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INSTALLATION, COMMISSIONING, OPERATION

& MAINTENANCE MANUAL

AIROCHEM

INDUSTRIAL FANS
E ngineered products – m oving air efficiently since 1975

CLIENT: Themax Ltd (Enviro Division).

PROJECT:

ORDER NO:

AIROCHEM ENGINEERING COMPANY


Plot No. B – 57, MIDC, Shiroli, Kolhapur, 416 122, Maharashatra, (INDIA)

E-mail - klp_airochem@sancharnet.in
Telephone - 91-230 – 2468107, 2468306
Fax No. - 91-231 – 2658312 & 91-230-2460734
Web site - www.airochemeng.com
INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

INDEX

CHAPTER PARTICULARS PAGE NOS


NO
I NAME-PLATE DETAILS 3
II OPERATING SPECIFICATIONS 4
III GENERAL 5
RECEIVING, HANDLING & STORAGE OF 6
IV
EQUIPMENTS
V INSTALLATION INSTRUCTIONS 8
PRE-COMMISSIONING & COMMISSIONING
VI 11
INSTRUCTIONS
VII BEARING LUBRICATION 15
VIII BEARING CLEARANCES 17
IX MAINTENANCE INSTRUCTIONS 18
LIST OF SPARE PARTS FOR TWO YEARS 20
X
OPERATIONS
XI MOTOR STARTER RELAY SELECTION TABLE 21
XII SELECTION OF ELECTRICAL CABLES 23
XIII TROUBLE SHOOTING GUIDE FOR FANS 24

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter I - Name Plate Details of Fans

AIROCHEM Industrial Fans -

Sr.No Identification ID Fan


1. Type Centrifugal
2. Size / Model
3. Capacity ( cum/Sec.)
4. Static Pressure @ optg.
Temp.(mmWG)
5. Speed (RPM)
6. Drive
7. Motor Details
8. Starter Details
9. Serial No.
10. Year of Manufacture

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter II - Operating Specifications of Fans

Sr. Identification ID Fan


No
1. Sr.No.
2. Fan Type Centrifugal

3. Model
4. Gas Handled
5. OperatingTemp. (oC)
6. Capacity (cum/ Sec.)
7. Gas Density (kg/m3)
8. SP at operating
Temp (mmWG)
9. TP at operating
Temp. (mmWG)
10. Impeller Diameter (mm)
GD2(kg-m2)
11. Impeller Speed (RPM)
12. Drive Type

13. Power consumed at optg.


Temp. in KW
14. Fan Efficiency (Static) at shaft
in %
15. Electric Motor
Details
16. G.A. Drawing No.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter III – General

The fan manufacturer, the driver manufacturer or the contractor building the installation can
carry out the installation of fans. Large fans are usually installed as early as possible while
access to the site is at its best. Small fans can usually be fitted in at any time.

The certified fan drawings must be available to allow foundations or structural steelwork to
be designed and manufactured before the fan is delivered.

The space allocated for a fan must be sufficient to permit installation, care, disassembly and
maintenance. Transport routes and lifting facilities must be available. Sufficient space must
be allocated around the installed fan for the access of personnel. Operation may need to make
frequent running adjustments. Maintenance personnel will require space to remove
components and assemblies. Some fan designs require space at the non drive end. The motor
may need space for the withdrawal of the rotor.

The ventilation of the fan site is very important. The electric motor must receive the
necessary cooling. If the hazardous gases, harmful to the environment or highly flammable,
are to be extracted, special ventilation requirements must be observed. It should be noted that
the heat generated by the fans electric motor can be considerable. The electrical and control
systems for the fan must also be protected against damage.

Mounting the fan unit on isolation mounting can create ducting and bearing problems.
Ducting close to the fan can fracture if it vibrates. Using flexible connections adjacent to the
fan can solve this problem. Short bearing life can be a problem if the fan does move
appreciably on its isolation mountings. It is better to use an isolated foundation block.

It’s the user’s responsibility to ensure the fan unit is stored in suitable conditions and that the
factory preservation instructions have been followed.
Before placing the fan on foundation, thoroughly clean the top of the foundation, remove any
thin ridges and roughen the top to provide good key for the grout. Prepare enough shims to
level the baseplate, two sets for each foundation bolt. The shims should be longer than the
width of bottom flange.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter IV - Receiving, Handling & Storage of Equipments

4.1) Receiving

Most fans have been correctly, checked and inspected prior to delivery. They have also been
subjected to a run test before leaving factory. When you receive the equipment, examine it
carefully for damage caused in transit. If anything is wrong, both the manufacturer and
carriers should be contacted within three days of receipt.
Check that all items indicated in accompanying challans and /or packing slips have been
received and if not contact the manufacturer immediately.
If the fans are to be received by non-engineering personnel, it is recommended that skilled
person carry out inspection on receipt.

If Fan assembly is received in CKD condition, ensure that all fan components are generally
received as per list below, and as per challan/ packing slip in particular.

1) Casing in two or three parts, each having flanged opening with joining screws and nuts
with spring washers. 2) Impeller with front locking washer, in case of overhung design & no
washer, in case of simply supported design. 3) Inlet Cone. 4) Inlet Box. 5) Inlet VIV or
Multivane Damper 6) Inlet and outlet flexible connections 7) Fan shaft with keys, bearings,
adapter sleeves, locating rings and Plummer blacks assembled or bare shaft with keys and
other items packed suitably. 8) Motor Pulley with locking washer. 9) Shaft Pulley with
lacking washer 10) Foundation Bolts. 11) Shaft and /or motor assembly mounting pedestal,
for overhung design.12) Plummer Block mounting pedestal, for simply supported design. 13)
Motor mounting base. 14) Vee- belt guard/ or Coupling guard

4.2) Handling

The equipment should be handled carefully to prevent damage. Always use lifting points
provided. Extra care should be given to Impeller or dynamic balance may be affected. The
Shaft and Bearings are also important for on them depends the vibration-free running. Where
the fan has been despatched as complete unit, never ‘sling’ under the shaft.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

4.3) Storage

When fans are to be stored or installed for any length of time before running, special
care should be taken as follows:

a) Where not specifically designed for outdoor use, they should be protected against
elements, special care being given to bearings, motors, and rotating parts.
b) Slowly run rotating parts at regular intervals to re-distribute the bearing lubricant,
making sure that the shaft finishes at 180 deg. to its former position. Never leave the
Fans stationary for any length of time adjacent to other vibrating machinery. These
precautions will diminish the possibility of brinelling of the bearing and /or serious
damage shaft damage.
c) It is recommended that fans stored for any length of time should be
Inspected again by the manufacturers representative before installation and start-up.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter V - Installation Instructions

5.1) Concrete Foundations

Check the height and ensure that there is required grouting allowance between the foundation
and the fan base. Suitable pockets should provided for the bolts to be grouted in after
levelling and aligning. For vee belt drives, the foundation bolts should be of adequate length
and well embedded in the concrete. The location of plinth should be checked in relation to
the fan layout drawing. Use steel shims to obtain the correct height; the shims should be of
the same width as base plate and placed each side of and close to foundation bolts.
Pour the grout and ensure that the top of the foundation is covered evenly. If full depth cross
members are fitted, ensure complete support. Remove the shuttering after five days, but
allow the grout to harden for at least ten days. Do not allow the grout to dry not too quickly,
and protect it from direct sunlight. In hot environments it may be necessary to cover the grout
with damp sacks.
Check the coupling alignment and adjust the shimming under the motor feet if necessary.
Record all alignment settings.
The suction and discharge ducting should be connected after the grout has hardened and final
alignment has been completed. The ductwork must line up naturally with the fan
connections. Do not force ductwork into alignment. Remove the ducting connections
adjacent to the fan and clean out the ductwork, as best as possible. Recheck the coupling
alignment with recorded figures and modify the ductwork if required.

5.2) Vibration Isolators

Use of vibration isolators, if recommended, use Dunlop or Polybond make isolators only, of
appropriate capacity by consulting the manufacturer of vibration isolators or as supplied
along with this fan.

5.3) Flexible Connections

If any inlet and / or outlet ducting is to be connected to fan, the same should be connected
through flexible connections. Material of flexible connection should suit the temperature and

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

other properties of gases handled. Expansion joints should be provided wherever hot gases
are being handled e.g. Flue Gases.

5.4) Fan assembly with common base for Fan & Motor

Lift the assembly & rest it on the foundation block. Align this assembly for exact matching of
Suction & Discharge Centre Line. Insert correct size foundation bolts in the foundation
pockets and through holes in common base.

Level the base frame with spirit level or water level by keeping in mind horizontalness of
discharge flange & verticality of suction flange.

Now pour cement slurry into each foundation pocket around bolt. Allow for setting time of
cement before fan is commissioned.

5.5) Fan assembly with common base for Fan only & separately for Motor

If fan is supplied with separate motor base frame, follow above procedure for foundation,
with due care being taken for alignment of motor pulley and shaft pulley grooves, in one
plane.

5.6) Fan supplied in knocked down condition ( CKD)

If fan is supplied in CKD condition, housing may have been supplied in split condition,
separate shaft assembly, bearing mounting pedestal and separate motor foundation frame etc.
In such a case, foundations will be cast as three separate foundation blocks or composite
block as per drawing,. But all the three components will have to be separately grouted in
following sequence.

5.6.1) Check top levels of all foundation blocks as per drawing.


5.6.2) Keep Lower Half of the casing on the foundation block. Align the same with respect
to its Centre Line.
5.6.3) Keep Bearing Pedestals/Shaft Assembly in place on the foundation.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

5.6.4) Fix shaft assembly onto these pedestals and check center line & level of the shaft by
keeping spirit level on the machined surface.
5.6.5) Check all clearances / distances as per drawing.
5.6.6) Insert correct size foundation bolt in place for Casing & Bearing pedestals.
5.6.7) Half grout all foundation bolts with cement slurry and allow for twenty four hours to
set.
5.6.8) Assemble fan impeller on the shaft at one end & driven pulley at the other end with
key & locking washers in place, inlet cone and casing top part.
5.6.9) Spin Impeller to see if the rotation is free and does not bind or rub.
5.6.10) Inspect Impeller to see if it is the proper handing of the fan design.
5.6.11) Due care will be taken to maintain distance (both straight & angular between various
center lines accurately)
5.6.12) Now carry out final grouting of all foundation bolts.
5.6.13) Assemble Inlet Box & Inlet / Outlet dampers, inlet outlet expansion joints, expansion
joints, inlet outlet flexible connections.
5.6.14) Grout the motor foundation frame in place with driving motor & pulley or half
coupling in place.
5.6.15) Align Driving and driven pulleys or Fan shaft & Motor shaft in case of coupled
drive.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter VI - Pre-commissioning & Commissioning Instructions

IMPORTANT

6.1) Ensure that you have following important tools/ equipments / instruments with you
for pre-commissioning.

Metallic Shims Set of Spanners Torque Wrench Measuring Tape


Steel rule Belt Tension Meter Tachometer Ammeter
Voltmeter Megger Dial Gauge Set of Filler Gauges
Spirit Level Plumb Line Hook Spanner

6.2) Start-Up Check List.

Before putting any fan in operation the following operations should be completed.

6.2.1) Check and tighten all foundation bolts.


6.2.2) Check all set screws and tighten if necessary.
6.2.3) Check v-belt drive or coupling for alignment.
6.2.4) Use recommended belt tension.
6.2.5) Check the v-belt drive for proper pulley selection and make sure that they are not
reversed.
6.2.6) Check & confirm that DE shaft bearing is made non-locating.
6.2.7) Make certain that no foreign loose material in ductwork to and from fanor in the
fan itself.
6.2.8) Properly secure all safety guards.
6.2.9) Close any inlet and outlet dampers.
6.2.10) Ensure correct direction of rotation of motor shaft.
6.2.11) In case VIV damper is provided at suction end of fan, confirm that while opening
of damper, air enters suction of fan is with pre-rotation in direction of rotation of
impeller. If this does not happen, get the opening direction of damper changed
suitably. This is very important, which otherwise will result in disturbance in
fan performance.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

6.2.12) Check whether the ball bearing are adequately greased as per greasing standards
and locknuts of taper sleeves are tightened and locked properly after checking for
required clearance between Balls / Rollers & Inner / Outer race of each bearing.
6.2.13) In case of vee belt driven fan, NEVER FORCE BELTS OVER PULLEYS OR ROLL
THEM OVER PULLEYS WHILE SHAFT IN ROTATION.

6.2.14) Check electrical wiring for using adequate capacity cable and starter. As
precautionary measure, check following in the presence of authorized person from
electrical department.
6.2.14) Motor name plate details like HP rating, Speed, Full Load Current of Motor to
Concur with recommended specifications.
6.2.15) Confirm that cable size and type is adequate for full load current of motor. Kindly
refer to cable manufacturers catalogue. Improper size or excessive length of
cable will result in excessive voltage drop at the motor terminals.
6.2.16) Check type of starter, relay current setting and confirm its suitability.
6.2.17) Carry out Megger test for electric motor between windings and body. Minimum
resistance should be around 15 to 20 megaohm.

6.3) In case of Double Inlet Double width (DIDW) type fans, confirm that impeller is
correctly mounted on shaft, which will result in Impeller running with fan blades backward
inclined or as marked on Impeller.

6.4) Very Important Points Before Start-up for v-belt driven fans.

6.4.1) Check all pulleys groove surfaces for smoothness. Any sharp edges or burrs
should be filed off, so that outer jacket of vee belt is not damaged.
6.4.2) Correct belt tension as per following table

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Tensioning Forces for Wedge Belts

Belt Small Pulley Force required to deflect belt 16mm per meter of span
Section Diameter Newton (N) Kilogram force (kgf)
(mm)
SPB 160 to224 35 to 50 3.6 to 5.1
236 to 315 50 to 65 5.1 to 6.6
SPC 224 to 355 60 to 90 6.1 to 9.2
375 to 560 90-120 9.2 to 12.2

6.4.3) Check alignment of both pulleys correctly which otherwise will result in rupturing
of outside jacket of vee belts and hence failure of belts very fast.
6.4.3) Under no circumstances ID fan Damper should be opened completely till full
temperature is reached & motor current is below name plate figure.
6.4.5) Important Note – Following precautions will be taken without fail to get
maximum life of v-belts & for smooth operation of fan.

6.4.5.1) Check correct installation and take-up allowance for motor sliding
Slots as per the following table.

Installation and Take-up allowances in mm length

Installation Allowance Take up


in mm allowance in mm
Belt Pitch length SPB SPC
in mm
1510 to 1830 50
1840 to 2170 60
2180 to 3500 75
2840 to 3500 30 100
3520 to 4160 50 125
4170 to 5140 160

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

6.4.5.2) After tightening of V-belts, measure belt tension with the help of
tension meter as above.
6.4.5.3) Never run V-belt driven fan without applying correct V-belt tension.

6.5) Switch on electrical supply and allow the fan to reach full speed.
6.6) Progressively open damper, making sure that the system continues to function
satisfactorily and motor does not overload.
6.7) Check carefully for
- Correct impeller rotation
- Excessive vibration
- Unusual noise
- If any problem is indicated, switch off the fan. Cut out electrical supply, check
carefully the cause of the trouble, and correct as necessary
6.8) Even if the fan appears to be operating satisfactorily, shut down after brief period and
recheck items from (6.2.1) to (6.2.8) as initial start- up may have relieved tightness of
belts and set screws, again ensuring that electric supply is cut out before attemting
other checks.

6.9) The fan may now put into operation, but during the first eight hours of running it should be
periodically observed and checked for excessive vibration and noise. At the same time checks
should be made on motor input current and motor temperatures to ensure that they do not
exceed manufacturer’s recommendations.

After eight hours of satisfactory operation, the fan should be shut down and the power cut to
check the following items and adjust if necessary.
a) All set screws and foundation bolts including guard fixings.
b) Drive coupling alignment.
c) Vee-Belt drive alignment.
d) Vee- Belt drive tensions should be readjusted to recommended tension.
e) Security of flexible connections.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter VII - Bearing Lubrication

7.1) Grease Lubrication

Fill the space between the balls or rollers with a grease which is suitable for the operating
conditions. The free space around the bearing should normally be between a third and half-
filled with grease. If the bearing is to operate at very high speeds, the quantity of grease in
the free space should be just less than one third. Or, where the bearing is to operate at very
slow speeds, the free space may be completely filled with grease.

An excess supply of grease is not recommended for ball or roller bearings. Heat is generated
more often by too much of lubricants than too little. Heating takes place when rotating parts
move through a large amount of lubricant, especially at high speeds..

7.2) Relubrication:

The service life of lubricating greases is limited. Mechanical stresses and ageing gradually
reduces the lubricity. Ageing concerns mainly on oxidation process accelerated by high
temperatures or the separating of the grease into the base oil & thickener. Morever, during
use, grease becomes impregnated with particles from the rolling & sliding surfaces. It is
therefore necessary in most bearing arrangement to replenish or renew the grease filling
periodically.

The relubrication interval depends on stressing of the grease by friction, speed &
environmental conditions. The relubrication period can be decided by referring to actual
conditions and Bearing Hand Book.

7.3) Amount of relubrication grease

At the moment of relubrication, the bearing generally still contains a certain amount of
grease. In order to avoid excessive greasing with closed housing space, the relubrication
amount must be limited and decrease further if the relubrication intervals are shorter.
In absence of any recommendations, the quantity of grease to be used can be

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Calculated from following equation,

G = 0.005 DB gms.
Where, G = Grease quantity, gramms.
D = Bearing outside Diameter, in mm.
B = Bearing width in mm.

7.4) Initial Grease Filling Required Per Bearing

Plummer Block No. Grease Qty. in Grams.


SNA-510 100
SNA-511 130
SNA-512 160
SNA-513 200
SNA-516 250
SNA-517 300
SNA-518 320
SNA-520 350
SNA-522 400
SNA-524 500
SNA-526 600
SNA-528 700
SNA-530 850

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter- VIII – Bearings Clearances

The following table gives Bearing Internal Clearance values before and after mounting.
8.1) Internal Radial Clearances of Spherical Roller Bearings with Taper Bore.
Nominal Clearance under zero measured Clearance under load in microns
Bore Size, D load in microns
mm Foe initial Foe initial C3 Foe initial Foe initial C3
Normal clearance clearance Normal clearance clearance
Bearings Bearings Bearings Bearings
30-40 35-40 50-65 15 25
40-50 45-60 60-80 20 30
50-65 55-75 75-95 25 35
65-80 70-95 95-120 25 40
80-100 80-100 110-140 35 50
100-120 100-135 135-170 50 65
120-140 120-160 160-200 55 80
140-160 130-180 180-230 55 90
160-180 140-200 200-260 60 100

8.3) Internal Radial Clearances of Double Row Self Aligned Bearings with Taper
Bore.
Nominal Clearance under zero measured Clearance under load in microns
Bore Size, D load in microns
mm Foe initial Normal Foe initial C3 Foe initial Normal Foe initial C3
clearance Bearings clearance Clearance Bearings clearance
Bearings Bearings
24-30 15-23 23-33 0 20
30-40 19-29 29-40 0 25
40-50 22-33 33-45 0 30
50-65 27-41 41-56 0 35
65-80 33-50 50-69 0 40
80-100 42-62 62-84 0 50
100-120 50-75 75-100 0 65

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter IX - Maintenance Instructions

9.1) AIROCHEM make fan supplied to you is a professionally manufactured piece of machine
and as such will need least maintenance. However, frequency of checking various
components will depend upon conditions like, Nature of gas handled, Temperature of gases,
Speed of rotation & Atmospheric conditions, where the fan is located. Generalization of fsn
maintenance is waste of time. Fans operate in widely differing circumstances with vast array
of materials. The best policy is to initiate a strict, very regular, routine inspection of
equipments and continue this till a pattern of equipment behavior is apparent. At this stage it
may be possible to relax the inspection routine in some areas. In absence of any specific
instructions, the following are suggested.

9.2) Routine Maintenance Chart

EVERY SHIFT When taking over plant at beginning of the shift, operator
should check that all bearings are cool.
EVERY WEEK Check for undue vibration. If present, stop fan at earliest
opportunity and remove the cause.
EVERY 3 MONTHS Check grease lubricated bearings for saponificatoin.
EVERY 6 MONTHS 1) Consult motor manufacturers manual and carry out
instructions.
2) Examine v-belt pulleys for any chipping, tension of v-belts,
OR,
3) Check coupling alignment and condition.
EVERY 12 1) Examine impeller, fan bearings, and inlet cones. Check v-
MONTHS belts, pulleys, or coupling elements. If any wear, replace as
necessary.
2) Check clearance at impeller, level at shaft, and general
alignment. Adjust as necessary.
3) Check all foundation bolts for tightness.
4) Refer to Motor and control gear manufacturer’s maintenance
instructions and act accordingly.
Grease lubricated bearings should be cleaned out and grease renewed.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

9.3) Special Maintenance care for ID Fans

Induced Draft fans of bagasse-fired boilers are normally preceeded by installation of fly ash
removal equipment such as Dry Multiclone Dust Collector, Wet Scrubber or Electrostatic
Precipitator.

These equipments bring down suspended particulate matter in flue gas below specified limits
& thus save impeller of ID fan from abrasion.

However some times due to malfunctioning of such equipments, ID fan impeller does get
eroded fast & this phenomenon has to be watched carefully.

In case Wet Scrubbers installed before ID fan, due care has to be taken to ensure that outlet
flue gas temp. from Wet Scrubber does not fall below 900C to avoid water vapour
condensation. This will result in fast corrosion of not only impeller but casing also.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter X ) List of spares for Two years Operation

(Except Electricals)

Sr.No Description Drg. No Make Material Size Quantity


01 Impeller Assembly 1 No.
02 Shaft with keys and 1 Set
locking bolts.
03 Shaft Bearings 2 Nos.
04 Bearing Housing 1 No.
05 Taper Sleeves with lock 2 Sets.
nut.
06 Locating Rings. 1 Set.
07 Motor Bearings (DE) 1 No.
08 Motor Bearings (NDE) 1 No.
09 Motor Cooling Fan 1 No.
10 Shaft Seal Assembly 1 Set.
11 Bearing Seal Assembly. 1 Set
12 Impeller Lock Nut 1 No.
13 Impeller Fixing Key 1 No.
14 Driving pulley fixing 1 No.
key.
15 Driven pulley fixing key. 1 No.
16 Vee belts 1 Set.
17 Impeller Locking Washer 1 Set
with bolts.
18 Driving Pulley Locking 1 Set.
Washer with bolts.
19 Driven Pulley, Locking 1 Set.
washer with bolts

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter XI ) Squirrel Cage Induction Motor Starter Relay


Selection Table

Sr. Motor H.P. Full load Relay Scale Relay Scale Back-up HRC Fuse
No. Current for DOL for Star Delta Rating for
Amps starter starter
in Amps in Amps DOL Delta
Starter Starter
In Amps In Amps.

01 0.5 1.05 1 – 1.6 - 6 -


02 0.75 1.5 1.5 – 2.5 - 6 -
03 1 1.8 1.5 – 2.5 - 6 -
04 1.5 2.5 2.5 – 4 - 10 -
05 2 3.40 2.5 – 4 - 10 -
06 3 4.60 2.5 – 6.5 - 16 -
07 5 7.30 6.0 – 10 - 20 -
08 7.5 10.5 9.0 – 14.0 - 25 -
09 10 14 10 – 16 - 25 -
10 15 20.60 18 – 24 10 – 16 50 35
11 20 28 20 - 32 13 – 21 63 63
12 30 40 28 – 42 20 – 32 100 63
13 40 52 45 – 70 28 – 42 160 100
14 50 64 60 – 100 28 – 42 160 100
15 60 76 - 45 – 70 - 120
16 75 96 - 45 – 70 - 160
17 100 140 - 60 – 100 - 200
18 125 156 - 90 – 150 - 250
19 150 190 - 90 – 150 - 250
20 170 215 - 120 – 200 - 320
21 220 278 - 120 – 200 - 350
22 245 310 - 120 - 200 - 350

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23 270 345 - 180 – 300 - 400


24 340 430 - 180 – 300 - 400

Note: - a) Above motor rating in HP are at 415 V, 3PH, 50 HZ supply.


b) Actual ratings value & current may change from manufacturer to manufacturer.

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter XII ) Selection of Electrical Cable

Current Ratings (AC) in Amps. for 650 / 1100 volts Armoured or Unarmoured 3 or 3.5 core
Copper / Aluminum cable.

Nominal Cross Current Rating in Amps.


Section Area
sq. mm. Laid in ground at 300C In Air at 400C

Copper Aluminum Copper Aluminum

1.5 21 16 17 13
2.5 27 21 24 18
4.0 36 28 30 23
6.0 45 35 39 30
10.0 60 46 52 40
16.0 77 60 66 51
25.0 99 76 90 70
35.0 120 92 110 86
50.0 145 110 135 105
70.0 175 135 165 130
95.0 210 165 200 155
120.0 240 185 230 180
150.0 270 210 265 205
185.0 300 235 305 240
240.0 345 275 355 280
300.0 385 305 400 315
400.0 425 335 455 375

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INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Chapter XIII -Trouble shooting for Fans

Symptom Possible cause Remedial Action


Fan won’t start Low voltage at motor terminals Check cable size and length
Power failure Check all power supplies
Blown fuses Check all fuses
Motor single phasing Check motor and wiring
Control switch contacts open Check all instrument switches in
motor contactoer circuit
Low flow Inlet and/or outlet damper closed Check dampers position and
correct.
Excessive system resistance Check calculations, gas temp,
etc.
Fan speed very low Check drive, frequency, and
Impeller partially blocked voltage.
Wrong direction of rotation Clean impeller and rebalance.
Reverse 2 phases in 3-phase
Wrong direction of VIV damper rotation motor.
Remove viv damper and correct.
High flow System resistance lower than specs. Check calculations, throttle
damper, and reduce fan speed.
Fan speed high. Check motor frequency, pulley
ratio.
High power High flow Check as above.
consumption Electrical faults Voltage frequency incorrect,
check supply.
Motor problem, check motor
High bearing Wrong selection of grease quality. Check and correct.
Temperature Over- greasing or under- greasing. Fill with proper quantity of
grease.
Looseness of sleeve Tighten sleeve.
Improper clearance between outer race Check clearance with filler
and rollers. gauge and correct.

AIROCHEM ENGINEERING COMPANY 24


INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

Outer race rotating in housing. Tighten cap properly or change


plummer block.
Fan vibration Poor alignment Check for alignment and any
bearing related problems.
Check coupling or v-belt drive
assembly.
Check base plate grouting.
Check ducting.
Damaged Impeller Check vibration harmonics,
clean and/ or repair impeller,
rebalance

Motor Vibration Poor alignment Check alignment and coupling/


vee drive assembly.
Check base plate grouting.
Check bearing clearances
Bearing Problems Check vibration signature for
bearing faults.
Check motor for loose rotor bars.

AIROCHEM ENGINEERING COMPANY 25