ID Fan Manual

INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE MANUAL

AIROCHEM

INDUSTRIAL FANS E ngineered products E ngineered products E ngineered products E ngineered products –––– m oving air efficiently since 1975m oving air efficiently since 1975m oving air efficiently since 1975m oving air efficiently since 1975

CLIENT: Themax Ltd (Enviro Division). PROJECT: ORDER NO:

AIROCHEM ENGINEERING COMPANY

Plot No. B – 57, MIDC, Shiroli, Kolhapur, 416 122, Maharashatra, (INDIA)

E-mail - [email protected]

Telephone - 91-230 – 2468107, 2468306

Fax No. - 91-231 – 2658312 & 91-230-2460734

Web site - www.airochemeng.com


AIROCHEM ENGINEERING COMPANY 2

INDEX

CHAPTER

NO

PARTICULARS PAGE NOS

I NAME-PLATE DETAILS 3

II OPERATING SPECIFICATIONS 4

III GENERAL 5

IV RECEIVING, HANDLING & STORAGE OF

EQUIPMENTS

6

V INSTALLATION INSTRUCTIONS 8

VI PRE-COMMISSIONING & COMMISSIONING

INSTRUCTIONS 11

VII BEARING LUBRICATION 15

VIII BEARING CLEARANCES 17

IX MAINTENANCE INSTRUCTIONS 18

X LIST OF SPARE PARTS FOR TWO YEARS

OPERATIONS

20

XI MOTOR STARTER RELAY SELECTION TABLE 21

XII SELECTION OF ELECTRICAL CABLES 23

XIII TROUBLE SHOOTING GUIDE FOR FANS 24



Chapter I - Name Plate Details of Fans

AIROCHEM Industrial Fans -

Sr.No Identification ID Fan

1. Type Centrifugal

2. Size / Model

3. Capacity ( cum/Sec.)

4. Static Pressure @ optg.

Temp.(mmWG)

5. Speed (RPM)

6. Drive

7. Motor Details

8. Starter Details

9. Serial No.

10. Year of Manufacture



Chapter II - Operating Specifications of Fans

Sr.

No

Identification ID Fan

1. Sr.No.

2. Fan Type Centrifugal

3. Model

4. Gas Handled

5. OperatingTemp. (oC)

6. Capacity (cum/ Sec.)

7. Gas Density (kg/m3)

8. SP at operating

Temp (mmWG)

9. TP at operating

Temp. (mmWG)

10. Impeller Diameter (mm)

GD2(kg-m2)

11. Impeller Speed (RPM)

12. Drive Type

13. Power consumed at optg.

Temp. in KW

14. Fan Efficiency (Static) at shaft

in %

15. Electric Motor

Details

16. G.A. Drawing No.



Chapter III – General

The fan manufacturer, the driver manufacturer or the contractor building the installation can

carry out the installation of fans. Large fans are usually installed as early as possible while

access to the site is at its best. Small fans can usually be fitted in at any time.

The certified fan drawings must be available to allow foundations or structural steelwork to

be designed and manufactured before the fan is delivered.

The space allocated for a fan must be sufficient to permit installation, care, disassembly and

maintenance. Transport routes and lifting facilities must be available. Sufficient space must

be allocated around the installed fan for the access of personnel. Operation may need to make

frequent running adjustments. Maintenance personnel will require space to remove

components and assemblies. Some fan designs require space at the non drive end. The motor

may need space for the withdrawal of the rotor.

The ventilation of the fan site is very important. The electric motor must receive the

necessary cooling. If the hazardous gases, harmful to the environment or highly flammable,

are to be extracted, special ventilation requirements must be observed. It should be noted that

the heat generated by the fans electric motor can be considerable. The electrical and control

systems for the fan must also be protected against damage.

Mounting the fan unit on isolation mounting can create ducting and bearing problems.

Ducting close to the fan can fracture if it vibrates. Using flexible connections adjacent to the

fan can solve this problem. Short bearing life can be a problem if the fan does move

appreciably on its isolation mountings. It is better to use an isolated foundation block.

It’s the user’s responsibility to ensure the fan unit is stored in suitable conditions and that the

factory preservation instructions have been followed.

Before placing the fan on foundation, thoroughly clean the top of the foundation, remove any

thin ridges and roughen the top to provide good key for the grout. Prepare enough shims to

level the baseplate, two sets for each foundation bolt. The shims should be longer than the

width of bottom flange.



Chapter IV - Receiving, Handling & Storage of Equipments

4.1) Receiving

Most fans have been correctly, checked and inspected prior to delivery. They have also been

subjected to a run test before leaving factory. When you receive the equipment, examine it

carefully for damage caused in transit. If anything is wrong, both the manufacturer and

carriers should be contacted within three days of receipt.

Check that all items indicated in accompanying challans and /or packing slips have been

received and if not contact the manufacturer immediately.

If the fans are to be received by non-engineering personnel, it is recommended that skilled

person carry out inspection on receipt.

If Fan assembly is received in CKD condition, ensure that all fan components are generally

received as per list below, and as per challan/ packing slip in particular.

1) Casing in two or three parts, each having flanged opening with joining screws and nuts

with spring washers. 2) Impeller with front locking washer, in case of overhung design & no

washer, in case of simply supported design. 3) Inlet Cone. 4) Inlet Box. 5) Inlet VIV or

Multivane Damper 6) Inlet and outlet flexible connections 7) Fan shaft with keys, bearings,

adapter sleeves, locating rings and Plummer blacks assembled or bare shaft with keys and

other items packed suitably. 8) Motor Pulley with locking washer. 9) Shaft Pulley with

lacking washer 10) Foundation Bolts. 11) Shaft and /or motor assembly mounting pedestal,

for overhung design.12) Plummer Block mounting pedestal, for simply supported design. 13)

Motor mounting base. 14) Vee- belt guard/ or Coupling guard

4.2) Handling

The equipment should be handled carefully to prevent damage. Always use lifting points

provided. Extra care should be given to Impeller or dynamic balance may be affected. The

Shaft and Bearings are also important for on them depends the vibration-free running. Where

the fan has been despatched as complete unit, never ‘sling’ under the shaft.



4.3) Storage

When fans are to be stored or installed for any length of time before running, special

care should be taken as follows:

a) Where not specifically designed for outdoor use, they should be protected against

elements, special care being given to bearings, motors, and rotating parts.

b) Slowly run rotating parts at regular intervals to re-distribute the bearing lubricant,

making sure that the shaft finishes at 180 deg. to its former position. Never leave the

Fans stationary for any length of time adjacent to other vibrating machinery. These

precautions will diminish the possibility of brinelling of the bearing and /or serious

damage shaft damage.

c) It is recommended that fans stored for any length of time should be

Inspected again by the manufacturers representative before installation and start-up.



Chapter V - Installation Instructions

5.1) Concrete Foundations

Check the height and ensure that there is required grouting allowance between the foundation

and the fan base. Suitable pockets should provided for the bolts to be grouted in after

levelling and aligning. For vee belt drives, the foundation bolts should be of adequate length

and well embedded in the concrete. The location of plinth should be checked in relation to

the fan layout drawing. Use steel shims to obtain the correct height; the shims should be of

the same width as base plate and placed each side of and close to foundation bolts.

Pour the grout and ensure that the top of the foundation is covered evenly. If full depth cross

members are fitted, ensure complete support. Remove the shuttering after five days, but

allow the grout to harden for at least ten days. Do not allow the grout to dry not too quickly,

and protect it from direct sunlight. In hot environments it may be necessary to cover the grout

with damp sacks.

Check the coupling alignment and adjust the shimming under the motor feet if necessary.

Record all alignment settings.

The suction and discharge ducting should be connected after the grout has hardened and final

alignment has been completed. The ductwork must line up naturally with the fan

connections. Do not force ductwork into alignment. Remove the ducting connections

adjacent to the fan and clean out the ductwork, as best as possible. Recheck the coupling

alignment with recorded figures and modify the ductwork if required.

5.2) Vibration Isolators

Use of vibration isolators, if recommended, use Dunlop or Polybond make isolators only, of

appropriate capacity by consulting the manufacturer of vibration isolators or as supplied

along with this fan.

5.3) Flexible Connections

If any inlet and / or outlet ducting is to be connected to fan, the same should be connected

through flexible connections. Material of flexible connection should suit the temperature and



other properties of gases handled. Expansion joints should be provided wherever hot gases

are being handled e.g. Flue Gases.

5.4) Fan assembly with common base for Fan & Motor

Lift the assembly & rest it on the foundation block. Align this assembly for exact matching of

Suction & Discharge Centre Line. Insert correct size foundation bolts in the foundation

pockets and through holes in common base.

Level the base frame with spirit level or water level by keeping in mind horizontalness of

discharge flange & verticality of suction flange.

Now pour cement slurry into each foundation pocket around bolt. Allow for setting time of

cement before fan is commissioned.

5.5) Fan assembly with common base for Fan only & separately for Motor

If fan is supplied with separate motor base frame, follow above procedure for foundation,

with due care being taken for alignment of motor pulley and shaft pulley grooves, in one

plane.

5.6) Fan supplied in knocked down condition ( CKD)

If fan is supplied in CKD condition, housing may have been supplied in split condition,

separate shaft assembly, bearing mounting pedestal and separate motor foundation frame etc.

In such a case, foundations will be cast as three separate foundation blocks or composite

block as per drawing,. But all the three components will have to be separately grouted in

following sequence.

5.6.1) Check top levels of all foundation blocks as per drawing.

5.6.2) Keep Lower Half of the casing on the foundation block. Align the same with respect

to its Centre Line.

5.6.3) Keep Bearing Pedestals/Shaft Assembly in place on the foundation.



5.6.4) Fix shaft assembly onto these pedestals and check center line & level of the shaft by

keeping spirit level on the machined surface.

5.6.5) Check all clearances / distances as per drawing.

5.6.6) Insert correct size foundation bolt in place for Casing & Bearing pedestals.

5.6.7) Half grout all foundation bolts with cement slurry and allow for twenty four hours to

set.

5.6.8) Assemble fan impeller on the shaft at one end & driven pulley at the other end with

key & locking washers in place, inlet cone and casing top part.

5.6.9) Spin Impeller to see if the rotation is free and does not bind or rub.

5.6.10) Inspect Impeller to see if it is the proper handing of the fan design.

5.6.11) Due care will be taken to maintain distance (both straight & angular between various

center lines accurately)

5.6.12) Now carry out final grouting of all foundation bolts.

5.6.13) Assemble Inlet Box & Inlet / Outlet dampers, inlet outlet expansion joints, expansion

joints, inlet outlet flexible connections.

5.6.14) Grout the motor foundation frame in place with driving motor & pulley or half

coupling in place.

5.6.15) Align Driving and driven pulleys or Fan shaft & Motor shaft in case of coupled

drive.



Chapter VI - Pre-commissioning & Commissioning Instructions

IMPORTANT

6.1) Ensure that you have following important tools/ equipments / instruments with you

for pre-commissioning.

Metallic Shims Set of Spanners Torque Wrench Measuring Tape

Steel rule Belt Tension Meter Tachometer Ammeter

Voltmeter Megger Dial Gauge Set of Filler Gauges

Spirit Level Plumb Line Hook Spanner

6.2) Start-Up Check List.

Before putting any fan in operation the following operations should be completed.

6.2.1) Check and tighten all foundation bolts.

6.2.2) Check all set screws and tighten if necessary.

6.2.3) Check v-belt drive or coupling for alignment.

6.2.4) Use recommended belt tension.

6.2.5) Check the v-belt drive for proper pulley selection and make sure that they are not

reversed.

6.2.6) Check & confirm that DE shaft bearing is made non-locating.

6.2.7) Make certain that no foreign loose material in ductwork to and from fanor in the

fan itself.

6.2.8) Properly secure all safety guards.

6.2.9) Close any inlet and outlet dampers.

6.2.10) Ensure correct direction of rotation of motor shaft.

6.2.11) In case VIV damper is provided at suction end of fan, confirm that while opening

of damper, air enters suction of fan is with pre-rotation in direction of rotation of

impeller. If this does not happen, get the opening direction of damper changed

suitably. This is very important, which otherwise will result in disturbance in

fan performance.



6.2.12) Check whether the ball bearing are adequately greased as per greasing standards

and locknuts of taper sleeves are tightened and locked properly after checking for

required clearance between Balls / Rollers & Inner / Outer race of each bearing.

6.2.13) In case of vee belt driven fan, NEVER FORCE BELTS OVER PULLEYS OR ROLL

THEM OVER PULLEYS WHILE SHAFT IN ROTATION .

6.2.14) Check electrical wiring for using adequate capacity cable and starter. As

precautionary measure, check following in the presence of authorized person from

electrical department.

6.2.14) Motor name plate details like HP rating, Speed, Full Load Current of Motor to

Concur with recommended specifications.

6.2.15) Confirm that cable size and type is adequate for full load current of motor. Kindly

refer to cable manufacturers catalogue. Improper size or excessive length of

cable will result in excessive voltage drop at the motor terminals.

6.2.16) Check type of starter, relay current setting and confirm its suitability.

6.2.17) Carry out Megger test for electric motor between windings and body. Minimum

resistance should be around 15 to 20 megaohm.

6.3) In case of Double Inlet Double width (DIDW) type fans, confirm that impeller is

correctly mounted on shaft, which will result in Impeller running with fan blades backward

inclined or as marked on Impeller.

6.4) Very Important Points Before Start-up for v-belt driven fans.

6.4.1) Check all pulleys groove surfaces for smoothness. Any sharp edges or burrs

should be filed off, so that outer jacket of vee belt is not damaged.

6.4.2) Correct belt tension as per following table



Tensioning Forces for Wedge Belts

Belt

Section

Small Pulley

Diameter

(mm)

Force required to deflect belt 16mm per meter of span

Newton (N) Kilogram force (kgf)

SPB 160 to224 35 to 50 3.6 to 5.1

236 to 315 50 to 65 5.1 to 6.6

SPC 224 to 355 60 to 90 6.1 to 9.2

375 to 560 90-120 9.2 to 12.2

6.4.3) Check alignment of both pulleys correctly which otherwise will result in rupturing

of outside jacket of vee belts and hence failure of belts very fast.

6.4.3) Under no circumstances ID fan Damper should be opened completely till full

temperature is reached & motor current is below name plate figure.

6.4.5) Important Note – Following precautions will be taken without fail to get

maximum life of v-belts & for smooth operation of fan.

6.4.5.1) Check correct installation and take-up allowance for motor sliding

Slots as per the following table.

Installation and Take-up allowances in mm length

Installation Allowance

in mm

Take up

allowance in mm

Belt Pitch length

in mm

SPB SPC

1510 to 1830 50

1840 to 2170 60

2180 to 3500 75

2840 to 3500 30 100

3520 to 4160 50 125

4170 to 5140 160



6.4.5.2) After tightening of V-belts, measure belt tension with the help of

tension meter as above.

6.4.5.3) Never run V-belt driven fan without applying correct V-belt tension.

6.5) Switch on electrical supply and allow the fan to reach full speed.

6.6) Progressively open damper, making sure that the system continues to function

satisfactorily and motor does not overload.

6.7) Check carefully for

- Correct impeller rotation

- Excessive vibration

- Unusual noise

- If any problem is indicated, switch off the fan. Cut out electrical supply, check

carefully the cause of the trouble, and correct as necessary

6.8) Even if the fan appears to be operating satisfactorily, shut down after brief period and

recheck items from (6.2.1) to (6.2.8) as initial start- up may have relieved tightness of

belts and set screws, again ensuring that electric supply is cut out before attemting

other checks.

6.9) The fan may now put into operation, but during the first eight hours of running it should be

periodically observed and checked for excessive vibration and noise. At the same time checks

should be made on motor input current and motor temperatures to ensure that they do not

exceed manufacturer’s recommendations.

After eight hours of satisfactory operation, the fan should be shut down and the power cut to

check the following items and adjust if necessary.

a) All set screws and foundation bolts including guard fixings.

b) Drive coupling alignment.

c) Vee-Belt drive alignment.

d) Vee- Belt drive tensions should be readjusted to recommended tension.

e) Security of flexible connections.



Chapter VII - Bearing Lubrication

7.1) Grease Lubrication

Fill the space between the balls or rollers with a grease which is suitable for the operating

conditions. The free space around the bearing should normally be between a third and half-

filled with grease. If the bearing is to operate at very high speeds, the quantity of grease in

the free space should be just less than one third. Or, where the bearing is to operate at very

slow speeds, the free space may be completely filled with grease.

An excess supply of grease is not recommended for ball or roller bearings. Heat is generated

more often by too much of lubricants than too little. Heating takes place when rotating parts

move through a large amount of lubricant, especially at high speeds..

7.2) Relubrication:

The service life of lubricating greases is limited. Mechanical stresses and ageing gradually

reduces the lubricity. Ageing concerns mainly on oxidation process accelerated by high

temperatures or the separating of the grease into the base oil & thickener. Morever, during

use, grease becomes impregnated with particles from the rolling & sliding surfaces. It is

therefore necessary in most bearing arrangement to replenish or renew the grease filling

periodically.

The relubrication interval depends on stressing of the grease by friction, speed &

environmental conditions. The relubrication period can be decided by referring to actual

conditions and Bearing Hand Book.

7.3) Amount of relubrication grease

At the moment of relubrication, the bearing generally still contains a certain amount of

grease. In order to avoid excessive greasing with closed housing space, the relubrication

amount must be limited and decrease further if the relubrication intervals are shorter.

In absence of any recommendations, the quantity of grease to be used can be



Calculated from following equation,

G = 0.005 DB gms.

Where, G = Grease quantity, gramms.

D = Bearing outside Diameter, in mm.

B = Bearing width in mm.

7.4) Initial Grease Filling Required Per Bearing

Plummer Block No. Grease Qty. in Grams.

SNA-510 100

SNA-511 130

SNA-512 160

SNA-513 200

SNA-516 250

SNA-517 300

SNA-518 320

SNA-520 350

SNA-522 400

SNA-524 500

SNA-526 600

SNA-528 700

SNA-530 850



Chapter- VIII – Bearings Clearances

The following table gives Bearing Internal Clearance values before and after mounting.

8.1) Internal Radial Clearances of Spherical Roller Bearings with Taper Bore.

Nominal

Bore Size, D

mm

Clearance under zero measured

load in microns

Clearance under load in microns

Foe initial

Normal clearance

Bearings

Foe initial C3

clearance

Bearings

Foe initial

Normal clearance

Bearings

Foe initial C3

clearance

Bearings

30-40 35-40 50-65 15 25

40-50 45-60 60-80 20 30

50-65 55-75 75-95 25 35

65-80 70-95 95-120 25 40

80-100 80-100 110-140 35 50

100-120 100-135 135-170 50 65

120-140 120-160 160-200 55 80

140-160 130-180 180-230 55 90

160-180 140-200 200-260 60 100

8.3) Internal Radial Clearances of Double Row Self Aligned Bearings with Taper

Bore.

Nominal

Bore Size, D

mm

Clearance under zero measured

load in microns

Clearance under load in microns

Foe initial Normal

clearance Bearings

Foe initial C3

clearance

Bearings

Foe initial Normal

Clearance Bearings

Foe initial C3

clearance

Bearings

24-30 15-23 23-33 0 20

30-40 19-29 29-40 0 25

40-50 22-33 33-45 0 30

50-65 27-41 41-56 0 35

65-80 33-50 50-69 0 40

80-100 42-62 62-84 0 50

100-120 50-75 75-100 0 65



Chapter IX - Maintenance Instructions

9.1) AIROCHEM make fan supplied to you is a professionally manufactured piece of machine

and as such will need least maintenance. However, frequency of checking various

components will depend upon conditions like, Nature of gas handled, Temperature of gases,

Speed of rotation & Atmospheric conditions, where the fan is located. Generalization of fsn

maintenance is waste of time. Fans operate in widely differing circumstances with vast array

of materials. The best policy is to initiate a strict, very regular, routine inspection of

equipments and continue this till a pattern of equipment behavior is apparent. At this stage it

may be possible to relax the inspection routine in some areas. In absence of any specific

instructions, the following are suggested.

9.2) Routine Maintenance Chart

EVERY SHIFT When taking over plant at beginning of the shift, operator

should check that all bearings are cool.

EVERY WEEK Check for undue vibration. If present, stop fan at earliest

opportunity and remove the cause.

EVERY 3 MONTHS Check grease lubricated bearings for saponificatoin.

EVERY 6 MONTHS 1) Consult motor manufacturers manual and carry out

instructions.

2) Examine v-belt pulleys for any chipping, tension of v-belts,

OR,

3) Check coupling alignment and condition.

EVERY 12

MONTHS

1) Examine impeller, fan bearings, and inlet cones. Check v-

belts, pulleys, or coupling elements. If any wear, replace as

necessary.

2) Check clearance at impeller, level at shaft, and general

alignment. Adjust as necessary.

3) Check all foundation bolts for tightness.

4) Refer to Motor and control gear manufacturer’s maintenance

instructions and act accordingly.

Grease lubricated bearings should be cleaned out and grease renewed.



9.3) Special Maintenance care for ID Fans

Induced Draft fans of bagasse-fired boilers are normally preceeded by installation of fly ash

removal equipment such as Dry Multiclone Dust Collector, Wet Scrubber or Electrostatic

Precipitator.

These equipments bring down suspended particulate matter in flue gas below specified limits

& thus save impeller of ID fan from abrasion.

However some times due to malfunctioning of such equipments, ID fan impeller does get

eroded fast & this phenomenon has to be watched carefully.

In case Wet Scrubbers installed before ID fan, due care has to be taken to ensure that outlet

flue gas temp. from Wet Scrubber does not fall below 900C to avoid water vapour

condensation. This will result in fast corrosion of not only impeller but casing also.



Chapter X ) List of spares for Two years Operation

(Except Electricals)

Sr.No Description Drg. No Make Material Size Quantity

01 Impeller Assembly 1 No.

02 Shaft with keys and

locking bolts.

1 Set

03 Shaft Bearings 2 Nos.

04 Bearing Housing 1 No.

05 Taper Sleeves with lock

nut.

2 Sets.

06 Locating Rings. 1 Set.

07 Motor Bearings (DE) 1 No.

08 Motor Bearings (NDE) 1 No.

09 Motor Cooling Fan 1 No.

10 Shaft Seal Assembly 1 Set.

11 Bearing Seal Assembly. 1 Set

12 Impeller Lock Nut 1 No.

13 Impeller Fixing Key 1 No.

14 Driving pulley fixing

key.

1 No.

15 Driven pulley fixing key. 1 No.

16 Vee belts 1 Set.

17 Impeller Locking Washer

with bolts.

1 Set

18 Driving Pulley Locking

Washer with bolts.

1 Set.

19 Driven Pulley, Locking

washer with bolts

1 Set.



Chapter XI ) Squirrel Cage Induction Motor Starter Relay

Selection Table

Sr.

No.

Motor H.P. Full load

Current

Amps

Relay Scale

for DOL

starter

in Amps

Relay Scale

for Star Delta

starter

in Amps

Back-up HRC Fuse

Rating for

DOL Delta

Starter Starter

In Amps In Amps.

01 0.5 1.05 1 – 1.6 - 6 -

02 0.75 1.5 1.5 – 2.5 - 6 -

03 1 1.8 1.5 – 2.5 - 6 -

04 1.5 2.5 2.5 – 4 - 10 -

05 2 3.40 2.5 – 4 - 10 -

06 3 4.60 2.5 – 6.5 - 16 -

07 5 7.30 6.0 – 10 - 20 -

08 7.5 10.5 9.0 – 14.0 - 25 -

09 10 14 10 – 16 - 25 -

10 15 20.60 18 – 24 10 – 16 50 35

11 20 28 20 - 32 13 – 21 63 63

12 30 40 28 – 42 20 – 32 100 63

13 40 52 45 – 70 28 – 42 160 100

14 50 64 60 – 100 28 – 42 160 100

15 60 76 - 45 – 70 - 120

16 75 96 - 45 – 70 - 160

17 100 140 - 60 – 100 - 200

18 125 156 - 90 – 150 - 250

19 150 190 - 90 – 150 - 250

20 170 215 - 120 – 200 - 320

21 220 278 - 120 – 200 - 350

22 245 310 - 120 - 200 - 350



23 270 345 - 180 – 300 - 400

24 340 430 - 180 – 300 - 400

Note: - a) Above motor rating in HP are at 415 V, 3PH, 50 HZ supply.

b) Actual ratings value & current may change from manufacturer to manufacturer.



Chapter XII ) Selection of Electrical Cable

Current Ratings (AC) in Amps. for 650 / 1100 volts Armoured or Unarmoured 3 or 3.5 core

Copper / Aluminum cable.

Nominal Cross Current Rating in Amps.

Section Area

sq. mm. Laid in ground at 300C In Air at 400C

Copper Aluminum Copper Aluminum

1.5 21 16 17 13

2.5 27 21 24 18

4.0 36 28 30 23

6.0 45 35 39 30

10.0 60 46 52 40

16.0 77 60 66 51

25.0 99 76 90 70

35.0 120 92 110 86

50.0 145 110 135 105

70.0 175 135 165 130

95.0 210 165 200 155

120.0 240 185 230 180

150.0 270 210 265 205

185.0 300 235 305 240

240.0 345 275 355 280

300.0 385 305 400 315

400.0 425 335 455 375



Chapter XIII -Trouble shooting for Fans

Symptom Possible cause Remedial Action

Fan won’t start Low voltage at motor terminals

Power failure

Blown fuses

Motor single phasing

Control switch contacts open

Check cable size and length

Check all power supplies

Check all fuses

Check motor and wiring

Check all instrument switches in

motor contactoer circuit

Low flow Inlet and/or outlet damper closed

Excessive system resistance

Fan speed very low

Impeller partially blocked

Wrong direction of rotation

Wrong direction of VIV damper rotation

Check dampers position and

correct.

Check calculations, gas temp,

etc.

Check drive, frequency, and

voltage.

Clean impeller and rebalance.

Reverse 2 phases in 3-phase

motor.

Remove viv damper and correct.

High flow System resistance lower than specs.

Fan speed high.

Check calculations, throttle

damper, and reduce fan speed.

Check motor frequency, pulley

ratio.

High power

consumption

High flow

Electrical faults

Check as above.

Voltage frequency incorrect,

check supply.

Motor problem, check motor

High bearing

Temperature

Wrong selection of grease quality.

Over- greasing or under- greasing.

Looseness of sleeve

Improper clearance between outer race

and rollers.

Check and correct.

Fill with proper quantity of

grease.

Tighten sleeve.

Check clearance with filler

gauge and correct.



Outer race rotating in housing. Tighten cap properly or change

plummer block.

Fan vibration Poor alignment

Damaged Impeller

Check for alignment and any

bearing related problems.

Check coupling or v-belt drive

assembly.

Check base plate grouting.

Check ducting.

Check vibration harmonics,

clean and/ or repair impeller,

rebalance

Motor Vibration

Poor alignment

Bearing Problems

Check alignment and coupling/

vee drive assembly.

Check base plate grouting.

Check bearing clearances

Check vibration signature for

bearing faults.

Check motor for loose rotor bars.

ID Fan Manual

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Transcript of ID Fan Manual