Jindal India Thermal Power Limited Integrated Management System

JINDAL INDIA THERMAL POWER LIMITED
INTEGRATED MANAGEMENT SYSTEM

DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF FD FAN
REV.NO : 00
JITPL/SMP/Mech/006 DATE:1.10.2014
1.PURPOSE
: MAINTENANCE OF FD FAN
2.SCOPE
: FD FAN
3.REFERENCE
: JITPL/SMP/Mech/006
Page 1 of 10
Prepared By:
Checked By:
Reviewed By:
Approved By:
NAME:
NAME:
NAME:
NAME:
DESIGNATION:
DESIGNATION:
DESIGNATION:
DESIGNATION:
SIGNATURE:
SIGNATURE:
SIGNATURE:
SIGNATURE:

REV.NO : 00
Page 2 of 10
1.0 Purpose:
This Procedure is intended to provide guidance and instructions for carrying out the F.D Fans
Maintenance
2.0 Constructional Features :
When looking in floor direction, 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, one impeller with blades, the blade bearing assemblies, the
hydraulic impeller blade adjustment system and Main bearing assy (Anti-friction bearings)
Fan Accessories 1. Spring shackle coupling

2. Oil circulation unit
3. Drive Motor
4. Silencers
5. Special Tools, Maintenance devices
Minimum General storage requirements-
SI.No
Fan Component
1
2
Suction Box
Diffuser
Silencer
OGV Assembly
5
6
7
8
9
10
11
Impeller Housing
Shaft with Brg Assy
Impeller and Hydraulic Adjustment device
Spring Shackle coupling
Machined packers and shims
Instruments
Lub oil system
Storage Location
Outdoor(a)
Outdoor(a)
Weather Protected
(b)
Weather Protected
(b)
Weather Protected
(b)
Indoor
Indoor
Indoor
Indoor
Indoor
Indoor
Frequency of
Inspection (D)
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly

REV.NO : 00
Page 3 of 10
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 the rust removing solution (Phosphoric acid 10%)
3. Re-preserve by applying the following :
a) One coat of TRP 1706 rust preventive fluid.
b) After drying, apply one coat of TRP 1710 and
c) After drying, apply one more coat of TRP 1710.
4. Tarpaulin and wooden pieces dis-assembled are not to be used at site.
5. The preserved surfaces shall be wrapped with HDPE (High Density Poly Ethylene) sheets.
6. Keep the shafts in covered storage.
7. Inspect the machined surfaces every month and re preserve as mentioned above.
Procedure for Preservation of Anti-Friction Bearings :
1. The store room must be free from dust.
2. Ideal ambient temperature should be 20 to 30 deg C
3. Relative air humidity should not exceed 60%. It may be necessary to install air
dehumidifier in places where relative humidity is high.
4. If the bearing is found to be dry and dirty, it should be thoroughly washed and cleaned
before re-packing.
5. The bearing should be first kept in a vessel filled with kerosene for about half an hour
and then washed to take out the dirt.
6. It should then be cleaned in another vessel with filtered Kerosene.
7. The final cleaning is to be done by using petrol of mineral turpentine oil.
8. It should be then allowed to dry completely. Pressurised air for cleaning or drying
purpose is not recommended.
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.
Recommended Preservative Components-
Application
Brand Name
Machined Surfaces (Indoor

Storage)
TRP 1706, TRP 1710 HDPE(High Density

poly Ethlene) sheets
Machined Surfaces (Outdoor

Storage)
Weldments
Shaft with bearing assembly
TRP
De-oxy Aluminates
Oil ISO VG 68 Equivalent : SERVO PRIME 68

REV.NO : 00
Page 4 of 10
Maintenance of Fan
Prior to taking the equipment out of service during a planned maintenance program, the
following checks are to be carried out. These checks are designed to help in scheduling the
maintenance activity and to avoid unforeseen delays in re-commissioning the Fan.
Record vibration level on all bearings. Such of those bearings whose vibration levels
are beyond the permissible levels of satisfactory operation may be subjected to
vibration/ signature analysis to carry out the corrective actions.
Ensure the availability of operational data such as vibration level, Bearing
temperature, Motor amperage, blade position etc before stopping the Fan.
Pay Specific attention to any abnormal noise emanating from any of the machine
components like bearings etc.
Observe for any leakage in the fan like oil, air at Fan connections etc. Observe for
any erosion of impeller/ Casing.
Availability of operational spares and other materials in connection with the
observations made above.
After the Fan is stopped the following data may be recorded / ensured for reference
during re commissioning.
Couple alignment.
Marking the assembled components by match marks.
Servo motor operating time.
Actuator linearity w.r.t control room indication and actual blade position.
Between Planned Shutdown :

To ensure the long term proper operation of the Fan various maintenance services are required,
Every 8 operating hours-record the vibration level.
Every 500 operating hours or at least once in three months
Clean the lub oil filter. Clean it before the above mentioned time has elapsed when the
differential pressure contact indicator indicates that the filter is dirty.
Every 2000 operating hours or at least once in six months
Test the oil, if water is found, find the cause and eliminate it.
Every 4000 operating hours or at least once in Year
Retighten all the fixing bolts.

Check the quality of oil, if required, change the oil.
Every 8000 operating hours or after 2 Years-

REV.NO : 00
Page 5 of 10
Check operation the normal inspection and complete over haul.
Forced Shutdown
If the plant shutdown is owing to other parts, it may be possible to inspect the Fan. We
recommend the following jobs.
Check whether there is oil leakage inside the Fan.

Check Impeller blades for wear, If any.
Check whether all blades are equally set when actuating the hydraulic adjustment
device.
Check whether the hydraulic adjustment device is oil tight.
Planned Shutdown
We recommend to effect overhaul for every 8000 to 10000 operating hours or at least once in
two years. This job should be performed under the guidance of the specialist of the Fan
manufacturer.
a) Check on Impellers
b)
c)
d)
e)
f)
g)
Check Impellers and blades for deposits and rust.

Clean the Impeller
Check blade fixing bolts.
Check inlet edge of Impeller blade, for wear.
Check for position and fixation of compensating weights.
Check blade bearings for damages.
Entirely remove old lubricant in blade gearings and fill new lubricant.
Replace sealing elements in blade bearings.
Check lever, slide ring and adjusting disc for wear and inspect jewel bearing
assembly.
Effect all checks as described under between planned shut down and forced shut down
Clean inlet and outlet oil lines.
Eliminate oil leakage
Check the clearance of main bearings.
Ensure free rotation of Fan rotor by hand freely.
Replace correct oil hoses for hydraulic adjustment device if required.
Dismantling and Reassembly-

REV.NO : 00
Page 6 of 10
BHEL specialist should service Fan. Our instructions have only one objective, namely to keep the
Fan ready for operation and to avoid longer standstills. Basic requirements for the installation and
removal of such parts are a clean job and avoidance of any kind of force.
Lubrication InstructionsThe lubricating oil for the fan bearings are supplied by the centralized oil pumps which supply oil
for the hydraulic servomotor also. It must be borne in mind that the quality of oil flowing to the
bearings and its pressure must be maintained as recommended. The flow control device provided
in the oil system ( lube oil inlet fine) is to be covered arid protected.
The oil to be used shall be a turbine quality oil to suit the following specifications :
ISO Viscosity Grade
:
Kinematic Viscosity at 40C
:
Viscosity Index
:
Flash Point
Pour Point
Neutralization No-mg KOH/gm
68
64-72 cst
95 min
: 210C
: -6C (max)
: 0.2
The oil must not foam during operation. Foam removing agents containing silicon must not be
utilised. The oil must have good anti-corrosion properties.
Lubricant FillingFill 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 CheckAt 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 oil tank. Then fill in again the
oil through the fine mesh strainer.
Care of LubricantTest the quality of the oil every month and if found unsatisfactory and oil containing water/dirt
the oil should be changed immediately. The maximum permissible limit of contamination is 100
ppm.

REV.NO : 00
Page 7 of 10
Recommended Lubrication Chart-
SI.N
o
Compone
nt
Lubrican
t
Servo
prime 68
Fan main
Turbinol
bearings and
68
hydraullic
Bharat
adjustment
turbol 68
device.
Tersso
68
Mobil
Glygolye
Blade shaft
30 and
bearing
Mobil
assembly
grease 28/
Burutox
M21
Blade shaft
bearing
Molykote
bushing and microfine
pushrod
graphite
guide
powder
bushing
Bearing
shaft and
indication
shaft
Mobil
grease 28/
Burutox
M21
Blade bolt
and other
bolt
Molykote
1000
paste
Suppli
er
M/s IOC
M/s
HPC
M/s BPC
(Others)
See
note.3
See
note.3
See
note.3
Locatio
n
Frequen
cy
Observati
on
Qty/Fa
n
Oil tank
Once in 2
years or
based on
the oil
quality see
note 2
Daily
See
note 1
Inside
Rotor
During
over haul(
once in 2
years) see
note 4
****
10 Ltr,
1 Kg
Inside
Rotor
During
over haul(
once in 2
years) see
note 4
****
0.5 Kg
Outside
Rotor
During
over haul(
once in 2
years) see
note 4
****
0.2 Kg
Commo
n
0.5 Kg

REV.NO : 00
Page 8 of 10
Notes :
1. Oil quantity depends on tank capacity. Levels marked in the oil tank level guage.
2. The frequency of filling shown is for normal 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 overhaul of the
Fan (usually once in two years). This has to be done only by trained person. BHEL person
may be requisitioned for supervision.
Recommended list of spares
We recommended stocking at least one set of the components per boiler shown in the diagram
of Rotor assembly, Shaft with bearing assembly, and blade bearing assembly, as spare to meet
the O&M requirement apart from having a stock of one assembled set of rotor assembly to meet
emergency requirement.

REV.NO : 00
TECHNICAL DATA SHEET

1
APPLICATION
FORCED AIR FAN
FAN TYPE
FAF 24/11.8-1
NO/BOILER
MEDIUM
LOCATION
FAN DESIGN RATING

CAPACITY (M/S)
ATMOSPHERIC AIR
OUTDOOR
235
TEMP.OF MEDIUM (DEG.C)
50
DENSITY(KG/M)
1.054
SPEED(RPM)
990
TOTAL HEAD DEVELOPED(MMWC)

7
TWO
390
FAN REVERSE
FLOW(%)
42.6
PRESSURE(%)
63.8
SPACER TYPE
8 FAN DRIVE COUPLING

MAKE/TYPE
9
DRIVE MOTOR (VFD)

MAKE
BHEL
TYPE
1LA7800-6P TETV IP6
RATING (KW)
1200
994
SPEED(RPM)
Page 9 of 10

REV.NO : 00
VOLTS (VOLT)
10
Page 10 of 10
6600
LUBRICATING EQUIPMENT
FAN
20 LPM/35BAR FLOS(OIL-ISO VG 69)
MOTOR
GREASE LUBRICATED(SERVOGEM-3)
11 TYPE OF FAN REGULATION
BLADE PITCH CONTROL
12 BEARINGS
FIXED BEARING
7248 C3
FREE BEARING
NU 236 C3

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JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM