Standard boiler 500 mwerection manual (boiler auxiliaries)

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This manual will help you to technical details required during erection of 500 mw boiler. very neatly crafted manual by BHEL.hats off t them.

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Standard boiler 500 mwerection manual (boiler auxiliaries)

  1. 1. STANDARD ERECTION MANUAL (Boiler Auxiliaries) Prepared by Power Sector – Technical Services (HQ) Noida Corporate Quality Assurance Bharat Heavy Electricals Limited, New Delhi 1
  2. 2. CFBC Boiler Erection (250 MW) AIR PREHEATER FOR QUAD SECTOR AIR PREHEATERS NEYVELI (R300 & R 301)THE COPYRIGHT OF ALL DOCUMENTS AND DRAWINGSARE THE PROPERTY OF BHARAT HEAVY ELECTRICALLIMITED. THIS SHALL NOT BE USED WITHOUT THEIRWRITTEN PERMISSION IN ANY FORM OR PART THEREOFFOR ANY OTHER PURPOSES THAT FOR WHICH THISPUBLICATION IS SENT TO THE RECEIVER. 2
  3. 3. 3
  4. 4. CONTENTS1. CONTRACT DETAILS.2. REGENERATIVE AIR PREHEATER – BRIEF DESCRIPTION3. ERECTION ASSISTANCE POLICY4. GENERAL FIELD ERECTION PROCEDURE NOTE5. IMPORTANT INSTRUCTING DO‟S & DONT‟S6. LIST OF APPLICABLE PGMA‟S7. LIST OF INSTALLATION DRAWINGS,8. RECEIPTS & STORAGE OF APH COMPONENTS9. SUGGESTED FIELD INSTALLATION PROCEDURE10. GUIDE TRUNNION TAPER FIR CHECKING PROCEDURE11. SEAL CLEARANCE CHARTS12. LUBRICATION CHARTS13. AIR PREHEATER FIRE14. LIST OF ILLUSTRATIONS15. LAY-UP PROCEDURE16. SEALANTS, THREAD LUBRICANT AND COATING COMPOUNDS 4
  5. 5. 01. CONTRACT DETAILSCUSTOMER NUMBER : R 300 & R 301PROJECT : NLC – NEYVELI 2 X 250 MWLOCATION : NEYVELIAIR PREHEATER SIZE : 29 VIMQ 1850 (80O PA)NOS. / BLR : TWOAIR PREHEATER SL. NO : 0633, 0634, 0635 & 0636TOTAL ELEMENT DEPTH : 1850HOT END ELEMENT : 0.63 DU 700 CARBON STEELHOT END INT. ELEMENT : 1.21 NF6 300 CORTEN STEEL 5
  6. 6. 02. REGENERATIVE AIR PREHEATER – BRIEF DESCRIPTIONGeneralThe Regenerative air Preheater shall be Quad- sector type in which thePrimary air sector is flanked between the Secondary air sectors.In this type of heat exchange the heating surfaces are alternatively heated upby the flue gas passing through and cooled by the air passing over it. Theheat is absorbed by the heat transfer matrix from the flue gases and releasesto the air, The design of the air heater is such that it can give trouble freeservice for extended periods of time, without plugging of flow areas betweenheating element sheets,The regenerative heat exchanger will have a gas tight insulated casing andmust be rested on necessary steel structures.DescriptionEach regenerative heat exchanger shall consist of the following salientcomponents/ assemblies. 1. Modular Rotor 2. Rotor Housing and Connecting Plates. 3. Heating Elements 4. Sealing System. 5. Support Bearing and Guide Bearing. 6. Lubricating Oil circulation system. 7. Drive Mechanism including Auxiliary Drive. 8. Access Doors 9. Observation Port and Light. 10. Cleaning and Washing Devices 11. Rotor Stoppage Alarm 12. Deluge System 13. Element handling Arrangement 14. Fire Sensing Device 6
  7. 7. 1. Modular RotorThe rotor is made up of 24 numbers of full sector modules that are attached tothe rotor post by pinned connections. The modules are loaded with elementsand shipped to site for easier, speedy and quality erection.2. Rotor Housing and Connecting PlatesThe housing is octagonal in shape and consists of the following: Two mainpedestals, two side pedestals, four axial seal plates, two primary air panels,four other panels. And connecting plated with integral support beams.Sandwiched between the top and bottom connecting plated are the panelswhich form an integral structure to take axial and radial loads and also form agas tight enclosure for the of fluids.3. Heating ElementsEach air heater is provided with multi0 layers of heating elements. The coldend elements are basketed for each removal and replacement from the sides.Hot end elements are removable from the top of the gas ducts.4. Sealing SystemOver many years of continuous operation, the sealing has provided to beeffective with minimum maintenance requirements. The design takesadvantage of normal thermal growth to keep sealing surfaces in properalignment.The rotor is divided into equal forming a separate air or gas passage throughthe rotor. Fixed leaf type metal seals are radially and axially attached to therotor structure between each sector. Sector shaped unrestrained radialsealing plates provide the sealing surfaces that divide the rotor into air andgas passage.Because the seals are applied to the shortest leakage path and the sealingsurfaces are externally adjustable, the most effective and continuous leakagecontrol is assured. A circumferential bypass seal is provided to prevent air andgas from bypassing the rotor through the small space between the rotor andhousing.The sealing surfaces are adjustable from outside by loosening the lock nuts.The circumferential bypass seals can be adjusted only from inside of the rotor.As these seals control only bypassing of flow through rotor and the leakage inthat path is being controlled by axial seals, there is no need to adjust themfrom outside.5. Support bearing and guide bearingThe support bearing is of spherical roller thrust bearing type and is located atthe bottom connecting plate. The guide bearing is of spherical roller type andis located at the top connecting plate. The bearing housings are designed toat as oil reservoirs for provision of integral oil circulation system. 7
  8. 8. 6. Lubricating Oil Circulation SystemBoth the support and guide bearings are provided with independent oilcirculation systems. The oil circulation system consists of oil pump, oil coolerpressure and temperature indicators and flow switches. The lubricating oilsystem proposed is a proven design. An identical unit is also connected asstandby.7. Drive Mechanism Including Emergency DriveThe drive system envisaged is of peripheral pin rack- pinion type. It consistsof a three input speed reducer one electric motor for main drive, anotherelectric motor as standby drive, fluid coupling / centrifugal clutch, handcracking facility for manual rotation and a pinion for meshing with the pin rackof the rotor. Normally drive is through the main electric motor and in the eventof electrical trip out, the standby electric motor comes into operationautomatically.8. Access DoorsAdequate numbers of access doors are provided, both at the inlet and outletducts and also in the housing panels for inspection and maintenance.9. Observation Port and LightObservation Port and vapour proof light are provided. These are suitablylocated at the air inlet side to have a complete view of the cold end elementswhile in operation.10. Cleaning and Washing Devices A) Cleaning Device The heat exchanger is provided with a swiveling arm type power driven cleaning device at gas inlet side & gas outlet side, for on load cleaning of air heater elements. The cleaning device unit is located on the hot end & cold end centre section wall with nozzle transversing horizontally in an area across the radius of the rotor, a short distance away from the element packs. B) Off- Load Water Washing Device Two fixed multi- nozzle washing pipes are fitted on one above and one below the rotor. Terminal points of the pipes to which surface connection can be given are located adjacent to rotor housing.11. Rotor Stoppage AlarmRotor stoppage alarm is provided to indicate the slowing down of the rotor.This consists mainly of control unit, vane operated limit switch and vaneswhich are mounted on the trunnion. If the vanes fail to pass under the limitswitch within the set time interval, the timer in the control unit transfers its 8
  9. 9. contact to give an alarm in the control panel, to warn the operator that therotor is slowing down.Control RequirementAn alarm or annunciation is to be provided in the control panel to indicate therotor slowing down condition.12. ‘De Luge’ SystemTwo fixed multi- nozzle fire fighting manifolds are fitted on one above and onebelow the rotor. Terminal points of the pipes to which surface connection canbe given are located adjacent to the rotor housing. During an air heater fire,both fire fighting and water washing manifolds must be used.13. Element Handling ArrangementHeat exchanger is provided with a hand operated hoist and trolley for handlingof hot end elements from inside of the air preheater to the air preheateroperating floor.14. Fire Sensing Device - Thermocouple TypeShell type thermocouple elements mounted on the measuring probe arearranged (in radial direction in the air outlet and gas outlet ducts close to rotorface, such that there is a measuring point between each tangential walls ofthe rotor.The increase in temperature, due to fire, causes a momentarily and recurringincrease of the thermo – electric voltage and the signal released by thermoelements is given to customer DCS at UCB for suitable alarm / annunciation.In the event of an fire alarm, the deluge system valves and water washsystem valves shall be opened manually. This is essential because in theevent of a fire alarm, inspection of the Rotor/ , APH is a must before delugingthe rotor with water. 9
  10. 10. 04. GENERAL FIELD ERECTION PROCEDURE NOTE General arrangement drawing is very important. It should be displayed and used during all phases of erection. Shipping lists carry dispatch components with required drawings. This should be used at the beginning for component identification and supply position. Notes on drawings take precedence over information in the installation manual. If there is a conflict of information between drawings and erection manual, BHEL / Ranipet engineering department should be Drawings carry instruction for erection, designated as “ER NOTES” or “NOTES TO ERECTOR”. Temporary braces and / or blocks are painted yellow. All items painted yellow must be removed prior to operation of the air preheater. Transport and handling damages of the components are to be rectified before installation / assembly. Hydraulic pump & jacks and radial seal straight edge (aluminum channel) are to be handed over to customer after installation is completed. Over lapping of radial and axial seals are to be trimmed by grinding only, not by gas cutting. Trimming of sealing tabs to be done by grinding/hacksaw cutting only. 10
  11. 11.  Check for match marks for all assy. Components and install accordingly to match marks. Use low hydrogen electrodes E-7018 unless otherwise specified. Proper preheating of electrodes and other precautions to be taken. 05. IMPORTANT INSTRUCTION: DO’S & DONT’S Plan in advance the sequence of installation. Refer pert diagram given in this manual. Keep the necessary tools and tackles ready before start of installation. Contact the air preheater engineering department, if any deviation or rectification is to be made. Apply rust preventive oil protect components from rusting due to long storage and bad weather. Store the rotor modules in semi- covered shed or covered with tarpaulin, element cover sheets can be removed before light up of boiler. Maintain the required accuracy in installation which leads fro a satisfactory operation. Tighten bolts to the required torgue wherever given. Fill the bearings with specified oil or equivalent even during installation. Rotate the air preheater in the correct direction of rotation. Keep a record of readings in the FQA check sheets which shall be dispatched for the reference of air preheater engineering department. Weld rotor housing panels, connecting plates (hot & cold) to housing panels, connecting plates (hot & cold) to air and gas ducts as per drawing.IMPORTANT INSTRUCTIONS: DON’TS Do not mix up items belonging to different air preheaters. Do not use shop lugs for lifting other components / assemblies. Do not support any components on cold end / hot end centre sections / connecting plates while lifting them. Do not carryout the bearing assemblies in open, dusty atmosphere. Do not spoil the seal leaf by standing on the, by any other external load or interference with foreign material or by wring direction of rotation. 11
  12. 12.  Do not allow any foreign particle, such as electrode bits, glass wool etc., Enter heat transfer elements during erection. Do not carryout final welds before final alignments, checks, etc. Do not spoil the seal straight edge during trial run. Do not start air preheater without filling with specified lubricants during erection check up. Do not operate air motor without filter and lubricator even during trial run. Oil level of support and guide bearings are to be checked only after stopping of lub oil units. 12
  13. 13. 06. LIST OF APPLICABLE PG MA’SPG MA DESCRIPTION52 – 000 ITEMS PER CONTRACT52 – 010 ROTOR ASSEMBLY52 – 011 POST AND TRUNNION ASSEMBLY52 – 012 PIN RACK ASSEMBLY52 – 013 RADIAL SEAL ASSEMBLY52 – 030 ROTOR HOUSING ASSEMBLY52 – 041 HOT END CONNECTING PLATE ASSEMBLY52 – 042 COLD END CONNECTING PLATE ASSEMBLY52 – 054 AXIAL SEAL ASEMBLY52 – 055 BY PASS SEAL ASSEMBLY52 – 100 ROTOR DRIVE ASSEMBLY52 – 210 ACCESS DOOR ASSEMBLY52 – 211 AIR SEAL PIPING52 – 212 OBSERVATION PORT AND LIGHT ASSEMBLY52 – 217 ROTOR STOPPAGE ALARM 13
  14. 14. PG MA DESCRIPTION52 – 220 GENERAL DETAILS52 – 261 GUIDE BEARING ASSEMBLY52 - 262 SUPPORT BEARING ASSEMBLY52 – 271 OIL PIPING ASSEMBLY (GUIDE BEARING)52 – 272 OIL PIPING ASSEMBLY (SUPPORT BEARING)52 – 274 OIL CIRCULATION UNIT52 – 301 DELUGE AND WASH PIPE ASSEMBLY (GAS INLET)52 – 302 DELUGE AND WASH PIPE ASSEMBLY (GAS OUTLET)52 – 325 TWIN NOZZLE CLEANING DEVICE ARRGT (HE)52 – 326 TWIN NOZZLE CLEANING DEVICE ARRGT (CE)52 – 329 CLEANING EQUIPMENT DRIVE UNIT52 – 360 FIRE SENSING DEVICE52 – 988 COMMISSIONNING SPARES52 – 610 STEAM COIL AIR PREHEATER 14
  15. 15. 08. RECEIPT AND STORAGE OF COMPONENTSParticular attention is to be paid with regard to receipt and storage of Airpreheater components. All components of the Air preheater have amplestrength to withstand the operating conditions and are well protected againstdamage in normal transit. However, rough handling during transit orthoughtless unloading at site may result in distortion and damage whichshould be rectified before erection starts.Care and good judgment must be exercised when transporting and lifting thecomponents so as to avoid bending or twisting, as such distortions willseriously hinder erection and possibly affect the performance of the completeAir preheater.The elements, bearings, oil circulation units, rotor drives, power drivencleaning devices and electrical equipment must be stored in a closed dryplace immediately after unloading to protect them against corrosion. When thebearings or heating surfaces elements are not to be used for an extendedperiod, they should be protected by using a non-drying water repellent rustpreventive oil such as RP 102 of Indian Oil Corporation. They must also beprotected after erection of the boiler house has not been completed. Allremaining parts may be stored in the open, provided they are laid down toavoid any distortion. No rain water should be allowed to collect in any of thecomponents. The pin-rack and machined surfaces of sector plates and, ingeneral, all the machined surfaces should be protected.Note: Also refer the storage manual issued by Power Sector.Storage and Preservation of Heating element Baskets, ref, figAnti rust oils for use on heating surfaces: - RP 102 OF INDIAN OIL CORPORATION - KOTE 203 OR RUSTOP 173 OF HINDUSTAN PETROLEUM - RUSTROL 152 OF BHARAT PETROLEUM - RUSGARD P – 214 Plastipeel chemicals & plastic Ltd, Thane.A pressure pump, garden type spray can of 5 to 10 litres capacity is suitableto apply anti-rust oils with good penetration.Note: Overlooking of minor details of drawings will lead to major rework.In the above oils the “Carrier” oil is volatile and will usually evaporate inseveral weeks under ambient conditions, leaving a protective coating. Thiscoating is water soluble and for this reason the material thus coated must bestored indoors or under protective covering at outdoors. 15
  16. 16. The elements need not be cleaned with water at the time of light – up, if theprotective coating was applied before 3 months.Method of Cleaning and CoatingIt is preferred that element baskets be stored inside of space is available.However, outdoor storage can be achieved with proper protection. The cratesor boxes as shipped shall be opened and the elements should be sprayedwith the recommended oil. If rust scales are noticed, the baskets can becleaned with a jet of compressed air (6 ata) (a nozzle can be attached to thehose to be effective) first and then oil is applied over the rust which will absorbthe oil and deter further rusting.Method of StorageBaskets after coating with oil shall be supported on timbers high enough to befree from the defects of surface water. Timbers (100 mm x 100 mm) or othermeans should be placed on top of the basket piles. Protective covering shouldbe applied over the piles and extending down the sides and securely fastenedto prevent deterioration. It will be necessary to periodically check the coveringfor deterioration‟s and the baskets for rusting. If rusting is observed, the areasshould be re-sprayed with rust inhibiting oil. 16
  17. 17. 09. SUGGESTED FIELD ERECTION PROCEDURE1. Check the elevation of supporting steel and note for any difference. If steel work is out of level by more than 10 mm, rectification of structures is to be carried out. Record readings in CHECK SHEET.2. Mark Centre line on supporting steel for Air preheater location as per General Arrangement Drawing. Record readings in CHECK SHEET.3. If variation of steel work is upto or below 10 mm but more than 1 mm, add suitable thickness of single plate and weld it with the structure. Grind off the top surface of the plate to be within a variation of ± 1 mm. If it is more than 10 mm, correct the structure. Note: The plate that is welded with structure should have breather holes.4. Locate the expansion arrangements in position on support steel and level them with shims provided. The tolerance on elevation should be within ± 1 mm. The surface level should be within 0.1 mm/M. Record final readings in CHECK SHEETS. Sliding surface of the expansion arrangement is self lubricated and this side is to be kept upper side.5. Erect Main pedestals on expansion arrangements and support them temporarily, after maintaining the vertically and elevation. Note: Wherever check sheets are mentioned refer FQA check sheets.6. Pre- assemble support bearing assembly temporarily in cold end centre section.7. Erect cold end centre section along with support bearing assembly.8. Level the cold end centre section flange as per CHECK SHEET. Record the readings in CHECK SHEET. Ensure the gap between the hanger plates and cold end centre section web as given in the drawing in all the four corners.9. Weld the cold end centre section webs with hanger plates by means of cleat angles provided as specified in the drawing of cold end connecting plate assy. Weld is to be tested with L.P.I.10. Trial assemble Hot end centre section on main pedestal. Check diagonal distance between the split line corners of the centre sections as per check sheet. Maintain tolerance as per the CHECK SHEET.11. Ensure the centre of the bore of the centre sections by plumbing. Check the distance between cold end & hot end centre sections in both sides, if variation found more than tolerance given in drawing it is to be corrected. At this position drill and install a drift taper pin between hot end centre 17
  18. 18. section and main pedestals. Remove the hot end centre section and keep it aside.12. Erect the side pedestals on expansion arrangement at proper elevation.13. Erect cold end primary centre section - I & II to the elevation of main centre section.14. Assemble the remaining portion of cold end connecting plate to cold end centre section. All splits are provided with drift pins which must be driven before bolting to achieve good alignment. Install pipe braces. Install the other housing panels. Bolt and tack weld the panels together to hold them in position.15. Ensure vertically and elevation of all pedestals and panels with in 2 mm. Slight shifting may be required to achieve final alignment and record the readings in CHECK SHEET.16. Level the Support bearing housing approximately to 0.1 mm / M with the help of segmental shims. However the housing has to be relevelled at the time of positioning the rotor with respect to housing splits. Open the support bearing housing temporary cover. Clean the internals of the bearing, adapter plate etc. Cover the bearing housing with a single sheet of gasket & cloth to avoid falling of foreign material into the bearing housing which would cause serious damages to the bearing.17. Remove the temporary cover of support bearing housing. Install rotor post and trunnion assembly on the support bearing in accordance with the post and trunnion assembly drawing. This assembly must be lifted and suspended by using the lifting lugs provided on the rotor post. When lowering the post assembly on to the support bearing, jacks must be used to prevent damage to the support bearing and trunnion. Jacks must be located on the centre section assembly in accordance with information provided in the “ROTOR JACKING ARRANGEMENT”- drawing.18. Plumb the rotor assembly and brace it temporarily.CAUTION: Do not unhook the rotor post assembly from the crane until theassembly has been lowered on to the support bearing and is plumbed andadequately braced.19. Lift the hot end centre section assembly using lugs provided and place it on main pedestals with reference to the previous match marks and refix the drift & taper pins and flange bolts.20. Install hot end primary centre section assembly – I & II.21. Install hot end connecting plate assembly including pipe braces. All splits are provided with drift and taper pins which must be driven before bolting to achieve good alignment.22. Use proper lifting devices for handling guide bearing assy. 18
  19. 19. 23. Clean the guide trunnion and guide bearing assembly.24. Install Guide bearing housing assembly as per drawing with proper orientation.25. Ensure the taper fir between the guide trunnion and adapter sleeve by applying oil pressure (300 kg/sq.cm) through trunnion oil hole. Detailed procedure for pressure testing is given in this manual.26. Assemble Guide bearing assembly and torque the cap screws to the specified torque value.NOTE:a) Tighten the screws cyclically to achieve the specified value. b) Rotate the rotor post to four 90” positions and check the tightness of the cap screws at each location.27. a) Recheck the levels of cold end connecting plate, housing assembly and hot end connecting plate and adjust if necessary. b) Complete the welding of the connecting plates. Housing assemblies and connecting plate to housing assembly as per the drawing EXCEPT THE ROTOR DRIVE PANEL. Drive panel may be in lack welded condition till the drive unit assembly is mounted and aligned. After drive unit leveling and pinion alignment with pin rack, the panel can be welded as per drawing. c) Extreme care should be taken to avoid weld distortions. Step back method of welding is to be followed. Use E – 7018 low hydrogen electrodes, small electrodes and low current.28. Adjust the shims at the support bearing housing to achieve the correct elevation of rotor post between the splits.NOTE: a) Keep the cold end split distance as 101 mm so that it will become 95 mm after loading / erection of modules. b) Level the support bearing housing. Recommended levelness of the bearing is within 0.1 mm/M. Check with master level at four places 90” apart. Apply sealing compounds in all the mating surfaces as specified in the drawing. Record the readings in CHECK SHEET. Torque tighten the hold down colts as specified in the drawing. c) Surfaces above the oil level in the bearing housing must be coated with tight oil to prevent rusting during the period preceding start up of Air preheater. d) If necessary, to expedite erection, a good grade of non-detergent motor oil of not less than SAE 50 may be used as temporary oil during erection. 19
  20. 20. 29. Level Guide bearing housing assembly to achieve the required elevation of housing sleeve above guide bearing housing as shown in the drawing.Note: Keep the Critical dimension 6 mm more than the drawing dimension sothat it will become required dimension after loading of modules.30. Fill the specified lubricant as per the lubricant chat enclosed in this manual.31 Level the rotor post. Use a suitable fixture and master level to get vertically of rotor post.32. Lock the support bearing housing as specified in the drawing.33. Lock the guide bearing housing as specified in the drawing.34. Securely anchor the heater housing expansion arrangement to prevent shifting.35. Give temporary blocks at the bottom to support the hot end tracking spool and cut the temporary bracings.36. Align the tracking spool concentric to the rotor post and install tracking rods and stationary spool assembly as per drawing.37. Remove the portion of the tracking spool flange which is screwed to facilitate the assembly of pins to the module with rotor post.38. Remove side pedestal panel (Gas side) and upper connecting plate centre duct section for access to install modules. Attach housing pedestal bracing as shown in the illustration. Centre portion of hot end ducting must be left off for access above the area where modules are to be installed.39. Attach module lifting extensions to module stay plates and torque bolts as specified on module lifting arrangement drawing. For torque value refer table / drawing.40. Attach module lifting beams to lifting stay plate extensions.41. Install turning lug to top of rotor post header as shown in illustration.42. Turn post assembly to align module mounting holes with access opening in spool. Turning is accomplished by using the turning lug assembly which pinned to the rotor post header.43. Proceed to install first rotor module taking care to align with mounting holes in post assembly.44. Install post module mounting pins using hydraulic rams if needed.45. Be sure the upper rotor pin is fully engaged and the lower lug is fully resting on the lower ring prior to removing the module lifting arrangement. 20
  21. 21. 46. With first and second modules installed temporarily space ad install four bolts between first and second modules at periphery.47. Install additional modules, as per the erection instructions of the rotor assembly drawing.48. A additional modules are attached continuously, check and correct chord dimensions by adding or removing spacers are required.49. Following installation of last module, proceed to install permanent spacers and bolts in all the modules. Full length axial spacers are to be provided for installation at this time.50. Check the chord dimensions and record in CHECK SHEET.51. Check and correct rotor level to be within 0.1 mm/M record in CHECK SHEET.52. Weld the permanent lock to the guide bearing as specified in the drawing.53. With permanent spacers ad bolts in place, proceed to install pin risk. At this point the rotor assembly must be grounded (earthed) at all time. Grounding of the rotor is necessary to prevent flow of current through the bearing causing damage by arcing between bearing surfaces while welding is done on the rotor.54. Install al Access doors in hot and cold end connecting plates and ensure proper approach platforms for all manhole doors.55. Clean all the pin-racks. Place pin rack tabs in the pin-rack as per drawing before installing. Locate the pin rack in the rotor shell as per the rotor assembly drawing / pin – rack assembly drawing.56. Assembly the pin racks as per drawing with clamps and adjusters/ wedges. Check the joints with pin space gauge tack weld the assembly. Manually rotate the rotor and examine for circularity of the pin-rack. Make temporary wedges and supports locally from scrap materials.57. All the pin rack joint welds have to be carried out with extreme care to avoid weld distortions. Use small electrodes, low currents and special clamps.58. Recheck the radial and axial run outs and record the readings in CHECK SHEET. The maximum radial run out variation of pins is 3 mm. The maximum axial run out variation of rack is 3 mm. Mark radial high points of pin and axial high point of pin0 rack by welding.59. Install rotor drive assembly as per drawing. 21
  22. 22. NOTE: Check the direction of rotation of pinion with respect to rotor directionof rotation before installation as per GAD.60. Turn rotor and locate the radial high point of pin and axial high point of lower bar that is closest to the pinion.61. Adjust the drive assembly to the clearances shown as per drawing. Check and correct the root gap and bottom gap of pinion. If required drive panel may be adjusted to achieve drive unit & pinion dimension. Record the readings in CHECK SHEET.62. Check pinion teeth for line contact with pins of pin rack by applying blue shim and adjust as required for full contact.63. After the alignment of drive unit assembly and pinion aligment, weld the drive panel with adjacent panels, hot end connecting plates and cold end connecting plates.64. Check to fill the specified oil to the required level as per lubrication chart.66. Install pinion cover as per drawing..67. With rotor drive in place and operable, weld module pins to post rings as specified in the drawing. Assemble the removed portion of the static spool flange with screws.68. Align rotor and maintain the axial run out within 3 mm and record the readings in CHECK SHEET.69. Weld rotor angles as per module assembly drawing and radial seal drawing to get correct elevation of T –bars as per seal setting drawing.70. Install T- bar as given in the radial seal assembly drawing.71. Align T-bar as given below:72. a) Establish radius from rotor post to outer face of the T-bar. b) Attach stationary reference pointer to rotor housing. c) Adjust pointer to the established radius plus thickness of the gauge blocks or feelers. NOTE: Trim T-bars & T- bar tabs of necessary to achieve alignment. CAUTION: Attach reference pointer such that measurements will be made at point of seal contact of T-bars. (Refer seal setting drawing d) Turn rotor and adjust T-bar. Maximum allowable variation is 3 mm for radial and axial run outs. 22
  23. 23. CAUTION: T-bar holding bolt should be tightened to the specified torque as given in the radial seal assembly drawing. Tightening the holding bolts beyond the specified torque is not advisable. e) Check the T-bars & pin-pack bars radial with reference to pointer and record the readings in CHECK SHEET. Pin rack bars should not protrude beyond T-bars.73. Remove the panel bracing from side pedestal and install the panel and weld. Install remaining connecting plate duct portions and weld as per drawing.74. Adjust the bypass seal holding angle as given below: a) Establish the radius of holding angle from T-bar radial high point. Refer seal installation and by-pass seal assembly drawing. b) Set up a pointer with reference to T-bar radial high point and adjust to established radius less thickness of feelers or other type of gauge block. c) Turn rotor and adjust angle to this radius by loosening the retaining bolts and welding angles in o out as necessary. Maximum allowable variation is 3 mm. d) Weld the angle with connecting plate as per the connecting plate assembly drawing.75. Adjust the sector plates as shown in the seal installation and setting drawing. The level of sector plate should be recorded in the CHECK SHEET. CAUTION: Ensure proper tightness of shims in the adjuster box assemblies to avoid failure during operation. Refer the table for torque tightening of the adjuster bolts. Use spherical washer supplied. b) Maintain 0.75 ± 0.25 mm gap between hot end sector plate to tracking spool.76. Align cold end stationary spool and weld segmental plates as per cold end static seat assembly drawing.77. Install and weld rotor post seals as per Radial seal drawing. If necessary trim excess material from the ends of the seal sections to provide butt joints.78. Install axial seals as per axial seal assembly drawing.79. Adjust axial seal plate for seal clearance as per seal setting chart. Record axial seal clearance in CHECK SHEET. Install axial seal tabs near T-bar and pinrack bar as per drawing. Trim if necessary. 23
  24. 24. NOTE: Use the straight edge provided to assist in proper adjustment. Refer drawing “Axial seal straight edge ashy”. CAUTION: Check the direction of rotation and fit the seals in the leading side of seal holding bar.80. Adjust the axial seal plate to sector plate seal such that the seal will butt against the sector plate tight by turning the screws. Refer figure.81. a) Install bypass seals ass shown in bypass seal assy, drawing. b) Adjust seal clearances as shown in seal clearance chart and record in check sheet. c) Provide three layers of bypass seals near sector plates.82. Install Radial seals as given below: a) Fix the aluminum finger tabs provided at inboard and outboard of diaphragm plate and check the sector plates closer to the rotor. This is the established sector plate. b) Move this diaphragm plate under the established sector and adjust the finger tabs to the required seal clearance. c) Set the channel type straight edge (Aluminum channel) at a convenient location. CAUTION: Radial seal straight edge support brackets which are to be left as it is, must be so located as not to interfere with cleaning device lance movement. If necessary, support the straight edge at the centre to prevent sagging. d) Move the finger tabs under the straight edge and set the straight edge t sit over the tabs. Firmly clamp the straight edge. e) Set one radial seal assembly butting the seal leaves with the straight edge. Move the seal under the established sector plate and confirm the correctness of the straight edge setting. f) Then proceed with the installation of the rest of the radial seals. CAUTION: Before setting the seals, ensure the correct direction of rotor rotation. Fit seals on the leading side of the diaphragm. After the seals are set, the rotor must not be turned backward. Radial seals will be damaged of done so. It will be easier for rotating the rotor for setting the seals if the cold end radial seals are set first and then the hot end radial seals. 24
  25. 25. 83. Install out board radial seal tabs as per radial seal assy drawing. Size of the tabs can be trimmed off by grinding to obtain proper fitment. Records radial seal clearance in CHECK SHEET.84. Install inboard and outboard static seal assembly as per the drawing. CAUTION: Welding of static seals to be done with extreme care. e) Set one radial seal assembly butting the seal leaves with the straight edge. Move the seal under the established sector plate and confirm the correctness of the straight edge setting. f) Then proceed with the installation of the rest of the radial seals. CAUTION: Before setting the seals, ensure the correct direction of rotor rotation. Fit seals on the leading side of the diaphragm. After the seals are set, the rotor must not be turned backward. Radial seals will be damaged if done so. It will be easier for rotating the rotor for setting the seals if the cold end radial seals are set first and then the hot end radial seals.83. Install out boar radial seal tabs as per radial seal assy drawing. Size of the tabs can be trimmed off by grinding to obtain proper fitment. Record radial seal clearance in CHECK SHEET.84. Install inboard and outboard static seal assembly as per the drawing. CAUTION: Welding of static seals to be done with extreme care.85. Install axial static seals as per the drawing.86. Install thermostat as per drawing for support and guide bearing assemblies.87. Install Dipstick assembly as given below for guide and support bearing. a) Make out proper orientation of the piping. b) Thoroughly clean all pipes and fitting before installation. c) Seal all pipe and fitting connection as shown. d) All horizontal run of pipes must be level. e) Refer to guide bearing assembly drawing and support bearing assembly drawing for necessary instructions to establish oil level. f) Acid clean all the pipe lines after welding. 25
  26. 26. 88. Install oil circulation system fro support and guide bearing assy. Refer to fig. for block diagram of oil circulation systems.89. Erect water washing and deluge pipe as given below: a) Refer to the general arrangement drawing for proper orientation relating to the rotor rotation. b) Install water washing and deluge pipe assy, as per drawing. c) Rotate the nozzle pipe assy, in the hangers to line up discharge opening of the jets parallel to the heating surface and set expansion tolerance before welding. d) Check customer piping is carried out as suggested.90. Refer to the General Arrangement drawing for location and orientation of the cleaning device. a) Install cleaning device as per drawing at hot end and cold end. b) Use Air tight sealing compound and / or gaskets when attaching and leveling cleaning device to duct transition. CAUTION: The cleaning device must be leveled and the nozzle set to the dimension as given in the cleaning device drawing. The variation should not exceed 12.5 mm. When checked at four equidistance points through traverse area of the cleaning device nozzle. c) Check the cleaning device nozzle traverse dimension relating to heating element. d) Check customer steam piping is installed as suggested. e) Cleaning device nozzle should be parked at inboard end during operation of the boiler.91. Install Observation port and light assembly as per the drawing. Locate Port and light assembly in such a place in the air inlet duct to obtain full view of cold end elements. Adjust light to illuminate the most of the cold end elements across the air duct. NOTE: Accessibility to the port and light is very important.92. Install Fire sensing device in accordance with the drawing.93. Install Rotor stoppage alarm as per drawing.94. Install Oil carry over detector assembly and ensure water supply to the assembly. 26
  27. 27. 95. After installation is completed in all respects remove basket protection sheets and clean the Air preheater internals check up and cold test run have to be made in accordance with the check sheets in the presence of BHEL Ranipet Representatives.96. After conducting an air leak test on the casing of the Air preheater insulation is to be applied as per the recommendation.97. Fix aluminum finger tabs (seat gauges) as per the seal gauge drawing in HE & CE radial seals and axial seals.98. Provide temporary covers / roof for drive unit. LOP units, soot blowers and Guide bearing assemblies to protect from dust / water using scrap materials. 27
  28. 28. 10. GUIDE TRUNNION TAPER FIT CHECKING PROCEDURE1. Lock rotor by welding 150 mm channels at four sides between rotor and shell.2. Remove the adapter sleeve, housing sleeve and guide bearing assembly and clean them using clean cloth.3. Remove the guide bearing housing and keep it aside.4. Clean the taper surface of the guide trunnion. Ensure that the oil hole and the groove in the trunnion are free from any blockage, by pumping oil through the oil hole.5. Lower the adapter sleeve and housing sleeve assembly carefully on the trunnion. Scribe a line on the adapter sleeve and trunnion top and punch mark on the line.6. Install the cap plate and cap screws.7. Tighten the cap screws in a cyclic order to the specified torque.8. Loosen the cap screws and withdraw them by 6 mm.9. Connect the hydraulic pump with pressure gauge and connect it to the oil hole in the trunnion top through suitable hoses and nipples. Check for any leakage.10. Pump oil keeping an eye on the pressure gauge. Hold (200 kg/sq.cm for bearing nos. 23052 & 23060. 250 kg /sq.cm for bearing no. 23072 and 300 kg/sq.cm for bearing No. 23192) pressure and watch for any pressure drop. If there is no pressure drop pump again till the release of adapter sleeve. Note down carefully the pressure at which the adapter sleeve is getting released from the trunnion. 28
  29. 29. 29
  30. 30. 12. RECOMMENDED LUBRICATION CHARTCUSTOMER NOs: R300 & R301 PROJECT: NEYVELI: 1 & 2AIR PREHEATERS: 2 Nos. / BOILER EQUIPMENT QTY/ Fre. of SL IOC HPC BP DESCRIPTION APH Change Main & Standby Servogem01 Elec. Motor Lithon 3 MP Grease 3 0.4 Kg 6 months 3 Brgs. Servo Bharatturbol02 Fluid Coupling Turbinal 46 6.8 lts Yearly prime 46 46 Main drive Servomesh Parathan EP 100 Lts reducer SP 220 Amocam 220 Yearly03 220 0.3 kg a) Gear case Servogem Bharat MP 3 6 month Lithon 3 b) Bearing 3 Support Servocyl Cyncol Bharat Engol04 100 Lts Yearly Bearing C- 680 TC – 680 J- 680 Servocyl Cyncol Bharat Engol05 Guide Bearing 100 Lts Yearly C – 680 TC- 680 J – 680 Lub Oil Pump & Servogem06 Lithon 3 MP Grease 3 0.5 kg 6 months Motor bearings 307 Cleaning Device a) Motor Servogem Lithon 3 MP grease 3 1 KG 6 months bearings & 3 worm gear reducer b) Two stage Servomesh Gear oil ST Spirol 140 EP 1 Lit 6 months worm gear box SP 460 140 c) Sleeve Servogem ---- ---- 0.2 kg 6 months Bearing HT XXNote: Check Oil Level After Stopping of Lub Oil Systems.Caution: Over Filling of Oil in Guide Bearing Assembly May Cause AirPreheater Fire. 30
  31. 31. 13. AIR PREHEATER FIRESAir preheater fires are rare. A fire may occur during cold start up on oil or startup following hot stand by because of poor combustion of the fuel. Theimproper combustion results in unburnt or partially burnt oil condensing anddepositing on the Airpreaheater element surface. As the temperature enteringthe Air preheater increases, this deposit is baked to a hard varnish likematerial. These deposits can ignite as temperature increase to 315 – 370Ocrange. This ignition usually starts in a small area of the deposit. During theearly stages of deposit ignition, external effects are not very apparent. Thedeposit restricts the flow of gas or air so that very little of the heat generatedis carried away from the area of its origin. Downstream generated is carriedaway from the area of its origin. Downstream mixing of the fluids furtherminimizes any external effect. Most of the heat generated is absorbed by themetal heat transfer element nearby. The actual temperature build up duringthis period is relatively slow, If the condition can be detected at that time, theamount of water required to reduce the temperatures quickly to below theignition temperature, is much less.If the ignited deposit remains undetected it will continue to generate heat untilthe metal heat transfer element reaches 730- 765Oc At this point, metal mayignite with temperature reaching 1650 Oc and higher in a matter of minutes.Metal fires are self- sustaining and would require more water than is normallyavailable to drop the temperature to a reasonable level. It should be notedthat Co2, halon and other extinguishing agents are ineffective under thesecircumstances. 14. LIST OF ILLUSTRATIONS01 Exploded view of Modular Air preheater.02 Support bearing assembly – Integral type03 Modified method of tracking hot end sector plate04 Radial seal installation.05 Axial seal installation06 Axial seal plate to sector plate seal adjustable design.07 Block Diagram for oil circulation system – GB08 Oil circulation system09 Recommended swivel joint and cleaning device piping support.10 Storage and preservation of heating element baskets.11 Pinion assy with Worthington hub. 31
  32. 32. 32
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  36. 36. 36
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  41. 41. OIL CIRCULATION UNIT 41
  42. 42. 42
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  44. 44. STORAGE AND PRESERVATION OF HEATING ELEMENT BASKETS 44
  45. 45. 45
  46. 46. 15. LAY UP PROCEDURE FOR AIR PREHEATER1. After completion of installation if there is going top be considerable delay in commissioning the boiler the following preservation procedures have to be adopted.2. All parts exposed outside should be cleaned from dust, debris etc. the drive assembly, bearing assembly; lubricant system shall be covered suitable. (ii) Wherever applicable the correct lubricant should be filled up to the required level.3. The heater should be rotated once in five days a few turns to avoid brinelling of bearings.4. Apply rust preventive to heating elements and cover them completely.5. In general all other rotating parts can be given a few minutes run once in two weeks.6. External loads should not be kept on the heater and care shall be taken from falling objects on Air preheater which may affect seal settings. 46
  47. 47. 16.0 SEALANTS, THREAD LUBRICANT AND COATING COMPOUNDSHIGH TEMPERATURE THREAD LUBRICANTThere are a number of bolts which require to be tightened to a specifiedtorque, further they are subjected to high temperature during operationcausing them to seize making it extremely difficult of their removal if needed.A special lubricant is applied to the bolt threads and contact surface of the bolthead to acquire proper torque during tightening and also to serve as a antiseize medium during temperature service. Typical example: Turnnion bolt,support bearing mounting bolt, sector plate and Axial seal adjustors, axial sealplate to sector plate seal adjustors. Name of Lubricant: 1. Molycote – Imported 2. Mahomoly anti seize thread lubricant.THREAD COATING COMPOUNDA number of threaded fasteners which ma7 require removal at a later date,are exposed to the gases and ambient air. The exposure of the fasteners tosuch adverse environment may result in corrosion and possibly the fastenermay be damaged permanently. Removal also may be very difficult. Suchfasteners are coated with a special compound which protects them duringservice and enables easy removal of them.Typical example: Rotor basket door, cover bolts, bearing housing cover bolts.Name of compounds: 1. Felpro5A – importedSEALING COMPOUNDThere are certain joints made of rough surfaces (fabricated or cast) which areto be sealed by suitable agent to avoid leakage of air and dust. A sealingcompound is provided for this purpose which has to be applied to covers intrunnions and drive pinion.Name of compounds: 1. Armcote - imported 2. Molysulf dust tight joints sealant and thinner.A suitable thinner is also provided to remove the excess compound.GASKET COMPOUNDAt the joints of machined surfaces normally gaskets are used. For largesurfaces a bead of the gasket compound is applied and the surfaces are 47
  48. 48. tightened. The compound dries and forms a leak proof gasket type layerswhich is pliable for removal. This can be applied to even threaded joints.Example: Baring housing cover, water shield cover, sealing tube, etc.Compounds: 1. Felpro – 51169 – imported. 2. GS- 2SEALING TAPETo make threaded joints leak proof Teflon tape is provided. They can bewound on the male thread to a suitable thickness and screwed on to make aliquid tight connection.Note: Locations for the applicable of the above mentioned items are clearlyindicated in the drawings.Attention: Some of the compounds have low shelf- life. SEALING AND ANTI - SEIZE COMPOUNDS FOR AIR PREHEATER Qty/ SUGGESTED SL ITEM APPLICATION BRAND Blr SUPPLIERS M/s ASV Air sealing Industry 334, Sealing Molysulf – covers in Champaklal compound Armocote 01 trunnion and 2kg lts Sion for dust or drive pinion koliwada tight joints equivalent covers Road Mumbai – 400 022. M/s Anabond (p) Ltd 3A, To remove Molysulf – Adyar bridge 0.5 02 Thinner excess thinner or Rd III floor, kg compound equivalent Adyar Chennai- 600 020 Hold tight / Gas tight Drive pinion air 0.5 M/s Jai 03 Shalloc or compound seal cover kg Ganesh equivalent Chemicals, 5, Bearing First main housing covers Holdtight / Gasket 1.0 road, 04 & water shield Shalloc or sealer kg Kasturiba assembly equivalent nagar, Adyar- covers Chennai- 20 48
  49. 49. Ranipet RADIAL FAN (NDZV WITH SLEEVE BEARING) DOUBLE SUCTION ERECTION MANUALPreparation by Checked by Approved by S.SELVAM J.MOORTHY M.DESIGAN 49
  50. 50. DOUBLE SUCTION (NDZV) WITH SLEEVE BEARING 4.0 CONSTRUCTIONAL FEATURESNDZV fans are single stage, double inlet centrifugal machines. The rotor issimply supported by sleeve bearings located on both side of the impeller.The major sub-assemblies of the fan are as follows:  Impeller with shaft assembly.  Bearings and thermometers.  Suction chamber and spiral casing.  Flow regulating devices.  Shaft seals.  Couplings.IMPELLER WITH SHAFT ASSEMBLYThe impeller is a completely welded structure and is made from high tensilesteel with backward curved blades. The selection of the material andthickness for the impeller/ shaft are computed on the basis of the stressanalysis / critical speed programme carried out for each impeller and shaft.The impeller consists of centre plate, blade cover plate and impeller ring. Allweldments are inspected thoroughly by NDT methods. The back plate of theimpeller and the shaft flange has a machined groove which ensures correctlocation of the wheel relative to the shaft during assembly. Impeller is boltedto the shaft flange and locked by means of locking plates. Conical coverplates are provided at the inlet (bolts to the center plate) to guide the inlet flowand to protect the fasteners from exposure to the medium handled by the fan.The impeller is strees relived upon completion of all welding operation and isdynamically balanced after final machining. Replaceable wear liners areprovided in the impeller blades. The shaft is machined to a high degree ofsurface finish for location of impeller, bearings and coupling half etc. thecompleted shaft is dynamically balanced. The critical speed of the rotor is wellabove the operating speed.BEARING AND THERMOMETERSThe fan rotor is supported in between a fixed bearing and a free bearing. Thefixed bearing is arranged on the coupling side. The fans are provided withsleeve bearings and oil lubrication. Provision for mounting temperaturegauges (Mercury in steel thermometers and RTDs) are available on thebearing housings for local and remote (UCB) indication of bearing 50
  51. 51. temperatures. Platinum resistance thermometers (RTD) are provided withalarm and trip connections and for remote indication (control room) of bearingtemperatures.SUCTION CHAMBER AND SPIRAL CASINGSuction chamber and spiral casing are fully welded structures and arefabricated from sheet steel with adequate stiffeners. These are split suitably tofacilitate easy handling and maintenance of rotor, etc. the oblique cone whichforms the entrance to the impeller helps in accelerating the floe. The lowerpart of fan casing rests on the supporting brackets on the foundation.FLOW REGULATING DEVICESFan outlet flow is controlled by inlet guide vane assembly or by inlet damperor by variable speed (VFD/ Hydraulic coupling). (Refer Technical forapplicable flow control device)a) INLET GUIDE VANE ASSEMBLYInlet vanes control device regulates the fan output (flow). The inlet vaneassembly is locates at the inlet of the suction chamber for regulating the flowthrough the fan for different system demand. It consists of single piece casing,vanes, bearings for vane shafts and actuating lever.The bearing housings are supported on the sidewalls of the casing. Leversand links for connection to the actuating lever connect the vane shafts. Thevanes are actuated by means of an actuator. A graduated dial plate indicatesthe vanes position in degrees. The Direction of Opening of Inlet Guide Vane shall be in the Opposite direction of rotation of impeller viewing from suction side.b) DAMPER CONTROL ASSEMBLYThe damper control assembly is located at the inlet of the suction chamber forregulating the flow through the fans for different system demand. It consists ofsingle piece casing, vanes, bearings for vane shafts and actuating lever.The bearing housings are supported on the side walls of the casing. Leversand links for connection to the actuating lever connect the damper shafts. Thevanes are actuated by means of an actuator. A graduated dial plate indicatesthe vanes position in degrees. The Direction of Opening of inlet damper flaps shall be in the same direction of rotation of impeller viewing from suction end.SHAFT SEALSSeals for the shafts are provided to reduce the leakage through the gapswhen the shaft passes through the suction chambers. It consists of labyrinthsection for axial sealing. The labyrinth seal is centrally located and mounted in 51
  52. 52. bearing pedestal / casing wall which helps in precisely controlling the labyrinthpassage.COUPLINGSThe fan and the drive motor is coupled by means of flexible couplings.FAN DRIVEThe fan is driven by an electric motor. For detailed instructions, the respectiveinstruction manual should be referred. 52
  53. 53. 5.0 IMPORTANT INSTRUCTIONS Care should be exercised while lifting the rotor assembly. Balance the rotor assembly and use the right type of lifting tackles. Machined surface. If the same is found to have burns, shall be deburred locally using a smooth file/emery sheet. For installation of primary packers and Conbextra grouting refer relevant chapter. Ensure that the bases of the Fan parts are tightened without strain. Refer Annexure, for details A table of tightening torques is provided in this manual, These values may be used only when specific values are not indicated in the drawings. Refer annexure for tightening torque values. Ensure that the alignment of the coupling is done within 0.05mm. Ensure that all critical clearances of the rotor to stator are properly maintained. Ensure proper calibration of all instruments before installing them. Before starting the Fan, ensure absence of foreign materials like welding electrodes, bolts, nuts, debris etc, in the interior of the Fan casing / ducts. Never run the Fan/Motor without proper functioning of interlocks / protection. Note: For commissioning the fan, Refer O & M Manual. 53
  54. 54. 6.0 TRANSPORT, INSPECTION, STORAGE AND PRESERVATIONTRANSPORTFans are dispatched in dismantled condition with proper packing. Handle allFan parts carefully during transport. Avoid damaging control device, spiralcasing and rotor by careless installation or by chains of lifting devices. Payparticular attention to impeller bearing housing and bearings. They should notbe dropped on the floor or should not be mishandled. During transport of theshaft, avoid damaging the shaft seats and journal surfaces.INSPECTIONWhen packages are received at site, check all parts with the help of thepacking list and drawing, If necessary. Hake the list of missing parts (in caseof shortage) and initiate action for replacement, insurance claim etc. checkany damage which may have occurred to the parts during transit. Take stepsto repair the damages, if any, in consultation with the manufacturer. Check themating dimension like bores and key ways of coupling, suitable for Fan andmotor as per drawing. Note down the product numbers of match or referencenumbers punched/ painted on the parts to ensure proper assembly.STORAGEDue attention given towards storage of Fan components shall pay richdividends. Fan parts, comprising of many components, are expected toperform certain specific functions. They require due care and attention fromthe time that are received at the site. Proper awareness in this sphere hasaverted costly repairs and delay in commissioning of projects. MINIMUM GENERAL STORAGE REQUIREMENTS SL.No. Fan Component Storage Locations Frequency (D) 1. Spiral casing Outdoor (a) Monthly 2. Suction chamber Outdoor (a) Monthly 3. Fabricated impeller Weather protected (b) Monthly Flow regulating 4. Weather protected (b) Monthly devices 5. Bearing pedestals Indoor (c) Monthly 6. Bearing Indoor (c) Monthly 7. Fan shaft @ Indoor (c) Monthly Connecting 8. Indoor (c) Monthly couplings 54
  55. 55. Note: a. Above ground, on blocks, exposed to weather. b. Out doors, above ground, on blocks covered with Tarpaulins and vented fro air circulation c. Clean and dry warehouse. d. Inspect the components at the given frequency and re preserve it suitably. @ Preserve fan shaft as per the instructions givenPROCEDURE FOR PRESERVATION OF MACHINED SURFACES OF FANSHAFTS AT SITE 1. Inspect the machined surfaces of the fan shafts immediately on receipt at site. 2. Clean the machined surfaces, if required, by using kerosene or mineral turpentine Exposed rust to be removed by rust removing solution (Phosphoric acid 10%). 3. Re-preserve by applying the following: a) One cost of TRP 1706 RUST PREVENTIVE FLUID. b) After drying, apply one coat of TRP 1710 and c) After drying apply one more coat of TRP 1710. 4. Tarpaulin and wooden pieces dis-assembled are not to be used at site. 5. The preserved surfaces shall be wrapped with HDPE (High Density Poly Ethylene) sheets 6. Keep the shafts in covered storage. 7. Inspect the machined surfaces every month and re preserve as mentioned above. 55
  56. 56. RECOMMENDED PRESERVATIVE COMPONENTS APPLICATION BRAND NAME TRP 1706, TRP 1710 Machined surfaces (Indoor storage) HDPE (High Density Poly Ethylene) sheets. Machined surfaces (Outdoor TRP storage) Weldments De-oxy AluminatesPRESERVATION TILL ERECTIONDisassembled Fan parts are to be stored in their ex-works packing. Weldedplate parts are to be protected against the influence of weather under thecovers of tarpaulin and on square timber protected against splash water andrain. These parts should not be piled up. They must be stored piece by pieceso that no deformations can occur. The areas where paint is suspected to begiving way to the atmospheric action must be repainted after cleaning withfine emery paper.Parts packed in boxes are to be stored in covered sheds fro protection againstmechanical, chemical damage and contamination. These parts are to beunpacked in sequence of their erection just before they are installed.Wherever possible, these parts should be transported to site as per erectionsequence in – packed condition. The active an effective life of protectivemedia has its own life, In such cases, the protected items may need periodicre-inspection and reapplication of the protective. To ensure perfect safety ofthe equipment the instruction given in this regard must be strictly followed.PRESERVATION OF FAN UP TO COMMISSIONINGAfter erection of Fan at site, conservation must be ensured up tocommissioning and during trial operation. All bright surfaces must be sprayedwith anti-corrosive agents / rust preventives.PRESERVATION OF FANS DURING LONG SHUT DOWNNo special preservation is required for a shut down period up to 2 weeks.Since the maximum effective life, of rust preventive oil/ anti-corrosive agents,when applied, has its own life (3 months), re preservation has to be carriedout after 3 months.The following procedure shall be adopted for long shut down / stand stillperiod. Remove the preservation using suitable solvent. 56
  57. 57.  Brush or paint or spray with anti corrosive coating / Rust preventive oil on all the machined and bright surfaces which are exposed. Replace the oil completely which is originally put Inside the bearing housings. The bearing housings and the regulating device arc to be fully covered with polythene sheets and tied to prevent rain water entering or dust accumulation. Rotate the rotor of Fans by hand once in a week to new position 90o away from the original position. This is done to avoid permanent set of the rotor as well as pitting of shaft and elements of bearings. Run the Fan once in every month for at least 2 hours after removing the polythene cover on bearing housing and regulating device. After each running repeat the above steps. 57
  58. 58. 7.0 PREPARATION FOR ERECTIONThe following details shall be thoroughly studied with the individual contractsregarding size, range, application and scope of supply with reference to theproduct offered.  System layout  Fan assembly drawing  Fan installation plan  System &Equipment foundation plan  Scope of supply and works by BIIEL and Customer  Shipping list with connected erection drawings.All the dispatchable units received at site shall be properly identified withrespect to documents and drawings. Any short supply or damaged items shallbe immediately intimated to the concerned agencies, for transport, inspection,storage and preservation refer the relevant chapter.The exposed machined surfaces and threaded portions leave the factory withprotective preservatives. During storage, these preservative coatings shall bere-established if necessary.Plan for tools, tackles, ringing and handling facilities required for theinstallation of Fans, Special attention may be paid to the size, shape andweight of the components as well… as the space limitation while proceedingwith the Installation.After the concrete pedestal is cast and set, visually inspect the foundation forstrength and soundless. Check for cracks, holes, exposed steelreinforcements. Especially pay attention to check for any left out woodenshuddering material. The fittings around the foundation should be firm. Do notcut off the exposed ends of reinforcement as long as they are well with in thestipulated height of concrete pedestal. This may offer a good bondingbetween the mounting plate and the concrete pedestal.Concrete foundation pier checking should be done with respect to the axis ofthe plant as shown in the layout drawing. The disposition of the Fanfoundation bolt holes and Fan motor foundation pocket holes should bechecked. The elevation of foundation should be checked with reference to thedatum. Chipping of concrete to be done to the correct elevation. For thepermissible tolerances in the foundation the concern foundation plan drawingmay be referred. 58
  59. 59. Mark the center lien of foundation with respect to plant centre line, Identify theareas where primary packers are to be positioned. Ensure provision ofembedded angles in the foundation. These should be in compliance with therelevant drawings.The chipped areas at the already identified locations should be in excess ofthe primary packer plate dimension by 100 mm all around.Inspect the primary packer and base plates and ensure the following:  Flatness of primary packer.  Dimensional compliance of bolt holes.Grouting of primary packer/ bearing pedestal should be done in accordancewith the procedure given in the relevant Chapter.Remove the preservative coatings from machined components just beforecommencing erection. For their removal only liquid solvents should be used.Mechanical process like scrapping, grinding etc should not be employed. Ifany burrs are present remove them locally by using oil stones or emery paper.A thin layer of Molykote paste may be applied at mating surfaces viz.machined components, like coupling bore, shaft ends, machined base, baseplates etc., before commencing erection.Attention should be paid to presence of match marks for components that aresplit to facilitate erection/ maintenance. Such of those components should beduly matched during assembly.All threaded fasteners pertaining to rotor components should be a quality ofclass 8.8 or better, unless specified in the drawing. 59
  60. 60. 8.0 GROUTING INSTRUCTIONOBJECTThis document specifies the technical requirement and procedure to beobserved by erection engineers to achieve correct shimming and non shrinkgrouting of fans. To take care of any special requirements, procedure andlayout of primary packers, your attention is drawn to the concerned drawingson this subject supplied to your project.REFERENCE DOCUMENTThe following documents are essential along with this manual for the correctperformance of the work described in this specification.  Fan general arrangement drawing.  Layout of primary packers and shimming.  Civil drawings provided by Civil Designs / Consultant.GENERAL REQUIREMENT FOR EXECUTIONThe operation of shimming and anchoring the fans are mechanical operationrequiring greatest care. The working areas must, therefore, be kept cleanedand isolated from all other activities, in order to achieve the requiredalignment precision and the items can remain stable.SEQUENCEAll operations and inspection described hereunder must be performed in thechronological order. On completion of works, necessary protocols must bedrawn up.LAY OUT OF FOUNDATION WITH POCKET HOLES AND PLANRefer the general arrangement drawing and plan. Mark the longitudinal andtransverse axes of machine and the reference axis in foundation. Before anyerection work, all the dimension of the foundation and all positions of pocketsmust be checked and compared with general arrangement drawing.Foundation plan and elevation tolerance should be as mentioned in generalarrangement drawing. 60
  61. 61. PREPARATION OF FOUNDATIONHAMMER DRESSINGAll the locations where primary / packers are to be placed shall be hammerdressed to remove all loose concrete/mortar present in the foundation.The purpose is to  Eliminate loose concrete grout present and o reach hard sound concrete to ensure adherence of the subsequent layer of concrete.  Reach the proper level of primary packer specification in the drawing.  Enable free flow of grout.This dressing is to be done additionally 100 mm all around the area of primarypackers and also ensure 25 to 75 mm gap between primary packer bottomand dressed concrete depending upon the grade of grout material.FOUNDATION POCKET DESIGNSFor the foundation pocket design refer the relevant drawing.PRIMARY PACKERPrimary packers (Sole plates) are steel plates with nuts welded to the sides toform a tripod. All primary packers are manufactured and supplied as rawplates. Ensure the flatness of the primary packers. It will have holes suitablefor accommodating the foundation bolts. Three numbers of M16 nuts andthree screws of M16X125 mm are supplied as loose dispatch able units.These three nuts are to be welded to the primary packet at alto at suitablelocation to form a tripod.PLACEMENT OF PRIMARY PACKER ON FOUNDATIONPrimary packers shall be located on the machine foot location on thefoundation after hammer dressing is carried out. Refer arrangement ofprimary packer drawing supplied to your project.PREPARATION OF SHIMS AT SITEStainless steel shims will be supplied by BHEL, Ranipet for fans, For primemovers, the suppliers will supply necessary shims. Maximum height of shimsaggregate must be less than 5 mm. Sheet or roll of 350 mm width will besupplied in calculated length for each type of fan. Customer/consultant to referthe motor drawing/erection manual for the exact arrangement of groundingetc., for motor.Where ever the shims are inserted, they will be prepared at site to have Uslots as shown in the relevant drawing. 61
  62. 62. Each shim is to be prepared based on actual requirement to ensure maximum contact. Maximum number of shall not be more than 7THE FOOT OF THE EQUIPMENTThe height from centre line will be maintained at our works within 0 and – 3mm tolerance with taper not exceeding 1 mm / mtr.LAYING OF PRIMARY PACKERES IN THE HORIZINTAL PLANEThe primary packers shall be laid according to the drawing released for yourproject.LEVELING OF PRIMARY PACKERS  Primary packers shall be leveled by adjusting the screws.  Adjust the elevation of top surface of primary packer in relation to the reference level (Fan axis level.  Adjust the elevation at all points of primary packer.  Check the elevation. This check can be carried out by a theodolitte/ water level. The maximum permissible level change is + 0 to -2mm. The taper shall not exceed 1 mm/mtr.  Lock the level adjusting screws by tack welding with nut.  Primary packer top surface shall be applied with rust preventive.EMBEDMENT OF PRIMARY PACKERThe primary packers shall be embedded with NON SHRINK GROUNT strictlyfollowing the instruction of the grout supplier. The curing time shall be as permanufacturer‟s data. After curing check the level of primary packer and cut offthe adjusting screws flush with grout. Before taking up the grouting, the grout material should be sample tested to meet manufacturer’s specification.Ensure that the foundation pocket is NOT filled with the grout (where ever asshown in the drawing) by putting a thermo Cole as shown in the drawing toavoid grouting of foundation bolts.SHIMMINGThe positioning of the fan components shall be adjusted to achieve the finalalignment (elevation) tolerances specified as before. Shims are to beprepared at site as per the requirement. Shims are to be placed between theprimary packer and the machine foot. Shims are to be placed after cleaningthe top surface of the primary packer. The erection Engineers shall choose 62
  63. 63. minimum number of shims. The shims must be slipped side ways betweenprimary packer and machine foot with out altering or de-forming theembedded primary packer or machine foot. Tack weld the shims together andalso with primary packer.ASSEMBLY OF FAN CASINGThe casing parts can be assembled together by means of connecting flanges,fir bolts and guide plates. The horizontal ad vertical dividing flanges should beconnected with sealing ropes. All parts are identified by match marks forproper assembly. Ensure dimensional compliance of the spiral casing.GROUTING OF PRIMARY PACKERS OF FAN CASINGLevel and grout the primary packer with out any air pockets, by maintaining itselevation with respect to the fan center line, Refer chapter on GroundingInstructions.ALIGNMENT IF SPIRAL CASINGPosition the bottom half of the spiral casing and by suitable shimming, ensure(by water balance) the relative elevation at four corners of the spiral casing.Ensure vertically of the spiral casing. Ensure alignment of spiral casing withrespect to fan centre lines.INSTALLATION OF BERAING PEDESTALPosition the bearing pedestal and align it with respect to foundation and spiralcasing. Ensure elevation of pedestal with respect to fan center line.Ensure horizontality shall not exceed 0.04mm-mtr on the machined surface ofthe pedestal by using leveling spindles along the perpendicular to the fan axisand grout It using NON SHRINK GROUT with out any air pockets. Referchapter Instructions.ASSEMBLY AND INSTALLATION OF ROTORThe following points must be checked and verified during assembly of rotor atsite.  Clean the shaft flange groove and the Impeller groove with liquid solvents like CTC. Scrapping is not permitted.  Check for any burns at the mating flange and if found, remove them using smooth file or emery paper.  Apply rust preventive like MOLYKOTE 321R or OKS 511 at the mating surface and also on the fixing bolts.  Position the impeller with the shaft flange. Ensure proper seating of the locating groove in the shaft flange with the impeller. The impeller can be assembled with the shaft flange at any position. 63
  64. 64.  Fasten with supplied bolts. These bolts must be of quality 8.8 or better. Tighten to the rated torque. The tightening of the bolts must be sequential.  Zero gap between the impeller and the shaft flange mating planes.  Provision of locking plates as shown in the drawing.  Tightness of impeller fixing bolts to the rated torque value.  Assembly of conical cover plates with reference to the match marks.  Provision of asbestos cord between shaft ring and conical cover plate.  Zero gap between impeller and conical cover plate mating face.  Tightness of fixing bolts of conical cover plate to the rated torque values.  The shaft at the bearing seating area, apply to lub oil and cover with clean cloth.MOUNTING OF BEARINGSPosition the bottom half of the bearing housing on the bearing pedestals. Ensure above 80% Blue matching between bearing housing and the bearing pedestals.PRECAUTIONIt is required that every possible care to be taken so that the bearings areassembled properly. It is utmost important that the instructions given in theannexure regarding the assembly of the bearings are strictly adhered to in thesame sequence as indicated to avoid any future problems.Make sure that the bearing bore and shaft diameters are in accordance withthe drawings. For the bearing clearances, refer drawing / Fan Technical Data.No bearing shall be accepted if it found pitted rusted or damaged.Wipe the bearings with clean cloth. For assembly details refer annexure.ROTOR ALIGNMENT  The following points are to be checked and confirmed during rotor alignment.  Dimensional compliance of the bearing as per the drawing.  Correct elevation of bearing pedestal and Horizontality of bearing housing to 0.04mm/ mtr. 64
  65. 65.  The shaft at fixed ed bearing should be leveled to within 0.04mm/mtr. To achieve this, the free end bearing housing may be raised or lowered as required.  Provide shims of thickness 2 to 3 mm between the bearing housing and bearing pedestal fro future maintenance purpose.  Record the bearing clearances after assembly.  For the bearing clearances, refer drawing/ Technical Data.COMPLETION OF ERECTIONCoupling bores and shaft end dimensions should be recorded prior toassembly.Coupling halves may be heated in oil bath to around 90 Deg C above ambienttemperature for easy mounting. (But never exceed a temperature of 120 DegC.) (Soaking time 2 hrs). Mount the coupling halves. Mount the top half ofspiral casing ensuring provision of sealing cords as indicated in the drawing.Check and record the impeller clearances. Install the inlet damper assembly.Ensure its orientation. The flaps of damper shall open in the same direction ofrotation of impeller viewing from suction side. Couple the two damperassemblies and then connect to actuator. Ensure identical operation ofdamper flaps.Ensure that, duct loads are not supported on the fan casing. This can beascertained by the position of flexible elements in the expansion joints. Installthe motor (any hydraulic coupling if applicable as per the guide lines given bythe manufacturer. Motor is to be aligned to 0.05mm with respect to fan in bothradial and axial direction. Ensure correct coupling gap (and hot alignment ofthe hydraulic coupling if applicable). Refer supplier‟s catalogue.If the connecting couplings are GEAR / BIBBY type, fill the connectingcoupling with recommended grease. Refer lubrication chart. All the couplingbolts should be tightened to the rated torque. Mount labyrinth shaft seal atshaft end. A minimum radial clearance of 0.1 mm should be maintainedbetween labyrinth elements and shaft surface. As a final step in completion oferection, dowel all the areas as specified in the drawing after satisfactory trialrun of fan and after rechecking fan- motor alignment. Necessary protocols are to be recorded as per the QPI. 65
  66. 66. 10.0 LUBRICATINO INSTRUCTIONSThe fan bearings are lubricated by means of Oil lubricationOIL SPECIFICATIONThe oil to be used shall be a turbine quality. The oil must not foam duringoperation. Foam removing agents containing silicon must not be utilized. Theoil must have well anti- corrosion properties.RECOMMENDED OILRefer Technical Data Sheet Chapter 2.0LUBRICANT FILLINGFill the recommended lube oil (through a fine mesh strainer only up to therequired level. Do not mix lubricants of different grade and make.LUBRICANR CHECKAt first commissioning and after a basic overhaul, the entire oil must bedrained after an operating period of 100 hrs. All dirt should be eliminated fromthe bearing housing. Then fill in again the oil through the fine mesh strainer.CARE OF LUBRICANRTest the quality of the oil every month and if found unsatisfactory and orcontaining water / dirt the oil should be changed immediately.FREQUENCY OF OIL CHANGEFirst change of oil : After 100 hrs. of initial operation.Subsequent changes : Refer Technical Data sheet (chapter 2.0)Check for oil contamination between oil changes as above.During each oil change, drain flushes and refill. 66
  67. 67. Ranipet RADIAL FAN (NDV WITH ANTI-FRICTION BEARING) SINGLE SUCTION ERECTION MANUALPreparation by Checked by Approved by S.SELVAM J.MOORTHY M.DESIGAN 67
  68. 68. 4.0 CONSTRUCTIONAL FEATURESNDV fans are single stage, single inlet centrifugal machines. The rotor issimply supported by anti-friction bearings located on both side of the impeller.The major sub-assemblies of the fan are as follows.  Impeller with shaft assembly  Bearings and thermometers.  Suction chamber and spiral casing.  Flow regulating devices.  Shaft seals.  Couplings  DrivesIMPELLER WITH SHAFT ASSEMBLYThe impeller is a completely welded structure and is made from high tensilesteel with backward curved blades. The selection of the material andthickness for the impeller/shaft are computed on the basis of the stressanalysis/critical speed programme carried out for each impeller and shaft. Theimpeller consists of back plate, blade, and cover plate and impeller ring. AllWeldments are inspected thoroughly by NDT methods. The back plate of theimpeller and the shaft flange has a machined groove, which ensures correctlocation of the wheel relative to the shaft during assembly.Impeller is bolted to the shaft flange and locked plates. Conical cover platesare provided at the inlet (bolted to the back plate to guide the inlet flow and toprotect the fasteners from exposure to the medium handed by the fan. Fan,the impeller is stress relived upon completion of all welding operation and isdynamically balanced after final machining. The shaft is machined to a finishfor location of impeller, bearings and coupling half.etc. The completed shaft isdynamically balanced. The critical speed of the rotor is well above theoperating speed.BEARING AND THERMOMETERSThe fan rotor is supported in between a fixed bearing and a free bearing. Thefixed bearing is arranged on the coupling side. The Fans are provided withanti-friction bearings and oil lubrication. Provision for mounting temperaturegauges (mercury in steel thermometers and RTDs) are available on thebearing housings for local and remote (UCB) indication of bearing 68
  69. 69. temperatures. Platinum resistance thermometers (RTD) are provided withalarm and trip connections and for remote indication (control room) of bearingtemperatures.SUCTION CHAMBER AND SPIRAL CASINGSuction chamber and spiral bearing are fully welded structures and arefabricated from sheet steel with adequate stiffeners. These are split suitably tofacilitate easy handling and maintenance of rotor, etc. the oblique cone whichforms the entrance to the impeller helps in accelerating the flow. The lowerpart of fan casing rests on the supporting brackets on the foundation.FLOW REGULATING DEVICESFan outlet flow is controlled by inlet guide vane assembly or by inlet damperor by variable speed hydraulic coupling or by VFD motor. (Refer asapplicable)a) INLET GUIDE VANE ASSEMBLYInlet vanes control device regulates the fan output (flow). The inlet vaneassembly is located at the inlet the suction chamber for regulating the flowthrough the fan for different system demand. In consists of single piececasing, vanes, bearings for vane shafts and actuating lever. The bearinghousings are supported on the sidewalls of the guide vane casing.Levers and links for connection to the actuating lever connect the vane shafts.The vanes are actuated by means of an actuator. A graduated dial plateindicates the vanes position in degrees. The Direction of Opening of Inlet Guide Vane shall be in the Opposite direction or rotation of impeller viewing from suction side.b) DAMPER CONTROL ASSEMBLYThe damper control assembly is located at the inlet of the suction chamber forregulating the flow through the fan for different system demand. It consists ofsingle piece casing, flaps, bearings for flap shafts and actuating lever. Thebearing housings are supported on the side walls of the casing.Levers and links for connection to the actuating lever connect the dampershafts. The flaps are actuated by means of an actuator. A graduated dial plateindicates the flaps position in degrees. The Direction of Opening of inlet damper flaps shall be in the same direction of rotation of impeller viewing from suction end. 69
  70. 70. SHAFT SEALSSeals for the shafts are provided to reduce the leakage through the gapswhen the shaft passes through the suction chambers. It consists of a labyrinthsection fro axial sealing. The labyrinth seal is centrally located and mountedon both side bearing pedestal. Casing wall which helps in precisely controllingthe labyrinth passage.The fan and the drive motor is coupled by means of flexible couplings.FAN DRIVEThe fan is driven by an electric motor. For detailed instructions, the respectiveinstruction manual should be referred. 70
  71. 71. 5.0 IMPORTANT INSTRUCTIONS Care should be exercised while lifting the rotor assembly. Balance the rotor assembly and use the right type of lifting tackles. Machined surface. If the same is found to have burrs, shall be deburred locally using a smooth file/ emery sheet. For Installation of primary packers and Conbextra grouting refer relevant chapter. Ensure that the cases of the Fan parts are tightened without strain. Refer Annexure, for details. A table of tightening torque is provided in this manual. These values may be used only when specific values are not indicated in the drawings. Refer Annexure for tightening torque values. Ensure that the alignment of the coupling is done within 0.05mm. Ensure that all critical clearances of the rotor to stator are properly maintained. Ensure that all critical clearances of the rotor to stator are properly maintained. Ensure proper calibration of all instruments before installing them. Before starting the Fan, ensure absence of foreign materials like welding electrodes, bolts, nuts, debris etc, in interior of the Fan casing/ ducts. Never run the Fan/Motor without proper functioning of interlocks/ protection. For commissioning the fan, operation and maintenance manual. 71
  72. 72. 6.0 TRANSPORT, INSPECTION, STORAGE AND PRESERVATIONTRANSPORTFans are dispatched in dismantled condition with proper packing. Handle allFan parts carefully during transport. Avoid damaging control device, spiralcasing and rotor by careless installation or, by chains of lifting devices. Palparticular attention to impeller bearing housing and bearings. They should notbe dropped on the floor or should not be mishandled. During transport of theshaft, avoid damaging the shaft seats and journal surfaces.INSPECTIONWhen packages are received at site, check all parts with the help of thepacking list and drawing. If necessary. Hake the list of missing parts (in caseof shortage) and initiate action for replacement insurance claim etc. check anydamages which may have occurred to the [parts during transit. Take steps torepair the damages, if any, in consultation with the manufacturer. Check themating dimensions like bores and key ways pf coupling, suitable for Fan andmotor as per drawing. Note down the product numbers or match marks orreference numbers punched/painted on the parts to ensure proper assembly.STORAGEDue attention given towards storage of Fan components shall pay richdividends. Fan parts, comprising of many components, are expected toperform certain specific functions. They require due care and attention fromthe time they are received at the site. Proper awareness in this sphere hasaverted costly repairs and delay in commissioning of projects. MINIMUM GENERAL STORAGE REQUIREMENTS Sl. No. Fan Component Storage Locations Frequency (D) 1. Spiral casing Outdoor (a Monthly 2. Suction chamber Outdoor (a) Monthly 3. Fabricated impeller Weather protected (b) Monthly Flow regulating 4. Weather protected (b) Monthly devices 5. Bearing pedestals Indoor (c) Monthly 6. Bearings Indoor (c) Monthly 7. Fan shaft @ Indoor (c) Monthly 8. Connecting couplings Indoor (c) Monthly 72
  73. 73. Note: a) Above ground, on blocks, exposed to weather. b) Out doors, above grounds, on blocks covered with Tarpaulins and vented for air circulation. c) Clean and dry warehouse. d) Inspect the components at the given frequency and re preserve it suitably. @ Preserve fan shaft as per the instructions givenPROCEDURE FOR PRESERVATION OF MACHINED SURFACES OF FANSHAFTS AT SITE 1. Inspect the machined surfaces of the fan shafts immediately on receipt at site 2. Clean the machined surfaces, if required, by using kerosene or mineral turpentine. Exposed rust to be removed by rust removing solution (Phosphoric acid 10%) 3. Re-preserve by applying the following: a) One coat at TRP 1706 rust preventive fluid. b) After drying, apply one coat of TRP 1710 and c) After drying, apply one more coat of TRP 1710. 4. Tarpaulin and wooden pieces dis-assembled are not to e used at site. 5. The preserved surfaces shall be wrapped with HDPE (High Density Poly Ethylene) sheets. 6. Keep the shafts in covered storage. 7. Inspect the machined surfaces every month and re preserve as mentioned above.PROCEDURE FOR PRESERVATION OF ANTI-FRICTION BEARINGS 1. The store room must be free from dust. 2. Ideal ambient temperature should be 20 to 30 deg c. 3. Relative air humidity should nor exceed 60%. It may be necessary to install air dehumidifier in places where relative humidity is high. 4. If the bearing is found to be dry and dirty, it should be thoroughly washed and cleaned before re-packing, 73

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