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AXIAL FAN
(TLT DESIGN)

SINGLE STAGE

OPERATION & MAINTENANCE MANUAL

Prepared by

Checked by

Approved by

S.SELVAM

J.MOORTHY

M.DESIGAN

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

Ranipet

Axial Reaction Fan Single Stage (TLT)

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 4.1 PRE-COMMISSIONING CHECKS

Before commencing commissioning activity on the Fan, the following points should have been verified. Some of the check points may not be possible to be verified after completing the assembly of the Fan. However, the connected agencies should confirm that these have been ensured during various stages of erection. ENSURE THE FOLLOWING The bases of Fan parts are tightened without strain. Tightness of all foundation bolts of Fan / motor. Tightness of connecting bolts of bearing housing and impeller housing. Verticality of impeller housing / horizonitality of shaft within 0.04 mm/m. The impeller blades are of the same series, also ensure that the blades are mounted in the serial order and that the rounded nose of the blades are on the suction side of each impeller. Tightness of blade fixing screws to the required torque values. Radial clearance of blade tip with respect to longest blade. Radial clearance of blade root and impeller hub for both full open and full close positions of blades. Axial gaps between rotor and stator parts. Match marks on the coupling parts. Tightness of coupling bolts of spring shackle coupling. Correct setting of coupling gap. Alignment of couplings to be within 0.05 mm. Correct assembly of links. Acid cleaning of all incoming and outgoing oil pipes. Gravity inclination of all returns oil pipes. The oil tank is adequately filled with correct quality of oil. Early commissioning of the oil system to facilitate checks on the impeller. Proper connection of inlet and outlet of lube oil piping to the main bearings. Proper connection of oil pipes to the hydraulic adjustment device assembly. There is no pre-load in hydraulic adjustment device assembly introduced by flexible hoses. Linearity of blades position w. r. t . local / control room Indication. Proper setting of mechanical stoppers. Rotate rotor by hand and ensure free rotation without any mechanical rubbing. Removal all transport stiffeners (Yellow painted). Calibration of all instruments for Fan, Motor and Lube oil system.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

Ranipet

Axial Reaction Fan Single Stage (TLT)


Proper functioning of interlocks / protections. Proper assembly of all expansion joints. No foreign matter is left inside Fan casing. No loose pieces are found in the suction side ducting of the Fan. Precautions laid down by Motor/Oil system suppliers are complied with. Start lube oil pump and allow it to run for about two hours. Clean filters. Check level in the tank. Ensure proper oil flow. Check the pressures and setting of relief valve. Check proper functioning of Emergency Off switch. Proper direction of rotation of motor. Never run the Fan/Motor with out protections / interlocks.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 4.2 START UP AND OPERATION

In this chapter, the starting sequence for the Fan is described as individual equipment. For details connected with the boiler system, refer Fan panel control diagram provided in the boiler control and instrumentation manual. Protection interlocks for drive motor shall be as recommended by the respective supplier. START SEQUENCE OF THE FAN: a) Tank oil level b) Tank oil temp c) Control oil pressure d) Lub oil pressure e) Bearing temp f) Control blade adjustment g) Impeller blades position h) Discharge damper/gate i) Fan Motor > 50% > 25 deg C (Manual) > 20 bar > 4 bar < 95 deg C : Manual : Close : Close : ON

ALARM & TRIP VALUES When the fan is kept under service, the following values may be applied as reference limit and in case the values are found exceeding, suitable corrective actions may be carried out to maintain the following values below alarm limit. DESCRIPTION Fan Bearing Temperature Fan Bearing Vibration (Vel -rms) For Fans erected on Solid Concrete foundation. Fan Bearing Vibration (Vel - rms) For Fans erected on Spring Isolator Differential Pressure across oil filter Lub Oil Pressure low Control Oil Pressure low Oil Level In The Tank low Refer Logic Diagram For Additional Interlocks.
Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006. 4

ALARM 95 deg C 4.5 mm/s 7.0 mm/S 5 bar 4 bar 14 bar < 50 %

TRIP 105 deg C 9.0 mm/s 14 mm/s **** **** **** ****

Ranipet

Axial Reaction Fan Single Stage (TLT)

STARTING OF THE FAN Ensure that all protections and interlocks are functioning properly. Start the motor. Check for correct direction of rotation of motor. This fan should rotate in Anti-clockwise while viewing from motor. Test run the motor for 8 hours. If found satisfactory, couple the fan with motor. Operate the impeller blades to minimum position (Full close). Keep the delivery damper in full close position. Start the Fan and note starting time. Ensure that the discharge damper/ gate starts open simultaneously with the start of fan motor. Measure static pressure at Fan discharge with blades in minimum position. Ensure at least + 20 mm of WC. If not, readjust minimum blade setting for this value. Measure the vibration and temperature of the bearing. Record the vibration and bearing temperature every 15 minutes for first half an hour of run and every 30 minutes for the subsequent 2 hours of run and every hour till trial run completion. Check for any abnormal noise in the Fan. Check and record the motor current, voltage, and blade opening position. Test run for 8 hours. Caution: Fan should be trial run in the normal operating condition. Loading the fan with few man hole doors opened/discharge blocked condition is not permissible. CHECKS DURING NORMAL OPERATION OF THE FAN During continuos operation of the Fan the data should be logged as per the format: information is to be logged at fixed convenient intervals. Vibration level Oil level in the tank Leakage in lub and control oil line Differential pressure indication of oil filter.

Operational parameter . Apart from the data logged in the format the following additional

AERODYNAMIC OPERATING CONDITIONS This term refers to the range in which the Fan can be run in continuous operation without risk of damage. Throughout a wide range, the performance of AP Fans can be adopted to site requirements by adjusting the impeller blades. Operation outside that range, in particular if it lasts longer can result in damages.
Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006. 5

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Axial Reaction Fan Single Stage (TLT)


(a) If the inlet volume capacity is too little (i.e. the discharge gate is fully closed) rotating stall with subsequent stalling will occur. Operation with rotating stall leads to increased loads acting in some components, in particular the Fan blades. (b) If the inlet volume capacity is too little the power Input may result in non-permissible heating of Fans.

The operating ranges that are Off limits for continuous operation are represented in performance graph. For operating range permissible for the Fan supplied, refer to operating parameters and characteristics curves. MINIMUM POSITION OF AP FAN BLADES During trial operation, a check should be affected. If the machine is operated with damper/gate opened fully on the discharge side, the pressure at the diffuser should be at least +20 mm of WC. This condition can be ensured by the help of a static pressure tapping at the end of diffuser casing. Adjustments on the minimum position of the blades could then be achieved by individual blade assembly. PARALLEL OPERATION OF FD (AP TYPE) FANS These fans are provided with blade pitch control (flow regulation by actuating the blades) and outlet damper/gate of open close type. The boiler is provided with Two numbers of FD fans. CHARACTERISTIC CURVE OF THE AP FAN Refer the typical Characteristic curve of the fan (Fig - 1). The X axis is the volume flow through each fan and the Y axis is the total pressure rise by the individual fan. The numerical values (320), (-280), (-120), (+40), (+80), (+120), (+160) and (+280) etc., are the different blade angles, which corresponds to different loading of the fan. The stable operating range of the fan is limited by the characteristic fan line for the maximum pressure / volume on the right side and by the stall line at the top.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

BEHAVIOUR OF FAN The pressure developed by the fan is just equal to the system demand. Refer Fig 1. For a blade angle say (+40) let us assume, the volume flow is a m3/ sec and the pressure developed is b mmWC when the system resistance is say m . If the resistance of the system is changed to say n and the blade angle remain same (+40), then the volume flow through fan will come down to c m3/ sec and the pressure developed will increase to d mmWC. If this system resistance is close to the stall line, the fan sheds the load and delivers lower volume and low pressure depending on the characteristic of the fan, that is, the operation will be nearer to the deepest point of the stall line. Similarly, if the system resistance is decreased to say p and the blade angle remain same (+40) , then the volume flow through fan will increase to e mm3/ sec and the pressure developed will decrease to f mmWC. STARTING THE FANS The control logic recommended (apart from other start permissive parameters) for starting the fan is with its blade full close position and the discharge damper/gate fully closed. As soon as the fan reaches its rated speed, the discharge damper/gate should be opened fully. The blades of the fan can be opened to the required level to suit the system demand. PARALLEL OPERATION During the single fan operation, the volume and pressure demanded by the system will be high. Under this condition, if the second fan is started as per the starting sequence mentioned above, it is expected that the second fan will handle some amount of flow. Correspondingly, the volume handled by the first fan, which is operating, reduces. Then pressure developed by the first fan increases along its characteristic line at the same blade position. At this point, there is a chance that the second fan will go to unstable zone and as a result, the second fan will remain unloaded irrespective of its blade position. Therefore in order to bring equal load on both fans, it is required to follow certain procedure given below. STARTING A SECOND FAN One fan (Fan A) is running and another fan (Fan B) is to be started. Even here the sequence of operation must be such that neither of the two fans runs in the unstable range of the performance graph. The ranges in which parallel fan (Second Fan) can be started is cross-hatched as shown in the typical performance characteristic of an axial reaction fan (fig-2).

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

Refer Fig 3. Let us assume Fan A runs at point A1 that is the pressure developed is more than the deepest point S of the stall line.

Fan B is now shut off from the system by means of damper/ gate. Before starting Fan B, the pressure developed by the Fan A should be brought down to A2 (Ref fig 4) that is less the deepest point S of the stall line. Then Fan B is started as per the starting sequence. By opening of blades in Fan B, it will deliver certain volume. As Fan B is sharing certain volume, the volume handled by the Fan A will be decreased and there will be slight increase in pressure at the same blade position. So, close the blade position of Fan A by approximately 5%. As the aim is to make both fan

operating at the same duty point on the performance graph, alternatively open the blades of Fan B by approximately 5% and close the blades of Fan A by approximately 5%. Continue this operation step by step, till the duty points like blade position and Motor current are same in both fans. From this point onwards, increasing / decreasing the load on the fans will be simultaneous and similar in both fans. If not, the phenomena called Loading / Unloading Of Fans will occur.
Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006. 8

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Axial Reaction Fan Single Stage (TLT)

Remember the fan should not be permitted to run on or above stall line of the performance graph continuously. If the operating (duty) point of both fans is same in the performance graph, the auto control system will adjust both fans identically to meet the system demand. To achieve this, the following Mechanical checks should have been performed and logged prior to commissioning of the fans. The actual blade positions are calibrated w.r.t control room reading and are identical in both fans. There is no mechanical backlash in the linkages of hydraulic adjustment device Actuator. SHUTDOWN OF FAN

Take the Fan operation to manual from auto operation. Set the blades to minimum. Stop the Fan. Close the discharge damper Note the deceleration time of the Fan. Stop the lub. oil system after about 2 hours.

PRESERVATION OF FANS DURING LONG SHUT DOWN No special preservation is required for a shut down period up to 2 weeks. Since the maximum effective life of rust preventive oil/anti corrosive agents, when applied, has its own life (3 months), re preservation has to he carried out after 3 months. Paint or spray with a rust preventive compound/oil on polished or machined outer surfaces.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

THE COMPOUND / OIL SHALL CONFIRM TO THE FOLLOWING SPECIFICATIONS Specific Gravity Flash point Film thickness at 25oC Film description Non-volume content Coverage at 25o C 100% Humidity at 50 C Steam blow / Lubricating oil.
THE FOLLOWING PROCEDURE SHALL BE ADOPTED FOR LONG SHUTDOWNS/STAND STILL PERIOD.
o

: : : : : : :

0.850 40o C (MIN) 10 microns Thin transparent dry film 40 - 48% 12 Sq.M / Liter 30 Days (mm)

Remove the preservative prior to commissioning, using suitable solvent like Kerosene / Alkali wash /

Rotate the rotor by hand for few revolutions once in two days and set rest at a new position 90 Deg away from the original position. This is done to avoid permanent set of the rotor as well as pitting of shaft and elements of bearings. Blow the rotor with compressed air once in ten days to remove hard deposits on the blades. Once in ten days, run the lub oil pump and operate the hydraulic adjustment device from blades full open to blades full close several times. Run the fan once in fifteen days for at least half an hour. After each running, repeat the above steps.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 4.3 VIBRATION AND SAFE RUNNING OF FAN

VIBRATION CHARACTERISTICS Vibration in the simplest form may be considered as the motion of a part of a machine back and forth from its position of rest end can be expressed as a simple harmonic motion. DISPLACEMENT The total distance of movement of the part is peak to peak displacement or Double Amplitude in microns. VELOCITY The speed at which the part is vibrating in mm/sec. FREQUENCY The number of cycles of this movement for a given period of time is the frequency.
Condition of Machine as per ISO 10816 3: 1998: Part 3 Description Good Up to V rms in mm/s Machine Group G (Solid concrete) 580 rpm Displacement in microns for speed 740 rpm 990 rpm 1480 rpm 2880 rpm V rms in mm/s Machine Group T (Spring Isolator) 580 rpm 740 rpm Displacement in microns for speed 990 rpm 1480 rpm 2880 rpm 1.8 80 64 48 32 16 2.8 126 100 75 50 25 Satisfy Above 1.8 80 64 48 32 16 2.8 126 100 75 50 25 Up to 4.5 200 160 120 80 40 7.0 320 250 188 125 65 Just Satisfy Above 4.5 200 160 120 80 40 7.0 320 250 188 125 65 Up to 11.0 400 320 240 160 80 18.0 640 500 375 250 125 Un satisfy Above 11.0 400 320 240 160 80 18.0 640 500 375 250 125 Operating instruction Alarm Above 4.5 200 160 120 80 40 7.0 320 250 188 125 65 Trip At 9.0 400 320 240 160 80 14.0 640 500 375 250 125

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 4.4. OPERATIONAL PROBLEMS CAUSES AND REMEDIES

Alarm Signals

Possible Causes @ * Dampers in wrong position

Remedy * Dampers to be moved into the correct position * Blades pitch to be reduced

Surge operation ( diff. pressure)

> max

* Operating point out of the fan performance range * Cooler is damaged or out of order * Heater is not switched off * Bearing damage * High unbalance (blade wear, deposits on blades etc.) * Fan in stall condition * Bearing damage (check for high bearing temp.) * Fan foundation bolts loose * Oil pressure is dropped down, because of: Leaking oil lines or Defect oil pump * Set point for switch-over is too low * Oil leakage at the oil unit or the oil lines (outside) * Oil leakage inside the fan (bearing assembly, hydr. adjusting device etc.) * Oil cooler does not work properly

Bearing Temperatures

> high

* Cooler has to be replaced * Check control system and temperature sensor * Replace the bearing assembly * Clean or replace the blade set * Blade pitch to be reduced * Replace the bearing assembly * Tighten the bolts * Replace defect oil hoses or oil pump * Reset the pressure switch * Repair or replace defect parts * Replace the leaking parts(or the whole rotor) * Check for cooling water inlet temperature and cooling water flow rate * Check control system and temperature sensor * Replace damaged valve * Reset the pressure relief valve * Inspect and clean the oil lines and the oil filter * * * * Reset the relief valve Replace defect valve Replace leaking parts Replace the hydr. adjusting device

Vibrations

> high

Bypass oil pump

on

Oil level

< min

Oil temperature

> max

* Heater is not switched off * Temperature control valve is damaged * Oil pressure is too low * Oil lines are blocked

Lube oil flow

< min

Control oil pressure < min

* * * *

Set point of the relief valve is too low Relieve valve is damaged Oil leakage Damage at the hydr. adjusting device

Lube oil pressure

< min

* Set point of the relief valve is too low * Relieve valve is damaged * Oil leakage * Filter is blocked by deposits

* Reset the relief valve * Replace defect valve * Replace leaking parts * Switch-over to the bypass filter; Clean the filter cartridge Replace the rotor or the bearing assembly * Check the operating conditions (Damper position, sufficient fan performance) * Replace the blade set; Repair other fan parts, as required

Oil filter ( diff. Pressure) Bearing Temp

> max > max

* Bearings are damaged * Fan was operated under stall conditions * Broken blades or other rotor parts

Vibrations

> max

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

Other troubles Blades are moving too slow

Possible Causes @ * Set point of the pressure relief valve is too low * Setting drive is too slow * Oil lines are leaking * High friction or blockage inside the impeller * Hydr. adjusting device is defect (sealings)

Remedy * Increase the pressure set point at the relief valve * Repair the setting drive * Repair or replace leaking parts * Repair or replace the rotor * Replace the hydr. adjusting device

Unusual noise, combined with increasing bearing temperatures and/or vibrations Metallic particles are found at the oil filter

* Broken blades/rotor parts * Damage of the bearings * Broken coupling spring shackles

* Replace defect parts * Replace the bearing assembly

* Damage of the bearings or other parts of the bearing assembly/hydr. Adjusting device

*Analyse the particles for the chem. composition; Inspect the bearing assembly and hydr. adjusting device for damages/wear *Replace defect parts ( Pin, lamellas, coupling)

High hysteresis between blade pitch set point and actual blade position

* Setting- and/or indication shaft parts are damaged (pin, lamellas, coupling etc)

@ Always check first whether the measurement itself is correct (e.g. correct set point, proper function of the instrument etc.)

For attending the hydraulic Adjustment device and blade bearing assembly, assistance from the fan manufacturer should be sought since these works calls for the special tools and skills.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 5.1 CONSTRUCTIONAL FEATURES

When looking in flow direction, the fan consists of the following Components. Stator consisting of Suction Box, Fan housing, Outlet Guide Vane housing with guide vanes and Diffuser Rotor consisting of shaft, one impeller with blades, the blade bearing assemblies, the Hydraulic impeller blade adjustment system and Main bearing assy (Anti-friction bearings)

STATOR Suction Box, fan housing Outlet Guide Vane housing with guide vanes and diffuser are welded structural steel fabrications, reinforced by flanges and gussets, resting on the foundation on supporting feet. On its impeller side, the Suction Box is designed as an inlet nozzle. Guide vanes of axial flow type are installed in the fan and guide vane housings, in order to guide the flow. Suction Box and Fan Housing, Outlet Guide Vane housing and diffuser are flexibly connected via expansion joints. Fan and Outlet guide vane housings are horizontally split, in order to facilitate access of the rotor for dismantling and assembly. Those parts of the Hydraulic impeller blade adjustment system unit which are arranged in the guide vane and diffuser cores are accessible through manual door. The fan is driven from the inlet side. The shaft runs on Anti-friction bearings. The main bearings are accommodated in the core of the bearing housing. The impeller is fitted to the shaft in overhung position. The centrifugal and the setting forces of the impeller blades are absorbed by the blade bearings. For this purpose, the blade shafts are being held in combination of radial and axial anti-friction bearings. Each blade bearing is sealed off by means of several seals, in both directions (towards the inside and outside).

ROTOR ASSEMBLY
The rotor assembly consists of a main bearing assembly and two impellers with blades, the blade bearing assemblies, the hydraulic impeller blade adjustment system. MAIN BEARING ASSEMBLY The main bearing, a compact unit, is centered and screwed in the lower half of the fan housing. The main bearing assembly is accommodated with Cylindrical Roller bearing and Angular Contact

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

Ball bearings. Double contact tele-thermometers and double resistance thermometers monitor the bearing temperature. These thermometers must be connected to signaling instruments at the site. Simmer rings are always installed. The oil ventilated through the air vent pipe, which opens into the oil reservoir. The main bearing is lubricated by oil circulation. For this purpose an oil supply unit is attached outside the fan. IMPELLER The impellers consist of a hub, a supporting disk, a solid load ring for taking up the centrifugal forces and a guide ring. Hub and fan shaft are connected by interference fit and secured with a key. To permit mounting of the impeller on the shaft the hub opening is widened oil-hydraulically. The centrifugal forces of the blades and blade shafts are transferred via axial deep groove ball bearings into relatively small load ring. Before delivery the complete rotor assembly will be balanced statically and dynamically. HYDRAULIC BLADE ADJUSTMENT SYSTEM The blades will be adjusted and kept in position during operation by the hydraulic impeller blade adjustment system. The adjusting range is indicated in the rotor assembly drawing. The blades, fixed at the outer end of the shaft, will be adjusted and kept in position by means of a lever, which is provided with a sliding block and which is located at the inner end of the shaft. Those levers and sliding blocks are embrace by the adjusting disks. The adjusting disks are connected with the cylinder of the hydraulic impeller blade adjustment system via the thrust device. The control of this cylinder is affected via the control slide valve in the control head. The pressure oil in the space of the control slide valve can reach the respective side of the adjusting cylinder via the borings through the respective ducts which are opened by the control slide valve. Now the adjusting cylinder is displaced accordingly and the blades are adjusted in the same way via levers. The oil on the other side of the cylinder returns through ducts which are also opened by the control slide valve. To the same extent as the adjusting cylinder is moved, the return rod will also be
Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006. 16

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Axial Reaction Fan Single Stage (TLT)

moved (as it is fixed at the adjusting cylinder and arranged in the rotational axis). Thus the borings, released by the control slide valve, will be shut via gearwheels and gear racks installed in the control head. Upon reaching the given position the adjusting procedure is finished. ADJUSTING SHAFTS The mechanical connection between the hydraulic impeller blade adjustment system and the respective components outside of the fan housing is attained via an indicator shaft and a setting shaft. An external actuator effects the hydraulic impeller blade adjustment system via the setting shaft.

FAN ACCESSORIES
SPRING SHACKLE COUPLING The fan shaft is connected to the motor shaft by means of Spring Shackle couplings while the distance between the shaft ends is bridged by an intermediate shaft which is a part of the coupling assembly. The spring shackle coupling can absorb radial and angular mismatch up to a certain extend. No lubrication is required for the coupling parts. OIL CIRCULATION UNIT The oil unit consists of an oil tank, two pumps (one standby), filters, coolers and other necessary fittings and instruments. A pressure relief valve maintains the pressure in the system. The lubricating oil is fed through a pressure compensated flow-regulating valve. DRIVE MOTOR Constant speed synchronous induction motors drive these fans. For installation, operation and maintenance reference is drawn to the instructions of the respective motor suppliers. SILENCERS These fans are provided with a silencer to attenuate airborne noise to acceptable level. silencer consists of baffles packed with sound absorbing wool retained by perforated plates. SPECIAL TOOLS, MAINTENANCE DEVICES For the maintenance of the fan some special bolts and devices are necessary. To mount and dismount the impeller from the main shaft, the mounting and dismounting device has to be used. The

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

MINIMUM GENERAL STORAGE REQUIREMENTS


Sl.No. 01 02 03 04 05 06 08 09 10 11 12 Suction Box Diffuser Silencer OGV Assembly Impeller Housing Shaft with Brg Assy @ Fan Component Storage Locations Outdoor (a) Outdoor (a) Weather Protected (b) Weather Protected (b) Weather Protected (b) Indoor (c) Indoor (c) Indoor (c) Indoor(c) Indoor(c) Indoor(c) Frequency Of Inspection (D) Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly

Impeller and Hydraulic Adjustment Divice @ Spring shackle coupling Machined packers and Shims Instruments Lub oil system

Note:a) Above ground, on blocks, exposed to weather. b) Out door, above ground, on blocks covered With Tarpaulins and vented for air circulation c) Clean and dry warehouse. d) Inspect the components at the given frequency and re preserve it suitably.

Specific attention should be given to ensure that the Shaft with brg assy, Impeller and hydraulic adjustment device is stored inside the covered shed and preserved properly. This rotor is assembled in our works in a air conditioned hall.

PROCEDURE FOR PRESERVATION OF MACHINED SURFACES OF FAN SPARE SHAFTS AT SITE

1. Inspect the machined surfaces of the fan shafts immediately on receipt at site. 2. Clean the machined surfaces, if required, by using kerosene or mineral turpentine. Exposed rust to be removed by rust removing solution (Phosphoric acid 10%). 3. Re-preserve by applying the following: a) One coat of TRP 1706 rust preventive fluid. b) After drying, apply one coat of TRP 1710 and c) After drying apply one more coat of TRP 1710. 4. Tarpaulin and wooden pieces dis-assembled are not to be used at site. 5. The preserved surfaces shall be wrapped with HDPE (High Density Poly Ethylene) sheets 6. Keep the shafts in covered storage. 7. Inspect the machined surfaces every month and re preserve as mentioned above.
Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006. 18

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Axial Reaction Fan Single Stage (TLT)

PROCEDURE FOR PRESERVATION OF ANTI-FRICTION BEARINGS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. The store room must be free from dust. Ideal ambient temperature should be 20 to 30 deg c. Relative air humidity should not exceed 60%. It may be necessary to install air dehumidifier in places where relative humidity is high. If the bearing is found to be dry and dirty, it should be thoroughly washed and cleaned before re-packing. The bearing should be first kept in a vessel filled with kerosene for about half an hour and then washed to take out the dirt. It should then be cleaned in another vessel with filtered kerosene. The final cleaning is to be done by using petrol of mineral turpentine oil. It should be then allowed to dry completely. Pressuraised air for cleaning or drying purpose is not recommended. (RUST GARD P214) The washed and dry bearing is to be dipped in anti-corrosive oil. The excess oil should be allowed to escape and bearing should be repacked in a waterproof sealable plastic bag and put in to the carton again. RECOMMENDED PRESERVATIVE COMPONENTS APPLICATION Machined surfaces ( Indoor storage ) Machined surfaces ( Outdoor storage ) Weldments Shaft with bearing assembly BRAND NAME TRP 1706, TRP 1710 HDPE (High Density Poly Ethylene) sheets. TRP De-oxy Aluminates Oil ISO VG 68 Equivalent: SERVO PRIME 68

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 5.2 MAINTENANCE OF FAN

Prior to taking the equipment out of service during a planned maintenance program, the following checks are to be carried out. These checks are designed to help in scheduling the maintenance activity and to avoid unforeseen delays in re-commissioning the Fan. Record vibration level on all bearings. Such of those bearings whose vibration levels are beyond the permissible levels of satisfactory operation may be subjected to vibration/signature analysis to carry out the corrective actions.

Ensure the availability of operational data such as Vibration level, Bearing temperature, Motor amperage, blade position etc before stopping the Fan. Pay specific attention to any abnormal noise emanating from any of the machine components like bearings etc. Observe for any leakage in the Fan like oil, air at Fan connections etc. Observe for any erosion of Impeller / casing. Availability of operational spares and other materials in connection with the observations made above. After the Fan is stopped the following data may be recorded/ensured for reference during re commissioning. Coupling alignment Marking the assembled components by match marks Servo motor operating time Actuator linearity w. r. t control room indication and actual blade position

BETWEEN PLANNED SHUTDOWN To ensure the long term proper operation of the fan various maintenance services are required,

Every 8 operating hours - record the vibration level. Every 500 operating hours or at least once in three months
Clean the lub oil filter. Clean it before the above mentioned time has elapsed when the differential pressure contact indicator indicates that the filter is dirty.

Every 2000 operating hours or at least once in every six months


Test the oil, if water is found, find the cause and eliminate it.

Every 4000 operating hours or at least once in a year

Retighten all the fixing bolts. Check the quality of oil, if required, change the oil.
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Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

Every 8000 operating hours, or after 2 years Check Operation the normal inspection and Complete over haul FORCED SHUTDOWN If the plant shutdown is owing to other parts, it-may be possible to inspect the Fan. We recommend the following jobs. Check whether there is oil leakage inside the Fan. Check impeller blades for wear, if any. Check whether all blades are equally set when actuating the hydraulic adjustment device. Check whether the hydraulic adjustment device is oil tight.

PLANNED SHUTDOWN We recommend to effect overhauls for every 8,000 to 10,000 operating hours or at least once in two years. This job should be performed under the guidance of the specialist of the Fan manufacturer. a) CHECK ON IMPELLERS

Check Impellers and blades for deposits and rust. Clean the impeller. Check blade fixing bolts. Check Inlet edge of impeller blade, for wear. Check for position and fixation of compensating weights. Check blade bearings for damages. Entirely remove old lubricant in blade bearings and fill new lubricant. Replace sealing elements in blade bearings. Check lever, slide ring and adjusting disc for wear and inspect jewel bearing assembly.

b) c) d) e) f) g)

Effect all checks as described under between planned shut down and forced shut down Clean inlet and outlet oil lines. Eliminate oil leakages. Check the clearances of main bearings. Ensure free rotation of fan rotor by hand freely. Replace correct Oil hoses for hydraulic adjustment device if required.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 5.3 DISMANTLING AND REASSEMBLY

BHEL specialists should service fan. Our instructions have only one objective, namely to keep the Fan ready for operation and to avoid longer standstills. Basic requirements for the installation and removal of such parts are a clean job and avoidance of any kind of force. INSTALLATION AND REMOVAL OF COUPLING Refer Annexure. REMOVAL OF THE FAN HOUSINGS UPPER PART Remove the sound insulation in the area of the expansion joints and longitudinal flanges of the housing as well as the suspension eyes. Detach the expansion joints on suction and on discharge side and the protection devices (discharge side: out and inside) Remove the connection bolts and the locating pins Remove the upper part of the fan housing using the connection bolts for separation. For this very purpose, the longitudinal flanges of the fan housings lower part have been provided with through holes. Move blades into " closed " position Suspend the upper part of the fan housing; take care that it is balanced precisely Lift the upper part of the fan housing vertically until it can no longer touch the blades Put down fan housings upper part at a suitable place

REMOVAL OF THE ROTOR ASSEMBLY (Drg. No : 0 55 214 00897) Remove fan housings upper part Disconnection of the adjustment and indicating shaft from the hydraulic impeller blade adjustment system Disconnection of the oil pipes, hoses and cables of the temperature probes from the main bearing assembly Disconnection of the oil pipes from the main bearing assembly Disconnection of the oil pipes from the hydraulic impeller blade adjustment system Detach locking device from the hydraulic impeller blade adjustment system Disconnect the intermediate shaft from the coupling stop on fan side by removing the connecting bolts. Secure the intermediate shaft in the nose of suction box. Release the connecting screws between the main bearing flanges and the supporting rings in the lower part of the fan housing

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Suspend the rotor as shown in the enclosed draft

Attention: In order to avoid damages to the blades, the labyrinth rings and the coating, the rotor assembly must be removed and suspended securely balanced. During storage, the bearing assembly should be supported in such a way, that the blades do not touch the ground, using the support supplied by BHEL. Re-assemble in reverse order; the connecting bolts should be tightened in accordance with the prescribed torque (ref. also rotor assembly drawing ) DISMANTLING OF THE IMPELLER All connecting surfaces must be cleaned carefully and make match mark. Then, generate an oil pressure p for expansion and increase mounting force F. Maintain oil pressure p at possible maximum pressure and assemble at the same time. Mounting will be carried out acc. to sketch " Mounting of Impeller". At the end of the mounting procedure, a built up pressure loading with about 1000 KN. Reduce expansion oil pressure p and only unload the feed shaft once oil pressure p has dissipated. Dismounting of the impeller

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

Mounting of the impeller

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT)

DISMANTLING AND REASSEMBLY OF THE HYDRAULIC IMPELLER BLADE ADJUSTMENT SYSTEM (0 55 214 00897) Disconnect the hydraulic oil pipes from the hydraulic impeller blade adjustment system Disconnect the locking device between impeller blade adjustment system and fan housing Disconnect the adjusting and indicating shaft from the hydraulic impeller blade adjustment system. Release the centering bolts (1) Unscrew the connecting bolts (2) Unscrew the connecting pins (3) Remove the support (4) Suspend the adjustment system to a lifting jack Unscrew the connecting pins (5) and disengage the hydraulic unit from the guide bushing in the fan shaft This work can be carried also when the fan housings upper part is closed. Access is given through the two man holes in the diffuser.
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The component can be taken out through the a.m. opening by means of a lifting gear suspended in the hub of the housing. (Weight of hydr. adjustment system 58 kg) Assembly in reverse order. The alignment of the hydraulic impeller blade adjustment system effected by means of the centering screws (1) Aligning accuracy and measuring methods see draft. The torque for the connecting bolts are shown in the rotor assembly drawings.

DISASSEMBLY AND ASSEMBLY OF THE BLADES Prior to assembly the threads of the blade bolts should be treated as shown in the rotor assembly drawing. The assembly is to be permed in the correct order. The impeller blades have to be checked for wear. Remove the screws connecting the blades and blade shafts and extracts each blade form its fit. The quality of the surface permits this (no rust, no damages) which should he ensured by visual checks. They have been, and will be, tightened to the correct torque, with a calibrated torque wrench. During the blade mounting process, the impeller must be secured against rotation by suitable blocking devices.

Clean and lubricate fixing surfaces, shaft bearing bushing, bushing, and shaft flange, place seal rings on blade foot, mount blades at the circumference of the sequence impeller according to their number, fasten bolts to

prescribed tightening torque, according to the sequences shown in Figure .

Screws must be coated with Molykote and have to be tightened to the specified torque. Make sure that the screws are loaded uniformly

Before assembling the blades, commission the lube oil system and ensure cleanliness

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of the oil lines by oil flushing. (Refer Commissioning of lube oil system). Connect oil lines to the hydraulic adjustment device. Switch off the lub oil pump till all the blades are mounted. The impeller blades are identified by an alphabet series. They are also marked serially. Example A1, A2 B1, B2 ........ ........ An Bn

Ensure that the blades to be mounted belong to the same series. Usually the impeller hub is also marked serially. However, blades may be mounted on the hub starting from anyone location and proceeding in the serial order as marked on the blades. They may be assembled proceeding in the clock-wise or counter clockwise direction. Ensure that the round nose of the blades is fixed on the suction side. Assemble the blades. Ensure that the blades are positioned and tightened in identical position. This is to avoid uneven gap between blades. Tighten the blade fixing screws. Tighten to the required torque values. At blade full close position, ensure that the blades are not fouling with each other. There can be minimum gap between blades. Note: The entire site made oil lines must be acid cleaned and neutralized. Prior to connecting
the flexible oil hoses with the hydraulic adjustment device, the lub oil system must be thoroughly flushed for at least 8 hours or till no dirt/ sediments are found in the oil filters. Oil flushing should be done bye passing the fan bearings and hydraulic adjustment device.

The torques please find in the rotor assembly drawing. BLADE GAP MEASUREMENT Turn the rotor and pre-check the blade gap in the lower part of the fan housing. Place upper part of housing and fasten nuts hand tight. Check the blade gap according to the following procedure: The blade angle has to be adjusted to closed position

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Measure all blade gaps at the same position x to find out the longest blade. Mark the respective blade accordingly Carry out the blade gap measurement first with the longest blade at each of the positions P (eight points at the circumference). Countercheck the gaps at the horizontal flanges ( 3 and 9) Compare with permissible gap acc. to the drawing and prepare records

ASSEMBLY OF THE BLADE SHAFT BEARINGS The blade shaft bearings are constructed with axial deep groove ball bearings as supporting bearings and angular ball bearings as thrust bearings and guide bearings. Following the cleaning, checking, and, if necessary, replacement of parts during inspection, the blade bearings should be assembled essentially as described below: Attention: All functional surfaces must be processed, cleaned, molycoted, oiled, greased, degreased, etc., as shown in the rotor assembly drawing.

SHAFT GUIDE BUSHING AND BLADE FOOT SEAL Install the shaft bearing bushing (6) into the neck bearing by bonding.

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SUPPORT BEARING UNIT

Insert axial deep groove ball bearing (7) into the bearing shell (8) as follows: Insert the bearing ring into the bearing shell (8)

Add the balls, diameter and dimensions per rotor assembly drawing Put the bearing ring over the balls

Mount dynamic seal (9, 10) into the bearing mount (8) Put shaft nut (11) over the deep groove axial ball bearing (7)
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Turn the complete unit by 180 and insert static seals (12) Grease O-ring with solid lubricant on Teflon basis

GUIDE BEARING UNIT

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Insert the dynamic seals (13, 14) into the bearing cover and grease slightly Fit the O-ring (15) into the bearing cover (16) and grease solid lubricant on Teflon basis Fill the guide bearing with grease. Press the guide bearing (17) into the support ring (16) and check for correct position as per rotor assembly drawing

BEARING SHIELD Static seal (18) and dynamic seal (19, 20) have to be mounted onto the bearing shield (21) Grease slightly

ADJUSTING LEVER The surface of sliding block shaft should be covered with graphite powder. Press sliding block (22) onto the adjusting lever (23) Secure sliding block with the snap ring (24)

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SHAFT Coat shaft guide bushing (6) with graphite powder. Grease mounting surfaces of counter weight (25) and guide bearing (17) slightly with "Antiseize ASA16". Grease shaft thread surface (26) and centering seat of the shaft nut (11) with Molykote 1000". Degrease adjusting lever seat (23)

Fit key (27) into the shaft groove Set O-ring (28) into the radial groove of the shaft

MOUNTING OF THE BLADE SHAFT BEARING ASSEMBLY Grease face of guide bearing (17) and bearing cup (8) with "Antiseize ASA 16". Press bearing shield with seal (18) consisting of O-ring (20) and Teflon labyrinth ring (19) into the borehole of the guide ring Insert greased and preassembled guide bearing (17) in the appropriate guide ring boring and assemble with support (16)

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Put preassembled supporting bearing, including seal (12), in the support ring boring and secure its position with appropriate spacers between support and guide bearing

Put counter weight (25) on top of the supporting ring boring (check impeller assembly drawing for position of the groove)

MOUNTING OF THE BLADE SHAFT, SUPPORT AND GUIDE BEARING ASSEMBLY Insert the blade shaft (26) into the "support bearing assembly" from above through the blade shaft bearing bushing (6) until the blade shaft thread rests on the blade shaft nut thread. Lubricate the blade shaft thread before inserting the blade shaft.
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Lift counter weight (25) and deposit it on two identical supports Turn shaft nut (11) several times Fasten blade shaft nut (11) until the faces of the bearing pot (8) and the guide bushing (17) sit on the particular opposite surface .The torque increases suddenly when contact is made. The blade shaft nut is secured by a retaining spring (29) and a retaining ring (30) It may be necessary to tighten the blade shaft nut a little more in order to cover the retaining grooves between the blade shaft and the blade shaft nut Unscrewing the blade shaft nut too far, i.e., releasing the pretension, may result in a malfunction of the seals (9,10,12,13 and14)

ASSEMBLY OF THE BLADE AND THE ADJUSTING LEVER Pull the adjusting lever (23) onto blade shaft (26), after degreasing the mounting surfaces An appropriate wedge, applied to the provided slot in the adjusting lever, will expand the boring enough to ease assembly

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The pretreated locking screws (31) and the locking nut (32) are put in loosely into the adjusting lever Apply "Antiseize ASA 16" marked. Grease thread and support area of the blade connection bolt with "Molykote 1000". Insert seals (33, 34) in the borehole of the outer impeller casing Screw blades (35) onto the blade shaft by means of the blade shaft bolts. For torque requirements please ref. rotor assembly drawing

Attention: The position of the blade towards the counter weight must be set acc. to the drawing Put the blades (35) and the adjusting lever (23) into central position; ref. impeller assembly drawing. Generally, the adjusting levers are mounted in direction of rotation of the fan. The adjusting lever is in central position, too. Tighten the safety nut (32) with the torque shown in the impeller assembly drawing; add the friction torque between safety nut (32) and clamping screw (31) to the torque of the screw.
DISASSEMBLY AND ASSEMBLY OF THE SHAFT WITH BEARING ASSEMBLY (Drg No: 0 55 214 00897)

Remove the cap screw (40) Remove the bearing cover (41) Remove the cap screw (43) Remove the bearing cover I (44) Remove the impeller side oil ring (45) After remove the above components reposition the assembly as coupling side in top on the stand. Remove the cap screw (40) Remove the bearing cover (42) Remove the cap screw (43) Remove the bearing cover II (44) Remove the coupling side oil ring (45) Use a eye bolt, slowly pull out shaft from impeller side end to coupling side end (towards
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coupling side) including Angular contact Ball bearings and Cylindrical Roller bearing inner race.

Remove the angular contact ball bearing (46) Remove the outer spacer (47) and inner spacer (48) Remove the angular contact ball bearing (49) and inner race of the cylindrical roller bearing (50). Remove the cylindrical Roller bearing outer race (51) from the housing. Using a hydraulic pump to admit pressure to the contact areas of the anti-friction bearings. For pulling of the bearings, use tools as recommended by the manufacturer. To protect bearing shoulders, races, cages and the balls or rollers and do not employ any force (do not use hammer)

Anti-friction bearings have to be Installed or removed in accordance with the instructions of the bearing manufactures. Remove the protective coatings / old grease by means of liquid solvents like turpentine from the shaft surface / bearings and related components. Thoroughly clean the bearings and shaft surfaces.

Make sure that the bearings housing bore and shaft diameters are in accordance with the drawings. Ensure the condition of the rolling elements and proper tolerance of the bearings. No bearing shall be accepted, if the same is found pitted, rusted or damaged. Wipe the bearings with clean cloth. Make arrangements to heat the bearing elements in oil bath. The heating container should be clean. Immerse the bearings completely in oil bath. Take care that the bearing should not touch the walls as well as the bottom of the container.

Slowly heat the oil to about 100 centigrade (But never exceed a temperature of 100o centigrade). Ensure the temperature, and allow sufficient soaking time before mounting. For the bearing radial clearances, refer bearing catalogue/drawing/Fan Technical Data. The sealing elements must not be damaged. The bearing clearances indicated also must be ensured. Install the bearing with the shaft in reverse sequence.

Precaution:It is required that every possible care to be taken, so that the bearings are mounted properly. It is of utmost importance that the instructions given here, regarding mounting of the bearings, are strictly adhered to, in the same sequence, as indicated, to avoid any future problems.
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HYDRAULIC IMPELLER BLADE ADJUSTMENT SYSTEM For inspection, disassembly and assembly, please require a BHEL supervisor or return the entire hydraulic impeller blade adjustment system with the control head to the factory for overhaul. COMMISSIONING OF FAN AFTER MAJOR OVERHAUL Prior to starting the fan after a major overhaul, ensure all checks as mentioned in the chapter Pre commissioning checks - chapter no 4.1

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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Axial Reaction Fan Single Stage (TLT) 5.4. LUBRICATION INSTRUCTIONS

The Lubricating oil for the Fan bearings are supplied by the centralized oil pumps which supply oil for the hydraulic servomotor also. It must be borne In mind that the quality of oil flowing to the bearings and its pressure must be maintained as recommended. The flow control device provided in the oil system (lube oil inlet Fine) is to be covered arid protected. The oil to be used shall be a turbine quality oil to suit the following specifications: ISO Viscosity Grade Kinematic Viscosity at 40 C Viscosity index Flash point Pour point Neutralization No - mg KOH/gm
o

: 68 : 64-72 cst : 95 min : 210o C (min) : -6o C (max) : 0.2

The oil must not foam during operation. Foam removing agents containing silicon must not be utilised. The oil must have good anti-corrosion properties. LUBRICANT FILLING Fill the recommended lube oil (through a fine mesh strainer only) up to the required level. Do not mix lubricants of different grade and make. LUBRICANT CHECK At first commissioning and after a basic overhaul, the entire oil must be drained after an operating period of 100 hrs. All dirt should be eliminated from the oil tank. Then fill in again the oil through the fine mesh strainer. CARE OF LUBRICANT Test the quality of the oil every month and if found unsatisfactory and oil containing water/dirt the oil should be changed immediately. The maximum permissible limit of contamination is 100 ppm.

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RECOMMENDED LUBRICATION CHART


Sl.no Component Fan main Bearings and Hydraulic adjustment device Blade shaft bearing assembly Blade shaft bearing bushing and pushrod guide bushing Bearing shaft and indication shaft Blade bolt and other bolt Lubricant Servo prime 68 Turbinol 68 Bharat turbol 68 Teresso 68 Mobil Glygoyle 30 and Mobil grease 28 / Burutox M21 Molykote microfine graphite powder Mobil grease 28 / Burutox M21 Molykote paste 1000 Supplier M/s IOC M/s HPC M/s BPC (Others) See note.3 See note.3 See note.3 Location Frequency Once in 2 years or Based on the oil quality see note 2 During Over haul (once in 2 years) see note 4 During Over haul (once in 2 years) see note 4 During Over haul (once in 2 years) see note 4 Obser vation Daily Qty / Fan See note 1 10 Ltr ***** 1 Kg 0.5 Kg

01

Oil tank

02

Inside Rotor Inside Rotor Outside Rotor Common

03

*****

04 05

*****

0.2 kg 0.5 Kg

NOTES :
1) Oil quantity depends on tank capacity. Levels marked in the oil tank level gauge. 2) The frequency of filling shown is for normal operation. For initial operation follow lubricating instructions given in this manual. 3) The blade bearing assembly lubricants are presently imported. Development of indigenous supplier is under study. 4) The lubricants of blade bearing assembly are renewed only during major overhauls of the Fan (usually once in two years). This has to be done only by trained personnel. BHEL personnel may be requisitioned for supervision.

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Axial Reaction Fan Single Stage (TLT) 5.5 RECOMMENDED LIST OF SPARES

We recommend stocking atleast one set of the components per boiler shown in the drawings of Rotor assembly, Shaft with bearing assembly, and Blade bearing assembly as spare to meet the O & M requirement apart from having a stock of one assembled set of rotor assembly to meet emergency requirement. Hydraulic adjustment device should be ordered as assembled set only and no loose components will be supplied. While ordering spares, kindly quote drawing number, item number, description and quantity required.

CONTACT ADDRESS FOR GETTING SPARES The Additional General Manager (Spares Business) Bharat Heavy Electricals Limited, Boiler Auxiliaries Plant, Ranipet, Tamil Nadu, Pin Code-632406.

Doc. Ref: FES-Fans/T03/FAF-OM:02/Rev:00/Dt:25.06.2006.

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