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Unit 2, Shrewley Farm Five Ways Road Hatton, Warwicks CV35 7AT Tel : +44(0)1926 840233 Fax : +44(0)1926

840237

Operation and Maintenance Manual for Simdean Air Extraction System

Client: Amey Cespa (WM) Ltd , Waterbeach MBT, Cambs Your Ref.: PO.1000000230 and Amey Cespa Sub-contract Order Waterbeach MBT Air Handling Works Our Ref.: Job No. JB 1164-13 Date: December 2013 Issue No: Draft

Simdean Envirotec Ltd.

Index

Section 1................

Introduction & Certificate of Conformity Safety Description Installation Operating Instructions Maintenance Instructions Control System Drawings Control system listing Proprietary Equipment

Section 2 ................ Section 3 ................ Section 4 ................ Section 5 ................ Section 6 ................ Section 7 .. Section 8 ............... Section 9 ................ Section 10...............

Simdean Envirotec Ltd.

Section 1

Introduction
This manual is provided with each Simdean ventilation system to ensure all Personnel who are responsible for its use are conversant with how to operate the unit. We would suggest that the Manual is read in detail and any queries relating to the operation of the air extraction system should be addressed to Simdean Envirotec Ltd. as soon as possible. In addition we would suggest that any queries along with any maintenance work or modifications to the system should be recorded within the Manual. The plant will only operate at optimum efficiency if it is adequately maintained. We would stress that the procedures incorporated into this manual are adhered to.

Note
The descriptions, instructions and drawings within this Manual have been where possible based on the unit installed. In some areas the details relate to a standard carbon adsorber system. If there are areas where it is felt that additional information is required, please do not hesitate to contact our Service Department on the following numbers:Telephone Fax Mobile Telephone +44 (0)1477)537553 +44 (0)1926 840233

+44 (0)1926 840237 +44 (0)7831 807238

Email : nick@simdean.co.uk

Simdean Envirotec Ltd.

Certificate of Conformity
Simdean Envirotec Ltd herby certify that the equipment detailed and referred to in this Operating & Maintenance Manual are either proprietary equipment or products produced within our factory. The equipment where applicable is in conformity with the following standards. All equipment where applicable complies with the Low voltage directive 73/23/EC, EMC Directive 89/336/EC and Machinery Directive 89/392/EEC (Amended 98/37/EEC) and is CE marked Any extract ductwork has been designed manufactured and installed in accordance with HVCA DW154 guidelines We thus certify that the equipment has been designed, supplied, installed and commissioned in conformity with the requirements of the contract between Simdean Envirotec Ltd and Amey Cespa (WM) Ltd

Simdean Envirotec Ltd.

Section 2

Safety
As with all items of Process Plant, care must be taken when carrying out all Maintenance and Operational procedures There are two main areas of potential danger to personnel when operating or maintaining the odour control systems. To ensure complete safety it is important these safety instructions are read and fully understood.

Mechanical
The only moving parts capable of being accessed within the air extraction system are the extract fans. It is important that when carrying out any maintenance procedures on the plant that the system fans are electrically isolated and that the motors cannot be switched on accidentally. .

Electrical
The system fans installed on the system are fitted with 415V 3 ph motors. The control panel is located to the exhaust and as such the exhaust fan motor are both fitted with a local isolator . When working on either of the system fans it is essential that the isolator is switched off and locked to avoid any accidental switching of the isolator thus allowing the motors to become live. The damper actuators are powered at 240 V any work to be performed on these actuators should be performed with the actuators isolated from the electrical supply All other electrical items on the odour control systems are supplied with a voltage of equal to or less than 110V. Although this reduced voltage is used on the plant, we would stress that no electrical work on the system is undertaken without the control panel being isolated from the mains supply unless the person performing the work is a suitably qualified electrician.

Simdean Envirotec Ltd.

Section 3

Odour control systems Description


General
A layout drawing of the equipment is contained within Section 8 of this Operating & Maintenance Manual

Materials of Construction
In general the majority of the extract ducting within the building is constructed from polypropylene sheet. External to the building the interconnecting ducting between the major items of plant are constructed from GRP clad Celmar (fabric backed Polypropylene sheet). The system exhaust fan is constructed with all contact parts manufactured from stainless steel sheet. The use of unprotected ferrous metals has been minimized to ensure corrosion of the system is reduced to a minimum.

Control
Control of the overall system is effected by a relatively simple PLC controller and HMI screen linked to a pair of ABB inverter for speed control of the exhaust fans and pressure and velocity sensors for monitoring of the process variables. The operating and maintenance manual for the control system and the inverter drive are contained in separate sections to this manual with the Control system in Section 7 and the inverter drive details contained within Section 9

Simdean Envirotec Ltd.

Section 4

Installation/Relocation
The system has been installed on site by our own fitters, should any major relocation of the plant be required we would recommend that this is carried out by our personnel. For any minor modifications to the plant we would suggest that you contact us to discuss the most advantageous method

Commissioning
The air flowrate through the odour control system can be adjusted HMI screen on the front of the control panel. Details of how this can be altered are given below:-

HMI Screen

Control Panel layout

Simdean Envirotec Ltd.

Either of the fan speeds can be altered by changing the value of the fan speed Hz. On touching the value in the boxes 2 & 3 a keyboard will pop up and the new value can be entered . Once this has been entered the return or enter key must be pressed, the Keyboard will disappear and the new value will appear in the boxes 2 and /or 3. The values shown in red are the actual speed the fan are running. These are read from the actual inverters and as such are read only values and cannot be altered.

The design values for the total flowrate through the system is as follows:-

Central corridor Extract Air Flowrate

100, 000 m3/h

Additional Extract Air Flowrate

55,000 m3/h

Simdean Envirotec Ltd.

Section 5

Operating Instructions
The simple operation of the odour control system is at present controlled as per the details listed in section 4 of this O&M manual

Pressure drop
The pressure level on the inlet to the fans are measured using a simple pressure sensor located external to the building adjacent to the access stairs on the discharge end of the composting hall,

The sensors used are CMR Controls Ltd P sensors and these indicate the indicate the static pressure within the extract ductwork at 2 locations viz:Inlet to the Main central corridor extract fan Inlet to additional exhaust fan

In addition to the pressure sensors monitoring there are a further 2 off sensors linked to veloprobes. The veloprobes are Stainless Steel are duct velocity sensors which have been designed to be installed in any duct. The Velo Probes work in conjunction with the CMR V-Sensor. As a complete system, the Velo Probes and V-Sensor generate a linear velocity pressure measurement and provide a signal output which is a linear volume flow. The probes are manufactured to measure by CMR. The veloprobes are installed in the ductwork between the Technium scrubbers and the biofilters and also between the Henze scrubber and the biofilter inlets

The operating and Maintenance manuals for the Veloprobes , P sensors and V sensors are Section 9 of this manual

Section 6

Maintenance
In general the air extraction system is relatively maintenance free. However, to keep the system running efficiently it is vital that the other proprietary items of equipment are regularly inspected and serviced. Where appropriate we include the operating and

Simdean Envirotec Ltd.

maintenance manuals for the particular proprietary equipment. These are included in Section 9 of this manual. In general terms we would make the following observations

Ducting
Should be inspected regularly for damage and leakage with particular attention being given to damage of the ductwork at high level within the section of the ductwork within the buildings. The condition of the extract grilles should be examined on a monthly basis to check for any blockage via particulates in the air stream.

System Exhaust fans


The extract fan are central to the operation of the odour control plant and should be regularly inspected and serviced. Please refer to the Operating and Maintenance manual supplied within Section 9 of this manual.

General Maintenance Schedules


The table shown below details the preventative maintenance schedules for the overall plant. For detailed maintenance instructions consult the appropriate proprietary equipment maintenance manuals

Equipment Exhaust Fans & Ducting Verify Speed and ampage of fan on inverter BOP screen Inspect extract grilles in ductwork for build up of particulate or blocking Inspect impellors for signs of excessive vibration, corrosion or solids build up Inspect external housing for signs of corrosion or wear

Daily

Monthly

3 Monthly

Annually

10

Simdean Envirotec Ltd.

System set points

Section 7

Control System
In general the overall control of the system is performed by the PLC controller and HMI screen using an ABB inverter. A separate operating and maintenance manual for the automatic control system is included below. However in the event of the control system failure it is possible to operate the exhaust fan manually. The exhaust fans can be operated in the manual mode as follows It is essential that this is only preformed by a qualified electrician Power down the control panel and open the main door with isolator Open the panel door containing the inverters Shut the main door and switch the isolator back on :Manual mode control Exhaust fans . The inverter control panel is fitted with a BOP (basic operating panel) for the inverter. Whilst the detailed operating and maintenance instructions for the drives are given in section 8 of the inverter manual instructions for changing the speed of the fans via the inverter drive control panel mode are shown below:-

Refer to DriveIT low Voltage AC drives Users manual (an electronic copy is available with the manual together with a hard copy located within the control panel ) The operator panel normally displays the following items on the front face

11

Simdean Envirotec Ltd.

Hand operation is achieved pressing the hand button on the drive panel, switch off of the drive by pressing the off button and Auto by pressing the auto switch. With the inverter in hand operation the speed of the fan can be varied by pressing the up button to increased the frequency and the down button to reduce the frequency of the fan An operating procedure for both resetting of the inverter drive if a fault occurs is shown below

12

Simdean Envirotec Ltd.

A full list of fault conditions fault codes and description and recommended corrective action is covered in Chapter 9 of the User Manual for the drive

Automatic System The control system for the PLC and HMI system is listed below. We would not recommend that alterations are made to this control system unless the person doing so is suitably qualified and are conversant with Siemens control systems . The overall details of the control system are given below in Section 9 of this manual

13

Simdean Envirotec Ltd.

Section 8

Drawings
Control Panel Wiring Diagram

14

Simdean Envirotec Ltd.

Unit 2, Shrewley Farm Five Ways Road Hatton, Warwicks CV35 7AT Tel : +44(0)1926 840233 Fax : +44(0)1926 840237

Control Panel Wiring Diagram for Amey Cespa Waterbeach MBT JB 1164-13 Draft December 2013

15

Simdean Envirotec Ltd.

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Simdean Envirotec Ltd.

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Simdean Envirotec Ltd.

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Section 9

Control System

27

Simdean Envirotec Ltd.

Waterbeach 051213 / Waterbeach_plc1 [CPU 1214C DC/DC/Rly] / Program blocks


Main [OB1]
Main Properties General Name Type Information Title Comment Version Name Temp

Main OB.ProgramCycle "Main Program Sweep (Cycle)" 0.1 Data type

Number Language Author Family User-defined ID Comment

1 LAD

Offset

Network 1: First scan, system run

%M5.0 "FirstScan"

MOVE 0 EN IN ENO %QW4 "Main Fan Control Speed Ref"

OUT1 MOVE 0 EN IN ENO

OUT1

%QW16 "Small Fan Control Speed Ref"

Symbol "Main Fan Control Speed Ref" "Small Fan Control Speed Ref" "FirstScan"

Address %QW4 %QW16 %M5.0

Type Word Word Bool

Comment

Network 2: Safety relay checking

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

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Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

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1-1

%I0.2 "Estop healthy"

%M0.2 "System Healthy" S

%I0.2 "Estop healthy"

%M0.2 "System Healthy" R

Symbol "Estop healthy" "System Healthy"

Address %I0.2 %M0.2

Type Bool Bool

Comment

Network 3: System Start and stop from HMI or Manual

%I0.0 "start button"

%M0.2 "System Healthy"

%M0.3 "System run" S

%I0.1 "stop button"

%M0.3 "System run" R

%M0.2 "System Healthy"

Symbol "System Healthy" "start button" "System run" "stop button"

Address %M0.2 %I0.0 %M0.3 %I0.1

Type Bool Bool Bool Bool

Comment

Network 4: First Scan network to set Inverter


D

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

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Network 4: First Scan network to set Inverter (1.1 / 2.1)

%DB2 "start on delay timer" %M0.3 "System run" T#5S %M0.0 "fan control word init" 16#0476 EN IN OUT1 MOVE 16#0476 EN IN OUT1 %M0.0 "fan control word init" 16#047F EN IN OUT1 MOVE 16#047F EN IN OUT1 %DB3 "PID State Delay Timer" TON Time IN PT Q ET ... ENO %QW14 "Small Fan Control Word" ENO %QW14 "Small Fan Control Word" IN PT TON Time Q ET ...

%M0.0 "fan control word init"

MOVE ENO %QW2 "Main Fan Control Word"

MOVE ENO %QW2 "Main Fan Control Word"

%M0.0 "fan control word init" T#2S

%DB4 "PID State Pulse timer" TP Time T#300MS IN PT Q ET 1 ...

2.1 ( Page1 - 4)
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Network 4: First Scan network to set Inverter (2.1 / 2.1) 1.1 ( Page1 - 3)

1 3

MOVE EN IN OUT1 MOVE 3 EN IN OUT1 ENO "Small_Fan_ Inverter_PID". sRet.i_Mode ENO "Main_Fan_ Inverter_PID". sRet.i_Mode

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

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Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

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Symbol "Main Fan Control Word" "Small Fan Control Word" "fan control word init" "start on delay timer" "PID State Delay Tim er" "PID State Pulse timer" "Main_Fan_Inver ter_PID" "Main_Fan_Inver ter_PID".sRet.i_Mode "Small_Fan_Inver ter_PID" "Small_Fan_Inver ter_PID".sRet.i_Mode "System run"

Address %QW2 %QW14 %M0.0 %DB2 %DB3 %DB4 %DB6

Type Word Word Bool IEC_Timer IEC_Timer IEC_Timer Block_FB Int

Comment

%DB5

Block_FB Int

set to change status (0=Inactive;1=SUT; 2=TIR;3=Automatic;4=Hand) set to change status (0=Inactive;1=SUT; 2=TIR;3=Automatic;4=Hand)

%M0.3

Bool

Network 5:

%M0.3 "System run"

%M0.4 "AutoMan switch"

%M0.5 "Auto run"

%M0.3 "System run"

%M0.4 "AutoMan switch"

%M0.6 "Man Run"

Symbol "System run" "AutoMan switch" "Auto run" "Man Run"

Address %M0.3 %M0.4 %M0.5 %M0.6

Type Bool Bool Bool Bool

Comment

Network 6: Man control of fan speed

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

12/13/2013 10:21:59 AM

Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

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%M0.6 "Man Run" EN %MW30 "Man fan1" 40 %M0.6 "Man Run" EN %MW18 "man fan 3" IN IN1 IN2

MUL Int ENO OUT %MW18 "man fan 3"

MOVE ENO %QW4 "Main Fan Control Speed Ref"

OUT1

%M0.6 "Man Run" EN %MW20 "man fan 4" IN

MOVE ENO %QW16 "Small Fan Control Speed Ref"

OUT1 %M0.6 "Man Run" EN %MW34 "Man Fan 2" IN1 IN2 MUL Int ENO OUT

%MW20 "man fan 4"

C
Symbol "Main Fan Control Speed Ref" "Small Fan Control Speed Ref" "Man Run" "Man fan1" "Man Fan 2" "man fan 3" "man fan 4" Address %QW4 %QW16 %M0.6 %MW30 %MW34 %MW18 %MW20

40

Type Word Word Bool Word Word Word Int

Comment

Network 7: Pressure and Velocity conversions

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

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Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

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Network 7: Pressure and Velocity conversions (1.1 / 2.1)

NORM_X Int to Real 0 %IW96 "Pressure sensor small fan inlet" 27648 EN MIN OUT ENO %MD36 "Psmallfan" 1

VALUE MAX NORM_X Int to Real

B
0 %IW100 "Pressure sensor main fan inlet" 27648 EN MIN

ENO OUT %MD44 "Pmainlfan"

VALUE MAX NORM_X Int to Real

EN MIN

ENO OUT %MD52 "Vsmallfan"

%IW98 "Velocity sensor control small fan" 27648

VALUE MAX NORM_X Int to Real

0 %IW102 "Velocity sensor control main fan"

EN MIN

ENO OUT %MD60 "Vmainfan"

27648

VALUE MAX MUL Auto (Real) EN ENO %MD68 "Small_fan_ volume"

%MD56 "Small_fan_ velocity" 4071.0

IN1 IN2

OUT

MUL Auto (Real) EN %MD64 "Main_fan_ velocity" 7238.0 ENO %MD72 "Main_fan_ volume"

IN1 IN2

OUT

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Owner Projectname Project Path Operator

Waterbeach 051213

Date

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Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

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1
MUL Auto (Real)

Network 7: Pressure and Velocity conversions (2.1 / 2.1)


7238.0 IN2 SCALE_X Real to Real 1 0.0 %MD36 "Psmallfan" 2500.0 EN MIN VALUE MAX OUT ENO %MD40 "Small_fan_ inlet_Pressure"

1.1 ( Page1 - 7)

B
2 0.0 %MD44 "Pmainlfan" 2500.0 EN MIN VALUE MAX

SCALE_X Real to Real ENO %MD48 "Main_fan_ inlet_Pressure"

OUT

SCALE_X Real to Real 3 0.0 %MD52 "Vsmallfan" 20.4 EN MIN VALUE MAX OUT ENO %MD56 "Small_fan_ velocity"

SCALE_X Real to Real 4 0.0 %MD60 "Vmainfan" 20.4 EN MIN VALUE MAX OUT ENO %MD64 "Main_fan_ velocity"

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

12/13/2013 10:21:59 AM

Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

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Sheet

1-8

Symbol Address "Pressure sensor small %IW96 fan inlet" "Psmallfan" %MD36 "Small_fan_inlet_Pres %MD40 sure" "Pressure sensor main %IW100 fan inlet" "Pmainlfan" %MD44 "Main_fan_inlet_Pres %MD48 sure" "Velocity sensor con %IW98 trol small fan" "Vsmallfan" %MD52 "Small_fan_velocity" %MD56 "Velocity sensor con %IW102 trol main fan" "Vmainfan" %MD60 "Main_fan_velocity" %MD64 "Small_fan_volume" %MD68 "Main_fan_volume" %MD72

Type Word Real Real Word Real Real Word Real Real Word Real Real Real Real

Comment

Network 8: Fan speed reading


C
CONV Int to Real EN %IW16 "Small fan actual control speed" ENO %MD76 "small_fan_ speed" %MD76 "small_fan_ speed" 400.0 DIV Auto (Real) EN ENO OUT IN1 IN2 DIV Auto (Real) ENO %MD84 "main_fan_ speed" %MD84 "main_fan_ speed" 400.0 EN ENO OUT IN1 IN2 %MD88 "main_fan_Hz" %MD80 "small_fan_Hz"

OUT IN CONV Int to Real EN

%IW4 "Main fan actual control speed"

OUT IN

Symbol "Small fan actual con trol speed" "small_fan_speed" "small_fan_Hz" "Main fan actual con trol speed" "main_fan_speed" "main_fan_Hz"

Address %IW16 %MD76 %MD80 %IW4 %MD84 %MD88

Type Word Real Real Word Real Real

Comment

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

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Screens
Screen_1
Hardcopy of Screen_1

General Name Grid color Template Layers Active layer Layer_0 Layer_1 Layer_2 Layer_3 Layer_4 Layer_5 Layer_6 Layer_7 Layer_8 Layer_9 Layer_10 Layer_11 Layer_12 Layer_13 Layer_14 Layer_15 Layer_16 Layer_17 Layer_18 Layer_19 Layer_20 Layer_21 Layer_22
Owner

Screen_1 182, 182, 182

Background color Number Tooltip

109, 109, 109 1

0 Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked
Projectname Project Path

Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

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Layer_23 Layer_24 Layer_25 Layer_26 Layer_27 Layer_28 Layer_29 Layer_30 Layer_31

Checked Checked Checked Checked Checked Checked Checked Checked Checked

Switch_1
B
Type General Label text Value status ON Text OFF Appearance Background color Design 3D border style Layout Fit to size X position Width Text Font Switch Switch 1 Manual 72, 72, 72 Checked Unchecked 47 114 Tahoma, 12px, style=Bold Mode Process value Text ON Foreground color Focus color Height Y position Switch with text Auto 255, 0, 31 145, 182, 227 42 15

Vertical alignment Middle Limits Color for High limit 255, 109, 118 violated Miscellaneous Tooltip Name Switch_1 Security Authorization Dynamizations\Tag connection Property name Process value

Horizontal align ment

Centered

Color for Low limit 255, 218, 44 violated Layer 0 - Layer_0

Allow operator con Checked trol Tag AutoMan switch

Text field_1
Type General Text Appearance Background color Border color Border width Foreground color
Owner

Text field Set Main Fan speed Hz 145, 145, 145 0, 0, 0 1 218, 218, 218
Projectname Project Path

Background fill pat Transparent tern 3D border style Unchecked Line style None

Waterbeach 051213

Date

Operator

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Layout Bottom margin Height Left margin Y position Width Text Font Line break Flashing Flashing Miscellaneous Layer

0 16 0 77 144 Tahoma, 12px, style=Bold Unchecked None 0 - Layer_0

Fit to size X position Right margin Top margin

Checked 106 2 2

Horizontal align Left ment Vertical alignment Middle

Name

Text field_1

Text field_2
Type General Text Appearance Background color Border color Border width Foreground color Layout Bottom margin Height Left margin Y position Width Text Font Line break Flashing Flashing Miscellaneous Layer Text field Set Small Fan speed Hz 145, 145, 145 0, 0, 0 1 218, 218, 218 0 16 0 161 147 Tahoma, 12px, style=Bold Unchecked None 0 - Layer_0 Name Text field_2 Background fill pat Transparent tern 3D border style Unchecked Line style None

Fit to size X position Right margin Top margin

Checked 107 2 2

Horizontal align Left ment Vertical alignment Middle

I/O field_1
Type General Display format Format pattern Process value Show leading zeros Appearance Background color Border color
Owner

I/O field Decimal 9999 Unchecked 218, 218, 218 0, 0, 0


Projectname Project Path

Field length 4 Mode Input/output Shift decimal point 1

Background fill pat Solid tern 3D border style Unchecked

Waterbeach 051213

Date

Operator

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Line style Unit Characteristics Hidden input Layout Bottom margin Height Left margin Y position Width Text Font

Solid

Foreground color

36, 36, 36

Unchecked 2 34 5 70 72 Tahoma, 9px, style=Bold Fit to size X position Right margin Top margin Unchecked 14 2 2

Line break Unchecked Limits Color for High limit 255, 0, 31 violated Miscellaneous Tooltip Name I/O field_1 Security Authorization Dynamizations\Tag connection Property name Process value

Horizontal align Centered ment Vertical alignment Middle Color for Low limit 218, 255, 44 violated Layer 0 - Layer_0

Allow operator con Checked trol Tag Man fan1

I/O field_2
Type General Display format Format pattern Process value Show leading zeros Appearance Background color Border color Line style Unit Characteristics Hidden input Layout Bottom margin Height Left margin Y position Width Text Font Line break
Owner

I/O field Decimal 9999 0 Unchecked 218, 218, 218 0, 0, 0 Solid Field length 4 Mode Input/output Shift decimal point 1

Background fill pat Solid tern 3D border style Unchecked Foreground color 36, 36, 36

Unchecked 2 29 5 157 76 Tahoma, 9px, style=Bold Unchecked


Projectname Project Path

Fit to size X position Right margin Top margin

Unchecked 14 2 2

Horizontal align Centered ment Vertical alignment Middle


Date

Waterbeach 051213

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

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Limits Color for High limit 255, 0, 31 violated Miscellaneous Tooltip Name I/O field_2 Security Authorization Dynamizations\Tag connection Property name Process value

Color for Low limit 218, 255, 44 violated Layer 0 - Layer_0

Allow operator con Checked trol Tag Man Fan 2

Softkey_F2
Type General Authorization LED tag Graphic Function key Global assignment Unchecked Bit in the LED tag 0

Dynamizations\Event Event name

Press key

Function list\ActivateScreen
C
Screen name Screen_2 Object number 0

Softkey_F1
Type General Authorization LED tag Graphic Function key Global assignment Unchecked Bit in the LED tag 0

I/O field_3
D
Type General Display format Format pattern Process value Show leading zeros Appearance Background color Border color Line style Unit Characteristics Hidden input Layout Bottom margin Height
Owner

I/O field Decimal 99.9 Unchecked 218, 218, 218 0, 0, 0 Solid Field length 4 Mode Output Shift decimal point 0

Background fill pat Solid tern 3D border style Unchecked Foreground color 255, 0, 31

Unchecked 2 34
Projectname Project Path

Fit to size X position

Unchecked 14
Date

Waterbeach 051213

Operator

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Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

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Left margin Y position Width Text Font

5 112 72 Tahoma, 9px, style=Bold

Right margin Top margin

2 2

Line break Unchecked Limits Color for High limit 255, 0, 31 violated Miscellaneous Tooltip Name I/O field_3 Security Authorization Dynamizations\Tag connection Property name Process value

Horizontal align Centered ment Vertical alignment Middle Color for Low limit 218, 255, 44 violated Layer 0 - Layer_0

Allow operator con Checked trol Tag main_fan_Hz

I/O field_4
Type General Display format Format pattern Process value Show leading zeros Appearance Background color Border color Line style Unit Characteristics Hidden input Layout Bottom margin Height Left margin Y position Width Text Font I/O field Decimal 99.9 Unchecked 218, 218, 218 0, 0, 0 Solid Field length 4 Mode Output Shift decimal point 0

Background fill pat Solid tern 3D border style Unchecked Foreground color 255, 0, 31

Unchecked 2 34 5 195 72 Tahoma, 9px, style=Bold Fit to size X position Right margin Top margin Unchecked 14 2 2

Line break Unchecked Limits Color for High limit 255, 0, 31 violated Miscellaneous Tooltip Name I/O field_4

Horizontal align Centered ment Vertical alignment Middle Color for Low limit 218, 255, 44 violated Layer 0 - Layer_0

Owner

Projectname Project Path

Waterbeach 051213

Date

Operator

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C:\Users\Nick\Documents\Automation\Waterbeach 051213

12/15/2013 3:09:18 PM

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C:\Users\Nick\Documents\Automation\Waterbeach 051213

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Waterbeach 051213

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C:\Users\Nick\Documents\Automation\Waterbeach 051213

12/15/2013 3:09:18 PM

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en-US
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Waterbeach 051213

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

12/15/2013 3:09:18 PM

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en-US
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Waterbeach 051213

Date

Operator

C:\Users\Nick\Documents\Automation\Waterbeach 051213

12/15/2013 3:09:18 PM

Location Designed By Checked By Approved By Description 1st Description 2nd 1st View Language Version

en-US
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Section 10

Proprietary equipment

28

Simdean Envirotec Ltd.

STOCKBRIDGE AIRCO F.S.S Ltd


Operating & Maintenance Instructions for Belt Driven Fans

Newton Moor Ind. Est., Newton, Hyde, Cheshire SK14 4LD Tel: 0161 303 3229 Fax: 0161 350 1980 (o/seas replace 0161 with ++4461) e-mail: fans@ stockbridge-airco.com Web site: www.stockbridge-airco.com

STOCKBRIDGE AIRCO F.S.S Ltd


Newton Moor Ind. Est., Newton, Hyde, Cheshire SK14 4LD Tel: 0161 303 3229 Fax: 0161 350 1980
(o/seas replace 0161 with ++4461)

Web site: www.stockbridge-airco.com


INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS FOR CENTRIFUGAL FANS Covering: Intended use Initial inspection Long term storage Installation and application In service procedures & routine maintenance *Read these instructions first. *Use the correct tools. *Always check that relevant mandatory & voluntary safety practices are observed. *Ensure that guards are fitted before operating equipment. *Rotate fans regularly if they stand idle for long periods. *Isolate and disconnect electricity supply before servicing or any other work is carried out on the unit. *If in doubt contact Stockbridge Airco Ltd Service Dept. To maintain warranty all service & maintenance work must be arranged via STOCKBRIDGE AIRCO FSS LTD!

CAUTION: All necessary steps have been taken to ensure, as far as is practical,
that fans are designed and manufactured to be safe when used properly. These instructions are however, general and it is important that the user observes all statutory plant and other safety requirements. It is further assumed that the fans will be installed and used by appropriately qualified, experienced and competent people, for whom these instructions have been written. STOCKBRIDGE AIRCO FAN(S) MUST BE INSTALLED IN ACCORDANCE WITH OUR OPERATING AND MAINTENANCE INSTRUCTIONS. IN THE ABSENCE OF ANY VIBRATION MEASUREMENT AND VIBRATION TRIP SWITCHES, THE FAN UNIT MUST BE INSPECTED, ON A REGULAR BASIS, AND VIBRATION READINGS TAKEN TO WARN OF ANY POTENTIAL FAILURE (SEE ATTACHMENT A FOR DETAILS). THIS IS ONLY NECESSARY IF THE VIBRATION EQUIPMENT IS NOT PERMANENTLY IN OPERATION & BEING MONITORED BY A SAFETY TRIP SYSTEM. ONUS IS PLACED ON THE OPERATORS & USERS OF THE EQUIPMENT THAT NO FOREIGN BODIES, OTHER THAN THOSE THE FAN IS INTENDED TO HANDLE OR COME INTO CONTACT WITH, WILL ENTER THE SYSTEM.

Intended use
All Airco fans are specifically designed to operate as fully ducted units, inlet & outlet, unless otherwise stated. Units supplied for use as open inlet and/or discharge will be supplied with appropriate guards in place. Under NO circumstances should a unit be used for any other purpose other than that for which it was originally intended without prior consultation and approval in writing from Stockbridge Airco Ltd. Any work undertaken to modify any aspect of the unit, including purposes of use, must not take place without prior consultation and written approval from Stockbridge Airco FSS Ltd, failure to do so will render any warranty, guarantee and CE marking (if applicable) invalid. NOTES Use only Stockbridge Airco spares to maintain warranty.

If in doubt please contact our Service Department.

1) Inspection on delivery 1.1 1.2 Thoroughly inspect the fan for signs of transit damage. Loose fasteners, chipped paint and external damage can often indicate potentially serious damage to the fan set. Report shortage or damage to the carrier and Stockbridge Airco Ltd before signing for receipt of the equipment.

2) Storage NOTE if the fan cannot be installed soon after delivery: 2.1 2.2 2.3 2.4 Always store the right way up. Protect bearings against ingress of moisture, heat, dirt or other foreign materials. Protect exposed metal parts against atmospheric corrosion and rust. Cover all openings to prevent loose materials entering the fan case or interfering with the impeller. 2.5 Turn fan and motor slowly, check that they rotate freely at least once per week, this should help prevent brinelling of the races. 2.6 Do not store near vibrating machinery or bearings may suffer damage of the same kind. 2.7 Stand by fan sets should be used in conjunction with main fan sets where possible.

3) Pre Assembly Inspection 3.1...Check all fasteners for tightness. 3.2 Confirm that bearings have adequate lubricant. 3.3 Remove any loose materials from inside the fan case.Turn fan slowly and ensure that the impeller rotates freely, is in balance and does not fall back when released. 3.4 Confirm that the fan will be used on the application for which it was originally specified. 3.5 Check that the correct tools and lifting gear are available. 4) Location and Site Installation 4.1 Do not drop or jar the fan. 4.2 Use the lugs provided to lift if using mechanical lifting aids to avoid distortion. DO NOT LIFT BY SHAFT, MOTOR OR IMPELLER. 4.3 Where fans are supplied with Anti-Vibration mounts they MUST be used. 4.4 Plug fans or Fans not supplied with Anti Vibration mountings should be rigidly mounted with no casing distortion. This is particularly important where the fan is driven through a coupling. Distortion of the fan during mounting will cause misalignment & damage to the coupling. 4.5 Fan units mounted on elevated structures must be rigidly fixed to a mass at least six times the mass of the rotating parts. The structure must be cross-braced for live load support. 4.6 The fan must not carry, nor be carried by the associated ductwork without prior consultation with Stockbridge Airco Ltd.

5) Fitting the Fan 5.1 5.2 5.3 Position the fan on site and tighten all fasteners. Wire up the motor according to manufacturers instructions. Adjust starter overload trips accordingly. When fitting the fan unit ensure that there is adequate air space around the motor end cowl for cooling.

6) Starting up 6.1 Check the clearance between the impeller and inlet cone, it should be equal all around, if not adjust as necessary. 6.2 Check that bearings have sufficient lubricant. 6.3 Rotate fan and motor slowly, check that they both turn freely. 6.4 Where flexible connections are fitted they must be smooth and free from protrusion into the airway and between connected parts. They must not be used as a means of connecting misaligned parts. 6.5 Check status of dampers. Start centrifugal fans only against closed dampers for reduced power start up requirements. FOR HOT AIR FANS WHERE MOTOR IS SELECTED FOR HIGH TEMPERATURE CONDITIONS THIS IS MANDATORY. 6.6 Before starting check that all 3 phases are live at starter terminals connected to 3 phase machines. 6.7 Start up fan and confirm that it rotates in the right direction without excessive vibration.

The fan is now ready for service and with regular maintenance should run trouble free. (Please contact our service dept for details on maintenance contracts).
7) In service procedures and routine maintenance 7.1 The fan should not be operated in conditions outside of those for which it was originally specified. Severe throttling of the airflow can lead to inefficient and uncontrollable operation. 7.2 Air entering the fan should be thoroughly mixed. The temperature differential between any two points in the impeller should not exceed 10 deg C. The rate of change of air temperature entering the fan should not exceed 15 o C per minute. 7.3 Investigate and rectify any vibration as soon as possible. Excessive vibration is a sign of incorrect running and will cause damage.Table 1.1 is a general guide to acceptable vibration levels. 7.4 Inspect impellers every 3 months for signs of excessive vibration, corrosion or solids build up which can detract from fan performance and cause out of balance vibration. 7.5 Inspect metal parts for signs of wear or corrosion every 3 months. 7.6 DO NOT shut down fan immediately after a period of hot running (140C +). Leave fan running while system cools to ambient temp. 7.7 Follow recommended lubrication schedule (attached if applicable) This is a general guide only.

Trouble shooting
Dont forget that where a fan system is not functioning properly there may be more than one cause. Look for all possible causes and eliminate systematically. Fan system malfunction may show up as one or more of the following. Insufficient air flow Too much air flow High power consumption Bad starting Air surging, noise or vibration

Insufficient air flow


At correct operating speed this is usually accompanied by reduced power consumption on centrifugal fans, especially on those having forward curved or radial tipped blades. Power consumption is less affected on centrifugal fans having backward curved blades and can, in some cases of unusual application, be slightly increased. This can also be the case with some axial fans. Action list. 1) Check running of rotation. A centrifugal fan running backwards will Still blow some air through the system. A suggestion : Only a few mm of shaft is ever exposed, drop one end of a ruler onto it, a kick to one side will indicate direction of rotation. 2) Check impeller handing. 3) Check running speed. 4a) Choose a straight section of ducting, where disturbance from upstream conditions is likely to be minimal, preferably upstream of the fan, and traverse by pilot tube to determine the actual volume. 4b) Measure total pressure on the inlet side and static pressure on the outlet as appropriate. The algebraic difference is the fan static pressure. 4c) Check 4a and 4b against design data. 4) If 4a is LOW and 4b is EQUAL TO OR GREATER THAN design pressure the main fault probably lies in the system away from the fan beyond the test points. Explore sections of the system to identify points of excessive loss. This can be done y taking static or total pressure measurements at strategic points in the system. Apart from inaccurate estimation of normal losses excessive losses may arise from: 5.1) Badly adjusted dampers. 5.2) Two or more bends, obstructions or changes of section in close proximity. 5.3) An inlet or outlet grille or guard of excessive density, e.g. due to air flow contraction through sharp openings a punched or expanded metal guard over an opening may have an effective free area 30% or more below its measured free area. 5.4) An overloaded filter. 5.5) An accumulation of foreign matter. 5.6) Air swirl.

5.7) Air swirl followed by a contraction. (Very bad) 5.8) Less than a 2.5D length of straight duct at the fan discharge. Action for elimination of 5.6 & 5.7 fit anti swirl device. 6) If both 4a and 4b are low the main fault probably lies in the fan or its immediate connections though system faults may also contribute. Having made checks 1,2 and 3 proceed with further checks as follows: Check for foreign matter in impeller. Check flexible connections or jointing at fan inlet and outlet to see that there is no intrusion in the airway. Is leakage or recirculation between test points and fan causing reduced effective flow. (Inc. leakage at test holes) Swirl at fan inlet in same direction as rotation will cause reduced air flow and pressure. Adverse factors at inlet e.g. bend or offset Adverse factors at outlet e.g. sudden expansion, bend or other obstruction which does not permit recovery of flow distribution to a normal pattern. Is the fan rated for the density of air gas it is handling? A fan rated for handling cold air at sea level will develop reduced pressure at altitude or if handling hot gas.

7) 8) 9) 10) 11) 12) 13)

Too much air flow


At correct operating speed this causes excessive power consumption on forward curved centrifugal fans. Power consumption is also high on radial tipped centrifugal fans but it is not affected on most backward curved centrifugal fans. Power may be slightly reduced on some axial fans. Action list: Check impeller handing. A backward curved or inclined impeller (centrifugal) of the wrong hand running as forward curved will give too much air and take excessive power. Choose a straight section of ducting where disturbance from upstream conditions is likely to be minimal and traverse by pilot tube to determine the actual air flow. Compare this with the design volume rating. The degree of excessive volume may provide a clue to the cause, e.g. up to about 10% above design rating may indicate over estimation of system resistance. A significantly higher disparity may indicate a major system fault. Dampers or registers not set correctly or system components not installed. Air leakage beyond test point. Bypass damper not fully closed. Over estimation of system resistance. Slow down fan or close dampers until required duty is achieved.

1)

2)

3) 4) 5) 6)

Power consumption high


May occur with any of the following: 1) 2) 3) 4) 5) A centrifugal fan having forward curved, radial or nearly radial tipped blades handling too much air. A centrifugal fan having backward curved blades running in the wrong direction or wrong hand impeller running correctly. Swirl at fan inlet in the opposite direction to fan rotation. Single phasing on a 3phase motor. (A supply fault) Any A.C. motor running below its design speed due to a winding or starting fault, or low supply voltage.

Bad starting
May arise due to one of the causes in previous section but may also arise from: 1) 2) 3) 4) 5) 6) Low supply voltage Starting voltage tappings too low on auto-transformer starter. Wrong type of fuses fitted. A motor fault. Failure to take full account of inertia of fan and drive components in motor selection. Wrong capacitor value.

With all centrifugal fans closing the system dampers until full speed has been achieved can reduce the starting load.

Air surging, noise or vibration.


Air surging results from instability of flow and may arise from various causes, among which are the following: 1) 2) 3) Hunting of fans in parallel operation. An obstruction or bad connection at fan inlet creating unstable air entry (e.g. reversed vortex condition). Alternate break away and re-attachment of flow to walls of a diverging airway.

Noise
Noise arises to some degree from practically every fan but is only a problem when its level is unacceptable. It may be generated as air noise, mechanical noise or electrical hum or a combination of all three. While air noise can be aggravated by some obstruction in close proximity to the inlet or outlet of the fan it most commonly results from unsuitable selection of the fan. This latter condition can only be cured by substituting a quieter fan (usually larger diameter lower speed) or by applying sound attenuating techniques. Mechanical Noise Mechanical noise can arise from moving parts touching, faulty or wrongly selected bearings, panel vibration etc. Causes are usually self-evident but a stethoscope can be very useful in checking noise from bearings or motors. Electrical Noise Electrical noise can arise from eccentricity between rotor and stator, porosity or faults in rotor castings, vibration if winding etc. It is nearly always present to some extent. Certain types and sizes of singlephase motor can be particularly troublesome from this point of view. Noise can be greatly increased or decreased according to method of mounting.

Vibration
Vibration at an unacceptable level can arise from genuine out-of-balance or from an unsuitable mounting structure or a combination of both. When a natural frequency of a mounting structure is somewhere near the fan running speed no amount of accurate balancing will cure the problem. Steps must be taken to strengthen the structure or in some way significantly alter its natural frequency (e.g. adding weight). For genuine out-of-balance contact Stockbridge Airco Ltd. Vibration Level guide

Condition

Velocity (mm/sec) RMS

<15kw 15kw> Very good <0.7 <1.8 Good 0.7 - 1.8 1.8 - 4.5 Fair 1.8 - 4.5 4.5 - 7.1 Plan for attention as soon as possible Poor >4.5 >7.1 Requires attention urgently
TABLE 1.1

Volume control devices


Inlet dampers These can be fitted in the ductwork and should be at least 6 equivalent diameters from the inlet. Parallel blade dampers may, however, be used in an inlet box and should be installed with the blades in parallel with the fan shaft so that when closing they create swirl in the direction of fan rotation producing a similar effect to inlet vane control. Inlet vane control To maintain a fair degree of fan efficiency at reduced airflow conditions, this form of control is used on the fan inlet itself. When partially closed it creates a spin in the same direction as the impeller rotation, which reduces the pressure/volume characteristic of the fan. When it is intended to use this type of control Stockbridge Airco should approve it.

Outlet dampers It is generally recommended that, where outlet dampers are required, the opposed blade damper should be utilised. Both parallel and opposed blade dampers are suitable for fitting to the fan outlet although 2 diameters of duct between the fan outlet and damper is preferred, provided the effect of the damper on the flow pattern in the subsequent system is appreciated.

STOCKBRIDGE AIRCO F.S.S Ltd


Operating & Maintenance Instructions for Belt Driven Fans

Newton Moor Ind. Est., Newton, Hyde, Cheshire SK14 4LD Tel: 0161 303 3229 Fax: 0161 350 1980
(o/seas replace 0161 with ++4461)

e-mail: fans@@ @ stockbridge-airco.com Web site: www.stockbridge-airco.com

STOCKBRIDGE AIRCO F.S.S Ltd


Newton Moor Ind. Est., Newton, Hyde, Cheshire SK14 4LD Tel: 0161 303 3229 Fax: 0161 350 1980
(o/seas replace 0161 with ++4461)

Web site: www.stockbridge-airco.com


INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS FOR CENTRIFUGAL & AXIAL FANS Covering: Intended use Initial inspection Long term storage Installation and application In service procedures & routine maintenance *Read these instructions first. *Use the correct tools. *Always check that relevant mandatory & voluntary safety practices are observed. *Ensure that guards are fitted before operating equipment. *Rotate fans regularly if they stand idle for long periods. *Isolate and disconnect electricity supply before servicing or any other work is carried out on the unit. *If in doubt contact Stockbridge Airco FSS Ltd Service Dept. To maintain warranty all service & maintenance work must be arranged via STOCKBRIDGE AIRCO FSS LTD!

CAUTION: All necessary steps have been taken to ensure, as far as is practical, that
fans are designed and manufactured to be safe when used properly. These instructions are however, general and it is important that the user observes all statutory plant and other safety requirements. It is further assumed that the fans will be installed and used by appropriately qualified, experienced and competent people, for whom these instructions have been written. STOCKBRIDGE AIRCO FAN(S) MUST BE INSTALLED IN ACCORDANCE WITH OUR OPERATING AND MAINTENANCE INSTRUCTIONS. IN THE ABSENCE OF ANY VIBRATION MEASUREMENT AND VIBRATION TRIP SWITCHES, THE FAN UNIT MUST BE INSPECTED, ON A REGULAR BASIS, AND VIBRATION READINGS TAKEN TO WARN OF ANY POTENTIAL FAILURE (SEE ATTACHMENT A FOR DETAILS). THIS IS ONLY NECESSARY IF THE VIBRATION EQUIPMENT IS NOT PERMANENTLY IN OPERATION & BEING MONITORED BY A SAFETY TRIP SYSTEM. ONUS IS PLACED ON THE OPERATORS & USERS OF THE EQUIPMENT THAT NO FOREIGN BODIES, OTHER THAN THOSE THE FAN IS INTENDED TO HANDLE OR COME INTO CONTACT WITH, WILL ENTER THE SYSTEM.

Intended use
All Airco fans are specifically designed to operate as fully ducted units, inlet & outlet, unless otherwise stated. Units supplied for use as open inlet and/or discharge will be supplied with appropriate guards in place. Under NO circumstances should a unit be used for any other purpose other than that for which it was originally intended without prior consultation and approval in writing from Stockbridge Airco FSS Ltd. Any work undertaken to modify any aspect of the unit, including purposes of use, must not take place without prior consultation and written approval from Stockbridge Airco Ltd, failure to do so will render any warranty, guarantee and CE marking (if applicable) invalid. NOTES Use only Stockbridge Airco spares to maintain warranty.
SEALANT USED ON FANS High Velocity Duct Sealant 40-113 Manufacturer Bostik Findley Ltd (Stafford UK)

If in doubt please contact our Service Department.

1) Inspection on delivery 1.1 1.2 Thoroughly inspect the fan for signs of transit damage. Loose fasteners, chipped paint and external damage can often indicate potentially serious damage to the fan set. Report shortage or damage to the carrier and Stockbridge Airco Ltd before signing for receipt of the equipment.

2) Storage NOTE if the fan cannot be installed soon after delivery: 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Always store the right way up. Protect bearings against ingress of moisture, heat, dirt or other foreign materials. Protect exposed metal parts against atmospheric corrosion and rust. Cover all openings to prevent loose materials entering the fan case or interfering with the impeller. Take the tension out of the fan belts. Turn fan and motor slowly, check that they rotate freely at least once per week, this should help prevent brinelling of the races. Do not store near vibrating machinery or bearings may suffer damage of the same kind. Stand by fan sets should be used in conjunction with main fan sets where possible.

3) Pre Assembly Inspection 3.1...Check all fasteners for tightness. 3.2 Check belt tension.(Table 1.2 & Diagram 1.1, Page 10) 3.3 Confirm that bearings have adequate lubricant. 3.4 Remove any loose materials from inside the fan case. 3.5 Turn fan slowly and ensure that the impeller rotates freely, is in balance and does not fall back when released. 3.6 Confirm that the fan will be used on the application for which it was originally specified. 3.7 Check that the correct tools and lifting gear are available. 4) Location and Site Installation 4.1 Do not drop or jar the fan. 4.2 Use the lugs provided to lift if using mechanical lifting aids to avoid distortion. DO NOT LIFT BY SHAFT, MOTOR OR IMPELLER. 4.3 Where fans are supplied with Anti-Vibration mounts they MUST be used. 4.4 Plug fans or Fans not supplied with Anti Vibration mountings should be rigidly mounted with no casing distortion. This is particularly important where the fan is driven through a coupling. Distortion of the fan during mounting will cause misalignment & damage to the coupling. 4.5 Fan units mounted on elevated structures must be rigidly fixed to a mass at least six times the mass of the rotating parts. The structure must be cross-braced for live load support. 4.6 The fan must not carry, nor be carried by the associated ductwork without prior consultation with Stockbridge Airco Ltd.

5) Fitting the Fan 5.1 5.2 5.3 5.4 Position the fan on site and tighten all fasteners. Wire up the motor according to manufacturers instructions. Adjust starter overload trips accordingly. When fitting the fan unit ensure that there is adequate air space around the motor end cowl for cooling. For belt driven fans check pulley alignment and tension. See recommendations for Fenner belt drives. (Table 1.2 & diagram 1.1, page 10)

6) Starting up 6.1 Check the clearance between the impeller and inlet cone, it should be equal all around, if not adjust as necessary. 6.2 Check that bearings have sufficient lubricant. 6.3 Rotate fan and motor slowly, check that they both turn freely. 6.4 Where flexible connections are fitted they must be smooth and free from protrusion into the airway and between connected parts. They must not be used as a means of connecting misaligned parts. 6.5 Check status of dampers. Axial fans may stall against closed damper Conditions. Start centrifugal fans only against closed dampers for reduced power start up requirements. FOR HOT AIR FANS WHERE MOTOR IS SELECTED FOR HIGH TEMPERATURE CONDITIONS THIS IS MANDATORY. Note - Severe throttling of the airflow can lead to inefficient and uncontrollable operation. 6.6 Before starting check that all 3phases are live at starter terminals connected to 3phase machines. 6.6 Start up fan and confirm that it rotates in the right direction without excessive vibration or belt slip. 6.8 Run for about 30 minutes, stop the fan and check belt tension, adjust if necessary. (see page10) 6.9 Run for a further 24hr cycle, stop the fan and check belt tension, adjust if necessary. (see page10) 6.10 The fan is now ready for service and with regular maintenance should run trouble free. (Please contact our service dept for details on maintenance contracts). 7) In service procedures and routine maintenance 7.1 The fan should not be operated in conditions outside of those for which it was originally specified. 7.2 Air entering the fan should be thoroughly mixed. The temperature differential between any two points in the impeller should not exceed 10 deg C. The rate of change of air temperature entering the fan should not exceed 15 oC per minute. 7.3 Investigate and rectify any vibration as soon as possible. Excessive vibration is a sign of incorrect running and will cause damage.Table 1.1 is a general guide to acceptable vibration levels. 7.4 Inspect impellers every 3 months for signs of excessive vibration, corrosion or solids build up which can detract from fan performance and cause out of balance vibration. 7.5 Inspect metal parts for signs of wear or corrosion every 3 months. 7.6 Check drive belt tension after 24hrs and 1week. Check monthly for signs of damage or fretting. 7.7 DO NOT shut down fan immediately after a period of hot running (140C +). Leave fan running while system cools to ambient temp. 7.8 Follow recommended lubrication schedule (attached if applicable) This is a general guide only. 7.9 Belt drive axials use sealed for life bearings and therefore should not be lubricated as this invalidates bearing warranty.
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Trouble shooting
Dont forget that where a fan system is not functioning properly there may be more than one cause. Look for all possible causes and eliminate systematically. Fan system malfunction may show up as one or more of the following. Insufficient air flow Too much air flow High power consumption Bad starting Air surging, noise or vibration

Insufficient air flow


At correct operating speed this is usually accompanied by reduced power consumption on centrifugal fans, especially on those having forward curved or radial tipped blades. Power consumption is less affected on centrifugal fans having backward curved blades and can, in some cases of unusual application, be slightly increased. This can also be the case with some axial fans. Action list. 1) Check running of rotation. A centrifugal fan running backwards will Still blow some air through the system. A suggestion : Only a few mm of shaft is ever exposed, drop one end of a ruler onto it, a kick to one side will indicate direction of rotation. 2) Check impeller handing. 3) Check running speed and that belts are not slipping. 4a) Choose a straight section of ducting, where disturbance from upstream conditions is likely to be minimal, preferably upstream of the fan, and traverse by pilot tube to determine the actual volume. 4b) Measure total pressure on the inlet side and static pressure on the outlet as appropriate. The algebraic difference is the fan static pressure. 4c) Check 4a and 4b against design data. 4) If 4a is LOW and 4b is EQUAL TO OR GREATER THAN design pressure the main fault probably lies in the system away from the fan beyond the test points. Explore sections of the system to identify points of excessive loss. This can be done y taking static or total pressure measurements at strategic points in the system. Apart from inaccurate estimation of normal losses excessive losses may arise from: 5.1) Badly adjusted dampers. 5.2) Two or more bends, obstructions or changes of section in close proximity. 5.3) An inlet or outlet grille or guard of excessive density, e.g. due to air flow contraction through sharp openings a punched or expanded metal guard over an opening may have an effective free area 30% or more below its measured free area. 5.4) An overloaded filter. 5.5) An accumulation of foreign matter. 5.6) Air swirl. 5.7) Air swirl followed by a contraction. (Very bad) 5.8) Less than a 2.5D length of straight duct at the fan discharge. Action for elimination of 5.6 & 5.7 fit anti swirl device.
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6)

7) 8) 9) 10) 11) 12) 13)

If both 4a and 4b are low the main fault probably lies in the fan or its immediate connections though system faults may also contribute. Having made checks 1,2 and 3 proceed with further checks as follows: Check for foreign matter in impeller. Check flexible connections or jointing at fan inlet and outlet to see that there is no intrusion in the airway. Is leakage or recirculation between test points and fan causing reduced effective flow. (Inc. leakage at test holes) Swirl at fan inlet in same direction as rotation will cause reduced air flow and pressure. Adverse factors at inlet e.g. bend or offset Adverse factors at outlet e.g. sudden expansion, bend or other obstruction which does not permit recovery of flow distribution to a normal pattern. Is the fan rated for the density of air gas it is handling? A fan rated for handling cold air at sea level will develop reduced pressure at altitude or if handling hot gas.

Too much air flow


At correct operating speed this causes excessive power consumption on forward curved centrifugal fans. Power consumption is also high on radial tipped centrifugal fans but it is not affected on most backward curved centrifugal fans. Power may be slightly reduced on some axial fans. Action list: Check impeller handing. A backward curved or inclined impeller (centrifugal) of the wrong hand running as forward curved will give too much air and take excessive power. Fan speed too high? (Pulleys wrong size or interchanged). Choose a straight section of ducting where disturbance from upstream conditions is likely to be minimal and traverse by pilot tube to determine the actual air flow. Compare this with the design volume rating. The degree of excessive volume may provide a clue to the cause, e.g. up to about 10% above design rating may indicate over estimation of system resistance. A significantly higher disparity may indicate a major system fault. Dampers or registers not set correctly or system components not installed. Air leakage beyond test point. Bypass damper not fully closed. Over estimation of system resistance. Slow down fan or close dampers until required duty is achieved.

1) 2) 3)

4) 5) 6) 7)

Power consumption high


May occur with any of the following: 1) 2) 3) 4) 5) 6) A centrifugal fan having forward curved, radial or nearly radial tipped blades handling too much air. A centrifugal fan having backward curved blades running in the wrong direction or wrong hand impeller running correctly. Swirl at fan inlet in the opposite direction to fan rotation. A fine pitch axial fan operating against excessive back pressure. Single phasing on a 3phase motor. (A supply fault) Any A.C. motor running below its design speed due to a winding or starting fault, or low supply voltage.

Bad starting
May arise due to one of the causes in previous section but may also arise from: 1) 2) 3) 4) 5) 6) Low supply voltage Starting voltage tappings too low on auto-transformer starter. Wrong type of fuses fitted. A motor fault. Failure to take full account of inertia of fan and drive components in motor selection. Wrong capacitor value.

With all centrifugal fans closing the system dampers until full speed has been achieved can reduce the starting load. This does not apply to axial fans.

Air surging, noise or vibration.


Air surging results from instability of flow and may arise from various causes, among which are the following: 1) 2) 3) 4) 5) An axial fan operating far back on its characteristic in stall. Most other fan types operating near zero volume condition. Hunting of fans in parallel operation. An obstruction or bad connection at fan inlet creating unstable air entry (e.g. reversed vortex condition). Alternate break away and re-attachment of flow to walls of a diverging airway.

Noise
Noise arises to some degree from practically every fan but is only a problem when its level is unacceptable. It may be generated as air noise, mechanical noise or electrical hum or a combination of all three. While air noise can be aggravated by some obstruction in close proximity to the inlet or outlet of the fan it most commonly results from unsuitable selection of the fan. This latter condition can only be cured by substituting a quieter fan (usually larger diameter lower speed) or by applying sound attenuating techniques.
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Mechanical Noise Mechanical noise can arise from moving parts touching, faulty or wrongly selected bearings, panel vibration etc. Causes are usually self-evident but a stethoscope can be very useful in checking noise from bearings or motors.

Electrical Noise Electrical noise can arise from eccentricity between rotor and stator, porosity or faults in rotor castings, vibration if winding etc. It is nearly always present to some extent. Certain types and sizes of singlephase motor can be particularly troublesome from this point of view. Noise can be greatly increased or decreased according to method of mounting.

Vibration
Vibration at an unacceptable level can arise from genuine out-of-balance or from an unsuitable mounting structure or a combination of both. When a natural frequency of a mounting structure is somewhere near the fan running speed no amount of accurate balancing will cure the problem. Steps must be taken to strengthen the structure or in some way significantly alter its natural frequency (e.g. adding weight). For genuine out-of-balance contact Stockbridge Airco FSS Ltd. Vibration Level guide

Condition

Velocity (mm/sec) RMS

<15kw 15kw> Very good <0.7 <1.8 Good 0.7 - 1.8 1.8 - 4.5 Fair 1.8 - 4.5 4.5 - 7.1 Plan for attention as soon as possible Poor >4.5 >7.1 Requires attention urgently
TABLE 1.1

Volume control devices


Inlet dampers These can be fitted in the ductwork and should be at least 6 equivalent diameters from the inlet. Parallel blade dampers may, however, be used in an inlet box and should be installed with the blades in parallel with the fan shaft so that when closing they create swirl in the direction of fan rotation producing a similar effect to inlet vane control. Inlet vane control To maintain a fair degree of fan efficiency at reduced airflow conditions, this form of control is used on the fan inlet itself. When partially closed it creates a spin in the same direction as the impeller rotation, which reduces the pressure/volume characteristic of the fan. When it is intended to use this type of control Stockbridge Airco should approve it.

Outlet dampers It is generally recommended that, where outlet dampers are required, the opposed blade damper should be utilised. Both parallel and opposed blade dampers are suitable for fitting to the fan outlet although 2 diameters of duct between the fan outlet and damper is preferred, provided the effect of the damper on the flow pattern in the subsequent system is appreciated.

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Fenner belt tension guide


The belt will be tensioned correctly when the applied force (Newtons), deflects the belt at its mid-point by a distance D, calculated from: D mm = 16 x pulley centre span (m) Force N to deflect belt 16mm/span

Belt type SPZ SPA SPB SPC

Small pulley dia mm 59 - 95 100 - 140 80 - 132 140 - 200 112 - 224 236 - 315 224 - 355 375 - 560

Force/Newton 13 - 20 20 - 25 25 - 35 35 - 45 45 - 65 65 - 85 85 - 115 115 - 150

Belt tension indicator To mid centre distance (16mm deflection/1metre span)

TABLE 1.2

DIAGRAM 1.1
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