1
3.1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.1 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.2 Main components of the machine . . . . . . . . . . . . . . . . . . 2
Rev. 0, 2008.05.21 TABLE OF CONTENS Seite 1 of 4

TMXIVZ.fm
5 ERECTION WORK and TRANSPORT . . . . . . 1
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.6 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.7 Cold test (preparation for initial start-up) . . . . . . . . . . . 9
6 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.3 Prerequisites for start-up. . . . . . . . . . . . . . . . . . . . . . . . . 2
6.4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7.4 Control via DCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.5 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.6 Re-start after emergency stop . . . . . . . . . . . . . . . . . . . . 3
7.7 Operating malfunctions and troubleshooting . . . . . . . . 4
Rev. 0, 2008.05.21 TABLE OF CONTENTS Seite 2 of 4

TMXIVZ.fm
8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 1
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.4 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.5 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.8 Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.9 Installation and removal of propeller . . . . . . . . . . . . . . . 9
8.10 Installation and removal of the propeller vanes . . . . . . 10
8.11 Setting the propeller vanes . . . . . . . . . . . . . . . . . . . . . . 11
8.12 Changing the mechanical seal . . . . . . . . . . . . . . . . . . . . 12
8.13 Installation and removal of the shaft protection sleeve 13
8.14 Changing the V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.15 Checking the V-belt tension . . . . . . . . . . . . . . . . . . . . . 15
8.16 Installation and removal of belt pulley . . . . . . . . . . . . . 16
8.17 Installation and removal of bearings . . . . . . . . . . . . . . . 18
Rev. 0, 2008.05.21 TABLE OF CONTENS Seite 3 of 4

TMXIVZ.fm
Rev. 0, 2008.05.21 TABLE OF CONTENTS Seite 4 of 4

TMXIVZ.fm
1 INTRODUCTION
This manual is part of the Andritz AG technical documentation for the
plant. It is intended as a supplement to the training provided, to supply the
basic knowledge required for proper, safe and economical use of the
equipment delivered by Andritz AG. Observing these instructions helps
avoid hazards and reduce repair and downtime costs, as well as
increasing the reliability and useful life of machines.
1.1 Use
Target group This operating manual is intended for users with a knowledge of
mechanical engineering and is for the exclusive use of the operator of the
mill and his personnel.
Personnel entrusted with work on the machine must have read and
understood these operating instructions and comply with them. This refers
in particular to the following tasks:
• Handling, starting and stopping
• Troubleshooting
• Maintenance and upkeep
• Transport
• Maintenance and disposal of process materials, cleaning of machine
and area around the machine.
The following sections are especially important:
• the Chapter on SAFETY,
• Safety instructions contained in various other chapters
Supplementary The mill operator shall complete this manual by adding national
instructions regulations on safety at work, health protection and environmental
protection.
Instructions on any special operational conditions concerning work
organization, sequence of work/operations and the personnel assigned to
the job shall also be added. This also includes instructions on supervising
and reporting obligations.
Safekeeping Keep the entire operating manual near the place where the machine is
installed and within easy reach.
1.2 Standards and guidelines

The machine/plant has been built in accordance with state-of-the-art
standards and the recognized safety rules. The equipment conforms to
the equivalent European standards.
Rev. 0, 2008.05.21 INTRODUCTION Kap.1 , Seite 1 of 4

01-Introduction.FM
1.3 How to use the manual
Presentation • Chapter and paragraph headings are printed in capitals in the

continuous text.
Chapter on SAFETY
• Designations of indicating and handling elements are written in
inverted commas in the continuous text.
Operate switch ”xxx”
• Lists without numbering do not require operations to be carried out in a
certain order.
Pictograms The following pictograms are used in the manual:
Warning signs
Warning signs are shown with an explanation of the

type of hazard.
The meaning of the different graduations of hazards

are described in the Chapter on SAFETY.
Marks an instruction on handling of the machine or

system.
Marks a useful piece of information
Marks a cross-reference to another Chapter with

absolute path indication.
e.g. /MACHINE/SAFETY

01-Introduction.FM
Work steps Work steps are presented in tables. Work steps are numbered and must
(operations) be carried out in the order specified.
Numbering of
pages, tables and
figures Pages Consecutive numbering of Chapters 2-1
Tables Tab.+ Consecutive numbering of Chapters Tab. 2-1
Figures Fig. + Consecutive numbering of Chapters Fig. 2-1
Abbreviations
Tab. Table
Fig. Figure
Illustrations and The illustrations and graphic charts show the basic design of the machine.
graphic charts This may not necessarily correspond exactly to the design supplied.
Detailed information on the equipment supplied
.../ENGINEERING DOCUMENTATION/PARTS BOOK
.../SUPPLIER DOCUMENTATION
1.4 Warranty and guarantee

Andritz AG's general terms of delivery and sale shall apply.
Guarantee and liability claims on Andritz AG shall become void if personal
injury or material damage is caused by one or several of the following:
• Use of the machine/system for any purpose other than its designated
use.
• Non-conformity of erection work, start-up and handling of the
machine/system.
• Non-observance of the safety instructions in the manual.
• Non-authorized structural changes to the machine/system.
• Non-observance of the maintenance and upkeep instructions.
In the event of a claim for repair under guarantee, ANDRITZ AG reserves
the right to assess the damage to the machine/system.

01-Introduction.FM
1.5 Manufacturer's name and address

Andritz AG
Stattegger Strasse 18
A-8045 Graz
Our Service Department will be pleased to help you and can be contacted
at:
Andritz AG
Stattegger Strasse 18
A-8045 Graz
Pulp Technology Service Department
Tel.: +43/316-6902-2759
Fax: +43/316-6902-424
e-mail: [email protected]
In case of emergency outside working hours:

Tel.: +43 316 6902-0
1.6 Copyright
The operating manual is protected by copyright. All usual rights reserved.
It must not be wholly or partly reproduced without authorization by Andritz
AG. Contraventions shall entail damage claims and may have penal
consequences. All rights shall also be reserved for any patents granted,
registration of trade marks and technical modifications without prior
notification.
© 2005 Andritz AG

01-Introduction.FM
2 SAFETY
2.1 General safety regulations
The chapter on safety contains general safety regulations which must be
observed when working on the machine/plant.
The chapters dealing with individual tasks in the operating manual contain
further safety regulations in addition to those provided here. These are
marked by DANGER SIGNS.
Safety instructions on components not supplied by Andritz AG are
contained in the descriptions of the components provided by
sub-suppliers.
/TURBOMIX™ TMX1000A/SUPPLIER DOCUMENTATION
The safety instructions supplement ANDRITZ AG's operating instructions.
All safety instructions must be observed. Disregarding the safety
instructions may cause a risk to life and limb, environmental pollution
hazards and/or damage to property.
Andritz requires the operator to provide the following:
• The operator must compile a comprehensive general safety program.
Anyone working at or in the vicinity of the machine must have received
training for working on plants of this type and on the process running
there, including where to mount barriers and markings.
Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 1 of 16

02-Safety.FM
2.2 Danger and warning signs

The entire SAFETY chapter is of extreme importance and relevant to
safety. The information in this chapter, therefore, is not marked with
special danger symbols.
In the Chapters on ERECTION WORK, START-UP, OPERATION, and
MAINTENANCE in this Manual, warnings are marked by a pictogram. The
following warning signs are used:
This symbol indicates there may be a risk to life and limb.

Non-compliance with the warning signs may lead to serious health
DANGER problems or even fatal injuries, and can cause extensive damage to
property.
This symbol points to an imminent health risk, as well as a risk of

environmental pollution and of damage to property.
WARNING Non-compliance with the warning signs may cause moderate health
problems and/or extensive environmental pollution and damage to
property.
This symbol points to a dangerous situation.

Non-observance of these signs may cause environmental pollution and
CAUTION damage to property.
Further symbols and pictograms used are described in the

INTRODUCTION.
2.3 Designated use

The TurboMix™ should only be used according to the specifications
forming part of the purchase order.
Use of the machine/plant for any other purpose is considered contrary to
its designated use.
Any modifications to the scope of supply made without the agreement of
Andritz AG are considered contrary to the designated use.
The term designated use also covers adherence to the operating
instructions, compliance with the operating, inspection and maintenance
conditions and with the regulations on cleaning and upkeep.

02-Safety.FM
2.4 General remarks on machine/plant safety

The machine/plant has been built in accordance with state-of-the-art
standards and the recognized safety rules. Nevertheless, its use may
constitute a risk to life and limb of the user or of third parties, or cause
damage to the machine/plant and to other material property.
The machine/plant may only be operated when in perfect condition and
with due consideration to safety and the risks involved. All protective
devices and the emergency cut-out devices must be in place and fully
functional.
Malfunctions and unforeseen changes to the machine/plant must be
remedied immediately.
2.5 Hazardous applications

The machine was developed specially for the process specified in the
sales contract. All changes to this process must be checked and
approved because Andritz knows in detail the chemical and biological
properties of the numerous materials that can be processed in this
machine. The machine as-sold is not suitable for safe processing of
hazardous materials unless additional precautions are taken.
Before processing materials that are already combustible, explosive,
toxic, or hazardous in other ways or which can become hazardous in a
reaction, the operator must conduct a thorough hazard analysis and risk
evaluation of the entire process. This includes drawing up of contingency
plans for handling process errors and faults.
In particular, the following must be observed:
1. If combustible or potentially explosive materials are to be processed,
all electric motors, cabling and operating elements MUST be
explosion-proof. Furthermore, maintenance work on the plant MUST
be performed using non-sparking tools. Smoking is forbidden.
2. If the material processed is toxic, appropriate safety measures MUST
be implemented.

02-Safety.FM
2.6 User's obligations
Designated use The user of the machine is responsible for its designated use.
Work instructions In addition to the operating instructions, applicable legal stipulations in the
user countries and other rules governing the safety at work, health and
environmental protection must be observed and personnel instructed in
these matters.
Qualification of The machine/plant may only be operated, maintained and serviced by

personnel authorized, skilled personnel with hands-on training.
assigned
Personnel must be of the legal minimum age.
Any person undergoing training or in apprenticeship or under instruction
may only work on the machine/plant after receiving instruction on the
theory and only under the supervision of an experienced person.
Instructions The customer's operating and maintenance personnel is to be instructed

by qualified persons after completion of the installation work.
The user undertakes to have new, additional operating and maintenance
personnel instructed in machine/plant operation and maintenance to the
same extent and applying the same care, and with due consideration to
the safety instructions.
Workers entrusted with the transportation, erection work, start-up,
operation, and maintenance of the machine/plant must have read and
understood the operating instructions, especially the chapter on SAFETY,
the safety instructions concerning a certain activity, as well as the safety
instructions issued by sub-suppliers.
Definition of fields The user shall be responsible for:

of responsibility
• definition of the machine operator's responsibility and his right to give
instructions
• definition of the contents and responsibility for keeping the records on
functioning and any failure of the monitoring equipment (log book)
• personnel areas of responsibility in terms of operating, tooling,
maintenance and upkeep.

02-Safety.FM
Inspections The operator undertakes

• to check at regular intervals whether the safety instructions and
regulations governing work on the machine are observed.
• to carry out regular training to confirm the level of knowledge of the
operating and maintenance personnel.
Attaching safety The operator shall ensure that all regulations relevant to security are
devices observed and that all symbols and signs are mounted in the production
area in accordance with local regulations.
• Safety devices and regulations (see Chapter 2.8)
In addition, Andritz recommends mounting the following devices, symbols
and signs, in as far as these are not already included in the local
regulations.
• Markings on the floor for vehicle routes, protective fencing and danger
areas (yellow)
• Fencings and covers
• Railings (foot, centre and chest height)
• Emergency lighting
• Shut-off device for drive motor
• Signs on fire-fighting equipment
• Signs for emergency calls
• Direction arrows to exits
• Direction arrows to escape routes
• Signs to first-aid post
• Emergency-OFF button
The national fire protection regulations must be observed.

02-Safety.FM
2.7 General obligations of personnel

To avoid personal and material damage, all persons working on the
machine shall observe the following safety instructions:
• Observe the safety regulations in the operating instructions and on the
machine.
• In the event of a safety-relevant functional disorder, stop and secure
the part of the plant affected. Report disorders and have them repaired
immediately.
• Do not perform any work in a manner disregarding safety
considerations.
• Use only the machine accesses, paths and passages foreseen for this
purpose.
• Do not touch moving and rotating parts and/or reach out beyond them.
• Keep the machine and the workplace clean. Do not place tools and
other objects on the machine/plant.
• Do not wear any garments/pieces of jewelry which might get stuck on
moving machine/plant parts. This includes ties, scarves, rings and
necklaces.
• Do not wear long hair hanging down.
• Familiarize yourself with the function and any failure of machine
monitoring equipment (log book) before starting work.
• No smoking in the vicinity of the machine/plant.
• Wear personal protective apparel when working on the machine/plant
(see section 2.8).

02-Safety.FM
2.8 Safety devices

The machine/plant must not be operated without effective safety
equipment.
Safety equipment must not be circumvented, dismantled or made
unserviceable during operations. The safety equipment is there to protect
operating personnel.
Safety equipment and access thereto must be kept clear.
Emergency-off The machine/plant must have emergency-off buttons to stop it in case of

switch, emergency an emergency.
cut-out
Indicative, warning Indicative, warning and prohibiting signs must be observed. They must be
and prohibiting checked regularly for legibility and completeness and they must not be
signs removed or obstructed.
The following indicative, warning and prohibiting signs are attached to the
plant.
Caution! Do not enter Caution! Put

the container unless you protective equipment
have written permission in place before
to do so! starting machine.

02-Safety.FM
2.9 Personal protective apparel
General protective Operating personnel must use and carry personal protective equipment
apparel along with them in accordance with the national regulations or as
specified by the plant operator.
It should be compulsory to wear hard-toed boots throughout the entire mill
premises.
In adddition to the regulations applying, we recommend using the
following safety equipment for certain work:
Activity Safety equipment

Time spent in the immediate
vicinity of the machine when
running
Taking pulp samples
Field installation and

maintenance work for which
parts of the machine have to be
removed
Tab. 2-1 Recommended safety equipment for certain work
Key to symbols
Protective clothing to prevent the safety shoes as protection

pulp from coming into contact against foot injuries
with the skin
gloves to prevent hand injuries ear protection to prevent damage

to hearing
goggles to prevent eye injuries standard hard hat as protection

against head injuries
Tab. 2-2 Purpose of the safety equipment

02-Safety.FM
2.10 Safety at the machine installation site

A suitably large, clear, and unconfined working area must be created on
all sides of the machine. Pipework, ducting, etc. must be laid such as not
to impede access to the machine.
All operating and maintenance areas of the machine must have adequate
lighting and ventilation (industrial lighting).
The foundations must be sized to withstand the loads caused by the
machine. Area around machine and marked escapes to be kept clear.
Area around machine must be marked as danger zone. It must be
possible to enter and leave the operating area unimpeded.
Make sure machine and surrounding area are kept clean. In particular, oil
and grease on the floor and on machine elements may cause slipping.
This is therefore a considerable source of injuries, as are tools that have
not been put down in a safe place. The operating area must be clear of
waste materials, tools and other extraneous objects.
The floor around the machine must be provided with a non-slip finish.
In order to prevent any falls from or damage to the machine, it is forbidden
to climb onto machine elements or on the machine (except for the
treading areas provided). Use ladders or similar equipment in accordance
with recognised standards.
Ramps, platforms and lifts must be used to avoid injury or excessive
physical effort.
2.11 Noise
The total noise emissions from all machines in the production room can
restrict spoken communication and impair hearing.
The machine is designed such that no operator is required in the
immediate vicinity of the machine during normal operation. Appropriate
hearing protection should be worn throughout maintenance and adjusting
work while the machine is running.
2.12 Electrical equipment

All work on the electrical equipment, without exception, must be carried
out by skilled electricians.
Any form of contact with electrical equipment may cause fatal injuries.
Before beginning any maintenance or repair work, the operator must
disconnect the energy supply to all drives securely. This can be achieved
with a maintenance switch, lockable racks in the MCC, or with other
suitable measures that comply with the safety regulations.
Employees performing work on live parts should be accompanied by an
assistant who can operate the emergency switch if necessary.

02-Safety.FM
Users of medical electronic equipment, such as pacemakers, must not

enter the electric danger zone.
Machine must be grounded to avoid electrostatic loading. Machine, gears
and motors must be connected to the grounding system.
2.13 Welding work

In general, welding work is only permitted after consulting Andritz AG. Any
welding work that is described in detail in the maintenance instructions is
excluded from this ruling.
When performing welding work, always observe the relevant safety
regulations and the appropriate safety regulations for work performed in
enclosed and confined spaces.
HOT WORK PERMIT REQUIRED!

Danger of fire or explosion!
There is a considerable risk of fire or explosion during welding work.
DANGER
Always take the appropriate fire precautions before beginning work,
e.g. keep fire extinguishers at the ready.
All motors should be disconnected before carrying out electric welding

work.
During electric welding work the grounding should never be allowed to run
over the rolling bearings. A grounding cable is to be connected up in the
immediate vicinity of the welding area.

02-Safety.FM
2.14 Fluids, (liquids, gases, vapour or smoke)

Unintended chemical reactions may take place in fibre pulps during a
prolonged standstill and hazardous fumes may be produced.
The machine must be thoroughly cleaned after prolonged stoppages.
The area must be adequately ventilated.
Before beginning work on the machine, ensure that no liquids, gases,
vapours or smoke can enter the working area from feed pipes, discharge
pipes or shafts.
If it is not possible to reliably exclude the risk of liquids, gases, vapours or
smoke flowing in, all persons working in the danger zone must be
equipped with a safety harness and a safety rope. Each worker must be
monitored by a second person outside the danger zone.
It must always be possible to evacuate a worker from the danger zone
without delay.
2.15 Oils and greases

The safety instructions for the products concerned must be observed
when handling oil, grease and other chemical substances.
Suitable skin protection is required when handling aggressive media. See
manufacturers' information for the type of skin protection required.
Also observe relevant requirements for disposal.

02-Safety.FM
2.16 Work in enclosed vessels and in confined spaces
Definition All operating equipment that is closed off towards the surrounding
atmosphere is considered an enclosed vessel. This includes shafts,
channels, pipework and cavities in machines.
Procedure
Step Procedure
1 The safety measures must be defined in writing before
beginning any work.
The safety measures must be defined by a competent expert
in this field.
2 Permit to enter an enclosed vessel, to be issued by a
supervisor who is present at all times.
This supervisor must check personally that the measures
defined in writing are implemented and thus, that it is safe to
enter the enclosed vessel.
3 Permanent supervisor available for rescue measures.
There must always be someone present who is well versed in
the required protective and safety measures. This person
must be capable of rescuing whoever is inside the enclosed
vessel or of fetching help without actually leaving the place of
the incident.
4 Approval for re-start to be given by permanent
supervisor.
Tab. 2-3 Working in enclosed vessels - procedure
Specimen permit to enter an enclosed vessel, see section 2.17.
Emptying and The enclosed vessel must be disconnected effectively from all pipes
cleaning leading to and from it.
Possible cleaning methods:
• Flushing out
• Steaming out
• Using high-pressure cleaning equipment.
If high-pressure cleaning equipment is used in a potentially explosive
atmosphere, the cleaning lance must always be made of non-sparking
material.
The enclosed vessel should only be cleaned mechanically in exceptional
cases as this work requires someone to enter the vessel.

02-Safety.FM
Ventilation – The ventilation system must be sized such as to maintain the

protective concentration of noxious substances below the maximum concentration
breathing permitted in the work place and also to ensure that sufficient oxygen is
equipment available. This will ensure that it is possible to work without protective
breathing equipment and that there is no risk of fire or explosion.
Ventilation is only permitted with air. It is forbidden to ventilate using pure
oxygen or air with an increased oxygen content!
If the concentration of noxious substances exceed the maximum
permitted value, suitable protective breathing equipment must be used.
Protective breathing equipment

Oxygen content Harmful substance Safety measures
concentration
> 17% < MAC at place of None
work
> 17% > MAC at place of Filter mask
work
< Retaining capacity
> 17% > MAC at place of Independent
work protective breathing
> Retaining capacity equipment
< 17% Independent
protective breathing
equipment
> 50% of lower Entry is forbidden
explosion limit
Rules for ventilation

• Solvent vapours are heavier than air, thus they must be extracted by
suction at the lowest point of the vessel.
• Fresh air should be blown in close to the respiratory organs.
• Ventilating efficiency should be monitored with measuring
instruments.
• If substances presenting a fire hazard are extracted, the risk of
explosion must be considered.

02-Safety.FM
Further Gas bottles

regulations and
measures It is forbidden to take gas bottles or liquid fuel (liquid gas) into an enclosed
vessel. (e.g. welding equipment, lamps or soldering tools).
Safety harness
If it is necessary to enter an enclosed vessel in which there is a danger of
fire or of harmful work substances being present or a risk of oxygen
deficiency, the person entering the vessel should be roped up with a
safety harness.
The following points must be observed:
• The end of the rope must be secured outside the vessel.
• Each worker must be monitored by a second person outside the
danger zone.
• It must always be possible to evacuate a worker from the danger zone
without delay.
• If the only rescue route is upwards, use only approved rescue
equipment, such as cable winches or manual lifting devices.
In the presence of working substances that may ignite, rescue ropes must
either be plastic-sheathed steel ropes or ropes with at least equivalent
heat-resistance properties.
If roping up is not possible, suitable escape hatches must be available
that will allow anyone inside the vessel to climb out without assistance
from outside.

02-Safety.FM
2.17 Permit for work in enclosed / confined spaces

Object / location / point at which work is performed: . . . . . . . . . . . . . .
Type of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supervisor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparatory Which substances are or were present?

protective
measures Amount / concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What substances can form?

Amount / concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Existing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment brought in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access ports to be cleared:

No. / size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition of safety Vessel to be emptied yes no Type:. . . . . . .

measures Residue to be removed yes no Type: . . . . . . .
Ventilation: natural technical Type: . . . . . . . . . . . . . . . . . . . . .
Air analysis required . . . . . . . . . . . . . . . . . . . . . . . . . . . yes no
Protective breathing equipment required . . . . . . . . . . . yes no
Equipment available or brought in . . . . . . . . . . . . . . . . yes no
if so, what are the safety measures? . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal protective apparel required . . . . . . . . . . . . . . yes no
if so, what protection measures? . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explosion protection measures required . . . . . . . . . . . . yes no
if so, what protection measures? . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Look-out personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes no
Required rescue equipment . . . . . . . . . . . . . . . . . . . . . yes no
Safety measures by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cancelled Safety measures mentioned were observed: . . . . . . . . . . . . . . . . . . . .
Approved
from __________ at _______ hrs to __________ at _________ hrs
________________________ ___________________________
(Supervisor) (Contractor or sub-contractor)

02-Safety.FM

02-Safety.FM
3 TECHNICAL DATA
3.1 Data
Operating data TurboMix™ TMX1000A

Propeller speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 rpm
Idle running under nominal conditions . . . . . . . . . . . . . 30 kW / 50 Hz
Sealing water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 - 2 l/min

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 bar
Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 20°C
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Micron (Frischwasser)
Weights Total weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 980 kg

Welding ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50kg
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385kg
Drive shaft with bearing assembly . . . . . . . . . . . . . . . . . . . . . . 220 kg
Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 kg
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 kg
Safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 kg
Main drive Motor . . . . . . . see project data sheet and/or supplier documentation
Rev. 0, 2008.05.21 TECHNICAL DATA Kap.3 , Seite 1 of 2

03-Technical Data.FM
Rev. 0, 2008.05.21 TECHNICAL DATA Kap.3 , Seite 2 of 2

03-Technical Data.FM
4 DESCRIPTION
4.1 Field of application
The TurboMix™ TMX1000A is used to mix or agitate fibre pulp
suspensions.
Fig. 4-1 TurboMix™ TMX1000A
Rev. 0, 2008.05.21 DESCRIPTION Kap.4 , Seite 1 of 6

04-Description.FM
4.2 Main components of the machine
2 6 7
4 7 3 7
Item Component Item Component

1 Welding ring 5 Propeller
2 Bracket 6 Drive
3 Storage 7 Safety covers
4 Seal 8 Guide plate

04-Description.FM
Welding ring Function: Mounting the TurboMix™ at the chest.

(Item 1)
Design: The welding ring is a massive flange made of acid-proof stainless
steel and is welded into the shell of the chest.
Bracket (Item 2) Function: Holding the bearing, the seal and the drive.
Design:Welded structure made of steel.
Bearing assembly Function: Holding and supporting the agitating element.

(Item 3)
Design: Two split pedestal bearing housings are screwed to the bracket.
The steel drive shaft is supported on two bearings.
Fig. 4-3 Storage
Seal (Item 4) Function: The seal prevents the medium from escaping from the chest.
The seal must have a continuous supply of sealing water. The connecting
dimension and water requirement are indicated in the arrangement
drawing.
Design: Im Stopfbüchsengehäuse sind fünf Packungsringe und der
Laternenring montiert. Der Sperrwasseranschluß befindet sich am
Stopfbüchsengehäuse.
Fig. 4-4 Seal

04-Description.FM
Propeller (Item 5) Function: The propeller ensures that the medium is circulated in the chest.
Design: The propeller consists of a hub with three acid-proof, stainless
steel vanes screwed onto it.
Fig. 4-5 Propeller
Drive (Item 6) Function: Driving the propeller.

Design:
• 3-phase asynchronous motor
• V-belt pulley
• V-belt
Fig. 4-6 Drive

04-Description.FM
Safety covers Function: The safety guard prevents direct access to rotating parts and
(Item 7) protects the TurboMix™ against foreign objects.
Design: The safety guards are made of sheet steel and mounted on the
bracket. They can be removed quickly for maintenance work.
Guide plate Function: The guide plate influences flow of the medium.
(Item 8)
Design: Welded structure made of acid-proof stainless steel. The guide
plate is screwed to the bracket (Item 2).
Fig. 4-7 Guide plate

04-Description.FM

04-Description.FM
5 ERECTION WORK and TRANSPORT

5.1 General
This chapter describes certain steps for transport, storage and installation
of the TurboMix™ TMX1000A, which may be the responsibility of the
machine operator.
Activities which are carried out by ANDRITZ AG, including works
assembly, are not the subject of this description.
5.2 Safety regulations
Disregarding the safety regulations may cause a risk to life and limb.
If the safety regulations are disregarded, this may cause a risk to life
and limb and damage to the machine or its components.
DANGER
All safety instructions in this section must be strictly observed.
General safety All applicable accident prevention rules must be observed.

instructions
The applicable regulations for work in enclosed and confined spaces must
be observed ( /TURBOMIX™ TMX1000A/ SAFETY).
Potential risks caused by gases and vapours forming must be analysed in
detail. The appropriate safety measures must be implemented.
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads to prevent them from falling.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus, strictly forbidden.
Jolts must be avoided. This refers especially to the handling of
pre-assembled machines.
Qualification of Transport and unloading is to be carried out by personnel specially

personnel familiar with such work.
assigned
Workers entrusted with lifting and conveying equipment must have the
required national qualification.
Start-up may only be carried out by trained, skilled workers.
Rev. 0, 2008.05.21 ERECTION WORK and TRANSPORT Kap.5 , Seite 1 of 10

05-Erection.FM
Personal The following protective equipment must be worn when carrying out field
protective apparel installation and transport work:
• Hard hat
• Protective clothing
• Protective gloves
• Protective shoes
• Goggles
5.3 Transport
During transport of rolls or loading/unloading there is a risk to life

and limb and also a danger that components of the plant may be
damaged.
DANGER
Do not lift machine and transport crates except at the points marked
for lifting by crane or forklift.
If the entire machine is lifted and there are several different types of
lifting lug available, personnel should only use suitable lugs for the
work in hand and which are marked as such.
Do not step or walk below suspended loads.
Supply The TurboMix™ is supplied pre-assembled. Machine components and

auxiliary materials are packed in crates.
Transport sizes and weights are stated in the shipping documents.
Largest supply weights:
/TURBOMIX™ TMX1000A/ TECHNICAL DATA

05-Erection.FM
Transport sketch
Fig. 5-1 Transport of TurboMix™
Acceptance • Check whether supply is complete (against shipping documents and

packing lists) and in perfect condition.
• In the event of transport damage or short supply, do not accept goods
but notify forwarder and ANDRITZ AG's shipping department.
• If there is a hidden defect or damage, notify forwarder and ANDRITZ
AG's shipping department within two weeks.
5.4 Storage
The following instructions must be observed if the system is not to be
installed immediately.
• Please inform ANDRITZ AG's shipping department.
• Provide weather protection for stored machine components. In
particular, avoid wide variations in temperature and ensure that the
equipment is kept clean.
• Incidentals should be protected against damage and unauthorized
withdrawal by storing in a lockable room.
• Packing should not be removed until field installation work begins.

05-Erection.FM
5.5 Installation
General
Disregarding the sequence plan and the installation instructions

may result in hazardous situations causing a danger to life and limb,
as well as machine damage.
WARNING
The sequence of erection work is important and must be strictly
observed.
Completion of the various steps must be documented in the certificate of

completion of erection work.
The sequence of erection work is shown in step-by-step tables. Individual

activities are numbered in their order of precedence.
Required The following supplementary documentation must be available at the

documentation at beginning of field installation work:
installation site
• Foundation and arrangement drawing
• Pipe connection diagram
• Documentation on electrical, measuring and control equipment
• Packing lists for each individual consignment
Preservation
Corrodible machine parts are protected with "Cortec VCI 369"
preservative grease.
The preservative grease need not be removed.
Machines or machine components may fall during transport at

installation site.
Do not lift machine and transport crates except at the points marked
DANGER
for lifting by crane or forklift.
Do not step or walk below suspended loads.
Parts of the body may be caught or crushed during installation work.

Do not insert your hand below suspended loads.
DANGER Wear your personal protective apparel.

05-Erection.FM
Mounting the Mount the welding ring according to the following table:
welding ring
Step Activity
1 Position the welding ring according to Fig. 5-2. Align the first
bore hole in the welding ring to the axle.
2 Seal the welding ring tightly with a 5 mm fillet weld on both
sides according to Fig. 5-2.
Tab. 5-1 Mounting the welding ring
sealed
sealed
Welding ring
Fig. 5-2 Mounting the welding ring

DANGER

05-Erection.FM
Mounting the Mount the TurboMix™ according to the following table:

TurboMix™
Step Activity
1 Apply seal (Item 1) to the welding ring.
2 Attach the TurboMix™ according to Fig. 5-1.
3 Screw the TurboMix™ to the welding ring (Item 2).
4 Mount the propeller (see /TURBOMIX™
TMX1000A/MAINTENANCE).
Tab. 5-2 Mounting the TurboMix™
2
Fig. 5-3 Mounting the TurboMix™

05-Erection.FM
Mounting the Mount the motor according to the following table:

motor
Step Activity
1 Place the motor (Item 1) on the bracket, insert and tighten the
screws (Item 2).
2 Loosen nuts (Item 3).
3 Lower the bracket (Item 4) by screwing the adjusting nuts
(Item 5) downwards.
4 Insert the keys (Item 6) in the shaft groove.
5 Mount the V-belt pulleys and V-belts
(see /TURBOMIX™ TMX1000A/MAINTENANCE).
Tab. 5-3 Mounting the motor
1
2 6
3
4
5
Fig. 5-4 Mounting the motor

05-Erection.FM
5.6 Connections
Sealing water All connections and connecting dimensions at the TurboMix™ are shown
connection in the arrangement drawing.
Errors in the installation of pipework and hoses may result in risks

to life and limb and in damage to the machine.
Mount all pipes stress-free and free of vibration.
CAUTION
The pipework must be mounted such that it does not stress the
machine during operation (e.g. by heat expansion of the pipes).
Electrical • Complete electrical installations according to electrical documentation

equipment provided by Andritz AG.
Safety devices The following safety devices are to be provided by the operator:
• Emergency-off button near the TurboMix™ drive
• Automatic monitoring of sealing water
• Device for safe disconnecting of all drives from the power supply
during maintenance and repair work. This can be achieved with a
maintenance switch, lockable racks in the MCC, or with other suitable
measures that comply with the safety regulations.
Risk of injury from rotating parts!

Clothing and parts of the body can be caught up in rotating parts.
CAUTION
Other work Other work to be completed:

• Clean the machine.
• Mount safety covers.

05-Erection.FM
5.7 Cold test (preparation for initial start-up)
Prerequisites The following utilities must be available:

• Electric power
• Sealing water (the pipe must be flushed out and connected up).
Lubrication • Initial filling of lubricant according to lubricating schedule (bearings,

etc.).
Damage to machine due to use of wrong lubricants.

Only use lubricants with the properties listed in the lubrication
CAUTION schedules.
Cold test The checks to be performed must be carried out according to the cold test
report and ticked off after completion.

05-Erection.FM

05-Erection.FM
6 START-UP
6.1 General
This Chapter describes the preparations and steps required for initial
start-up of the TurboMix™ TMX1000A.
If safety regulations are disregarded, this may cause a risk to life
DANGER

instructions
Qualification of Start-up may only be carried out by skilled workers with the appropriate
personnel training.
assigned
Personal The following protective equipment must be worn when carrying out
protective apparel start-up and erection work:
• Hard hat
• Goggles
Rev. 0, 2008.05.21 START-UP Kap.6 , Seite 1 of 4

06-Startup.FM
6.3 Prerequisites for start-up

The following must be checked before start-up:
• Erection work completed.
• Cold test completed.
• Location has been cleared and is clean.
• Power and water supply are available.
• Check supply of sealing water to stuffing box.
• All safety guards mounted.
• First filling of lubricants (bearings, etc.) provided.
• All chest agitator vanes have been set identically.
• All electric interlocks are functional and checked.
• Sense of rotation of the motor has been checked.
• All personnel know the location of the EMERGENCY OFF switch.
• All control circuits have been installed and tested.
• Process control system (DCS) installed and tested.

06-Startup.FM
6.4 Start-up
Proceed according to the following table at start-up:
Step Activity
1 Fill chest; see Fig. 6-1 for minimum level.
2 Sperrwasserzufuhr öffnen.
3 Start the TurboMix(tm).
Tab. 6-1 Start-up
Fig. 6-1 Minimum level in tank
The level of the medium in the tank must be at least 1.5 - times the
diameter of the propeller.
If this requirement is not met, there may be a risk to life and limb and
CAUTION a risk of damaging the machine or its components.

06-Startup.FM

06-Startup.FM
7 OPERATION
7.1 General
This chapter describes the activities required for starting, operating and
stopping the TurboMix™. Possible malfunctions and troubleshooting
methods are also presented.
If safety regulations are disregarded, this may cause a risk to life
DANGER

instructions
The regulations for work in containers and enclosed spaces must be
observed.
Qualification of The equipment may only be operated by qualified personnel.

personnel
assigned Operating personnel must know where the emergency-off switches and
the escape routes are located.
Operating personnel must have been instructed in the function and

possible failure of machine monitoring equipment, and in carrying out
maintenance and inspection work (shift log book, maintenance inspection
records).
Personal The following personal protective equipment/apparel shall be used when

protective apparel performing work on the machine (e.g. troubleshooting):
• Hard hat
• Goggles
Rev. 0, 2008.05.21 OPERATION Kap.7 , Seite 1 of 4

07-Operation.FM
7.3 Operating conditions
Fig. 7-1 Minimum level in tank
The level of the medium in the tank must be at least 1.5 - times the
diameter of the propeller.
If this requirement is not met, there may be a risk to life and limb and
CAUTION a risk of damaging the machine or its components.

07-Operation.FM
7.4 Control via DCS

The TurboMix™ is started up and stopped entirely from the DCS. The
TurboMix™ and all auxiliary units are started and stopped with the group
start and stop function.
Manual start-up When starting up the TurboMix™ manually, proceed according to the
start-up instructions ( /TURBOMIX™ TMX1000A/ START-UP).
7.5 Normal operation
During operation, operating personnel must make sure that data are
recorded in the shift log book and data recording sheets, and also carry
out the following work.
Daily jobs and The following work has to be performed in normal operation:
checks
Activity
Level in tank Check or adjust
In case of a malfunction, proceed according to section 7.7 (Operating

faults and troubleshooting).
7.6 Re-start after emergency stop
Prerequisites for In the event of power failures or emergency shutdown the machine should
starting not be started up again until the following requirements are met:
• Danger or fault has been eliminated
• EMERGENCY-OFF switch has been reset
The chemicals added may cause hazardous fumes.

Contact with the pulp or breathing in the fumes can result in
dangerous situations.
WARNING
Personal protective apparel must be worn.
Personnel working with the fiber stock should not be allergic to it.

07-Operation.FM
7.7 Operating malfunctions and troubleshooting
Malfunction Cause Remedy

Increased power Consistency in the chest is too high. Set consistency.
consumption by drive. Foreign objects or dirt in the chest. Empty the chest and remove
foreign objects.
Bearing of TurboMix™ is worn. Replace bearing
( /../ MAINTENANCE).
Insufficient circulation. Level in the chest is too high. Reduce level.
Consistency in the chest is too high. Set consistency.
Propeller vanes are worn. Repair propeller vanes
( /../ MAINTENANCE)
Propeller vanes are not adjusted to Adjust propeller vanes.
the optimum setting. ( /TURBOMIX™
TMX1000A/ MAINTENANCE).
Fiber proportion too high Sealing water pressure is too low. Increase sealing water
in sealing water escaping pressure
Stuffing box packings are worn. Replace stuffing box packings
( /../ WARTUNG)
Stuffing box becoming Too little flow of sealing water Set flow of sealing water
too hot. pressure.
Sealing water supply is clogged. Clean the locking water feed
pipe.
Stuffing box gland is too tight. Loosen the screw fitting at the
stuffing box gland.
Set flow of sealing water.
Bearings becoming too Insufficient lubrication. Re-grease bearing
hot. Bearing is worn. Replace bearing
Tab. 7-1 Operating malfunctions and troubleshooting

07-Operation.FM
8 MAINTENANCE
8.1 General
This chapter describes the maintenance and upkeep of the TurboMix™,
which is the responsibility of the machine operator.
All activities mentioned in this chapter must be performed at the correct
time.
The ANDRITZ AG service department is at your disposal for
troubleshooting, as well as for extensive maintenance and repair work.
/TURBOMIX™ TMX1000A/INTRODUCTION.
Repair work on the plant components must be carried out at the
manufacturer's works.
Workers trained and authorized by Andritz AG may carry out repairs on
site after obtaining consent from AAG.
If the safety regulations are disregarded, this may cause a risk to life
DANGER

instructions
Sufficient space for maintenance work must be included right away in the
arrangement drawing.
Maintenance and service work is not permitted while the machine is in
operation.
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads against falling down.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus, strictly forbidden.
Machine must be thoroughly cleaned before carrying out any
maintenance work.
Use only original spare parts.
When carrying out maintenance and repair work, use only new-value
fixtures in perfect condition and new seals.
Rev. 0, 2008.05.21 MAINTENANCE Kap.8 , Seite 1 of 22

08-Maintenance.FM
Safety guards After completion of maintenance work, all required safety guards must be
mounted again.
Energy supply Before beginning any maintenance or repair work the operator must
disconnect the energy supply to all drives securely. This can be achieved
with a maintenance switch, lockable racks in the MCC, or with other
suitable measures that comply with the safety regulations.
Lighting The operator shall ensure that adequate lighting is provided (with
extra-low voltage bulbs) during service and repair work.
Qualification of Maintenance and upkeep must be carried out by specially trained, skilled
personnel personnel only.
assigned
All work on the electrical equipment without exception must be carried out
by skilled electricians.
Personal The following protective equipment must be worn when carrying out
protective apparel cleaning and maintenance work:
• Hard hat
• Goggles
Welding work In general, welding work is only permitted after consulting Andritz AG.
When performing welding work, always observe the relevant safety
regulations and the appropriate safety regulations for work performed in
enclosed and confined spaces.

DANGER
All motors should be disconnected before carrying out electric welding

work.

08-Maintenance.FM
Gases, steam or Before beginning any service work, ensure that no gas, vapour or smoke
smoke can enter the working area from feed pipes, discharge pipes or shafts.
If it is not possible to reliably exclude the risk of gas, steam or smoke
flowing in, all persons working in the danger zone must be equipped with
a safety harness and a safety rope. Each worker must be supervised by a
second person outside the danger zone.
It must always be possible to evacuate a worker from the danger zone
without delay.
8.3 Regular maintenance

For machines operating continuously (24 hours/day, 7 days/week), a
prescheduled maintenance period every two weeks is recommended.
During these periods the machine should be shut down, thoroughly
cleaned and checked for wear.
Machines operating less than 24 hours per day should undergo these
routine checks and be cleaned at each shutdown.
General machine The following checks should be made when the machine has been shut
checks down:
Component Checks
Sealing water supply Check connections for leaks.
V-belt Check tension and for wear.
Tab. 8-1 General machine checks
In the course of general machine checks, all additional units should also
be checked to guarantee that the entire plant functions satisfactorily. For
these checks, the attached maintenance and upkeep instructions
provided by the manufacturer must be observed.
Malfunctions and inadmissible changes found during these checks must
be rectified immediately.

08-Maintenance.FM
Cleaning Machine must be cleaned before carrying out any maintenance work.
Toxic gases and vapour can form or collect in the container.

observed!
WARNING
Complete entry permit!
Contact with the fiber pulps may cause skin damage and burning.
Persons working with the pulp should not suffer from any allergic
condition to such substances!
WARNING
Personal protective apparel must be worn.
Do not use caustic agents for cleaning.

Make sure no water, steam or other cleaning agents enter electrical
CAUTION components.

08-Maintenance.FM
8.4 Maintenance schedule

In addition to the work outlined below, maintenance has to be carried out
in accordance with section 8.3 and normal operation work.
/TURBOMIX™ TMX1000A/OPERATION
Every 2 weeks The following maintenance work is to be carried out every 2 weeks.
Component Activity
Bearings • Check temperature and for noises.
Stuffing box • Check leaking water rate.
V-belt • Check tension.
Tab. 8-2 Every 2 weeks
Quarterly The following maintenance work is to be carried out at quarterly intervals.
Component Activity
V-belt • Check for wear.
Tab. 8-3 Quarterly
Annually The following maintenance work is to be carried out at annual intervals.
Component Activity
Screws/bolts • Check that screws are firm and tighten if
necessary.
Stuffing box • Check for function and wear.
Emergency-OFF button • Check function.
Tab. 8-4 Annually

08-Maintenance.FM
8.5 Fasteners
Screw/bolt Bolts and screws are manufactured in several classes of material. The
material heads of these screws and bolts are marked to show the strength class.
Damaged or lost fasteners should only be replaced with fasteners of the
same material.
Check Unless they are suitably tightened, screws/bolts can work loose or fail
under operating conditions. This is why all connecting screws/bolts must
be checked in the course of maintenance work.
• During the first six months: every 2 to 2½ months
• After the first six months: 6-monthly
Tighten During checks and maintenance work it is imperative to tighten all

connecting screws/bolts to the torque specified for each one in the
drawings or in the table below.
Pre-stressing forces and tightening torques in the table apply to normal
screwed/bolted connections. Please contact Andritz AG if you have
special requirements.
Tab. 8-5 Tightening Torques and Pre-Loads for Set Screws (coarse thread)
The thread and screw head should be lubricated with an appropriate

lubricant (for example Molyslide Plus from Loctite).
Wrong torque tightening may cause machine damage and hazards

leading to personal injury.
The above pre-loads and tightening torques
CAUTION
must be observed.

08-Maintenance.FM
8.6 Spare parts

A list of the spare parts required for the TurboMix™ can be found in the
parts book.
/TurboMix™ TMX/PARTS BOOK
Details on spare parts from sub-suppliers are also included in
specifications from component suppliers.
8.7 Lubrication
Before start-up, check whether all lubrication points have been filled with
the appropriate lubricants.
Details on lubrication are also included in specifications from component
suppliers.
Please also observe maintenance instructions on the maintenance signs
and nameplates attached to machine/components.
Improper disposal of lubricant endangers our environment!

Do not add foreign matter such as solvents, brake fluid or cooling
CAUTION liquid.

08-Maintenance.FM
8.8 Lubrication schedule
1 2
Lubricating point Quantity / grammes Intervals /

Operating hours
Item Structural No. Designation Recommended First Refill Refill Oil/Grease

component lubricant filling change
1 Storage 1 Spherical roller NLGI Class 2 1000 g 25 g 150 8000

bearing DIN 51818
(Mobilux EP 2)
2 Storage 1 Spherical roller NLGI Class 2 1000 g 25 g 150 8000
bearing DIN 51818
(Mobilux EP 2)

08-Maintenance.FM
8.9 Installation and removal of propeller

observed!
WARNING
Removing the Proceed according to the following table when removing the propeller:
propeller
Step Procedure
1 Shut down drive at all poles and secure against accidental
start.
2 Empty the chest completely, then clean it.
3 Loosen screw (Item 1) and remove.
4 Remove the washer (Item 2).
5 Remove O-rings (Items 3 and 4).
6 Pull the hub (Item 5) off the shaft (Item 6).
7 Remove seal (Item 7).
Tab. 8-6 Removing the propeller
4 5
2
6
3
7
1
Fig. 8-2 Removing the propeller
Installing the Propeller installation in reverse order.

propeller
• Replace the seals each time the propeller is removed.

08-Maintenance.FM
8.10 Installation and removal of the propeller vanes

observed!
WARNING
Removing the Remove the propeller vanes according to the following table:
propeller vanes
Step Procedure
1 Shut down all drives at all poles and secure against
accidental start.
2 Empty the chest completely, then clean it.
3 Mark the position of the propeller vane.
4 Detach the socket head cap screws (Item 1) and remove
together with the washers (Item 2).
5 Remove the propeller vanes (Item 3).
Tab. 8-7 Removing the propeller vanes
Fig. 8-3 Removing the propeller vanes
Installing the Installation of the propeller vanes in reverse order.

propeller vanes
• Set the orientation of the propeller vanes (see Section 8.11).

08-Maintenance.FM
8.11 Setting the propeller vanes
Setting the Set the propeller vanes according to the following table:
propeller vanes
Step Procedure
1 Loosen socket head cap screws (Item 1).
2 Align propeller vanes (Item 2).
3 Tighten socket head cap screws (Item 1).
Setting at works assembly 0°.

Maximum angle of adjustment +/-15°.
+/-15°
Fig. 8-4 Setting the propeller vanes
All propeller vanes must be aligned identically in order to avoid

unsymmetrical loads on the shaft and bearings.
CAUTION

08-Maintenance.FM
8.12 Installation and removal of gland packing
Removing the Proceed according to the following table when removing the packing:
stuffing box
packing
Step Procedure
1 Shut down all drives at all poles and secure against
accidental start.
2 Clean the machine (see section 8.3).
3 Turn out adjusting screws (Item 1).
4 Push the stuffing box casing (Item 3) with the screws (Item 2)
to the sealing ring (Item 4) .
5 Undo the screws (Item 5) and remove the stuffing box gland
(Item 6).
6 Remove the stuffing box packings (Item 7).
7 Remove lantern ring (Item 8).
8 Then remove the remaining stuffing box packings.
9 Clean the stuffing box gland, lantern ring and packing area
thoroughly.
10 Check shaft protection sleeve (Item 9) and replace if worn
(see Section 8.14).
Notches or grooves on the surface of the shaft protection

sleeve cause excessive wear on the stuffing box
packing!
Tab. 8-8 Removing the stuffing box packing
9 3 7 2 6
5
8
Fig. 8-5 Changing the stuffing box packing
• Steps 2 to 4 can be omitted if the chest has been emptied.

08-Maintenance.FM
Installing the Proceed according to the following table when installing the packing:
stuffing box
packing
Step Procedure
1 Mark packing (see Fig. 8-6) and cut to the appropriate length.
Keep the stuffing box clean. Neither stretch nor squeeze

while measuring and cutting!
2 Wrap the packing round the shaft protection sleeve, then
push the first packing ring into the stuffing box, starting at the
butt joint.
The ends of the ring must form a butt joint with no gap.
3 Push the first packing ring right in using a suitable tool. Mount
the second packing ring with the butt joint offset by 120
degrees.
4 After inserting the second packing ring, mount the lantern
ring.
5 Mount the remaining packing rings with the butt joints offset
by 120 degrees.
6 When the stuffing box gland has been installed, tighten all
nuts (Item 5) evenly according to the setting guidelines
provided below.
7 Undo the screws (Item 2) and turn in the adjusting screws
(Item 1) until there is a gap of approximately 3 mm between
the sealing ring (Item 3) and the casing receiver (Item 4).
8 Tighten the screws (Item 2).
Tab. 8-9 Installing the stuffing box packing
Packing cord
Flush joint, no gap
Packing marking
Fig. 8-6 Marking the stuffing box packing

08-Maintenance.FM
8.13 Setting the stuffing box gland
New packings swell because they absorb water. This increases the
surface pressure on the shaft and the large amount of sealing water that
escapes at first is then reduced.
The stuffing box packing will be damaged if the stuffing box gland is
screwed too tight.
If the stuffing box gland is too tight, this will cause burning on the
CAUTION seal surfaces.
Set the stuffing box gland according to the following table:
Step Procedure
1 Tighten the screw fitting slightly at the stuffing box gland.
2 Turn on supply of sealing water.
3 Start up the machine.
4 Shut down the machine after a few minutes and check the
temperature of the stuffing box seal.
The temperature of the seal casing must not exceed 40°C.
5 Tighten the stuffing box gland further until there is less
sealing water escaping.
Tab. 8-10 Setting the stuffing box gland
• The stuffing box should be checked at short intervals during the first
few hours in operation.
• Set the stuffing box such that the shaft at the stuffing box gland is
always moist.
• Loosen the screw fitting at the stuffing box gland if the stuffing box
overheats.

08-Maintenance.FM
8.14 Installation and removal of the shaft protection sleeve
Removing the Remove the shaft protection sleeve according to the following table:
shaft protection
sleeve
Step Procedure
1 Dismantle the propeller with key (see Section 8.9).
2 Pull protective tube (Item 1) off the shaft.
3 Remove seals (Item 2).
4 Remove splash guard (Item 3).
5 Dismantle the stuffing box packings (see Section 8.12).
6 Detach set screws (Item 4).
7 Pull the shaft protection sleeve (Item 5) off the shaft.
Tab. 8-11 Removing the shaft protection sleeve
1 2 5 4 3
Fig. 8-7 Removing the shaft protection sleeve
Mounting the shaft Re-install in reverse order

protection sleeve
• Replace the seals (Items 3 and 4) each time the shaft protection
sleeve is removed.

08-Maintenance.FM
8.15 Changing the V-belts
When a V-belt becomes loose, the load transmission drops and

there is more wear (smell of rubber).
CAUTION!
Always replace the complete set of V-belts!

INFORMATION
Changing the Change the V-belts according to the following table:

V-belts
Step Procedure
1 Shut down drive at all poles and secure against accidental
start.
2 Detach screws (Item 1) and dismantle top section of safety
cover (Item 2).
3 Relieve tension on V-belts (Item 5). To do this, loosen the
counter-nuts (Item 3) and turn the adjusting nuts (Item 4)
downwards at the tensioning device.
4 Remove the V-belts (Item 5) from the pulleys.
5 Mount the new V-belts.
6 Tension the V-belts with the tensioning device. Both belt
pulleys must be aligned to one another. Approximate values
for tensioning, see Fig. 8-8.
7 Rotate the drive completely several times to distribute the
tension evenly.
8 Check the V-belt tension once again.
9 Mount safety cover.
Tab. 8-12 Changing the V-belts

08-Maintenance.FM
Fig. 8-8 Changing the V-belts
Re-tension new V-belts after a few hours in operation.
8.16 Checking the V-belt tension
Fig. 8-9 V-belt tension
At a checking force of F= 50N per V-belt, the depth of impression Ea is

approx. 15 mm.

08-Maintenance.FM
8.17 Installation and removal of belt pulley
Removing the belt Remove the belt pulleys according to the following table:
pulleys
Step Procedure
1 Remove the V-belts according to Section 8.14.
2 Turn out the socket head cap screws in the taper sleeve.
3 Turn one of the screws into the push-off bore hole and push
the taper sleeve off (see Fig. 8-9).
4 Pull the unit off the shaft.
Tab. 8-13 Removing the belt pulleys
V-belt pulley Taper sleeve Push-off bore hole
tighten tight push off
Fig. 8-10 Taper-Lock taper sleeve

08-Maintenance.FM
Installing a belt Install the belt pulley according to the following table:
pulley
Step Procedure
1 Clean shaft, hub bore hole and taper sleeve. Remove
protective varnish or oil.
2 Place the taper sleeve and the belt pulley inside one another
and match up the bore holes. Turn in screws loosely.
3 Push belt pulley and taper sleeve onto the shaft in one unit.
4 Tighten opposite screws evenly with the required torque
according to Tab. 8-13.
5 Mount the V-belts and safety cover according to Fig. 8-7.
Tab. 8-14 Installing a belt pulley
Clamp the bushing onto the shaft first of all. Then align the hub by
moving it on the bushing.
Caution
Component Tightening torque

Belt pulley on propeller side • 162 Nm
V-belt pulley on motor side • 90113 Nm
Tab. 8-15 Tightening torques

08-Maintenance.FM
8.18 Installation and removal of bearings
Removing the Proceed according to the following table when removing the bearings:
bearing
Step Procedure
1 Shut down all drives at all poles and secure against accidental
start.
2 Empty the chest and clean it (see Section 8.3).
3 Loosen screws (Item 1) and remove the safety covers (Item 2).
4 Dismantle the V-belts (see Section 8.15).
5 Dismantle the propeller (see Section 8.9).
6 Ensure that the drive shaft is properly secured and cannot fall
down. Detach the screws (Item 3) in the plummer block.
7 Pull shaft out of the chest.
8 Dismantle the shaft protection sleeve (see Section 8.13).
9 Take the belt pulleys off the drive shaft (see Section 8.16).
10 Open plummer block (Item 4) and dismantle top and bottom
sections.
11 Remove locating rings (Item 6) from fixed bearing.
12 Remove bearing grease.
13 Mark the position of the taper sleeves Item 5) on the shaft
before removing them.
14 Bend locking plates (Item 7) upwards and loosen lock nuts
(Item 8).
15 Loosen the taper sleeves (Item 5) by striking the lock nuts
lightly.
16 Remove lock nuts and taper sleeves.
17 Take the bearing off the shaft.
Tab. 8-16 Removal of bearing

08-Maintenance.FM
2 1 9 2 6 3 4
9 5 7,8
Fig. 8-11 Removal of bearing
Installing the The spherical roller bearings are installed in reverse order.
bearing
• Clean all parts before assembling.
• Position the taper sleeves at the marking.
• Set the radial play of the bearings using a lock nut according to the
manufacturer's instructions.
• Replace the seals in the bearing housing (Item 9) each time the
bearing is removed.
• Fill the plummer blocks with grease (see Section 8.8 Lubricating
schedule).

08-Maintenance.FM

08-Maintenance.FM

TMX1000A

Uploaded by

Copyright:

Available Formats

TMX1000A

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TMX1000A

Uploaded by

Copyright:

Available Formats

TurboMix™ - TMX1000A

Diana Joint Stock Corporation, PF U1085/07

Erection Work, Operating and Maintenance

Rev. 0, 2008.05.21 TITLE PAGE

Rev. 0, 2008.05.21 TITLE PAGE

2.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 1

4.1 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Rev. 0, 2008.05.21 TABLE OF CONTENS Seite 1 of 4

5 ERECTION WORK and TRANSPORT . . . . . . 1

Rev. 0, 2008.05.21 TABLE OF CONTENTS Seite 2 of 4

Rev. 0, 2008.05.21 TABLE OF CONTENS Seite 3 of 4

Rev. 0, 2008.05.21 TABLE OF CONTENTS Seite 4 of 4

1.2 Standards and guidelines

Rev. 0, 2008.05.21 INTRODUCTION Kap.1 , Seite 1 of 4

1.3 How to use the manual

Presentation • Chapter and paragraph headings are printed in capitals in the

Pictograms The following pictograms are used in the manual:

Warning signs are shown with an explanation of the

The meaning of the different graduations of hazards

Marks an instruction on handling of the machine or

Marks a useful piece of information

Marks a cross-reference to another Chapter with

Rev. 0, 2008.05.21 INTRODUCTION Kap.1 , Seite 2 of 4

1.4 Warranty and guarantee

Rev. 0, 2008.05.21 INTRODUCTION Kap.1 , Seite 3 of 4

1.5 Manufacturer's name and address

In case of emergency outside working hours:

Rev. 0, 2008.05.21 INTRODUCTION Kap.1 , Seite 4 of 4

Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 1 of 16

2.2 Danger and warning signs

This symbol indicates there may be a risk to life and limb.

This symbol points to an imminent health risk, as well as a risk of

This symbol points to a dangerous situation.

Further symbols and pictograms used are described in the

2.3 Designated use

Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 2 of 16

2.4 General remarks on machine/plant safety

2.5 Hazardous applications

Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 3 of 16

2.6 User's obligations

Qualification of The machine/plant may only be operated, maintained and serviced by

Instructions The customer's operating and maintenance personnel is to be instructed

Definition of fields The user shall be responsible for:

Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 4 of 16

Inspections The operator undertakes

The national fire protection regulations must be observed.

Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 5 of 16

2.7 General obligations of personnel

Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 6 of 16

2.8 Safety devices

Emergency-off The machine/plant must have emergency-off buttons to stop it in case of

Caution! Do not enter Caution! Put

Rev. 0, 2008.05.21 SAFETY Kap.2 , Seite 7 of 16

2.9 Personal protective apparel

Activity Safety equipment

Taking pulp samples

Field installation and

Tab. 2-1 Recommended safety equipment for certain work

Protective clothing to prevent the safety shoes as protection

gloves to prevent hand injuries ear protection to prevent damage