Electric submersible agitators play a key role in submersible operations, used to mix, stir and homogenize various liquids, ensuring that the liquids in tanks, ponds and other containers are fully stirred. However, such equipment will inevitably encounter the need for repair and maintenance during use. There are usually some established repair processes and preventive maintenance measures to deal with common failures or maintenance needs. These measures are designed to extend the life of the equipment and ensure its stable operation.

Common Issues And Causes

Electric submersible agitators often face a variety of challenges in operation, which directly affect their performance and service life. Prompt identification and resolution of these issues is essential to maintaining the equipment. Here is an overview of some common problems:

Seal failure: Mechanical seals are key components that prevent liquids from entering the motor. Long-term use, improper installation or contact with abrasives can cause seal failure, which in turn causes leakage and motor damage.

Motor overheating: The motor may overheat due to unstable voltage, overload or poor insulation performance, accompanied by a burning smell, which may cause shutdown in severe cases.

Impeller damage: During mixing operations, the impeller may be damaged due to collision with hard objects, cavitation or abrasive erosion, resulting in reduced mixing efficiency and abnormal vibration.

Bearing wear: Bearings support the rotating parts of the mixer. Inadequate lubrication, contamination or improper installation can cause bearing wear, resulting in noise, increased vibration and reduced performance.

Component corrosion: Mixers operating in harsh chemical environments or salt water conditions are susceptible to corrosion of components such as motor housings, shafts and impellers, which affects structural strength.

Electrical connection problems: Electrical connections can fail due to moisture intrusion, loose connections or aging wires, resulting in erratic operation or complete failure of the equipment.

Recognizing the existence of these problems and their causes is key to effective maintenance. Regular inspections and prompt response to any signs of trouble can prevent minor problems from becoming serious, ensuring continued reliable operation of the submersible agitator.

Repair Process

The repair steps of an electric submersible agitator are outlined below:

Preliminary Assessment: Thoroughly inspect the mixer, observe all accessible parts for damage, wear or corrosion, and perform electrical tests.

Disassembly: Using special tools, carefully disassemble the mixer and record the position and orientation of each component.

Cleaning: Thoroughly clean all components to remove debris, scale and corrosion.

Detailed Inspection: Use measuring tools to inspect each component for wear and damage and identify components that need to be replaced or repaired.

Repair or Replacement: Replace damaged mechanical seals; rewind stator coils for burned motors; balance and trim slightly damaged impellers; try to straighten bent shafts and replace if necessary; replace worn bearings.

Reassembly: Ensure that all components are properly aligned and securely fastened, paying attention to bolt torque and seal installation.

Testing: Idle test to check for noise and vibration; insulation resistance test to verify the electrical system; load test to confirm that the mixer is operating normally under working conditions.

Final Inspection and Calibration: Thoroughly check the quality of the repair and perform necessary calibrations.

Records: Record the entire repair process, including parts replaced and adjustments made, to facilitate subsequent monitoring.

These steps require expertise and tools to ensure your agitator is restored to optimal condition. Tianjin Kairun Pump Industry has a professional repair service that can provide the necessary expertise and equipment.

Preventative Maintenance

Preventive maintenance is important for electric submersibleagitators to help them last longer and reduce unexpected downtime. Here are some key preventive maintenance strategies:

Regular inspections: Perform visual and operational inspections of the agitator on a predetermined schedule, looking for any signs of wear, corrosion or unusual sounds.

Vibration monitoring: Perform regular vibration inspections to detect problems such as bearing wear, shaft misalignment or impeller imbalance at an early stage.

Oil analysis: For mixers with lubricating or transmission oil, perform oil analysis regularly to check for contaminants, metal debris or changes in oil quality.

Electrical testing: Insulation resistance and motor current testing are performed to evaluate the electrical performance of the motor and to identify possible problems with the winding or rotor in advance.

Sealing verification: Regularly check the sealing components to see if there are any damaged locations to avoid liquid penetration into the motor due to component damage and prevent damage.

Impeller maintenance: Check the impeller for wear, cavitation or material accumulation, and clean or replace it if necessary.

Lubrication management: Lubricate bearings and other moving parts according to the manufacturer's recommendations, use appropriate lubricants, and replace them on schedule.

Anti-corrosion measures: In corrosive environments, take appropriate anti-corrosion measures, such as using anti-corrosion coatings or installing anti-corrosion equipment, and regularly check the effectiveness of these measures.

Clean water flushing: Agitators used in polluted environments such as wastewater need to be regularly flushed with clean water to remove sediment and reduce component wear.

Training and records: Operators and maintenance personnel need to be trained and familiar with agitator operation and maintenance. At the same time, maintenance activities, repairs and operating parameters need to be recorded.

Regular maintenance can reduce the frequency of failures, improve safety, enhance equipment reliability, and improve operating efficiency. A comprehensive maintenance plan will help improve agitator performance and extend its service life.

About Tianjin Kairun Pump Co., Ltd.

Tianjin Kairun Pump is a professional manufacturer in the field of electric submersible agitators and related industrial equipment.

Kairun's comprehensive approach to mixer repair and maintenance includes:

- State-of-the-art repair facilities equipped with advanced diagnostic tools and testing equipment

- A team of highly skilled technicians with extensive experience in submersible agitator repairs

- A wide range of genuine spare parts to ensure optimal performance and life of repaired equipment

- Maintenance plans tailored to the specific needs of each customer's operating environment

- Continuous research and development to improve repair technology and extend equipment life

The company's commitment to customer satisfaction is not limited to repair services. Kairun provides expert consultation on mixer selection, installation and optimization to ensure that customers receive the best solution for their specific application.

Welcome to contact us at catherine@kairunpump.com, we are online 24 hours a day, 7 days a week.

References

1. Grundfos. (2021). Submersible mixers and flowmakers.

2. KSB. (2022). Submersible motor agitators.

3. Xylem. (2023). Flygt submersible mixers.

4. International Organization for Standardization. (2015). ISO 9001:2015 Quality management systems — Requirements.

5. Hydraulic Institute. (2020). Rotodynamic (Centrifugal) Slurry Pump Standard. ANSI/HI 12.1-12.6-2020.