Erection PDF

ERECTION
MANUAL
PROJECT :
M/S. PRAYAGARAJ BARA PROJECT
3 x 600 MW
( Customer No. R620 - R 622 )
BHARAT HEAVY ELECTRICALS LIMITED

BOILER AUXILIARIES PLANT
RANIPET – 632 406
OPERATION AND MAINTENANCE MANUALS
INTRODUCTION
The design and construction of the unforeseen operating conditions. From this
equipment covered in the manual involve point of view, the instructions given out in
close co-ordination among many this manual are of general nature and it
disciplines in Engineering . Successful and should be further detailed and
efficient operation of the equipment calls supplemented through actual experience in
for intimate co-operation among different operating the units.
Engineering skills.
The personnel responsible for operation and
Every Unit of the equipment is a custom built maintenance of the plant must acquaint
product, tailored to specific needs of a themselves with this manual as well as the
particular set of situations. This instruction separate manual supplied for the various
manual has been prepared to give sufficient auxiliaries of the equipment along with
information to the operating and pertinent control equipment.
maintenance personnel to serve as guide in
operation and maintenance of the It is very much necessary to develop a well-
equipment supplied by this Company. The trained team of operation and
specification , description, instruction , etc. maintenance personnel to meet the various
described through various sections are services required for the safe and smooth
based on manufacturers own experience in operation of the equipment. Active
the field as well as their Collaborators, who participation in the construction and
have had many years of experience in the commissioning of the plant and equipment
technology. These instructions provide can provide them with very useful
insight into general description, basic experience . Instruction contained in this
design, parameters. Technical manual should be strictly adhered to and
specification and performance data of the these operating Instructions shall be
equipment, in addition to the pre-operation modified suitably depending upon the test
procedures, general principles of operation operation of the equipment and the valid
and unit operating procedures. suggestions by the attendant after
discussions with the company.
These Instruction Manuals need not be taken
as final, in the operation of the equipment. Individual instructions are provided
It is rather difficult to foresee each and separately for the sub-equipment under the
every contingency that may arise during the scope of company’s supply. For complete
entire life of the equipment. It must be details of these auxiliary equipment,
recognized that , no amount of written please refer to the instruction manual
instruction can replace intelligent thinking concerned. Make this manual available to
and reasoning on the part of the equipment the operating personnel freely.
operators, especially, when coping with
BHARAT HEAVY ELECTRICALS LTD

BOILER AUXILIARIES PLANT
RANIPET-632 406
FANS INDEX
1. FORCED DRAFT FAN
2 . INDUCED DRAFT FAN
3 . PRIMARY AIR FAN

4 . SEAL AIR FAN
5. COMMON ANNEXURES
ERECTION MANUAL
“FORCED DRAFT FAN”
M/s PRAYAGRAJ SUPER THERMAL

POWER PROJECT,PHASE-I
Cust. No: R620,R621 & R622

(A Govt. of India Undertaking)
Boiler Auxiliaries Plant
Ranipet 632 406 Tamil Nadu
Bharat Heavy Electricals Limited
FORMAT NO. :F1 REN. NO. : 00
ENGINEERING & DEVELOPMENT CENTRE
FIELD ENGINEERING SERVICES DATE:07.01.2013 PAGE: 01 OF 08
TABLE OF CONTENTS
PROJECT: M/s PRAYAGRAJ SUPER THERMAL POWER CUST.NO.
PROJECT,PHASE-I :R620,R621&R622
1. INTRODUCTION
2. TECHNICAL DATA
3. DESIGNATION
4. CONSTRUCTIONAL FEATURES
5. IMPORTANT INSTRUCTIONS
6. TRANSPORT, INSPECTION SRORAGE AND PRESERVATION
7. PREPARATION FOR ERECTION
8. GROUTING INSTRUCTION
9. ERECTION INSTRUCTIONS
10. LUBRICATION INSTRUCTION
Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

Signature : Signature : Signature :
1. INTRODUCTION
In the Axial reaction fans the major part of (about 80 %) energy transferred is converted into static
pressure in the impeller itself. The rest of the energy is converted into static pressure in the diffuser.
These fans are generally driven at constant speed. Varying the angle of incidence of impeller blades
controls the flow. It is therefore becomes possible by this process to achieve high efficiencies even
during part load operation. The blade pitching operation is performed by mechanical linkage
connected to a hydraulic adjustment device, which is flanged to the impeller.
This manual generally describes and outlines the constructional features and the method of erection
of the Forced Draft Fan supplied to M/s PRAYAGRAJ SUPER THERMAL POWER
PROJECT,PHASE-I
Before commencing erection of the fan, the concerned engineers must ensure that, they are familiar
with all the details required for erection. Incase of any doubt/ clarifications refer to Field
Engineering Services, Fans Engineering Division, BHEL- Ranipet, Tamil Nadu.
The contents in the manual have been written by taking every possible care to ensure correct
information. However it must be realized that no amount of written instructions can replace intelligent
thinking and reasoning on the part of the personnel concerned, especially when coping with individual
site conditions.
As continuous improvement on the basis of development and feed back are being made, BHEL
reserves the right to modify the technical details contained in this manual.

FIELD ENGINEERING SERVICES
DATE:07.01.2013 PAGE: 03 OF 08
2. TECHNICAL DATA SHEET

1. APPLICATION : Forced Draft Fan

2. FAN TYPE : FAF 26.6/12.5-1
3. No. OFF/ BOILER : Two
4. MEDIUM : Atmospheric Air
5. LOCATION : Outdoor
6. FAN DESIGN RATING
Capacity (m3/s) : 280
Total head developed (mmwc) : 448
Temp. of medium (deg.C) : 50
3
Density (kg/ m ) : 1.082
Speed (rpm) : 990
7. FAN RESERVE
Flow (%) : 30.6
Pressure (%) : 43.5
8. FAN DRIVE COUPLING
Type : Spacer Type
9. DRIVE MOTOR
Make : BHEL BHOPAL
Frame : 1LA7902-6
Rating (kW) : 1775
Speed (rpm) : 990
Volts (volt) : 11000

DATE:07.01.2013 PAGE: 04 OF 08

10. LUBRICATIN EQUIPMENT

Fan : 15 LPM/ 35 BAR FOLS (OIL-ISO VG68)
Motor : Grease lubricated (Servogem3)
11. TYPE OF FAN REGULATION : Blade Pitch Control
12. BEARINGS
Fixed Bearing : NU 238M+6238 M.C3
Free Bearing : NU 232 M.C3

3. DESIGNATION OF FAN
CUST.NO.
PROJECT: M/s PRAYAGRAJ SUPER THERMAL POWER PROJECT,PHASE-I
:R620,R621&R622
The Forced Draft Fan supplied to this project is of the following designation:
FAF 26.6/12.5-1
FAF  FORCED DRAFT FAN
26.6  Tip diameter in decimeter
12.5  Hub diameter in decimeter
1  Single stage
RECOMMENDED LUBRICATION CHART FOR “ FAN ” BEARINGS:
Lubricant & Supplier : Servo prime 68 of IOC

Bharat Turbol 68 of BP
Turbinol 68 of HPC
Teresso 68 (Others)
Filling location : Fan Bearing Housing
Frequency of filling : once in Six month or
based on oil test results
Frequency of observation : daily
Quantities per fan : 325 ltrs / fan

DATE:07.01.2013 PAGE: 06 OF 08
LIST OF DRAWINGS
Sl.No DESCRIPTION DRAWING NO
1. GENERAL ARRANGEMENT DRAWING 1-00- 098-21854
2. SILENCER ARRANGEMENT DRAWING 0-55-911-01169
3. FAN ASSEMBLY 0- 55- 215- 01285
4. SHAFT WITH BEARING ASSEMBLY 0-55-215-01272
5. ROTOR ASSEMBLY 0- 55- 215- 01281
6. HYDRAULIC ADJUSTMENT DEVICE 0- 55- 215- 01281
7. BLADE BEARING ASSEMBLY 1-55-215-01697
8. SETTING SHAFT ASSEMBLY 0- 55- 215 -01236
9. LINKAGE ASSEMBLY NA
10. LOS SCHEME DRAWING 2- 00 -107- 22078
11. FAN CHARACTERISTIC CURVE 3- 00 -102- 23428
12. TORQUE Vs SPEED CURVE 4- 00 -102- 23186
NOTE:
THE OWNERS ARE ADVISED TO PRESERVE THE DRAWINGS SUITABLY FOR FUTURE REFERENCE

DATE:07.01.2013 PAGE: 07 OF 08
LIST OF ANNEXURE
Sl.No DESCRIPTION
1. PROPER FASTENING FOR RIGIDITY
2. PROCEDURE FOR ENSURING SPRING BACK
3. MAXIMUM PERMISSIBLE TORQUE VALUES FOR TIGHTENING BOLT
4. MOUNTING AND DISMOUNTING PROCEDURE OF ANTI FRICTION BEARING
5. PRINCIPLE OF HYDRAULIC INSTALLATION AND EXTRACTION
6. ACID CLEANING PROCEDURE
7. INSTALLATION AND ALIGNMENT OF RIGIFLEX COUPLING

DATE:07.01.2013 PAGE: 08 OF 08
LIST OF VENDOR MANUAL/DATA SHEET

Sl.No DESCRIPTION REMARKS
1. LUBE OIL SYSTEM APPLICABLE
2. HYDRAULIC COUPLING NOT APPLICABLE
3. ACTUATOR APPLICABLE
4. MOTOR APPLICABLE
5. RIGIFLEX COUPLING(FLENDER) APPLICABLE

Ranipet
AXIAL FAN
(TLT DESIGN)
FD Application
(Single Stage)
ERECTION MANUAL
Prepared by Checked by Approved by
Hitesh Kumar T S Selvaraj M. Desigan
Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013.

Ranipet Axial Reaction Fan – Single Stage
4. General Information
The present assembly description is a general guide line for the erection and commissioning
preparation of the fans delivered by BHEL/BAP-Ranipet. This instruction is for axial forced draft
fans for power plants.
This description does not lay claim to completeness regarding details and changes, resulting
from our technical product development, project-specific specialties as well as from
documentation updates.
Assembly Work
The assembly work requires special knowledge and must only be carried out by assemblers
having many years of experience in fan construction. Where applicable the assembly work must
be adjusted to the circumstances on site and cannot be described in detail in this Assembly
Instruction. Therefore we recommend letting carry out the assembly solely by skilled and
qualified BHEL/Site personnel.
Minimum Requirement
The assembly work must imperatively be supervised by a BHEL-site engineer during the
whole assembly time.
 BHEL/Ranipet will not be liable for any damage caused by inappropriate

storage / assembly by agency staff.
First carefully read the complete assembly instructions to familiarize yourself with the
delivered machine.
Follow the country- specific legal regulations for occupational safety (e.g. accident prevention
regulations) and generally accepted industrial standards.
Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 1

4.1 Explanation of Used Symbols
The following symbols have been used in this Assembly Instruction:

4.2 Requirements on Site
Concrete foundations and stationary hoisting devices or crane rails have to be released by
the customer/BHEL-Site prior to the assembly and installation of the Fans. Ensure that
adjacent platforms, stairs, steps, and steel structures do not interfere with the assembly.
Prior to the assembly, the representatives of the customer and of BHEL/Site have to
mutually accept the scope of supply and inspect it for completeness.
4.3 Transport, Storage and Inspection of the Delivered Equipment
The delivered equipment has to be stored as per BHEL's transportation requirements and
storage regulations as well as per indications shown on the packing material and the
shipping notes (if any).
Avoid - in particular - storing structural steel elements on their mechanically treated

(machined) surfaces directly on the floor. Use timber or similar adequate materials for
storing the structural steel elements on it.
Carefully inspect the Fan components delivered by the transporters for shipping damage,
short delivery or other deficiencies. Prepare a separate inspection sheet for each cargo
unit.
Record damages and other deficiencies adequately (e.g. photo

documentation) and inform BHEL and / or the transporters.
The delivered components have to match the indications shown on the packing list and
shipping notes. In the event of damage, theft, short delivery, etc. the authorized
representatives of the customer as well as BHEL-Site have to be immediately informed to
be able to take the necessary measures.
If damage to the delivered components or incomplete deliveries has clearly been caused
during transportation, please immediately contact the shipping agent and BHEL. Indicate
improper deliveries on the shipping documents.

4.4 Responsibilities and Interfaces
In the event of effective claim for damages, the above-mentioned activities prevent
disputes and ease a fast handling. Reworking, repairing and replacement deliveries have
to be exactly performed according to BHEL requirements. Otherwise function and
warranty may be affected.
The delivery has to be checked upon receipt for the following:
 Accuracy and completeness

The delivered quantity of the equipment has to match the indications on the
packing lists, shipping documents and drawings.
 Damages in transit
Carefully check the BHEL equipment delivered by the transporters immediately
upon receipt for completeness, damages in transit or other visible deficiencies.
Use the packing lists and shipping list handed over by BHEL for this purpose.
 Damages at packages or at equipment being delivered unpacked
They have to be documented in detail and be acknowledged by the carrier/
transporter. Immediately compile a damage or deficiency report and hand it
over to the responsible construction supervisor as well as to BHEL, Ranipet
 Rework or repair at the equipment
They must only be carried out if approved by BHEL, Ranipet.
5.0 Safety Instructions:
This chapter is mainly addressed to the assembly or commissioning personnel as well as to
the operating and maintenance personnel of the plant operator.
The assembly, commissioning, operation and maintenance of the plant may, however, under
certain circumstances, be dangerous to persons and damage the plant. This chapter
therefore deals with general and especially noteworthy safety advice.
For your own safety, please read this chapter carefully and exactly follow the instructions
and prescriptions. It is the only way to protect you from danger and to avoid damage to the
plant.
All data in this chapter are general or valid for all machines. For the relevant precise safety
instructions please refer to the subsequent chapters of this instruction manual.
During operation and during any work at the fan, the appropriate accident prevention
regulations must be observed. Before commissioning please make sure to be informed about
the currently valid provisions at your site. Please follow in particular all international,
national and local legal requirements to guarantee the protection of safety and health in
the workplace.

5.1 Warnings
This operating manual contains indications you should follow for your own safety and in order
to avoid property damage.
The instructions for your own personal safety are highlighted by aid of a warning triangle and
combined with a signal word (danger, warning, caution). By aid of the signal words danger,
warning and caution the meaning of the warnings can be estimated much better. Instructions
on property damage have no warning triangle.
According to the degree of danger, the warning signals are presented as follows:
Imminent danger of individuals!

The disregard of this hazard warning will cause severe injuries or even
death of persons.
DANGER!
Danger of individuals!
The disregard of this warning may cause severe injuries or even death of
WARNING! individuals.
The disregard of this warning may cause slight injuries of individuals.
CAUTION!
5.2 Intended Use

The Fan is explicitly destined for the application described in the contract. An application
diverging from the one in the contract is not allowed. The Fan and its accessories must not
be changed arbitrarily.
Intended Use
Apply the fan explicitly according to the regulations only for the transfer of
those gaseous mediums that relate to process technology and that are
contractually defined.
The fan must not be applied for another purpose than the one described
here!
The assembly and operational manual have to be available at any time. The instructions and
advice given in these manuals must be followed in all points.
The signs and symbols fixed to the machine have to be observed. They must not be removed
and be completely readable at any time. The operating data of the machine must be kept
within the limits. Machine settings must not be altered arbitrarily.
BHEL/Ranipet does not assume liability for damage caused by an application the fan is not
intended for.

5.3 Demands on the Personnel

The fan as well as its service components may only be mounted, mechanically and
electrically connected, commissioned, maintained and operated by qualified personnel with
commensurate experience in mechanical engineering and be trained regarding the respective
work and safety regulations being effective. All activities have to be supervised by
responsible qualified personnel.
The personnel must completely read the assembly instructions prior to

working/operation to familiarize with the design of the machine and
especially with the safety requirements.
During working/operation the personnel must observe the assembly
instructions in all points.
BHEL/Ranipet does not assume liability for damage and accidents caused by disregarding the
assembly instructions.
Please feel free to contact BHEL/Ranipet for special training of your

personnel.
On-site the personnel must deeply familiarize with the machine and the working
environment.
The personnel must know the location and use of the following safety devices such as:
 Emergency stop button for adjacent equipment

 Emergency phone
 First-aid kits and first-aid devices
 Fire alarm and fire extinguisher
Qualified personnel must be instructed and authorized for the necessary activities by the
respective safety officer of the plant.
In particular the following demands are made on the assembling and commissioning
personnel:
 Only assign qualified personnel that are especially trained on assembling and
commissioning of BHEL large fans. We explicitly note that assembling and
commissioning activities must only be performed under responsible supervision of
a BHEL/Site supervisor or a commissioning engineer.
 The competencies of the personnel should be clearly defined for all appearing
activities.
 Make sure that personnel in training, being instructed or educated must only work
at the machine under constant supervision of an experienced person.
 Make sure that activities at the electrical equipment of the BHEL fan are only
performed by trained electricity specialists in accordance with the electro-
technical regulations.

 Activities at hydraulic equipment may only be performed by personnel having

knowledge and experience with hydraulics/hydraulic technique.
 Loading of cranes and instructing crane drivers must only be performed by
experienced and trained personnel.
5.4 General instructions to avoid danger

 You should be cautious working at the plant.
 You should observe the general health and safety regulations for the relevant part
of the plant.
 Make sure that the assembly instructions are followed.
 Wear protective clothing.
 Keep a safety distance of at least 1 metre from rotating parts.
 You should not stay under lifted equipment (e.g. rotor)
 In the event of any difficulties, please contact BHEL/Ranipet
5.5 General Instructions on Welding

Basically at assembled structural elements as well as electrical equipment, welding has to be
avoided. Specially at the following movable and complex elements such as
 Coupling,
 Local setting devices,
 Motors and their terminal boxes, actuators, etc.
Should, however, weld work at structural elements be indispensable, strictly follow the
following instructions:
 Prior to assembly work and welding the ordering customer/assembly performer must
establish a quality assurance schedule.
 Prior to welding a welding release has to be obtained from the responsible welding
specialist of the customer / assembly performer.
 The responsible welding specialist of the customer / assembly performer must
establish the corresponding welding instructions (WPS)
 Welding only with the fan not operating.
 Place earthing directly to the weld area.
 The welding current must not run through bearings or other structural parts.
 The required weld inspection may only be executed and recorded by authorised
specialists.

6.0 Transport and storage
6.1 General
Danger of injuries during loading and unloading!

Be careful and follow the applicable current accident prevention
CAUTION! regulations, the general transport regulations and the specific instructions
of the manufacturers.
Especially the following activities represent a risk of injuries to persons and damage
to delivered components.
 Unloading on site
 Transport on site
 Storing on site
6.2 Packaging
The components of the fan are delivered unpackaged or packaged depending on:
 Customer demands,
 Their size and application area,
 Kind and route of transport and
 Storage period.
Packing materials are raw materials and have to be disposed of environment-friendly. Hand
plastics and carton packages separately over to a place of collection or utilization. Do not
dispose of packing material as household garbage.
Dispose of packing material professionally according to the respective

relevant regulations for waste disposal.
6.2.1 Markings and Information

The shipping units include the shipping information given by the customer as well as markings
and symbols regarding transport, handling and storage as per international standards.
Follow the information on the shipping units as well as the indications

on the shipping documents.
6.2.2 Loose and Unpackaged Shipping Units

Structural steel elements for the fan are divided in the factory for transport and provided
with transport bracings (marked by yellow-black rings). These bracings must by no means be
removed or used for hoisting and transporting of the elements.
6.2.3 Packaging of Small Parts and Accessories

Small parts and accessories are transport-safe packed into boxes depending on the respective
package.

6.3 Transport
6.3.1 Hoisting and Lowering

Attaching boxes and loose parts represent an increased risk of accidents!
Danger caused by falling components!!

 Sling the boxes, structural steel elements and the rotor only to the
DANGER! identified load fastening points:
 Only the following being intended for this purpose has to be applied
 Suspension device
 Load fastening points
 Lifting eyes, etc.
NOTICE!
Structural steel elements must only be attached to the points marked by
a pictogram of the chain. It is not allowed to attach the elements to the
stiffeners (marking with yellow-black rings)!
 Apply only approved and certified slinging devices with adequate bearing capacity
(such as transportation device, ropes, straps, chains, hooks)!
 Attach the rotor only as shown on section 9.2.7 “Attaching the Rotor”. Apply the
ring bolts inside the bearing housing only for the hoisting of the bearing but never
for the entire rotor in a built-in condition!
 Machine parts must be attached and lifted carefully. They must not abut against
obstacles and must be carefully and slowly put down onto the prepared floor space.
6.3.2 Transport on site

The transport vehicles must be approved for permissible total weight. Take care that the
components are not damaged during transportation. Avoid damaging Suction Box, 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.
 Secure the components on the transport vehicle against moving and tilting.
 Unpacked components must be covered by a tarpaulin (e.g. rotor, drive motor).
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.

6.4 Storage on site

The period of storing of the supplied fan components on site depends on the agreements
stated in the contract. Based on these agreements the conservation and package of the fan
components was designed. 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.
If structural components are stored for a period longer than 3 months, they
have to be examined and re-conserved, if necessary (Under BHEL /Site
supervision).
BHEL has to be informed as soon as possible!
There is a risk of property damage if not stored professionally (e.g.

NOTICE!
corrosion). The removal of these damages may lead to high
expenditure.
6.4.1 Minimum General Storage Requirements

Frequency Of
Sl.No Fan Component Storage Locations
Inspection (D)
5.1 Suction Box Outdoor (a) Monthly
5.2 Diffuser Outdoor (a) Monthly
5.3 Silencer Weather Protected (b) Monthly
5.4 OGV Assembly Weather Protected (b) Monthly
5.5 Impeller Housing Weather Protected (b) Monthly
5.6 Rotor assembly Indoor c) Monthly
5.7 Spring shackle coupling Indoor c) Monthly
5.8 Machined packers and Shims Indoorc) Monthly
5.9 Instruments Indoorc) Monthly
5.10 Lub oil system Indoorc) Monthly
Note:-
a) Out door, above ground, exposed to weather, on blocks covered With Tarpaulins and
vented for air circulation.
b) Clean and dry warehouse.
c) Inspect the components at the given frequency and re preserve it suitably.
Specific attention should be given to ensure that the rotor assembly is stored
inside the covered shed and preserved properly. This rotor is assembled in
our works in an air conditioned hall.

6.4.2 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.
6.4.3 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.
6.4.4 Recommended Preservative Components
Application Brand Name

TRP 1706, TRP 1710 HDPE (High Density Poly
Machined surfaces ( Indoor storage )
Ethylene) sheets
Machined surfaces ( Outdoor storage ) TRP
Weldments De-oxy Aluminates
Shaft with bearing assembly Oil ISO VG 68 Equivalent: SERVO PRIME 68

6.4.5 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.
6.4.6 Preservation of Fan Up to Commissioning

After erection of fan at site, conservation must be ensured upto commissioning and during
trial operation. All bright surfaces must be sprayed with anticorrosive agents/rust
preventives.
6.4.7 Preservation of Fans During Long Shut Down

 No special preservation is required for a shutdown 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 hydraulic adjustment device
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.

7.0 Constructional Features
The fan is designed for a Forced Draft application. The unit is mounted on a foundation
block. An electric motor attached outside via an intermediate shaft with couplings provides
the necessary power. To adapt the respective load point with regard to the corresponding
quantity of air, the blades are adjusted hydraulically. A nose fairing provides favourable flow
conditions in front of the impeller. Straightener vanes welded behind the impeller ensure
best possible downstream conditions. A static pressure increase is achieved through change
from kinetic energy of air into static pressure energy by diffuser. To avoid transmission of
vibrations the fan is connected to adjacent sections via expansion joints on suction and
discharge side. These expansion joints are also able to absorb thermal expansion if
necessary. The fan consists of the following Components.
 Stator consisting of Suction Box, Fan housing, Outlet Guide Vane housing with guide
vanes and Diffuser
 Rotor consisting of shaft, impeller with blades, the blade bearing assemblies,
the Hydraulic impeller blade adjustment system and Main bearings (Anti-friction
bearings).

7.1 Stator Components
Suction Box, fan housing Outlet Guide Vane housing with guide vanes and diffuser are welded
structural steel fabrications, reinforced by flanges and gussets, resting on the foundation on
supporting feet.
7.1.1 Suction Box

The suction box has been arranged in upstream direction immediately ahead of the fan. It
deflects the flow with low loss by means of its well-designed construction. The suction box is
a welded steel construction consisting of:
 the suction box with the entry opening
 the inlet nozzle
 the intermediate shaft Cover and
The intermediate shaft Cover is hold by radial supports in the inlet nozzle. At the suction box
inlet and at the ring-shaped outlet there are measuring studs for Pressure measurement. The
internal protection cover surrounds the intermediate shaft from its entry into the suction box
until its entry into the nose fairing/Bullet.
7.1.2 Fan Housing with Guide Vanes

The fan housing is designed as a welding construction and Bolted with the outlet guide vanes
housing. Fan Housing and Outlet guide vane housings are horizontally split, in order to
facilitate access of the rotor for dismantling and assembly. The rotor is installed and screwed
in bearing saddle flanges.
Bearing saddle flanges are the integral part of the nose fairing /Bullet. Nose fairing /Bullet is
supported by radian supports in impeller housing. Nose fairing /Bullet facilitates the smooth
entry of air to the impeller. After the impeller a hub part (OGV Core) holds by guide vanes
and surrounding the hydraulic adjustment system. The guide vanes assume the following
duty:
 Axial alignment of the turning Air flow leaving the impeller.
Two radial guide vanes in the lower part of OGV and fan housing are hollow in order to
conduct Supply lines, measuring cables .Suction Box and Fan Housing, Outlet Guide Vane
housing and diffuser are flexibly connected via expansion joints.
7.1.3 Diffuser
The diffuser has been arranged directly behind the fan housing with OGV in downstream
direction. The extension of the flow diameter within the diffuser leads to:
 Delay of the flow speed and

 Increase of the static pressure.
This reduces the flow loss in the subsequent duct parts. The diffuser consists of the housing
and the hub hold by radial support plates that are both provided with a entry openings. The
hub is fixed by tangential plates to avoid torsional vibrations due to induced flow
turbulences. Gauge connections have been attached at the diffuser end to measure the static
pressure.

7.1.4 Insulation
The insulation has been measured corresponding to the acoustic and thermo technical-
calculations.
Any housing divisions, doors, assembly openings as well as parts to be maintained such as
bandages, expansion joints etc. have been provided with easily removable insulation
adapters (caps with self- locking fasteners).
The insulation at the fan has been placed in such a way to conserve the insulation at the
housing parts in the event of a possible disassembly of the fan rotor. Only the adapters must
be removed from the parts.
7.1.5 Expansion Joints

The expansion joints decouple the exhaust gas channel and the fan and detect movements in
the event of different heat expansion. Any one expansion joint is placed between:
 Suction side exhaust gas channel (transition piece) and suction box
 Between suction box and housing
 Between housing and diffuser
 Between diffuser and air duct channel on discharge side.
7.2 Rotor Components
The rotor assembly consists of a main bearing assembly and one impeller with blades, the
blade bearing assemblies, the hydraulic impeller blade adjustment system. The rotor
converts mechanic energy (kinetic energy) into flow energy. The following drawing shows the
rotor schematically:

7.2.1 Main Bearing

The main bearing is a part of the rotor and mainly consists of the bearing housing, the fan
shaft (main shaft), axial and radial bearings of various designs and of sealing elements.
The main bearing, a compact unit, is centred and screwed in the lower half of the fan
housing. Thermometers and resistance thermometers monitor the bearing temperature.
These thermometers must be connected to signalling instruments at the site.
Simmer rings as sealing elements are always installed, filled with grease. The oil circulated
through the oil return pipe, which opens into the oil reservoir. The main bearing is lubricated
by oil circulation. For this purpose an oil supply unit is attached outside the fan.
7.2.2 Impeller
The impeller consists of a weld-in hub, a supporting disk, a solid load ring for taking up the
centrifugal forces, impeller casing and a guide ring. The ribs, the load disk and the cover
plate together, give the impeller a strong stiffness. The drive torque is mainly led into the
load ring and the guide ring.
To absorb the natural and the centrifugal force of the impeller, the load ring is designed in a
very stable manner. Hub and fan shaft are connected by interference fit and secured with a
key. To permit mounting of the impeller on the shaft the hub opening is widened oil-
hydraulically.
7.2.3 Blade
The blades change mechanic energy (kinetic energy) into flow energy. The blades consist of
aluminium alloy. To get an ideal efficiency degree, their surface and other geometry data
(such as impeller profile) have been processed quite exactly. The blades are attached to the
shaft) by means of special bolts.

7.2.4 Blade Shaft Bearing Assy

The blade shaft bearing serves the absorption of the impeller blade centrifugal forces and
the continuous blade adjustment during operation. The blade shaft supports the screwed
blades, the counterweight and the adjusting lever.
The centrifugal forces of the blades and blade shafts are transferred via axial deep groove
ball bearings into relatively small load ring. The angular contact ball bearing and the blade
shaft bearing bushing absorb transverse forces from adjusting and aerodynamic torques.
Various static and dynamic sealings prevent:
 the emission of lubricants from the interior of the impeller and
 the entry of contaminations into the interior of the impeller.
The deep groove ball thrust bearing is lubricated with oil (oil ring lubrication!). The angular
contact ball bearing is filled with grease. Each blade bearing is sealed off by means of
several seals, in both directions (towards the inside and outside).
7.2.5 Hydraulic Impeller Blade Adjustment System

The blades will be adjusted and kept in position during operation by the hydraulic impeller
blade adjustment system. The adjusting range is indicated in the rotor assembly drawing.
The blades, fixed at the outer end of the shaft, will be adjusted and kept in position by
means of a lever, which is provided with a sliding block and which is located at the inner end
of the shaft. Those levers and sliding blocks are embrace by the adjusting disks.
The adjusting disks are connected with the cylinder of the hydraulic impeller blade
adjustment system via the thrust device. The control of this cylinder is affected via the
control slide valve in the control head.

The pressure oil in the space of the control slide valve can reach the respective side of the
adjusting cylinder via the borings through the respective ducts which are opened by the
control slide valve.
Now the adjusting cylinder is displaced accordingly and the blades are adjusted in the same
way via levers. The oil on the other side of the cylinder returns through ducts which are also
opened by the control slide valve.
To the same extent as the adjusting cylinder is moved, the return rod will also be moved (as
it is fixed at the adjusting cylinder and arranged in the rotational axis).
Thus the borings, released by the control slide valve, will be shut via gearwheels and gear
racks installed in the control head. Upon reaching the given position the adjusting procedure
is finished.
7.2.6 Adjusting Shafts

The mechanical connection between the hydraulic impeller blade adjustment system and the
respective components outside of the fan housing is attained via an indicator shaft and a
setting shaft. An external actuator effects the hydraulic impeller blade adjustment system
via the setting shaft.
Those parts of the Hydraulic impeller blade adjustment system unit which are arranged in
the guide vane and diffuser cores are accessible through assembly openings.
7.3 Fan Accessories
7.3.1 Spring Shackle Coupling

The fan shaft is connected to the motor shaft by means of Spring Shackle couplings
while the distance between the shaft ends is bridged by an intermediate shaft which is a
part of the coupling assembly. The spring shackle coupling can absorb radial and angular
mismatch up to a certain extend. No lubrication is required for the coupling parts.
Coupling Mounting
Mount the coupling on fan shaft as per the attached annexure-I
7.3.2 Oil Circulation Unit

The oil unit 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 flow-regulating valve.
7.3.3 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.
7.3.4 Special Tools, Maintenance Devices

For the maintenance of the fan some special bolts and devices are necessary. To mount and
dismount the impeller from the main shaft, the mounting and dismounting device has to be
used.

8.0 Assembly Requirements
The concrete foundation and steel structures, hoisting devices, means of transportation,
auxiliaries and tools have to be released by the customer/BHEL-Site prior to the assembly
and installation of the fan components.
Prior to start of the assembly, the foundation including the anchor holes (anchor boxes) has
to be inspected and accepted by a BHEL supervisor. A measuring report has to be compiled
by the customer or construction company.
8.1 Safety instructions

All fan components have to be assembled, commissioned, operated and maintained on site
considering the international, national and local legal regulations to guarantee safety and
health protection at the work place.
 Observe the accident prevention regulations of the assembling

country.
 Observe the internal occupational, operational and safety
regulations of the power plant!
Dirt and humidity may affect the function of the elements.

NOTICE!
If possible, do not work outdoor but in a workshop.
Protect the workplace when working outside.

Please only use faultless tools!
NOTICE! Machine parts may be damaged when put down

Underlay
 Housing parts with timber beams
 Metallic blank parts with corrugated cardboard or air bubble foil.
NOTICE! Machine parts may be damaged by rough disassembling and

assembling
Do not apply force.
Numbered parts or parts with markings in another way belong together.

Pay attention to:
 The marking and the consecutive order.
 The numbering / marking on the drawings.

8.2 Precautions Using Preservatives and Lubricants
Exposure to preservatives and lubricants may lead to serious injuries

of the eyes as well as to irritation of the skin.
Avoid exposure to preservatives and lubricants.
Read the respective safety data sheets of the products. They inform you
on accident prevention, health and environmental protection.
Wear protective gloves and clothing when working with preservatives and
lubricants!
Wear safety goggles when working with preservatives and lubricants!
Risk of skidding due to spilled oil!

 Eliminate existing leakages, if necessary.
NOTICE!
 Remove oil spills immediately with adequate oil binding agents.
 Use oil sumps.
When oil or grease hits a hot surface, there is a risk of fire.

 Do not spill oil.
NOTICE!
 Eliminate oil leakages.
 Eliminate grease remainders.
Oil and grease are harmful to water.

 They must not penetrate the soil and the sewage system.
 Have waste oil and grease disposed of by a specialized company
for waste disposal.

8.3 Hoisting Devices

For installation and assembly of the fan, hoisting devices and auxiliaries are needed for
hoisting. While slinging fan components there is a higher risk of accidents.
Danger caused by falling components!
DANGER!
When hoisting heavy fan components only use appropriate, approved and
certified hoisting and sling gear!
Also follow the following instructions on the suspension device.
When slinging structural steel elements, housing parts and the rotor
observe the respective drawing.
Slinging points and component weights are shown in the drawings.
Use the eye bolt at the bearing housing only to hoist the bearing (as
single part without impeller)!
 To lift the complete rotor, refer to section 6.2.7, “Slinging of rotor”.

Special lifting eye bolts to be mounted in the blade shafts of impeller.
High-Strength Eye Bolts
High-strength eye bolts are fixed to heavy components to enable a slinging to a hoisting
device as well as transporting of the components. Prior to application check if the eye bolts
are tight and show no damages (corrosion, deformation). Eye bolts with deformations should
no longer be used and not screwed in.
8.4 Necessary Tools, Devices and Auxiliaries

For the assembly the appropriate tools, devices and auxiliaries are needed to perform the
steelwork, work on machine parts and pipework as well as electrical installation.
The subsequent listings are basic requirements for tools, devices and auxiliaries according to
our experience. The statements, however, make no claim to be complete.
We recommend placing both, a workshop container and a container for assembly materials
next to the assembly work.
For all activities to be performed, the respective personal protective

equipment has to be hold ready.
For all activities to be performed apply only perfect and certified tools,
devices and auxiliaries.

8.4.1 Steelwork
Tools and standard devices for steelwork:
 Work bench with vice

 Fork lift truck
 TIG welder incl. Protective equipment and accessories
 Flame cutter incl. transfer vehicle and accessories
 Angle grinder Ø 178mm incl. discs
 Drill hammer incl. drill Ø 6-30 mm
 Drilling machine incl. drill Ø 1 -22 mm
 Halogen spot and hand lamp
 Extension cord
 Isolating transformer
 Mechanical jack 1,5-5 tons
 Hydraulic cylinder 50 tons incl. pump
 Chain hoist 1,5-3 tons
 Sling gear
 Round slings 1-10 tons
 Sledgehammer 3-5 kg
 Hammer 1-2 kg
 Chisel
 Mandrel Ø 8-30 mm
 Mounting lever
 Open ended wrench 8-65
 Ring spanner 36-65
 Open-end spanner 26-65
 Set of screw drivers
 Set of screw taps M 5-24 incl. ratchet and die wrench
 Set of solid square bolt die M 5-42
 Hack saw
 Files
 Ratchet box 10-55
 Tape measure 25 m
 Try square 250 mm
 Marking tool
 Center punch
 Water level

8.4.2 Mechanical Engineering

Tools and standard devices for work on machine parts:
 Frame (Sprit) level 0.02mm/m

 Torque wrench – Required torque range according to rotor assembly and general
assembly drawing
 Ring wrench 8-65 mm
 Allen wrench 2-36 mm
 Allen nuts 5-36 mm
 Vernier caliper 150-300 mm
 Vernier depth gauge 300 mm
 Dial gauge 0-10mm with magnetic support (4 pieces)
 Pipework
8.4.3 Tools and standard equipment for pipework:

 Pipe vice
 Pipe wrench 1“-2“
 Multigrip piers
 Pipe-bending device 6-30 mm
 Angle measuring device 500 mm
 Folding measure 500/1000 mm
 Flange try squares 500 mm
 TIG welder
 Finger grinder
 Mobile oil pump
8.4.4 Installation of Electrics, Measuring and Control System

Tools and standard equipment for electric installation:
 Multi-meter
 Combination pliers
 Diagonal cutting pliers
 Flange tool
 End sleeve pliers
 Hot-air gun
 Binders
 Insulating tape
 Heat-shrinkable sleeve

9.0 Assembly Instructions
9.1 Assembly Preparations

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 dispatched 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 has to be done to the correct elevation.
For the permissible tolerances in the foundation the concern foundation plan drawing may be
referred. Mark the center line of foundation with respect to plant center 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 bases plates and ensure 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 and base plates 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 minimum
quality of class 8.8 or better unless specified in the drawing.
9.1.1 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
 Civil drawings provided by civil designs / consultants
9.1.2 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.
9.1.3 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.
9.2 Erection Instructions
9.2.1 Lay Out of Foundation with Pocket Holes 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
9.2.2 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.
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 approx 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. All primary packers are manufactured and
supplied as raw plates. It will have holes suitable for accommodating the foundation bolts.
Leveling spindles is used to keep the primary packers in suitable height above the foundation
and level the primary packers.
Ensure above 80 % color match between the impeller housing foot and
primary packer.
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.
Position the primary packers with leveling spindles with a lining plate underneath on
foundation (leveling spindles should be placed adjacent to the each foundation bolt at both
side and 4 nos at the corners). Bring the leveling spindles of the 4 outer fixing points to the
correct height while considering the theoretical axis height of the lower part of the housing
and also considering approx. 75 mm gap between primary packer bottom and dressed
concrete for grouting material. The other leveling spindles must be some millimeters below
the level of the 4 adjusted leveling spindles.
Erect a barrier with an appropriate height around the anchor box holes (foundation pocket)
in order to avoid that the grouting will not enter the anchor box. The barrier may be made of
synthetic material, foam rubber/ thermo Cole or similar.
Ensure horizontality of the primary packers within 1 mm per meter 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 Theodolite). Adjust
the leveling spindles of the 4 outer fixing points to attain these values. Now bring the
remaining leveling spindles in touch with packers.
Customer/consultant to refer the motor drawing/erection manual for the exact arrangement
of grouting. 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.
9.2.3 Positioning of Fan Housing with Guide Vane Section

Screw together the lower parts of the fan housing and guide vane section by using the
provided bolts, nuts and adapter sleeves. Ensure that the OGV assembly is located
properly in the machined step of the housing flange.

Mount the upper part at the lower part of the fan housing by using the provided bolts, nuts
and adapter sleeves. Check that there is no axial and radial misalignment at the bearing
saddles of the fan housing. Afterwards separate again the upper part of the fan housing from
the lower part.
Measure the distance/height between the theoretical fan axis and the upper part of the
foundation. Install foundation bolts in the respective foundation pockets.
Position the impeller housing (lower half) on the primary packers and align to the center
lines of foundation. Ensure elevation at four corners by water balance at dividing plane.
Ensure verticality of impeller housing by spirit level within 0.04 mm/mtr. . Adjust the
leveling spindles of the 4 outer fixing points to attain these values. Now bring the remaining
leveling spindles in touch with packers.
Tighten the foundation bolts as tight as the fan housing cannot be moved anymore and
counter check verticality. Ensure that there are no undue distortions present during
tightening. Foundation bolts are only finally tightened after the grout has hardened.
The leveling of the lower part of the housing must be executed from the
lowest point of the machined bearing saddles that the rotor can be exactly
aligned horizontally.
9.2.4 Positioning of the Suction Box

The suction box is delivered in several large individual parts. Marks on the parts ensure their
final positioning in the fan housing structure. The parts of the suction box are pre-
mounted besides the foundation block. This requires a plane, preferably leveled
surface as well as a mobile crane with corresponding lifting capacity. As of this pre-
assembly area the bottom part of the fan will be placed onto the foundation block as
a complete unit. Arrange, align, measure, tack, reinforce, weld, re-measure and realign
suction box sections.
Note that the stiffeners for transportation (Yellow Painted) in the split
components for suction box and diffuser must only be removed after their
assembly and welding.
Place suction box onto the levelled primary packer and place nuts onto foundation bolts.
Exactly align according to the measuring points marked during installation preparation. Lay
the intermediate shaft cover into the lower part of the nose fairing. Align the intermediate
shaft cover at the passage of the suction box (rear panel of the suction box) according to
the fan axis. Attach the intermediate shaft cover by aid of the cover plate. The cover plate
to the rear panel of the suction box is tight welded later on (after the final alignment of the
fan).

9.2.5 Positioning of the Diffuser

Arrange, align measure, tack, reinforce, weld, re-measure, and realign diffuser
sections.
Lay out primary packers on the diffuser foundation; level to required height, insert
foundation bolts. Put down diffuser on levelled packers, place nuts onto foundation bolts and
tighten by hand. Exactly align the diffuser according to the fan axis.
Consider the required clearance between suction box – fan housing –

diffuser. To obtain an assembly gap to the housing, axially move the suction
box or the diffuser. After final alignment of the machine, the gaps are closed
with the delivered expansion joints
9.2.6 Alignment of the Stator Parts

Align suction box, fan housing and diffuser; particular attention must be paid to the
transition suction box of fan housing as well as fan housing to diffuser. Furthermore the
prescribed gap between suction box and fan housing as well as fan housing and diffuser has
to be met.
9.2.7 Preparatory Work for Rotor Installation

Laying of the Interior Oil Pipes
The bundles of pipes and small parts of the structural component are delivered in boxes for
small parts. The pipework is manufactured and installed on site according to the drawing "Oil
Pipes inside".
Assembly of the oil pipes
Lay the rigid oil pipes inside the hollow struts/hollow support vanes of the lower part of the
fan housing. Mount the provided fixtures and bulkhead unions according to the drawing. Make
sure that all connections are tightened.
Test and Preparation of the Machined Bearing Supports
 First clean the flanges at the main bearing and the machined bearing saddles in the
lower part of the fan housing.
 Examine the machined bearing saddles for damage.
 Prepare the fixation screws for the bearings.
Assembly of the Rotor in the Lower Part of the Housing

 When hoisting heavy fan components only use appropriate, approved and
DANGER! certified hoisting and sling gear!
The blades are only mounted after the rotor has been lifted and placed
into the fan housing.

 There are highly sensitive components in the rotor. If they corrode, the
NOTICE!
functioning of the rotor is not warranted anymore.
 The rotor must never be exposed to precipitation (rain, snow, dew, etc.)
in particular after the package of the rotor has been opened (e.g. to
attach the lifting lugs).
 Remove the sealing tape from the impeller drill holes for the blades not
until mounting of the blades.
 Re-examine the alignment of the fan housing on the basis of the defined fan axis. All
other structural steel elements are later on adjusted to the fan housing.
 Check if the internal pipework has been pre-mounted to ensure that later on the
rotor will not to be dismounted and mounted again.
 Lift the rotor out of the transportation stand, align it in horizontal direction and
carefully install it in the machined bearing saddles of the lower part of the fan
housing. Use the provided suspension device to hoist the rotor.
 Check the seat of the bearing housing inside the machined bearing support with a
feeler gauge. Ensure a uniform seating. Ensure that the bearing lies in the lower part
of the bearing saddles. Also check the axial gap between bearing housing flange to
bearing saddles flange. If any gap is noticed, use shims of appropriate thickness.
 Additionally check the horizontal alignment of the main bearing in the bearing saddles
by aid of a precision frame level via the flanges of the main bearing.
 Fasten the rotor by means of the provided screws and nuts considering the tightening
torques!

 Completion of the Internal Pipework. Connect the flexible high pressure hoses with the
rigid pipework.
The connection of the flexible hoses at the main bearing and the
hydraulic with the fixed inner oil piping system in the fan housing is
effected only after having purged the oil piping system. For that reason
the pipes are short-circuited. Supply pipe into return pipe!
 Screw the temperature sensors (for the monitoring of the bearing temperature) into
the main bearing housing and lead the connecting cables through the hollow vanes of
the lower part of the housing. Prior to the installation carry out a performance test
(resistance measurement / measurement of the thermoelectric voltage).
 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.).
Installation of Oil System
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 hydraulic adjustment device
(Control oil piping) and main bearings (lube oil piping) in accordance with the drawings.
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.
The entire site made oil lines must be acid cleaned and neutralized. Prior to connecting the
flexible oil hoses with the hydraulic adjustment device, 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.
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 cover of hydraulic
adjusting device. Position and support the rigid piping suitably.

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 hydraulic adjustment device.
Interconnect the respective inlet and outlet pipes of main bearings and hydraulic adjustment
device.
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 runs the next motor / pumps 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 hydraulic adjustment device. 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
hydraulic adjustment device for a few strokes. Ensure smooth and uniform movement of all
the impeller blades.
Arrest leakage, if present. Set the Pressure relief
valves and Lub Oil flow to the required parameter.
Stop the oil pump. Inspect the filters and clean them.
9.2.8 Blade Assembly

The blades of rotors are supplied separately. The
blades are mounted after having installed and fastened
the rotor inside the fan housing.
The blade sets are marked with a letter for the stage
and a consecutive number for the blade (resulting from
the moment weighing), e.g. A1, A2, A3, A4 ... or B1,
B2, B3, B4 …
 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
hydraulic adjustment device. Switch off the lub
oil pump till all the blades are mounted.
 During the blade mounting process, the impeller
must be secured against rotation by suitable
blocking devices.
 Remove protective items from the rotor, clean and

lubricate installation surfaces, shaft bearing
bushing, bushing, and shaft flange, place seal rings
on blade foot.

 Ensure that the round nose of the blades is fixed on the suction side.
 Mount blades at the circumference of the impeller according to their sequence number.
You can start with any blade shaft. They may be assembled proceeding in the clock-wise
or counter clockwise direction.
 Mount always two opposite blades to avoid an uncontrolled rotation of the rotor.
 Apply Molykote 1000 paste onto the threads and the bolt head contact surfaces of the
delivered blade bolts. Tighten the blade fixing screw to prescribed tightening torque,
according to the sequences shown in Figure.
 Ensure that the blades are positioned and tightened in identical position. This is to
avoid uneven gap between blades.
 At blade full close position, ensure that the blades are not fouling with each other. There
can be minimum gap between blades.
 Check the tip clearance between lower part of the housing and blade tip. The annular gap
has to be in the range of the defined tip clearance according to Rotor Assembly Drawing.
 Mark the longest and the shortest blade. If the tip clearance is too small at single points of
the fan housing impeller plane, the corresponding points must be grinded. If the whole tip
clearance is too short, it is necessary to grind the blade tips, if the blades have not
been specially coated against wear.
 If the blades have been specially coated please contact BHEL/Ranipet for further
information.
 Grinding of areas of the housing shell or complete grinding of the blade tips are to be
agreed with BHEL/Ranipet.
Caution!
Regrinding of areas in the machined impeller plane as well as regrinding of blade tips, if
necessary, has to be performed very carefully and only by very experienced personnel.
Upon assembly completion and positioning of the upper part of the fan
housing:
Re-examine the total tip clearance.
If necessary, the tip clearance has to be corrected as described above.
 Place upper part of housing and

fasten nuts hand tight. Check the
blade gap according to the
following procedure:
Blade Gap Measurement
 The blade angle has to be

adjusted to closed position.

 Measure all blade gaps at the same position “x” to find out the longest blade. Mark the
respective blade accordingly.
 Carry out the blade gap measurement first with the longest blade at each of the positions
P (eight points at the circumference).
 Countercheck the gaps at the horizontal flanges ( 3 and 9)

 Compare with permissible gap acc. to the drawing and prepare records
9.2.9 Actuator with Setting Shaft Assembly

The actuator and the blade pitch transmitter are installed outside the fan housing and
connected to the hydraulic adjusting device via the setting shaft.
Put the shafts in the intended passages of the guide vane section and connect them with the
flange and pillow block bearings. The shafts must not get in contact with the pipes they are
led through. Connect the shafts to the hydraulic blade adjustment. Beware! The spring disks
must not be axially tensioned when installed.
After mounting of the complete component group, the actuator as well as the blade pitch
transmitter has to be adjusted.
First, the blades have to be moved into the end positions, e.g. fully open and fully closed.
The adjusting range of the actuator has now to be limited according to Figure, e.g. the
possible adjusting range of the actuator must be slightly smaller than that of the hydraulic
adjusting device.
Adjusting Range Limitation

The blade pitch indication
transmitter now has to be adjusted:
 Move the blades into the closed
position and set the transmitter to
0 % (corresponding usually to
an output signal 4 mA).
 If the transmitter range has

already been pre-adjusted at the
workshop, the blade position “fully
open” should correspond with the
100% signal ( = 20 mA).
 In case of an adjustable range the 100%-signal (=20mA) has to be adjusted corresponding to

the max. blade position.
9.3 Intermediate Shaft with Couplings and Protection Cover

Refer Annexure for Coupling Mounting Procedure
Push the intermediate shaft from the motor side through the intermediate shaft protection
cover and support the intermediate shaft at the height of the fan axis by wooden

substructures. Connect the intermediate shaft with the fan side coupling half that has
already been mounted at the rotor. All contact surfaces of the flange must be clean before
assembly.
Align the nose fairing with the rotor. Use distance plates for perfect alignment. The
alignment must be concentric to the rotor hub. By means of supports the nose fairing is then
centrically aligned into the suction box transition nozzle. First only slightly tack the supports.
Welding in must only be performed after perfect centring of all fan components and
particularly after coupling alignment. Align the intermediate shaft cover at the suction box
shaft opening and tack it by means of appropriate connectors.
9.4 Assembly of the Motor and Fine Alignment of the Coupling

 Mount the coupling half on the motor shaft.
 Clean the bottom side of the motor sole plates. Measure the distance/height between
the theoretical fan axis and the upper part of the foundation. Install foundation bolts in
the respective foundation pockets. Erect a barrier with an appropriate height around
the foundation pocket in order to avoid that the grouting will enter the anchor box.
The barrier may be made of synthetic material, foam rubber or similar.
 Position the sole plate with leveling screw/spindles on foundation. Bring the leveling
screw /spindles of the 4 outer fixing points to the correct height while considering the
theoretical axis height of the lower part of the housing including shims (2 - 3 mm).
 Ensure horizontality of the sole plates below the Motor to within 0.04 mm per meter in
both axes and also maintain the same elevation between the left and right sole plate (Use
straight edge between these two sole plates and measure with spirit level). Adjust the
leveling screws to attain these values.
 It should still be possible to adjust the leveling spindles for several millimeters. The other
leveling spindles must be some millimeters below the level of the 4 adjusted leveling
spindles. Put the stainless steel shims on the primary.
 Position motor on the sole plate and roughly align it by aid of shims. Maintain the center
distance between fan & motor shaft coupling halves as per the applicable coupling
drawing.
 Remove “Transport pins/ spacers” connecting flexible flanges (in the intermediate shaft)
at both ends. Measure and note down the coupling gap and verify it with the coupling
drawing. In case of any variation, contact BHEL/Ranipet. Connect the coupling hub at
motor side with the coupling flange at the intermediate shaft.
Final 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.
 Re-check the values after completion of the alignment and record the values in the
alignment. After alignment of the coupling and intermediate shaft, align the intermediate
shaft cover at the penetration in the suction box wall. The intermediate shaft cover must
be concentric with the intermediate shaft.
Alignment of the Hydraulic Adjusting Device
After completing the shaft and coupling alignment and before final assembly of the housing,
the alignment of the hydraulic adjustment device should be checked. The value specified on
the rotor drawing, this value shall be considered the limit value that may not be exceeded.
Check the alignment of the hydraulic blade adjustment system according to "Rotor Assembly"
10.0 Grouting of the Foundation Anchoring

After fine alignment of the motor and fan coupling flange, 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 hardening of grouting compound, all foundation bolts are to be fully tightened.
Before taking up the grouting, the grout material should be sample tested to meet
manufacturer specification
Ensure that the foundation pockets are NOT filled with the grout as shown in the
drawing.
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 gasket of recommended thickness at the parting plane of impeller
housing. Carefully lower the housing top half on the bottom half of the impeller housing by
means of guide bars. 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.
 Mount the locating pins (taper fit) and 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.
Assembly of Expansion Joints
 Lay and clamp the flexible rubber expansion piece between the impeller housing and
Suction Box.
 Lay and clamp the flexible rubber expansion piece between OGV unit and diffuser
assembly.
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 Box as shown in the installation drawings.
11.0 Lubrication Instructions
The Lubricating oil for the Fan bearings are supplied by the centralized oil pumps which
supply oil for the hydraulic adjustment device 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 oil to be used shall be a turbine quality oil to suit the following specifications:
ISO Viscosity Grade : 68
Kinematic Viscosity at 40o 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
utilized. 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.
Recommended Lubrication Chart
Locatio Observ Qty /

Sl.no Component Lubricant Supplier Frequency
n ation Fan
During
Fan main Brgs Servo prime 68 M/s IOC
over haul
and Hydraulic Turbinol 68 M/s HPC See
01 Oil tank ( once in Daily
adjustment Bharat turbol 68 M/s BPC note 1
2 years )
device Teresso 68 (Others)
see note 2
During
Refer
Blade shaft Mobil Glygoyle 30 Over haul
Inside Rotor
02 bearing And Mobil grease See note.3 ( once in *****
Rotor assy
assembly 28 / Burutox M21 2 years )
drg
see note 4
During
Blade shaft
Molykote Over haul
bearing bushing Inside
03 microfine See note.3 ( once in ***** 0.5 Kg
and pushrod Rotor
graphite powder 2 years )
guide bushing
see note 4
During Refer
Over haul Rotor
Blade shaft Mobil grease 28 / Outside
04 See note.3 ( once in ***** assy
guide bearing Burutox M21 Rotor
2 years ) drg
see note 4
Blade bolt and Molykote 1000
05 Common 0.5 Kg
other bolt paste
Notes :
1) Oil quantity depends on tank capacity. 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 BHEL personnel.

ERECTION MANUAL
“INDUCED DRAFT FAN ”
M/S PRAYAGRAJ SUPER THERMAL

3X660
CUST.NO:R620,R621&R622

ENGINEERING & DEVELOPMENT
CENTRE
TABLE OF CONTENTS
PROJECT: M/S PRAYAGRAJ SUPER THERMAL POWER
PROJECT,PHASE-I
1. INTRODUCTION
2. TECHNICAL DATA
3. DESIGNATION

CENTRE
1.INTRODUCTION
PROJECT,PHASE-I
Radial Fans manufactured by BHEL are single stage, single/double suction, simply supported/overhung
centrifugal machines, which can be used to handle fresh air as well as hot gases, in power plant
applications. They are also used in process industries like, cement, steel plants and paper mills, etc.
In this type of fans, the medium handled enters the impeller axially and after passing through the
impeller leaves radially. A large part of the energy transferred to the medium is converted in to kinetic
energy as the medium passes through the impeller. The spiral casing converts part of the kinetic
energy in the medium to pressure energy. Constant speed motors generally drive these fans. The
output of the fan is usually controlled s by varying the speed of the fan by suitable speed control
device and also by inlet damper.
This Manual generally describes and outlines the methods and procedures for erection of the
Induced Draft Fan supplied toM/S PRAYAGRAJ SUPER THERMAL POWER PROJECT,PHASE-I.
with all the details required for erection. In case of any doubt/clarifications, refer to Field
Engineering Services, Fans Engineering Division, BHEL, Ranipet, Tamil Nadu.
information. However, it must be realized that no amount of written instructions can replace
intelligent thinking and reasoning on the part of the Personnel concerned, especially, when coping
with individual site conditions.
As continuous improvements on the basis of developments and feedback are being made, BHEL

DATE:07.01.2013 PAGE: 03 OF 08

PROJECT,PHASE-I
1. APPLICATION : Induced Draft Fan

2. FAN TYPE : SAF 38.5 / 25 - 1
4. MEDIUM : Flue Gas
Temp. of medium (deg.c) : 145
Density (kg/m3) : 0.822
Speed (rpm) : 745
9. FAN RESERVE
Flow (%) : 32.7
Pressure (%) : 57.8
10. FAN DRIVE COUPLING :
Type : Spacer Coupling
11. DRIVE MOTOR (VFD)

Make : BHEL / BHOPAL
Frame Size : 1 RN 1906-8
Rating (kW) : 5450
Speed (rpm) : 745
Volt (Volt) : 11000

DATE:07.01.2013 PAGE: 04 OF 08
2.TECHNICAL DATA SHEET

PROJECT,PHASE-I

Fan : 60 LPM / 45 BAR FLOS. (OIL-ISO VG 68)
Motor : Sump Oil (ISO VG 46), 26 ltrs/bearing
14. BEARINGS
Fixed bearing :
Free bearing :

CENTRE
3.DESIGNATION OF FAN AND LUBRICATION CHART

PROJECT,PHASE-I
Designation of fan
The Induced Draft Fan supplied to this project is of the following designation:
SAF 38.5/25-1
SAF  INDUCED DRAFT FAN
38.5  Tip diameter in decimeter
25  Hub diameter in decimeter
1  Single stage

Turbinol 68 of HPC
Teresso 68 (Others)

CENTRE
LIST OF DRAWINGS
PROJECT,PHASE-I
Sl DESCRIPTION DRAWING NO
No.
1. GENERAL ARRANGEMENT DRAWING 1-00-099-21855
2. SILENCER ARRANGEMENT DRAWING NA
3. FAN ASSEMBLY 0-55-228-01289
5. ROTOR ASSEMBLY 0-55-227-01288
7. SETTING SHAFT ASSEMBLY 0-55-227-01270
8. HYDRAULIC ADJUSTMENT DEVICE 0-55-227-01288
9. LOS SCHEME DRAWING 2-00-107-22079
10. FAN CHARACTERISTIC CURVE 3-00-103-23429
11. TORQUE Vs SPEED CURVE
4-00-103-23187
NOTE:

CENTRE
LIST OF ANNEXURE
PROJECT,PHASE-I
Sl.No DESCRIPTION
4. MOUNTING OF SPACER COUPLING
5. PROCEDURE FOR COUPLING ALIGNMENT

CENTRE

PROJECT,PHASE-I

Ranipet
AXIAL FAN
(TLT DESIGN)
ID Application
(Single Stage)
ERECTION MANUAL
Doc. Ref.: FES-Fans/T03/SAF-ER:05/Rev:00/Dt:14.03.2013.

4. General Information
preparation of the fans delivered by BHEL/BAP-Ranipet. This instruction is for axial induced
draft fans for power plants.
Assembly Work
Minimum Requirement
The assembly work must imperatively be supervised by a BHEL-site engineer

during the whole assembly time.

assembly by agency staff.
delivered machine.
Follow the country- specific legal regulations for occupational safety (e.g. accident
prevention regulations) and generally accepted industrial standards.
Doc. Ref.: FES-Fans/T03/SAF-ER:05/Rev:00/Dt:14.03.2013. 1





unit.





Transporter. Immediately compile a damage or deficiency report and hand it
5.0 General Safety Instructions :

plant. All data in this chapter are general or valid for all machines. For the relevant precise
safety instructions please refer to the subsequent chapters of this instruction manual.
the workplace.

5.1 Warnings

DANGER! death of persons.
WARNING! individuals.
CAUTION!
5.2 Intended Use

The fan is explicitly destined for the application described in the contract. An application
diverging from the one in the contract is not allowed. The fan and its accessories must not be
changed arbitrarily.
Intended Use
contractually defined.The fan must not be applied for another purpose than
the one described here!
and be completely readable at any time.
The operating data of the machine must be kept within the limits. Machine settings must not
be altered arbitrarily. BHEL/Ranipet does not assume liability for damage caused by an
application the fan is not intended for.



Pleasefeel free to contact BHEL/Ranipet for special training of your

personnel.
environment.
The personnel must know the location and use of the following safety devices such as:

 Emergency phone
personnel:
activities.



of the plant.

 Coupling,
 The welding current must not run through bearings or other structural
parts.
specialists.

6.1 General

 Storing on site
6.2 Packaging
 Storage period.


Followthe information on the shipping units as well as the indications


with transport bracings (marked by yellow-black rings). These bracings must by no means
be removed or used for hoisting and transporting of the elements.

package.

6.3 Transport


 Attach the rotor only as shown on section 9.2.7 “Attaching the Rotor”. Apply the
ring bolts inside the bearing housing only for the hoisting of the bearing but never
for the entire rotor in a built-in condition!

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.

6.4 Storage on site


supervision).

NOTICE!
expenditure.

Frequency Of
Inspection (d)
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.

6.4.2 Procedure For Preservation Of Machined Surfaces Of Fan Spare Shafts At Site
sheets
6.4.3 Procedure For Preservation Of Anti-Friction Bearings

drying purpose is not recommended. (RUST GARD P214)

Ethylene) sheets

fine emery paper.
followed.
6.4.6 Preservation of Fan up to Commissioning
preventives.
6.4.7 Preservation of Fans during Long Shut Down

months.
The following procedure shall be adopted for long shutdowns / stand still period.
blades.
the above steps.

The fan is designed for a Induced Draft application. The unit is mounted on a foundation
block. An electric motor attached outside via an intermediate shaft with couplings provides
the necessary power. To adapt the respective load point with regard to the corresponding
quantity of flue gas, the blades are adjusted hydraulically. A nose fairing provides favourable
flow conditions in front of the impeller. Straightener vanes welded behind the impeller
ensure best possible downstream conditions. A static pressure increase is achieved through
change from kinetic energy of air into static pressure energy by diffuser. To avoid
transmission of vibrations the fan is connected to adjacent sections via expansion joints on
suction and discharge side. These expansion joints are also able to absorb thermal expansion
if necessary. The fan consists of the following Components.
vanes and Diffuser
 Rotor consisting of shaft, impeller with blades, the blade bearing assemblies,
bearings).

supporting feet.
7.1.1 Suction Box

 the intermediate shaft fairing (heat insulated)
inlet and at the ring-shaped outlet there are measuring studs for Pressure measurement.
Safety Cover can be found inside and outside the suction box. The internal protection cover
surrounds the intermediate shaft from its entry into the suction box until its entry into the
nose fairing.

Bearing saddle flanges are the integral part of the nose fairing /Bullet. Nose fairing /Bullet is
supported by radian supports in impeller housing. Nose fairing /Bullet facilitates the smooth
entry of air to the impeller. Two heat insulated radial supports in the lower part of the fan
housing are hollow in order to conduct supply lines, measuring cables as well as cooling and
sealing air into the interior surrounding bearing assembly and Hydraulic Adjusting Device.
Behind the impeller a hub part (OGV Core) holds by guide vanes and surrounding the
hydraulic adjustment system. The guide vanes assume the following duty:
Suction Box and Fan Housing, Outlet Guide Vane housing and diffuser are flexibly connected
via expansion joints. Contact-free brass sealing has been installed between the impeller &
bearing saddle flange in the bullet hub and behind the impeller between impeller & OGV
core. Supported by the sealing air these brass sealing prevent the ingress of exhaust gas in
the interior of bullet hub and OGV core to protect the main bearing housing & HAD device
from heating.
7.1.3 Diffuser
direction.
The extension of the flow diameter within the diffuser leads to:

pressure.
7.1.4 Insulation
calculations.
The dew point of the exhaust gases will not be under-run at any point of
the internal walls being in contact with exhaust gas, except during start
and shutdown of the plant.
Any housing divisions, doors, assembly openings as well as parts to be maintained such as
bandages, expansion joints etc. have been provided with easily removable insulation
adapters (caps with self- locking fasteners).

 Between diffuser and exhaust gas channel on discharge side.
The rotor assembly consists of a main bearing assembly and one impeller with blades, the

7.2.1 Main Bearing

7.2.2 Impeller
hydraulically.
7.2.3 Blade
spheroidal graphite cast iron. To get an ideal efficiency degree, their surface and other
geometry data (such as impeller profile) have been processed quite exactly. The blades are
attached to the shaft) by means of special bolts.

Various static and dynamic sealings prevent:
7.2.4 Hydraulic Impeller Blade Adjustment System


is finished.
7.2.5 Adjusting Shafts

7.3 Fan Accessories
7.3.1 Spring Shackle Coupling

7.3.2 Oil Circulation Unit

7.3.3 Drive Motor

7.3.4 Special Tools, Maintenance Devices

used.


 Observe the accident prevention regulations of the assembling

country.
 Observe the internal occupational, operational and safety
regulations of the power plant!

NOTICE! If possible, do not work outdoor but in a workshop.
Protect the workplace when working outside.

Please only use faultless tools!

assembling
Do not apply force.

Pay attention to:


 respective safety data sheets of the products. They inform you

Read the
lubricants!

NOTICE!
 Use oil sumps.

NOTICE!  Eliminate oil leakages.

for waste disposal.



DANGER!
When slinging structural steel elements, housing parts and the rotor
 To lift the complete rotor, refer to section 9.2.7 “Slinging of rotor”.



For all
 activities to be performed apply only perfect and certified tools,

8.4.1 Steelwork

 Fork lift truck
 Extension cord
 Isolating transformer
 Sling gear
 Sledgehammer 3-5 kg
 Pinch bar 2 m
 Ladder 2-6 m
 Hammer 1-2 kg
 Chisel
 Mounting lever
 Hack saw
 Files
 Marking tool
 Center punch
 Water level
 Plumb line



assembly drawing
 Magnetic support for drilling machine
 Pipework

 Pipe vice
 Multigrip piers
 TIG welder
 Finger grinder
 Mobile oil pump

 Multi-meter
 Flange tool
 Hot-air gun
 Binders
 Insulating tape
 Etc.


 System layout
relevant chapter.
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. 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.
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.
like coupling bore, shaft ends, machined base, base plates etc before commencing erection.
assembly.
All threaded fasteners pertaining to rotor components should be a minimum quality of class
8.8 or better unless specified in the drawing.

stable.
9.1.3 Sequence

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
9.2.2 Preparation of Foundation

Hammer Dressing
all loose concrete / mortar present in the foundation. The purpose is to eliminate loose
also ensure approx. 75 mm gap between primary packer bottom and dressed concrete


Primary Packer
Ensure
 above 80 % color match between the impeller housing foot and
primary packer.

your project.

maximum contact.


the lower part.
Position the impeller housing (lower half) on the sliding and guide plate (primary packers)
and align to the center lines of foundation. Ensure elevation at four corners by water
balance at dividing plane. Ensure verticality of impeller housing by spirit level within
0.04 mm/mtr. Adjust the leveling spindles of the 4 outer fixing points to attain these values.
Now bring the remaining leveling spindles in touch with packers.
The
 leveling of the lower part of the housing must be executed from the
Fix the radial sealing with the provided bolts in order to seal the hydraulic room and the
bearing room in the housing before placing the rotor. Refer radial seal drawing.
final positioning in the fan housing structure. The parts of the suction box are pre-mounted
besides the foundation block. This requires a plane, preferably leveled surface as well as a
mobile crane with corresponding lifting capacity. As of this pre-assembly area the bottom
part of the fan will be placed onto the foundation block as a complete unit. Arrange, align,
measure, tack, reinforce, weld, re-measure and realign suction box sections.
Notethat the stiffeners for transportation (Yellow Painted) in the split

Place suction box onto the levelled fixed point plate, guide plate and sliding plate. Place
nuts onto the foundation bolts. Level the suction box up to the required height.
shaft cover at the passage of the suction box according to the fan axis. Attach the
intermediate shaft cover by aid of the cover plate. The cover plate to the rear panel of the
suction box is tight welded later on (after the final alignment of the fan).

9.2.5 Positioning of the Diffuser

Arrange, align measure, tack, reinforce, weld, re-measure, and realign diffuser sections.
Lay out sliding and guide plate (primary packers) on the diffuser foundation; level to
required height, insert foundation bolts. Put down diffuser on levelled packers, place nuts
onto foundation bolts and tighten by hand. Exactly align the diffuser according to the fan
axis.

with the delivered expansion joints.

to be met.

Pipes inside".

DANGER!

NOTICE!
 Mount the coupling on the fan shaft as per the attached annexure before lifting the
rotor. Lift the rotor out of the transportation stand, align it in horizontal direction and
feeler gauge. Ensure a uniform seating. Ensure that the bearing lies in the lower part

torques!
rigid pipework.
the pipes are short-circuited. Supply pipe into return pipe.
Installation of Oil System

purposes. The oil pipes leading from and to the console should be chemically cleaned to
The entire site made oil lines must be acid cleaned and neutralized. Prior to connecting
the flexible oil hoses with the hydraulic adjustment device, after chemical cleaning, the
pipelines should be assembled and clamped rigidly.
Mounting of Oil Inlet

Commissioning of Oil System

device.
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 runs the
next motor / pumps 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
hydraulic adjustment device. 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
hydraulic adjustment device for a few strokes. Ensure
smooth and uniform movement of all the impeller
blades.
Arrest leakage, if present. Set the Pressure relief
valves and Lub Oil flow to the required parameter.
Stop the oil pump. Inspect the filters and clean them.

The blades of rotors are supplied separately. The
blades are mounted after having installed and fastened
the rotor inside the fan housing.
the moment weighing), e.g. A1, A2, A3, A4 ... or B1,
B2, B3, B4 …
 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 hydraulic
adjustment device. Switch off the lube oil pump till
all the blades are mounted.
 During the blade mounting process, the impeller

must be secured against rotation by suitable blocking devices.

 Remove protective items from the rotor, clean and lubricate installation surfaces, shaft
bearing bushing, bushing, and shaft flange, place seal rings on blade foot.
 Ensure that the round nose of the blades is fixed on the suction side.
been specially coated against wear. If the blades have been specially coated please
contact BHEL/Ranipet for further information.
Caution!
Upon assembly completion and positioning of the upper part of the fan
housing, Re-examine the total tip clearance.
If necessary, the tip clearance has to be corrected as described above.

blade gap according to the following
procedure:
 The blade angle has to be adjusted

to closed position
 Measure all blade gaps at the same
position “x” to find out the longest

blade. Mark the respective blade accordingly.
 Countercheck the gaps at the horizontal flanges ( 3 and 9)
led through.
Connect the shafts to the hydraulic blade adjustment. Beware! The spring disks must not be
axially tensioned when installed. After mounting of the complete component group, the
actuator as well as the blade pitch transmitter has to be adjusted.
adjusting device.

100% signal ( = 20 mA).

9.3 Intermediate Shaft with Couplings and Protection Cover

substructures. Connect the intermediate shaft with the fan side coupling half that has

already been mounted at the rotor. All contact surfaces of the flange must be clean before
assembly.

 Clean the bottom side of the motor sole plates. Measure the distance/height between the
theoretical fan axis and the upper part of the foundation. Install foundation bolts in the
respective foundation pockets. Erect a barrier with an appropriate height around the
foundation pocket in order to avoid that the grouting will enter the anchor box. The
barrier may be made of synthetic material, foam rubber or similar.
both axes and also maintain the same elevation between the left and right sole plate (Use
straight edge between these two sole plates and measure with spirit level). Adjust the
leveling screws to attain these values.
drawing.
Final Alignment of Coupling

The angular misalignment (due to thermal expansion of fan housing) S1max, S1min and S1 at
motor side and at fan side must be brought to right dimension by alignment of the vertical
and horizontal position of the motor.
The measurement of S1max, S1min and S1 respectively, is to be performed on the outer
diameter of the coupling flanges.

The values to be adjusted of S1max, S1min and S1 depend on the following conditions:
 Construction and physical dimension of the coupling

 Design of the motor (size, Bearing type)
 Assembly and operating conditions (Ambient and operating Temperature)
For the values required for the alignment of the drive train for S1max, S1min and S1
respectively, contact BHEL/Ranipet. When selecting the values to be used, the correspondent
ambient temperature which is as close as possible to the temperature predominant during
assembly, must always be taken as a basis.
In practice, it is first aligned without vertical displacement and then the motor has to be
lifted by value informed by BHEL/Ranipet. Kindly contact BHEL/Ranipet for information on
difference in height (vertical displacement, motor shaft higher than fan shaft), which must
be set for compensating the vertical thermal expansion expected during operation.
Furthermore, also the elongation of the intermediate shaft Δl caused by temperature (axial
thermal strain) resulting from the difference between assembly and operating temperature is
to be considered.
Depending on the motor design (above all for antifriction bearing with fixed bearing) it might
be necessary to pre-stress the coupling during assembly in such a way that during assembly
the forces affecting the motor are limited to a certain value or that no forces occur (when
pre-stressing the coupling during assembly with a lager gap, the elongation of the
intermediate shaft during operation is “compensated” by the larger coupling gap). Possibly
requirements must previously be indicated by the motor manufacturer.

(Alignment of motor with Motor DE Sleeve bearing as Free Bearing)
For motors without fixed bearing (normally motors with sliding bearing), the expected
elongation of the intermediate shaft during operation, Δl, shall also be compensated.
The coupling gap is adjusted to the nominal coupling gap S1 (refer coupling drawing of your
project for S1 and Δl), and the motor shaft at the predominant assembly temperature is
axially shifted by the Δl value for the corresponding predominant assembly temperature.

Work Step for coupling alignment :
For Motor with Sleeve Bearing and Motor DE bearing as Free Bearing
 Take the trial run of motor in decoupled condition and mark the magnetic center of
motor. Move the motor shaft by required Δl towards fan from the magnetic center
maintaining nominal coupling gap S1 or move the motor body away from fan by Δl
while maintaining the nominal coupling gap S1.
 Do the coupling alignment within ±0.05mm (without difference in height between

motor and fan shaft center line).The coupling gap shall be the nominal value S1 (not
pre-stressed condition).
 Adjust the values for S1max in 12 o'clock position and S1min in 6 o'clock position in
the vertical level by lifting the motor (Refer Annexure-II for required height of shims
to be put underlying motor foot).Consider the required tolerance of ±0.05. Adjust the
values for S1 in 3 o'clock position and 9 o'clock position in the horizontal level by
aligning the motor.
alignment. After alignment of the coupling and intermediate shaft, align the
intermediate shaft cover at the penetration in the suction box wall. The intermediate
shaft cover must be concentrically with the intermediate shaft.
Alignment of the Hydraulic Adjusting Device
drawing.

Assembly of Impeller Housing (Top Half)
impeller housing.
Assembly of Expansion Joints
Suction Box.
assembly.
Installation of Silencer
The Lubricating oil for the Fan bearings are supplied by the centralized oil pumps which supply
oil for the hydraulic adjustment device also. It must be borne in mind that the quality of oil
flowing to the bearings and its pressure must be maintained as recommended.
Recommended Oils
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
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.
Obser Qty /
Sl.no Component Lubricant Supplier Location Frequency
vation Fan
During
over haul
2 years )
see note 2
During
Refer
Mobil Glygoyle 30 Over haul
Blade shaft Inside Rotor
02 And Mobil grease See note.3 ( once in *****
bearing assembly Rotor assy
28 / Burutox M21 2 years )
drg
see note 4
During
Blade shaft
Molykote Over haul
and pushrod Rotor
guide bushing
see note 4
During Refer
Over haul Rotor
Blade shaft guide Mobil grease 28 / Outside
bearing Burutox M21 Rotor
2 years ) drg
see note 4
05 Common 0.5 Kg
other bolt paste
Notes :
1) Oil quantity depends on tank capacity. 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 BHEL personnel.

ERECTION MANUAL
“PRIMARY AIR FAN”

3X660MW

FIELD ENGINEERING SERVICES DATE : 07.01.2013 PAGE: 01 OF 08
TABLE OF CONTENTS
PROJECT: M/s PRAYAGRAJ SUPER THERMAL POWER
CUST.NO : R620,R621&R622
PROJECT,PHASE-I
1. INTRODUTION
2. TECHNICAL DATA
3. DESIGNATION
Prepared By:R.SEKAR Reviewed By: Vinoth Kumar S Approved By: P.SAHA

1. INTRODUCTION
CUST.NO : R620,R621&R622
PROJECT,PHASE-I
In the Axial reaction fans the major part of (about 80 %) energy transferred is converted into static
pressure in the impeller itself. The rest of the energy is converted into static pressure in the diffuser.
These fans are generally driven at constant speed. Varying the angle of incidence of impeller blades
controls the flow. It is therefore becomes possible by this process to achieve high efficiencies even
during part load operation. The blade pitching operation is performed by mechanical linkage connected
to a hydraulic adjustment device, which is flanged to the impeller.
This manual generally describes and outlines the constructional features and the method of erection of
Primary air Fan supplied to M/s PRAYAGRAJ SUPER THERMAL POWER PROJECT,PHASE-I .
with all the details required for erection. Incase of any doubt/ clarifications refer to Field Engineering
Services, Fans Engineering Division, BHEL- Ranipet, Tamil Nadu.
information. However it must be realized that no amount of written instructions can replace intelligent
thinking and reasoning on the part of the personnel concerned, especially when coping with individual
site conditions.
As continuous improvement on the basis of development and feed back are being made, BHEL reserves
the right to modify the technical details contained in this manual.

DATE : 07.01.2013 PAGE: 03 OF 08

CUST.NO : R620,R621&R622
PROJECT,PHASE-I
1. APPLICATION : Primary air Fan

2. FAN TYPE : PAF 19/11.8-2
Temp. of medium (deg.C) : 50
3
Density (kg/ m ) : 1.076
Speed (rpm) : 1490
7. FAN RESERVE
Flow (%) : 103
Pressure (%) : 43.9
8. FAN DRIVE COUPLING
Type : Spacer Type
9. DRIVE MOTOR
Make : BHEL BHOPAL
Frame : 1 LA7924-4
Rating (kW) : 3250
Speed (rpm) : 1490
Volts (volt) : 11000

DATE : 07.01.2013 PAGE: 04 OF 08

CUST.NO: R620,R621&R622
PROJECT,PHASE-I

Fan : 40 LPM / 35 BAR FOLS (OIL-ISO VG68)
Motor : Grease lubricated (Servogem3)
12. BEARINGS
Fixed Bearing :
Free Bearing :

3. DESIGNATION OF FAN
CUST.NO. : R620,R621&R622
PROJECT,PHASE-I
The Primary air Fan supplied to this project is of the following designation:
PAF 19/11.8-2
PAF  PRIMARY AIR FAN
19  Tip diameter in decimeter
11.8  Hub diameter in decimeter
2  Double stage

Turbinol 68 of HPC
Teresso 68 (Others)

DATE : 07.01.2013 PAGE: 06 OF 08
LIST OF DRAWINGS
CUST.NO. : R620,R621&R622
PROJECT,PHASE-I
Sl.No DESCRIPTION DRAWING NO
1. GENERAL ARRANGEMENT DRAWING 1-00-100-21856
2. SILENCER ARRANGEMENT DRAWING 1-55-931-01576
3. FAN ASSEMBLY 0-55-334-01274
4. SECTIONAL ASSEMBLY -
5. ROTOR ASSEMBLY 0 55 334 01273

7. HYDRAULIC ADJUSTMENT DEVICE -
8. SERVOMOTOR MOTOR ASSEMBLY NA
9. SETTING SHAFT ASSEMBLY 0-55-334-01224
10. LINKAGE ASSEMBLY NA
11. LOS SCHEME DRAWING 2-00-107-22080
12. FAN CHARACTERISTIC CURVE 3-00-104-23430
13. TORQUE Vs SPEED CURVE 4-00-104-23189
NOTE:

DATE : 07.01.2013 PAGE: 07 OF 08
LIST OF ANNEXURE
CUST.NO. : R620,R621&R622
PROJECT,PHASE-I
Sl.No DESCRIPTION
4. MOUNTING AND DISMOUNTING PROCEDURE OF ANTI FRICTION BEARING
5. PRINCIPLE OF HYDRAULIC INSTALLATION AND EXTRACTION
6. ACID CLEANING PROCEDURE
7. INSTALLATION AND ALIGNMENT OF RIGIFLEX COUPLING

DATE : 07.01.2013 PAGE: 08 OF 08

CUST.NO. : R620,R621&R622
PROJECT,PHASE-I
4. MOTOR APPLICABLE
5. RIGIFLEX COUPLING(FLENDER) APPLICABLE

Ranipet
AXIAL FAN
(TLT DESIGN)
PA APPLICATION
(Double Stage)
ERECTION MANUAL
Doc. Ref.: FES-Fans/T03/PAF-ER:03/Rev:01/Dt:14.03.2013.

Ranipet Axial Reaction Fan – Double Stage
4.0 General
preparation of the fans delivered by BHEL/BAP-Ranipet. This instruction is for axial Primary air
fans for power plants.
Assembly Work
Minimum Requirement
The assembly work must imperatively be supervised by a BHEL-site engineer during the
whole assembly time.

storage / assembly by agency staff.
delivered machine.
Follow the country- specific legal regulations for occupational safety (e.g. accident
prevention regulations) and generally accepted industrial standards.
Doc. Ref.: FES-Fans/T03/PAF-ER:03/Rev:01/Dt:14.03.2013. 1




unit.




transporter. Immediately compile a damage or deficiency report and hand it
5.0 General Safety Instructions:

plant. All data in this chapter are general or valid for all machines. For the relevant precise
safety instructions please refer to the subsequent chapters of this instruction manual.
the workplace.
5.1 Warnings

death of persons.
DANGER!
WARNING!
individuals.
CAUTION!

5.2 Intended Use

The Fan is explicitly destined for the application described in the contract. An application
diverging from the one in the contract is not allowed. The Fan and its accessories must not
be changed arbitrarily.
Intended Use
contractually defined.
The fan must not be applied for another purpose than the one described
here!
and be completely readable at any time.
The operating data of the machine must be kept within the limits. Machine settings must not
be altered arbitrarily.
BHEL/Ranipet does not assume liability for damage caused by an application the fan is not
intended for.


Pleasefeel free to contact BHEL/Ranipet for special training of your

personnel.

environment. The personnel must know the location and use of the following safety devices
such as:

 Emergency phone
personnel:
activities.

of the plant.


 Coupling,
 The welding current must not run through bearings or other structural parts.
specialists.
6.1 General

 Storing on site
6.2 Packaging
 Storage period.



Followthe information on the shipping units as well as the indications


with transport bracings (marked by yellow-black rings). These bracings must by no means
be removed or used for hoisting and transporting of the elements.

package.
6.3 Transport


NOTICE!

 Attach the rotor only as shown on Error! Reference source not found.9.2.7
“Attaching the Rotor”. Apply the ring bolts inside the bearing housing only for the
hoisting of the bearing but never for the entire rotor in a built-in condition!

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.
6.4 Storage on site


supervision).

NOTICE!
expenditure.

Frequency Of
Inspection (d)
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.
6.4.2 Procedure for Preservation of Machined Surfaces of Fan Spare Shafts at Site
sheets.

6.4.3 Procedure for Preservation of Anti-Friction Bearings

drying purpose is not recommended. (RUST GARD P214).

Ethylene) sheets
fine emery paper.

followed.
6.4.6 Preservation of Fan up to Commissioning

preventives.
6.4.7 Preservation of Fans During Long Shut Down

months.
The following procedure shall be adopted for long shutdowns / stand still period:
blades.
the above steps.

The fan is designed for a Primary Air application. The unit is mounted on a foundation block.
An electric motor attached outside via an intermediate shaft with couplings provides the
necessary power. To adapt the respective load point with regard to the corresponding
quantity of air, the blades are adjusted hydraulically. A nose fairing provides favourable flow
conditions in front of the impeller. Straightener vanes welded behind the impeller ensure
best possible downstream conditions. A static pressure increase is achieved through change
from kinetic energy of air into static pressure energy by diffuser. To avoid transmission of
vibrations the fan is connected to adjacent sections via expansion joints on suction and
discharge side. These expansion joints are also able to absorb thermal expansion if
necessary. The fan consists of the following Components.
vanes and Diffuser
 Rotor consisting of shaft, impellers with blades, the blade bearing assemblies,
bearings).

supporting feet.
7.1.1 Suction Box


 the intermediate shaft Cover
 Nose fairing /Bullet
inlet and at the ring-shaped outlet there are measuring studs for Pressure measurement. The
internal protection cover surrounds the intermediate shaft from its entry into the suction box
until its entry into the nose fairing/Bullet. Nose fairing /Bullet is supported by radial
supports in suction chamber. Nose fairing /Bullet facilitates the smooth entry of air to the
impeller.

Bearing saddle flanges are supported by radial guide vanes in impeller housing after the first
stage impeller. Two radial guide vanes in the lower part of the fan housing are hollow in
order to conduct supply oil lines, measuring cables to the main bearing housing.
After the second stage impeller a hub part (OGV Core) holds by guide vanes and surrounding
the hydraulic adjustment system. The guide vanes assume the following duty:
Two radial guide vanes in the lower part of OGV are hollow in order to conduct Supply oil
lines, measuring cables to the hydraulic adjustment device .Suction Box and Fan Housing &
Outlet Guide Vane housing and diffuser are flexibly connected via expansion joints.
7.1.3 Diffuser
direction.
The extension of the flow diameter within the diffuser leads to:


pressure.
7.1.4 Insulation
calculations. Any housing divisions, doors, assembly openings as well as parts to be
maintained such as bandages, expansion joints etc. have been provided with easily
removable insulation adapters (caps with self- locking fasteners).

 Between diffuser and air duct channel on discharge side.

The rotor assembly consists of a main bearing assembly and Two impeller with blades, the

7.2.1 MAIN BEARING

7.2.2 IMPELLER
hydraulically.
7.2.3 Blade
aluminium alloy. To get an ideal efficiency degree, their surface and other geometry data
(such as impeller profile) have been processed quite exactly. The blades are attached to the
shaft) by means of special bolts.


Various static and dynamic sealing prevent:
7.2.5 HYDRAULIC IMPELLER BLADE ADJUSTMENT SYSTEM


is finished.
7.2.6 ADJUSTING SHAFTS
7.3 FAN ACCESSORIES
7.3.1 SPRING SHACKLE COUPLING

7.3.2 OIL CIRCULATION UNIT

7.3.3 DRIVE MOTOR

7.3.4 SPECIAL TOOLS, MAINTENANCE DEVICES

used.


Observe the accident prevention regulations of the assembling country.

 Observe the internal occupational, operational and safety regulations of
the power plant!

NOTICE!
If possible, do not work outdoor but in a workshop.
 Protect the workplace when working outside.

 Please only use faultless tools!
NOTICE! Machine parts may be damaged when put down

Underlay
 Housing parts with timber beams
 Metallic blank parts with corrugated cardboard or air bubble foil.

assembling
Do not apply force.

Pay attention to:


 respective safety data sheets of the products. They inform you

Read the
lubricants!

NOTICE!
 Use oil sumps.

NOTICE!
 Eliminate oil leakages.

for waste disposal.



DANGER! certified hoisting and sling gear!
When slinging structural steel elements, housing parts and the rotor
 To lift the complete rotor, refer to section 6.2.7, “Slinging of rotor”.



For all
 activities to be performed apply only perfect and certified tools,

8.4.1 Steelwork

 Fork lift truck
 Extension cord
 Sling gear
 Ladder 2-6 m
 Hammer 1-2 kg
 Chisel
 Mounting lever
 Hack saw
 Files
 Marking tool
 Center punch
 Water level
 Plumb line



assembly drawing
 Magnetic support for drilling machine

 Pipe vice
 Multigrip piers
 TIG welder
 Finger grinder
 Mobile oil pump

 Multi-meter
 Flange tool
 Hot-air gun
 Binders
 Insulating tape


 System layout
relevant chapter.
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. 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.
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.
like coupling bore, shaft ends, machined base, base plates etc before commencing erection.
assembly.
All threaded fasteners pertaining to rotor components should be a minimum quality of class
8.8 or better unless specified in the drawing.


stable.
9.1.3 Sequence

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
9.2.2 PREPARATION OF FOUNDATION

Hammer Dressing
all loose concrete / mortar present in the foundation. The purpose is to Eliminate loose
also ensure approx.75 mm gap between primary packer bottom and dressed concrete


PRIMARY PACKER
Ensure
 above 80 % color match between the impeller housing foot and
primary packer.

your project.

maximum contact.


the lower part.
Position the impeller housing (lower half) on the primary packers and align to the center
lines of foundation. Ensure elevation at four corners by water balance at dividing plane.
Ensure verticality of impeller housing by spirit level within 0.04 mm/mtr Adjust the leveling
spindles of the 4 outer fixing points to attain these values. Now bring the remaining leveling
spindles in touch with packers.
The
 leveling of the lower part of the housing must be executed from the

final positioning in the fan housing structure. The parts of the suction box are pre-
mounted besides the foundation block. This requires a plane, preferably leveled
surface as well as a mobile crane with corresponding lifting capacity. As of this pre-
assembly area the bottom part of the fan will be placed onto the foundation block as
a complete unit. Arrange, align, measure, tack, reinforce, weld, re-measure and realign
suction box sections.
Notethat the stiffeners for transportation (Yellow Painted) in the split

Place suction box onto the levelled primary packer and place nuts onto foundation bolts.
shaft cover at the passage of the suction box (rear panel of the suction box) according to
the fan axis. Attach the intermediate shaft cover by aid of the cover plate. The cover plate
to the rear panel of the suction box is tight welded later on (after the final alignment of the
fan).

9.2.5 Assembly of the Diffuser

Arrange, align measure, tack, reinforce, weld, re-measure, and realign diffuser
sections.
Lay out primary packers on the diffuser foundation; level to required height, insert
foundation bolts. Put down diffuser on levelled packers, place nuts onto foundation bolts and
tighten by hand. Exactly align the diffuser according to the fan axis.

with the delivered expansion joints

to be met.

Pipes inside".
 Prepare the fixation screws for the bearings.

DANGER!

NOTICE!
 Lift the rotor out of the transportation stand, align it in horizontal direction and
feeler gauge. Ensure an uniform seating. Ensure that the bearing lies in the lower part
torques!

rigid pipework.
the pipes are short-circuited. Supply pipe into return pipe!
Installation Of Oil System
purposes. The oil pipes leading from and to the console should be chemically cleaned to
The entire site made oil lines must be acid cleaned and neutralized. Prior to connecting the
flexible oil hoses with the hydraulic adjustment device, after chemical cleaning, the pipelines
should be assembled and clamped rigidly.
Mounting Of Oil Inlet
Commissioning Of Oil System

device.
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 runs the
next motor / pumps 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 hydraulic adjustment device. 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
hydraulic adjustment device for a few strokes. Ensure smooth and uniform movement of all
the impeller blades.
Arrest leakage, if present. Set the Pressure relief valves and Lub Oil flow to the required
parameter. Stop the oil pump. Inspect the filters and
clean them.

The blades of rotors are supplied separately. The blades
are mounted after having installed and fastened the
rotor inside the fan housing.
the moment weighing), e.g. A1, A2, A3, A4 ... or B1, B2,
B3, B4 …
 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 hydraulic
adjustment device. Switch off the lub oil pump till
all the blades are mounted.
 During the blade mounting process, the impeller must
be secured against rotation by suitable blocking
devices.
 Remove protective items from the rotor, clean and
lubricate installation surfaces, shaft bearing bushing,
bushing, and shaft flange, place seal rings on blade
foot
 Ensure that the round nose of the blades is fixed on
the suction side.

been specially coated against wear.
 If the blades have been specially coated please contact BHEL/Ranipet for further
information.
Caution!
Upon assembly completion and positioning of the upper part of the fan
housing:
Re-examine the total tip clearance. If necessary, the tip clearance has to
be corrected as described above.

blade gap according to the following
procedure:

 The blade angle has to be adjusted to
closed position.
 Measure all blade gaps at the same
position “x” to find out the longest

blade. Mark the respective blade accordingly.
 Countercheck the gaps at the horizontal flanges ( 3 and 9).

led through. Connect the shafts to the hydraulic blade adjustment. Beware! The spring disks
must not be axially tensioned when installed.
After mounting of the complete component group, the actuator as well as the blade pitch
transmitter has to be adjusted.
adjusting device.



100% signal ( = 20 mA).
9.3 Intermediate Shaft With Couplings And Protection Cover

substructures. Connect the intermediate shaft with the fan side drive disc that has already

been mounted on the Ist stage impeller. All contact surfaces of the flange must be clean
before assembly.

 Clean the bottom side of the motor sole plates. Measure the distance/height between the
theoretical fan axis and the upper part of the foundation. Install foundation bolts in the
respective foundation pockets. Erect a barrier with an appropriate height around the
foundation pocket in order to avoid that the grouting will enter the anchor box. The
barrier may be made of synthetic material, foam rubber or similar.
both axes and also maintain the same elevation between the left and right sole plate
(Use straight edge between these two sole plates and measure with spirit level). Adjust
the leveling screws to attain these values.
drawing.
Final Alignment Of Motor & Fan
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.
alignment. After alignment of the coupling and intermediate shaft, align the intermediate
shaft cover at the penetration in the suction box wall. The intermediate shaft cover must
be concentrical with the intermediate shaft.
Alignment Of The Hydraulic Adjusting Device

drawing.
Assembly Of Impeller Housing (Top Half)

impeller housing.

Assembly Of Expansion Joints
Suction Box.
assembly.
Installation Of Silencer
The Lubricating oil for the Fan bearings are supplied by the centralized oil pumps which
supply oil for the hydraulic adjustment device also. It must be borne in mind that the quality
of oil flowing to the bearings and its pressure must be maintained as recommended.
Recommended Oils
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
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.
Observ Qty /
Sl.no Component Lubricant Supplier Location Frequency
ation Fan
During
over haul
2 years )
see note 2
During
Refer
Mobil Glygoyle 30 Over haul
Blade shaft Inside Rotor
02 And Mobil grease See note.3 ( once in *****
bearing assembly Rotor assy
28 / Burutox M21 2 years )
drg
see note 4
During
Blade shaft
Molykote Over haul
and pushrod Rotor
guide bushing
see note 4
During Refer
Over haul Rotor
Blade shaft guide Mobil grease 28 / Outside
bearing Burutox M21 Rotor
2 years ) drg
see note 4
05 Common 0.5 Kg
other bolt paste
Notes :
1. Oil quantity depends on tank capacity. 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 BHEL
personnel.

ERECTION MANUAL
“SEAL AIR FAN”

POWER PROJECT PHASE-I
3X660MW
Cust. No: R 620,R621&R622

FORMAT NO.
REN. NO. : 00
ENGINEERING & DEVELOPMENT CENTRE :F2
FIELD ENGINEERING SERVICES DATE :
PAGE: 01 OF 08
07.01.2013
TABLE OF CONTENTS
PROJECT PHASE-I
1. INTRODUTION
2. TECHNICAL DATA
3. DESIGNATION
Prepared By: HITESH KUMAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA
FORMAT NO.
REN. NO. : 00
PAGE: 02 OF 08
07.01.2013
1. INTRODUCTION
PROJECT PHASE-I
Radial Fans manufactured by BHEL are single stage, single/double suction, simply supported/overhung
centrifugal machines, which can be used to handle fresh air as well as hot gases, in power plant
applications. They are also used in process industries like, cement, steel plants and paper mills, etc.
In this type of fans, the medium handled enters the impeller axially and after passing through the
impeller leaves radially. A large part of the energy transferred to the medium is converted in to kinetic
energy as the medium passes through the impeller. The spiral casing converts part of the kinetic
energy in the medium to pressure energy. Constant speed motors generally drive these fans. The
output of the fan is usually controlled s by varying the speed of the fan by suitable speed control
device and also by inlet damper.
This Manual generally describes and outlines the methods and procedures for erection of the Seal
Air Fan supplied to M/s. M/s PRAYAGRAJ SUPER THERMAL POWER PROJECT PHASE-I
with all the details required for erection. In case of any doubt/clarifications, refer to Field
Engineering Services, Fans Engineering Division, BHEL, Ranipet, Tamil Nadu.
information. However, it must be realized that no amount of written instructions can replace
intelligent thinking and reasoning on the part of the Personnel concerned, especially, when coping
with individual site conditions.
As continuous improvements on the basis of developments and feedback are being made, BHEL
Prepared By: R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA
FORMAT NO.
REN. NO. : 00
PAGE: 03 OF 08
07.01.2013

PROJECT PHASE-I
1. APPLICATION : Seal Air Fan

2. FAN TYPE : NDV-13 SIDOR
6. SUCTION ORIENTATION : Right Horizontal
7. DELIVERY ORIENTATION : Left vertical
Temp. of medium (deg.c) : 50
Density (kg/m3) : 1.076
Speed (rpm) : 1480
9. FAN DRIVE COUPLING :
Type : Pin Type Flexible
10. DRIVE MOTOR
Make : BHEL EML
Rating (kW) : 110
Speed (rpm) : 1480
Volt (V) : 415
FRAME SIZE : 315S
FORMAT NO.
REN. NO. : 00
PAGE: 04 OF 08
07.01.2013
2.TECHNICAL DATA SHEET
PROJECT PHASE-I
12. LUBRICATION EQUIPMENT

Fan : Sump Oil. (OIL-ISO VG 68)
13. TYPE OF FAN REGULATION : Inlet Damper While Starting Only
14. BEARINGS
Fixed bearing : 22216/C3
Free bearing : 2216/C3
FORMAT NO.
REN. NO. : 00
PAGE: 05 OF 08
07.01.2013
3.DESIGNATION OF FAN AND LUBRICATION CHART
PROJECT PHASE-I
Designation of fan
The Seal Air Fan supplied to this project is of the following designation
NDV13 S
NDV  Radial Single suction simply supported bearing
13  Impeller tip dia in decimeter
S  Type of impeller

Turbinol 68 of HPC
Teresso 68 (Others)
Quantities per fan : ~ 10 ltrs / fan
FORMAT NO.
REN. NO. : 00
PAGE: 06 OF 08
07.01.2013
LIST OF DRAWINGS
PROJECT PHASE-I
Sl.No DESCRIPTION DRADING NO
1. GENERAL ARRANGEMENT DRAWING 1- 00 -108- 21857
2. SILENCER ARRANGEMENT DRAWING NA
3. FAN ASSEMBLY 1-56-173-04456
4. SECTIONAL ASSEMBLY 1-56-173-03885
5. ROTOR ASSEMBLY 1-56-173-03884
7. DAMPER ASSEMBLY 1-56-113-03033
8. FIXED BEARING ASSEMBLY 1-56-173-03924
9. FREE BEARING ASSEMBLY 1-56-173-03890
10. LOS SCHEME DRAWING NA
11. FAN CHARACTERISTIC CURVE 3- 00 -106- 23431
12. TORQUE Vs SPEED CURVE
4- 00- 106 -23189
NOTE:
FORMAT NO.
REN. NO. : 00
PAGE: 07 OF 08
07.01.2013
LIST OF ANNEXURE
PROJECT PHASE-I
Sl.No DESCRIPTION
1. Proper fastening for rigidity
2. Procedure for ensuring spring back
3. Maximum permissible torque values for tightening bolt
4. Mounting and dismounting procedures of anti friction bearing
5. Mounting and dismounting procedures of anti friction bearing(SOFN)
FORMAT NO.
REN. NO. : 00
PAGE: 08 OF 08
07.01.2013
PROJECT PHASE-I
1. LUBE OIL SYSTEM NA
2. HYDRAULIC COUPLING NA
3. ACTUATOR NA
4. MOTOR APPLICABLE
Ranipet
RADIAL FAN
(NDV WITH ANTI- FRICTION BEARING)
SINGLE SUCTION
ERECTION MANUAL
S.SELVAM J.MOORTHY M. DESIGAN
Doc. Ref: FES-Fans/T03/NDV.AB/ER:15/Rev:00/Dt:13.10.2006.

Ranipet Single Suction (NDV) with Anti friction Bearing
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 by means of locking 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 handled by the 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 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 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 temperatures. Platinum
resistance thermometers (RTD) are provided with alarm and trip connections and for remote
indication (control room) of bearing temperatures.
Doc. Ref: FES-Fans/T03/NDV.AB/ER:15/Rev:00/Dt:13.10.2006. 1

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 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 control 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 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 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 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 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.

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 for 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.
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.

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 bases 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 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

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 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,
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
4. Flow regulating devices Weather protected (b) Monthly
5. Bearing pedestals Indoor (c) Monthly
6. Bearings Indoor (c) Monthly
7. Fan shaft @ Indoor (c) Monthly
8. Connecting couplings Indoor(c) Monthly

Note:
(a) Above ground, on blocks, exposed to weather.
(b) Out doors, 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.
@ Preserve fan shaft as per the instructions given
PROCEDURE FOR PRESERVATION OF MACHINED SURFACES OF FAN SHAFTS 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%).
5. The preserved surfaces shall be wrapped with HDPE (High Density Poly Ethylene) sheets
PROCEDURE FOR PRESERVATION OF ANTI-FRICTION BEARINGS

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.
8. It should be then allowed to dry completely. Pressuraised air for cleaning or drying
purpose is not recommended. (RUST GARD P214)

RECOMMENDED PRESERVATIVE COMPONENTS

TRP 1706, TRP 1710
HDPE (High Density Poly Ethylene) sheets.
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.
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 preservative using suitable solvent.

• 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.

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.
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.
soundness. Check for cracks, holes, 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.
Mark the center line of foundation with respect to plant center 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.

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 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 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.
• 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
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 despatch able
units. These three nuts are to be welded to the primary packer 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 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.
maximum contact. Maximum number of 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 / mtr.
LAYING OF PRIMARY PACKERS 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 levelled 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 GROUT strictly following the instruction
of the grout supplier. The curing time shall be as per manufacturer’s data. After curing check the
level or 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 thermocole as shown in the drawing to avoid grouting or 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 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.

9.0 ERECTION INSTRUCTIONS

ASSEMBLY OF FAN CASING
The casing parts can be assembled together by means of connecting flanges, fit bolts and guide
plates. The horizontal and 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 PACKER 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 Grouting Instructions.
ALIGNMENT OF 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 verticality of the spiral casing.
Ensure alignment of spiral casing with respect to fan centre lines.
INSTALLATION OF BEARING 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 0.04 mm/mtr on the machined surface of the pedestal by
using levelling spindles along the perpendicular to the fan axis and grout it using NON SHRINK
GROUT with out any air pockets. Refer chapter Grouting 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 burrs 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.

• 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 lub oil and cover with clean cloth.
MOUNTING OF BEARINGS
Position the bottom half of the bearing housing on the bearing pedestal.
Ensure above 80 % Blue matching between bearing housing and the bearing pedestal.
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.
• The shaft at fixed end bearing should be leveled to within 0.04 mm/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 for 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 clearance. 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 (and hydraulic coupling if applicable)
as per the guide lines given by the manufacturer. Motor is to be aligned to 0.05 mm 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

10.0 LUBRICATION INSTRUCTIOINS
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.
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 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.

ANNEXURES
COMMON ANNEXURES FOR

FD, ID, PA & SA
01. Mounting and Dismounting of Anti-friction Bearing
02. Information on Dodge Sleeve Oil Pillow Block ( RT )
03. Proper Fastening for Rigidity
04. Procedure for Ensuring Spring Back
05. Maximum Permissible Torque Values for tightening bolt
06. Principle of Hydraulic Installation and Extraction
07. Acid Cleaning Procedure
08. Installation and Alignment of Rigiflex Coupling
1.0 MOUNTING AND DISMOUNTING OF ROLLING BEARINGS
TABLE OF CONTENTS
GENERAL
STORAGE OF BEARINGS
HANDLING BEARING & COMPONENTS
INSPECTION OF COMPONENTS
MOUNTING ROLLING BEARINGS

BEARING WITH CYLINDRICAL BORE
RINGS WITH INTERFERENCE FIT
RINGS WITH CLEARANCE FIT
NON-SEPARABLE BEARINGS
SEPARABLE BEARINGS
AXIAL PRELOADING
BEARINGS WITH TAPER BORE
GENERAL INSTRUCTIONS
BEARINGS WITH ADAPTER SLEEVES
BEARINGS WITH WITHDRAWAL SLEEVES
BEARINGS ON TAPER SHAFTS
LUBRICATION AND TEST RUNNING

GREASE LUBIRCATION
OIL LUBRICATION
TEST RUNNING
DISMOUNTING ROLLING BEARINGS

PREPARATION
DISMOUNTING THEBEARINGS
TO DISMOUNT AN ADAPTER SLEEVE
WITHDRAWAL SLEEVES
TOOLS & METHODS USED IN MOUNTING & DISMOUNTING

SKF OIL-INJECTION METHOD
HYDRAULIC NUT
ELECTRICAL WITHDRAWAL TOOLS
CLEANING ROLLING BEARINGS

INORGANIC CHEMICAL CLEANERS
ORGANIC FLUID CLEANERS
CLEANINGNEW BEARINGS
CLEANING CONTAMINATED BEARINGS
MOUNTING AND DISMOUNTING ROLLING BEARINGS
1 GENERAL
Correct mounting is as important for reliability and efficiency of rolling bearings as is the
correct design and proper maintenance of the bearing scheme. The best construction is
of no benefit, if, during assembly, errors are made jeopardizing the reliability of
operation. Some failures, which occur time and again, could be avoided, if the rules of
mounting, dismounting and maintenance, are properly observed. Information on
mounting and dismounting procedures is given below, which, however, due to the variety
of applications possible, merely outlines methods to be followed. SKF will gladly give
advice and furnish data on request, to augment these general instructions.
It is advisable, before assembly, to refer to a drawing, showing the bearing application,

in order to obtain a clear picture of the sequence of mounting operations to be carried
out, so that, superfluous work and trial mountings and dismounting can be avoided.
2 Storage of Bearings:
Bearings should be stored in a room scrupulously clean and protected against moisture
and for similar reasons new bearings should be left in their original cartons or wrappings.
In the case of line production, bearings removed from their cartons should be conveyed
in covered containers. Sluicing grease, with which bearings are coated, should be
removed only from the bore of the inner ring and the outer surface of the outer ring
before mounting and should remain in the rest of the bearing to protect it.
Only when improper handling has contaminated new bearings, wrappings damaged for
instance, should then be washed before assembly. Slushing compound is rather thick for
small, high speed bearings and this should be removed by washing or by the application
of heat up to 50oC Benzene, white sprit, benzole or petroleum(kerosene) free from water
and acid are suitable cleansing agents. Cleaned bearings should be covered with fresh
grease, immediately after the washing compound has been removed. (Refer also to
“Cleaning Rolling Bearings”)
3 Handling Bearing and Components:
Rolling bearings must be protected against dirt and moisture. The entry of even the
smallest particles, causes noisy running and damage to the finish-machined heavily
loaded surfaces of tracks and rolling elements and leads to premature bearing failure.
Moisture causes rust, which in turn produces bearing wear.
A cardinal rule, therefore, is

UTMOST CLEANLINESS AND PROTECTION AGAINST MOISTURE.
All operations should be carried out in a special dust free room, away from machines
producing swarf or abrasive particles. Components must be carefully cleaned and free
from burrs; rough inside surfaces of housings must be free from moulding sand and
possible given a protective coating. Bearings must not be modified. Grooves, holes or
flats cause distortion of the rings due to the setting up of internal stresses, which may
result in bearing failure.
Felt seals must be soaked in oil, at a temperature of approximately 70oC, before they are
inserted into the housing grooves. They must be the correct size and fit the grooves
properly, so that, they do not have too loose or too tight a fit on the shaft. Too tight a
fit often causes overheating and shaft wear, whilst too loose a fit makes an ineffective
seal, if the belt is in strip form. It must be accurately cut to length, so that, there is no
gap after it has been fitted.
If a clean workbench is not available, components should be laid out on clean stiff paper
or some other suitable material.
4 Inspection of Components:
Before assembly, components should be checked carefully for correct dimensioning and
execution, in accordance with the relevant drawing. Bearings can only run satisfactorily,
if the fits specified for each application are adhered to. Bearings should not be used as
gauges for checking seating or housings.
5 MOUNTING ROLLING BEARINGS:
Bearing ringside faces, cages or rolling elements should not be subjected to hammer
blows, as the bearing will undoubtedly be damaged by such treatments. The mounting
force must not be transmitted through the rolling elements. The seating surfaces should
be lightly smeared with oil or grease.
6 Bearings with Cylindrical Bore:

Rings with interference fit should be those that the mounting force is applied to
and may be done either by driving them on with a hammer and a soft metal drift or
hollow punch; the blows must be applied evenly around the bearing to avoid
misalignment. The use of a tubular dolly, as in Fig.1, ensures even distribution of force,
by mechanical or hydraulic presses, particularly when mounting bearings in large
quantities (Fig 2); or by heating the bearings, rings or housings to a temperature of
approximately 80oC. Bearings or rings may be heated in an oil bath, a heating furnace,
or by special electric heating units, including electric hot plates. Attention should,
however, be paid to the fact that; no point of the bearing must be heated above 120 oC,
as this will affect the hardness. Small bearings can be suspended in the oil bath; grids or
baffles should be provided for larger bearings, in order to keep the bearing from making
contact with the heating surfaces. Container and oil must be free from impurities.
Bearings with side plates or seals on both sides (auxiliary designation-2Z and 2 RS,
respectively) are always supplied adequately greased and should be pressed on cold.
When handling bearings, only clean, non-fluffy rags or suitable tongs should be used.
The heated bearing should be pushed on to the journal and located against the shaft
shoulder, so that it is in complete alignment with the shaft. It must be secured by
means of a retaining nut until it cools off (Fig.3). Similar instructions apply, if bearings
are inserted in heated housings.
Rings with a clearance fit should be mounted in the normal way.
In the case of plummer blocks with split housings, the shaft complete with bearings
mounted on it should be inserted in the housings. The joint must be thoroughly cleaned
and should be smeared lightly with oil. Care must be taken to ensure that the housings
are assembled the right way round so that the bearing is not nipped, when the bolts are
tightened. Over tightening may also cause ovality.
In the case of solid housings, the bearings should be pushed in carefully to avoid any
misalignment. Force should not be applied to rectify a bearing, which has been put in its
housing at an angle. It should be withdrawn carefully and pushed in again. In the case
of bearings with self-aligning properties the swivelling of the outer ring is avoided by
fitting a flat washer with a diameter, somewhat less than that of the housing bore(see
Fig.4); the washer is removed after assembly. Housings and mountings should be set up
square by means of spirit level, plumb bob and set square, attention being paid to the
fact that the base of the housing is correctly supported in order to avoid fractures.
Normally, one bearing ensures the axial location of each shaft and it is important that it
is fitted in the right position. The remaining bearings are fitted with clearance to allow
for axial displacement. If the outer ring of a non-separable bearing has a stationary load
it must have a clearance fit in the housing so that, the bearing can follow the axial
movement of the shaft (Fig.5). An inner ring with a stationary load and clearance fit
occurs very seldom (see also tables - Selection of fits, pages 81,84 & 87). When fitting
axially free bearings, it must be ensured that the bearings have axial displacement in the
right direction.
Plummer blocks are supplied as free bearing units, but can be modified into locating
bearing units by inserting fixing rings in the housings. In the case of cylindrical roller
bearings, axial displacement may be effected within the bearing itself if one of the rings
is executed without flanges. In this instance both rings may be mounted with zero
clearance or with slight interference.
Non-separable bearings, i.e. bearings with rings, which may not be separated from
the rolling set, are usually mounted first on the shaft and then in the housings; the rings
are mounted with interference fit. In order to ensure that no mounting force is
transmitted from the inner ring to the outer ring, via the rolling elements, a flat washer
must be fitted infront of the bearing, to transmit the mounting force directly to the ring
being mounted (fig.6). If possible, the housing may be heated, so that the bearing on
the shaft may be inserted more easily.
Separable bearings, i.e. those from which one ring may be removed from the roller
set, which remains on the other ring, make it possible to fit inner and outer rings
separately on their seats or in their housings. Both rings may, therefore, be mounted
with interference fit, if required. When assembling cylindrical roller bearings care must
be taken to align correctly the rings and rolling elements.
Any scratches produced on these components are liable to cause premature bearing
failures (Fig.7).
Axial pre-loading of rolling bearing requires special care. In the case of angular
contact ball bearings and taper roller bearings mounted in pairs (Fig 8), the bearings are
preloaded by tightening up the locking nut until the correct amount of pre-load is
obtained or by using accurately machined spacing washers, as required. In some cases,
spring pressure is also used to pre-load bearings.
Bearings should not be fitted too tightly or too loosely. Pre-load must be adjusted,
according to the load to be carried. If axial expansion of components occur, due to
temperature rise, bearings must be mounted with more or less pre-load or even with
clearance.
During pre-loading, the housing or the shaft must be rotated, so that in the case of taper
roller bearings, particularly, the rolling members bear laterally against the guiding
flanges; otherwise clearance will remain in the components. This is sometimes checked
by rotating the wheel, housing or shaft concerned. In all cases, it is better to measure
the bearing clearance with a dial indicator. To pre-load such bearings accurately, a
special tool has been designed (DBP 826 383), by means of which, the bearings may be
adjusted free from clearance (Fig.9) The prongs of the tool engaged between the rolling
elements, so that the ball or roller set may be moved backwards and forwards. As long
as clearance is present in the bearing, the rolling members may be moved easily, almost
without force, but at that moment, when clearance becomes zero, resistance to the
movement totally increases so suddenly that, no special skill is required for this
adjustment of the bearing.
Thrust ball bearings are often axially preloaded by springs, particularly when they are
mounted in pairs. Excessive pre-loading is as undesirable as insufficient pre-loading.
When fitting thrust bearings, it must be remembered that, only the shaft washer fits the
shaft: bore, if the housing washer is somewhat larger to give clearance.
7 Bearings with Taper Bore:
Bearings with taper bore are mounted on cylindrical journals, by means of adapter to
withdrawal sleeves or direct on taper journals (Fig. 10). The bearing inner ring is
mounted by forcing it up the taper. The greater the load and the larger the bearing, the
tighter the fit must be. The outer ring may be fitted in its housing with a clearance or
interference fit, the type of fit depending on the running conditions.
8 General Instructions:
Whilst the fit of bearings with cylindrical bore is determined by the interference of the
shaft, the interference fit of bearings, with taper bore is obtained by driving the bearing
more or less, up on its taper seating. The inner ring is elastically expanded and the
expansion causes a decrease in the internal clearance of the bearing. This reduction in
clearance is a measure of the fit between the ring and the shaft.
It is important that, sleeves are tightened sufficiently to stop them becoming loose
during operation. In the case of self-aligning ball bearings, the sleeve nut should be
tightened until the outer ring can just be rotated and swivelled over the ball set without
difficulty.
In the case of spherical roller bearings, it is not sufficient to drive taper bearings on
merely by feel. The internal clearance reduction is used as an indication of the degree of
tightness of the fit of the inner ring on the shaft; the diametric clearance is checked
before and after mounting for this purpose. The table on page 88 shows the figures for
initial clearance, clearance reduction and smallest final clearing.
If it is not possible to measure the diametric clearance, the axial displacement of the
inner ring on the tapered journal or sleeve may be measured instead. The tables give
the values of this displacement for bearings with taper bores, when mounted on a solid
shaft.
When measuring diametric clearance, by the use of feeler gauge (Fig. 11), the outer ring
should be supported, so that all clearance is at the top of the bearing. Measurements
should, therefore, only be taken when the rollers are unloaded. The rollers should not be
allowed to roll over the feeler blade, during measurement. Select the thickest feeler
blade, which can be passed between the top rollers and the outer ring without force.
This will show the bearing clearance and should be noted.
In the case of small spherical roller bearings, it may be necessary to measure the axial
displacement, if the bearing clearance after mounting is too small to be measured by
feelers. Very large spherical roller bearings with taper sleeves are sometimes heated to
approximately 50°C above ambient temperature – in 5 to 10% cutting oil emulsion or in
machine oil – in order to simplify assembly, particularly where there is no suitable
mounting tool. As the clearance reduction may only be measured when the bearing has
cooled down, the axial displacement is again used as an indication of the fit.
In order to measure displacement, the inner ring must be positioned on the shaft, so that
it makes firm contact with the tapered surface of the shaft or sleeve. The bearing must,
therefore, be firmly placed on its taper – smaller bearings should be pushed on by hand,
larger bearings tapped on lightly by using a hammer and soft metal drift and the position
marked or dimensionally determined against a reference surface (Fig.12). The bearing is
then driven up, until the required axial displacement is obtained.
9 Bearings with Adapter Sleeves:
Unpack the sleeve and remove the nut and the locking plate, wipe off corrosion inhibitor
from the sleeve and coat it with oil or smear lightly with grease. Mount the sleeve in
correct sequence on the shaft. If mounting is difficult, expand the sleeve by inserting
the head of a screw-driver in the slot as in Fig. 13. Ensure that the sleeve is fitted in the
correct position.
Unpack the bearings, measure the radial clearance and note it down: if there are several
bearings, number them consecutively. The bearing is pushed on the sleeve, the locking
plate positioned in front and the nut screwed on. The nut should be tightened until the
required clearance reduction is obtained. In the case of large bearings, which may
require a considerable amount of clearance, reduction, put the sleeve nut on without the
locking plate, or if required, fit a soft metal washer. When desired clearance reduction
has been obtained, remove the nut, put on the locking plate and the nut and tighten up
again.
For shaft diameters of 200 mm and above nuts are locking with an MS locking device,
see Fig. 14. To tighten the nut on the adapter sleeve of self-aligning ball bearings and
small spherical roller bearings a series HN spanner, like that shown in Fig. 15 may be
used when the bearing is being fitted on its sleeve. If the inner ring abuts against a
soacer sleeve or shaft shoulder, so that the adapter
sleeve must be pulled through the bearing (i.e. must be pulled through the bearing and
the shaft), the mounting forces required will be increased and it may be necessary to use
a heavier hook spanner or a drift, as in Fig. 16, similar to those used in the mounting of
larger spherical roller bearings. Clearance reduction is obtained more easily when blows
are exerted tangentially on the adapter nut when tightening.
An excellent tool for use with larger bearings is the hydraulic nut (see page 72). Since
this device was introduced, it has given very good results in mounting and dismounting bearings
quickly and without difficulty. If a hydraulic nut is not available. The adapter nut should be
tightened by the hammer and drift method, as mentioned above. To avoid damaging the thread
or the inner ring, it is recommended that, the thread on the sleeve and the contacting surfaces of
the nut and the inner ring be coated with a mixture of white lead and vegetable oil. Adapted
sleeves are usually used on smooth shafts without shoulders for axial location. The position of
the bearing on the shaft must, therefore, be exactly determined and fixed during the mounting
procedure, by means of a clamping ring (see Fig. 17).
10 Bearings with withdrawal sleeves:
Unpack the bearing, measure the radial clearance and note it down (if there are several
bearings, number them consecutively). Push it on the shaft so that the smaller bore of
the inner ring abuts against the shaft collar or spacer sleeves.
Unpack the sleeve:
Wipe off the corrosion, inhibitor coat with oil or smear lightly with grease. Push the
sleeve on between the bearings and the shaft by hand, until it is firm on its seating. The
sleeve is then driven in, until the required clearance reduction is obtained.
Driving the sleeve in with a dolly and hammer can expand the inner ring. For larger
bearings, a hydraulic nut (see page 72) or a hydraulic or mechanical press can be used.
After clearance reduction, the shaft nut must be locked.
11 Bearings on Taper Shafts:
Basically, the mounting procedure is the same as that for mounting sleeves. It is
essential that, the taper seating carries the load over its full length and to ensure this, a
ring gauge is used to check the taper seating on the shaft.
To check whether the bearing is seating properly, lightly smear the bore of the inner ring
with marking blue and place it firmly on its taper seating. When removed the marking
transferred on to the seating will show the amount of area contact.
The mounting of large bearings with taper bore, whether on adapter or withdrawal
sleeves or on a tapered shaft, may be considerably simplified, by using the SKF oil-
injection method, which virtually eliminates the friction in the mating surfaces (see page
71).
12 LUBRICATION AND TEST RUNNING:
Rolling bearings may be oil or grease lubricated. The type of lubricant depends on the
operating conditions, particularly on the working temperatures. More detailed
information on this subject is contained in other SKF technical publications.
13 Grease Lubrication:
Grease lubrication is usually preferred, as bearings using this form of lubrication require
very little maintenance. Only approved bearing greases should be used; cup greases are
not suitable. The free spaces of the bearing should be filled with grease applied with a
spatula; the housing space should only be half filled; too mush grease will cause
excessive temperatures during operation except where bearings run at low speeds, in
which case the housings may be filled. Labyrinth seals, where fitted, should be packed
with grease to improve the sealing effect.
Choice of grease depends on the operating temperature and particularly on the

maximum temperature conditions liable to be experienced. Solubility in water is also an
important consideration in some applications and in the case of “walzerol” grease,
instructions regarding its properties are given on page 87.
It should be noted that, the grease “walzerol 1”, should not be mixed with greases
soluble in water, as the normal consistency will be adversely affected. “Walzerol 2” and
“Walzerol 3” may be mixed without detriment with other sodium-based greases.
“Walzerol 4”, however, should not be mixed with “Walzerol 2” and “Walzerol 3” or any
other sodium-based grease, as this action would reduce the maximum operating
temperature and impair the sealing properties.
Grease has a limited life, owing to the deterioration of its lubricating qualities. For
approved bearing greases, the diagram on page 64 (Fig 18) given an approximate
lubricating time ’t’ in operating hours relative to the bearing design, the bore diameter ‘d’
and the speed ‘n’. Lubrication schedules, based on the figures obtained from this
diagram are Recommended for large bearing applications. If relatively short lubrication
intervals result the incorporation of a grease valve, which allows the bearings to be re-
lubricated during operation is recommended. The quantity of grease to be supplied to
the bearings – regardless of whether a grease valve is fitted or not may be determined
from the formula G = D.B/200 (grams), where D is the outside diameter and B the
bearing width in millimeters. Brochures on lubrication and grease valves will be
forwarded on request. No special running-in measures are usually required for new
bearings. However, in the case of new spherical roller and taper roller bearings, rotating
at high speed, the following lubrication instruction should be observed: The bearing and
its housing, lubricating ducts and grease valve should be well filled with grease during
mounting. An hour after starting, the bearing should be given three times the quantity
of grease supplied at a normal re-lubricating period and this should be repeated 24 hours
later. Subsequently, the lubricating intervals and quantities of grease supplied should be
those recommended in Fig.18.
14 Oil Lubrication:
Only pure mineral oils should be used. The oil selected should have a viscosity of 12 to
22cSt at 50oC during operation.
Bearings should be given the requisite quantity of oil, when mounting has been
completed and the machine on site. If the machine has to be transported, however, only
a small quantity of oil should be put in the bearings to protect them against corrosion;
the remainder should only be put in when the machine is on site ready to operate.
15 Test Running:
Every bearing must be lubricated before it is put into service. Test run, howsoever short,
with dry bearings will inevitably result in bearing failure. After mounting, the smooth
running of the bearing should be checked. Turning a shaft by hand may be sufficient to
check the smooth running of the bearing; sometimes a test run is necessary. In the case
of high-speed motors the speed of operation should gradually be increased from slow
running to peak revolutions only, when everything is known to the satisfactory. The
bearing temperature will rise and attain its peak after several hours of operation and will
then fall to its final level provided mounting has been carried out correctly and that the
right lubricant has been chosen in adequate quantities. If the operating temperature is
too high during the test run, another more suitable lubricant should be used or
lubrication, nipping, etc. a smaller quantity of grease put in the bearing. Any irregular
noise during running indicates some defect, like dirt in the bearing, inadequate
DISMOUNTING OF ROLLING BEARINGS
16 Preparation:
Before dismounting, it is preferable to get a drawing showing clearly the design of the
bearing scheme. A dry, dust-free dismounting site should be prepared and housings and
adjacent component parts should be cleaned and removed so that the bearings are
accessible. It must be ensured that, blows from a dismounting sleeve are not
transmitted through the rolling elements from one bearing ring to the other, as this may
damage the bearing. Shafts being withdrawn during the dismantling of adjacent
components should be supported.
17 Dismounting the Bearings:
To identify components, it is recommended that, they be placed next to each other in the
sequence in which they were originally mounted. This facilitates assembly and its should
also help if, for any reason, the tracing of a possible failure is required.
It is, usually, a simple matter to withdraw bearings or rings having a loose fit once the
locking nut is unscrewed.
Bearings or rings, having interference fit, should be removed by applying light blows,
against an adjacent sleeve or similar fitting on the shaft, as shown in Figure 19; they
may be removed from their housings by pressure on strong dished plate washers, as in
Fig.20. It is better and sometimes more convenient to use proper withdrawal tools,
which may be obtained in various designs. The tools should engage direct on the rings
or other adjacent mounting components, such as sealing collars and sleeves or similar
items, as illustrated in Figures 21 and 22.
For larger bearings, which often require considerable withdrawal force, dismounting may
be facilitated by heating the rings fitted to the shaft. This should be done by placing
clothes saturated in hot oil over the ring in question, or by directing a steam jet evenly
around it. Heating by means of a soldering lamp or welding flame is not permitted as
distortion of the ring may easily occur. A better way still is to use the SKF oil-injection
method, see page 71, particularly when dismounting larger bearings.
Cylindrical roller bearing inner rings without shoulders or with one shoulder, may be
easily and quickly withdrawn, by means of electric withdrawal tool shown on page 72.
To dismount an adapter sleeve the adapter nut should be slackened off a few
threads and the inner ring removed by driving it down the tapered sleeve towards the
loosened nut. On the other hand, when driving out the adapter sleeve, it is advisable to
support the inner ring by a clamp or spacer on the side opposite the nut and then free
the adapter sleeve by heavy blows on the slackened nut, as in Figure 23.
Withdrawal sleeves are loosened by removing the lock nut and screwing on a
withdrawal nut (Fig.24). A withdrawal tool screwed to the sleeve thread may also be
used instead.
The removal of larger bearings on adapter or withdrawal sleeves is considerably

facilitated by the use of hydraulic nut. The oil-injection method should be used for
dismounting bearings from shafts, if 200mm or more but specially designed withdrawal
and adapter sleeve should be used.
Bearing fitted on a taper seat are loosened by applying force to the inner rings. The oil-
injection method is used to dismount larger bearings without difficulty. Oil injected
between the mating surfaces reduces friction, so that the bearing slides automatically
down the taper. If there is no space to apply a withdrawal tool to the bearing inner ring,
the withdrawal force must be transmitted through the rolling elements with a consequent
risk of the tracks being indented. This risk can be minimized, if the outer ring is rotated
during withdrawal.
TOOLS AND METHODS USED IN
MOUNTING AND DISMOUNTING
18.SKF Oil-injection Method:
To facilitate mounting and dismounting larger bearings, the oil-injection method should
be used. Oil is forced between the mating surfaces by means of an injector or a pump
creating an oil film in the joint and considerably reducing the friction, so that much
smaller forces are required to mount or to dismount the bearing (Fig.25). Bearings on a
taper seat automatically slide off the taper.
In order to apply the oil-injection method, ducts and grooves must be provided so that
oil may be channelled to the mating surfaces. To dismount a large number of identical
bearings economically, the manufacture of a special withdrawal tool is recommended. By
way of this, oil is forced to the contact surface by means of an adapter ring (Fig.26).
Instructions on this withdrawal procedure will be forwarded on request.

19 Hydraulic Nut:
The hydraulic nut is a tool for mounting and dismounting larger bearings with taper bore
and has proved very satisfactory in operation. By this means, it is possible to mount and
dismount bearings without having to use a hammer and drift.
The hydraulic nut consists of an internally threaded steel ring with a groove in one face,
into which is fitted an annular piston, sealed with plastic O-rings. When oil is pumped
into the space behind it, the piston is forced outwards; the force exerted is sufficient to
drive a bearing up a tapered sleeve or seating, or to dismount the bearing. See Fig.27.
Hydraulic nuts are supplied with a thread diameter from 90 up to 710 mm. Other
dimensions and examples of applications are given in SKF publications.
20 Electric Withdrawal Tools:
Electric withdrawal tools serve to dismount large cylindrical roller bearing inner rings,
without flanges or with only one flange, which have a tight fit on the shaft, see Fig.28.
Depending on bearing size and fit, withdrawal takes approximately from 15 seconds to 5
minutes.
Electric withdrawal tools consist of one or several induction coils, which are energized
with alternating current. The coils are arranged in such a way that, rapidly alternating
magnetic fields are created in the ring to be dismounted. Due to the Kelvin effect,
induced eddy current quickly heat and expand the ring, while the neck is heated more
slowly by heat conduction. Provided, the heat is generated quickly, the ring may be
withdrawn before the neck is expanded. More detailed information on the electric
withdrawal tool is given in SKF technical publications.
21 CEANING OF ROLLING BEARINGS
To clean rolling bearings, the following cleaning agents may be used:
Inorganic Chemical Cleaners:
• P3 Solutions (Approx.2%)
• Soda Solution (0.5 to 1%)
• Caustic Soda solution (10%)
Bearings should be flushed or sprayed with cleaning agent at a temperature of 70-80C or, if
carbonized, should be boiled. Bearings with light metal cages should not be cleaned with soda or
caustic soda solutions.
A solution of caustic soda is very liable to cause alkali burns to skin and clothing, and protective
goggles and rubber gloves should, therefore, be worn.
Organic Fluid Cleaners:
Inflammable products:
• Benzene
• White sprit (free from acid)
• Good quality paraffin
• Benzole
Due to fire risk, inflammable cleaning agents may only be used at ambient temperature
(approx.20oC), for flushing or immersion cleaning; white sprit, however, may be sprayed up
to approximately 50 oC, provided, the usual fire risk precautions are taken.
Non-inflammable products:
• Carbon tetrachloride
• Trichlorethelene
• Perchlorethylene
These agents may be used for immersion, flushing or spraying. After degreasing with
benzene, benzole, tetrachlorethylene, trichlorethylene and perchlorethylene the bearings
must at once be treated with a suitable protective agent, in order to prevent corrosion.
If chlorinated hydrocarbon is used. Accident prevention measures must be taken, as the

agents are harmful.
23 Cleaning New Bearings:
New bearings should be cleaned only in exceptional cases. Generally, the rust
preventive, with which the bearings are coated, should remain in the bearing, if the
carton is undamaged, only the bore and outer ring should be wiped clean.
Rust preventive consists in the main pure vaseline and may be mixed with lubricating
grease or oil during operation without any adverse effect. In the case of small bearings
rotating at high speeds, however, it is better to remove the rust preventive before
mounting to eliminate starting resistance. If, on the contrary, these bearings are initially
operated at slow speeds, the removal of the rust preventive is unnecessary.
New bearings in damaged cartons may be contaminated and must be treated differently.
They should be dealt with as follows:
24 Cleaning Contaminated Bearings:
Old grease should be removed from the bearing either by hand or with a suitable
wooden or rubber scraper. The bearing may effectively be blown out by compressed air.
It should then be washed in an approved cleaner (white sprit) in a suitable container.
The bearing should be rotated by hand and a stiff brush used to dislodge grease and
foreign matter. Care should be taken to ensure that bristles do not lodge in the bearing
between the rolling elements and the cage. Depending on the amount of dirt present
the bearing should be rinsed in one or two more baths of white sprit. After every
washing, the bearing can be blown through with filtered dry compressed air, care being
taken not to spin it too fast.
If they are not to be mounted and lubricated with ball bearing grease immediately, the
bearing should be oiled after cleaning. During this operation, it should be rotated slowly
so that oil reaches all parts. Grease lubricated bearings should also be turned, so that all
surfaces become coated and protected from rust. This applies in particular to bearings in
machines, which may have to stand for some time before being put into service.
Where bearings are to be stored unmounted for some time, after they have been
washed, they must be treated with more effective rust preventive than mineral oil. A
mixture of pure vaseline with a melting point of 45OC and refined machine oil in the
proportion 1:1 mixed together with approximately 3% pure, solid stearic acid. The
bearing should first be heated in this mixture to a temperature of 155-120 OC to
evaporate any moisture that might be present; they should then be cooled off in another
bath of a similar mixture to 60 OC. Finally, the bearings should be wrapped in waxed
paper and suitably packaged.
ROLLING BEARING FITS
Instructions for the selection of rolling bearing fits are contained in the DIN Sheet 5425,
the SKF catalogue and other publications.
The correct fit of bearing rings in relation to other components is essential to ensure
roller bearing reliability.
In principle, the ring which rotates relative to the direction of the radial load must be
mounted with a tight fit and the larger the bearing dimensions and the heavier the loads
the tighter the fit must be. If the load is stationary relative to the ring it should have a
clearance fit.
The majority of radial bearings – except angular contact ball bearings and taper bearings
– are usually supplied with radial clearance which reduces to the normal clearance
required for ordinary operating conditions.
If the inner and outer rings are fitted with an interference fit, or if one ring is mounted
with an interference fit, it is necessary to use bearings with clearance greater than
normal (C3 or C4 clearance). Regarding angular contact ball bearings and taper roller
bearings see pages 5 and 6.
When machining component parts, it is not only necessary to observe dimensional limits
but also form tolerance, i.e permissible out-of-round and taper.
Surface finish has a great influence on the type of fit that can be obtained. If the surface
is rough finished, the machining marks will be smoothed over during mounting and the
resultant fit will have less interference than that calculated. Hardened seats may permit
less tight fits to be used, but are not suitable for clearance fits. In the case of material
softer than cast iron, tighter fits should be used or sleeves of hardened material
employed. This is specially recommended if temperature expansion has to be
anticipated, e.g. in the case of light alloys.
INSTRUCTION MANUAL
"
INSTALLATION
AND
OPERATION & MAINTENANCE
INFORMATION ON DODGE SLEEVOIL

PILLOW BLOCKS (RT)
Bharat Heavy Electricals Ltd

Ranipet – 632406, Tamil Nadu.
DODGE SLEEVOIL BEARINGS (Type RT)
INSTRUCTIONS FOR ASSEMBLY OF SLEEVE BEARINGS:
SLEEVOIL RT pillow blocks are designed for applications requiring a bearing with high thrust
load capacities. RT (water cooled) pillow blocks is available in expansion or non-expansion
types and can be modified for circulating oil.
INSTALLATION
1. Check mounting structure making sure it is rigid level and well supported.
2. Disassemble and thoroughly clean all parts of the pillow block. HOUSING CAPS AND
LINER CAPS ARE MATCHED TO THEIR BASES AND SHOULD NOT BE
INTERCHANGED. HOUSING AND LINERS SHOULD BE INTERCHANGED AS
ASSEMBLIES ONLY.
3. Position housing base on pedestal so that oil gage is in position specified on construction
drawing. Do not tighten housing base to pedestal. Apply oil to the spherical seats in the
housing & base.
4. Set liner base in housing base. For fixing Resistance Temp. Detector (RTD) makes sure
the holes in the liner should align with the holes in the housing when the
pillow block is assembled. Apply oil to the liner bearing surface
5. Inspect shaft to ensure it is smooth (0.8 micron or better), within commercial tolerances
and free of burrs or rough spots. In bearing used for non-expansion (fixed) type. Check
thrust collar for burrs and scratches. Both sides' of the shaft thrust collar are
to be lapped if necessary using lapping compound to attain lapping finish. No
indentation marks or steps or tool marks are permitted on the collar surf ace. Check for
the square ness of shaft thrust collar with respect to the shaft (using tri-square). Light
should not pass through the mating surface.
6. Place oil ring around outside of liner base and over shaft. Install and peen oil ring screws
to ensure they are secure. Make sure rings rotate freely on shaft.
7. FOR NON-EXPANSION BEARINGS: Clean one set of the Babbitt faced thrust plates. Note
that the plates are matched halves and must not be interchanged. Carefully
smooth any scratches on babbitted face with steel wool or coir material (not emery cloth
or sand paper). Fill up the cavity of the bottom liner half with oil. Oil plate halves
generously. First install the plate half without milled slots in the steel back. Press the
babbitted face against the thrust collar and rotate plate around shaft into liner cavity.
Install retainer washer in. groove in liner base. Rotate plate until stopped by retainer
washer. Place other thrust plate half (half with two milled slots in steel back) against
thrust collar, making sure Babbitt faces the thrust collar. Clean and oil the second thrust
plate set and install in the same manner. It may be necessary to move the shaft slightly
to obtain enough clearance in the liner cavity to install the lower thrust plate half.
(Caution: The bearing is not yet fastened in place and can be moved). The total gap
between the shaft thrust collar and the thrust plates on the two sides, shall be min. 0.38
mm to max. 0.76 mm.
8. Apply oil to the bearing area of the liner cap. Locate liner cap on liner base (cap is not
reversible on base) and check match marks. Make sure oil rings rotate freely. End faces
of liner should have no appreciable offset. Install and tighten cap screws alternatively. If
liner cap on the non-expansion bearing will not drop into place remove it and reposition
thrust plates tightly against thrust collar. Then reinstall liner.
CAUTION: DO NOT COLOUR MATCH THE LINER AND SHAFT.
9. Check alignment of pillow block by noting clearance between housing bore and shaft at
each end of the housing clearance should be uniform within 1/32". Alignment of the
pillow block should be as accurate as possible. The self-alignment feature of the unit is to
compensate for normal shaft deflection and possible setting of the supports. Tighten
mounting bolts securely. Shaft should rotate freely.
10. Wrap the O-ring (rubber cord) around the shaft in the seal area and cut it to fit the
shaft. Disassemble one seal and place one half on shafts with finger facing liner.
Locate O-ring in seal groove and rotate seal half around shaft into housing 'base
groove. For most effective sealing, ends of O-ring must meet. Cementing ends
together is recommended. Install other half of seal and tighten screws. Install second
seal in same manner.
11. Position gasket on housing base. Loosen plunger screw and locate: housing cap on
housing base (cap is not reversible on base). "Be careful not to damage seals or
housing gasket. Tighten housing bolts, and then turn down plunger screw
snugly. The plunger screw must remain loose until housing bolts have
been tightened. Tighten plunger screw and locknut.
CAUTION: If coolant pipe in liner gets loosened, water may leak into oil and
damage the bearing itself.
13. For using a RTD/ thermocouple install it in one of the two holes specially machined in the
housing base above the mounting bolts. For non-expansion bearing the RTD/thermo-
couple should be located in the hole next to the thrust plate carrying the thrust load. In
single suction fans the thrust plate on the fan side carries the thrust load. For expansion
bearing the RTD/ thermocouple may be located at either end. Make sure probe extends
into the liner, use sealant on all threaded connections. Apply seal ant to the pipe plug
provided and install it in the other hole.
14. Make pipe connections required for coolant, making sure that all pipe lengths are correct
and unions are well aligned. Careless fitting will result in serious preloading of the
bearing. Suitable lengths of flexible hose between the pillow block and rigid
piping are recommended to avoid preloading of the bearing. A regulating valve
should be placed ahead of the Inlet and a sight glass at the outlet for liquid
coolants. The recommended method of pipe connection for liquid coolants is to
connect the inlet to one side of the pipe and the outlet to the other side of the
bearing liner. This will be done separately in top half and bottom half of the
liner.
Adjust coolant flow to rate specified or to suit conditions. Purge all coolant from liner by
blowing out with compressed air prior to connecting the flexible hoses. Bearing rating is
based on a maximum water inlet temperature of 32°C. The water pressure should never
exceed 5 Kg/cm 2.
15. Remove and reinstall, using sealant, all plugs not previously removed.
16. Since the satisfactory operation of the pillow block depends almost entirely on
the oil film being maintained between the shaft and bearing liner surface and
between the thrust collar and thrust plate surface, the 'use of a high quality oil
from a reputed manufacturer cannot be overemphasized. Oil of correct
grade/specification as recommended in the lubrication schedule only to be
employed.
17. Fill pillow block with oil to top of outer most circle in the oil gauge. During
operation open inspection covers and check to make sure oil rings are bringing
up oil. Operation should be checked frequently during the first few days. If
noise develops check alignment of housing, plunger screw and all operating parts. Check
all points and tighten screws and nuts after 48 hours of operation. Drain, flush
and refill with oil after 100 hrs of operation. For subsequent oil replacement, refer
lubrication schedule. Check oil for contamination periodically between oil changes.
Maintain oil level above bottom of center circle at all times while unit is in
operation. Any clarification on installation, maintenance and arrangement of
coolant or oil connections should be referred to the Engineering & Development
Centre, FANS, BHEL, RANIPET.
Caution: If it ever becomes necessary to remove liner cap, make certain that both
upper thrust plate halves remain in place next to the thrust collar. If a
plate half should remain in the liner cap, it can drop from the liner and
cause injury and damage to the thrust plates.
18. Precautions during first trial run
a) The first trial run with the bearings assembled as detailed above, shall be
taken or 10 minutes only.
b) During the above trial run, observe temperature rise in sump oil mercury in steel
thermometer and also in the RTD of thrust bearing. Manually record the
temperature rise of thrust bearing RTD, for every minute for the first 10 minutes.
c) During trial run, check for proper rotation of each oil ring and carrying up of the
oil by the ring through the inspection window.
d) Ensure maintenance of proper oil level in the sump
e) Stop the fan and inspect the bearing for
1. ANY scratch marks on thrust plate Babbitt surface. If present, this could be
due to improper surface finish of shaft thrust collar; or could be due to any
foreign materials in oil.
2. Any change of colour in collar/thrust plate surface. This could be due to
disintegration of oil due to excessive pressure or heat. Clean the surfaces
with thinner/solvents (Petrol).
3. Check oil for any silver colour particles (Babbitt material). This is
very important. This is due to removal of Babbitt particles from thrust
plate.
4. Any damage (Babbitt removal) on the top half of the liner assembly. If
present, this could be due to improper shaft finish/vibrations.
Note:
Under case 1 or 3 above, again inspect the Thrust collar for proper
surface finish, which shall be lapped to acceptable level (prior to
reassembly of bearing)
f) Clean the thrust collar and thrust plate. Reassemble the bearing. Trial run the
fan for 8 hrs. Inspect the bearing thrust surfaces once again. (Repeat step e and
f).
g) The bearings can be cleared for satisfactory operation, once the above steps are
completed.
19. In case the design warrants, an external lubrication system may be provided.
Insert the two small pipe nipples through the holes in the housing cap and screw
them tightly into the liner. Install Grommet plate (rubber washer) and collar over
each pipe. Press down the collar and tighten the collar set screw. Connect
circulating oil supply lines so that each inlet receives an equal amount of oil. A
flow control valve/ Orifice may be provided in the inlet line. An oil sight glass
should be provided in the drain pipe. Connection of oil lines from the piping
should be via flexible hoses only. Ensure quantity of oil flowing to the bearings is
in line with recommendations.
SLEEVOIL AUXILIARY SEAL AND END CLOSURE KITS
STANDARD AUXILIARY SEAL KIT
1. Remove parts from box, clean parts and inspect for damage. Remove any burrs or nicks
from auxiliary seal housing and pillow block housing tapered pilot.
2. Wrap cork seal around shaft next to pillow block. Wrap seal retainer around seal. Slide
free end of seal retainer thro clasp and pull tightly. Cut off excess retainer materials and
push down clasp lip. Seal retainer may be disengaged by straightening a paper clip,
inserting it between the bands (on each side of the serrations) and thro the clasp. Then
pull the free end of the retainer back out of the clasp.
3. Remove the protective covering from the gaskets to expose the pressure sensitive
adhesives. Place one gasket on each auxiliary seal housing half.
4. Position auxiliary seal housing halves on pillow block pilot so that "UP" is at the top and
tighten bolts while tapping auxiliary seal housing towards pillow block. This assures
proper seating of the taper. Torque bolts to 130 in lbs.
END CLOSURE KIT
1. Remove end closure housing from box. Clean and inspect for damage. Remove any burrs
or nicks from the end closure housing and the pillow block housing tapered pilot.
2. Install the neoprene disc in the seal groove of the pillow block housing base.
3. Install pillow block housing cap in accordance with the instructions detailed earlier for
sleeve bearing assembly.
4. Install end closure housing on pillow block pilot so that the set screws are at the bottom.
Tighten set screws while tapping end closure housing towards pillow block.
SHAFT WITH SPLIT THRUST COLLAR
In cases where the shaft is supplied without an integral thrust collar, split thrust collars are
supplied separately. Note that the collar halves are matches pairs and not interchangeable.
Refer to the instructions of bearing supplier under "RT pillow blocks".
04. THE PROPER FASTENING FOR RIGIDITY
Mechanical Looseness Mechanical Looseness is one of the main causes
for vibration and deterioration of machine by having
tendency to increase vibration in course of time
further and further.
Mechanical Looseness includes misalignment by

distortion due to looseness, excess bearing
clearances, etc. It means vibration components of
2xRPM and 3xRPM.
Criteria Mating planes should be perpendicular to axis of
bolt and mating planes should be parallel to each
other.
For proper transmission of loads, static and

dynamic – uniformly.
Requirement The machine should be on packers on both sides of
each bolt as above in its natural posture without
strain from tightening with permissible torque.
Ensure The measure of strain due to fastening is indicated
by Spring back. This occurs due to retrival of elastic
machine foot after relieving the strain due to
fastening by removing fasteners(nuts).
Target Measurement If spring is less than 50 microns (0.05 mm) then, the
fastening, packing, surface matching (blue
matching) etc., are OK.
Action to achieve target If not, check thoroughly from concrete, packers,
shims to machine foot and fasteners to ensure
criteria and measurement; wherever necessary
check by blue match the proper mating of surfaces
by ensuring at least 80% colour matching and level
horizontal planes within 0.4 mm/m.
Caution Spring back has to be certainly present as a
consequence of tightening.
This is to be studied in conjunction with the PROPER FASTENING FOR RIGIDITY attached with this
manual.
1. Remove all the nuts of a given feet of a machine.
2. Clean all the surfaces (including the threaded surfaces) of washers, nuts and screws by petrol or
kerosene or carbon tetrachloride to ensure removal of lubricants, grease or oil in them.
3. Measure outer diameter and pitch of screw thread with clean hands, gauges, tools, etc.
4. Find out the quality of the bolt from drawing or from the stamped marking on them.
5. Determine the allowable maximum torque (refer table for tightening torque for bolts).
6. Tighten all the nuts sequentially up to the required torque.
7. Choose any nut at a time.
8. Position dial gauge on top surface of this foot without touching washer and about 5 to 10 mm
away from the chosen washer.
9. Adjust the dial gauge to zero.
10. Loosen and remove this nut, keeping all nuts of other feet in position.
11. The foot may move upwards while loosening.
12. Note the reading of dial gauge, until the nut is completely loose and the dial gauge shows steady
reading.
13. If the movement is within 50 microns, fastening at this joint is OK. If not, more springing exists.
14. Repeat the procedure in an orderly fashion (diagonally opposite) for all other nuts one by one to
measure the amount of springing. As a reference take the least of the values and insert shims at
other feet suitably – relatively more spring back points require relatively more spring back points
require relatively thicker shims.
15. Repeat points 6 to 12 for finding the amount of springing. Ensure this springing is within 50
microns (0.05 mm).
16. If not, repeat the procedure until the amount of springing is within 50 microns at all bolt points
ensuring the given criteria enclosed for the proper fastening for rigidity.
17. By shimming above, if it is impossible to ensure springing movement within 50 microns, from
concrete to packers to feet require deeper study and measurements to confirm to the criteria
given.
18. Such corrections may affect the alignment of the machine. Hence, after these corrections and
before the machine is run, the machine alignment requires checking/correction.
06. MAXIMUM PERMISSIBLE TORQUE VALUES FOR
TIGHTENING BOLTS (IN KGM)
NORMAL THREAD
SIZE MATERIAL QUALITY
6.9 8.8 10.9 12.9
M4X0.7 0.25 0.29 0.41 0.49
M6X1 0.85 1.00 1.40 1.40
M8X1.25 2.10 2.50 3.50 4.10
M10X1.5 4.10 4.90 6.90 8.30
M12X1.75 7.20 8.60 12.00 14.50
M16X2 18.00 21.00 29.50 35.50
M20X2.5 34.50 41.00 58.00 69.00
M24X3 60.00 71.00 100.00 120.00
M27X3 89.00 105.00 150.00 180.00
M30X3.5 120.00 145.00 200.00 240.00
M33X3.5 159.00 189.00 266.00 319.00
M36X4.0 203.00 240.00 338.00 406.00
M42X4.5 325.00 385.00 541.00 649.00
M48X5.8 487.00 577.00 811.00 974.00
FINE THREAD
SIZE MATERIAL QUALITY
6.9 8.8 10.9 12.9
M8X1 2.30 2.70 3.80 4.50
M10X1.25 4.40 5.20 7.30 8.80
M12X1.25 8.00 9.50 13.50 16.00
M12X1.5 7.60 9.00 12.50 15.00
M14X1.5 12.50 15.00 21.00 25.00
M16X1.5 19.00 22.50 31.50 38.50
M18X1.5 27.50 32.50 46.00 55.00
M20X1.5 38.50 46.00 64.00 77.00
M22X1.5 52.00 61.00 86.00 105.00
M24X2 65.00 78.00 110.00 130.00
M27X2 97.00 115.00 160.00 195.00
M30X2 135.00 160.00 225.00 270.00
NOTE:
UNLESS SPECIFIED IN THE DRAWING 75% OF THE MAXIMUM TORQUE
INDICATED IN THE ABOVE TABLES MAY BE SUED FOR NORMAL
TIGHTENING.
ACID CLEANING PROCEDURE
The inlet and outlet of the lubricating oil to the bearing housings are connected to the oil
system by suitable pipelines. After laying the pipelines it should be dismantled and cleaned
properly. In order to remove the scales and oxidized layers, which might have formed in both
the pipelines, the acid cleaning process is recommended. The acid solution may be of the
following:
Commercial Hydrochloric Acid - 1 part

Clean Water - 6 parts
After mixing the solution thoroughly, fill the lines after plugging one end suitably. Keep the
solution for about three hours.
Prepare a neutralizing solution with soda and water (500 gms of soda for 10 ltrs. Of water).
Rinse the acid cleaned pipelines with neutralizing solution several times. After neutralization
rinse the pipes with crude oil or light oil.
Assemble the pipelines completely with the oil system and bearing housings. Loop the inlet
and outlet to each bearing suitably such that bearing are bypassed while flushing the piping.
Fill the LOS tank with recommended oil or flushing oil (one third filling would be sufficient).
Start the lube oil pump and flush the lines for atleast 8 hours. If dirt is seen, continue the
flushing till such time no dirt collection is noticed in the filter.
Assemble the oil lines to the bearing housings. Change the oil and the lube oil system is ready
for use.
CAUTION: HAND GLOVES MUST BE USED WHEN USING THE ACID AND CAUSTIC
SOLUTIONS.
MANUALS
SUBMITTED
BY
TECHNICAL SERVICES

Ranipet, India

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ERECTION

BHARAT HEAVY ELECTRICALS LIMITED

BHARAT HEAVY ELECTRICALS LTD

1. FORCED DRAFT FAN

2 . INDUCED DRAFT FAN

3 . PRIMARY AIR FAN

“FORCED DRAFT FAN”

M/s PRAYAGRAJ SUPER THERMAL

BHARAT HEAVY ELECTRICALS LTD

6. TRANSPORT, INSPECTION SRORAGE AND PRESERVATION

7. PREPARATION FOR ERECTION

10. LUBRICATION INSTRUCTION

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

2. TECHNICAL DATA SHEET

PROJECT: M/s PRAYAGRAJ SUPER THERMAL POWER CUST.NO.

1. APPLICATION : Forced Draft Fan

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

2. TECHNICAL DATA SHEET

10. LUBRICATIN EQUIPMENT

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

26.6  Tip diameter in decimeter

12.5  Hub diameter in decimeter

Lubricant & Supplier : Servo prime 68 of IOC

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

LIST OF VENDOR MANUAL/DATA SHEET

Prepared By:R.SEKAR Reviewed By: VINOTH KUMAR S Approved By: P.SAHA

Prepared by Checked by Approved by

Hitesh Kumar T S Selvaraj M. Desigan

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013.

 BHEL/Ranipet will not be liable for any damage caused by inappropriate

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 1

4.1 Explanation of Used Symbols

The following symbols have been used in this Assembly Instruction:

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 2

4.2 Requirements on Site

4.3 Transport, Storage and Inspection of the Delivered Equipment

Avoid - in particular - storing structural steel elements on their mechanically treated

Record damages and other deficiencies adequately (e.g. photo

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 3

4.4 Responsibilities and Interfaces

 Accuracy and completeness

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 4

Imminent danger of individuals!

5.2 Intended Use

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 5

5.3 Demands on the Personnel

The personnel must completely read the assembly instructions prior to

Please feel free to contact BHEL/Ranipet for special training of your

 Emergency stop button for adjacent equipment

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 6

 Activities at hydraulic equipment may only be performed by personnel having

5.4 General instructions to avoid danger

5.5 General Instructions on Welding

Doc. Ref.: FES-Fans/T03/FAF-ER:01/Rev:01/Dt:14.03.2013. 7

6.0 Transport and storage

Danger of injuries during loading and unloading!

Dispose of packing material professionally according to the respective

6.2.1 Markings and Information

Follow the information on the shipping units as well as the indications