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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
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...............
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
Email : nick@simdean.co.uk
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
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.
Section 3
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
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
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:-
55,000 m3/h
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
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.
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
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
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
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
Section 8
Drawings
Control Panel Wiring Diagram
14
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
16
17
18
19
20
21
22
23
24
25
26
Section 9
Control System
27
1 LAD
Offset
%M5.0 "FirstScan"
OUT1
Symbol "Main Fan Control Speed Ref" "Small Fan Control Speed Ref" "FirstScan"
Comment
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Waterbeach 051213
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%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 ...
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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
Waterbeach 051213
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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"
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:
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Owner
Waterbeach 051213
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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
OUT1
OUT1 %M0.6 "Man Run" EN %MW34 "Man Fan 2" IN1 IN2 MUL Int ENO OUT
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
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Waterbeach 051213
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NORM_X Int to Real 0 %IW96 "Pressure sensor small fan inlet" 27648 EN MIN OUT ENO %MD36 "Psmallfan" 1
B
0 %IW100 "Pressure sensor main fan inlet" 27648 EN MIN
EN MIN
EN MIN
27648
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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1
MUL Auto (Real)
1.1 ( Page1 - 7)
B
2 0.0 %MD44 "Pmainlfan" 2500.0 EN MIN VALUE MAX
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
Waterbeach 051213
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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
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"
Comment
Owner
Waterbeach 051213
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Screens
Screen_1
Hardcopy of Screen_1
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Owner
0 Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked Checked
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Waterbeach 051213
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Switch_1
B
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Layout Bottom margin Height Left margin Y position Width Text Font Line break Flashing Flashing Miscellaneous Layer
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Softkey_F2
Type General Authorization LED tag Graphic Function key Global assignment Unchecked Bit in the LED tag 0
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
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D
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Owner
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D
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Owner
I/O field Decimal 999999 Unchecked 218, 218, 218 0, 0, 0 Solid Field length 6 Mode Output Shift decimal point 0
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Checked 123 2 2
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
Owner
Text field Henze scrubber exit Velocity 145, 145, 145 0, 0, 0 1 218, 218, 218 0 16 0 54 175 Tahoma, 12px, style=Bold Unchecked
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Border color Border width Foreground color Layout Bottom margin Height Left margin Y position Width Text Font Line break Flashing Flashing Miscellaneous Layer
Checked 131 2 2
Text field_4
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Waterbeach 051213
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C:\Users\Nick\Documents\Automation\Waterbeach 051213
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Section 10
Proprietary equipment
28
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
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.
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
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.
1)
2)
3) 4) 5) 6)
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.
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
<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
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.
Newton Moor Ind. Est., Newton, Hyde, Cheshire SK14 4LD Tel: 0161 303 3229 Fax: 0161 350 1980
(o/seas replace 0161 with ++4461)
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)
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.
5
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
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.
1) 2) 3)
4) 5) 6) 7)
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.
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.
8
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
<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
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.
10
Small pulley dia mm 59 - 95 100 - 140 80 - 132 140 - 200 112 - 224 236 - 315 224 - 355 375 - 560
TABLE 1.2
DIAGRAM 1.1
11