ISO-9001: 2008

SWAM ROTARY (PISTON) BLOWER

(TRI-LOBE /TRI-LOBE TYPE)

1. Client : M/S METSO POWER INDIA PVT. LTD.,

2. Model : RM-450 WC TR

3. Project ID : 110157

4. P.O. No. : CAISACY041/PO/SM/13-14/004 DTD.-09.05.2013

5. Project : P.T. CIKARA, 2X135 MWE CFB BOILERS INDONESIA

6. Direction of rotation : Clockwise

(Viewed from drive shaft end)

7. ³
Capacity (NM /S) : ³
1.29 (5325M /Hr.)

8. Suction Temperature :

9. Discharge Temperature :

10. Discharge Pressure (Pa) : : 72400(0.72Kg/cm² )

11. Differential Pressure(Mpa) :

12. Power at shaft : : 130.8 BKW

13. Blower operating speed : 1200 RPM

14. Recommended Motor/Speed : 160/1500 (KW/RPM)

15. Type of cooling : Water Cooling

16. Max. discharge temperature :

17. Type of Blower : Tri Lobe

18. Max. Vacuum (If used as exhauster) : N.A.

O&M MANNUAL No.SP-OMM-211

 ISO-9001: 2000

TABLE OF CONTENTS
1.0 Important Instructions
2.0 Safety Instructions
3.0 Description
4.0 Working principle
5.0 Inspection
6.0 Storage
7.0 Installation
8.0 Accessories
9.0 Starting
10.0 Operating conditions
11.0 Lubrication schedule
12.0 Periodical maintenance
13.0 Maintenance & replacement
14.0 Dismantling the blower
15.0 Re-assembly
16.0 Putting Blower back into operation
17.0 Part identification list
18.0 Recommended spares
19.0 Operation of Oil Injection pump
20.0 Drawings and Documents:-

• Alignment of drive arrangement Fig. – 12

• Oil Injection Pump Fig. – 13
• Bearing fitting & removal Fig. – 14
• Gears fitting & removal Fig. – 15
• Mounting of anti vibration pads Fig. – 16
• Blower Cross sectional drawing Drg. –17
and part identification list Drg. –

O&M MANNUAL No.SP-OMM-211

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 ISO-9001: 2000

IMPORTANT

TO GET THE BEST OF THE MACHINE, FOLLOW THE FOLLIWING INSTRUCTIONS

EVEN THE BEST MACHINE WILL NOT PERFORM SATISFACTORILY IF NOT

PROPERLY, INSTALLED AND MAINTAINED AND HENCE, TO GET THE BEST OF
THIS BLOWER, THE INSTALLATION AND OPERATING PERSONNEL, SHOULD
FOLLOW INSTRUCTIONS CONTAINED HEREIN METICULOUSLY. IF THESE
INSTRUCTIONS ARE NOT FOLLOWED AND DAMAGE OCCURS TO BLOWER, DUE
TO NEGLIGENCE, THE GUARANTEE CONTAINED IN OUR CONDITIONS OF
SUPPLY SEIZES TO OPERATE AND WOULD BECOME VOID.

THE BLOWER IS DESPATCHED AFTER HAVING TEST RUN FOR SEVERAL HOURS
TO MEASURE THE FAD, PRESSURE AND POWER CONSUMPTION ETC. TEST
CERTIFICATES ARE AVAILABLE FOR INSPECTION AND CAN BE FORWARDED ON
REQUEST. AFTER COMPLETION OF TESTS, LUBRICATING OIL IS DRAINED OFF
AND BLOWER IS DESPATCHED WITHOUT OIL.

THEREFORE, BEFORE STARTUP, TAKE ALL PRECAUTIONS SET-OUT HEREIN

AND IN CASE OF DOUBT OR DIFFICULTY, SEEK ASSISTANCE FROM OUR
TRAINED PERSONNEL.

SWAM PRODUCTS ARE SOLD SUBJECT TO THE GENERAL TERMS OF SALE, AND
WARRANTY POLICY.

IT IS TAKEN THAT THE CLIENT/USER HAS GONE THROUGH ALL THE CONTENTS
OF THE MANUAL & HAS AGREED TO ABIDE BY IT IN TOTALITY. ANY CHANGES
OR MODIFICATION OR REPLACEMENT DONE BY CLIENT WITHOUT ANY
APPROVAL FROM SWAM, WOULD BE TREATED AS NON COMPLIANCE AND THE
EQUIPMENT WARRANTY WOULD BECOME VOID.

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 ISO-9001: 2000

1.0 IMPORTANT NOTES:

† Check the shipment for damage. If found damaged immediately contact the
forwarder and notify Swam HQ.
† Unpack shipment carefully, and check contents against packing list. Notify Swam
if a shortage appears, within 48 Hrs. of the shipment opening.
† Store in a clean, dry location until ready for installation. Lift by methods discussed
under Installation to avoid straining or distorting the equipment. Keep covers on
all openings, protected against weather and corrosion. If outdoor storage is
necessary extra precautions are required.
† Read Operating Limitations and Installation sections in this manual and plan
the complete installation accordingly.
† Provide for adequate safeguards against accidents to persons working on or near
the equipment during both installation and operation. See SAFETY
PRECAUTIONS.
† Install all equipments correctly. Foundation design must be adequate and piping
carefully done. Use recommended accessories for operating protection.
† Make sure both driving and driven equipments are correctly lubricated before
start-up. See LUBRICATION.
† Read starting check points under OPERATION. Run equipment briefly to check
for installation errors and make corrections. Follow with a trial run under normal
operating conditions.
† In event of trouble during installation or operation, do not attempt repairs. Notify
SWAM giving all nameplate information plus an outline of operating conditions
and a description of the trouble. Unauthorized attempts at equipment repair would
void SWAM warranty.
† Units out of warranty may be repaired or adjusted by the owner if they so wish to.
It is recommended that such work be limited to the operations described in this
manual, using SWAM parts. Good inspection and maintenance practices would
reduce the need for repairs.
NOTE: Information in this manual is correct as of the date of publication and SWAM
reserves the right to make design or material changes without notice, and without
obligation to make similar changes on equipment of previous supply.
Contact Customer Care at H.Q. at swamatic@airtelmail.in or swamtlb@vsnl.com or Fax
at +91-120-2443283.

2.0 SAFETY INSTRUCTIONS

2.10 GENERAL:
It is important that all personnel observe safety precautions to minimize the chances of
injury. Among many considerations, the following should be particularly noted:

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 ISO-9001: 2000

• Blower casing and associated piping or accessories may become hot enough to
cause major skin burns on contact.

• Internal and external rotating parts of the blower and driving equipment can produce
serious physical injuries. Do not reach into any opening in the blower while it is
operating, or while subject to accidental starting. Protect external moving parts with
adequate guards.

• Disconnect power before doing any work, and avoid bypassing or rendering
inoperative any safety or protective devices.

• If blower is operated with piping disconnected, place a strong coarse screen over the
inlet and avoid standing in the discharge air stream.
CAUTION: Never cover the blower inlet with your hand or other part of body.

• Stay clear of open inlet piping (suction area) of pressure blowers, and the open
discharge blast from vacuum blowers.

• Use proper care and good procedures in handling, lifting, installing, operating and
maintaining the equipment.

• Casing pressure must not exceed the rated or max. working pressure as described
on no. plate or 14.3 PSI (1000 mbar) gauge unless expressly permitted. Do not
pressurize vented cavities from an external source, nor restrict the vents without
consulting SWAM.

• Do not use air blowers on explosive or hazardous gases.

• Other potential hazards to safety may also be associated with operation of this
equipment. All personnel working in or passing through the area should be trained to
exercise adequate general safety precautions.

• Operating personnel must ensure smooth operation of machine.

• Use of safety devices must be ensured

• The user’s plant operating personnel must have thorough understanding of the
requirement as per the O&M manual.

• The user is entirely responsible for ensuring that no unauthorized person is attending
to the blowers and that the machines are operating in the proper working condition.

• The user is also responsible for not changing the originality of the machines in
respect of any modification without any written confirmation for the same by SWAM.

• Management must inform operating personnel of the need to wear safety clothing,
safety glasses & hearing protection.

• Operating personnel have the obligation of advising their superior of any changes
occurring to the machine and which reduce the safety of its operation.

• By means of appropriate procedures and controls, the user must guarantee

cleanliness in the work place and ease of access to and around the machines.
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 ISO-9001: 2000

• Under absolutely no circumstances may safety devices be removed or disabled.

• Do not run the blower without lubricating oil on the drive & non drive side.

• Work on electrical components must be carried out by authorized persons only.

• While carrying out machine verification tasks, and in particular when opening the
acoustic hood, the use of hearing protection is compulsory.

• The discharge piping may reach a temperature of upto 150°C and must not be
touched.

• Piping must not be disassembled prior to having been depressurized and purged
with a neutral gas (Only for blower working as Gas Booster).

• Pressurized lube and instrumentation lines must not be opened, and the connections
must not be tightened. There is risk of injury, for example resulting from escaping oil.
Any changes done in piping or system would effect on the performance of the
machine and in such case, the user would be entirely responsible. The changes
would be allowed only on authorization by SWAM.

• Safety devices, for example Pressure Relief Valves, Coupling guards, Belt guards,
contact thermometers, and contact switches, must not be removed or modified.

• Conversions and modifications not authorized by the manufacturer are not allowed.

2.20 SPARE PARTS AND ACCESSORIES:

The replacement of parts and accessories not supplied by us and not approved by us is
not agreed, and we exempt ourselves from any liability for damages resulting from the
use of such parts and accessories. Further if any changes or replacement of any item or
accessories is done by client without our pre-information, and specific approval, it shall
be client’s own decision and the guarantee clause would thus become void with
immediate effect.

3.0 DESCRIPTION
The Rotary blowers are very precision machines. The clearances between Rotor to
Rotor and Rotor to casing are very fine and hence, its maintenance and operation
requires lot of care. The slightest negligence on its operation may result into damage of
the machine parts. Therefore, the operating instructions should be understood by the
actual operator and not merely by the maintenance engineer. In case of major repair of
overhaul of the machine, reference may be made to the company for assistance or
deputation of expert service engineer to attend to it.

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4.0 WORKING PRINCIPLE

The two rotors, each having Two or Three lobes of identical profile, rotate in unison
without touching each other or the casing. Very close clearances are maintained
between rotors and rotor to casing for optimizing efficiency and the output. No part inside
the compression chamber, however, touches each other, and air is compressed and
delivered completely oil free. There is thus no wear of compression chamber or of Rotor-
lobe. The drive shaft is rotated through the external drive (Motor or I.C. Engine etc.). The
second rotor is driven through gear train located at the other end.

5.0 INSPECTION

Check the unit and the accessories as per packing list. Any shortage, loss or damage be
reported immediately for SWAM. Check also the Blower against any transit damage.
Rotate the rotor shaft with hand. It should rotate freely.

6.0 STORAGE

If the unit has to be stored before use, it should be kept in a dry, clean and well covered
space. The unit’s internals and machined surface should be properly protected from
moisture and dust and for this suction and delivery openings should be kept closed until
the machine is installed. In case of negligence, the attack of moisture and dust will have
detrimental effect on the Blower’s performance. In case the units are required to be
stored for a longer period and there is likely to be attack from dampners, the flanges,
machines surfaces and internals must be coated or rust preventive with protective oils.
Contact SWAM’S H.Q. in such situation for the specific oil to be used.

7.0 INSTALLATION

The unit can be installed outdoors or indoors, but the preference should be given to a
clean dry indoor location.

The foundation should be properly leveled to a maximum of 0.5mm/meter. and provide

anti vibration pads between foundation and base frame level the top of base frame upto
a maximum of 0.2 mm per linear meter. If required fix steel shims between anti vibration
mounting and base frame pad and tighten the foundation bolts. Before, placing the
Blower on to the base frame, level it perfectly. The shaft position should be within 0.05
mm per linear meter in horizontal/vertical planes. The motor shaft should be parallel to
blower shaft. Tighten the hold down bolts. In case of uneven level or gap found between
base frame blower pad and blower feet, steel shims should be provided for making up
the gap or unevenness.

Rotate the Blower drive shaft with hand. It should rotate as freely as before installation. If
not then check for uneven leveling etc.

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 ISO-9001: 2000

Follow the general arrangement drawing for installation, and connect up various
accessories, instrument etc. Please ensure no external stress gets induced in any
part of blower or accessory after installation.

SWAM blowers are treated after factory assembly for protection against normal
atmospheric corrosion. The maximum period of internal protection is considered to be
one year under average conditions, if shipping plugs and seals are not removed.
Protection against chemical or salt water atmosphere is not provided. Avoid opening the
unit until ready to start installation, as corrosion protection will be quickly lost.

If there is to be an extended period between installation and startup, the following steps
should be taken to ensure corrosion protection.
„ Coat internals of blower, Rotor-lobe and drive and bearing reservoir with rust
preventive oil. Repeat once a year or as conditions may require.
„ Coat shaft extension, inlet and discharge flanges, and all other exposed surfaces
with rust prevention oil.
„ Seal inlet, discharge, and vent openings. It is not recommended that the unit be set
in place, piled to the system, and allowed to remain idle for extended periods. If any
part is left open to the atmosphere, the oil vapor will escape and lose its
effectiveness
„ Protect units from excessive vibration during storage.
„ Rotate shaft three or four revolutions every two weeks.
„ Prior to start up, remove flange covers on both inlet and discharge and inspect
internals to insure absence of rust. Check all internal clearances. Also, at this time,
remove drive and non drive end-covers and inspect gear teeth and bearings for rust.
Supervision of the installation by SWAM service Engineer is required for these units.
Workmen with experience in installing light to medium weight machinery should be able
to produce satisfactory results. Handling of the equipment needs to be accomplished
with care, and in compliance with safe practices. Unit mounting must be solid, without
strain or twist, and air piping must be clean, accurately aligned and properly connected.
BARE-SHAFT UNITS: Do not use the suction flange or lifting lugs on end plate for
lifting. Place the slinger below the blower body.
PACKAGED UNITS: When the unit is supplied mounted on a base plate, with or
without a driver, use of lifting slings passing under the base flanges is required.
Arrange these slings so that no strains are placed on the unit casing or mounting
feet, or on any mounted accessory equipment. DO NOT use the lifting lugs in the
top of the unit head plates or suction flange.
Before starting the installation, remove plugs, covers or seals from unit inlet and
discharge connections and inspect the interior completely for foreign material. If cleaning
is required, finish by washing the CASING and the impeller with a petroleum solvent.
Turn the drive shaft by hand to make sure that the Impellers turn freely at all points. Anti-
rust compound on the connection flanges and drive shaft extension may also be
removed at this time with the same solvent. Cover the flanges until ready to connect
piping.
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The proper & correct installation is the most important aspect of the performance of the
rotating machines. The right procedure and sequence be followed and a complete
erection & installation details be forwarded to SWAM or SWAM’s representative. If there
is any misalignment, stresses improper leveling, it would have adverse effect on the
blower performance. The vibration mounts must be placed on the foundation and then
properly leveled and then place the base frame, level again and then the blower & motor
level again and the do the alignment of the unit, coupling or v-belt as the case is
Subsequently place the accessories one by one starting from suction silencer going to
filter and from the discharge silencer to the check valve. If the sequence is not properly
followed and there is found to be misalignment, or unequal compression of vibration
mounts or pipe stresses passing on the blower nozzle, check and correct. In all these
circumstances the client/installing personnel would be held responsible and the damage
caused to blower would be their responsibility. The client is required to maintain, as a
proof the complete log book.

7.1 PREPARATION
Before transporting the unit to the prepared base, all surfaces which would come into
contact with the base should be cleaned of oil and grease to ensure proper contact.
Leave the caps on the flanges until the pipe work is ready to be finally connected.

7.2 TYPE OF FOUNDATION

Rotary piston blowers should be mounted on a flat, vibration-free foundation. The
dimensions for the foundations should be taken from our drawings. If the unit is to be
located on a steel structure or a deck which is capable of vibrating, then we
recommended that it be mounted on elastic machine feet which absorb transmitted –
vibration. In this case, the blower and its drive motor are mounted on a single common
steel base frame, a cast concrete bed slab, laid on rubber blocks, is also suitable.

7.3 PREPARING THE FOUNDATION

The surface of the foundation should be roughened and then cleaned. Blow out the
anchoring holes.

7.4 ALIGNMENT
Place the blower unit into the foundation, and adjust it until it is accurately levelled, using
steel shim plates (no wedges!). Use a machinist’s level on machined surfaces or on the
drive shaft.
The maximum permitted deviation from the horizontal is 0.20mm per meter length. The
steel shim plates should be pushed in under the base frame so that it completely covers
them. If the blower and the drive motor are not mounted on the same base, then the
blower should be mounted higher to enable the subsequent alignment to be carried out
properly.

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 ISO-9001: 2000

7.5 ANCHORING BOLTS

After leveling has been completed, the anchoring bolts should be grouted in, and once
the grout has set and hardened, tighten it. It should be possible to turn the blower easily
by hand: If, there is any resistance, then this indicates that either the base plate or the
housing is distorted, or there is dirt in the blower cylinder. In cases where the blower will
be subjected to wide temperature variations, only the feet on the drive side should be
rigidly fixed to the foundation: the rear feet should be held by means of spacer bushes in
such a way that a slight movement parallel to the shaft is possible to allow for thermal
expansion of the housing.

7.6 COUPLINGS AND PULLEYS

The shaft journal be thoroughly cleaned of rust-preventing varnish or oil before fitting the
pulleys or the couplings. A suitable jig must be used for fitting the pulleys or coupling; the
jig is centered in the centering hole on the end of the shaft.

7.7 FINAL ADJUSTMENT

For the final adjustment, the shaft of the blower should be taken as the fixed reference
point. The drive motor shaft should be adjusted by means of steel shims, until the shafts
match up. Each shim must be of at least the same area as the foot which it supports.
The gap between the two halves of the coupling must be precisely set as stated in the
specification. If spacer couplings are used, follow the fitting instructions accurately.
The coupling must be tested for true running using dial gauges. If the two halves of the
coupling have identical flange diameters, this check can also be carried out using a
straight edge and a feeler gauge.

7.8 PIPING CONNECTION

During piping connections, care should be taken that no undue stress or strain is caused
to the machine. The pipe size should preferably be same as that of Blower’s suction and
discharge opening. The bends should be as fewer as possible and should have large
radius not less than 90°.
Make sure that the pipes, bends and other appurtenances are clean of dust, rust and
welding slags. If suction is from atmosphere, a suitable filter should be fitted, depending
on its dust conditions. After completion of piping again rotate the rotor shaft with hand
and it should rotate as freely as before. If not check for uneven mountings, piping strain
etc.
While, doing the suction & discharge connections, please ensure no stresses are passed
on to these blower nozzles. This stress would adversely effects on the performance of
the blower.

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7.9 WATER PIPING

Cooling water line for the Water cooled model should be laid as per the drawing and
should be ensure that cooling water pressure does not exceed the stipulated pressure or
else use pressure regulating device. The water flow sight indicator and pressure and
temperature gauges be installed in compliance to the drawing.

7.10 MOTOR & DRIVE ARRANGEMENT

If Blower is not supplied with motor, belt drive or coupling, then following care should be
taken while installing it:-
(A) When Directly coupled to Electric Motor:
i) The Blower and motor shaft should be so aligned that they are exactly in
one line.
ii) As far as possible the flexible coupling should be used.
iii) Coupling alignment error should not exceed 0.05mm in any direction or
plane. This is an extremely important aspect.
(B) When Connected to V-Belt Drive:
i) Both the Blower and motor should be placed in horizontal plane.
ii) The pulleys should be properly fixed on drive shaft.
iii) The shaft of the motor as well as of Blower, should be parallel and the
pulleys fitted on the shaft should be in straight line.

iv) The blower alignment should be within 0.05 mm per linear meter in each
plane. Either it is directly coupled or V-belt driven.
A protective screen is recommended in suction of the blower. This screen is to be
taken out after at least 800 working hours.

8.0 ACCESSORIEES
8.1 SILENCERS
The fitting of silencer on the discharge side of the machine is recommended in the
majority of the cases. The silencer at suction side is also recommended. In some cases
a sound attenuation chamber Acoustic enclosure/Acoustic hood is supplied for a silent
operation.

8.2 Intake Air Filters:

The intake filter safeguards the machine against dust, dirt and any foreign materials
entering the compression chamber. Hence, the reliability of Blower performance
depends to great extent on the quality and efficiency of intake filters.

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8.3 NON-RETURN VALVE

Non-return valves isolate the machine from line pressure and also prevents it from
turning back when suddenly switched off. The valve should be fitted in horizontal plan
just after the discharge silencer. Ensure that NRV is correctly installed, the arrow mark
given there indicated direction of air flow. The flapper should have easy swing and in the
direction of air flow.

8.4 PRESSURE RELIEF VALVE/VACUUM RELIEF VALVE

A pressure relief valve is provided with every unit to protect it from excessive increase of
pressure. The valve should be mounted in such a way that it is readily accessible. A
pressure relief valve should always be mounted prior to any isolation.

8.5 MEASURING AND MONITORING DEVICES

In general, the pressure gauge, temperature gauge are quite sufficient to monitor the
machine operation. It should be connected by a heat resistant flexible tube at least 2
meters in length just at outlet to the unit and shall be mounted on the wall free from
vibration. An inter locked pressure / temperature monitoring system can be supplied on
request at extra cost.
The temperature & pressure switch/transmitter must be installed at the blower down
stream, to protect against high temperature and high pressure. This must be ensured by
client.

8.6 STANDARD ACCESSORIES

The Blower unit comprises intake filter, suction silencer, discharge silencer, pressure
relief valve, non-return valve, base frame, coupling or pulleys, V-belts and its safety
guards, pressure gauge, anti-vibration mountings or pads.

8.7 ACOUSTIC ENCLOSURE:

When a Blower is supplied with an acoustic enclosure care should be taken to install the
enclosure. After Blower installation the enclosure holding down frame is to be kept on
foundation pocket. The acoustic panel having the pipe opening be aligned properly with
the pipe connection while doing so the frame may be suitably lifted and after that all the
panels are fitted. The frame be grouted properly. It is to be noted that all the gaps below
the frame are sealed off, by cement mixtures. The pipe opening gaps are to be sealed
off by felt pad. Any openings unattended would be source of noise emission & the
responsibility of such would be on the installation and operating personnel. If the noise
level is subsequently during operation is measured high, it is important to first close the
gaps and openings properly.

8.8 OIL INJECTION PUMP KIT:

The oil injection pump and its attachments form ‘the special maintenance kit’ & is
required for the fitment and removal of timing gears. This ‘kit’ is not part of our standard
maintenance tools, but is recommended to be kept in stock.

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9.0 STARTING
Follow these checks before start-up:-
i) Ensure that no foreign material such as bolts, tools, nuts etc., has been left inside
the compression chamber.

ii) Ensure that inlet piping is free of any dust particles or weld slags etc., which may
get sucked into the Blower chamber.

iii) Turn drive shaft by hand to make sure that impellers rotate free.

iv) Ensure that the filter is fitted on the suction side.

v) Ensure that proper belt-tension has been given for belt drives. And there is
proper coupling alignment within the specified range for direct coupled
arrangement.

vi) Make sure oil levels are correct in the oil sumps & both the drive side and
non drive side covers are filled with oil to level indicated in the oil
indicators which is slight above the centre of the indicator.

vii) Keep the valves open on the suction and discharge side so that the Blower
starts on NO LOAD.
viii) Check the direction of rotation. It should agree with the direction marked. Check
also the positioning of NRV. It should open in the direction of air flow.
ix) Please ensure that there are no stresses on the blower nozzles and it is tension
free.
x) For water cooled model, please ensure that the end-covers are supplied the
cooling water before start-up. The client must provide water flow switch or
indicator for ensuring water supply. Also please check that the pressure of water
is not more than 3.5 to 4.0 Kg/Cm2 or 3.5 to 4.0 bar. If higher, use the pressure
reducing device.
If all the above points are O.K. then Blower is ready for trial operation on no load
conditions. Now start the Blower and check for the following:-
a) Start Blower and accelerate it to full speed then stop it. Listen for quite running as
speed slows down.
b) Repeat above but let it run for 5 minutes. Check for silent & vibration free
running. If the values are high stop & check for the causes and immediately
report SWAM.
c) Run the Blower for 10-17 minutes and feel the casing and end plates surfaces for
any undue development of spots too hot to touch.
d) Check the ‘V’ belt tension, if it is V belt drive. If require re-tighten it. In case the
belt strands are loose then the belts may result in a premature failure. For
coupling drive, check for the run out alignment details.
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e) Check for any oil leakage. If yes, locate the reason and it must be immediately
addressed. Do not change anything till written confirmation is given from SWAM.
Assuming all trails are satisfactory, the Blower is now ready for full load run. If the blower
is made to run on full load after satisfactory trails of above then it is important to ensure
proper maintenance schedule is done.
† Do not run the unit without an intake filter at suction
† Do not run the unit without proper alignment
† Do not run the unit without proper leveling
† The mountings must be leveled properly, it must not be put to unequal load &
made to uneven compress.
† For special water cooled models, please ensure water supply prior to starting
† Check also that the lubricating oil filled to the required level in both end sumps.

10.0 OPERATING CONDITIONS

The rated operating condition viz. pressure and the volume of air delivered at the
indicated speed are marked on the name plate. For any change, please check with us.

10.1 OPERATING LIMITATIONS

A Rotary blower or exhauster must be operated within certain approved limiting
conditions to enable continued satisfactory performance. Warranty is contingent on such
operation.
Maximum limits for pressure, temperature and speed are as specified in the front sheet
of the manual. These limits apply to the units of normal construction, when operated
under standard atmospheric conditions. Be sure to arrange connections or taps for
thermometers and pressure or vacuum gauges at or near the inlet and discharge
connections of the unit. These, along with a good tachometer, will enable periodic
checks of operating conditions.

PRESSURE: The pressure rise, between inlet and discharge, must not exceed the figure
listed for the specific unit. Never should the maximum allowable differential pressure be
exceeded.

On vacuum service, with the discharge to atmospheric pressure, the inlet suction or
vacuum must not be greater than values indicated.
TEMPERATURE: Blower are approved only for installations where the following
temperature limitations can be maintained in service:

• Measured temperature rise must not exceed the listed values when the inlet is at
ambient temperature. Ambient is considered as the general temperature of the
space around the unit. This is not outdoor temperature unless the unit is installed
outdoors.

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• If inlet temperature is higher than ambient, the listed allowable temperature rise
values must be reduced by 2/3 of the difference between the actual measured inlet
temperature and the ambient temperature.

• The average of the inlet and discharge temperature must not exceed the value as
given in technical documents.
SPEED: These blowers may be operated at speeds up to the maximum listed for the
blower model. They may be direct coupled to suitable constant speed drivers if
pressure/temperature conditions are also within limits. At low speeds, excessive
temperature rise may be a limiting factor.
SPECIAL NOTE: The listed maximum allowable temperature rise for any particular
blower may occur well before its maximum pressure is reached. This may occur at high
altitude, low vacuum or at very low speed. The units’ operating limit is always
determined by the maximum rating reached first. It can be any one of the three:
Pressure, Temperature or Speed.
For blower handling critical gases, ask for separate instruction.
DUSTY AREA OPERATION: If the blower is operating in areas of high dust content,
then the filter cleaning & replacement cycle would change. There would also be change
in the lube oil change and seal changes time period. The dust content load must be
informed and frequent checks be made on the blower. Any effect on blower operation
resulting in higher frequency of oil change, filter change and damage of seal shall be
clients responsibility.

11.0 LUBRICATION SCHEDULE

Proper lubrication is very important for the satisfactory performance of the Blower. Any
negligence thereon can be harmful. It is, important that it is properly and thoroughly
understood by those who are responsible for actual maintenance/ working of the
machines. Please do not use any sulphur phosphorus based oil or any synthetic oils.
Proper lubrication is usually the most important single consideration in obtaining
maximum service life and the satisfactory operation from the unit. Unless the operating
condition are quite severe, a weekly check of oil level and necessary addition of
lubrication should be sufficient. During the first week of operation, check the oil sumps
about once in a day and watch for leaks. Please note if the blower is operating in dusty
and severe environment on operating condition, the oil replacement frequency would
change and thus must be monitored and maintained by the user.
Replenish as necessary. Thereafter an occasional check should be sufficient. It is
recommended that the 1st change is done in 100 Hrs. of operation. Frequent oil changing
is not necessary unless the blower is operated in a very dusty location.

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O&M MANNUAL No.SP-OMM-211 13
 ISO-9001: 2000

11.1 First Oil fill Second Oil charge Subsequent change

Before starting After 100 operating Every 2000 Operating
the unit hours hours or whenever the
discoloration starts.
Please Note, whenever oil refill is required it should be done on stand still machine.
Drain out previous oil, purge compressed air to remove left out inside the oil chambers.
Close the drain plugs and refill the lubricating oil up to the marking on oil sight glass (In
case of round gauge glass oil level to be kept 4 mm over the center of glass). Check
also the correctness of oil fill by watch the oil turbulence through the level glass.
11.2 Oil Quality:
„ Antifoam & anti-wear circulating type lubricating/gear Oil.
„ Viscosity : 315-350 cSt (mm2/s) at 40° or 220 cSt and thermal stability atleast at
200°C in continuous operation.
FOR REFERENCE:
BRAND TYPE
India Oil Servosystem-320
Bharat petroleum Enclo – 320
Hindustan Petroleum Hylube – 320
Castrol Alfa Zn-220
ELF ELF Movixa-320
BP BP Energol CS-320
Shell Shell Tellous Oct C-320

11.3 LUBRICATION: For Units with Splash Lubrication on both ends

Bearings and oil seals are lubricated by the action of the timing gears or oil flingers
which dip into the main oil sumps causing oil to splash directly on gears and into
bearings. A drain port is provided below each bearing to prevent an excessive amount of
oil in the bearings. Seals located inboard of the bearings in each head plate effectively
regain oil within the sumps. Any small leakage that may occur into a cavity of each
vented end-plate and is drained downward.
Oil sumps on each end of the blower are filled by removing top vent plugs and filling until
oil reaches the middle of the oil level sight gauge.
Initial filling of the sumps should be accomplished with the blower not operating, in order
to obtain the correct oil level. Use a good grade of industrial type non-detergent, rust
inhibiting, anti-foaming oil and of correct viscosity.
The oil level should not fall below the middle of the site gauge when the blower is idle. It
may rise on the gauge during operation to an extent depending somewhat on oil
temperature and blower speed. Page 18 of 42
O&M MANNUAL No.SP-OMM-211 14
 ISO-9001: 2000

CHECK OIL TEMPERATURE: For best result, keep it below 70°C.

LUBRICATION: For Unit with External forced lubrication and splash oil
lubrication.
In additional keep checking on the oil levels in the oil pipeline, there must be regular
checks for any oil line chocking. No modification should be done without our instruction.
It is strictly against warranty.
The heat exchanger/cooler must be regularly cleaned first in 200 Hrs. of operation. The
pump must also be cleaned, oil filter must be cleaned every 200 Hrs. with 1st after 100
hrs. of operation. Keep watch on the oil temperature. It should not exceed 70°C.

12.0 PERIODICAL MAINTENANCE:

12.1 WEEKLY CHECK : (or after every 250 hours)

The following checks and maintenance work has to be carried out every week:

The gear wheels end covers, bearings and the Blowers casing must regularly be
checked for temperature. Check oil level on the gear side and pulley side. It should not
fall below the center of oil level indicated. If necessary, make up oil to the level marked
at indicator, while the blower is in stand –still condition.

Check for smooth running of the machine and ensure that lobes do not strike in any
position. If metallic sound or grinding noise is heard, stop the blower immediately and
inform our service department for its thorough check.

Clean inlet filter by back blowing of air. In case of dry bag filter, the pressure drop across
the filter element should not be more than 50 mmwg. In case of higher pressure drop,
clean it well by back blowing of compressed air through the element.
Please ensure that the minimum spares for operation as recommended must be kept in
stock.
Blower operating in high temperature & dusty environment would require more frequent
change of seals, lube oil and air intake filters. Also ensure protection of filter element
from direct dust ingress can use protection device over the element or use a coarse pre-
filter.

12.2 MONTHLY CHECK: (or after each 750 working hours)

¾ Clean inlet filter
¾ Check the tightness of the belts.
¾ Check functioning of Pressure relief valve
¾ Check the color/condition of lube oil
¾ Check the condition of seal

12.3 OIL CHANGES

The lubricating oil is to be changed as per the lubricating schedule or as per the
operating condition and thus the user is required to have a regular check on this.
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O&M MANNUAL No.SP-OMM-211 15
 ISO-9001: 2000

12.4 OVER HAULING

We recommend over hauling of Blower unit by our service engineer 1st after 2,000
operating hours and subsequently once in a year. In this connection, please contact our
CUSTOMER SERVICE CELL. Any overhauling or maintenance or change done by client
would lead to withdrawal of the guarantees.

13.0 MAINTENANCE & REPLACEMENTS:

Major cause of trouble is if erection & commissioning is not done properly. This can be
ensured by following all instruction and maintaining a log book, the details of which must
be given to SWAM on request. By following proper maintenance schedule and using
right genuine spares from SWAM can improve the working of blower else it may
deteriorate the performance and the client/user would be responsible for this.

A good program of inspection and maintenance is the most reliable method of

minimizing repairs to a blower. A simple record will help keep this work on a regular
schedule. Basic service needs are:-

• Lubrication
• Checking for hot spots
• Checking for increases or changes in vibration and noise.
• Recording of operating pressures and temperatures
• Check for the air filter cleanliness
• Check for the seal & bearing condition

Above all, a blower must be operated within its specified rating limits, to obtain
satisfactory service life and if operating in dusty environment, frequent regular checks
are required.

A newly installed blower should be checked often during the first month of full-time
operation. Attention thereafter may be less frequent assuming satisfactory performance.
Lubrication is normally the most important consideration and weekly checks of lubricant
levels in the gearbox and bearing reservoirs should be customary. Complete oil change
schedules are discussed under LUBRICATION.

Driver lubrication practices should be in accordance with the manufacturer’s instruction.

If direct connected to the blower through a lubricated type coupling, the coupling should
be checked and greased each time blower oil is changed. This will help reduce wear and
prevent unnecessary vibration. In a belted drive system, check belt tension periodically
and inspect for frayed or cracked belts.

In a new, and properly installed, unit there is no contact between the two impellers, or
between the impellers and cylinders, or headplates. Wear is confined to the bearings
(which support and locate the shafts) the oil seals, and the timing gears. All are
lubricated and wear should be minimal if clean oil of the correct grade is always used.
Seals are subject to deterioration as well as wear, and may require replacement at
varying periods.

Most important aspect is that the client/user must use the original spares from
SWAM. Any unauthorized non genuine spares if used, would deteriorate the
performance of the blower and the client/user would be responsible for this.
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O&M MANNUAL No.SP-OMM-211 16
 ISO-9001: 2000

Shaft bearings are designed for optimum life under average conditions with proper
lubrication and are critical to the service life of the blower. Gradual bearing wear may
allow a shaft position to change slightly, until rubbing develops between impeller and
casing. This will cause spot heating, which can be detected by observing these surfaces.
Sudden bearing failure is usually more serious. Since the shaft and impeller are no
longer supported and properly located extensive general damage to the blower casing
and gears is likely to occur.

Sealing effectiveness can vary considerably from seal to seal and is also affected to
surprising degree by shaft finish under the seal lip. Because of these normal variables,
minor seal leakage should not be considered as indicating seal replacement.

Timing gear wear, when correct lubrication is maintained, should be negligible over a
period of years. Gear teeth are precisely ground to provide the correct amount of
backlash, and gears correctly mounted on the shafts will accommodate a normal amount
of tooth wear without permitting contact between lobes of the two impellers. However,
too high an oil level will cause churning and excessive heating. This is indicated by
unsually high temperature at the bottom of the gear housing. Consequent heating of the
gears will result in loss of tooth precision. Continuation of this tooth wear will eventually
cause impeller touching (knocking), and from this point serious damage will be
unavoidable if blower operation is continued. A similar situation can be produced
suddenly by gear tooth fracture, which is usually brought on by sustained overloading or
momentary shock loads.
Problems may also develop from causes other than internal parts failure. Operating
clearances within a blower are only a few thousandths of an inch. This makes it possible
for Impeller interference or casing rubs to result from shifts in the blower mounting, or
from changes in piping support. If this type of trouble is experienced, and the blower is
found to be heating, try removing contacting strains. Loosen blower mounting bolts and
reset the leveling and drive alignment. Then tighten mounting again, and make sure that
all piping meet blower connections accurately and squarely Foreign materials in the
blower will also cause trouble which can only be cured by disconnecting the piping and
thoroughly cleaning the blower interior.

A wide range of causes & solutions for operating troubles are covered in the
TROUBLE SHOOTING CHECKLIST. The remedies suggested should be performed
by qualified mechanics with a good background, using procedures detailed in this
manual. Major repairs generally are to be considered beyond the scope of
maintenance, and should be referred to SWAM.
Warranty failures should not be repaired or changed at all, unless specific
approval has been obtained through SWAM before starting work. Unauthorised
disassembly within the warranty period will void the warranty.
Best of machines would not operate properly if proper care is not taken in
installation, erection, commissioning and in proper running through frequent
checks.

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O&M MANNUAL No.SP-OMM-211 17
 ISO-9001: 2000

13.1 TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE REMEDY
NO FLOW Speed too low Check by tachometer and compare with
published performance date
Wrong rotation Compare actual rotation with the drawing.
Change driver if wrong.
Obstruction in piping Check piping, valves, silencer to assure
open flow path.
LOW CAPACITY Speed too low See the VFD drive or check the motor
(This must be voltage for direct coupled. See item 1, if
measured as per belt drive, check for slippage and readjust
the approved tension
procedure Excessive pressure Check inlet vacuum and discharge
rise pressure and compare with performance
data
Obstruction in piping See above.
Excessive slip Check inside of casing for worn or eroded
surfaces causing excessive clearances.
Excessive resistance Clean the filter or change it immediately.
at the intake filter.
Filter is dusty.
EXCESSIVE Speed too high Check speed and compare with published
POWER performance
Excessive pressure See pressure gauge & pressure relief
rise valve.
Impeller rubbing Inspect outside of cylinder for high
temperature areas, then check for
Impeller contact at these points. Correct
blower mounting, drive alignment
Scale, sludge, rust or Clean blower appropriately
product build up
OVERHEATING OF Check for Inadequate Check oil sump levels in gear and drive
BEARING OR lubrication end head plates
GEARS Excessive lubrication Check oil levels. If correct, drain and refill
with clean oil of recommended grade.
Excessive pressure Check the discharge pressure
rise

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O&M MANNUAL No.SP-OMM-211 18
 ISO-9001: 2000

TROUBLE POSSIBLE CAUSE REMEDY

VIBRATION Coupling/Belts Check the belts or coupling
Misalignment
Impellers rubbing Check the Impellers
Worn bearings/gears Check gear backlash and condition of
bearings, and replace as indicated
Unbalanced or Scale or process material may build up on
rubbing impeller casing and impellers, or inside impellers.
Remove build-up to restore original
clearances and impeller balance
Driver or blower loose Tighten mounting bolts securely
Piping resonances Determine whether standing wave
pressure pulsations are present in the
piping
Scale/sludge build- Clean out interior of impeller lobes to
ups inside the blower restore dynamic balance
Casing under strain Re-work piping alignment to remove
excess strain.
DRIVER STOPS, Impeller stuck Check for excessive hot spot on head
OR WILL NOT plate or cylinder. Look for defective shaft
START bearing and/or gear teeth
Scale, sludge, rust or Clean blower appropriately
product build-up
EXCESSIVE Broken seal Replace seals
BREATHER
BLOW-BY OR Defective or damaged Replace seals and ‘O’ Ring
EXCESSIVE OIL ‘O’ Ring
LEAKAGE TO
VENT AREA
ABNORMAL Excessive backlash Remove non drive side oil chamber and
NOISE COMING between tooth flanks measure the amount of backlash around
FROM BLOWER of timing gear wheels the entire circumference of the gear
UNIT WHILE wheels, in dry and clean condition.
RUNNING Should this check reveal that the
backlash exceeds the specified limits new
set of timing gear wheel must be fitted
Excessive clearance Measure bearing clearances, by using
in the bearings feeler gauge. Compare the results with
permitted clearances. If clearances are
excessive, bearings be replaced. New
bearings should have C3 clearance.

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O&M MANNUAL No.SP-OMM-211 19

Rotor fouling blower
chamber walls or
rubbing against each
other
INTAKE FILTER Excessive resistance
CLOGGED to air suction coupled
with a decrease in
volumetric efficiency
Excessive oil Excessive oil level, or
temperature and too high viscosity
of the oil will cause
additional friction and
thus increase the
temperature of the
Blower
For Water cooled
models inadequate
water flow.
Blower Room If the plant room is
temperature high insufficiently
ventilated, the
ambient temperature
may rise to high level
OIL LEAKAGE Oil level too high
INTO
COMPRESSION
CHAMBER
Oil pressure too high
(For units with forced
oil lubrication)
HIGH POWER Blower over loaded.
CONSUMPTION Internal friction.
Page 24 of 42
O&M MANNUAL No.SP-OMM-211
ISO-9001: 2000
Rotor fouling Blower chamber wall as a
result of over loading.
Measure operating pressures and temp.
and compare the reading obtained with
the data supplied with the purchase
order.
Rotor rubbing each other or Blower
chamber walls due to a built up of dirt on
rotors. Clean all parts and check rotor’s
concentricity and shaft deflection.
Clean filter or replace filter.
Reduce oil level and or check for
correct oil.
Check the cooling water supply through
the cooling chamber, if inadequate –
correct it.
There may be formation hard seek in
the cooling chamber, clean it using
diluted acid.
Ensure proper ventilation.
Reduce this to correct level and flush
out Blower chamber, using a suitable
degreasing media. For this operation
please disconnect the piping and
unscrew condensate sealing plugs
Reduce oil pressure by adjusting relief
valve in lube oil system
Actual working conditions differ from
those indicated in name plate or
purchase order. Convert output data to
working conditions and compare results
with the values as ascertained by actual
measurement
20
 ISO-9001: 2000

14.0 DISMANTLING THE BLOWER UNIT

The Blower be dismantled and reassembled only by a person who has the proper
experience of maintenance of such Blowers.

14.1 The piping connection be first disconnected from the unit. The electrical connection of
motor be disconnected. Remove the safety guard and remove belt strand. Remove the
Blower unit from its base frame and keep it at a clean place.

14.2 Drain off its lubricating oil from oil chamber, by unscrewing the drain plug. Remove
pulley or coupling from the drive shaft. Remove the sealing bracket unscrewing the Hex
bolt. Remove both the oil chambers unscrewing it hold down bolts and dowel pin.
Remove lead through shaft seal floating bearing and remove spring assembly.

Unscrew the nut gear lock nut, Remove gear wheel set using Oil-Injection Tool kit. Keep
both rotor in vertical position and insert a wooden piece between these to keep in
vertical position.

14.3 REMOVAL OF NON DRIVE SIDE BEARINGS:

Unscrew the lock nut, remove bearing stopper by unscrewing bolts and draw out bearing
housing by means of puller.

14.4 REMOVAL OF DRIVE SIDE BEARINGS:

Remove oil splasher by unscrewing hex screw and bearing lock plate and draw out
bearing.

14.5 DISMANTLING OF END COVER - NON DRIVE SIDE:

To draw out end cover. Remove dowel pin.

Unscrew all the hex bolts and
Lift and remove the end cover.
Remove the seal unit.

14.6 Dismantling of drive side end cover.

Dismantling process is similar to the NDE end cover.

14.7 Drive rotor and non drive rotor now be extracted from compression chamber. Remove
shaft sleeve, Oil throwers piston rings, and ‘O’ rings as assembled condition from shaft.

REMEMBER : TO PUT SOME IDENTIFICATION ON BOTH THE NON DRIVE END

SHAFT SLEEVES AND SHIMS FOR BEARING HOUSING THIS WILL HELP AT
ASSEMBLY TIME TO FIT THE RELATED SHIMS AND SHAFT SLEEVES
ACCORDINGLY.

15.0 RE-ASSEMBLY:
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O&M MANNUAL No.SP-OMM-211 21
 ISO-9001: 2000

15.1 Insert rotor into the compression chamber. Before doing so, clean the surfaces of rotor
and shaft & keep it in vertical position. Insert Al. strip between chamber and rotors at
bottom. Insert also the wooden piece between two rotors. Clean and degrease the
mating surface of the Blower chamber and end cover on drive side. Make a coat with a
liquid gasket to the mating surface of Blower, end cover fitted by dowel and hex bolt.

15.2 Fit non drive side end cover. In a same manner fit the respective shaft sleeve assembled
with piston rings and ‘O’ Rings by compressing the piston rings and slowly the shaft
sleeve.

15.3 Fit the non drive side bearing. Lock the bearing outer race by bearing lock nut apply lock
fit).

15.4 Fit drive side end-cover bearings in same manner as non drive shaft floated bearing lock
it.

Fix the disc spring assembly. Fix inner race of bearing

Fix drive end oil chamber, fix dowel tighten all the Hex bolts, apply liquid gasket, fixing
the chamber on mating surface, lock the outer race of by lead through bracket, fit lead
through seal ‘O’ Ring and retainer.

15.5 Check side clearance of rotor on gear side, and axial play of non-drive side bearing.
Check radial clearance between rotors and Blower chamber and compare its data from
manufacturer.

15.6 Fit the key for oil flinger and fit DISC spring and holder for DISC spring. Fit the drive side
oil chamber using dowel and hex bolts. Fit lead through shaft seal. Lock it by pressure
plate/sealing bracket.

15.7 GEAR FITTING

Clean the shaft seat and gear bore thoroughly and put a thin oil film on both shaft seats
and gear bore. Withdraw the Al. strip and wooden piece. Put the gear wheel on the shaft
(rotors would be in vertical position with respect to each other). Lock the gear wheel
using tool kit slightly. Rotate it anti clockwise viewed from drive end and check the
rotors clearance inserting a feeler gauges from discharge side. Take care to keep the
unit above the ground (about 2” using parallel blocks). Ensure the exact rotor timing and
lock the gear wheel by hand simultaneously. Re-check the clearance, if disturbed correct
it.

Connect the pumps on both the shaft centers by nipple and tube. Insert Al. strip between
gear teeth. Lock the to gear wheel by operating the oil injection pump.

Release the pump pressure and remove its accessories. Lock the gear wheel by means
of lock nut. Use locktite thread lock for all lock nuts after cleaning it and its taped hole
with a suitable degreasing media. Fit the oil chamber non drive side, screw drain plug
and pour fresh oil to the oil chamber by unscrewing filling plug. After, which the unit is
ready after service. Put the unit to its base frame, and REALIGN it.

Page 26 of 42
O&M MANNUAL No.SP-OMM-211 22
 ISO-9001: 2000

Gear fitment and Rotor alignment is a precision job and the persons doing it should have
the requisite training and experience to do so. Do not run the blower, if not correctly
aligned. Starting the blower with improperly aligned, can cause accident.

16.0 PUTTING BLOWER BACK INTO OPERATION:

Fill up with lubricating oil in accordance with maintenance instruction, i.e. up to center
line of sight glass. Use only a specified brand of oil.

For gastight design oil should be pressed in sealing bracket keeping in mind that no air
should be trapped in side the sealing bracket. Screw the oil container & fill oil. For this
design the unit should be kept idle as soaking time of sealant is at least 24 hrs.
Thereafter, the assembly should be checked for any possible leakage.

Under simulated running conditions, check all the fail safe instruments.

Make sure that the maximum safe working pressure as shown on the data plate is not
exceeded.

The following points should be kept under observation.

16.1 No mechanical sound from blower and motor.

16.2 Temperature of Blower chamber is not high.

16.3 Effectiveness of shaft seals.

16.4 Check free running-down period after switch-off. It should not stop suddenly or with a
jerk.

16.5 Ease of rotation when rotors are turned over by hand.

17.0 PART IDENTIFICATION LIST:

For identification of various parts of Blower ref. drawing attached. The identification list is
also attached for reference.

18.0 RECOMMENDED SPARES:

18.1 Following spares are recommended to be kept in stock. While ordering spares, the part
identification No. must be stated in the enquiry. The Rotors and gear wheels are
recommended to be changed as pairs.

• Pair of rotor with shaft (*)

• Pair of gear wheels (timing gears) (*)
• Set of shaft sleeves
• Set of blower seals
• Set of ‘O’ rings
• Lead through shaft seal
Page 27 of 42
O&M MANNUAL No.SP-OMM-211 23
 ISO-9001: 2000

• Set of Suction filter

• Set of Bearings
• Oil splasher
• Set of oil indicators

(*) These parts must be procured & replaced as pair only.

18.2 RECOMMENDED ACCESSORIES:

™ Set of anti vibration pads/mounts

™ Set of flexible bellows
™ Set of suction filter
™ Set of coupling or V-belts
™ Safety relief valve
™ Check valve
™ Special maintenance Kit (Maintenance Kit consisting of Oil Injection Pump and
fixtures. The Kit is useful in fitting and removal of taper mounted gears).

19.0 OPERATION OF OIL INJECTION PUMP:

Introduction :
For the transmission of high torque with extreme reliability, the interference fit (shrunk fit)
is probably the most widely used modern method of connecting components. However,
shrunk fit components are difficult to separate without causing them damage. This
disadvantage is totally eliminated by using a high pressure oil injection system. It offers a
quick cost-effective and free-of-damage assembled and disassembly of components.

19.1 SYSTEM
The system consists of injecting oil at higher-than bonding pressure into the area of
component-contact, through oil ducts built into the arrangement. This is achieved by
screwing oil injector into the components, directly or using a connector pipe. With
reciprocating strokes of the oil injector, oil is forced in between the mating surfaces.
Once the oil pressure exceeds the bonding pressure the component floats on an oil film,
and then can be moved forward with a small force.

Oil injector pump is designed to operate upto pressure of 3000 Kg/Cm2 giving adequate
pressure for mounting and dismounting of taper bore gears. The system is provided with
proper accessories.

It is very important to use the specified oil having the correct viscosity.

The recommended oil is pure mineral oil having a viscosity of 40 cst at 50°C.

Page 28 of 42
O&M MANNUAL No.SP-OMM-211 24
 ISO-9001: 2000

19.2 BASIC EQUIPMENT:

The injector pump basically is hand operated piston pump. It is fitted with a spring
loaded oil feeder. The pump is able to produce pressure up to 3000 Kg/cm2. The pump
is mounted on the bracket or is directly connected to the system where pressurized oil is
required. If the pump is mounted on the bracket, it is connected from the bracket to the
component by means of a flexible high pressure tubing.

19.3 OPERATION OF THE PUMP

The nozzle of the oil feeder is immersed in an oil container and the piston pulled back by
hand. The nozzle is then turned upwards and the ball valve is depressed and the valve
opens to allow free flow of oil in to the injector of the lever should be made be slightly
opened and a few strokes of the lever should be made until clear bubble-free oil begins
to flow around the threads. The valve screw is then tightened and with further strokes
the pressurized oil will force into the system.

19.4 ACCESSORIES
The following accessories from part of oil-injection pump system:

19.41 PUMP BRACKET

The bracket is required to connect the oil injection pump. The pipe from the bracket is
connected to the system where pressurized oil source is required. Pressure gauge can
be mounted for direct pressure reading.

19.42 FLEXIBLE HIGH PRESSURE TUBING.

The tubings are made out of high pressure steel pipe which are specially heat-treated to
give it the required flexibility. On both ends, the tubing is fitted with hardened steel balls
and threaded nipples so that the pressure source can be connected to the system.

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O&M MANNUAL No.SP-OMM-211 25
 ISO-9001: 2000

19.43 ADAPTER NIPPLES & EXTENSION PIPES

The adapter nipples and extension pipes of special dimensions are used to connect
components which have threads different from those of the tubings.

For details check with us.

19.44 VALVE NIPPLES

Valve nipples are used to retain oil under pressure in the components which the injector
is being re-charged. They are also used to retain the oil pressure if the injector is taken
out from the system for use in injecting oil in another duct in the same assembly.

19.45 MOUNTING – BASE

ÆÆÆÆÆ

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O&M MANNUAL No.SP-OMM-211 26
Page 31 of 42
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Page 36 of 42
 PART IDENTIFICATION LIST FOR MODEL RM‐450 WC TR

SL.NO. PART NO. PART DISCRIPTION QTY. EACH BLOWER

1 5 2 2 2 0 0 1 BLOWER CASING 1 No.
2 5 2 2 2 0 0 2 DRIVE SIDE END COVER 1 No.
3 5 2 2 2 0 0 3 NON‐DRIVE SIDE END COVER 1 No.
4 5 2 2 2 0 0 4 DRIVE ROTOR WITH SHAFT 1 No.
5 5 2 2 2 0 0 5 NON DRIVE ROTOR WITH SHAFT 1 No.
6 5 2 2 2 0 0 6 TIMING GEAR  2 Nos.
7 5 2 2 2 0 0 7 GEAR LOCK WASHER 2 Nos.
8 5 2 2 2 0 0 8 GEAR LOCK NUT 2 Nos.
9 5 2 2 2 0 0 9 OIL SPLASHER 1 No.
10 5 2 2 2 0 1 0 SPRING DOWEL FOR OIL SPLASHER 1 No.
11 5 2 2 2 0 1 1 BEARING HOUSING 2 Nos.
12 5 2 2 2 0 1 2 HEX.BOLT FOR BEARING HOUSING 3 Nos.
13 5 2 2 2 0 1 3 BEARING STOPPER 2 Nos.
14 5 2 2 2 0 1 4 O' RING FOR BEARING HOUSING 2 Nos.
15 5 2 2 2 0 1 5 GEAR SPACER (GEAR SIDE) 2 Nos.
16 5 2 2 2 0 1 6 SPACER FOR INNER RACE(GEAR SIDE) 2 Nos.
17 5 2 2 2 0 1 7 LOCKED BEARING 4 Nos.
18 5 2 2 2 0 1 8 FLOATED BEARING (NDE) 2 Nos.
19 5 2 2 2 0 1 9 FLOATED BEARING (DE) (NDS) 1 No.
20 5 2 2 2 0 2 0 FLOATED BEARING (DE) (DS) 1 No.
21 5 2 2 2 0 2 1 INNER CIRCLIP 3 Nos.
22 5 2 2 2 0 2 2 CONDENSATE SEALING RING 4 Nos.
23 5 2 2 2 0 2 3 SHAFT SLEEVE 3 Nos.
24 5 2 2 2 0 2 4 SHAFT SLEEVE (DE) 1 No.
25 5 2 2 2 0 2 5 PISTON RING 16 Nos.
26 5 2 2 2 0 2 6 OIL THROWER 3 Nos.
27 5 2 2 2 0 2 7 OIL THROWER (DE) 1 No.
28 5 2 2 2 0 2 8 O' RING FOR OIL THROWER 3 Nos.
29 5 2 2 2 0 2 9 O' RING FOR OIL THROWER (DE) 1 No.
30 5 2 2 2 0 3 0 O' RING FOR SHAFT SLEEVE 3 Nos.
31 5 2 2 2 0 3 1 O' RING FOR SHAFT SLEEVE (DE) 1 No.
32 5 2 2 2 0 3 2 DISC SPRING 2 Nos.
33 5 2 2 2 0 3 3 DISC SPRING HOLDERS 2 Nos.
34 5 2 2 2 0 3 4 OIL FLINGER 1 No.
35 5 2 2 2 0 3 5 KEY FOR OIL FLINGER 1 No.
36 5 2 2 2 0 3 6 OIL SEAL BUSH 2 Nos.
37 5 2 2 2 0 3 7 O' RING FOR OIL SEAL BUSH 1 No.
38 5 2 2 2 0 3 8 OIL SEAL (DE) 1 No.
39 5 2 2 2 0 3 9 LOCK NUT (DE) 1 No.
40 5 2 2 2 0 4 0 OIL SEAL CARRIER 1 No.
41 5 2 2 2 0 4 1 KEY FOR PULLEY 1 No.
42 5 2 2 2 0 4 2 LOCK WASHER FOR PULLEY 1 No.
43 5 2 2 2 0 4 3 LOCK BOLT FOR PULLEY 1 No.
44 5 2 2 2 0 4 4 FILLING PLUG 2 Nos.
45 5 2 2 2 0 4 5 DRAIN PLUG 2 Nos.
46 5 2 2 2 0 4 6 OIL LEVEL INDICATOR 2 Nos.
47 5 2 2 2 0 4 7 HEX.BOLT FOR GEAR COVER TO END COVER 20 Nos.
48 5 2 2 2 0 4 8 CONDENSATE SEALING PLUG 4 Nos.
49 5 2 2 2 0 4 9 HEX.BOLT FOR CASING TO END COVER 40 Nos.
50 5 2 2 2 0 5 0 DOWEL FOR CASING TO END COVER 4 Nos.
51 5 2 2 2 0 5 1 HEX.BOLT FOR PULLEY COVER TO END COVER.  20 Nos.
52 5 2 2 2 0 5 2 DOWEL FOR PULLEY COVER  2 Nos.
53 5 2 2 2 0 5 3 BEARING LOCK PLATE (NDS) (DE) 1 No.
54 5 2 2 2 0 5 4 HEX.BOLT FOR LOCK PLATE (NDS)(DE) 1 No.
55 5 2 2 2 0 5 5 HEX.BOLT FOR OUTER RACE (NDS) (DS) 1 No.
56 5 2 2 2 0 5 6 HEX.BOLT&WASHER FOR OUTER RACE (DS) (DE) 1 No.
57 5 2 2 2 0 5 7 PULLEY COVER  1 No.
58 5 2 2 2 0 5 8 GEAR COVER 1 No.
59 5 2 2 2 0 5 9 HEX.BOLT&WASHER FOR CARRIER 4 Nos.
60 5 2 2 2 0 6 0 GASKETS  3 Nos.
61 5 2 2 2 0 6 1 HEX.BOLT FOR BEARING STOPPER 12 Nos.
 PART IDENTIFICATION LIST FOR MODEL RM‐450 WC TR
QTY. EACH 
SL.NO. PART NO. ACCESSORIES OF BLOWER
BLOWER
101 5 2 2 2 0 1 0 1 SUCTION FILTER ELEMENT 1 No.
102 5 2 2 2 0 1 0 2 SUCTION SILENCER 1 No.
103 5 2 2 2 0 1 0 3 DISCHARGE BEND WITH CONNECTING PIPE 1 No.
104 5 2 2 2 0 1 0 4 NON‐RETURN VALVE 1 No.
105 5 2 2 2 0 1 0 5 PRESSURE RELIEF VALVE 1 No.
106 5 2 2 2 0 1 3 6 SPACER METALLIC COUPLING 1 No.
107 5 2 2 2 0 1 3 7 COUPLING GUARD 1 No.
108 5 2 2 2 0 1 0 8 ANTI VIBRATION  PADS 10 Nos.
109 5 2 2 2 0 1 0 9 PRESSURE GAUGE WITH ISOLATING VALVE 1 No.
110 5 2 2 2 0 1 1 0 FLEXIBLE BELLOW AT DISCHARGE 1 No.
111 5 2 2 2 0 1 1 1 DISCHARGE DISTANCE PIPE 1 No.
112 5 2 2 2 0 1 2 8 SUCTION RUBBER SLEEVE 1 No.
113 5 2 2 2 0 1 1 3 SUCTION SILENCER SUPPORT  1 No.
114 5 2 2 2 0 1 1 4 SUPPORT FOR DISCHARGE DISTANCE PIPE 1 No.
115 5 2 2 2 0 1 1 5 COMPANION FLANGE 1 No.
116 5 2 2 2 0 1 1 6 FOUNDATION BOLTS WITH NUT & WASHER 10 Nos.
117 5 2 2 2 0 1 1 7 HEX. BOLTS  FOR BLOWER WITH BASE FRAME 4 Nos.
118 5 2 2 2 0 1 1 8 HEX. BOLTS FOR MOTOR WITH BASE FRAME  4 Nos.
119 5 2 2 2 0 1 1 9 BASE FRAME FOR BLOWER & MOTOR 1 No.
120 5 2 2 2 0 1 3 1 COOLING WATER INLET/OUTLET CONNECTION  4 Nos.
121 5 2 2 2 0 1 2 1 HEX.BOLTS & WASHER FOR SUCTION SILENCER  12 Nos.
122 5 2 2 2 0 1 2 2 HEX.BOLTS & WASHER FOR DISCHARGE SILENCER  12 Nos.
123 5 2 2 2 0 1 2 3 HEX.BOLT,NUT& WASHER FOR SAFETY VALVE 8 Nos.
124 5 2 2 2 0 1 2 4 ANCHOR BOLTS FOR DISCH. DISTANCE PIPE SUPPORT 4 Nos.
125 5 2 2 2 0 1 2 5 HEX BOLTS,NUTS & WASHERS FOR DISCHARGE BEND PIPE TO DISCH. DISTANCE PIPE 12 Nos.
126 5 2 2 2 0 1 2 6 HEX BOLTS,NUTS & WASHERS FOR DISCH. DISTANCE PIPE TO BELLOW 12 Nos.
127 5 2 2 2 0 1 2 7 HEX BOLTS,NUTS & WASHERS FOR BELLOW TO TERMINATING FLANGE WITH NRV 12 Nos.

PART IDENTIFICATION LIST FOR MODEL RM‐450 WC TR
QTY. EACH 
SL.NO. PART NO. ACOUSTIC OF BLOWER
BLOWER
151 5 2 2 2 0 1 5 1 ISMC CHANNEL 2 Nos.
152 5 2 2 2 0 1 5 2 ISMC CHANNEL 2 Nos.
153 5 2 2 2 0 1 5 3 FABRICATED COLUMN 4 Nos.
154 5 2 2 2 0 1 5 4 DOORS 4 Nos.
155 5 2 2 2 0 1 5 5 DOOR LOCKS 4 Nos.
156 5 2 2 2 0 1 5 6 HINGES 1 Set
157 5 2 2 2 0 1 5 7 PANELS 9 Nos.
158 5 2 2 2 0 1 5 8 FILTER HOUSING 1 No.
159 5 2 2 2 0 1 5 9 DUCT  FOR FILTER 1 No.
160 5 2 2 2 0 1 6 0 EXHAUST FAN 1 No.
161 5 2 2 2 0 1 6 1 EXHAUST FAN DUCT 1 No.
162 5 2 2 2 0 1 6 2 BACK UP PLATE FOR EXHAUST FAN 1 No.
163 5 2 2 2 0 1 6 3 ROOF PANEL 2 Nos.
164 5 2 2 2 0 1 6 4 TOUGHENED GLASS WINDOW 1 No.
165 5 2 2 2 0 1 6 5 FAN CONDUIT 1 No.
166 5 2 2 2 0 1 6 6 FUONDATION BOLTS 6 Nos.
167 5 2 2 2 0 1 6 7 COVER PLATES FOR DISCHARGE SILENCER CUTOUT  2 Nos.