Attch a - Woodcock Fan PMI Schedule.pdf

Client:

Client PO/No:

Fan Serial No:

Fan Type: BFN 450 100 - 75 Date of Manufacture:

1.0 Preparation.

1.1 Introduction

1.2 Receiving

1.3 Handling

1.4 Storage

2.0 Technical Data.

2.1 Fan

2.2 Motor

2.5 Ancillary Equipment

3.0 Fan Installation

3.1 Foundation

3.2 Erection and Alignment

3.3 Tightening Torques

4.0 Operation

4.1 General

4.2 Pre Commissioning Checks

4.3 Starting Procedure

4.4 Commissioning

5.0 Routine Inspection and Maintenance

6.0 Faults and Possible Causes

7.0 Drawings

8.0 Spares

9.0 Drawings and Manufacturers Data Sheets / Instructions

10. Disassemble, recycling or disposal at End of Life

11.0 Balance Certificate

Certificate Number 6897

Airstream Works, Blackmoorfoot Road, Crosland Hill, Huddersfield, HD4 7AA, United Kingdom Internet: www.fanmanufacturers.com E-mail: sales@fanmanufacturers.com

Tel: +44 (0) 1484 462 777 Fax: +44 (0) 1484 462 777 Registered In England No: 1353953

A thorough annual inspection and maintenance procedure should be carried out by an engineer experienced in Fan applications. (Contact Richard Wilson: richardwilson@fanmanufacturers.com)

Installation, Operation and Maintenance Instructions Manual , including Commissioning and Pre-Commissioning Checks

Contents

E1146 W20750

Turbo Air Ltd

31 October 2013

Page M1 http://www.fanmanufacturers.com mailto:sales@fanmanufacturers.com mailto:richardwilson@fanmanufacturers.com

1.0 Preparation

1.1 Introduction

1.2 Receiving

1.3 Handling

1.4 Storage

At the end of the storage period, remove the fan bearing housing covers and examine the bearings for moisture contamination. If the grease has hardened or become contaminated clean it out and replenish with the appropriate quantity of the specified grea

Each fan is inspected and usually works run before leaving the factory. It is adequately prepared for transport. All equipment must be carefully inspected when received on site and quantities checked against delivery notes, particular attention should be made to fasteners when supplied loose. Any shortage or damage should be reported at once to the carrier and to Woodcock & Wilson, whether discovered immediately on receipt or later during assembly where hidden damage may at not first be evident.

Where lifting eyes or lugs are provided these should be used, where not supplied the points of lift should be selected with care to prevent distortion of any part. Do not lay fan parts on uneven ground and always ensure that heavy parts are packed level to avoid distortion. Shafts, machined parts, motors, bearings etc.

should not be left in the open and adequate cover should be provided. Assembled fans must not be lifted by the impeller, shaft, bearings , couplings or drives.

Woodcock & Wilson industrial fans are carefully designed to suit the specified operating conditions and if they are used in accordance with these conditions and maintained as advised in their instruction manuals they will give many years of satisfactory service. A variety of arrangements are available with a choice of impellers to suit differing environments and characteristic requirements. The specific details for the fan or fans to which this manual applies are summarised in section 2, technical data. The manual also incorporates data on Installation, Commissioning and Maintenance along with specific Fan requirements. PLEASE

ENSURE THAT THIS MANUAL REACHES THE PERSONNEL RESPONSIBLE FOR THESE

OPERATIONS.

If a fan cannot be installed immediately it must be protected from environmental conditions. Store the fan in a clean, dry, vibration free location and turn its shaft by hand several turns each week to keep a film of lubricant on the bearing faces and to prevent indenting of the races by stationary rolling elements. If the fan motor has anti condensation heaters it is advisable to energise them. Any scratches or scrapes on the fan components must be re-touched with suitable paint to prevent rusting.

Observe also any storage requirements detailed in supplementary manufacturers publications included in this manual.

Page M2

2.0 Technical Data

2.1 Fan

Fan Type BFN 450

Flowrate: 0.94 m³/s

Fan Inlet Pressure: 373.63 Pa

Fan Discharge Pressure 0 Pa

Fan Differential Pressure 373.63 Pa

Fan Speed 1420 rpm

Fan Power Absorbed 3/5 KW

Air/Gas Density: 1 1/5

C

Static

IP55

00 January 1900 m³/s

Pa kW rpm

2.2 Motor

Manufacturer

Power kW

Pole

Frame Size

Area Classification

Volts

Ph

Hz

Fan Efficiency

Measurement Category

Efficiency Category

Operating Details at Optimum Energy Efficiency

Flow Rate

0.75

Safe Area

System Operating Method

Year Of Manufacture

Running Speed

Input Power

Efficiency Grade at Optimum Energy Efficiency Point

Pressure

380-420

Electrical Supply

The fan case is fully welded externally, however it cannot be classed "leak proof" due to the shaft seal and inlet and outlet connections which may not be totally gas tight.

ABB MOTORS

Page M3

2.3 Ancillary Equipment

Page M4

3.0 Fan Installation

3.1 Foundation

3.2 Erection and Alignment

3.3 Tightening Torques - Metric Course Threads - Material Grade 8.8

Size

Nm Lbs Ft Nm Lbs Ft Nm Lbs Ft

M8 24 18 16 12 23 17

M10 47 35 31 23 38 28

M12 81 60 54 40 61 45

M16 198 146 135 100 149 110

M20 386 285 258 190 270 200

M24 668 492 440 325 454 335

Note: The above figures apply to dry bolts and nuts in joints clamping steel or similar components.

STAINLESS STEEL (A470 OR 316)

Size

Nm Lbs Ft Nm Lbs Ft

M6 5.5 4 8 6

M8 15.5 11.5 22.5 16

M10 28.5 21 35 26

M12 51.5 38 58 43

M16 131.5 97 144.5 106.5

M20 244 180 254 187.5

M24 393 290 405 299

Note: The above figures apply to dry bolts and nuts in joints clamping steel or similar components.

Special care is necessary where fan sets are mounted on steel structures, these can be used but must be level and well braced in all directions to ensure adequate rigidity.

Cadmium Plated Screws in Tapped Holes or Cadmium Plated Bolts and Standard

Cadmium Plated Nuts

If the fan is not supplied or fitted with anti vibration mounts or other means of isolation, appropriate measures must be taken to ensure that no external vibrations from adjacent machinery is transferred to the fan bearings.

Untreated Bolts & Nuts

The User/Installer shall ensure that the fans fitted with inlet or outlet ducts shall also be fitted with an upstream or downstream IP20 barrier that prevents the entry of foreign particles into the fan mechanism.

The fan is supplied as an assembled unit and need only be bolted down securely to a level substantial foundation, taking care to align the inlet and outlet connections with the associated plant duct work or equipment. Ensure that no external forces are being applied to the fan case from the connecting ducts.

Flexible connectors are incorporated for small discrepancies and differential expansion, care must be taken to support and pull down evenly otherwise distortion may occur leading to misalignment. Note: certain checks are required prior to fitting inlet and outlet ducting, see section 4.2.

Cadmium Plated Bolts with Cadmium Plated Self Locking

Nuts (e.g. Philidas)

Plated Screws in Tapped Holes or Plated Bolts and Standard

Plated Nuts

Plated Bolts with Plated Self Locking Nuts (e.g. Philidas)

Reinforced concrete is recommended as the best type of foundation for fans. The minimum weight of concrete should be about four times the combined weight of all rotating parts or twice the dead weight of the complete fan set whichever is the greater.

Page M5

4.0 Operation

4.1 General

4.2 Pre Commissioning Checks Checked

Checks prior to attachment of inlet and discharge ducting.

Checks after fitting inlet and discharge ducting.

It is advisable to engage the services of a Woodcock & Wilson service engineer to carry out or supervise commissioning of the fan, however if the client or clients representative is to carry out this work the following pre commissioning checks, starting and commissioning procedures must be adhered too. The check lists must be completed, signed, dated and returned to Woodcock & Wilson.

2. Check inside fan case for dirt and foreign items. It will be necessary to remove inspection / access doors.

2. Check that anti-vibration mounts, if fitted, have been levelled. If not level in accordance with details in installation and maintenance instructions.

The recommended procedure for pre-commissioning checks, starting procedure and commissioning is outlined in this section. It should be considered that the fan may form part of a system in which sequential starting along with other apparatus may be involved. In the case of fans designed to handle hot gases it should be remembered that when running cold the shaft power will increase and could possibly overload the drive, unless measures are taken to avoid this. This can be achieved by reducing speed partially, fully closing inlet vanes or dampers or fitting an inlet or discharge isolation plate.

On arrival at site the fan flow rate and velocity etc. should be checked to confirm compliance with site requirements.

1. Check fan inlet and discharge for dirt and foreign items, if possible check the inlet ducting and discharge ducting for same.

3. Check running clearance between inlet cone and impeller eye.

4. Check that all moving parts can rotate freely and that no fouling occurs.

4. If flexible connections are fitted with inner sleeves check that the inner sleeves do not protrude into fan inlet or discharge duct.

3. Check that all guards and terminal covers are in place, fitted correctly and firmly secured.

1. Check that the fan is firmly bolted to the floor or steelwork.

Page M6

4.3 Starting Procedure

Temperature Readings

Electrical

Vibration

Where vibration monitoring Equipment is fitted this must be utilised and readings noted for future reference.

Measure vibration levels at motor DE & NDE bearings. These readings should be generally in line with figures shown in Fan Balance Section of User Instructions Documentation.

The fan should be run for an extended period and the following items measured and logged.

Motor DE bearing endcap surface temperature. This should be in line with motor O & M Manual.

4.4 Commissioning

Measure motor line voltage and input current on each phase, log and check that average current is below full load current on motor nameplate.

Where temperature monitoring equipment is fitted to bearings and case this must be utilised and readings noted for future reference.

Instruction manuals for the control gear and any monitoring equipment must be consulted for starting and controlling the fan. High temperature fans should be started with closed inlet vanes or damper to reduce the load at start up progressively opening the vanes as the temperature rises. If the fan has to start in sequence with other apparatus ensure that the appropriate instructions are observed. When satisfied that the fan is fit to start, and it is safe to do so, energise the motor for a short time to ensure that the direction of rotation is in accordance with the arrangement drawing and rotation arrows.

Page M7

5. Routine Inspection & Maintenance (Excluding motor and electrical equipment)

Daily

Monthly (Or every 600 running hours)

Annually

Examine the condition of brass anti-spark materials for wear, corrosion or deterioration and replace if necessary.

Remove casing inspection doors and look inside for excessive dirt build up and clean if necessary. Check for damage to impeller or evidence of any rubbing contact. If possible check running clearance between impeller eye and inlet cone.

Check shaft seal for damage or wear and replace if necessary.

Note: This is for guidance only. In the light of operating experience it may be found necessary to inspect at different intervals to those suggested.

Check balance & vibration levels are still within specified limits and re-balance if necessary.

N.B. BEFORE COMMENCING MAINTENANCE OTHER THAN SUPERFICIAL EXAMINATION, ENSURE

THAT THE ELECTRICITY SUPPLY IS ISOLATED AND LOCKED OFF.

Examine superficially for escape of lubricant and for any unusual vibration or noise. Check security of guards.

Please note if removing shaft, anti rust on non finished parts must be removed prior to withdrawl on bearings and taperlock with thinners or penetrating oil.

Where applicable with the fans stopped remove the fan casing drain plug, allow any accumulation of liquid to drain away and then replace the plug.

Ensure any monitoring devices are operating correctly.

Thoroughly examine flexible joints for damage or deterioration.

Inspect all steelwork and repair any damaged paint areas.

This should be carried out by an engineer experienced in Fan applications.

Contact Richard Wilson (richardwilson@fanmanufacturers.com)

Page M8 mailto:(richardwilson@fanmanufacturers.com)

Page M9

6.0 Faults and Possible Causes

6.1 Excessive vibration / noise

a. Worn or damaged impeller

b. Paper / dirt build up on blades causing imbalance

c. Rotating parts rubbing

d. Bent motor shaft

e. Motor shaft out of alignment

f. Impeller loose on shaft

g. Faulty or loose motor bearings

h. Weak foundations or loose foundation bolts

i. Motor out of balance or having an electrical fault

j. Faulty monitoring system indicating excessive vibration or noise

6.2 Motor Overload

a. Impeller rubbing

b. Failed motor bearing

c. Motor winding fault

d. Switch gear fault / single phasing (loss of one supply line)

e. Fan speed too high

g. Low gas temperature on hot gas fans

6.3 Fan fails to Start

a. Impeller scraping heavily on scroll or object inside preventing rotation

b. Motor single phasing e.g. Due to fuse failure in one line.

c. Electrical fault resulting in power not reaching motor.

d. Trip circuits in motor not re-set.

6.4 Motor trips out on run-up

a. Overload relay in control gear incorrectly adjusted or unsuitable.

b. Run up time in control gear incorrectly set.

c. Motor overloads See 6.3 above.

7.0 Drawings

Fan GA Drawing W20750 -GA

8.0 Spares

9.0 Drawings and Manufacturers Data Sheets / Instructions

10. Fan disassemble, recycling or disposal at End of Life

Note: When disassemble, recycling or disposal of fan at end of life please contact Woodcock & Wilson Ltd. We will arrange and organise all work required .

Note: If motor cooling ribs or cooling fan guard become fouled up, overheating may occur without necessarily indicating overload (depending on the type of motor protection)

Note: Any Spare or replacement part not fitted by Woodcock & Wilson Ltd Engineer, must be fitted by an engineer experienced in Fan applications. After fitting the replacement parts, the pre-commissioning & commissioning procedures listed in this manual mu

d. Excessive run-up time e.g. due to shortage of accelerating torque from motor which could be due to excessive voltage drop in supply cables.

f. System resistance too low on fans with an overloading power characteristic (restriction / dampering or speed reduction required)

Page M10