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.

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. CFBC Boiler Erection (250 MW)
AIR PREHEATER
FOR QUAD SECTOR AIR PREHEATERS
NEYVELI (R300 & R 301)
THE COPYRIGHT OF ALL DOCUMENTS AND DRAWINGS
ARE THE PROPERTY OF BHARAT HEAVY ELECTRICAL
LIMITED. THIS SHALL NOT BE USED WITHOUT THEIR
WRITTEN PERMISSION IN ANY FORM OR PART THEREOF
FOR ANY OTHER PURPOSES THAT FOR WHICH THIS
PUBLICATION IS SENT TO THE RECEIVER.
2

3. 3

4. CONTENTS
1. CONTRACT DETAILS.
2. REGENERATIVE AIR PREHEATER – BRIEF DESCRIPTION
3. ERECTION ASSISTANCE POLICY
4. GENERAL FIELD ERECTION PROCEDURE NOTE
5. IMPORTANT INSTRUCTING DO‟S & DONT‟S
6. LIST OF APPLICABLE PGMA‟S
7. LIST OF INSTALLATION DRAWINGS,
8. RECEIPTS & STORAGE OF APH COMPONENTS
9. SUGGESTED FIELD INSTALLATION PROCEDURE
10. GUIDE TRUNNION TAPER FIR CHECKING PROCEDURE
11. SEAL CLEARANCE CHARTS
12. LUBRICATION CHARTS
13. AIR PREHEATER FIRE
14. LIST OF ILLUSTRATIONS
15. LAY-UP PROCEDURE
16. SEALANTS, THREAD LUBRICANT AND COATING COMPOUNDS
4

5. 01. CONTRACT DETAILS
CUSTOMER NUMBER : R 300 & R 301
PROJECT : NLC – NEYVELI 2 X 250 MW
LOCATION : NEYVELI
AIR PREHEATER SIZE : 29 VIMQ 1850 (80O PA)
NOS. / BLR : TWO
AIR PREHEATER SL. NO : 0633, 0634, 0635 & 0636
TOTAL ELEMENT DEPTH : 1850
HOT END ELEMENT : 0.63 DU 700 CARBON STEEL
HOT END INT. ELEMENT : 1.21 NF6 300 CORTEN STEEL
5

6. 02. REGENERATIVE AIR PREHEATER – BRIEF DESCRIPTION
General
The Regenerative air Preheater shall be Quad- sector type in which the
Primary air sector is flanked between the Secondary air sectors.
In this type of heat exchange the heating surfaces are alternatively heated up
by the flue gas passing through and cooled by the air passing over it. The
heat is absorbed by the heat transfer matrix from the flue gases and releases
to the air, The design of the air heater is such that it can give trouble free
service for extended periods of time, without plugging of flow areas between
heating element sheets,
The regenerative heat exchanger will have a gas tight insulated casing and
must be rested on necessary steel structures.
Description
Each regenerative heat exchanger shall consist of the following salient
components/ 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. 1. Modular Rotor
The rotor is made up of 24 numbers of full sector modules that are attached to
the rotor post by pinned connections. The modules are loaded with elements
and shipped to site for easier, speedy and quality erection.
2. Rotor Housing and Connecting Plates
The housing is octagonal in shape and consists of the following: Two main
pedestals, 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 panels
which form an integral structure to take axial and radial loads and also form a
gas tight enclosure for the of fluids.
3. Heating Elements
Each air heater is provided with multi0 layers of heating elements. The cold
end 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 System
Over many years of continuous operation, the sealing has provided to be
effective with minimum maintenance requirements. The design takes
advantage of normal thermal growth to keep sealing surfaces in proper
alignment.
The rotor is divided into equal forming a separate air or gas passage through
the rotor. Fixed leaf type metal seals are radially and axially attached to the
rotor structure between each sector. Sector shaped unrestrained radial
sealing plates provide the sealing surfaces that divide the rotor into air and
gas passage.
Because the seals are applied to the shortest leakage path and the sealing
surfaces are externally adjustable, the most effective and continuous leakage
control is assured. A circumferential bypass seal is provided to prevent air and
gas from bypassing the rotor through the small space between the rotor and
housing.
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 in
that path is being controlled by axial seals, there is no need to adjust them
from outside.
5. Support bearing and guide bearing
The support bearing is of spherical roller thrust bearing type and is located at
the bottom connecting plate. The guide bearing is of spherical roller type and
is located at the top connecting plate. The bearing housings are designed to
at as oil reservoirs for provision of integral oil circulation system.
7

8. 6. Lubricating Oil Circulation System
Both the support and guide bearings are provided with independent oil
circulation systems. The oil circulation system consists of oil pump, oil cooler
pressure and temperature indicators and flow switches. The lubricating oil
system proposed is a proven design. An identical unit is also connected as
standby.
7. Drive Mechanism Including Emergency Drive
The drive system envisaged is of peripheral pin rack- pinion type. It consists
of a three input speed reducer one electric motor for main drive, another
electric motor as standby drive, fluid coupling / centrifugal clutch, hand
cracking facility for manual rotation and a pinion for meshing with the pin rack
of the rotor. Normally drive is through the main electric motor and in the event
of electrical trip out, the standby electric motor comes into operation
automatically.
8. Access Doors
Adequate numbers of access doors are provided, both at the inlet and outlet
ducts and also in the housing panels for inspection and maintenance.
9. Observation Port and Light
Observation Port and vapour proof light are provided. These are suitably
located at the air inlet side to have a complete view of the cold end elements
while 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 Alarm
Rotor stoppage alarm is provided to indicate the slowing down of the rotor.
This consists mainly of control unit, vane operated limit switch and vanes
which are mounted on the trunnion. If the vanes fail to pass under the limit
switch within the set time interval, the timer in the control unit transfers its
8

9. contact to give an alarm in the control panel, to warn the operator that the
rotor is slowing down.
Control Requirement
An alarm or annunciation is to be provided in the control panel to indicate the
rotor slowing down condition.
12. ‘De Luge’ System
Two fixed multi- nozzle fire fighting manifolds 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 the rotor housing. During an air heater fire,
both fire fighting and water washing manifolds must be used.
13. Element Handling Arrangement
Heat exchanger is provided with a hand operated hoist and trolley for handling
of hot end elements from inside of the air preheater to the air preheater
operating floor.
14. Fire Sensing Device - Thermocouple Type
Shell type thermocouple elements mounted on the measuring probe are
arranged (in radial direction in the air outlet and gas outlet ducts close to rotor
face, such that there is a measuring point between each tangential walls of
the rotor.
The increase in temperature, due to fire, causes a momentarily and recurring
increase of the thermo – electric voltage and the signal released by thermo
elements is given to customer DCS at UCB for suitable alarm / annunciation.
In the event of an fire alarm, the deluge system valves and water wash
system valves shall be opened manually. This is essential because in the
event of a fire alarm, inspection of the Rotor/ , APH is a must before deluging
the rotor with water.
9

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.  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.
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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.
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13. 06. LIST OF APPLICABLE PG MA’S
PG MA DESCRIPTION
52 – 000 ITEMS PER CONTRACT
52 – 010 ROTOR ASSEMBLY
52 – 011 POST AND TRUNNION ASSEMBLY
52 – 012 PIN RACK ASSEMBLY
52 – 013 RADIAL SEAL ASSEMBLY
52 – 030 ROTOR HOUSING ASSEMBLY
52 – 041 HOT END CONNECTING PLATE ASSEMBLY
52 – 042 COLD END CONNECTING PLATE ASSEMBLY
52 – 054 AXIAL SEAL ASEMBLY
52 – 055 BY PASS SEAL ASSEMBLY
52 – 100 ROTOR DRIVE ASSEMBLY
52 – 210 ACCESS DOOR ASSEMBLY
52 – 211 AIR SEAL PIPING
52 – 212 OBSERVATION PORT AND LIGHT ASSEMBLY
52 – 217 ROTOR STOPPAGE ALARM
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14. PG MA DESCRIPTION
52 – 220 GENERAL DETAILS
52 – 261 GUIDE BEARING ASSEMBLY
52 - 262 SUPPORT BEARING ASSEMBLY
52 – 271 OIL PIPING ASSEMBLY (GUIDE BEARING)
52 – 272 OIL PIPING ASSEMBLY (SUPPORT BEARING)
52 – 274 OIL CIRCULATION UNIT
52 – 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 UNIT
52 – 360 FIRE SENSING DEVICE
52 – 988 COMMISSIONNING SPARES
52 – 610 STEAM COIL AIR PREHEATER
14

15. 08. RECEIPT AND STORAGE OF COMPONENTS
Particular attention is to be paid with regard to receipt and storage of Air
preheater components. All components of the Air preheater have ample
strength to withstand the operating conditions and are well protected against
damage in normal transit. However, rough handling during transit or
thoughtless unloading at site may result in distortion and damage which
should be rectified before erection starts.
Care and good judgment must be exercised when transporting and lifting the
components so as to avoid bending or twisting, as such distortions will
seriously hinder erection and possibly affect the performance of the complete
Air preheater.
The elements, bearings, oil circulation units, rotor drives, power driven
cleaning devices and electrical equipment must be stored in a closed dry
place immediately after unloading to protect them against corrosion. When the
bearings or heating surfaces elements are not to be used for an extended
period, they should be protected by using a non-drying water repellent rust
preventive oil such as RP 102 of Indian Oil Corporation. They must also be
protected after erection of the boiler house has not been completed. All
remaining parts may be stored in the open, provided they are laid down to
avoid any distortion. No rain water should be allowed to collect in any of the
components. The pin-rack and machined surfaces of sector plates and, in
general, 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, fig
Anti 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 suitable
to 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 in
several weeks under ambient conditions, leaving a protective coating. This
coating is water soluble and for this reason the material thus coated must be
stored indoors or under protective covering at outdoors.
15

16. The elements need not be cleaned with water at the time of light – up, if the
protective coating was applied before 3 months.
Method of Cleaning and Coating
It is preferred that element baskets be stored inside of space is available.
However, outdoor storage can be achieved with proper protection. The crates
or boxes as shipped shall be opened and the elements should be sprayed
with the recommended oil. If rust scales are noticed, the baskets can be
cleaned with a jet of compressed air (6 ata) (a nozzle can be attached to the
hose to be effective) first and then oil is applied over the rust which will absorb
the oil and deter further rusting.
Method of Storage
Baskets after coating with oil shall be supported on timbers high enough to be
free from the defects of surface water. Timbers (100 mm x 100 mm) or other
means should be placed on top of the basket piles. Protective covering should
be applied over the piles and extending down the sides and securely fastened
to prevent deterioration. It will be necessary to periodically check the covering
for deterioration‟s and the baskets for rusting. If rusting is observed, the areas
should be re-sprayed with rust inhibiting oil.
16

17. 09. SUGGESTED FIELD ERECTION PROCEDURE
1. 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. 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 the
assembly has been lowered on to the support bearing and is plumbed and
adequately 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. 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. 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 so
that 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. 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. NOTE: Check the direction of rotation of pinion with respect to rotor direction
of 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. 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. 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. 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. 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. 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. 10. GUIDE TRUNNION TAPER FIT CHECKING PROCEDURE
1. 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

30. 12. RECOMMENDED LUBRICATION CHART
CUSTOMER NOs: R300 & R301 PROJECT: NEYVELI: 1 & 2
AIR PREHEATERS: 2 Nos. / BOILER
EQUIPMENT QTY/ Fre. of
SL IOC HPC BP
DESCRIPTION APH Change
Main & Standby
Servogem
01 Elec. Motor Lithon 3 MP Grease 3 0.4 Kg 6 months
3
Brgs.
Servo Bharatturbol
02 Fluid Coupling Turbinal 46 6.8 lts Yearly
prime 46 46
Main drive Servomesh
Parathan EP 100 Lts
reducer SP 220 Amocam 220 Yearly
03 220 0.3 kg
a) Gear case Servogem Bharat MP 3 6 month
Lithon 3
b) Bearing 3
Support Servocyl Cyncol Bharat Engol
04 100 Lts Yearly
Bearing C- 680 TC – 680 J- 680
Servocyl Cyncol Bharat Engol
05 Guide Bearing 100 Lts Yearly
C – 680 TC- 680 J – 680
Lub Oil Pump & Servogem
06 Lithon 3 MP Grease 3 0.5 kg 6 months
Motor bearings 3
07 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 XX
Note: Check Oil Level After Stopping of Lub Oil Systems.
Caution: Over Filling of Oil in Guide Bearing Assembly May Cause Air
Preheater Fire.
30

31. 13. AIR PREHEATER FIRES
Air preheater fires are rare. A fire may occur during cold start up on oil or start
up following hot stand by because of poor combustion of the fuel. The
improper combustion results in unburnt or partially burnt oil condensing and
depositing on the Airpreaheater element surface. As the temperature entering
the Air preheater increases, this deposit is baked to a hard varnish like
material. These deposits can ignite as temperature increase to 315 – 370Oc
range. This ignition usually starts in a small area of the deposit. During the
early stages of deposit ignition, external effects are not very apparent. The
deposit restricts the flow of gas or air so that very little of the heat generated
is carried away from the area of its origin. Downstream generated is carried
away from the area of its origin. Downstream mixing of the fluids further
minimizes any external effect. Most of the heat generated is absorbed by the
metal heat transfer element nearby. The actual temperature build up during
this period is relatively slow, If the condition can be detected at that time, the
amount of water required to reduce the temperatures quickly to below the
ignition temperature, is much less.
If the ignited deposit remains undetected it will continue to generate heat until
the metal heat transfer element reaches 730- 765Oc At this point, metal may
ignite with temperature reaching 1650 Oc and higher in a matter of minutes.
Metal fires are self- sustaining and would require more water than is normally
available to drop the temperature to a reasonable level. It should be noted
that Co2, halon and other extinguishing agents are ineffective under these
circumstances.
14. LIST OF ILLUSTRATIONS
01 Exploded view of Modular Air preheater.
02 Support bearing assembly – Integral type
03 Modified method of tracking hot end sector plate
04 Radial seal installation.
05 Axial seal installation
06 Axial seal plate to sector plate seal adjustable design.
07 Block Diagram for oil circulation system – GB
08 Oil circulation system
09 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

33. 33

34. 34

35. 35

36. 36

37. 37

38. 38

39. 39

40. 40

41. OIL CIRCULATION UNIT
41

42. 42

43. 43

44. STORAGE AND PRESERVATION OF HEATING ELEMENT BASKETS
44

45. 45

46. 15. LAY UP PROCEDURE FOR AIR PREHEATER
1. 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. 16.0 SEALANTS, THREAD LUBRICANT AND COATING COMPOUNDS
HIGH TEMPERATURE THREAD LUBRICANT
There are a number of bolts which require to be tightened to a specified
torque, further they are subjected to high temperature during operation
causing 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 bolt
head to acquire proper torque during tightening and also to serve as a anti
seize medium during temperature service. Typical example: Turnnion bolt,
support bearing mounting bolt, sector plate and Axial seal adjustors, axial seal
plate to sector plate seal adjustors. Name of Lubricant:
1. Molycote – Imported
2. Mahomoly anti seize thread lubricant.
THREAD COATING COMPOUND
A 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 to
such adverse environment may result in corrosion and possibly the fastener
may be damaged permanently. Removal also may be very difficult. Such
fasteners are coated with a special compound which protects them during
service and enables easy removal of them.
Typical example: Rotor basket door, cover bolts, bearing housing cover bolts.
Name of compounds: 1. Felpro5A – imported
SEALING COMPOUND
There are certain joints made of rough surfaces (fabricated or cast) which are
to be sealed by suitable agent to avoid leakage of air and dust. A sealing
compound is provided for this purpose which has to be applied to covers in
trunnions 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 COMPOUND
At the joints of machined surfaces normally gaskets are used. For large
surfaces a bead of the gasket compound is applied and the surfaces are
47

48. tightened. The compound dries and forms a leak proof gasket type layers
which 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- 2
SEALING TAPE
To make threaded joints leak proof Teflon tape is provided. They can be
wound on the male thread to a suitable thickness and screwed on to make a
liquid tight connection.
Note: Locations for the applicable of the above mentioned items are clearly
indicated 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. Ranipet
RADIAL FAN
(NDZV WITH SLEEVE BEARING)
DOUBLE SUCTION
ERECTION MANUAL
Preparation by Checked by Approved by
S.SELVAM J.MOORTHY M.DESIGAN
49

50. DOUBLE SUCTION (NDZV) WITH SLEEVE BEARING
4.0 CONSTRUCTIONAL FEATURES
NDZV fans are single stage, double inlet centrifugal machines. The rotor is
simply 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 ASSEMBLY
The impeller is a completely welded structure and is made from high tensile
steel with backward curved blades. The selection of the material and
thickness for the impeller/ shaft are computed on the basis of the stress
analysis / critical speed programme carried out for each impeller and shaft.
The impeller consists of centre plate, blade cover plate and impeller ring. All
weldments are inspected thoroughly by NDT methods. The back plate of the
impeller and the shaft flange has a machined groove which ensures correct
location of the wheel relative to the shaft during assembly. Impeller is bolted
to the shaft flange and locked by means of locking plates. Conical cover
plates are provided at the inlet (bolts to the center plate) to guide the inlet flow
and 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 is
dynamically balanced after final machining. Replaceable wear liners are
provided in the impeller blades. The shaft is machined to a high degree of
surface finish for location of impeller, bearings and coupling half etc. the
completed shaft is dynamically balanced. The critical speed of the rotor is well
above the operating speed.
BEARING AND THERMOMETERS
The fan rotor is supported in between a fixed bearing and a free bearing. The
fixed bearing is arranged on the coupling side. The fans are provided with
sleeve bearings and oil lubrication. Provision for mounting temperature
gauges (Mercury in steel thermometers and RTDs) are available on the
bearing housings for local and remote (UCB) indication of bearing
50

51. temperatures. Platinum resistance thermometers (RTD) are provided with
alarm and trip connections and for remote indication (control room) of bearing
temperatures.
SUCTION CHAMBER AND SPIRAL CASING
Suction chamber and spiral casing are fully welded structures and are
fabricated from sheet steel with adequate stiffeners. These are split suitably to
facilitate easy handling and maintenance of rotor, etc. the oblique cone which
forms the entrance to the impeller helps in accelerating the floe. The lower
part of fan casing rests on the supporting brackets on the foundation.
FLOW REGULATING DEVICES
Fan outlet flow is controlled by inlet guide vane assembly or by inlet damper
or by variable speed (VFD/ Hydraulic coupling). (Refer Technical for
applicable flow control device)
a) INLET GUIDE VANE ASSEMBLY
Inlet vanes control device regulates the fan output (flow). The inlet vane
assembly is locates at the inlet of the suction chamber for regulating the flow
through 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. 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 plate indicates
the 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 ASSEMBLY
The damper control assembly is located at the inlet of the suction chamber for
regulating the flow through the fans 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 side walls of the casing. Levers
and links for connection to the actuating lever connect the damper shafts. The
vanes are actuated by means of an actuator. A graduated dial plate indicates
the 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 SEALS
Seals for the shafts are provided to reduce the leakage through the gaps
when the shaft passes through the suction chambers. It consists of labyrinth
section for axial sealing. The labyrinth seal is centrally located and mounted in
51

52. bearing pedestal / casing wall which helps in precisely controlling the labyrinth
passage.
COUPLINGS
The fan and the drive motor is coupled by means of flexible couplings.
FAN DRIVE
The fan is driven by an electric motor. For detailed instructions, the respective
instruction manual should be referred.
52

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. 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 control device, spiral
casing and rotor by careless installation or by chains of lifting devices. Pay
particular attention to impeller bearing housing and bearings. They should not
be dropped on the floor or should not be mishandled. During transport of the
shaft, avoid damaging the shaft seats and journal surfaces.
INSPECTION
When packages are received at site, check all parts with the help of the
packing list and drawing, If necessary. Hake the list of missing parts (in case
of shortage) and initiate action for replacement, insurance claim etc. check
any damage 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 dimension like bores and key ways of coupling, suitable for Fan and
motor as per drawing. Note down the product numbers of match 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, comprising of many components, are expected to
perform certain specific functions. They require due care and attention from
the time that 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)
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. 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 given
PROCEDURE FOR PRESERVATION OF MACHINED SURFACES OF FAN
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 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. 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 Aluminates
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 deformations 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 fro protection against
mechanical, chemical damage and contamination. These parts are to be
unpacked in 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 an 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.
PRESERVATION OF FAN UP TO 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 anti-corrosive agents / rust preventives.
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 shut down / stand still
period.
 Remove the preservation using suitable solvent.
56

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. 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 BIIEL 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 storage, these preservative coatings shall be
re-established if necessary.
Plan for tools, tackles, ringing 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 soundless. Check for cracks, holes, exposed steel
reinforcements. Especially pay attention to check for any left out wooden
shuddering material. The fittings around the foundation should be firm. Do not
cut off the exposed ends of reinforcement as long as they are well with in 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.
58

59. Mark the center lien 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 ensure the following:
 Flatness of primary packer.
 Dimensional compliance of bolt holes.
Grouting of primary packer/ bearing pedestal 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.
59

60. 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 requirements, procedure and
layout of primary packers, your attention is drawn to the concerned drawings
on this subject supplied to your project.
REFERENCE 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 / Consultant.
GENERAL REQUIREMENT FOR EXECUTION
The operation 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 hereunder must be performed in the
chronological order. On completion of works, 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 tolerance should be as mentioned in general
arrangement drawing.
60

61. 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 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 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. Ensure the flatness of the primary packers. 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 dispatch able units.
These three nuts are to be welded to the primary packet at alto 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 suppliers 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 grounding
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.
61

62. Each shim is to be prepared based on actual requirement to ensure
maximum contact. Maximum number of shall not be more than 7
THE FOOT OF THE EQUIPMENT
The height from centre line will be maintained at our works within 0 and – 3
mm tolerance with taper not exceeding 1 mm / mtr.
LAYING OF PRIMARY PACKERES IN THE HORIZINTAL PLANE
The primary packers shall be laid according to the drawing released for your
project.
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 PACKER
The primary packers shall be embedded with NON SHRINK GROUNT strictly
following the instruction of the grout supplier. The curing time shall be as per
manufacturer‟s 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’s specification.
Ensure that the foundation pocket is NOT filled with the grout (where ever as
shown in the drawing) by putting a thermo Cole as shown in the drawing to
avoid grouting of foundation bolts.
SHIMMING
The positioning of the fan components shall be adjusted to achieve the final
alignment (elevation) tolerances specified as before. Shims are to be
prepared at site as per the requirement. Shims are to be placed between the
primary packer and the machine foot. Shims are to be placed after cleaning
the top surface of the primary packer. The erection Engineers shall choose
62

63. minimum number of shims. The shims must be slipped side ways between
primary packer and machine foot with out altering or de-forming the
embedded primary packer or machine foot. Tack weld the shims together and
also with primary packer.
ASSEMBLY OF FAN CASING
The casing parts can be assembled together by means of connecting flanges,
fir bolts and guide plates. The horizontal ad vertical dividing flanges should be
connected with sealing ropes. All parts are identified by match marks for
proper assembly. Ensure dimensional compliance of the spiral casing.
GROUTING OF PRIMARY PACKERS OF FAN CASING
Level and grout the primary packer with out any air pockets, by maintaining its
elevation with respect to the fan center line, Refer chapter on Grounding
Instructions.
ALIGNMENT IF SPIRAL CASING
Position 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 with
respect to fan centre lines.
INSTALLATION OF BERAING PEDESTAL
Position the bearing pedestal and align it with respect to foundation and spiral
casing. Ensure elevation of pedestal with respect to fan center line.
Ensure horizontality shall not exceed 0.04mm-mtr on the machined surface of
the pedestal by using leveling spindles along the perpendicular to the fan axis
and grout It using NON SHRINK GROUT with out any air pockets. Refer
chapter Instructions.
ASSEMBLY AND INSTALLATION OF ROTOR
The following points must be checked and verified during assembly of rotor at
site.
 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.  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 BEARINGS
Position the bottom half of the bearing housing on the bearing pedestals.
Ensure above 80% Blue matching between bearing housing and the
bearing pedestals.
PRECAUTION
It is required that every possible care to be taken so that the bearings are
assembled properly. It is utmost important that the instructions given in the
annexure regarding the assembly of the bearings are strictly adhered to in the
same sequence as indicated to avoid any future problems.
Make sure that the bearing bore and shaft diameters are in accordance with
the 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.  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 ERECTION
Coupling bores and shaft end dimensions should be recorded prior to
assembly.
Coupling halves may be heated in oil bath to around 90 Deg C above ambient
temperature for easy mounting. (But never exceed a temperature of 120 Deg
C.) (Soaking time 2 hrs). Mount the coupling halves. Mount the top half of
spiral 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 of
rotation of impeller viewing from suction side. Couple the two damper
assemblies and then connect to actuator. Ensure identical operation of
damper flaps.
Ensure that, duct loads are not supported on the fan casing. This can be
ascertained by the position of flexible elements in the expansion joints. Install
the motor (any hydraulic coupling if applicable as per the guide lines given by
the manufacturer. Motor is to be aligned to 0.05mm with respect to fan in both
radial and axial direction. Ensure correct coupling gap (and hot alignment of
the hydraulic coupling if applicable). Refer supplier‟s catalogue.
If the connecting couplings are GEAR / BIBBY type, fill the connecting
coupling with recommended grease. Refer lubrication chart. All the coupling
bolts should be tightened to the rated torque. Mount labyrinth shaft seal at
shaft end. A minimum radial clearance of 0.1 mm should be maintained
between labyrinth elements and shaft surface. As a final step in completion of
erection, dowel all the areas as specified in the drawing after satisfactory trial
run of fan and after rechecking fan- motor alignment.
Necessary protocols are to be recorded as per the QPI.
65

66. 10.0 LUBRICATINO INSTRUCTIONS
The fan bearings are lubricated by means of Oil lubrication
OIL SPECIFICATION
The oil to be used shall be a turbine quality. The oil must not foam during
operation. Foam removing agents containing silicon must not be utilized. The
oil must have well anti- corrosion properties.
RECOMMENDED OIL
Refer Technical Data Sheet Chapter 2.0
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.
LUBRICANR 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 LUBRICANR
Test the quality of the oil every month and if found unsatisfactory and or
containing water / dirt the oil should be changed immediately.
FREQUENCY OF OIL CHANGE
First 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. Ranipet
RADIAL FAN
(NDV WITH ANTI-FRICTION BEARING)
SINGLE SUCTION
ERECTION MANUAL
Preparation by Checked by Approved by
S.SELVAM J.MOORTHY M.DESIGAN
67

68. 4.0 CONSTRUCTIONAL FEATURES
NDV fans are single stage, single inlet centrifugal machines. The rotor is
simply 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
 Drives
IMPELLER WITH SHAFT ASSEMBLY
The impeller is a completely welded structure and is made from high tensile
steel with backward curved blades. The selection of the material and
thickness for the impeller/shaft are computed on the basis of the stress
analysis/critical speed programme carried out for each impeller and shaft. The
impeller consists of back plate, blade, and cover plate and impeller ring. All
Weldments are inspected thoroughly by NDT methods. The back plate of the
impeller and the shaft flange has a machined groove, which ensures correct
location of the wheel relative to the shaft during assembly.
Impeller is bolted to the shaft flange and locked plates. Conical cover plates
are provided at the inlet (bolted to the back plate to guide the inlet flow and to
protect the fasteners from exposure to the medium handed by the fan. Fan,
the impeller is stress relived upon completion of all welding operation and is
dynamically balanced after final machining. The shaft is machined to a finish
for location of impeller, bearings and coupling half.etc. The completed shaft is
dynamically balanced. The critical speed of the rotor is well above the
operating speed.
BEARING AND THERMOMETERS
The fan rotor is supported in between a fixed bearing and a free bearing. The
fixed bearing is arranged on the coupling side. The Fans are provided with
anti-friction bearings and oil lubrication. Provision for mounting temperature
gauges (mercury in steel thermometers and RTDs) are available on the
bearing housings for local and remote (UCB) indication of bearing
68

69. temperatures. Platinum resistance thermometers (RTD) are provided with
alarm and trip connections and for remote indication (control room) of bearing
temperatures.
SUCTION CHAMBER AND SPIRAL CASING
Suction chamber and spiral bearing are fully welded structures and are
fabricated from sheet steel with adequate stiffeners. These are split suitably to
facilitate easy handling and maintenance of rotor, etc. the oblique cone which
forms the entrance to the impeller helps in accelerating the flow. The lower
part of fan casing rests on the supporting brackets on the foundation.
FLOW REGULATING DEVICES
Fan outlet flow is controlled by inlet guide vane assembly or by inlet damper
or by variable speed hydraulic coupling or by VFD motor. (Refer as
applicable)
a) INLET GUIDE VANE ASSEMBLY
Inlet vanes control device regulates the fan output (flow). The inlet vane
assembly is located at the inlet the suction chamber for regulating the flow
through the fan for different system demand. In consists of single piece
casing, vanes, bearings for vane shafts and actuating lever. The bearing
housings 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 plate
indicates 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 ASSEMBLY
The damper control assembly is located at the inlet of the suction chamber for
regulating the flow through the fan for different system demand. It consists of
single piece casing, flaps, bearings for flap shafts and actuating lever. The
bearing housings are supported on the side walls of the casing.
Levers and links for connection to the actuating lever connect the damper
shafts. The flaps are actuated by means of an actuator. A graduated dial plate
indicates 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. SHAFT SEALS
Seals for the shafts are provided to reduce the leakage through the gaps
when the shaft passes through the suction chambers. It consists of a labyrinth
section fro axial sealing. The labyrinth seal is centrally located and mounted
on both side bearing pedestal. Casing wall which helps in precisely controlling
the labyrinth passage.
The fan and the drive motor is coupled by means of flexible couplings.
FAN DRIVE
The fan is driven by an electric motor. For detailed instructions, the respective
instruction manual should be referred.
70

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. 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 control device, spiral
casing and rotor by careless installation or, by chains of lifting devices. Pal
particular attention to impeller bearing housing and bearings. They should not
be dropped on the floor or should not be mishandled. During transport of the
shaft, avoid damaging the shaft seats and journal surfaces.
INSPECTION
When packages are received at site, check all parts with the help of the
packing list and drawing. If necessary. Hake 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 pf 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, comprising 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)
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. 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 given
PROCEDURE FOR PRESERVATION OF MACHINED SURFACES OF FAN
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 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

74. 5. The bearing should be first kept in a vessel filled with kerosene fro
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 any 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.
RECOMMENDED PRESERVATIVE COMPONENTS
Application Brand Name
Machined surfaces (Indoor
TRP 1706, TRP 1710
storage)
Machined surfaces (Outdoor HDPE (High Density Poly
storage) Ethylene) sheets.
Weldments De-oxy Aluminates
PRESERVATION TILL ERECTION
Disassembled Fan parts are to be stored in their ex-works packing. Welded
plat 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
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.
74