Ranipet

AXIAL FAN
(KKK DESIGN 11 HUB FLANGE)

SINGLE STAGE

ERECTION MANUAL

Prepared by Checked by Approved by

S.SELVAM J.MOORTHY M. DESIGAN

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

4.0 CONSTRUCTIONAL FEATURES

When looking in flow direction, the fan consists of the following Components.

• Suction Chamber
• Fan housing
• Rotor consisting of shaft, one impeller with adjustable blades with pitch control mechanism.
• Main bearings (Anti-friction bearings)
• Outlet Guide Vane housing with guide vanes
• Diffuser

STATOR

Suction chamber, fan housing and diffuser are welded structural steel fabrications, reinforced by
flanges and gussets, resting on the foundation on supporting feet. The supporting feet are fixed on
the foundation in such a way that they slide and without clearance at the sliding supports of suction
chamber and diffuser. On its impeller side, the suction chamber is designed as an inlet nozzle.
Guide vanes of axial flow type are installed in the fan and guide vane housings, in order to guide
the flow.

• Suction Chamber and Fan Housing, Outlet Guide Vane housing and diffuser are flexibly
connected via expansion joints.
• Fan and Outlet guide vane housings are horizontally split, in order to facilitate access of the
rotor for dismantling and assembly. Those parts of the pitch control unit, which are arranged in
the guide vane and diffuser cores are accessible through assembly openings.
• The fan is driven from the inlet side. The shaft runs on Anti-friction bearings. The main bearings
are accommodated in the core of the bearing housing. The impeller is fitted to the shaft in
overhung position.
• The centrifugal and the setting forces of the impeller blades are absorbed by the blade bearings.
For this purpose, the blade shafts are being held in combination of radial and axial anti-friction
bearings. Each blade bearing is sealed off by means of several seals, in both directions
(towards the inside and outside).

ROTOR

The rotor consists of a shaft, impeller, and a servomotor. The rotor is accommodated in Cylindrical
Roller bearings. In addition, Angular Contact Ball bearing is arranged on the coupling side in order
to absorb the axial thrust. Double contact tele-thermometers and double resistance thermometers

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

monitor the bearing temperature. These thermometers must be connected to signaling instruments
at the site. Lubrication and cooling of these bearings are ensured by a combination of oil bath and
circulating lubrication. Simmer rings are always installed, filled with grease. The oil ventilated
through the lube oil return pipe, which opens into the oil reservoir. The ventilation hood is mounted
on the reservoir.

FAN ACCESSORIES
COUPLING
The fan shaft is connected to the motor shaft by means of Flexible couplings while intermediate
shaft bridges the distance between the shaft ends, which are a part of the coupling assembly.
These couplings are capable of compensating mounting and operational inaccuracies to a certain
extent. The close-fit, high strength spring plates are firmly retained. No lubrication is required for
the coupling parts.

OIL CIRCULATION SYSTEM

The oil system consists of an oil tank, two pumps (one standby), filters, coolers and other necessary
fittings and instruments. A pressure relief valve maintains the pressure in the system. The
lubricating oil is fed through a pressure compensated flow-regulating valve. A Hydraulic
Accumulator (Pressure Reservoir) in the system absorbs the pressure fluctuations during blade
adjustment.

DRIVE MOTOR
Constant speed synchronous induction motors drive these fans. For installation, operation and
maintenance reference is drawn to the instructions of the respective motor suppliers.

SILENCERS

These fans are provided with a silencer to attenuate airborne noise to acceptable level. The
silencer consists of baffles packed with sound absorbing wool retained by perforated plates.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

5.0 IMPORTANT INSTRUCTIONS

• Care should be exercised while lifting the shaft assembly. Balance the shaft assembly and
use the right type of lifting tackles.
• Machined surfaces if found to have burrs, shall be deburred locally using a smooth file /
emery sheet.
• For installation of primary packers and Conbextra grouting refer Chapter 8.0
• Ensure that the bases of the fan parts are tightened without strain. Refer Annexure for
details.
• A table of tightening torque is enclosed in the annexure of this manual. These values may
ONLY be used if specific values are not indicated in the drawings.
• Ensure that the alignment of the coupling is done within 0.05mm.
• Ensure early commissioning of lub oil system to facilitate checks on impeller blades.
• 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.

For commissioning the fan, refer Operation and Maintenance Manual.

Protocols are to be signed by BHEL and customer for the FQPs made at site.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

6.0 TRANSPORT, INSPECTION, STORAGE AND PRESERVATION

TRANSPORT

Fans are dispatched in dismantled condition with proper packing. Handle all fan parts carefully
during transport. Avoid damaging Suction chamber, Impeller housing, OGV Assembly, Diffuser and
Rotor by careless installation or by chains of lifting devices. Pay particular attention to Rotor. It
should not be dropped on the floor or be mishandled. During transport of the rotor, avoid damaging
the impeller and servomotor.

INSPECTION

When packages are received at site, check all parts with the help of the packing list and drawing, if
necessary. Make the list of missing parts (in case of shortage) and initiate action for replacement,
insurance claim etc. Check any damages, which may have occurred to the parts during transit. Take
steps to repair the damages, if any, in consultation with the manufacturer. Check the mating
dimensions like bores and key ways of coupling, suitable for fan and motor as per drawing. Note
down the product numbers or match marks or reference numbers punched / painted on the parts to
ensure proper assembly.

STORAGE

Due attention given towards storage of fan components shall pay rich dividends. Fan parts
comprises of many components are expected to perform certain specific functions. They require
due care and attention from the time they are received at the site. Proper awareness in this sphere
has averted costly repairs and delay in commissioning of projects.
MINIMUM GENERAL STORAGE REQUIREMENTS

Sl.No. Fan Component Storage Locations Frequency (D)

01 Suction Chamber Outdoor (a) Monthly
02 Diffuser & Core Outdoor (a) Monthly
03 Silencer Weather Protected (b) Monthly
04 OGV Assembly Weather Protected (b) Monthly
05 Impeller Housing Weather Protected (b) Monthly
06 Shaft with Brg Assy @ Indoor (c) Monthly
08 Impeller and Servomotor assembly Indoor (c) @ Monthly
09 Rigiflex coupling Indoor (c) Monthly
10 Machined packers and Shims Indoor(c) Monthly
11 Instruments Indoor(c) Monthly
12 Lub oil system Indoor(c) Monthly

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Note:-
a) Above ground, on blocks, exposed to weather.
b) Out door, above ground, 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.
@ Specific attention should be given to ensure that the Shaft with bearing assembly, Impeller and Servomotor is stored

inside the covered shed and preserved properly. This rotor is assembled in our works in an air-conditioned hall.

PROCEDURE FOR PRESERVATION OF MACHINED SURFACES OF FAN SPARE SHAFTS 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 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.

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 not 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.
5. The bearing should be first kept in a vessel filled with kerosene for about half an hour and
then washed to take out the dirt.
6. It should then be cleaned in another vessel with filtered kerosene.
7. The final cleaning is to be done by using petrol of mineral turpentine oil.
8. It should be then allowed to dry completely. Pressuraised air for cleaning or drying
purpose is not recommended. (RUST GARD P214)
9. The washed and dry bearing is to be dipped in anti-corrosive oil.
10. The excess oil should be allowed to escape and bearing should be repacked in a
waterproof sealable plastic bag and put in to the carton again.

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RECOMMENDED PRESERVATIVE COMPONENTS

Application Brand Name

TRP 1706, TRP 1710

Machined surfaces ( Indoor storage )
HDPE (High Density polyethylene) sheets.

Machined surfaces ( Outdoor storage ) TRP

Weldments De-oxy Aluminates

Shaft with bearing assembly Oil ISO VG 68 Equivalent: SERVO PRIME 68

PRESERVATION TILL ERECTION

Disassembled fan parts are to be stored in their ex-works packing. Welded plate parts are to be
protected against the influence of weather under the covers of tarpaulin and on square timber
protected against splash water and rain. These parts should not be piled up. They must be stored
piece by piece so that no deformation can occur.

The areas where paint is suspected to be giving way to the atmospheric action must be repainted
after cleaning with fine emery paper. Parts packed in boxes are to be stored in covered sheds for
protection against mechanical, chemical damage and contamination. These parts are to be
unpacked in the sequence of their erection just before they are installed. Wherever possible, these
parts should be transported to site as per erection sequence in packed condition.

The active and effective life of protective media has its own life. In such cases, the protected items
may need periodic re-inspection and reapplication of the protective. To ensure perfect safety of the
equipment the instruction given in this regard must be strictly followed.

The shaft with bearing assembly is filled with preservative oil and dispatched from our works. The
shaft should be hand rotated for few turns once in a week in order to lubricate the upper part of
the bearings and avoid pitting of bearings. If by any chance, necessity arises to preserve the
bearing assembly for a longer period, the preservative oil should be drained and refilled with fresh
oil once in a year.

PRESERVATION OF FAN UPTO COMMISSIONING

After erection of fan at site, conservation must be ensured up to commissioning and during trial
operation. All bright surfaces must be sprayed with anticorrosive agents/rust preventives.

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PRESERVATION OF FANS DURING LONG SHUT DOWN

No 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 carried out after 3 months.

THE FOLLOWING PROCEDURE SHALL BE ADOPTED FOR LONG SHUTDOWNS / STAND STILL
PERIOD.

• Rotate the rotor by hand for few revolutions once in two days and set rest at a new
position 90 Deg away from the original position. This is done to avoid permanent set of the
rotor as well as pitting of shaft and elements of bearings.
• Blow the rotor with compressed air once in ten days to remove hard deposits on the
blades.
• Once in ten days, run the lub oil pump and operate the servomotor from blades full open
to blades full close several times.
• Run the fan once in fifteen days for at least half an hour. After each running, repeat the
above steps.

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7.0 PREPARATION FOR ERECTION

The following details shall be thoroughly studied with the individual contracts regarding size, range,
application and scope of supply with reference to the product offered.

• System layout
• Fan assembly drawing
• Fan installation plan
• System & Equipment foundation plan
• Scope of supply and works by BHEL and Customer
• Shipping list with connected erection drawings

All the dispatchable units received at site shall be properly identified with respect to documents and
drawings. Any short supply or damaged items shall be 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 with protective
preservatives. During site storage, these preservative coatings shall be re-established if necessary.

Plan for tools, tackles, rigging and handling facilities required for the installation of fans. Special
attention may be paid to the size, shape and weight of the components as well as the space
limitation while proceeding with the installation.

After the concrete pedestal is cast and set, visually inspect the foundation for strength and
soundness. Check for cracks, holes, and exposed steel reinforcements. Especially pay attention to
check for any left out wooden shuddering materials. The fittings around the foundation should be
firm.

Do not cut off the exposed ends of reinforcement as long as they are well within the stipulated
height of concrete pedestal. This may offer a good bonding between the mounting plate and the
concrete pedestal.
Concrete foundation pier checking should be done with respect to the axis of the plant as shown in
the layout drawing. The disposition of the fan foundation bolt holes and fan motor foundation
pocket holes should be checked. The elevation of foundation should be checked with reference to
the datum. Chipping of concrete to be done to the correct elevation. For the permissible tolerances
in the foundation the concern foundation plan drawing may be referred.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

Mark the centre line of foundation with respect to plant centre line. Identify the areas where
primary packers are to be positioned. Ensure provision of embedded angles in the foundation.
These should be in compliance with the relevant drawings.

The chipped areas at the already identified locations should be in excess of the primary packer plate
dimension by 100 mm all around.

Inspect the primary packer and base plates and ensures the following.

• Flatness of primary packer.

• Dimensional compliance of bolt holes.

Grouting of primary packer should be done in accordance with the procedure given in the relevant
Chapter.

Remove the preservative coatings from machined components just before commencing erection.
For their removal only liquid solvents should be used. Mechanical process like scrapping, grinding
etc should not be employed. If any 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, base plates etc before commencing erection.

Attention should be paid to presence of match marks for components that are split to facilitate
erection / maintenance. Such of those components should be duly matched during assembly.

All threaded fasteners pertaining to rotor components should be a quality of class 8.8 or better
unless specified in the drawing.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

8.0 GROUTING INSTRUCTION

OBJECT

This document specifies the technical requirement and procedure to be observed by erection
engineers to achieve correct shimming and non-shrink grouting of fans. To take care of any special
requirement, procedure and layout of primary packers, your attention is drawn to refer to the
concerned drawings on this subject supplied to your project.

REFERANCE DOCUMENT

The following documents are essential along with this manual for the correct performance of the
work described in this specification.
• Fan general arrangement drawing.
• Layout of primary packers and shimming.
• Civil drawings provided by civil designs / consultants.

GENERAL REQUIREMENT FOR EXECUTION

The operations of shimming and anchoring the fans are mechanical operation requiring greatest
care. The working areas must therefore be kept cleaned and isolated from all other activities in
order to achieve the required alignment precision and the items can remain stable.

SEQUENCE

All operations and inspection described here under must be performed in the chronological order
mentioned. On completion of work, necessary protocols must be drawn up.

LAY OUT OF FOUNDATION WITH POCKET HOLES AND PLAN

Refer the general arrangement drawing and plan. Mark the longitudinal and transverse axes of
machine and the reference axis in foundation. Before any erection work, all the dimension of the
foundation and all positions of pockets must be checked and compared with general arrangement
drawing. Foundation plan and elevation tolerances should be as mentioned in general arrangement
drawing.

PREPARATION OF FOUNDATION
HAMMER DRESSING
All the locations where primary packers are to be placed shall be hammer dressed to remove all
loose concrete/mortar present in the foundation. The purpose is to eliminate loose concrete grout
present and to reach hard sound concrete to ensure adherence of the subsequent layer of concrete.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

Reach the proper level of primary packer specified in the drawing. Enable free flow of grout.
This dressing is to be done additionally 100 mm all around the area of primary packers and also
ensure 25 to 75 mm gap between primary packer bottom and dressed concrete depending upon the
grade of grout material.

FOUNDATION POCKET DESIGNS

For the foundation pocket design refer the relevant drawing.

PRIMARY PACKER

Primary packers (Sole plates) are steel plates with nuts welded to the sides to form a tripod. All
primary packers are manufactured and supplied as raw plates. It will have holes suitable for
accommodating the foundation bolts. Three numbers of M16 nuts and three screws of M16X125
mm are supplied as loose dispatchable units. These three nuts are to be welded to the primary
packer at site at suitable location to form a tripod.

PLACEMENT OF PRIMARY PACKER ON FOUNDATION

Primary packers shall be located on the machine foot location on the foundation after hammer
dressing is carried out. Refer arrangement of primary packer drawing supplied to your project.

PREPARATION OF SHIMS AT SITE

Stainless steel shims will be supplied by BHEL Ranipet for fans. For prime movers the supplier will
supply necessary shims. Maximum height of shims aggregate must be less than 5 mm. Sheet or roll
of 350 mm width will be supplied in calculated length for each type of fan. Customer / consultant to
refer the motor drawing/erection manual for the exact arrangement of grouting etc. for motor.
Where ever the shims are inserted they will be prepared at site to have U slots as shown in the
relevant drawing.

Each shim is to be prepared based on actual requirement to ensure

maximum contact. Maximum number of shims shall not be more than 7.

THE FOOT OF THE EQUIPMENT

The height from center line will be maintained at our works within 0 and -3 mm tolerance with
taper not exceeding 1 mm / meter.

LAYING OF PRIMARY PACKERS IN THE HORIZONTAL PLANE

The primary packers shall be laid according to the drawing released for your project.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

LEVELING OF PRIMARY PACKERS

• Adjusting the screws shall level primary packers.

• Adjust the elevation of top surface of primary packer in relation to the reference level (Example
Fan axis level etc.).
• Adjust the elevation at all points of primary packer.
• Check the elevation. This check can be carried out by a Theodalite / water level. The maximum
permissible level change is +0 to -2mm. The taper shall not exceed 1mm/mtr.
• Lock the level adjusting screws by tack welding with nut.
• Primary packer top surface shall be applied with rust preventive.

EMBEDMENT OF PRIMARY PACKER

The primary packers shall be embedded with non-shrink grout strictly following the instruction of
the grout supplier. The curing time shall be as per manufacturer data. After curing check the level
of primary packer and cut off the adjusting screws flush with grout.

Before taking up the grouting, the grout material should be sample tested to meet
manufacturer specification

Ensure that the foundation pockets are filled with the grout as shown in the drawing.

SHIMMING

The positioning of the fan components shall be adjusted to achieve the final alignment (elevation)
tolerances as specified.
Shims are to be prepared at site as per the requirement. Shims are to be placed between the
primary packer and the base plate. Shims are to be placed after cleaning the top surface of the
primary packer.

The Erection Engineers shall choose minimum number of shims. The shims must be slipped side
ways between primary packer and base plate with out altering or deforming the embedded primary
packer or base plate. Tack weld the shims together and also with primary packer.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

9.0 ERECTION INSTRUCTIONS

INSTALLATION OF PRIMARY PACKER / FOUNDATION PLATE

• Install foundation bolts in the respective foundation pockets. Place the primary packer after
welding the 3 nuts with it to form tripod.
• Ensure straightness of the primary packer before placing them on the foundation.
• Ensure above 80 % colour match between the impeller housing foot and primary
packer.
• Ensure positive locking of foundation bolts with the embedment in the pockets.
• Ensure horizontality of the primary packers below the impeller housing to with in 0.04 mm
per metre in both axes and also maintain the same elevation between the left and right
primary packer (Use straight edge between these two primary packers and measure with
spirit level/Use Theodalite).
• Adjust the leveling screws to attain these values. The horizontality of the primary packers
below the suction chamber and the diffuser may be maintained as per the drawing.
• Ensure distance between the fan centre line and the top surface of the primary packers as
per the drawing.
• Ensure gap between foundation and primary packer as per the drawing.
• Grout the primary packers using shrink free cements like Conbextra GP or Shrinkomp or
Pagel IV. Follow supplier’s instructions.

Refer Grouting Instruction Chapter 8.0.

ERECTION OF IMPELLER HOUSING

• Position the impeller housing (lower half) on the primary packer and align to the centre lines
of foundation.
• Ensure elevation at Four Corners by water balance at dividing plane. Use stainless shims
between primary packer and impeller housing.
• Ensure verticality of impeller housing by spirit level. Tighten the foundation bolts fully and
counter check verticality.
• Ensure that there are no undue distortions present during tightening. Refer Annexure.
• Assemble the bottom half of the Outlet Guide Vane assembly with the Impeller housing.
• Ensure that the OGV assembly is located properly in the machined step of the housing
flange. Tighten the bolts.

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ERECTION OF BEARING HOUSING ASSEMBLY

• The rotor assembly is dispatched as follows:

1. Main bearing assembly with shaft.

2. Impeller assembly with servomotor.
3. Blades.

• Remove dummy flange from the lube oil drain of the bearing housing.
• Drain the preservative oil from the bearing housing. Refill the bearing housing with clean,
fresh lub oil of viscosity grade ISO VG 68 (Qty approx. 10 ltrs.).
• Ensure provision of standpipe assembly at the oil drain from the fan bearing
assembly.
• Mount the flexible hose at the bottom of bearing housing for lube oil return connection.
• Install the shaft with bearing assembly in position and ensure the following when the
bearing housing bolts are tightened only moderately.
• Complete seating of the bearing housing in the impeller housing lower half.
• Horizontality of the shaft end. This shall be maintained to a tolerance of within 0.04 mm/m.
Adjust shims below impeller housing to achieve shaft level.
• Cleanliness of lube oil drain pipe and proper connection to the bearing housing.
• Sequentially tighten the fixing bolts to the required torque values.
• Counter check shaft level again to ensure that this remains as adjusted.

ERECTION OF IMPELLER

• Lift the impeller assembly carefully thro two lifting eyes assembled at two blade shafts.
• Take extreme care not to make any scratch on the impeller / servomotor while handling the
impeller.
• Clean the shaft flange groove and the Impeller groove with liquid solvents like CTC.
Scrapping is not permitted.
• Check for any burrs at the mating flange and if found, remove them using smooth file or
emery paper.
• Ensure no foreign material inside the impeller. 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.

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• 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.
• Remove the lifting eyes and Hands rotate the impeller and ensure free rotation.
• Ensure suitable plugging of thermometer and oil inlet holes in the bearing housing.
• Cover the impeller and bearing assembly with tarpaulin / polythene cover so that no rain
water / dust enters the impeller.

INSTALLATION OF SUCTION CHAMBER

Place the suction chamber assembly on the respective primary packer and align with respect to
foundation and impeller housing. Stainless steel shims to be used to align the suction chamber.
Maintain uniform axial gap between suction chamber and impeller housing.
Tighten the foundation bolts. Ensure gap at free supports.

INSTALLATION OF DIFFUSER ASSEMBLY

Place the diffuser assembly on the respective primary packer and align with respect to foundation
and outlet guide vane assembly. Stainless steel shims to be used to align the diffuser. Maintain
uniform axial gap between diffuser and outlet guide vane assembly. Tighten the foundation bolts.
Ensure gap at free supports.

MOUNTING OF OIL INLET

Mount the lub oil & control oil inlet and outlet etc., as shown in the drawing. Ensure leak-proof
joints for oil inlet, outlet connections. Run LOP and check for any oil leakage. Ensure that the
flexible hoses do not get strained and also not rubbing with the servomotor for the entire range of
operation. Position and support the rigid piping suitably.

ASSEMBLY OF IMPELLER BLADES

Before assembling the blades, commission the lube oil system and ensure cleanliness of the oil lines
by oil flushing. (Refer Commissioning of lube oil system). Connect oil lines to the servomotor.
• Extract the piston by hand so that the position of blade shafts corresponds to
blade full close position.
• Switch off the lub oil pump till all the blades are mounted.
• The impeller blades are identified by an alphabet series. They are also marked serially.

Example :
A1, A2 ........ A23

CC1, CC2 ........ CC23

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

• Ensure that the blades to be mounted belong to the same series. Usually the impeller hub is
also marked serially. However, blades may be mounted on the hub starting from anyone
location and proceeding in the serial order as marked on the blades. They may be
assembled proceeding in the clock-wise or counter clockwise direction.
• Ensure that the round nose of the blades is fixed on the suction side.
• Assemble the blades. Ensure that the blades are positioned and tightened in
identical position. This is to avoid uneven gap between blades.
• Tighten the blade fixing screws. Use the special adapter supplied for tightening. Tighten to
the required torque values.
• At blade full close position, ensure that the blades are not fouling with each other. There
can be minimum gap between blades. The mechanical stoppers of the servomotor actuator
can be set suitably, if required, to achieve this.

Note: - The entire site made oil lines must be acid cleaned and neutralized. Prior to
connecting the flexible oil hoses with the servomotor, the lub oil system must be
thoroughly flushed for at least 8 hours or till no dirt/ sediments are found in the
oil filters. Oil flushing should be done bye passing the fan bearings and
servomotor. The servomotor oil line routing should be such that the flexible oil
hoses are not getting strained for the entire operation range.

MOUNTING OF INSTRUMENTS

Mount the thermometers / RTD etc., as shown in the drawing. Ensure proper calibration of
instruments.

ASSEMBLY OF IMPELLER HOUSING (TOP HALF)

Mount the top half of OGV unit to the top half of impeller housing. Ensure that the OGV assembly
is located properly in the machined step of the housing flange. Tighten the bolts. Ensure provision
of machined washers (tack welded to the lower half) and packing rope at the parting plane of
impeller housing.

Carefully lower the housing top half on the bottom half of the impeller housing by means of locating
pins. The blades may be kept at full close position. Ensure that there is no scratch / damage
done to the impeller blades while lowering the impeller housing. Tighten the connecting
bolts.
Measure and record the clearances of the impeller and blades with respect to the stator according
to the QUALITY PLAN FOR INSTALLATION of this fan.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

INSTALLATION OF SCREEN PLATE ASSEMBLY

Assemble screen plate to OGV core. Maintain recommended clearance between the screen plate
and servomotor.

ASSEMBLY OF EXPANSION JOINTS

Lay and clamp the flexible rubber expansion piece between the impeller housing and suction
chamber. Assemble the expansion piece between the OGV core and diffuser core. Lay and clamp
the flexible rubber expansion piece between OGV unit and diffuser assembly.

MOUNTING OF COUPLING

Record shaft-end and coupling bore dimensions and ensure dimensional compliance with product
drawings. Mount the coupling halves to the respective shafts after heating them in oil bath to about
80 deg C above ambient temperatures but never exceed 120 deg C.

MOUNTING AND ADJUSTMENT OF LINKAGE ASSEMBLY

Position the supporting brackets and align with respect to fan axis. Assemble the actuating shaft
and the bearings. The locating bearing is to be positioned inside the diffuser core. Assemble the
actuating rod with hinge head and fork lever. Maintain distance as per drawing. Keep the bolt of
the forked lever loose. Tack welds the supporting brackets for the above-aligned position of the
linkage assembly. Final welding shall be done after completion of adjustment. Start oil pump and
ensure desired control oil pressure. Move the control slide of the servomotor for a few strokes.
Note the time taken for one full stroke of the servomotor piston. With reference to a fixed point,
measure the distance through which the control rod is projecting out for both full close and full
open position of blades. (a1 and a2 respectively). The net travel distance will be 70 mm for this
servomotor.

The mid position of the travel with reference to the already fixed reference point should measure

A1 - A2
--------- + A2 mm.
2

When the piston is in its mid-position, the forked lever must be kept vertical and the actuating lever
should be kept horizontal. In this position, the pointer should be set for the mid-position of the dial
plate. Tighten the bolt of the forked lever to the required torque value as shown in the drawing.
The mechanical stoppers at inside of core and outside of casing should be fixed as shown in the
drawings.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

The lock nuts of the screws should be tightened for the minimum & maximum of the piston travel
leaving about 1 mm at both ends. That is, for full open the distance from the reference point shall
be (A2 + 1) mm and for full close (A1 - 1) mm. After the mechanical stoppers have been set, the
travel distance of the servomotor shall be 68 mm.

MINIMUM POSITION OF BLADES

When the impeller blades are fully closed it may result in reverse flow at least at the tip sections of
the blades. This is not desirable. Hence it should be ensured, during trial operation of the fan, that
the minimum positions of the blades are set such that a static pressure of about +25 mmWC at the
fan outlet is released. Adjust the mechanical stoppers (both inside and outside) to suit this for the
“blades minimum” position. After this final adjustment, the travel distance of the servomotor may
be less than 68 mm.

INSTALLATION OF MOTOR

Ensure the motor is erected as per the directions of the motor supplier.

MOUNTING OF INTERMEDIATE SHAFT

Connect the Intermediate shaft to either coupling. Tighten the coupling bolts to the required
torques. Do not tighten the spring plate bolts. Maintain the required coupling gap by adjusting the
motor position axially.

ALIGNMENT OF COUPLING

Before commencement of alignment, the following should have been carried out positively.

Checks and corrections to eliminate mechanical looseness/distortions. Alignment of motor shaft and
intermediate shaft with fan shaft is carried out using dial gauge on both the couplings (2 dial
gauges 180 Degree apart in axial direction). The dial gauges should be fixed firmly by means of
sturdy clamps. Uses of magnetic bases are not recommended. The maximum allowable
misalignment in both the couplings is 0.05 mm. During alignment ensure proper axial gaps in the
couplings (both fan end and motor end) as per drawings. For achieving the required tolerance
adjustment should be done on motor only, having fixed the fan.

INSTALLATION OF SILENCER

Install the silencer assembly in accordance with the fan assembly drawing. Ensure that the silencer
load is not transferred to the fan foundation. Assemble the expansion joints between silencer and
suction chamber as shown in the installation drawings.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

ASSEMBLY OF SHAFT PROTECTING TUBE

Assemble the top half of the bullet. Assemble the two halves of shaft protecting tube to the
respective halves of suction chamber. Provide asbestos ropes as per drawings. Mount the coupling
guards to the front wall of suction chamber as shown.

INSTALLATION OF OIL SYSTEM

Ensure early commissioning of oil system to facilitate checks on impeller blades.

The oil circulation system is supplied as a complete assembly. Mark the foundation for the
requirement of the oil system. Erect the console properly taking care of proper leveling and
elevation. Ensure proper orientation of the oil system as per installation plan. All the openings for
oil admission and return in the console will be closed by means of sealing and blind flanges.
Remove them.

Trial assembles the pipelines for servomotor (Control oil piping) and main bearings (lube oil piping)
in accordance with the drawings. Maintain sufficient distance between the servomotor and steel oil
piping such that the flexible hoses are not strained for the entire range of servomotor operation.
Ensure that all the return oil pipelines are inclined towards the tank. A minimum slope of 1 in 10
may be ensured (Gravity inclination).

While doing the trial assembly itself, finalize the supports to be provided for the oil pipes. Make
suitable brackets/clamps for supporting purposes. The oil pipes leading from and to the console
should be chemically cleaned to remove the scales and oxidized layers. Follow procedure given in
Annexure. The control oil inlet, control oil outlet and leak oil return of the oil head assembly should
be carefully connected to the oil system. Mix up of these lines will lead to mal-operation.

• Verify and ensure that the inner dia of the flexible hoses, which are connected to the
servomotor, is 3/8” through out.
• If the servomotor operation time is abnormally high, i.e., if it is more than 30
seconds, verify the control oil flexible hose inner diameter.

Provide a suitable size Orifice in the control oil return line in order to maintain backpressure in the
servomotor during operation.

The size of the orifice should be selected by trial and error method, such that it should
not abnormally increase the servomotor operation time.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

• The independent operation timing of actuator must always be greater than the
independent timing of the servomotor operation.
After chemical cleaning, the pipelines should be assembled and clamped rigidly. Ensure that all the
joints are leak proof and free from distortion / strain. Install all the instruments (Caution: Ensure
correct calibration of the instruments) like pressure gauges, thermometers, pressure switches,
flow switches, level switches, thermostats etc. When connecting the coolers, first open the water
flow and then the oil flow. The cooling water shall be free of lime or other corrosive chemicals.

COMMISSIONING OF OIL SYSTEM

Ensure cleanliness of oil tank and fill up the tank to the required level with the recommended oil /
flushing, oil. Ensure proper quality of oil. Oils of different quality / make should never be mixed.
The oil should be filled only through fine meshed strainer. Ensure cleanliness of filters. Service the
filters. Bump the motor and check for proper direction of rotation. (This shall be done for the
standby pump motor also)

Before running the pump, disconnect the oil lines leading to main bearings and servomotor.
Interconnect the respective inlet and outlet pipes of main bearings and servomotor.
Run the pump and ensure smooth operation. Oil will be running through the pipelines flushing the
lines. Continue flushing and periodically inspect the filters. Flushing should be continued for at
least 8 hours / till the filters are clean whichever is later. Trial run the next motor/pump also during
the process of flushing.

After completion of flushing, drain the tank and wipe it clean. Connect the piping to the main
bearings and servomotor. Refill the tank by the required grade of oil and restart the lube oil motor.
Flush the bearings for a few hours. Also operate the servomotor for a few strokes.

Do not operate the servomotor without adequate control oil pressure (8 to 12 bar). This
is a critical requirement and may be communicated to all concerned engineers like
C & I, operation and mechanical maintenance group.

Ensure smooth and uniform movement of all the impeller blades. Arrest leakage, if present. Set the
overflow value in the system to the required pressure. Stop the oil pump. Inspect the filters and
clean them. Now the fan is ready for trial run. After successful trial run of drive motor, couple the
fan with motor and clear for fan trial run.

Refer fan O & M manual for commissioning of fan.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

10. LUBRICATION INSTRUCTIONS

The Lubricating oil for the Fan bearings are supplied by the centralized oil pumps which supply oil
for the hydraulic servomotor also. It must be borne in mind that the quality of oil flowing to
the bearings and its pressure must be maintained as recommended. The flow control device
provided in the oil system (lube oil inlet Fine) is to be covered arid protected.

The oil to be used shall be a turbine quality oil to suit the following specifications:

ISO Viscosity Grade : 68

o
Kinematic Viscosity at 40 C : 64-72 cst
Viscosity index : 95 min
Flash point : 210o C (min)
Pour point : -6o C (max)
Neutralization, No. mg KOH/gm : 0.2

The oil must not foam during operation. Foam removing agents containing silicon must not be
utilised. The oil must have good anti-corrosion properties.

RECOMMENDED OILS

a) Servo prime 68 of IOC

b) Turbinol 68 of HPC
c) Bharat Turbol 68 of BPC
d) Teresso 68

LUBRICANT FILLING

Fill the recommended lube oil (through a fine mesh strainer only) up to the required level. Do not
mix lubricants of different grade and make.

LUBRICANT CHECK

At first commissioning and after a basic overhaul, the entire oil must be drained after an operating
period of 100 hrs. All dirt should be eliminated from the bearing housing. Then fill in again the oil
through the fine mesh strainer.
CARE OF LUBRICANT
Test the quality of the oil every month and if found unsatisfactory and oil containing water/dirt the
oil should be changed immediately.

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Ranipet Axial Reaction Fan – Single stage (11 Hub) Flange

RECOMMENDED LUBRICATION CHART

Obser Qty /
S.no Component Lubricant Supplier Location Frequency
vation Fan
Once in
Fan main Brg Servo prime 68 M/s IOC
2 years or
and Hydraulic Turbinol 68 M/s HPC See
01 Oil tank based on oil Daily
Servomotor Bharat turbol 68 M/s BPC note.1
quality.
Mechanism Teresso 68 (Others)
See note 2
Axial ball During Over
Mobil Glygoyle 80
bearing See Inside haul (Once in Three
02 OR *****
(Blade bearing note.3 Rotor 2 years) Kg
Berusynth EP 460
assembly) See note 4
Deep groove
ball bearing & Poly-Butyl During Over
Angular contact cuprysil See Inside haul (Once in Two
03 *****
ball bearing (Copper base note.3 Rotor 2 years) Tins
(Blade bearing grease) See note 4
assembly)
Spherical plain During Over
Molykote Spray
bearing See Inside haul (Once in Four
04 321R OR *****
( Blade lever) note.3 Rotor 2 years) Cans
OKS 511
See note 4

Notes:
1) Oil quantity depends on tank capacity (Approximately 400 ltrs ). Levels marked in the oil tank level gauge.
2) The frequency of filling shown is for normal operation. For initial operation follow lubricating instructions
given in this manual.
3) The blade bearing assembly lubricants are presently imported. Development of indigenous supplier is
under study.
4) The lubricants of blade bearing assembly are renewed only during major overhauls of the Fan ( usually
once in two years ). This has to be done only by trained personnel. BHEL personnel may be requisitioned
for supervision.

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