Axial Reaction Fan - Double Stage: Operation & Maintenance Manual

AXIAL REACTION FAN – DOUBLE STAGE
-1– OPERATION & MAINTENANCE MANUAL

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 with out 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/rn.
• Proper clearance and gap at free supports.
• The impeller blades of each impeller 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.
• For the given blade position, the blades are Identical in both Lie 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 marks on the coupling parts.
• Tightness 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 return 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.
CAUTION :
NEVER OPERATE THE SERVOMOTOR WITH OUT CONTROL OIL FLOW.
• Proper connection of inlet and outlet of lube oil piping to the main bearings.
• Proper connection of oil pipes to the oil head assembly.
• There is no pre-load in oil head assembly introduced by flexible hoses.
• The servomotor stroke length is maintained as per the drawing and mechanically
stopped.
• The independent operation timing of actuator from zero to 100 % and vice versa is
more than the servomotor timing (From full close to full open and vice versa).
• 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 Lub oil system.
• 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
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.

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 PERMISSIVE:
(a) Control oil pressure = > 8 ata
(b) Lub oil pressure = > 0.8 ata
• Impeller blades in minimum position

• Discharge dampers full close
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 ALARM TRIP

FAN BEARING TEMPERATURE =/> 95 DEG C =/> 105 DEG C
FAN BEARING VIBRATION (VEL – PEAK) =/>6.3 MM/S =/>12.6 MM/S
DIFFERENTIAL PRESSURE ACROSS OIL FILTER =/> 0.6 BAR ****
LUB OIL PRESSURE =/< 0.4 BAR ****
CONTROL OIL PRESSURE =/< 6.0 BAR ****
OIL LEVEL IN THE TANK < 50 % ****
REFER LOGIC DIAGRAM FOR ADDITIONAL INTERLOCKS.

STARTING OF THE FAN:
Ensure that all protections and interlocks are functioning properly.

Start the motor. Check for correct direction of rotat1on of motor. This fan should rotate in Anti-
clockwise while viewing from motor.
Test run the motor for 8 hours. If found satisfactory, couple Fan with 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.
CAUTION: OPERATION OF THE FAN WITH DISCHARGE DAMPER FULLY CLOSED IS

NOT PERMISSIBLE.
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.

CHECKS DURING NORMAL OPERATION OF THE FAN
During continuos 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 :
• Control oil pressure 12 bar

• Lub. oil pressure 1.5 bar
• Bearing temperature 105 deg c
• Maximum oil temperature 70 Deg C
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.
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 little1 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 b1ades :

During trial operation, a check should be effected. If the machine is operated with dampers 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 blade could then be achieved by setting limits at the
external actuator for actuation of the impeller blades as well as the hydraulic servomotor.
PARALLEL OPERATION OF PA (AP TYPE) FANS:

The axial reaction (AP) fans are given normally for FD and PA application of 500 MW/ 250 MW
boiler. 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 and
Two numbers of PA fans.
CHARACTERISTIC CURVE OF THE PA 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 (-
400), (-360), (-280), (-120), (+40), (+80), (+120) and (+160) 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.

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” m^3/ 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” m^3/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 deliver 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” m^3/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.
- 10 – OPERATION & MAINTENANCE MANUAL

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).
Fig – 2

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 than
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.
EFFECT ON FAN PERFORMANCE 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
control 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 % 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 tripping 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 60% - 50%
by closing the blades in any one fan (Say Fan – A). Close the blade fully in other fan (Say Fan –
B) and keep running it. Now, the Fan A in which the blade position is 60% - 50% 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 CONTINIOUSLY.
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 servomotor operating time is less than the operating time of the actuator in de-coupled
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 control room reading and are identical in both fans
• There is no mechanical backlash in the linkages of Servomotor – 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 conservation is required for a shutdown of upto two weeks. In case of standstill period
upto 12 months, the following may be adopted.
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.
The compound/oil shall confirm to the following specifications:
Specific Gravity 0.850
Flash point 40oC(MIN)
Film thickness at 25oC 10 microns
Film description Thin transparent dry film
Non-volume content 40-48%
Coverage at 25o C 12 Sq.M/Liter
100% Humidity at 50o C 30 Days (mm)
Remove the preservative prior to commissioning, using suitable solvent like Kerosene / Alkali wash
/ Steam blow / Lubricating oil.

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 A WEEK:
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:
Blow the rotor with compressed air to remove hard deposits on the blades.
ONCE IN TWO WEEKS:
Run the Fan for about half an hour and ensure smooth operation.

4.3 VIBRATION AND SAFE RUNNING OF FAN
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 peak 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 PER OPERATING
VDI 2056 INSTRUCTION
Just Unsatis-
GOOD Satisfactory ALARM TRIP
Satisfactory factory
At &
Upto Above Upto Above Upto Above At
Above
Velocity(Pk) in
2.54 2.54 6.3 6.3 15.55 15.55 6.3 12.7
mm/sà
G 540
80 80 200 200 500 500 200 400
R rpm
O 740
Displacement 64 64 160 160 400 400 160 320
rpm
U (Pk-Pk)
990
P in microns 48 48 120 120 300 300 120 240
rpm
For
1480
Speed = 32 32 80 80 200 200 80 160
“G” rpm
2980
16 16 40 40 100 100 40 80
rpm
Velocity(Pk) in
3.96 3.96 9.9 9.9 25.4 25.4 9.9 19.8
mm/sà
G 540
126 126 320 320 800 800 320 640
R rpm
O 740
Displacement 100 100 250 250 640 640 250 500
rpm
U (Pk-Pk)
990
P in microns 75 75 188 480 480 480 188 375
rpm
For
1480
Speed = 50 50 125 125 320 320 125 250
“T” rpm
2980
25 25 63 63 160 160 63 125
rpm

4.4 OPERATIONAL PROBLEMS CAUSES AND REMEDIES
Sl.No. Problems Probable cause Remedial Action
1 Frequent drop in oil Leak in the oil system . Inspect and rectify leaks.
level in the tank
Damaged shaft seals at Dismantle bearing assembly and
main bearings. change seals.
Damaged seals at Dismantle servomotor and replace

servomotor. seals.
2 Water contamination Leakage in oil cooler. Analyse oil for water

in oil contamination. Conduct hydraulic
test on the oil cooler tubes and
rectify leaking tubes.

3 Drop in oil pressure. Filter element clogged. Check for pressure drop across
filter. Changeover to standby filter,
clean the clogged filter.
Leakage in oil system Check for the leakage in pipelines

and ensure leak free joints.
Check for flexible hose damages
and replace it, if necessary.
Change over to standby cooler end
clean the defective one.
High oil temp. Check oil level in the oil tank. Fill
oil, if necessary. Ensure for no
No flow through return leaks through the oil tank. Change
oil pipe (check through over filter & clean filter elements.
sight glasses). Check the pump suction strainer
and clean.
Change the over flow valve and
reset it.
Damaged over flow
valve.

4 Large pressure Improper setting of over Check setting of over flow valve,
fluctuation in the flow valve. open fully. Close the bypass valve,
control oil circuit. gradually close the over flow valve
till the required pressure Is ach-
ieved.
Pressure reservoir Check for rated pressure fill
nitrogen, if necessary.
5 Control Slide Jamming No oil to control slide. Dismount the servomotor
assembly. Dismount the control
slide and check control slide,
control rod and piston for con-
centricity and oil flow.
6 High bearing Oil temperature in oil Check oil cooler for choking.
temperature tank too high.
Oil too viscous. Change, use specified oil.
Bearing damages. Replace the bearings.
Bearing clearance too Check bearing clearance and
small. replace with proper bearing.
Lubrication failure. Check the oil flow regulator for its
proper functioning.

7 Unquiet running.
Unbalance due to Remove deposits.
deposits on rotor.
Bearing clearance too Change the bearings if required.

large.
Shutdown the Fan immediately.
Blades touching impeller Check blades for cracks. Adjust
casing. impeller casing for achieving the
recommended clearances.
Check and maintain the clearance

Rotating and stationary between rotating and static parts
parts touching

8 Fan absorbs full load Impeller blades in full Stop the Fan and examine blade
current immediately open position position. If it is not in full close
after starting. condition reset the Impeller blades.
9 Power absorption of Fork lever on drive shaft Tighten fork lever. Set blade
the Fan cannot be loose. position. Check actuating drive and
altered tighten fixing bolts.
Blade jammed. 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.
Servomotor defective.
Check and service servomotor.

Two Fans Servomotor stroke Check stroke length for

10
operating in setting not identical for uniformity. Set blade position
parallel do not the two Fans. uniformity. Check actuating
absorb same drive and tighten the fixing
power. bolts.
System resistance not Check for closed dampers in
identical in Fan flow the ducting
path
11 High vibration Forced Vibration or Conduct vibration analysis.
resonance. Conform the cause and take
remedial measure.
Improper fixing of Check for proper seating of hub
Impeller hub. on shaft flange and bearing
housing. Secure the required
tightness of fixing bolts.
Impeller blades not Check for number punch marks
fixed serially. on the blade and ensure that
the blades are fixed serially of
the same series.
Deposits on impeller Check for deposits and clean
blades blades.
FOR ATTENDING THE HYDRAULIC SERVOMOTOR AND BLADE BEARING

ASSEMBLY, ASSISTANCE FROM THE FAN MANUFACTURER SHOULD BE SOUGHT
SINCE THESE WORKS CALLS FOR THE SPECIAL TOOLS AND SKILLS.


5.1 CONSTRUCTIONAL FEATURES
When looking in flow direction, the fan consists of the following Components.
• Suction Chamber
• Impeller housing with guide vanes
• Rotor consisting of shaft, two impellers with adjustable blades with pitch control mechanism.
• Main bearings (Anti-friction bearings)
• Outlet Guide Vane housing with guide vanes
• Diffuser
STATOR:
Suction chamber, fan housing and diffuser are welded structural 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 its 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, 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 pitch control unit which are arranged 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 impellers are fitted to the shaft on
either side of the bearing assembly 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:
he rotor consists of a shaft, two impellers, and a servomotor.
The rotor is accommodated In Cylindrical Roller bearing. In addition, two Angular Contact Ball
bearings are arranged on the driven side in order to absorb the axial thrust.
Double contact Tele—thermometers and double resistance thermometers monitor the bearing
temperature. These thermometers must be connected to signaling instruments 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 return
pipe, which opens into the oil reservoir. The ventilation hood is mounted on the reservoir.

FAN ACCESSORIES :
RIGIFLEX SHAFT COUPLING :
The fan shaft is connected to the motor shaft by means of Regiflex couplings while an intermediate
shaft bridge the distance between the shaft ends, 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
parts.
OIL CIRCULATION SYSTEM:
The oil system 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. A Hydraulic
Accumulator (Pressure Reservoir) in the system absorbs the pressure fluctuations during blade
adjustment.
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. The silencer
consists of baffles packed with sound absorbing wool retained by perforated plates.

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 :

Every 8 operating hours - record the vibration level.
Every 500 operating hours or at least once in three months –
• Clean the 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.
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 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.
• Check whether the servomotor is oil tight.
• Check for the stroke of hydraulic servomotor.

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) CHECK OF SERVOMOTOR :

• required.
• Check control 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 actuating drive,
consider all criteria applicable to blade adjustment.

c) EFFECT ALL CHECKS AS DESCRIBED UNDER ‘BTEWEEN PLANNED

SHUT DOWN AND FORCED SHUT DOWN’
d) CLEAN INLET AND OUTLET OIL LINES.
e) ELIMINATE OIL LEAKAGES.
f) CHECK THE CLEARANCES OF MAIN BEARINGS.
g) ENSURE FREE ROTATION BY HAND.
h) REPLACE HIGH PRESSURE HOSES FOR SERVOMOTOR IF REQUIRED.
i) ENSURE THE ID OF THE FLEXIBLE HOSES SHOULD BE 3/8”.

5.3 DISASSEMBLY AND REASSEMULY
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.
INSTALLATION AND REMOVAL OF THE IMPELLER BLADES :
The impeller blades have to be checked for wear. Remove the inspection cover from the upper half
of the Fan housing.
Remove the screws connecting the blades and blade shafts and extract each blade form its fit.
Install the impeller blades in accordance with the instructions.
Screws must be coated with Molykote and have to be tightened to the specified torque. Make sure
that the screws 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 (0%)
Remove the expansion bands at the upper halves 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 fixing screws :

Where new blades must be installed, the new screws delivered with them also should be used.
Screws can be re used 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 correct torque, with a calibrated torque
wrench.
REMOVAL AND INSTALLATION OF ROTOR, COMPLETE WITH BEARINGS AND

SERVOMOTOR : (REFERANCE DRG NO.0-55-335-00669)
Open the impeller blades (100% open)

Remove the expansion bands at the upper half of the housings.
Remove the screws connecting the joining areas of the Fan housings.
Open the man-hole door from the diffuser core.
Remove the screws from the jointing areas in the guide vane core.

Remove the linkages of the actuating drive, the connections on the servomotor and oil supply head
(11).
Lift the upper half of the impeller and guide vane housings.
Remove the blades.
Disconnect the coupling.
Remove all mounting screws and all connection instruments and pipe work from the bearing
housings.
Suspend each impeller at two suspension lugs. The suspension lugs have to be screwed in to the
blade shafts after the removal of the blades.
Remove the rotor complete with bearings and servomotor and place it on an appropriate support.
Installation has to be carried out in reverse sequence. Ensure correct alignment. Before assembling
the blades, keep the servomotor in full close position (0% open)
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 been left inside the Fan and remove the same.

REMOVAL AND INSTALLATION OF THE SERVOMOTOR FROM THE DISMOUNTED ROTOR

: ( REFERANCE DRG NO. 0 55 335 00669 )
Suspend the servomotor.
Remove the screws (01) connecting servomotor and impeller. Replace three fixing screws by three
pins.
Move the servomotor as far as possible towards the adjusting pistons. Remove the screws (02)
through the gap between servomotor cylinder and impeller.
Remove the two part flange (03) from the centering and dismount the servomotor.
The Installation should be carried out in reverse sequence. All the screws must be tightened to the
correct torque.
DISMOUNTING AND MOUNTING THE IMPELLERS IN AN EXTRACTED ROTOR : (

REFERANCE DRG NO 0 55 335 00669 )
DRIVE END IMPELLER :

Remove half coupling and drive disc (04).
Remove screws (05),flange (06),two part insertion ring (07),and spacer (08).
Suspend the impeller. Remove screws connecting impeller and hub disc, and dismount the impeller.
SERVOMOTOR END IMPELLER :

Suspend the impeller.
• Remove the screws correcting the impeller and hub plate, dismount the impeller.
• The impeller should be installed in reverse sequence, all screws being tightened to the
correct torque.

DISASSEMBLY AND INSTALLATION OF THE SHAFT AND BEARING AFTER REMOVAL OF

THE BEARING HOUSING :
• Dismount the hub discs ( refer Annexure Principle of hydraulic installation and extraction )
• Unscrew the threaded pins in the shaft nuts and remove.
• Remove the mounting screws of the bearing covers and take out the covers.
• Press out the INA rings and splash rings by means of threaded pins.
• For the HUB MOUNTING DATA dimensions and permissible pressure, refer relevant drawing.
DISMANTLING AND ASSEMBLY OF SERVOMOTOR:

( REFERANCE DRG NO 0 55 335 00669 )
• Remove the screws (12) and flange (13).

• Dismantle the bush (14), control sleeve (15) and control rod (16).
• Remove the screws (17) and cover.
• Remove the piston assembly (19).
• 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 ASSEMBLING OF BLADE BEARING ASSEMBLY :

(REFERANCE DRG NO: 0 55 335 00669)
• Remove the lever assembly(2O), locknut(21), counter weight(22), shaft(23), connecting

ring(24) and distance ring assembly(25).
• Remove bearing assembly(26) along with cup springs.
• Replace all the oil seals and bearings.
• Apply fresh lubricants.
The installation should be carried out in reverse sequence. All the screws must be tightened to the
correct torque.
COMMISSIOIIING OF FAN AFTER MAJOR OVERHAUL :
Prior to starting of the Fan after a major overhaul, ensure all checks as mentioned in the chapter “
PRE COMMISSIONING CHECKS - CHAPTER NO 4.1 ”

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 :68

o
Kinematic Viscosity at 40 C : 64-72 cst
Viscosity index : 95 min
Flashpoint :210oC(min)
Pour point : -6o C (max)
Neutralization, No. mg KOH/gm : 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.
Recommended Oils :
a) Servo prime 68 of BC
b) Turblnol 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.

LUBRICANTS :
RECOMMENDED LUBRICATION CHART
Sl. LOCATI FREQUE OBSERV QTY /

COMPONENT LUBRICANT SUPPLIER
No ON NCY ATION FAN
Servoprime M /s
68 I.O.C
Fan main
Turbinol 68 M/s During
Bearings
Bharat H.P.C over haul
and See
01 turbol Oil tank ( once in Daily
Hydraulic note 1
68 M/s 2 years )
Servomotor
Teresso B.P.C see note 2
Mechanism
68 ( Others )
During
Mobil Over haul
Axial ball
Glygoyle 80 ( once in
bearing See note – Inside
02 OR 2 years ) ***** Six Kg
( Blade bearing 3 Rotor
Berusynth see note
assembly )
EP 460 4
Deep groove
ball bearing & During
Angular Poly-Buty Over haul
contact ball Cuprysil See note – Inside ( once in Four
03 *****
bearing (copper base 3 Rotor 2 years ) Tins
( Blade bearing grease) see note
assembly ) 4
During
Spherical plain Molykote Over haul
bearing Spray 321R See note – Inside ( once in Eight
04 *****
( Blade lever) OR 3 Rotor 2 years ) cans
OKS 511 see note
4

NOTES :
1. Oil quantity depends on tank capacity(Approximately 400 ltrs). 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.

5.5 RECOMMENDED LIST OF SPARES
WE RECOMMEND TO STOCK ATLEAST ONE SET OF THE COMPONENTS PER BOILER

SHOWN IN THE DRAWINGS OF ROTOR ASSEMBLY, SHAFT WITH BEARING ASSEMBLY,
SERVO MOTOR ASEMBLY 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.
WHILE ORDERING SPARES, K1NDLY QUOTE DRAWING NUMBER, ITEM NUMBER,

DESCRIPTTON AND QUANTITY REQUIRED.
CONTACT ADDRESS FOR GETTING SPARES:
THE ADDL GENERAL MANAGER

SPARES BUSINESS
HIGH PRESSURE BOILER PLANT
BHARAT HEAVY ELECTRICALS LIM ITED
TIRUCHIRAPALLI,
TAMIL NADU, PIN CODE-620014

Axial Reaction Fan - Double Stage: Operation & Maintenance Manual

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Axial Reaction Fan - Double Stage: Operation & Maintenance Manual

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AXIAL REACTION FAN – DOUBLE STAGE

-1– OPERATION & MAINTENANCE MANUAL

4.1 PRE-COMMISSIONING CHECKS

ENSURE THE FOLLOWING:

• The bases of Fan parts are tightened with out strain.

-2– OPERATION & MAINTENANCE MANUAL

• Free movement of hinge heads.

-3– OPERATION & MAINTENANCE MANUAL

-4– OPERATION & MAINTENANCE MANUAL

4.2 START UP AND OPERATION

(a) Control oil pressure = > 8 ata

(b) Lub oil pressure = > 0.8 ata

• Impeller blades in minimum position

ALARM & TRIP VALUES:

DESCRIPTION ALARM TRIP

REFER LOGIC DIAGRAM FOR ADDITIONAL INTERLOCKS.

-5– OPERATION & MAINTENANCE MANUAL

STARTING OF THE FAN:

Ensure that all protections and interlocks are functioning properly.

CAUTION: OPERATION OF THE FAN WITH DISCHARGE DAMPER FULLY CLOSED IS

Check for any abnormal noise in the Fan.

Test run for 8 hours.

-6– OPERATION & MAINTENANCE MANUAL

CHECKS DURING NORMAL OPERATION OF THE FAN

Highest permissible values :

• Control oil pressure 12 bar

Aerodynamic operating conditions:

-7– OPERATION & MAINTENANCE MANUAL

Minimum position of AP Fan b1ades :

PARALLEL OPERATION OF PA (AP TYPE) FANS:

CHARACTERISTIC CURVE OF THE PA FAN :

-8– OPERATION & MAINTENANCE MANUAL

-9– OPERATION & MAINTENANCE MANUAL

STARTING THE FANS :

- 10 – OPERATION & MAINTENANCE MANUAL

STARTING A SECOND FAN:

- 11 – OPERATION & MAINTENANCE MANUAL

- 12 – OPERATION & MAINTENANCE MANUAL

- 13 – OPERATION & MAINTENANCE MANUAL

EFFECT ON FAN PERFORMANCE DURING SUDDEN CHANGE IN SYSTEM RESISTANCE:

- 14 – OPERATION & MAINTENANCE MANUAL

- 15 – OPERATION & MAINTENANCE MANUAL

PRESERVATION OF FANS DURING LONG SHUT DOWN :

- 16 – OPERATION & MAINTENANCE MANUAL

During prolonged shut down of commissioned equipment ;

ONCE IN TWO DAYS:

ONCE IN TEN DAYS:

ONCE IN TWO WEEKS:

- 17 – OPERATION & MAINTENANCE MANUAL

4.3 VIBRATION AND SAFE RUNNING OF FAN

The speed at which the part is vibrating in mm/sec.

- 18 – OPERATION & MAINTENANCE MANUAL

- 19 – OPERATION & MAINTENANCE MANUAL

4.4 OPERATIONAL PROBLEMS CAUSES AND REMEDIES

Sl.No. Problems Probable cause Remedial Action

Damaged seals at Dismantle servomotor and replace

2 Water contamination Leakage in oil cooler. Analyse oil for water

- 20 – OPERATION & MAINTENANCE MANUAL

Sl.No. Problems Probable cause Remedial Action

Leakage in oil system Check for the leakage in pipelines

- 21 – OPERATION & MAINTENANCE MANUAL

Sl.No. Problems Probable cause Remedial Action