Description: Operation & Maintenance Manual Part 1 - Technical Specification

Operation & Maintenance Manual 1
FORCED DRAFT FAN BBU Code 11HLB FA, 12HLB FA

Part 1 – Technical Specification
DESCRIPTION
Contents
SPECIFICATION KEY............................................................................2
GENERAL ..............................................................................................3
DESIGN AND FUNCTION......................................................................5

General.............................................................................................5
Inlet box ............................................................................................6
Impeller casing .................................................................................6
Main Bearing Assembly ....................................................................8
Impeller.............................................................................................9
Diffuser ...........................................................................................11
Tool box..........................................................................................12
Pitch control system .......................................................................13
Control mechanism.........................................................................14
Positioner mechanism ....................................................................15
Control cabinet ...............................................................................16
Pitch control and position indication ...............................................16
MONITORING AND ALARMS..............................................................17
FLOW MEASUREMENT AND STALL PROTECTION SYSTEM..........19
FAN VOLUME FLOW AND TOTAL PRESSURE RISE:.......................22

Control Criteria, Stall protection:.....................................................22
V5003837 SIPAT FläktWoods

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SPECIFICATION KEY

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GENERAL
The axial-flow PFS (Propeller Fan with Single impellers) fan is used
as a Forced Draft fan. Main component parts of the fan are:
1. Inlet box
2. Impeller
3. Impeller casing
4. Diffuser
The electric motor is connected to the main shaft via a steel coupling.
Figure 1. Axial-flow fan type PFS
Continuously adjustable impeller blades utilize control of the gas flow

while the fan is in operation.
A sensor registers the flow (actual value) at the location selected and
transmits a corresponding signal to a regulator. The regulator is set for
the flow required (set value). If actual and set values do not coincide,
a deviation signal is transmitted to the control electronics causing it to
actuate the proportional valve. Thus the blade pitch is changed to
make the actual value coincide with the set value.

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Figure 2 illustrates how the pitch control system is employed.
Figure 2. Overview, pitch control system
The hydraulic unit supplies oil at a constant pressure to the

proportional valve. From the proportional valve the hydraulic oil is
led into the hydraulic cylinder that actuates the mechanical pitch
control system, thereby changing the angle of the impeller blades.
This change causes the flow to change.
When the fan is in operation the main shaft-bearing assembly as well

as the motor bearings are lubricated by circulating-oil supplied by the
hydraulic unit. Sensors are fitted in the bearings to facilitate the
monitoring of temperature and vibrations.

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DESIGN AND FUNCTION

General
Figure 3 shows the PFS fan and its component parts.
Figure 3. Main Component parts, PFS fan
1. Flexible connection, inlet 7. Main bearing assembly

2. Inlet box 8. Impeller
3. Impeller casing 9. Control mechanism
4. Diffuser 10. Hydraulic unit
5. Flexible connection, outlet 11. Control cabinet
6. Motor 12. Shaft coupling
All static parts of the fan, e.g. inlet box, impeller casing and diffuser
are of fabricated design and fastened together with bolts. Moving
parts are of fabricated design and castings. The impeller blades are
made of sand-cast aluminium whereas other parts are fabricated
mainly in steel and spheroid graphite cast iron.
Access doors are provided for the purpose of inspection and service of
the fan. Lifting eyes and rollers are fitted to facilitate maintenance.
These devices help separating the diffuser from the impeller casing.

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The entire fan installation is insulated with mineral wool to reduce

noise or heat radiation from the fan.
Inlet box
As shown in figure 4, the inlet box is designed to distribute the
airflow evenly over the entire impeller. This is accomplished by
means of the aerodynamic shape of the box outlet and the guide vanes
fitted in the same outlet. Providing support for the bearing assembly
the inlet box also transfers shaft forces to the foundation.
Access doors facilitate inspection and service. A lifting eye fitted in
the central part of the inlet box is intended as a lifting attachment in
conjunction with installation or removal of the bearing assembly.
Figure 4. Inlet box
1. Guide vanes
2. Access doors
Impeller casing
The impeller is enclosed in a protective casing, see figure 5. A bolted
access door is provided to facilitate replacement of impeller blades.
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Inside surfaces of the casings are machined in order to achieve a

minimum of impeller blade tip clearance.
Figure 5. Impeller casing
1. Lifting lug
2. Access door

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Main Bearing Assembly
Motor
end
Impeller
end
Figure 6. Main Bearing Assembly
1. Pilot bearing end

2. Non locating bearing end
3. Bearing housing
4. Main shaft
The shaft onto which the impeller is fitted is supported by two anti
friction bearings in a common housing, see figure 6. The bearing
nearest to the motor, the pilot bearing, which is a Paired single row
taper roller bearings, takes up both thrust and radial forces while the
other bearing, the non-locating bearing which is a Spherical roller
bearing, takes up radial forces only. The bearings are fitted directly
onto the shaft.
The bearings are lubricated by forced oil lubrication from a common

lubrication and hydraulic system.
Vibration sensors are fitted on both bearings. The sensors are

connected to a monitor located in the control cabinet adjacent to the
fan. The monitor is equipped with relay outputs for alarm/trip circuits
set at two different levels.
Bearing temperature is monitored by means of temperature sensors on

both bearings. The sensors are wired to the same control cabinet.

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The fan shaft is connected to the motor shaft via a steel coupling.
Impeller
Figure 7. Impeller
1. Hub 9. Blade shaft

2. Hub rim 10. Control disc
3. Fairing 11. Control arm
4. Hub plate 12. Control stud
5. Blade 13. Hydraulic cylinder
6. Blade bearing 14. Impeller disc
7. Blade holder
8. Bearing cap

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Figure 7 shows the design and main components of the impeller of the
PFS-fan.
− The hub is secured onto the shaft by means of a key and a

retaining washer
− The hub-rim and the faring are attached via the hub plate to
the hub.
− The hub rim carries the blade and blade bearing assembly
(Blade holder, Blade bearing, Bearing cap) via the blade
shaft
− The control disc slides on the hub. The control arms are
attached to the control disk. The outer end of each control
arm is connected to the respective blade holder by means of
an eccentrically supported control stud. The control stud
turns the bearing assembly thus varying the blade pitch angle
− The control mechanism is mounted to the control disc and

driven by a hydraulic cylinder
− The impeller disc protects the internal moving parts of the

impeller

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Diffuser
The purpose of the diffuser, shown in figure 9, is to obtain an even
and undisturbed reduction of the gas velocity. The guide vanes and
the gradually increasing outer diameter of the diffuser accomplish
this. The central part of the diffuser contains a rotating union for the
pitch control system and a linkage system, which transfers the motion
of the control mechanism to an electrical position sensor.
6
5
Figure 9. Diffuser
1. Guide vanes 6. Foot with roller

2. Bracing 7. Positioner
3. Centre core 8. Rotating union
4. Access door
5. Oil lead-through

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Tool box
A steel metal toolbox with all necessary special tools is supplied for
maintenance of the equipment. See Drawing entitled Tool Box (part
7).

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Pitch control system

Design
Figure 10 is an overview of the pitch control system and its main component
parts:
Figure 10. Pitch control system
1. Hydraulic unit (See Part 5 Component descriptions Hydraulic Unit).

2. Hydraulic piping between the hydraulic unit and the control
mechanism
3. Rotating Union
4. Positioner mechanism with limit switches
5. Control cabinet containing the control equipment
In addition to the above-mentioned items the system includes

equipment for position indication and alarm, and a sensor and a
regulator for control signals from the boiler. Since the customer
supplies this equipment no detailed description is contained in this
manual.

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Control mechanism
Figure 11 shows the control mechanism and its main component
parts:
1. Rotating union
2. Four control rods
3. Double-acting hydraulic cylinder
4. Piston rod flange.
5. Control disc
Figure 11. Control mechanism
The positioning of the control mechanism is determined by changing

the direction of the hydraulic oil, which reaches the piston rod by way
of the rotating union. In the center of the piston rod are two passages
from which the oil is directed into the hydraulic cylinder via two ports
on the piston rod; one port each side of the piston.
One end of the piston rod is attached to the control disk by means of a
flange and four control rods.

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Positioner mechanism
The positioner mechanism, shown in figure 12, consists mainly of a
linkage system and a control box.
Rotating union
Feed back box
Turning shaft
Feed back transmiter
Limit switches
Figure 12. Positioner mechanism
The linkage system transfers the axial motion of the control

mechanism to a capacitive position sensor in the control box. The box
also contains four limit switches that are actuated when the control
mechanism reaches the respective end position. Two of the switches
are for min. blade angle and the other two for max. blade angle. One
of each switch is spare.

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Control cabinet
The control cabinet contains the electronic equipment of the pitch
control system. See also Part 8 Electrical drawings.
Pitch control and position indication

Conditions:
a) The fan and the hydraulic unit are in operation.

b) The fan flow is too low.
A signal from a sensor to the regulator indicates that the airflow is too
low. This means that the signal for required pitch setting (command
value) from the regulator to the amplifier is changed.
The amplifier compares the signal for required pitch setting with the
signal for actual pitch setting (actual value) obtained from the position
transducer. The comparison is made with respect to both magnitude
and direction to determine how much the blades should be turned and
in which direction. The resulting output from the amplifier is a control
signal to the proportional valve.
The hydraulic cylinder is fixed mounted to the impeller hub and the
piston rod to the control mechanism; see Fig 11. One control arm per
blade is mounted to the control disc and is via a spherical bearing
connected to the blade holder. Axial motion of the piston is than
transferred to the impeller blades. Via the rotating union and the
mechanical linkage system the motion is also transferred to the
positioner.
It is the linear motion of the control arms that is transformed into a

rotary motion of the impeller blades. In this example the angle of the
blades will increase which means that the airflow through the fan will
increase.
The axial motion of the position adjustment linkage is transferred to

the position transmitter causing a change of sensor capacitance and,
consequently, a change of the actual-value signal from the positioner.
The signal is transmitted to the amplifier where the comparison
between actual and command-value signals is continuously repeated.
The difference between the signals is gradually reduced causing the
control signal from the amplifier to decrease. As a result, the motion
of the impeller blades will slow as they approach the desired blade
pitch. When the actual and command values coincide there will be no
control signal from the amplifier and the proportional valve will close.

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MONITORING AND ALARMS

All signals are DCS logic controlled.
The hydraulic unit starts from the control panel. The start command
remains ON until all pressure switches close.
The following events take place on power up:
• The pump motor starts
• Oil is pumped through one of the main filters
When the oil pressure from the pump exceeds 1,5 MPa the pressure
switch closes. In a similar way the lubrication oil pressure switch will
close when the oil pressure to the bearings exceeds 0,15 MPa.
The hydraulic unit now supplies oil under constant pressure to the
proportional valve of the control system and to the fan bearings. The
following functions are continually monitored:
• Filter differential pressure
• Pump pressure
• Bearing supply pressure
• Oil temperature and level in the tank
If any of the above switches opens, an alarm will be initiated. The

cause and effect of the various alarms are described below.
High filter differential pressure
The pressure switches will switch if the pressure drop across the main
filter exceeds the pre-set value. The alarm ”High differential pressure”
will then be initiated and the standby pump will start and direct the oil
through the standby filter. Both pumps/filter lines are equal and one is
standby for the other. It is recommended that the clogged filter be
changed at the first convenient opportunity. A filter can be changed
with the standby pump in operation.
Main pump unserviceable
The pressure switch will trip if the output oil pressure from the main
pump drops below 1,5 MPa. The alarm, ”Standby pump engaged”,
will then be activated. Following a short delay, which is incorporated
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in the pump start-up equipment, the standby pump will start and the
switch will return to its normal condition. The pump start-up
equipment will keep the standby pump in operation and the main
pump will be disengaged.
Low lubricant pressure
When the lubricant pressure drops below 0,15 MPa the pressure
switch will trip causing the alarm ”Low lubricant pressure” and the
proportional valve will shut off the oil-flow to the control mechanism.
In order to secure lubrication of the bearings while the fault is
rectified or the fan is shut down, all available oil-flow is directed to
the bearings via the overflow valve and the oil cooler.
High oil temperature or low level
If the oil temperature becomes >70 °C, the temperature switch will
open and initiate an alarm.
If the oil level in tank is too low, the switch will open and trigg an
alarm. At the same time the proportional valve shuts off the oil-flow
to the control mechanism using the same process as when the
lubricant pressure is too low. The start of the main motor is
interlocked if any of these alarms are active.
Stall protection system
The concept of this system is based on two steps. The first is a stall
warning line which is designed to send a warning signal to the main
control system, alerting when the evaluated duty point is above the
stall warning line and initiating the fan blade angle to be decreased.
These adjustments must be made within a time frame suitable for the
system.
The second step is a stall trip line. This is an automatic shutdown to

prevent damage to the fan. This shutdown occurs when the duty point
is on or above the stall trip line.

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FLOW MEASUREMENT AND STALL

PROTECTION SYSTEM.
Principal sketch:
Equipment and parameters:
dPT1-dPT3, PT0: Pressure transmitters (output signal 4-20 mA).

TT1: Temperature transmitter (output signal 4-20 mA).
PT0(atmospheric pressure) may be common for more than one fan.
dPT1-dPT3 are placed on each fan.
Basic data:
ρ0 (kg/m³)= gas density at 0°C and 1013mbar (data typical for the used gas, by client.
For FD-fan ρ0=1.293 kg/m³ are being used)
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Measured data:
pa (mbar)= atmospheric pressure
ps1 (Pa) = static pressure (relative to atmospheric pressure) at section 1, fan inlet (from
transmitter dPT1); Fan with inlet box.
ps3 (Pa) = static pressure (relative to atmospheric pressure) at section 3, fan diffuser
outlet (from transmitter dPT3)
∆p (Pa) = differential pressure between section 1 and 2 (from transmitter dPT2)
tgas (°C) = gas temperature (from transmitter TT1)
Calculated data:
ρ (kg/m³)= gas density at fan inlet
Q(m³/s) = Volume flow
Pt1 (Pa) = total pressure at section 1, fan inlet
Pt3 (Pa) = total pressure at section 3, fan outlet
Pt (Pa) = total pressure rise over the fan
Constants:
A1 = cross sectional area fan inlet (m2).
A2 = cross sectional area upstream fan impeller (m2)
A3 = cross sectional area fan outlet (m2)
C= Geometrical constant for volume flow calculation.
C= 1/SQRT((A2)-2- (A1)-2),
Fan volume flow and total pressure rise:
Take readings of tgas, pa, ps1, ps3, ∆p.
Calculations:
ρ= ρ0*((ps1+100*pa)/101325)*(273/(273+tgas))
Volume flow:
Flow = Q = Ckal*C*SQRT(2*∆p/ρ), where Ckal = Calibration constant for the actual

fan installation. Ckal =1 originally, finally established by site measurement.
Total pressure:
Pt1 = ps1 +ρ/2*(Q/A1)^2,
Pt3 = ps3 +ρ/2*(Q/A3)^2
Total pressure = Pt = 1.2/ρ*(Pt3-Pt1)

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Data for PFS 280-112, FD-fan:
A1(m²) 10.00
A2(m²) 5.25
A3(m²) 8.60
ρ0(kg/m³) 1.293
pa(mbar) To be measured (PT0)
ps1(Pa) To be measured (dPT1)
∆P(Pa) To be measured (dPT2)
ps3(Pa) To be measured (dPT3)
tgas(°C) To be measured (TT1)
ρ(kg/m³) ρ0*((ps1+100*pa)/101325)*(273/(273+tgas))
Ckal 1
Flow(m³/s)=Q Ckal*6.17*SQRT(2*∆p/ρ)
Pt3(Pa) ps3 +ρ/2*(Q/A3)^2
Pt1(Pa) ps1 +ρ/2*(Q/A1)^2
Pt(Pa) 1.2/ρ*(Pt3-Pt1)

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CONTROL CRITERIA, STALL PROTECTION:
Stall warning and trip lines
The evaluated duty point (volume flow, Q and total pressure rise, Pt) can be
compared to a stall warning line and a stall trip line.
If the evaluated duty point is above the stall warning line the fan blade pitch have to be
decreased by means of adjusting the duty point of the boiler. The adjustments have to
be made within a time frame which is suitable for the boiler.
If the duty point (Q,Pt) for some reason is on or above the stall trip line the fan
immediately have to be shut down.
Data for these lines are presented as polynomial equations at density 1.2 kg/m³:
Stall warning line :

Pt = 0.000000806148*Flow^4 -0.00069039726*Flow^3
+0.209254523716*Flow^2 -20.602094333436*Flow + 4093.84134825554
Stall trip line :
Pt = 0.000000789696*Flow^4 -0.00067630752*Flow^3 +
0.204984023232*Flow^2 -20.181643428672*Flow + 4010.29356563808
PFS- 280- 112- UG Speed: 990 RPM Density: 1.200 kg/m³
PF UG Hub Ratio 0.39811
6000 Stall Trip line

Total pressure, Pa
TB1
Stall line Stall Warning line
5000
Heater
Out TB2
BMCR
4000 60% 100%

80%
90
3000 50% 89
86
83
2000 81 83°
76
80°
71
61 75°
1000 70°
51
41 65°
31 60°
35° 40° 45° 50° 55°
0
0 100 200 300 400 500 600
Flow, m³/s

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Operation & Maintenance Manual 1

FORCED DRAFT FAN BBU Code 11HLB FA, 12HLB FA

DESIGN AND FUNCTION......................................................................5

MONITORING AND ALARMS..............................................................17

FLOW MEASUREMENT AND STALL PROTECTION SYSTEM..........19

FAN VOLUME FLOW AND TOTAL PRESSURE RISE:.......................22

V5003837 SIPAT FläktWoods

V5003837 SIPAT FläktWoods

Figure 1. Axial-flow fan type PFS

Continuously adjustable impeller blades utilize control of the gas flow

V5003837 SIPAT FläktWoods

Figure 2 illustrates how the pitch control system is employed.

Figure 2. Overview, pitch control system

The hydraulic unit supplies oil at a constant pressure to the

When the fan is in operation the main shaft-bearing assembly as well

V5003837 SIPAT FläktWoods

DESIGN AND FUNCTION

Figure 3. Main Component parts, PFS fan

1. Flexible connection, inlet 7. Main bearing assembly

V5003837 SIPAT FläktWoods

The entire fan installation is insulated with mineral wool to reduce

Figure 4. Inlet box

Inside surfaces of the casings are machined in order to achieve a

Figure 5. Impeller casing

V5003837 SIPAT FläktWoods

Main Bearing Assembly

Figure 6. Main Bearing Assembly

1. Pilot bearing end

The bearings are lubricated by forced oil lubrication from a common

Vibration sensors are fitted on both bearings. The sensors are

Bearing temperature is monitored by means of temperature sensors on

V5003837 SIPAT FläktWoods

1. Hub 9. Blade shaft

V5003837 SIPAT FläktWoods

− The hub is secured onto the shaft by means of a key and a

− The control mechanism is mounted to the control disc and

− The impeller disc protects the internal moving parts of the

V5003837 SIPAT FläktWoods

1. Guide vanes 6. Foot with roller

V5003837 SIPAT FläktWoods

V5003837 SIPAT FläktWoods

Pitch control system

Figure 10. Pitch control system

1. Hydraulic unit (See Part 5 Component descriptions Hydraulic Unit).

In addition to the above-mentioned items the system includes

V5003837 SIPAT FläktWoods

Figure 11. Control mechanism

The positioning of the control mechanism is determined by changing

V5003837 SIPAT FläktWoods

Figure 12. Positioner mechanism

The linkage system transfers the axial motion of the control

V5003837 SIPAT FläktWoods

Pitch control and position indication

a) The fan and the hydraulic unit are in operation.

It is the linear motion of the control arms that is transformed into a

The axial motion of the position adjustment linkage is transferred to

V5003837 SIPAT FläktWoods

MONITORING AND ALARMS

The following events take place on power up:

• The pump motor starts

• Oil is pumped through one of the main filters

• Filter differential pressure

• Bearing supply pressure

Flow = Q = CkalCSQRT(2*∆p/ρ), where Ckal = Calibration constant for the actual