1. The document discusses the fan erection sequence for a 2x660 MW power plant in Suratgarh. It includes steps like foundation work, assembly of components like the suction chamber and impeller housing, alignment of the rotor and motor, blade installation, and lube oil piping work. 2. Key steps include blue matching, leveling, coupling heating and alignment, grouting, and ensuring blade tip clearances are within specifications. Acid cleaning of lube oil piping is also described. 3. The document provides detailed guidance on fan assembly with visuals and remarks on each step to ensure proper execution.

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ID FAN ERECTION SEQUENCE
SURATGARH-(2X660 MW)
Prepared by: Suvendu Samal

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disclosures. Delete if not needed.Suratgarh -2X660 MW 2
INTRODUCTION
• Fans are provided to control the flow of air or gas through equipment or through a series
of components interconnected with a system of duct work. The fan increases the pressure
of a flow stream to offset the pressure losses that result from system resistance.
•Types of Fan : Draft fans are classified as either Centrifugal or Axial, according to the
direction of air or gas flow through the fans:
 Centrifugal fans move air or gas perpendicular to the impeller shaft.
 Axial fans move air or gas parallel to the impeller shaft.

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LIST OF ACTIVITIES
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Sl. No. Activities Remarks
1 Foundation take over
2 Blue matching of sole plate motor and impeller housing
3 Alignment of sole plate with respect to centre line as per drawing
4 Erection of suction chamber, impeller housing, diffuser assembly
5 Alignment and leveling of above wrt to center line
6 Coupling Measurement & Heating (Oil Bath or Induction Heating)
7 Erection of Motor with coupling
8 Erection of Rotor assembly
9 Alignment of Rotor assembly
Alignment Steps:-
a) Master Level of Rotor Assy (Tolerance: 0.04mm)
b) Torquing of Rotor Assy with Housing Bullet
c) level of Housing & Rotor Assy
10 Grouting of Housing Sole Plate
11 Alignment of motor with rotor assembly
12 Grouting of all sole plate and motor base plate
13 Erection of expansion bellow suction and discharge side N.A
14 Erection of Silencer assembly N.A
15 LOS system piping and flushing
16 Erection and alignment of blade pitch control power cylinder
17 Erection of linkage assembly
18 Erection of blades
19 Alignment of blades with bottom impeller housing
20 Erection of Seal air fan
21 Cleaning of silencer and silencer hood
22 Trial run of motor
23 Final alignment of motor with fan

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FOUNDATION CHIPPING
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BLUE MATCHING OF HOUSING SOLE
PLATE
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SOLE PLATE LEVELNESS
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MILL SOLE PLATE CENTRE LINE , FLATNESS AND ELEVATION CHECKING.

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ERECTION OF SUCTION CHAMBER,
HOUSING AND DIFFUSER
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ERECTION OF DIFFUSER, BEARING HOUSING AND SUCTION CHAMBER.

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BLUE MATCHING OF MOTOR SOLE PLATE
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BLUE MATCHING OF MOTOR SOLE PLATE IS CARRIED OUT BY MEANS OF
SCRAPING.

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DIMENSIONAL CHECK OF COUPLINGS..
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COUPLING MEASUREMENT BY INSIDE MICROMETER.

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COUPLING HEATING
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•The Coupling is heated by means of Coil heating.
•The Coupling heating temperature is elevated up to 150*C.

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COUPLING HEATING
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•The Motor Shaft Coupling and Rotor Shaft Coupling are mounted on them respectively.

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ERECTION OF ROTOR AND MOTOR
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MOTOR AND ROTOR ERECTION.

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RADIAL SEALING..
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•The Copper radial sealing are mounted on the Bearing housing to avoid the fly ash to
accumulate on the seating area of rotor and further to assist in free rotation of Rotor.

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CHECKING OF ROTOR LEVEL
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CHECKING OF ROTOR LEVELNESS WITH THE HELP OF SQUARE LEVEL.

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ROTOR ASSEMBLY TORQUEING
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TORQUEING OF ROTOR ASSEMBLY WITH HOUSING BULLET.

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GROUTING OF SUCTION CHAMBER,
BEARING HOUSING AND DIFFUSER
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GROUTING OF SOLE PLATES OF BEARING HOUSING, DIFFUSER AND SUCTION
CHAMBER.
•The shuttering work is carried out prior to grout of the sole plates. The Studs are protected
from grout material by surrounding the studs with thermacol.
• The Stud area is also filled with sand prior to grout in order to prevent the entrance of grout
material.

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ROUGH ALIGNMENT OF FAN AND MOTOR
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• Motor Side • Rotor Side
•The rough alignment of Fan and motor is to carried out prior to grouting of Motor
Sole plate.
• Reading has to be taken for vertical and Horizontal run out and the maximum
allowable tolerance to be kept at +/- 0.05mm.
•Then after the rough alignment the hot alignment has to carried-out where the
Horizontal run-out remains same and the vertical run-out is to be maintained as per
specifications.
ROUGH ALIGNMENT OF FAN AND MOTOR PRIOR TO
GROUT.

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HOT ALIGNMENT OF FAN AND MOTOR
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•This practice is to be followed for all Axial
Flow ID Fans, mainly in Super Critical
Design.
• In case of ID Fan (Axial) flow, as there is the Hot flue gas that flows through the Fan, it
has to be Hot Aligned or in other words, the motor has to be off aligned.
• The Angular misalignment (due to thermal expansion of fan housing) at motor and fan
side must be brought to right dimensions by alignment of Vertical and Horizontal dimension
of Motor.

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BLADE AND ACCESSORIES
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• List of Items:
 Piston Ring,
Spring Loaded Seal Ring,
 Bolt & Washer
•The Blade bolts are to be torqued up to 750 Nm.

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TYPE OF BLADES:
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• Backward Curved Blades : These are normally the Airfoil type. The airfoil blade is widely
used and has several advantages:
 Highest Efficiency,
 Low Noise Level,
 Stable Operation,
 Ideal Capabilities for high- speed service.
The use of backward curved blades should be avoided on applications where significant
levels of large or adhesive particles are present.
• Straight Blades : These are sometimes called radial blades. The Advantages are:-
 Wide range of capacities,
 Good Abrasion resistance,
 Simplified maintenance, easy for blade replacement
The disadvantage of straight blades is the relatively low operating efficiency and an
overloading horsepower characteristics.
• Radial Tip Blades : Radial blades are normally used for moderately erosive gas
applications. The Advantages are:-
 High capacity for size,
 Excellent Abrasion resistance,
 Essentially self cleaning capabilities
The disadvantage of radial tip blades is the efficiency is not as high as that of backward
curved blades.

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TYPE OF BLADES:
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•Typical Forced Draft (FD) Fan Blade •Induced Draft (ID) Fan Blade

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BLADE BOLT TORQUEING
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BLADE TIP CLEARANCE
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•Bearing Housing
1
2
3
4
5
6
7
8
• The Reading of each blade has to be recorded at the positions as note above
inside the bottom of Bearing Housing and after Box-up the clearance from top of the
Bearing housing to be recorded.
• The above dimensions are necessary to find the longest blade from the given sets
of blades been fixed on the rotor assembly.

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LUBE OIL SKID
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LUBE OIL STATION PIPING
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LUBE OIL STATION PIPING ROUTING
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LUBE OIL STATION PIPING LAYOUT
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• The Piping Layout as indicated in the above slide, shows us there are 3 terminals been
connected to Rotor Sump namely (RL)- Return Line/ Drain Line, (PL)-Pressure Oil Inlet Line to
Main Bearing, (AL)- Air Expansion Line. These points are connected to the main bearing.
• The Other 3 Terminal Points from the Lube Oil Station are connected to the HAD(Hydraulic
Actuator Device)/ Servo.
• The 3 points are namely (PH)- Pressure Oil Hydraulic, (LH)- Leakage Oil Hydraulic, (RH)-
Return Oil Hydraulic.
• The Main Purpose of the Oil Piping is to assist the Blade movement for Open/Close conditions
depending upon the requirement of air flow.

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ACID CLEANING OF LUBE OIL PIPING
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PROCEDURE FOR ACID CLEANING OF
PIPES
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• Lube oil systems and its oil lines are erected fully as per approved drawing.
• Lube Oil Lines are then dismantled and one end of each pipe is blocked by wooden plug
or temporary blank flange. Tight fitting of the wooden plug or blank flange with gasket and
bolt is ensured so that no leakage of chemicals occurs during acid cleaning process.
• The dissembled pipeline pieces are filled with DM water and flushed few times. It is to
ensure that there is no leakage through the wooden plug or temporary blank flange
provided at one end of the pipe.
• 5% Hydrochloric acid (HCL) solution is filled in the pipes. The solution is allowed to soak
in the pipes for 04 Hours and then drained in a safe place and neutralized. The pipes are
then flushed with DM water for 05 to 10 Minutes.
• The Pipes are again filled with 05% liquid ammonia solution. The solution is allowed to
soak for 30 minutes and then drained.
• The pipe is rinsed with DM water and the Flushed water is Checked with Universal PH
Indicator for a PH level in between 6.5 to 7.5.
• The Internal surface of the pipes is dried with dry compressed air.
• The lines are filled with Lube oil and uniform Oil film is achieved through out the internal
surface of the pipe.