L&T Onm HDF - 050414

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INSTRUCTION MANUAL Page 2 of 53
UID NO.:FAN MANUAL/Flakt2003
CONTENTS
FUNCTIONAL DESCRIPTION & DESIGN 4
SAFETY PRECAUTIONS 5
CONDITION ON DELIVERY 6
ERECTION
SIMPLY SUPPORTED FAN 7 - 8
CERAMIC ROPE FIXING DETAIL 9
BELLE VILLE WASHER FIXING DETAIL 9
RIGID & FLEXIBLE ATTACHMENT 10
ROTOR ASSEMBLY 11 - 12
LIFTING ARRANGEMENT OF ROTOR 13
ROTOR ALIGNMENT 14
INLET CONE FIXING DETAIL 15
COUPLING ALIGNMENT 16
SEALING PLATE FIXING DETAIL 17
OVERHUNG FAN 18
ASSEMBLY PROCEDURE OF BEARINGS 19 - 23
IMPELLER LOCKING ARRANGEMENT 24
SOME IMPORTANT NOTES 25
FANS ON VIBRATION ISOLATOR 26
ACCESSORIES 27 - 28
COMMISSIONING PROCEDURE
ASSEMBLY & START UP CHECK LIST 29
PRECAUTIONS BEFORE STARTING 30
CHECK UP DURING RUNNING 31
CONTENTS
MAINTENANCE
RUNNING MAINTENANCE 32
SHUTDOWN MAINTENANCE 32
LUBRICATION 33 - 35
VIBRATION ACCEPTANCE NORMS 36 - 37
LOCATION FIXED & FREE BEARINGS 38
AFTER MOUNTING CLEARANCE OF BEARINGS 39
SOFN HOUSING
BEARING ASSEMBLY 40
OIL LEVEL 41
LUBRICATION 42
MOUNTING/DISMOUNTING 43
MAINTENANCE 43
INLET DIMENSION 44
LIST OF SPARE 45
ANNEX
DATA RECORDED DURING TRIAL RUNNING
46
OF FAN
DOS & DON'T'S 47
BRIEF DESCRIPTION OF FAN COMPONENTS 48
TROUBLE SHOOTING CAN HELP WHEN YOU
49 - 51
SUSPECT A PROBLEM
HOW TO ORDER 52
ADDRESS & CONTACT NO. 53
YOUR FANS.. .. DESCRIPTION AND IDENTIFICATION

FUNCTIONAL DESCRIPTION AND DESIGN
SOLYVENT SERIES
FAN IMPELLER
DISC
BLADE CENTRIFUGAL FAN TERMINOLOGY

SEALS
SQUARE FLANGE
SCROLL PLATE
INLET DAMPER
INLET
INSPECTION DOOR
SHROUD
SHAPPED INLET
SHAFT TECHNOLOGY
SQUARE FLANGE
STRAIGHT SHAFT FOR SINGLE INLET IMPELLER

INLET BOX
STIFFENER
STRAIGHT SHAFT FOR IMPELLER OUTLET
BETWEEN BEARINGS
SPLIT FLANGE
SOLEPLATE
STEPPED SHAFT DIFFUSOR

PEDESTAL
OR
PELICAN
SQUARE FLANGE
BEARING
SHAFT WITH INTEGRATED FLANGE FAN STATOR

SAFETY PRECAUTIONS
The operation and maintenance of machinery of any kind requires a person to be

cautions and aware of the damages that exist. In order to avoid injuries to
personal and damage to machinery, the following precautions are very important.
1. Never apply power to the fan motor for any reason until the fan has been
completely installed in its system, and the system inspected to be sure that no
debris has been left in the fan & ducts, and it is known that the inspection
doors at the inlet and outlet of the air passages are shut. The usual procedure
is to remove the fuses from the disconnect switch and open its safety
isolation switch until the installation is completed and inspected.
2. Start the fan momentarily and disconnect it. Observe rotation of the wheel or
the drive rotation is correct. Do not allow the fan to run backward, except
momentarily.
3. Do not open or access inspection doors while the fan is running.
4. Always open the disconnect switch and lock it in the open position with a
padlock before doing any service or maintenance work on the fan.
5. After service of any kind make certain that all adjustment have been properly
made and tightened ,inspection doors closed, there is no debris in the air
passages and all tools have been removed before unlocking the disconnect
switch to place the fan in operation.
6. Make a periodic inspection of the fan wheel, bearings and coupling to be sure
that corrosion has not set in to weaken them. Where there are signs of
corrosion there is danger of mechanical failure. Corroded parts should be
replaced.
7. Always use caution in every maintenance or operational procedure.

CONDITION ON DELIVERY
A. Transport :
The fans are dispatched in dismantled condition with proper packing.
Handle all fan parts with care. Use lifting lugs and good rigging techniques. Slings and
timbers should never be passed through the casing and impeller in order to assist in
rigging.
Pay particular attention to rotor assembly consisting impeller, hub, shaft, bearing
housings and bearings. Avoid any shocks that could damage the parts and their
coatings or alter the impeller balance. If the impeller is damaged slightly, it will have
to be repaired and balanced again.
B. Check for Transportation Damages :

When packages are received at site, check all parts with the help of the packing list
and drawing. If necessary ,make a list of the missing parts ( in case of shortage)
and initiate action for replacement, insurance etc. Check the condition of the parts
that may have been damaged during transport. In case of damages, take steps to
repair the damages in consultation with manufacturer
C. Storage :
General :-
As soon as received ,the different parts of the fan should be placed in clean and dry
covered premises.
Long term storage
Storage for a period of more than three months must be ensured in the best
possible condition, basically protected from dampness so as to avoid oxidisation of
the different parts of the fan unit.
The mechanical parts with machined surfaces are coated with anti-corrosion varnish.
In the case of prolonged storage, before putting in to service, the equipment will be
inspected periodically and the machined parts will be protected from time to time
using protective coating in case of need.
They will be stored in sufficiently large premises, thus providing space for inspection
and easy maintenance of the equipment stored. Moreover , the storage premises will
protect the equipment from sudden changes in temperature, dust, foreign matter,
etc.
The impeller and bearing assembly should be rotated at a very low speed ( rotation
by hand) for about thirty minutes, once a week.
Storage of bearing
As a general rule, the bearings are given a rust prevention treatment in the works
before being packed. They can be preserved for several years, in their original
packing , on a condition that the relative humidity in the storage premises is not over
60 % A higher degree of relative humidity, up to 75% is however permissible for
short term storage.
ERECTION
SIMPLE SUPPORTED FANS
1. Ensure that the concrete foundation has been made at site as per general assembly
drawing.
2. Check foundation for evenness, and its different levels.
3. Mark centre lines of fan and foundation pockets on the foundation.
NOTE: REFER ENCLOSED ASSEMBLY DRAWING.

FOLLOW MATCH MARK OF EACH COMPONENTS FOR ASSEMBLY.
♦ FOUNDATION BOLTS, FAN ON BASE FRAME: -
4. Place the foundation bolts in all foundation pockets as required and hook up with the
common holding rods provided in the foundation.
5. Clean the threaded portion of the bolt.
6. Generally the concrete block foundation provided to support the fan unit should be at a
level lower than the final installation level by about 50mm. This clearance allows
correction of the civil engineering false level. It is therefore necessary to maintain the
center of the fan and the level of installation.
7. Place the steel packers in between the foundation bolts to the required height.
8. Place the base frame on the packers and bolt together at four corners.
9. Fasten the foundation bolts with base frame.
10. Adjust the horizontal level of the base frame by adjusting steel packers by using
dumpy level. The dimensions to be maintained as per the GA drawing. Check up the
diagonal dimensions for assuring the squareness of the base frame.
♦ BEARING PEDESTALS, CASING
11. Place the bearing pedestals on the base frame and bolt with base frame. Check up the
horizontal level of the bearing pedestals by using water level/dumpy level. The level of
pedestal to be checked with water level/dumpy level.
12. Check up the center to center distance of bearing pedestal and diagonal of holes on the
pedestal for ensuring the squarness. This should be maintained as per the drg.
Temporary locking arrangement to be provided for the base frame to avoid disturbance
of the base frame during grouting. The temporary locking can be removed after
grouting.
13. Put the grouting materials for the foundation bolts up to the pocket level.
NOTE: Make sure that non-shrinkage type grout materials are used. Allow the
grout to dry long enough.
14. Again check the level and height of bearing pedestals and record the values.
NOTE: Top surface level of bearing pedestals should be checked by master level.
Permissible deviation is 2 division of master level having accuracy 0.02mm/meter.
This level should be obtained by adjusting steel packers in-between base frame and
foundation. Please avoid shims providing between base frame and pedestal.
15. Bolt the bottom half of the casing with inlet box. Provide ceramic rope in between
the flanges as per the fig. 11.
16. Place lower part of casing on base frame and bolt it. Provide Belleville washer in
casing with base frame fixing bolt, as shown in fig. 12.
17. Check the center line of casing, shaft and impeller axis with respect to base frame
and bearing pedestals.
18. Weld the rigid attachment at motor end in-between casing and base frame as per
fig. 13.
FIG. No. 11
CERAMIC ROPE
CERAMIC ROPE FIXING DETAIL
19. Weld the flexible attachment at free end on inlet box and base frame as per fig. 14.
FIG. No. 12
(WHEREVER APPLICABLE)
FIG. No. 13
FIG. No. 14
ROTOR ASSEMBLY :-
20. Assemble the bearings in shaft as per the instruction given in the enclosed manual.
21. Sling the fan rotor assembly consisting of impeller, hub, shaft, bearings and bearing
housings with inlet cone as shown in fig. 15.
22. Position the fan rotor assembly with inlet cone on the bearing pedestals. Bolt the
bearing housing with the bearing pedestals, The holding bolt is of high tensile grade
and should have plain washer, spring washer, main nut and lock nuts are to be used.
23. Check level of shaft and align shaft axis for approx. gap between inlet cone to impeller
shroud.
24. To achieve the shaft level at coupling end to horizontal, follow the procedure as
explained here.
For Simply supporte fan

Place the master level on the machined surface of shaft at coupling seating portion and
check the level. This level should be within 0.05mm. For achieving this lift the shaft at
non drive end in such a way that the drive end is levelled to zero horizontally as shown
in fig. 16. For this suitable thickness stainless shim to be inserted between bearing
housing and bearing pedestal at non drive end.
For Overhung fans
Ckeck the master level in between bearings.
25. Tighten the bearing housing fixing bolts.
26. Install top half of the casing and inlet box and bolt it. Put ceramic rope in-between
parting flanges as shown in fig.11
27. Tighten the parting flange bolts, all bolts should be provided with plain washer.
28. Bolt the supporting plates which is welded on the bottom casing as shown in fig. 17.
with the top casing.
29. Position the inlet cone on its place with fixing clamp or bolted arrangement (refer GA
drawing.)
30. Check overlap and clearance between impeller and inlet cone and note down the value in
annex. The back mark dimension between the casing and impeller disc also to be
maintained as per the drawing. After achieving the dimensions as per the drg. weld the
cone with its flange as per fig. 18(In some cases cones are not welded with flange at
our workshop to facilitate adjustment at site.) . While welding the cone with its angle
flange sequence welding is to be adopted (not continuous welding) to avoid distortion.
If the overlap dimension is deviating from the drawing, this can be achieved by cutting
the tack weld of the cone with the angle flange and can be moved as required.
31. Insert the coupling half on to the fan shaft by heating the coupling hub in hot oil bath
up to 125 °C. Please check up the bore and shaft dimensions.
32. Insert the other coupling half on to the motor shaft by heating the coupling hub in hot
oil bath up to 125 °C. Please check up the bore and shaft dimensions.
33. Place the motor base frame on the foundation with packing plates, and foundation
bolts. Level the base frame with water level by adjusting the packers placed below the
base frame.
34. Place the motor on the base frame and check up the coupling gap and coupling side and
up/down variations. If required adjust the same by moving the motor along with the
base frame.
35. Put the grouting materials for the foundation bolts of the motor base frame up to the
pocket level.
NOTE: Make sure that non-shrinkage type grout materials are used. Allow the grout to dry
long enough.
36. Gap between coupling halves should be maintained as per the dimensions shown in
assembly drawing.
FIG. No. 15
(same procedure for overhung rotor also)
FIG No. 16
ROTOR ALINGMENT
FIG. No. 17
Fig No. 18
(Wherever applicable)
COUPLING ALIGNMENT
1. Level and align the motor to the fan shaft level by using brass / stainless steel shims
underneath the motor pads.
2. Align the motor with respect to fan coupling. Alignment of the couplings should be done
using two axial dial gauges and one radial dial gauge as shown in fig. 19.
Allowable radial misalignment max. 0.05 mm.
Allowable axial misalignment max. 0.05 mm.
3. Arrange for final grouting of fan and motor base frame by using non-shrink type
grout material.
4. Couple the fan and motor through the coupling after taking a trial run of motor in de-
coupled condition.
FIG No. 19
FIG No.20
(Check Drg. if spring loaded bolts are applicable)
FIG No. 21
OVERHUNG FANS
1. Check up the civil foundation level for its surface level evenness, and different
elevation level as per the drawing. Chip off the uneven surface.
2. Check up and ensure that the foundation pocket dimensions are as per drawing.
3. Place the packers in between all the pockets. Place the foundation bolts on all the
packers.
4. Place the lower part of casing and common base frame on the packers and fix the
foundation bolts.
5. Check up and adjust the horizontal level of the base frame and casing using water level.
This can be adjusted by adding and removing the packer plates below the base frame.
6. Insert the bearing on the fan shaft as explained in the assembly procedure for
bearings.
7. Install the impeller on the base frame and bolt with the base frame.
8. Grout the foundation pockets with non shrinkage grout material upto the pocket level
allow long enough for proper curing.
9. Level the impeller shaft by using master level. The level has to be checked in between
the bearings. The shaft should be levelled with in 2divisions (0.04mm).
10. Install the top casing and inlet cone, put ceramic rope in between the parting flanges.
Check up the cone gap and overlap and record the values. If required the cone gap can
be adjusted by heating and hammering the inlet cone tip, to maintain the gap as per the
drawing.
11. Fix the inlet damper and flexible connection at fan inlet.
12. Fix Evase and outlet flexible connection at fan outlet.
13. Fix the coupling on the impeller and motor fan shaft.
14. Align the motor with respect to the fan shaft as explained earlier.
15. Fix cooling disc with cover (fig. 21), coupling cover and shaft cover.
16. After completing installation and alignment, final grouting of the foundation bolts shall
be carried out.
ASSEMBLY PROCEDURE FOR BEARING AND BEARING HOUSING
The following procedure will be applicable rotor, loose bearings and bearing housings, if and
when used.
1. PRE -ASSEMBLY CHECKING :
As the bearings are finished to high precision, thorough inspection and checking on the
following points are essential prior to assembly :
a) On opening the packing of bearings, the same shall be thoroughly checked for dirt or
other foreign matter and if found, same shall be carefully washed unless and until it is
necessary.
b) The shaft shall be checked for damage due to transport and handling. Particularly the
surfaces where the bearings are to be mounted should be checked for rusting, scoring
etc. Rust, if found, should be removed by rust remover. Heavy pitting on bearing
surfaces of shaft is not acceptable.
Localized scorings could be removed using oil stone.
If the shaft is found to have a bend, the same should not be used for assembly.
c) Bearing housings although made by precision machining to the given specifications, a

thorough checking is essential to make sure against any defects in the bearing seating
surfaces or dirt inclusion which can possibly result from handling, transportation etc.
The flaw, if any, is to be carefully corrected with the use of an oil stone or fine emery
paper and the dirt to be thoroughly washed off and cleaned.
d) Bearing to be mounted shall be taken out of the original protective packing only
immediately before mounting.
e) The mounting and dismounting tools and necessary jigs must be of proper dimension and
simple design so that they do not cause any mechanical damage to the bearings.
2) GENERAL INSTRUCTIONS :-
With tapered bore:
A bearing with tapered bore, which is seated direct on a shaft, or which is mounted with
an adapter sleeve, ordinarily requires a somewhat tighter fit than a bearing with
cylindrical bore. This fit is achieved by pressing on the inner ring by means of a nut or
by driving in the sleeve. In both cases, the inner bearing is expanded and this results in
a reduction of radial bearing clearance.
If a double row self aligning ball bearing is mounted on an adapter sleeve, the sleeve
nut might be tightened but not so much as to prevent the outer bearing from turning
easily and it must be possible to swing the outer race easily from one side to the other
side.
Double row spherical roller bearings which are used mostly in heavy load applications are
mounted with greater interference. The radial clearance is adapted to this fit and its
reduction can be measured while mounting by means of a feeler gauge. For checking the
correct fit of the inner ring, both the reduction of radial clearance and the distance of
the inner ring is driven axially on the tapered seating or on the adapter sleeve and is
measured. For solid shafts, the axial displacement is approximately fifteen times as
large as the desired clearance reduction.
ASSEMBLY PROCEDURE
a) Keep the bottom half of bearing housings on the bearing pedestal.
b) Clean the shaft with the use of white sprit.
c) Insert the brass seal on to the shaft at impeller end.
d) Insert the M.S cover plate on to the shaft at impeller end.
e) Keep the rotor assembly in position but slightly elevated position on supports above
the bearing housing bottom halves.
f) Insert the double - lip seal on to the shaft at impeller end if applicable.
g) Insert the taper sleeve on to the shaft to the location with thread portion outside.
h) Locate the bearing position and assemble the lock washer and nut with the taper
sleeve. (no locating ring for this bearing as this is free bearing).
i) Keep the gap between bearing to bearing housing to accommodate the expansion of
shaft as shown in our drawings.
j) Tighten the lock nut on the taper sleeve. For tightening the nut, do not use steel
chisel or rod but use either brass or copper rod for taking the force of hammer. The
necessary tightness is achieved when the brass or copper rod flares at the load
transfer end. Check for the clearance between roller and outer race as mentioned in
SKF catalogue.
k) Insert the another double-lip seal on to the shaft if applicable.
l) Now start assembly of drive side (coupling side) bearing by inserting the double lip
seal on to the shaft if applicable.
m) Insert the lock nut and lock washer on to the shaft.
n) Arrange the locating ring on one side or either side of bearing , as the case may be.
o) Insert the bearing with large dia of bore facing outside.
p) Insert the taper sleeve on to the shaft.
q) Locate the bearing position and assemble the lock washer and nut with the taper
sleeve.
r) Tighten the lock nut as explained in point no.
s) Now keep the lock washer teeth locked to the lock nut groove by bending.
t) Insert the another seal on to the shaft.
u) Rest the rotor on the bottom half of bearing housing.
v) Lubricate the bearings with recommended grease from one side of the bearing with
pressure, so that the grease comes at the other side of the bearing through roller
gapes. Check that the bearing is greased uniformly on both sides all around. Fill the
bottom half of the bearing housing with grease.
w) Place the top half bearing housing without applying any grease. Check for free
rotation of the rotor assembly.
x) Tighten the parting off bolts to the correct tightness.

WITH CYLINDRICAL BORE: -
The force needed to mount a bearing increases rapidly with bearing

size. Larger bearing can not easily be pressed on to a shaft or in to
a housing because of the mounting force required. Therefore, the
bearing or one bearing ring is heated before mounting.
The temperature difference between the bearing and its seating

depends on the magnitude of the interference fit and the bearing
size. Normally a bearing temperature of 80 to 90ºC (175ºF to 195ºF).
ing to a temperature greater than 125°C(255 °F), however, be-

cause the material may change metallurgically and produce alterna-
tions in diameter or hardness. Local overheating must be avoided.
When using a heating device, use a thermometer to check the
bearing's temperature.
Wear clean protective gloves when mounting a hot bearing. Lifting

(hoisting) gear can facilitate mounting. Push the bearing along the
shaft to its abutment and hold the bearing in position, pressing until
a tight fit is obtained.
SKF can supply heating tools, such as oil baths, induction heaters,
heating cabinets and electric and electric plates with adjustable thermostat and
cover, for all common mounting needs.
When a bearing requires an interference fit in the housing, a moder-

ate inctrease in the housing temperature, from 20 to 50°C (70 to
120°F) is normally sufficient, since the amount of interference is
seldom large. A heater or oil bath can be used for the job.
Bearings with
shields or seats
should not be
heated.
Lifting gear
(housing)
To facilitate future dismounting equip shafts with ducts

and distribution grooves for pressurized oil
SKF heaters are generally equipped with

adjustable thermostats Nevertheless it is
advisable to use a separate thermometer
to check bearing temperature immediately
before mounting. The thermometer is
also useful during test runs and Use clean protective gloves to hold the hot
for monitoring bearings bearing press it hard against the abutment
during operation face so that the inner ring fits snugly on the
A cabinet equipped wiyh an adjustable thermostat and a fan is a

versatile tool suitable for many heating operations. Bearings of dif-
ferent sizes or a large number of bearings can e heated together in a
cabinet. Small bearing housings can also be heated. Keep the cabi-
net clean to reduce the risk of bearing contamination. Bearings can
also be stored hot, ready to mount.
In addition to bearings, couplings, sleeves and other components

can also be heated in a cabinet.
Oil baths ensure even heating. They

also make it possible to heat and
maintain a bearing at a certain
temperature. Keep the oil in a clean
bath to prevent bearing contamination.
Bearing rings, or even complete bearings, can be

suspended in an oil bath.
Never place a bearing directly in contact with the sides
IMPELLER LOCKING ARRANGEMENT
SIMPLE SUPPORTED FAN OVERHUNG FAN
Fitting of impeller on shaft

Some important notes
! Direction of discharge
The fans are supplied in discharge direction as specified in order . This can be altered at
site .
! Connection of duct
Duct connection of the fan casing must not exert any load directly on the fan as the
casing may be deformed and the inlet cone may come in contact with impeller .
! Direction of impeller
The direction of rotation is indicated in fan casing .

Erection on vibration isolator
! Ensure of grouting pocket positions in civil foundation are as per GA drg.

! Bolt the isolators with base frame .
! Insert the grouting bolts in mounting holes of isolators.
! Place the base frame in position and at it's required elevation , level it in X- Y axis ;
provide temporary support under base frame .
! While positioning the base frame , ensure the grouting bolts are positioned at center
in their respective pockets .
! Grout the isolator pockets Use non shrinkable cement .
! Remove temporary support only after curing is complete . The isolators are loaded
now.
! Check level of shaft . If required , place shims between base frame and isolator .
Important point to be noted
! The main idea of providing vibration isolator is to avoid transmission of undue

vibration from the equipment to the surrounding structure and not to reduce
equipment vibration , in fact equipment vibration may be on higher side due to soft
foundation and vibration value 10 mm/s ( Peak Value ) is acceptable for Fans.
! We do not normally recommend to use vibration isolator when fans are installed at
ground level.
ACCESSORIES ( REFER ASSEMBLY DRAWING FOR ITEMS APPLICABLE)
5. Fix the evase with fan outlet.
6. Fix the inlet damper with inlet box (wherever applicable) /inlet
Ensure correct damper orientation; the close to open direction of damper will be same
with that of impeller rotation.
7. Fix the inlet and outlet flexible connection.
Ensure flexibility after installation ; For dust application flexible connection are
provided with sleeve . Follow the air flow mark for correct installation.
8. Fix the actuator bracket on the casing/foundation
9. Fix the actuator with actuator bracket.
10. Fix the linkage between actuator and damper. The operating lever on the actuator and
the lever on the damper should be in parallel and of equal length , for proper
operation of the damper.
11. Fix the sealing arrangement on inlet box as shown in fig. 20
12. Bolt the cooling disc halves together on the shaft.
Guard for cooling disc Tightening torque

Shaft
A kpm Nm
Dia. D ft lb
kgfm Nm
25-65 0 3 29.4 21.7
80 10
90-100 15 5 49 36.1
110 25
A
Assembly of disc halves
13. Weld the cooling disc guard fixing angle on the bearing pedestal as shown in fig. 21.
14. Weld the coupling guard fixing angle on the bearing pedestal.
15. After completing all erection and alignment work, full grouting of the foundation bolts
shall be carried out.
NOTE :
Whenever welding is carried out on the fan parts during erection at site condition, direct
earthing to be given, to avoid current passing through the bearings.

COMMISSIONING PROCEDURE
ASSEMBLY AND STARTING UP CHECK LIST.
DESCRIPTION REMARKS & MEASURED VALUES
Tightening of foundation bolts :
STATIC PARTS:
Positioning of the inlet cone :
Tightening of fixing bolts on the ducts :
Tightening of the fixing bolts of static :

parts
Closing of the inspection door :
ROTOR PARTS:
Shaft alignment :
Tightening of fixing bolts impeller / hub :
Expansion clearance on the free bearing :
Alignment of the coupling
LUBRICATION:
Fan bearings lubrication :
Inlet damper lubrication :
UTILITIES:
Connection to the electric circuit :
Connection to the control system :

PRECAUTIONS BEFORE FIRST STARTING OR BEFORE STARTING

AFTER DISMANTLING
1. Check the mounting of the bearing housings and electric motor.
2. Check that the coupling is tightened properly.
3. Check that the foundation bolts are properly tightened.
4. Check that the connecting flanges between the fan and ducting are good, and proper
packing is provided.
5. Check that the different components of the control system are correctly connected.
6. Check that the Inlet damper is fully closed.
7. Check that no foreign object has been left anywhere in side the fan.
8. Check that no water stays in the bottom of the casing and inlet box.
9. Check that the specified guards have been fitted.
10. Check that the inspection door on the casing and inlet box are correctly shut.
11. Check that the rotor can turn freely without rubbing with any static parts.
12. Check that the bearings have been correctly filled with bearing lubricant as it is
noted in the section `LUBRICATION”.
FIRST START AFTER ASSEMBLY

1. People responsible for the starting must always stay nearest as possible to the
emergency stop switch.
2. The fan is rotating in correct direction
T IMPELLER
P IMPELLER
B IMPELLER
3. The fan inlet must be shut.

4. During the acceleration phase, that there is no abnormal noise.
Once the fan has reached full speed, open the damper.
5. Check bearing vibration level. The vibration levels indicated in below are in full
accordance with the standard VDI 2056.
VELOCITY IN mm/sec (RMS)
FAN HEALTH FAN ON CONCRETE FANS ON VIBRATION

CONDITION FOUNDATION ISOLATOR
ADMISSIBLE 4.5 7
STILL ADMISSIBLE 7.1 15
ALARM LEVEL 10 18
TRIP LEVEL 11.2 20
Check that the bearing temperature is good.

Normally this temperature first raises and then decreases and stabilizes at particular
temperature.
SET THE ALARM POINT AT 100 ° C.
SET THE TRIPPING POINT AT 110 ° C.
If the bearing temperature is too high, this ♦ Improper assembly

generally indicates: ♦ Inner clearance is too small
♦ Jamming of bearings
♦ Excessive friction of seal
Improper lubrication in quantity or quality.
Check up the noise of the bearing housings :
♦ Grinding noise : Inadequate lubrication (Surface rubbing directly against one

another
♦ Whistling : Improper lubrication (Grade or quantity)
Clear noise at : Imprints in race of outer ring because of abnormal vibration.
regular intervals
♦ Intermittent : Rolling part deteriorated or damaged
noise
♦ Cracking noise : Presence of foreign particles
♦ Whining or high : Axial thrust from motor.

pitch noise
MAINTENANCE
RUNNING MAINTENANCE
1. Fill bearing lubricant of recommended specification and quantity at the specified

intervals for bearing housings. The interval should be determined based on local
condition like working environment etc.
2. Check periodically vibration levels of the fan at both bearings.
3. Check periodically the proper seating of fan on the foundation and for abnormal
vibration at any location.
4. Check for looseness of any bolts in the fan pedestals, casing, etc.
SHUT DOWN MAINTENANCE:
1. Open inspection door in casing. Clean the impeller blades and internals.
2. Check for erosion of the impeller.
3. Check the overlap and radial clearance between impeller shroud and inlet cone. If found
disturbed adjust the same.
4. Remove used bearing lubricant from bearing housing.
5. Check the bearing condition like roller clearance and the rolling surfaces of races.
6. Fill new lubricant in the bearing housing.
7. Check alignment of fan and motor. If necessary correct the same.
8. Check the Inlet damper flaps movement.
9. Apply grease for Inlet damper bearing housings.
10. Check the tightness of all fixing bolts.

LUBRICATION
FAN BEARINGS (GREASE LUBRICATION)
Requirement : Consistancy class : NLGI 2 (National Lubrication Grease Institute scale)
COMPANY BRAND NAME

BHARAT PETROLEUM BHARAT LINTHEX EP2
IOL SERVOGEM EP2
SKF ALFALUB LGMT No 2
ELF EPEXA No 2
ESSO STANDARD BEACON No 2
MOBIL OIL MOBILUX GREASE No 2
SHELL ALVANIA GREASE No 2
Quantity : Press grease from one side of the bearing till it comes out through the opposite
end. Continue the process and rotate the impeller slowly by hand till the bearing is
completely filled with grease. Put some extra grease (not more than !/3 rd of inside volume
of plummer block) inside the plummer block .
Note : Over greasing will cause overheating of bearing .
FAN BEARINGS (Oil LUBRICATION)
Requirement : Viscosity Grade 68
Type of Lubrication: Oil bathand circulation ring.

Lubrication : Mineral oil with anti foam, corrosion and anti oxidation additives.
Suggested lubricants.: BHARAT HYDROL 68 , SERVO SYSTEM 68 or Equivalent.
Fillinfg per bearing housing: As per maximum and minimum mark given on the Oil level
indicator.(revert to us in case of any doubt)
Note : Do not exceed the maximum mark , since excess oil would result overheating
And oil leakage thru’ the shaft passage.
INLET DAMPER
According to the installation conditions and the operating frequency of the inlet damper
following should be lubricated.
VANE BEARINGS : Make sure when topping up that the spent grease is discharged
normally.
LINK ROD PINS : Apply grease after cleaning if required.
Lubrication interval : Normally three months, to be changed as and when required.

Lubrication interval and amount
Grease
For fans provided with spherical roller bearing, the bearings housing are
fitted with grease nipples and are fitted with the correct amount of grease
when requested.
The lubrication intervals and the amount of grease necessary for relubrication
The chart is based on a temperature of 70°C. For every 15°C increase in
temperature the lubrication interval should be reduced to 50% of the value
obtained from the chart.
(Example : For a fan fitted with spherical roller bearings with the bearing bore
diameter of 120mm and running at 1000RPM the relubrication interval will be
800 operating hours if the bearing's temperature does not exceed 70°C).
Oil
When inspecting the oil level of a bearing, check to ensure that the right type of
oil is in use and that the oil level gauge's air vent is unobstructed.
Take a small sample of the oil and compare it with fresh oil. If the sample look's
cloudy, then it is mixed with water and should be replaced.
Dark or thick oil is a sign of dirt or indicates that the oil has started to carbonize.
Change the oil completely and, if possible, clean the bearing by flushing it with
fresh oil . When changing the oil, be sure that you are using the same type of oil ,
and that you refill to the required level .
A more reliable method for determining the oil condition is to analyze a sample .
If the oil is contaminated it may be worthwhile to change the seals or consider
filtration .
Oil in oil bath circulation systems requires change only once each year, providing
that the operating temperatures does not exceed 50 to 60 º C and the oil does
not become contaminated . Change the oil four times each year for operating
temperatures of 100 º C ; monthly for operating temperature of 100 º C.
RELUBRICATION INTERVALS IN OPERATING HOUR

c b a t = operating hours
2.5 2.5 3
4
10 2 2.5
6 1.5 2
4 4
1.5
10
2 8
4
3 10 D = DIAMETER OF BEARING
10 6 9
8 4 8
7
d=
6 3 6
10
5 2.5 5
m
m
20
4 2 4
40
60
100
120
80
160
3 1.5 3
200
240
280
360
2.5 2.5
420
2 10 500
2
1.5 7.5 1.5
3
10 5 103
9 4.5 9
8 4 8
7 3.5 7
6 6
5 2.5 5
4 2 4
3 1.5 3
2
2 10 2
1.5 7.5 1.5
2 2
10 10 2
10 2 3 4 5 6 789 103 2 3 4 5 6 7 89 104 2
N = RPM
a : radial ball bearings

b : cylindrical roller bearings
c : spherical roller bearings, taper roller bearings, thrust ball bearings; full complement cylindrical
roller bearing (0.2 t); crossed cylindrical roller bearings with cage (0.3 t); cylindrical roller thrust
bearings, needle roller thrust bearings, spherical roller thrust bearings (0.5 t).
General formula for

relubrication amount :
G = 0.005 DB SHAFT DIAMETER - mm
G = Grease qty. in gm
D = Bearing OD in mm
65 80 90 100 110 125 135 140 150 160
B = Bearing width in mm
AT MOUNTING gm 240 310 340 380 470 680 850 1000 1800 2200
AT RE-LUBRICATION gm 24 40 55 70 80 110 130 150 130 150

VIBRATION ACCEPTANCE NORMS AS PER VDI 2056 / ISO 2372
FOR RIGIDLY MOUNTED FANS
400
µ
315
250
Displacement s
200
160
s
IN
Displacement amplitude s
A
125
D
RM M
IS
100
S- S
va IB
80 lue
S of LE
T vib
63
IL ra
L tio
50 A nv
D elo
M cit
40 IS y
A S v
31.5
D IB
M LE =
IS rm 11
25 s mm
S /s
20 IB
G LE
v rm
16 O
O
s
=
D
4.
12.5
5m
m/
v rm
10
s
=
1.8
mm
/s
6.3
5
Vi
br
4 at
ion
lev
3.15
el
v of
rm hu
2.5
s= ma
0. np
11
2.0 mm er
/s ce
pt
1.6 ion
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
Fig. 13 Example of Vibration Severily for Machine Class III. Frequency in cpm
VIBRATION ACCEPTANCE NORMS AS PER VDI 2056 / ISO 2372
FANS ON VIBRATION ISOLATOR
MACHINE CLASS IV
400
µ
315
250
Displacement s
200
Displacement amplitude s
160
I
s
RM N
125 A
S- D
va M
100 lu I
S e S
of S
80 T vib I
I B
L ra L
63 L tio E
A n
D ve
50 M lo
I ci
S ty
40 A S
D I v
M B
31.5
I L
S E =
S 18
25
I mm
B /s
L
v rm
20 E
s
=
G
7m
16
O
m/
O
D
s
v rm
12.5
s
=
2.
8m
10
m/
s
6.3
5
Vi
br
4 at
io
n
le
3.15
ve
v lo
rm f
2.5 s = hu
0. ma
11
2.0
mm n pe
/s rc
1.6 ep
tio
n
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
Fig. 14 Example of Vibration Severily for Machine Class IV. Frequency in cpm
NSTRUCTION MANUAL Page 38 of 53
LOCATION OF FIXED AND FREE BEARING
FREE BRG. FIXED BRG.
FREE BRG.
FIXED BRG.
AFTER MOUNTING CLEARANCE OF BEARING WITH TAPERED BORE
NUT
ADEPTER BEARING LOCKING

SLEEVE WASHER
Bearing bore Reduction in Axial drive-up Taper 1:30 Minimum permissible residual
diameter radial internal Taper 1:12 on diameter clearance after mounting
d clearence on diameter bearings with initial clearance
Over incl. min max min max min max Normal 3 4

C C
mm mm mm mm
30 40 0.020 0.025 0.35 0.4 0.015 0.025 0.040
40 50 0.025 0.030 0.4 0.45 0.020 0.030 0.050
50 65 0.030 0.040 0.45 0.6 0.025 0.035 0.055
65 80 0.040 0.050 0.6 0.75 0.025 0.040 0.070
80 100 0.045 0.060 0.7 0.9 1.75 2.25 0.035 0.050 0.080
100 120 0.050 0.070 0.75 1.1 1.9 2.75 0.050 0.065 0.100
120 140 0.065 0.090 1.1 1.4 2.75 3.5 0.055 0.080 0.110
140 160 0.075 0.100 1.2 1.6 3.0 4.0 0.055 0.090 0.130
160 180 0.080 0.110 1.3 1.7 3.25 4.25 0.060 0.100 0.150
180 200 0.090 0.130 1.4 2.0 3.5 5.0 0.070 0.100 0.160
200 225 0.100 0.140 1.6 2.2 4.0 5.5 0.080 0.120 0.180
225 250 0.110 0.150 1.7 2.4 4.25 6.0 0.090 0.130 0.300
250 280 0.120 0.170 1.9 2.7 4.75 6.75 0.100 0.140 0.220
280 315 0.130 0.190 2.0 3.0 5.0 7.5 0.110 0.150 0.240
315 355 0.150 0.210 2.4 3.3 6.0 8.25 0.120 0.170 0.250
355 400 0.170 0.230 2.6 3.6 6.5 9.0 0.130 0.190 0.290
400 450 0.200 0.260 3.1 4.0 7.75 10 0.130 0.200 0.310
450 500 0.210 0.280 3.3 4.4 8.25 11 0.160 0.230 0.350
500 560 0.240 0.320 3.7 5.0 9.25 12.5 0.170 0.250 0.360
560 630 0.260 0.350 4.0 5.4 10 13.5 0.200 0.290 0.410
630 710 0.300 0.400 4.6 6.2 11.5 15.5 0.210 0.310 0.450.
710 800 0.340 0.450 5.3 7.0 13.3 17.5 0.230 0.350 0.510
800 900 0.370 0.500 5.7 7.8 14.3 19.5 0.270 0.390 0.570
900 1000 0.410 0.550 6.3 8.5 15.8 21 0.300 0.430 0.640
1000 1120 0.450 0.600 6.8 9.0 17 23 0.320 0.480 0.700
1120 1250 0.490 0.650 7.4 9.8 18.5 25 0.340 0.540 0.770
Bearing assembly in SOFN housing

Oil level in SOFN housing
BEARING WITH ADAPTER SLEEVE BEARING WITH CYLINDRICAL BORE

Housing Oil Oil Level Housing Oil Oil Level
Designation Quantity Mm Designation Quantity mm
Max. Max. Min. Max. Max. Min.
SOFN 610 0,3 53 33 SOFN 310 0,3 53 33
SOFN 611 0,4 53 37 SOFN 311 0,4 53 37
SOFN 612 0,5 60 40 SOFN 312 0,5 60 40
SOFN 614 0,6 65 45 SOFN 314 0,6 65 45
SOFN 616 1,0 73 45 SOFN 316 1,0 73 45
SOFN 517 0,7 63 42 SOFN 217 0,7 63 42
SOFN 518 0,8 68 45 SOFN 218 0,8 68 45
SOFN 618 1,4 80 55 SOFN 318 1,4 80 55
SOFN 519 0,9 70 50 SOFN 219 0,9 70 50
SOFN 520 1,0 70 50 SOFN 220 1,0 70 50
SOFN 620 1,8 85 57 SOFN 320 1,8 85 57
SOFN 522 1,3 77 50 SOFN 222 1,3 77 50
SOFN 622 2,0 95 67 SOFN 322 2,0 95 67
SOFN 524 1,7 80 60 SOFN 224 1,7 80 60
SOFN 624 2,8 100 65 SOFN 324 2,8 100 65
SOFN 526 2,3 85 60 SOFN 226 2,3 85 60
SOFN 626 3,4 105 70 SOFN 326 3,4 105 70
SOFN 528 2,4 85 60 SOFN 228 2,4 85 60
SOFN 628 4,2 115 70 SOFN 328 4,2 115 70
SOFN 530 2,8 90 60 SOFN 230 2,8 90 60
SOFN 630 6,0 120 75 SOFN 330 6,0 120 75
SOFN 532 3,3 95 65 SOFN 232 3,3 95 65
SOFN 632 6,5 125 80 SOFN 332 6,5 125 80
SOFN 534 5,0 105 75 SOFN 234 5,0 105 75
SOFN 634 7,5 130 85 SOFN 334 7,5 130 85
SOFN 536 5,2 115 80 SOFN 236 5,2 115 80
SOFN 636 10,5 155 90 SOFN 336 10,5 155 90
SOFN 538 5,8 120 85 SOFN 238 5,8 120 85
SOFN 540 7,0 125 85 SOFN 240 7,0 125 85
SOFN 544 8,5 140 95 SOFN 244 8,5 140 95
SOFN 548 9,5 155 110 SOFN 248 9,5 155 110
NOTE :- Oil level has to be measured from the bottom of the housing and not from the
bottom of the indicator.
Lubrication in SOFN housing
The spherical Roller Bearing in SOFN blocks are lubricated with oil: a pick-up ring
in the housing serves to bring about oil circulation . The pick-up ring hangs loosely
on a sleeve on the shaft at one side of the bearing and dips into oil in the lower
half of the housing. As the shaft rotates, the ring follows and transports oil from
the bottom of the housing to a collecting trough formed in the spigot (cylindrical
extension) of the one housing cover on a level with the rollers of the bearing under
the shaft thus permitting oil to enter the bearing. The oil then flows through an
opening in the spigot of the opposite housing cover back into the reservoir at the
bottom of the housing. The collecting trough is so dimensioned that the level of
the oil in the trough guarantees an optimum supply of lubricant to the bearing. The
oil in the rese3036rvoir at the bottom of the housing is cooled, depending on the
ambient temperature, before being re-circulated. This lubrication system permits
SOFN plummer blocks to be used for high-speed bearing applications. The
difference between the maximum and minimum oil levels in the reservoir may be
relatively large when a pick-up ring is employed. The intervals between oil
replenishment or oil change are correspondingly long. The requisite oil quantity for
each housing is given in the tables.
The oil level indicator supplied with the housing should be screwed into
one of the four threaded holes provided in the housing covers. The remaining holes
may be used for oil drainage. The "max." and "min" oil levels given in the tables
should be marked on the indicator.
Mounting/Dismounting - SOFN housing
The pick up ring must always be in position and it's freedom of movement should not be
restricted. If the ring is not incorporated . There will be an almost immediate danger of
bearing damage because of dry running .
It is recommended the pick up ring be positioned on the side of the bearing nearest the
shaft end in plummer blocks having bearings with cylindrical bore.
The side cover with four recesses in the spigot should be place in the same side of housing
as the pick up ring .
The vent of oil level indicator must not be plugged as otherwise an air cushion in the sight
glass may lead to false reading . The actual oil level will be too high and oil will leak out of
the plummer block shaft passage.
Maintenance - SOFN housing
Before starting up for the first time , the oil quantity quoted in the table should be put
into the housing . The maximum oil level guarantees lubrication of bearing when it starts
running before it can be supplied with the oil picked up by the ring . Thus the oil level
should be restored to maximum before starting up after long stoppage.
Even if the housing is carefully cleaned before use there is risk that some impurities will
be left. It is therefore advisable to change the oil after an initial trial running period of
few hours. Subsequent changes can the be made at convenient intervals but should be
undertaken at least once in a year. The bearing must be at a standstill when the oil is
changed.
If , during the trial run no oil leaves the housing , a monthly check of the oil level should be
adequate.
During operation , the oil level may sink to the minimum level given in the tables . If oil is to
be added during operation , it should be filled to a level some 5 mm beneath the maximum
oil level on the indicator to avoid overfilling , since some oil will be in circulation .
A blind hole with an M24 thread plugged with a plastic stopper , is provided in the housing
cap. If required , a thermometer or the sensor of some other temperature measuring
device , may be inserted .The hole stops just short of bearing outer ring , so that it is
possible to measure the temperature in close proximity of the source of heat. A more rapid
indication of temperature change is obtained , would be possible by measuring the
temperature of oil .
INLET DIMENSION
As refer to drawing
LIST OF SPARES
The following spare parts are recommended to be kept as stand by for two years normal
operating condition. Quantity of replacement depends on individual application.
1. Impeller with shaft and hub.

2. Fixed bearing . Refer drg. for brg. No.
3. Free bearing . . Refer drg. for brg. No.
4. Brass sealing plates(if applicable)
5. Coupling : - . Refer drg. for type and size.
ANNEX
DATA RECORDED DURING TRIAL RUNNING OF FAN
CUSTOMER: FAN TYPE:
ORDER REF. No.: APPLICATION:
DATE : STARTED AT : RUNNING
DURATION :
AMBIENT TEMP: ACCEL.TIME : STOPPED AT :
MEDIUM TEMP.: NO LOAD CURRENT :
VIBRATION LEVEL RECORD:
DISPLACEMENT IN MICRONS (PEAK TO PEAK) -VELOCITY IN mm / sec.(RMS).
H - Horizontal, V - Vertical, A - Axial
MEASUREMENT H V A FAN SPEED

LOCATION Dis. / Dis. / Vel. Dis. / Vel. & DAMPER
Vel. POSITION
FAN DE. BEARING
FAN NDE. BEARING
MOTOR DE. BEARING
MOTOR NDE. BEARING
SL.NO. TIME FAN BRG.TEMP °C MOTOR BRG.TEMP °C MOTOR POWER

kW
DE NDE DE NDE
1
2
3
4
5
6
7
CHECKED BY: WITNESSED BY :

ANNEX
DO’S & DONT’S
DO’S :
1. FILL BEARING LUBRICANT OF RECOMMENDED SPECIFICATION AND
QUANTITY AT THE SPECIFIED INTERVALS FOR BEARING HOUSING.
2. CHECK PERIODICALLY THE VIBRATION LEVELS ON BOTH THE BEARINGS OF
THE FAN.
3. CHECK PERIODICALLY THE PROPER SEATING OF THE FAN FOUNDATION AND
FOR ABNORMAL VIBRATION AT ANY LOCATION.
4. CHECK FOR LOOSENESS OF ANY BOLTS IN THE FAN PEDESTALS AND
CASING ETC.
5. AT THE TIME OF ERECTION / COMMISSIONING, OPEN THE BEARING
HOUSING AND CHANGE THE OLD OIL. CHECK IF ANY DIRT OR DUST IS
SETTLED INSIDE THE HOUSING AND CLEAN THOROUGHLY BEFORE
POURING NEW OIL.
6. ENSURE THE DAMPER IS IN CLOSED CONDITION WHILE STARTING THE FAN.
7. PROVIDE INSULATION OVER THE ENTIRE AREA OF FAN COMPONENTS FOR

HIGH TEMPERATURE FAN.
DONT’S :
1. DON’T REMOVE THE INSPECTION DOOR WHEN THE FAN IS IN RUNNING
CONDITION.
2. WHILE SHUT DOWN, ENSURE THE MOTOR POWER CONNECTION IS REMOVED
BEFORE ANYBODY ENTERS IN TO THE FAN FOR ANY VERIFICATION.

ANNEX
BRIEF DESCRIPTION OF FAN COMPONENTS
1. CASING WITH INLET BOX " IT HOUSES ROTOR & INLET CONE.
2. BASE FRAME " IT SUPPORTS CASING, INLETBOX,

BEARING PEDESTAL & MOTOR.
3. BEARING PEDESTALS " THIS IS FOR MOUNTING OF

BEARING HOUSING.
4. BEARING & BEARING HOUSING " THIS HAS BEEN BRIEFED IN OUR
O&M MANUAL UNDER THE
HEADING “ASSEMBLY PROCEDURE
FOR BEARING & BEARING
HOUSING”
5. INLET CONE " IT GUIDES THE ENTRY OF FLOW

MEDIA TOWARDS THE IMPELLER.
6. DAMPER/IVC " TO GUIDE AND CONTROL THE

FLOW AT THE INLET SIDE.
7. INLET/OUTLET FLEXIBLE CONNECTIONS " THIS IS TO TAKE CARE OF THE

CONNECTION DUCT MOVEMENTS
WHEN THE FAN IS IN OPERATION.
8. ROTOR ASSEMBLY " THIS IS COMPRISING OF

IMPELLER,SHAFT,HUB, BEARING &
BEARING HOUSING. IMPELLER
BLADES ARE BACKWARD CURVED
DESIGN.
ANNEX
Troubleshooting can help when you suspect a problem
TYPICAL AREA TO CHECK SOLUTION

POSSIBLE CAUSE
PROBLEM
Mounting of Fan Inadequate mass or stiffness Stiffen /Increase
of supporting structure weight
Misalignment during Shaft, coupling between shaft Correct alignment
installation and drive, belt pulley , shaft
got bent
Impeller Unbalance during Material build-up, corrosion, Install vibration
operation wear monitor to check the
trend ; Clean the
impeller periodically ;
Take preventive action
for corrosion and wear;
In-situ balancing of
impeller
Looseness In the mounting, Between Tighten fastening bolts
VIBRATION shaft and impeller, coupling / ; Replace coupling
pulley or bearing .pulley; tighten bearing
adapter sleeve as per
tolerance given in SKF
catalogue.
Aerodynamics Inlet condition non-uniform, Duct layout to be
pre-rotation of the air, system modified; baffle plate
effect, pulsation due to fan /straighteners may be
operating at surge zone used to achieve
uniform flow; Selection
of fan to be reviewed.
Vibration Impeller unbalance during In-situ balancing
operation
Mounting Inadequate mass or stiffness Stiffen /Increase
of supporting structure weight
PREMATURE
Lubrication Wrong type, overlubrication Check recommended
BEARING
lubrication , quantity
FAILURE
and interval
Environment Contaminants in lubricant, Change lubricant
Ambient temperature high . immediately; Review
selection of lubricant .
ANNEX

POSSIBLE CAUSE
PROBLEM
Alignment Shaft alignment, overtightened Correct alignment
bearings ;dismantle the bearing
refit with specified
PREMATURE
tolerance
BEARING
Loading Radial and/or thrust Review bearing
FAILURE
selection
Load Overload from belt drive or Review bearing
coupling selection
Thermal Shock Malfunctioning controls, Check controls and
sudden operational change system
Vibration System pulsation, looseness Check system ; check
fastening of bolts .
PREMATURE Abrasion/corrosion Excessive dust from system Ensure fan inlet dust
MATERIAL .Fans running with bypassed concentration within
FAILURE dust arrestor. Water/acid specified limit. Review
fume ingress in fan selection of impeller
material for aggressive
condition .
System Effect Turbulent Inlet condition, non- System correction
uniform flow, deviation of required
actual system resistance from
PERFORMANCE predicted one ,
DEFICIENCY IN pre-rotation or swirl at inlet
VOLUME OR Clearances Impeller and inlet Check for deviation
PRESSURE from drawing/manual;
correction .
Driver Belt slippage Belt tightness to be
adjusted.
Environmental Problems Problems Material build-up in Check and clean
casing , inlet or ductwork periodically. System
blockage correction required
Rotation Incorrect motor connection, Follow the indicated
improper Impeller rotation direction of rotation
given on casing by
arrow mark
ANNEX

POSSIBLE CAUSE
PROBLEM
Mechanical Interference Touching between impeller and Adjust inlet gap taking
inlet cone due to external forces care of expansion in
on casing or hot condition , check
Impeller /shaft movement or for expansion provision
thermal expansion and distortions in casing foot ; fixed
and expansion joint
wherever provided are
in place ; remove duct
NOISE load from fan casing by
providing flexible
connection piece.
Bearings Inadequate lubrication, pitted Replace bearing ;
bearing worn balls, races, seal correct alignment
failure, alignment improper,
Airborne High velocities Install Attunuator
Foreign Material in Fan Buildup on fan Impeller, casing Check and clean
Casing preiodically , system
correction required
Drive Belts too loose and squealing Adjust belt tension
Too much grease in Consult manual for
bearing lubrication amount and
interval
Poor alignment Correct
Bent shaft Replace
OVER HEATED Abnormal end thrust Check antithrust blade
BEARING in impeller
Dirt in bearing Clean
Pinching effect on bearing Interference fit of bearing outer Repalce housing with
outer race race in housing correct tolerance
Bearing outer race in Loose housing fit Repalce housing with
rotating in housing correct tolerance
HOW TO ORDER ….
YOUR DATA ABOUT THE :

Installation
process details and position of the fan
site elevation m electrical frequency Hz
Inlet conditions
Pressure : TOTAL or STATIC + mm W C
flow : m 3/s
temperature : °C
relative humidity %
Outlet conditions
Pressure : TOTAL or STATIC mm W C
Gas
dust concentration g/m 3
Possibility of: BUILD UP CO RRO SIO N EROSIO N
Fan
design temperature °C
flow regulation with : IN LET DAM PER IN LET VAN E CO NTROL
VARIABLE SPEED
general arrangement :SINGLE INLET DOUBLE INLET COUPLING
OVER HUNG IM PELLER IMPELLER BETW EEN BEARINGS BELT DRIVE
M ATERIAL or SEALS impositions

ADDRESS AND CONTACT NOS.
MARKETING OFFICES
ADDRESS TEL. NO FAX NO
Hyderabad 040 23390397 040 23390397
Flat no : 202 flakthyd@vsnl.net
Major Residency
(Near AP police officer's
Mess)
Masab Tank
Hyderabad-500028
Pune 020 5534442 020 5534442

Masters Executive Center flaktpune@vsnl.net
Pvt. Ltd.
"Sneha Leela"
1237 , Apte Road
Deccan Gymkhana
Pune - 411004
Mumbai 022 56978940-043 022 56978944
301-303, Chintamani Plaza kj.shah@flaktindia.com
3rd Floor
Andheri Kurla Road , Chakla
Andheri(East)
Mumbai - 400093
Landmark : Opp. German
Remedies
New Delhi 011 26484405. 011 26470630
Shivaram Busines Center 26484463,26484467,2
Greater Kailash Part 11 6286837,43
W-16 , New Delhi-110048 nokesh@flaktindia.com
MANUFACTURING ACTIVITIES
Kolkata 033 24901811 033 24902411
P.O & Villa. Jalkhura
Maheshtala
Dist : South 24 Pgns.
West Bengal -743352
Chennai 044 26272216 044 26272606

Village : Numbal
110, Poonamalle High Road
Chennai - 6000077
INSTRUCTION MANUAL
DESCRIPTION
IDENTIFICATION SHEET
FLAKT REFERENCE
REF. DRG. NO.
APPLICATION
CUSTOMER
FAN DESCRIPTION :-
MAIN CHARACTERISTICS
DEFINITION UNIT RATED LOAD
RATED GAS FLOW KG/S

DIFFERENTIAL STATIC PRESSURE (mmWC)/Pa
TOTAL EFFICIENCY %
RATED OPERATING TEMPERATURE °C
MECHANICAL DESIGN TEMPERATURE °C
FAN SPEED RPM
DENSITY AT 180 ° C Kg/AM³
CRITICAL SPEED RPM
RATED FAN POWER KW
MOTOR POWER KW
FAN WEIGHT KG
FAN ACESSORIES WEIGHT KG
MOTOR WEIGHT KG.
DYNAMIC LOAD DUE TO ROTOR KGF.
GD² VALUE kg.M²
IMPELLER DIA mm
IMPELLER WEIGHT KG.
DAMPER OPERATING FORCE N
ACTUATOR STROKE LENGTH mm
BEARING LUBRICATION
INSULATION AREA (M2) mm
SHAFT DIA AT BRG. mm

L&T Onm HDF - 050414

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FUNCTIONAL DESCRIPTION & DESIGN 4

ADDRESS & CONTACT NO. 53

YOUR FANS.. .. DESCRIPTION AND IDENTIFICATION

FUNCTIONAL DESCRIPTION AND DESIGN

BLADE CENTRIFUGAL FAN TERMINOLOGY

STRAIGHT SHAFT FOR SINGLE INLET IMPELLER

STEPPED SHAFT DIFFUSOR

SHAFT WITH INTEGRATED FLANGE FAN STATOR

The operation and maintenance of machinery of any kind requires a person to be

3. Do not open or access inspection doors while the fan is running.

7. Always use caution in every maintenance or operational procedure.

B. Check for Transportation Damages :

SIMPLE SUPPORTED FANS

2. Check foundation for evenness, and its different levels.

3. Mark centre lines of fan and foundation pockets on the foundation.

NOTE: REFER ENCLOSED ASSEMBLY DRAWING.

♦ FOUNDATION BOLTS, FAN ON BASE FRAME: -

5. Clean the threaded portion of the bolt.

9. Fasten the foundation bolts with base frame.

♦ BEARING PEDESTALS, CASING

CERAMIC ROPE FIXING DETAIL

For Simply supporte fan

ASSEMBLY PROCEDURE FOR BEARING AND BEARING HOUSING

1. PRE -ASSEMBLY CHECKING :

c) Bearing housings although made by precision machining to the given specifications, a

With tapered bore:

a) Keep the bottom half of bearing housings on the bearing pedestal.

b) Clean the shaft with the use of white sprit.

c) Insert the brass seal on to the shaft at impeller end.

d) Insert the M.S cover plate on to the shaft at impeller end.

k) Insert the another double-lip seal on to the shaft if applicable.

m) Insert the lock nut and lock washer on to the shaft.

o) Insert the bearing with large dia of bore facing outside.

p) Insert the taper sleeve on to the shaft.

r) Tighten the lock nut as explained in point no.

t) Insert the another seal on to the shaft.

u) Rest the rotor on the bottom half of bearing housing.

x) Tighten the parting off bolts to the correct tightness.

WITH CYLINDRICAL BORE: -

The force needed to mount a bearing increases rapidly with bearing

The temperature difference between the bearing and its seating

ing to a temperature greater than 125°C(255 °F), however, be-

Wear clean protective gloves when mounting a hot bearing. Lifting

When a bearing requires an interference fit in the housing, a moder-

To facilitate future dismounting equip shafts with ducts

SKF heaters are generally equipped with

A cabinet equipped wiyh an adjustable thermostat and a fan is a

In addition to bearings, couplings, sleeves and other components

Oil baths ensure even heating. They

Bearing rings, or even complete bearings, can be

IMPELLER LOCKING ARRANGEMENT

SIMPLE SUPPORTED FAN OVERHUNG FAN

Fitting of impeller on shaft

Some important notes

The direction of rotation is indicated in fan casing .

Erection on vibration isolator

! Ensure of grouting pocket positions in civil foundation are as per GA drg.

Important point to be noted

! The main idea of providing vibration isolator is to avoid transmission of undue

ACCESSORIES ( REFER ASSEMBLY DRAWING FOR ITEMS APPLICABLE)

5. Fix the evase with fan outlet.

7. Fix the inlet and outlet flexible connection.