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PA FAN Erection and O&M (2X60%)

PA FAN GENERAL VIEW


1. Inlet box 2. Fan motor 3. Impeller casings 4. Intermediate section 5. Diffuser

GENERAL ASSEMBLY

1. 2. 3. 4. 5. 6.

Inlet Box Impeller casing 1 Intermediate section Shaft coupling hubs Impeller 1 Impeller 2

7. Impeller casing 2 8. Diffuser 9. Fan Motor 10. Floating Shaft 11. Coupling guard

Erection procedure
1. Clean up the concrete foundation and the surrounding area. 2. Ensure that the holes for the foundation bolts are clean and free from water and foreign objects.

Inlet Box
3. Lift and move the inlet box assembly into position above the foundation. 4. Match the Fan center line & correct level.

Impeller Casings 1
5. Fix the Impeller casing 1 with Inlet box.

Intermediate Section.
6. Put the foundation bolts in the intended holes in the footplates of the intermediate section. 7. Mount and fasten the impeller casing 1 ( lower part) preliminary to the intermediate section.

Coupling
8. Put the coupling on the main shaft of the rotor assembly

Rotor assembly
9. Lift the rotor assembly and put in position in the intermediate section. 10. Support the impeller 1 in elevated position in the intermediate section by hydraulic jack

11. Fasten the bearing housing of the locating bearing preliminary to the intermediate section. 12. Mount and fasten two impeller blades in horizontal position on impeller 1 and check the clearance between impeller blade and lower casing.
13. Elevate the rotor assembly at the inlet box side to fit the bearing pedestal in the inlet box..

14. Move the intermediate section with rotor assembly towards the inlet box till the flanges of inlet cabinet and Impeller casing touches.

15. Lower the hydraulic jack at impeller 1

16. Adjust the intermediate section footplates on the foundation and put down the intermediate section assembly on the foundation.

17. When the alignment is satisfactory, fit the foundation bolts with nuts on both sides of the foot plate.

18. Mount and fasten the remaining impeller blades on impeller 1 and impeller 2.

Impeller blade assembly


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Blade Blade bolt Seal ring Bearing cap Locking screw Blade shaft O-ring Locking cone Bearing race(with smaller hole) Ball set with ball retainer Bearing race(with larger hole) Blade holder Regulating disc

. Impeller blade with ball bearing

19. Mounting impeller casings and upper part of the intermediate section

20. Adjust the impeller casings to achieve valid tip clearances.

Diffuser
21. Install main motor, flying shaft and coupling. 22. Verify the alignment of the complete assembly. 23. Lift and move the diffuser into position onto the foundation. 24. Move the diffuser towards the fan casing. 25. Verify the position of the diffuser and adjust if necessary. 26. Fasten the diffuser to the impeller casing

PA FAN erection.

Blade pitch control system


A control system that continuously adjusts the blade pitch, controls the air flow while the fan is operating. To maintain the desired air flow, the DCS (Distributed Control System) sends a signal to the control system. The actual pressure is transmitted to the DCS where it is compared to set points. If the pressure moves outside those set points a signal is transmitted to the control cabinet where the present blade angel is compared to the required blade angel. If the values do not coincide, a deviation signal is sent to the proportional valve, sending hydraulic oil to the proper side of the hydraulic inside the second stage impeller. The movement of the hydraulic changes the blade angel in both impellers. When the actual blade angel is equal to the required blade angel the hydraulic stops moving.

Pitch Control System


1. Combined oil unit 2. Hydraulic piping 3. Rotating union and control mechanism 4. Feedback mechanism with limit switches 5. Control cabinet
The positioning of the impeller blades is determined by changing the direction of the hydraulic oil, which reaches the piston rod (pos 2) by way of the rotating union (pos 1). In the centre of the piston rod there are two lines (pos 5) from which the oil is directed into the hydraulic cylinder (pos 3) via two ports, one on each side of the piston. One end of the piston rod is attached to the control disc (pos 7) by means of a flange (pos 4) and four control rods (pos 6).

FAN type Codification

Start-up Procedure
Proceed as follows: 1. Ensure that all measures on the fan motor are carried out according to the motor manual. 2. Initiate the start sequence for the fan from the DCS / Control room. Start sequence: combined oil unit start outlet damper close blade pitch set to minimum 30 min. delay due to the conditions main motor start outlet damper open blade pitch set to achieve desired pressure blade pitch set to automatic mode 3. Ensure that the inlet and outlet dampers are open. 4. Ensure that the combined oil unit has started. 5. Enter date and time of first start-up in the commissioning report. 6. Ensure that the fan motor is up to operating speed within stipulated time. For stipulated time, see the motor manual. 7. Ensure that no alarms are active.

Monitoring and Alarms


Particular Alarm
<30 kg/cm2

Trip Blade lock in current position


Blade lock in current position

Hydraulic pressure low Oil level low

<0.2 mtr.

Oil filter differential pressure high


(Pitch Control) Lubrication oil pressure low Oil flow to "Drive side bearing" fan low Oil flow, radial to "Non-Drive side" fan low Oil tank temperature high Fan bearing temperature high Fan bearing vibration high

>5 Bar
<1.5 kg/cm2 <0.7 l/min <0.5 l/min >70 C >95 C >4.5 mm/s RMS

--------------------------------------->105 C. >7.1 mm/s RMS.

Maintenance Schedule

FD FAN Erection and O&M Axial Type (single stage) (2X60%)

Fan data sheet


S. No.
1

Description

Unit

Value

Flow rate
Temperature Density Inlet pressure Pressure rise Outlet static pressure Power ratting Efficiency Speed

m3/s
deg C kg/m3 pa pa pa KW % RPM

171.30
48 1.054 -188 4142 3953 1025 84 1490

Fan Type Code Interpretation

Assembly drawing
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Flexible connection, Inlet Inlet box Impeller casing Diffuser Flexible connection , outlet Motor and motor stand Main bearing assembly Impeller Control mechanism Combined oil unit Control cabinet Coupling Transition

Erection procedure
1. Lift and move the inlet box assembly into position above the foundation. 2. Put the foundation bolts in the intended holes in the footplates of the inlet box. 3. Adjust the inlet box footplates on the Foundation and put down the inlet box assembly on the foundation. 4. Adjust the inlet box footplates on the foundation and put down the inlet box assembly on the foundation. 5. Adjust the flange of the inlet box (facing the impeller casing) in the vertical position.

Verify the vertical position of the plate for attachment of the bearing flange. Put the foundation bolts in the intended holes in the motor stand footplates. Adjust the motor stand footplates on the foundation and put down the motor stand assembly on the foundation. Attach the flange seal (glass fiber) on the inlet box flange.

Location of flange

Shaft erection
Put the coupling on the shaft end of the main bearing assembly. Install the lubricant fittings and the electrical connections for the temperature and the vibration monitoring system.

Lift the bearing assembly into the inlet box. Fit and fasten preliminary the bearing assembly to the flange in the inlet box on the pedestal and on the motor stand. Verify that the centre line of the shaft is aligned with the centre line of the fan assembly (including motor) and that it is horizontal (tolerance 10 mm).

When the alignment is satisfactory, fasten the foundation bolts to the inlet box and the motor stand footplates. Perform the pre-grouting of the foundation bolts for the inlet box and the motor stand. When the grouting has hardened, lower the nuts under the foot plate about 10-15 mm and tighten the upper nuts. Finally re-check the alignment and adjust if necessary.

Fit the seal ring onto the inlet box, concentric to the shaft. Fit the lifting eyes onto the impeller as shown in Figure 9. Lift the impeller and fit it onto the shaft using the mounting tools in the toolbox. Secure the impeller with the shaft end plate. Re-check the alignment. Mount and fasten the impeller blades on impeller. 1. Seal ring 2. Lifting eyes 3. Shaft 4. Impeller casing

Install the electric motor. Fasten the foundation bolts to the inlet box and the motor stand. Mount and fasten the lower and upper part of the impeller casing preliminary to the inlet box. Remove the transport support bars. Adjust the impeller casing to achieve valid tip clearances.

Fasten the lower and upper part of impeller casing to the inlet box Perform the final check of the tip clearances and enter measurements in the tip clearance report. Perform the final grouting of the foundation bolts for the inlet box and the motor stand. Fasten the main bearing assembly to the flange in the inlet box on the pedestal and on the motor stand. Complete the lubricating tube installation to the bearing assembly Verify the position of the diffuser and adjust if necessary.

Complete assembly of FD FAN

Oil Flushing procedure


Make a temporary by-pass for the rotating union inside the diffuser, by connecting both supply lines to the return line. Make a temporary by-pass of the lubrication, i.e. by-pass the main bearings. Start up the oil unit (one pump only). Verify that the motor is running in the direction of the arrow on the motor and that the pump is giving pressure. Flush the system for 5 hours. Stop the oil unit and turn the flush plate on the oil unit 180 (changing the flush direction) and flush for another 5 hours. When the flushing is complete, stop the oil unit and re-connect the supply lines and return line to the bearing housing. Disconnect the temporary by-pass hose. Remove the transport protection (screws) from the hydraulic cylinder.

Secure the rotating union in a vise and fit the three hoses to the rotating union. Fit the rotating union onto the hydraulic cylinder (control mechanism). Connect the hoses to the hydraulic supply and return pipes inside the diffuser. Change the oil in the oil unit. Change the oil filters. Fit the proportional valve instead of the flushing plate on the oil unit.

1. Rotating union 2. Pressure hoses 3. Return hose

Normal Start-up Procedure Start-up of Fan 2 when Fan 1 in Operation


1. Fan 1: Set the control system in manual mode for the running fan 2. Fan 2: Initiate the start sequence for the fan from the DCS / Control room. Observe the 30 min. delay of fan start due to the condition in the start sequence. 3. Fan 2: Keep the outlet damper closed. 4. Fan 2: Ensure that the combined oil unit has started. 5. Fan 2: Keep the control system in manual mode for the starting fan. 6. Fan 2: Set blade angle to "Minimum blade pitch". 7. Fan 1: Set the blade angle to 40% of normal operation condition or lower. 8. Fan 2: Open the outlet damper. 9. Fan 2: Increase the pitch for the fan until Fan 2 has the same pitch as Fan 1. 10. Fan 2: When the fan reaches the same blade angle (pitch) as Fan 1 (within 2%) the control system can be switched to automatic mode. 11. Fan 1: Set the control system in manual mode. 12. Fan 1 and Fan 2: Adjust the pitch control to the desired parameter.

Normal Shut-down Procedure Stop of Fan 2 and Keep Fan 1 in Operation


1. Fan 2: Set blade angle to "Minimum blade pitch". 2. Fan 2: Close the outlet damper. 3. Fan 2: Initiate stop sequence for the fan from the DCS / Control room. Observe the 30 min. delay for stop of the combined oil unit due to the condition in the stop sequence. 4. Fan 2: Ensure that the inlet and outlet dampers are closed.

ID FAN Erection and O&M Centrifugal double suction (2X60%)

ID FAN FOUNDATION

Spring location (Top view)

Spring size & load data

Fan data sheet


S. No.
1

Description Flow rate Gas Temperature at Fan inlet

Unit m3/s deg C

Design load 265.84 152

Static pressure inlet


Static pressure outlet Speed Mechanical design temp. Power ratting Fixed bearing Free Bearing Bearing housing type

mmWC
mmWC RPM C KW

-300
10 960 200 1042 SKF 22234 cc/w33/c3 SKF 22234 cc/w33/c3 SOFN 234 BF SOFN 234 BL

Erection procedure
Ensure that the concrete foundation has been made at site as per general assembly drawing. Check foundation for evenness , and its different levels. Mark centre lines of fan and foundation pockets on the foundation. Place lower part of casing and base frame. Fasten the foundation bolts with base frame. Place the bearing with impeller shaft on the base frame and bolt with it. Check the horizontal level of bearing and center to center & diagonal distance of bearing. Bolt the bottom half of the casing with inlet box. Install top casing and inlet cone. Check the center line of casing, shaft and impeller axis with respect to base frame and bearing pedestals.

Fix the inlet damper and flexible connections. Fix the coupling on the impeller and motor fan shaft Align the motor with respect to Fan shaft. Fix cooling disc with cover, shaft cover and coupling cover. After completing installation and alignment ,final grouting of the foundation bolts shall be carried out.

Alarm and Trip


Particular Alarm Trip

Fan bearing temperature high

>100 C

>110 C.

Fan bearing vibration high

>18 mm/s RMS

>20 mm/s RMS.

Thank you