M

OPERATION & MAINTENANCE MANUAL VOLUME

.

III

DRAUGHT PLAI{T ( FAI|S )

T/S. TAHAGEXCO . KHAPERKHEDA TPS { x 5OO tW, CUST No. R5O8

Bharat Heavy Electricals Ltd. (A Govt. of India undertaking)

Boiler Auxiliaries Plant Ranipet 632 4OG Tamil Nadu

r

OPERATION & MAINTENANCE MANUAL

* FORCED DRAFT FAN ''

M/s MAHAGENCO-Khaperkheda Cust. No : R5O8

BHARAT HEAVY ELECTRICALS LTD (A Govt. of India Undertaking)

Boiler Auxiliaries Plant Ranipet 6324OG Tamil Nadu

Bharat

Electricals Limited

FORMAT NO.

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DATE:07.04.2010

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:00

PAGE: 01 OF 08

TABLE OF CONTENTS PROJECT: M/s MAHAGENCO-KHAPERKEDA TPS

1.

INTRODUNON

2.

TECHNICAL DATA

3.

DESIGNATION

4.

OPEMTION

4.T 4,2 4.3 4,4 5.

CUST.NO. : R 508

PRE COMMISSIOING CHECK LIST

START UP AND OPEMTION

VIBMTION AND SAFE RUNNING OF

FAN

OPEMTIONAL PROBLEMS CASUES AND REMEDIES

MAINTENANCE

5.1 5.2 5.3 5.4 5.5

Preoared Bv: R SEKAR Siqnature

CONSTRUCTIONALFEATURE MAINTENANCE OF FAN DISASSEMBLY AND ASSEMBLY

LUBRICANONINSTRUCTIONS RECOMMENDED I.:IST OF SPARES

Reviewed By:

Siqnature

:

I

Moorthv

Approved By:P.SAHA Siqnature

Bharat ENGINEERING & DEVELOPMENT CENTRE FIELD ENGINEERING SERVICES

FORMAT NO.

Electricals Limited

iFl

REN. NO.

DATE : 07.04.2010

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PAGE: 02 OF 08

l.INTRODUCTION PROJECT: M/s MAHAGEI{CO-KHAPERKEDA TPS In the Axial reaction fans the major part of (about 80

CUST.NO. : R 508

o/o) energy

transferred is convefted into static

pressure in the impeller itself. The rest of the energy is converted into static pressure in the diffuser.

These fans are generally driven at constant speed. Varying the angle of incidence of impeller blades

controls the flow.

It

is therefore becomes possible by this process to achieve high efficiencies even

during paft load operation. The blade pitching operation

is

performed

by

mechanical linkage

connected to a hydraulic adjustment device, which is flanged to the impeller,

This manual generally describes and outlines the constructional features and the method of operation and maantenance of the Forced Draft Fan supplied to M/S.MAHAGENCOKHAPERKEDATPS.

Before commencing operation and maintenance of the Fan, the Engineers concerned must ensure that, they are familiar with all the details required for proper operation & maintenance of the fan. This

may include all the relevant drawings on assembly, system logic etc.. Incase of any doubt/ clarifications refer to Field Engineering services, Fans Engineering Division, BHEL- Ranipet, Tamil Nadu. The contents in the manual have been written by taking every possible care to ensure correct information. However it must be realised that no amount of written instructions can replace intelligent thinking and reasoning on the part of the personnel concerned, especially when coping with individual site conditions.

As continuous improvement on the basis of development and feed back are being made, BHEL reserves the right to modiry the technical details contained in this manual.

Preoared Bv: R SEKAR Siqnature

l-

Reviewed By: J Moorthv

Siqnature

:

Approved By:P.SAHA Siqnature

Bharat ENGINEERING & DEVELOPMENT CENTRE FIELD ENGINEERING SERVICES

EI ectricals

Limited

:00

FORMAT NO. :F1

REN. NO.

DATE:07.04.2010

PAGE: 03 OF 08

2. TECHNICAT DATA SHEET

PROJECT: M/s MAHAGENCO-KHAPERKEDA TPS

t.

CUST.NO. : R 508 Forced Draft Fan

APPLICATION

2.

FAN TYPE

APL-26116

3.

No. OFF/ BOILER

Two

4.

MEDIUM

Atmospheric Air

5.

LOCANON

Outdoor

6.

FAN DESIGN RATING

(m'/s)

Capacity

Total head developed (mmwc)

400

medium

(deg.C)

50

Density

(ks/

1.0369

Speed

(rpm)

980

Flow

(o/o)

45.4

Pressure

(vo)

68.7

Temp. of

7. 8.

210

m3)

FAN RESERVE

FAN DRIVE COUPLING

Type

Spacer Type

DRIVE MOTOR Make

BHEL BHOPAL

Type

SQ.IND.MOTOR

Frame

1 1A7716-6P,TETV,IP55,83

Rating Speed

Volts

Prepared Bv: R SEKAR Siqnature

I

(kw) (rpm)

(volt)

1025

994 6600

Reviewed By: J Moorthy Siqnature :

Approved By:P.SAHA Siqnature

Bharat FORMAT NO.

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2.TECHNICAL DATA SHEET

PROJECT: M/s MAHAGENCO-KHAPERKEDA TPS

10.

LUBRICANN EQUIPMENT

Fan Motor

i : 11. TYPE OF FAN REGUI-ATION : 12.

L7s LPM/12BAR FoLS (OIL-ISO VG68) Grease lubricated (Servogem3)

Blade Pitch Control

BEARINGS

Fixed

Bearing

:

NU 248 C3,7248 C3

Free

Bearing

:

NU 248 C3

Preoared Bv: R SEKAR Siqnature

I

CUST.NO. : R 508

Reviewed By: Siqnature :

I

Moorthv

Approved By:P.SAHA Siqnature

Bha rat

Electricals Limited

FORMAT NO. :F1

ENGINEERING & DEVELOPMENT CENTRE RELD ENGINEERING SERVICES

REN. NO. : 00

DATE:07.04.2010

PAGE: 05 OF 08

3.DESIGNATION OF FAN PROIECT: M/s MAHAGENCO.KHAPERKEDA TPS

CUST.NO. : R 508

The Forced Draft Fan supplied to this project is of the following designation:

APl-

26

I t6 AP -+ 1

-+

AXIAL PROFILE FAN NUMBER OF STAGE

26 --)

TIP DIA OF IMPELLER IN DECIMETER

16 -)

HUB DIA OF IMPELLER IN DECIMETER

RECOMMENDED LUBRICATION CHART

Lubricant &

Supplier

location Frequency of filling Filling

FOR' FAN " BEARII{GS:

:

: :

68 BharatTurbol 68 Turbinol 68 Teresso 68 Servo prime

of IOC of

BP

of

HPC

(Others)

Lube oil tank once in year or based on oil test results

observation : : Quantities per fan Frequency of

Prepared Bv: R SEKAR Siqnafure

daily 750 ltrs

Reviewed Bv: J Moorthv Siqnature :

/

fan

Approved By:P.SAHA Siqnature

Bharat ENGINEERING & DEVELOPMENT CENTRE FIELD ENGINEERING SERVICES

Electricals Limited

:00

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REN. NO.

DATE:07.04.2010

PAGE: 06 OF 08

LIST OF DRAWINGS PROJECT: M/s MAHAGENCO-KHAPERKEDA TPS Sl.No DESCRIPTIOl{

CUST.NO. : R 508 DRAWIT{G 1{O

1.

GENERAL ARRANGEMENT DMWING

0 00 098 21623

2.

SILENCER ARMNGEMENT DMWING

2 00 098 2t644

3.

FAN ASSEMBLY

0 55 216 01019

4.

SECTIONAL ASSEMBLY

5.

ROTOR ASSEMBLY

6.

SHAFT

7.

BLADE BEARING ASSEMBLY

8.

HYDMULIC AD]USTMENT DEVICE

NA

9.

SERVOMOTOR MOTOR ASSEMBLY

0 55 216 00824

-10.

WTft

0 5s 216 00994 0 55 216 00736 0 55 2L6 00447

BEARING ASSEMBLY

0 55 216 00405

SETNNG SHAFT ASSEMBLY

NA

11.

LINKAGE ASSEMBLY

L2.

oIL

PTPTNG(INSTDE)

NA

13.

oIL

PTPING(OUTSIDE)

NA

t4.

LOS SCHEME DRAWING

15.

FAN CHARACTERISTIC

16.

TORQUE Vs SPEED CURVE

1 55 216 013s5

CU

200 L07 21633 3 00 t022278t

RVE

4 00 102 219ss

NOTE: THE OWNERS ARE ADVISED TO PRESERVE THE DMWINGS SUITABLY FOR FUTURE REFERENCE

Prepared By: R Siqnature

I

SEI(AR

I Reviewed By: J Siqnature :

Moorthy

I

Approved By:p.SAHA Siqnature

Bha rat ENGINEERING & DEVELOPMENT CENTRE FIELD ENGINEERING SERVICES

E lectricals

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:00

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PAGE: 07 OF 08

LIST OF ANNEXURE PROJECT: M/s MAHAGENCO-KHAPERKEDA TPS Sl.ilo DESCRIPTION 1.

PROPER FASTENING FOR RIGIDITY

2.

PROCEDURE FOR ENSURING SPRING BACK

3.

MAXIMUM PERMISSIBLE TORQUE VALUES FOR NGHTENING BOLT

4.

MOUNTING AND DISMOUTITING PROCEDURE OF

5.

PRINCIPLE OF HYDRAUUC INSTALLATION AND D(TRACNON

6.

ACID CLEANING PROCEDURE

7.

INSTALI.ATION AND ALIGNMENT OF RIGIFLE( COUPUNG

Prepared By: R Siqnature

l\.

CUST.NO. : R 508

SEKAR

I Reviewed By: J

Siqnature

:

ANn

FRICTION BEARING

Moorthy

I

Approved By:P.SAHA Siqnature

W

Electricals Limited

ENGINEERING & DEVELOPMENT CENTRE FIELD ENGINEERING SERVICES

FORMAT NO. :F1

DATE:07.04.2010

LIST OF VENDOR MANUAT/DATA SHEET

PROIECT: M/s MAHAGENCO-KHAPERKEDA TPS DESCRIPTION LUBE OIL SYSTEM

HYDMULIC COUPLING ACTUATOR

RIGIFLE( COUPLING

l'

CUST.NO. : R 5O8

AXIAL FAN (KKK DESIGN 16 HUB)

SINGLE STAGE

OPERATION AND MAITENANCE MANUAL

Prepared by

Checked by

Approved by

S.SELVAM

J.MOORTHY

M. DESIGAN

Doc. Ref: FES-Fans/r03/AP1.16/OM:10/Rev:00/Du28.09.2006

W Ranip€t

Axial Reaction Fan - Single stage - 16 Hub

(ll OPERAIIOII

Doc.

Ref

: FEgFans[o3/APl.16/OM: 10/Rev:00/Dt:28.09.2006.

Axial Reaction Fan -

Ranipet

- 16 Hub

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 FOLLOWNG The bases of Fan parb are tightened with out strain. 1-ightness of all foundation bofcs of Fan

/

motor.

Tightness of connecting bolts of bearing housing and impeller housing. Verticality of impeller housing

/

horizontality of shaft witfiin 0.(H mm/mtr.

Proper clearance and gap at free supports.

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

tie

blades are on the suction side of each

impeller.

Tigh$ess of blade fixing screws to the required torque values, For the given blade position, the blades are Identical in both the impellers

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. Provision of locating pins and machined washers at parting planes of impeller housing. Match

mark on the coupling parts,

lighhess of coupling bolts of regiflex coupling. Correct setting of coupling gap. Alignment of couplings to be within 0.05 mm. Free movement of hinge heads.

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 conect quality of oil. Early commissioning of the oil system to facilitate checks on the impeller.

Caution

3

Never operate the

selomotor with out control oil flo$r.

Proper connection of inlet and outlet of lub€ oil piping to the main bearings. Proper connection of oil pipes to the oil head assembly,

Doc.

Ref

: FE5-Fansfr03/AP1.16/OM:10/Rev:00/Dt:28.09.2006.

Axial Reaction Fan - Si

Ranipet

- 16 Hub

There is no pre-load in oil head assembly inboduced by flexible hoses. The servomotor sboke length is maintained as per the drawing and mechanically stopped.

The independent operation timing of actuator from zero to 100

o/o

and vice versa is more

than the servomotor timing ( From full close to full op€n and vice versa ). Linearity of blades position w. r. t . local/ control room Indication. Proper setting of mechanical stopp€rs. 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. Proper functioning of interlock

/

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 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

Doc. Ref: FES-Fansfro3/APl.16/OM;10/Rev:00/Dt:28.09.2006.

/

interlocks.

Ranipet

In this chapter, the starting sequence for the Fan is described as individual equipment, For details connected with the boil€r system, refer Fan panel control diagram provided in the boiler conuol and

instrumentation manual. Protection interlocks for drive motor shall be as recommended by the respective supplier,

START PERMISSIVE

> >

(a)

Control oil pressure

(b)

Lub oil pressure

(o)

Impeller blades in minimum position

(d)

Discharge damper/ gate full close

8 ata

0.8 ata

ALARM & TRIP VALUES When the fan is kept under s€rvice, 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 lsolator

Alarm

>95degC

105 deg C

> 9.0 mm/s

7.0 mm/S

> 14 mm/s

Differ€ntial Pressure across oil filter

Xl.6 bar

Lub Oil Pressure

3 0.4 bar

Control Oil Pressure

S 6.0

Oil Level ln The Tank

:

mm/s

> 4.5

I

Trip

< 5O

bar olo

Refer logic diagram for additional interlocks. STARTING OF THE FAN

. o

Ensure that all protections and interlocks are functioning properly,

Start the motor. Check for correct direction of rotatlon of motor, This fan should rotate in Anticlockwise while viewing from motor.

.

Test runs the motor for 8 hours. If found satisfactory, couple Fan

Doc. Ref: FES-Fans/r03/AP1.16/OM:10/Rev:00iDt:28.09.2006.

witi

motor.

Start the lub. oil pump. Adjust control oil pressure to 8

-

12 bar and lub oil pressure

to 0.8 - 1.2 bar. 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 opens fully after the Fan has accelerated to full speed.

Operation of the fan with discharge damper fully clos€d is not permissible. Measure static pressure at Fan discharge with blades in minimum position. Ensure at

least + 20 mmWC. 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 bial run completion. Check for any abnormal noise in the Fan. Check and record the motor cunent, voltage,

and blade opening position and Test run for 8 hours, CHECKS DURING NORMAL OPERATION OF THE FAN During continuous operation of the Fan the data should be logged as per the format: "Operational parameter". Apart from the data logged in the format the following additional 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. HIGHEST PERMISSIBLE VALUES

. . . .

pressure Lub. oil pressure Elearing temperature

105 deg c

temperature

70 Deg C

Control oil

Maximum oil

12 bat 1.5 bar

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 type

of

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: FE9Fansfro3/AP1.15/OM:

10/Rev:00/DL28.09.2006.

W

Axial Reaction Fan - Single stage - 16 Hub

Ranipet

(a) If the inlet volume capacity is too litde (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 litdel 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. MINIMUi,I POSITION OF AP FAN BLADES During trial operation, a ched should be affected. If the machine is operated with dampers opened

fully on the discharge side, the pressure at the diffuser should be at least +20 mmWC. 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 blade could then be achieved by setting limits at the external actuator for actuation of the impeller blades as well as tfie hydraulic seryomotor.

PARALLEL OPERATION OF FD (AP TYPE) FANS The single stage axial reaction (AP) fans are given normally for FD application of power boilers. 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 PA FAN Refer the typical Characteristic curve of the fan (Fig

each fan and the Y

-

- 1).

The X

-

axis is the volume flow through

axis is the total pressure rise by the individual

fan, The

numerical values C

405, Ca50), C285, C125, (+40), (+80), (+120) and (+150) etc., are the different blade angtes, 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 at the top.

Doc. Ref: FES-Fansfio3/AP1.16/OM:10/Rev:00/Dt:28.09.2006.

/

volume on the right side and by the stall line

W Ran-ipei

Axial Reaction Fan - Single stage - 16 Hub

BEHAVIOUR OF FAN The pressure developed by the fan is just egual to the system demand. Refer Fag angle say (+40) let us assume, the volume flow is

"

mmwc when the system resistance is say say

"

m".

'a'

If

-

1. For a blade

m3/ sec and the pressure developed is "b"

the

resistance of the system is changed to

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

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 resistance is close

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" m3/ 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

L-

reaches its rated speed, the discharge damper/ gate should be opened fully. The blades of tfre 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. R€f: FES-Fans[03/AP1.15/OM:10/Rev:00/Dt:28.09.2006.

FiS-2

Ranipet

Refer Fig

- 3,

Let us assume Fan A runs at point

the deepest point

's" of the stall

'

A1" that is the pressure developed is more than

line.

Fa6-

t

Fan B is now shut off from the system by means of damper/ gate, Before starting Fan B, the pressure develop€d by the Fan A should be brought down to "A2" the deepest point

Cs) of the stall

, (Ref fig - 4) that is

less than

line.

ybl FIE

-,1

+

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

5olo.

to make both fan operating at the same duty point on the performance graph, altematively open the blades of Fan B by approximately 5olo and close the blades of Fan A by As the aim is

approximatety 5olo. Continue this operation step by step, till the duty points like blade position and

Doc. Ref: FES-Fansfr03/AP1.15/OM:10/Rev:00/Dt:28.09.2006.

W Eiifti

Axial Reaction Fan - Single stage - 16 Hub

Motor current are same in both fans. From this point onwardE increasing

the fans will be simultaneous and similar in both fans.

If

/

decreasing the load on

not, the phenomena called

.

Loading

/

Unloading Of Fans " will occur. EFFECT ON FAN PERFORIIANCE DURING SUDDEN CHANGE IN SYSTEM RESISTANCE Normally when two axial reaction fans are running parallel under stable load conditions, there is a chance of sudden variation in the system resistance.

For example, tripping of one mill or accidental closure of any damper in the down stream of the fan

etc., the effect of such sudden variation in system demand on the fan operation is explained below. During the sudden variation in system demand as explained above, when two pA fans are running under stable condition at higher blade position, the volume required to be handled by the Two pA fans reduces.

Under this condition, both the PA fans are likely to get unloaded

( Fan delivery pressure goes down

drastically ) when the blade positions are kept at same angle. The normal conbol provided in the C

&

I

scheme is that, the blade pitch angle will be further open when the fan delivery pressure goes

down.

Some times the blade position go

to 100

o/o

open. Even in this condition, the pressure developed by

the fan will remain same at lower value. Cases were reported that the operator switches off the pA fans during such conditions. This has resulted in Uipping of unit due to low-low header pressure.

In order to over come such situation, it is required to understand the parallel operation of this type of Fans. Under this condition the following guideline may be adopted. When two pA fan run in unloaded condition, bring the blade position to approximately 600/o any one fan (Say Fan

-

-

50o/o by closing

A). Close the blade fully in other fan (Say Fan

the blades in

- B) and keep running it.

Now, the Fan A in which the blade position is 600/o - 50o/o open will operate at stable zone.

Set the Fan out let pressure/ Header pressure at the required level. Bring in the second fan as and

when required by following the parallel operation procedure. 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 system will adjust both fans identically to meet the system demand.

Doc. Ref: FE5-FanS[03/AP1.15/OM:10/Rev:00/De28.09.2006.

graph, the auto control

W ffiiF

Axial Reaction Fan - Single stage - i6 Hub

To achieve this, the following Mechanical check should have been performed and logged prior to commissioning of the fans.

.

The servomotor operating time is less than the operatng time of the actuator in decoupled condition.

. . .

After coupling with actuator, the servomotor operating time is identical in both fans The servomotor stroke length is identical in both fans

The actual blade position is calibrated w.r.t conbol room reading and are identical in both fans

.

There is no mechanical backlash in the linkages of Servomotor

-

Actuator.

SHUTDOWN OF FA},I Take the Fan operation to manual from auto operation.

o . o o .

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 conservation is required for a shutdown

of up to two week. In case of standstill period

upto 12 months, the following may be adopted. Since the maximum effective life of rust preventive

oil/anti conosive agenb, 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. The compound

/ oil shall confirm to the following specifications: Specific Gravity

0.850

Flash point

40"c(MrN)

Film thickness at

25"C

Film description

Thin transparent dry film

Non-volume content

40'48Vo

Coverage at 25o C

12 m2lliter

1000/0 Humidity

Remove the preseryative prior Steam blow Doc.

Ref

/

at 50o C

l0

microns

30 Days (mm)

to commissioning, using suitable solvent like Kerosene/Alkali wash/

lubricating oil, During prolonged shut down of commissioned equipmenu

: FES-FansfIo3/AP1.15/OM: 10/Rev:0o/Dt:28.09.2006.

10

DURING PROLONGED SHUT DOWN OF COMMISSIONED EQUIPMENT ONCE IN TWO DAYS

.

Start the lube oil pump and operate the impeller blades from full open to full close several times.

ONCE IN TEN DAYS

.

Rotate the rotor of Fans by hand for a few revolutions 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 to avoid pitting of shaft and bearings.

ONCE IN TEN DAYS

o

Blow the rotor

witi

compressed air to remove hard deposits on the blades.

ONCE IN TWO WEEKS

o

Doc.

Ref

Run the Fan for about half an hour and ensure smooth operation.

: FES-Fansft03/AP1.16/OM:10/Rev:00/Dt:28.09.2006.

11

Axial Reaction Fan - Single stage - 16 Hub

VIBRATION CHARACTERISTICS

Vibration in the simplest form may be considered as the motion of apart 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 p€ak to peak displacement or Double Amplitude. 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. LIMITS OF VIBRATION Condition of Machine as pcr 150 10816

Descrlption

'v'ms (9a ral

3?

EP (90 olJ EE

€6

Hg

Displacement in microns for

'V'rms

c ll

tD

,b o

c

Just Satisry

Un

sausry

Alarm

Trip

Up to

Above

Up to

Above

Up to

Above

Above

At

1.8

1,8

4.5

4.5

11.O

11.O

4.5

9.0

580 rpm

80

80

200

200

400

400

200

400

740 rpm

4

g

160

160

320

320

160

320

990 rpm

48

48

t20

120

240

240

120

240

1,180 rpm

32

32

80

80

160

160

80

160

2880 rpm

16

16

40

40

80

80

40

80

2.8

2.4

7.O

7,O

18,O

18.0

7,O

14.0

126

320

320

o

640

320

640

in mm/s

in mm/s 580 rpm

9E oo 6'9

lnstructi-on

speed

E

o!

Satisfy

Good

Operating

- 3: 1998: Part 3

Displacement in microns for

t26

740 rpm

100

100

250

250

500

500

250

500

990 rpm

75

75

188

188

375

375

188

375

speed

E (,

12180

rpm

50

50

725

t25

250

250

125

250

E

2880 rpm

25

25

65

65

!25

125

55

125

c

Doc. Ref: FES-Fans[03/AP1.16/OM:10/Rev:00/0h28.09.2006.

t2

W Ean-iEi Sl.No 1

Axial Reaction Fan - Single stage - 16 Hub

Problems

Probable cause

Frequent drop in oil level in the tank

Leak in the oil system Damaged shaft s€als at main bearings Damaged seals at

Remedial Action

. . .

Inspect and rectify leaks. Dismantle bearing assembly and change seals. Dismantle servomotor and replace seals.

servomotor 2

3

Water contamination in oil.

.

Leakage in oil cooler

.

Ubes and rectiry leaking tubes.

Drop in oil

Filter element clogged

o

pressure Leakage in oil system

. o

High oil temp. No flow through retum oil pipe (check through sight glasses)

Damaged over flow valve-

4

Large pressure

Improper setting of over flow valve.

flucuation in the control oil circuit.

Pressure reservoir 5

conbol slide Jamming.

6

High bearing

temperature.

.

Fan absorbs tull

load current immediately after startinq,

No oil to control slide.

. . .

tank too high. Oil too viscous.

.

Lubrication failure.

o

7

Analyse oil for water contamination. Conduct hydraulic test on tle oil cooler

.

Oil temperature in oil

Bearing damages. Bearing clearance too small.

Impeller blades in full open position

Doc. Ref: FES-Fans[03/AP1.16/OM:10/Rev:00/D828.09.2006.

. . . .

. o

Check for pressure drop across filter. Changeover to standby filter, clean the clogged filter Check for the leakage in pipelines and ensure leak fiee joints. Check for flexible hose damages and replace it, if necessary. Change over to standby cooler and clean the defective oneCheck oil level in the oil tank. Fill oil, if necessary. Ensure for no leaks through the oil tank. Change over filter & clean filter elements. Check the pump suction strainer and clean. Change the over flow valve and reset it. Check setting of over flow valve, open Close the bypass vatue, gradually close the over flow valve till the required pressure Is achieved. Check for rated pressure fill nitrogen, if necessary. Dismount the servomotor assembly. Dismount the control slide and check conuol slide, conuol rod and piston for

fully.

. . . . . . . .

concenficity and oil flow. Check oil cooler choking. Change, us€ specified oll. Replace the bearings. Check bearing clearance and replace

with proper bearing. Check the oil flow regulator for its DroDer functioninq. Stop the Fan and examine blade

position. If it is not in full close condition reset the Impeller blades.

13

- 16 Hub

Sl.No 8

Problems Unquiet running.

9

Probable cause

. . .

Unbalance due to

deposits on rotor. Bearing clearance too large. Blades touching impeller casing.

Rotating and stationary parts touchinq Fork lever on drive shaft loose.

Power absorp-

tion of the Fan cannot be altered

10

Blade jammed.

Servomotor defective. Servomotor stroke setting not identical for the two Fans.

Two Fans operating in parallel do not absorb same

power.

System resistance not

Remedial Action

. . . .

Remove deposits. Change the bearings if required.

Shutdown the Fan immediately. Check blades for crack. Adjust impeller casing for achieving tfie recommended clearances. Check and maintain the clearance

between rotating and static parts

. .

o

. .

Tighten fo* lever. Set blade position. Check actuating drive and tighten fixing bolts. Stop the Fan and actuate blades. Check for gap between blade boss and

impeller hub. Dismantle Impeller hub and check for blade shaft, lever key ways, conduct hydraulic test on blade bearing assembly, Replace seals wherever necessary. Check and service servomotor, Check stroke length for uniformity. Set blade position uniformity. Check actuating drive and tighten the fixing

bolb. Check for closed dampers in the ducting

identical in Fan flow Dath

l1

High vibration

o

Forced Vibration or resonance.

.

Improper fixing of Impeller hub.

.

Impeller blades not fixed serially.

.

Deposits on impeller blades

. . . .

Conduct vibration analysis. Conform the cause and take remedial measure, Check for proper seating of hub on shaft flange and bearing housing. Secure the required tighhess of fixing bolts. Check for number punch marks on the blade and ensure that the blades are fixed serially of the same series. Check for deposits and clean blades.

For attending the Hydraulic s€womotor and glade bearing assembly, Aseistance from the fian manufacturer sbould b€ sought since these works calls for the special tools and skills.

Doc. Ref : FEgFanyro3/AP1.16/0M

:

10/Rev:0o/Dt;28.09.2006.

14

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W EiiEi

Axial Reaction Fan - Single stage - 16 Hub

5.0 l,lAllffil{trlCE

Doc. Ref: FES-Fansft03/AP1.16/OM:10/Rev:00/Dt:28.09.2006.

15

Axial Reaction Fan -

Ranipet

- 16 Hub

When looking in flow direction, the fan consists of the following Components,

. . .

Stator Rotor Fan accessofies

STATOR Suction chamber, fan housing and diffuser are welded suuctural steel fabrications, reinforced by flanges and gussets, resting on the foundation on supporting feet. The supporting feet are fixed on the foundation in such a way that they slide and without clearance at the sliding supports of suction

chamber and diffuser.

on ib impeller side, the suction chamber 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 chamber and Fan Housing, ouuet Guide vane housing and difftrser are flexibly connected via expansion joints. Fan and Ouuet guide vane housings are horizontally split, in order to facilitate access of the rotor for dismantling and assembly. Those parts of the pitch control unit, which are

ananged in the guide vane and diffuser cores, are accessible through assembly openings, 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 The rotor consists of a shaft, impeller, and a seryomotor. The rotor is accommodated with Cylindrical Roller bearings. In addition, Angular Contact Ball bearing is arranged on the coupling

side in order to absorb the axial thrust. Double contact tele-thermometers and double resistance

thermometeB monitor the bearing temperature. These thermometers must be connected to signaling instrumenb at the site. Lubrication and cooling of these bearings are ensured by a combination of oil bath and circulating lubrication. Simmer rings are always installed, filled with grease. The oil ventilated through the lube oil retum pipe, which opens into the oil reservoir. The

ventilation hood is mounted on the resewoir.

Doc. Ref: FES-Fansfr03/AP1.16/OM:10/Rev:00/Dt:28.09.2006.

16

Axial Reaction Fan - Single stage - 16 Hub

Ranipet

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

1. Inspect the machined surfaces of the fan shafo immediately on receipt at site. 2. Clean the machined surfaces, if required, by using keros€ne or mineral turpentine,

Exposed

rust to be removed by rust removing solution (Phosphoric acid 1090).

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 shafu in covered storage. PROCEDURE FOR PRESERVATION OF ANTI.FRICTION BEARJNGS

1. 2. 3,

The storeroom must be free from dust. Ideal ambient temperature should be 20 to 30 deg c.

Relative

air humidity should not exceed 500/0.

It

may be neceslFry

to

install air

dehumidifier in places where relative humidity is high.

4.

If the

bearing is found

to be dry and dirty, it should be thoroughly washed and

cleaned

before re-packing.

5.

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.

6. 7. 8.

It

should then be cleaned in another vessel with filtered kerosene.

The final cleaning is to be done by using petrol of mineral turp€ntine oil.

It

should be then allowed to dry completely. Pressuraised

air for cleaning or drying

purpose is not recommended, (RUST GARD P214)

9.

The washed and dry bearing is to be dipped in anti-corrosive oil.

10. The

excess

oil should be allowed to escape and bearing should be repacked in

waterproof sealable plastic bag and put in to the carton again. RECOMMENDED PRESERVATIVE COMPONENTS

Application

Brand Name

Machined surfaces ( Indoor storage )

TRP 1706, TRP 1710

Machined surfaces ( Outdoor storage )

TRP

weldments

De-ory Aluminates

Shaft with bearing assembly

HDPE (Hiqh Densitv Poly Ethvlene) sheets.

oit Iso vG 68 Eouivalent: SERVO PRIME 68

Doc. Ref : FESFans/ro3/AP1.16/OM:1o/Rev:00/Dt:28.09.2006.

t7

a

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Axial Reaction Fan - Single stage - 16 Hub

Ranipet

FAN ACCESSORIES RIGIFLEX SHAFT COUPLING The

fan shaft

is connected to the

motor shaft by means of Flexible couplings while the

distance between the shaft ends is bridged by an intermediate shaft which is a part of the coupling assembly. These couplings are capable of compensating mounting and operational inaccuracies to a certain

extent. The close-fit, high strength spring plates are firmly retained.

No

lubrication is required for the coupling parb,

OIL CIRCUI.ATION SYSTEM The oil system consists of an oil tank, two pumps, filters, coolers (one standby) and other necessary

fittings and instruments, A pressure relief valve maintains the pressure in the lubricating

oil is fed

through

a

system.

pressure compensated flow-regulating valve.

A

The

Hydraulic

Accumulator (Pressure Reservoir) in the system absorbs the pressure fluctuations during blade adjustment. Separate manual is enclosed for detailed reference.

\-

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.

Doc. Ref: FE9Fans/T03/AP1.16/OM:10/Rev:00/Dt:28.09.2006.

18

The

W 6ipet

Axial Reaction Fan - Single stage - 16 Hub

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.

o

Record vibration level on all bearings. Such

beyond

the

permissible levels

of

of those bearings whose vibration levels

satisfactory operation may

be

are

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 erosion of Impeller

o

/

at Fan connections etc. Observe for any

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 indicaton and actual blade position

BETWEEN PLANNED SHUTDOWN

Every 8 operating hours - record the vibration level. Every 50O op€rating hours or at least once in three months

.

-

Clean the filter. Oean it before the above mentioned time has elapsed when the

differential pressure contact indicator indicates that the filter is dirty.

Every 2O00 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 op€rating hours or at least once in a year

. .

Retighten all the fixing bolts. Check the quality of oil, if required change the oil.

Doc. Ref: FES-FansfrB/AP1.16/OM:10/Rev:00/Dt:28.09.2005.

19

F

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Axial Reaction Fan - Single stage - l6 Hub

Ranipet

FORCED SHUTDOWN

If the plant shutdown is owing to other parts, it-may-be possible to inspect the Fan. We recommend the following jobs.

. . o .

Check whether there is oil leakage inside the Fan.

Geck impeller blades and guide vanes for wear, if any. Check whether all blades are equally set when actuating the servomotor. Check the degree of wear at the articulated heads of the actuating drive, if any and lubricate

the pillow block bearings.

. o

Check whether the servomotor is oil tight, Check for the stroke of hydraulic servomotor,

PLAiINED 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 man ufactu rer.

(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. o Check lever, slide ring and adjusting disc for wear and insp€ct jewel bearing assembly.

(b) cHEcK oF SERVOMOTOR o Chock piston rings and replace them, if required. . Check contol rod, control bush for concentricity, . Check needle bearing of control slide, replace it if required. . Check degree of wear at inner dia of cylinder. . Then reassemble and check for proper operation of servomotor. Readjust actllating drive, consider all criteria applicable to blade adjustment,

Doc. Ref: FE9Fans/ro3/AP1.16/OM:10/Rev:00/Dt:28.09.2006.

20

\,

w ran-Gi (c)

Effect all checks as describ€d under' between planned shut down and forced shut down

(d) (e) (f) (S) (h)

Axial Reaction Fan - Single stage - 16 Hub

"

Clean inlet and outlet oil lines,

Eliminate oil leakages, Check the clearances of main bearings, Ensure free rotation by hand. Replace high pressune hoses for seruomotor if rcquir€d. Ensure the ID of the

flexible hoses should be 3/8',

I

Doc. Ref : FEgFansfrB/AP1.16/OM: 10/Rev:00/Dt:28.09.2006.

2l

w 6iEi BHEL specialists should service

Axial Reaction Fan - Single stage - 16 Hub

fan. Our instructions have only one objective, namely to keep the

Fan ready for operation and to avoid longer standstills. Basic requiremenb 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.

INSTALLATION AND REMOVAL OF THE IMPELLER BLADES

.

The impeller blades have to be checked for wear. Remove the inspection cover from the upper hatf of the Fan housing.

.

Remove the screws connecting the blades and blade shafts and extract each blade form its

fit.

. o

Install the impeller blades in accordance with the insuuctions, Screws must be coated with Molykote and have

to be tightened to the specified torque.

Make sure that the scrcws are loaded uniformly.

.

Before the complete set of impeller blades are replaced, the upper half of the housings must

be removed. Retract the impeller blades (0olo)

Remove the expansion bands

at the upper hafues of the housings. Remove the

screws

connecting the joint areas of the Fan housing and the guide vane housing. Remove the manhole door from the diffuser core. Remove the, connecting screws from the jointing areas in the guide vane core,

Lift the upper half of the impeller and guide vane housings. The impeller blades can now be replaced.

REUSABILITY OF BLADE FTXING SCREWS Where new blades must be installed, the new screws delivered wittr them also should be used. Screws can be re us€d if,

.

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 conect torque, with a calibrated torque wrench.

Doc. Ref: FE$Fansfr03/APl.16/OM:10/Rev:00/De28.09.2006.

22

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Axial Reaction Fan - Single stage - 16 Hub

REMOVAL AND INSTALLATION OF ROTOR (Drg No: 0 55 216 00736)

o .

Retract the impeller blades (0 o/o) Remove the expansion bands at the upper half of the housings. Remove the screws

connecting the joining areas of the Fan housings.

.

Remove the manhole door from the diffuser

core.

Remove the screws from the joining

areas in the guide vane core.

.

Remove the linkages supply head

. . .

(1).

of the actuating drive, the connections on the servomotor and oil

Ensure protection of oil openings.

Lift the upper half of the impeller housing and guide vane housings. Remove the blades and disconnect the coupling. Remove all mounting screws and all connecting instruments and pipe work from the bearing housings.

.

Suspend the rotor. The suspension lugs have to be screwed in to

tle

impeller and the

bearing housing.

.

Remove

the rotor complete with bearings and servomotor and place it on an appropriate

support.

'.

o

Installation has to be canied out in reverse sequence. Ensure conect alignment.

All screw connections have to be tightened to the torque shown in the drawing, with

a

calibrated torque wrench,

.

Check whether any tools, objects have be€n left inside the Fan and remove the same.

DISMOUNTING AND MOUNTING THE IMPELLER FROM AN EXTRACTED ROTOR

{Drg No: 0 55 216 00736)

.

Suspend the impeller. Remove screws connecting impeller and shaft flange and eject the impeller along with seryomotor.

.

The impeller should be installed in reverse sequence, all screws being tightened to the correct torque.

REMOVAL AND INSTALLATION OF THE SERVOMOTOR FROM THE ROTOR,

(Drg No: 0 55 216 00736)

. .

Suspend the servomotor. Remove the screws (02) connecting servomotor and impeller. Replace three fixing screws by three pins.

.

Move the servomotor as far as possible towards the adjustlng pistons. Remove the screws

(03) through the gap between servomotor cylinder and impeller. Doc.

R€f

: FES-Fansfro3/APl.16/OM:10/Rev:00/D[[email protected].

Remove the adjusting ring (04) from the disc and dismount the servomotor.

The installatlon should be carried out in reverse sequence. All the screws must be Ughtened

to the correct torque. DISASSEMBLY AND INSTALLATION OF THE SHAFT AND BE.ARING ASSEMBLY

(Drg No : 0 55 216 00736 )

. . . . . o

Remove coupling,

Dismount the hub disc (5) (Refer principle of hydraulic Installation and exfaction) Unscrew the

threadd pins in the shaft nuts (6) and remove.

Remove the mounting screws (7) of the bearing covers and take out the covers. Press of the inner rings (8) and splash rings

(9) by means of threaded pins.

Remove the screw plug from the coupling end of the bearing housing. Connect the hydraulic

pump and apply pressure to the contact area of the outer ring of the anti-friction bearing.

.

Slowly pull the shaft (10), with the coupling end components from the bearing housing towards the coupling,

.

The rest of the components can now be removed, using a hydraulic pump to admit pressure

to the contact areas of the anti-friction bearings,

.

For pulling of

f the

bearings, use tools as recommended by the manufacturer. To protect

bearing shoulders, races, cages and the balls or rollers, 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.

.

Install the bearing with the shaft in reverse sequence.

PRECAUTIONS

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 the mounting of the bearings are stricdy adhered to the same sequence, as indicated to avoid any future problems. Remove

the protective coatings/old grease by means of liquid solvents like CTgpetrol the

shaft surface

/

bearings and related components. Thoroughly clean the bearing and shaft

surfaces,

.

Make sure that the bearing housing bore and shaft diameters are in accordance with the

drawings, Ensure the condition of the rolling elements and proper C3 clearance of the bearings.

.

No bearing shall be accepted if the same is found

Doc. Ref: FES-Fans/r03/APl.l6lOM:10/Rev:00/D[28.ff].2005.

gitted

/

rust€d or damaged.

W

Axial Reaction Fan - Single stage - 16 Hub

Ranipet

. o

Pipe 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 b€aring should not touch the walls as well as the bottom of the container.

.

Slowty heat the oil to about 70o centigrde above ambient temperature

a temperaturc of

(But nev€r exceed

lOOo centigrade), Ensure the temperahrre, and allow sufficient

soaking time before mounting.

. o

For the bearing radial clearancet refer bearing catalogue/drawing/Fan Technical Data.

The sealing elements must not be damaged. The bearing clearances indicated else where must be ensured.

DISMANTLING AND ASSEiIBLY OF SERVOMOTOR (Drg No: 0 55 216 00736)

. o . o . .

\-

Remove the screws (11) and flange (12). DismanUe the bush (13), control sleeve (14) and control rod (15). Remove the screws (16) and cover. Remove the piston assembly (17)' Replace all the oil seals and bearings,

The Installation should be carried out in reverse sequence. All screws must be tightened to the correct torque.

'

DISMANTLING AND ASSEtttBLY OF BLADE BEARING ASSEMBLY (Drg No : 0 55 216 00736)

. o . . . .

Remove the lever assembly (18), lock-nut (19). Loosen the counter weight screw (22). Remove the shaft (21) counter weight (20), connecting ring (23) and distance ring assy (24). Remove bearing assembly (25) along with cup springs. Replace all the oil seals and bearings. Apply fresh lubricanb.

The installation should be canied out in reverse sequence. All the screws must be tightened to the correct torque.

COMMISSIONING OF FAN AFTER MAJOR OVERHAUL Prior

\

P?e

to starting the Fan after a major overhaul, ensure all checks as mentioned in the chapter

commissioning checks - chapter no 4.1"

Doc. Ref: FEgFans[03/APl.16/OM:10/Rev:00/Dt:28.09.2006.

25

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W Eiipei

Axial Reaction Fan - Single stage - 16 Hub

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 Mscosity at

68

4f

C

64-72

6t

Mscosity index

95 min

Flash point

21d

C (min)

Pour point

-6'

(max)

Neutralization, No. mg KOH/gm

:

C

0.2

The oil must not foam during operation. Foam removing agents containing silicon must not be utilized. The oil must have good anti-corrosion properties. RECOMMENDED OILS

a) Sewo prime 68 of IOC b) Turbinol 68 of HPC c) Bharat Turbol 68 of BPC d) Teresso 68 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 bearing housing. 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.

Doc.

Ref

: FES-Fans/t03/AP1.15/OM:10/Rev:00/Dh28.09.2006.

26

\_,

w Ran-iEi

Axial Reaction Fan - Single stage - 16 Hub RECOMMENDED LUBRICATION CHART

S.no

01

Component

Lubricant

Supplier

Fan main Brg

Servo prime 68 Turbinol 68 Bharat turbol 68

and Hydraulic Servomotor Mechanism

02

03

M

Axial ball bearing (Blade bearing assembful Deep groove ball bearing & Angular contact ball bearing (Blade bearing assemblv) sphericil plain bearing

(

Blade h\rer)

Location

Fr€quency

M/s IOC M/s Hrc M/s Brc (Others)

Oil tank

Once in 2 years or based on oil

S€e

Inside

note.3

Rotor

cuprysil

See

(copper base

note.3

Inside Rotor

S€e

Inside

note.3

Rotor

Teresso

68

Mobil Glygoyle 80 OR

Berusynth EP 460 Poly-BuWl

grease) Molykote spray

32lR OR oKs 511

obser vation

Daily

quality. See note 2 During Over haul (Once in 2 years) See note 4

atv

/

Fan

See

note.1

Three Kg

During Over haul (Once in 2 years) See note 4

Two Tins

During O'ver haul (Once in 2 years) See note 4

Four Cans

I{OTES :

1)

Oil quantity depends on tank capacity. Levels marked in the oil tank level gauqe.

2) The

ftequency

of filling shown is for normal operation. For initial

operation follow

lubricating instructions given in this manual.

3)

The blade bearing assembty lubricants are presenty 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.

Doc. Ref : FE$Fans/t03/AP1.16/0M: 10/Rev:00/Dt:28.09.2006.

27

Axial Reaction Fan - Si

\*

5.5

RECOMMENDED LIST OF SPARES

we recommend to stock at least one set of the componenb per boiler shown in the drawings of

rotor assembly, shaft with bearing assembly, seryo motor assembly and blade bearing assembly as spare

to

meet the O&M requirement apart from having a stock of one assembled set of rotor

ass€mbly to meet emergency requirement.

While ordering spares, klndly quote drawing number, item number, description and quantity required,

CONTACT ADDRESS FOR GETTING SPARES

The Additional General l,lanager (Spares Businoos)

Bharat Heavy Electricals Limited, Boiler Auxiliaries Plant, Ranipet, Tamil lladu, Pan Code-632406

Doc. Ref: FES.Fans/r03/AP1.16/OM:10/Rev:00/DL28.09.2006.

2a