1949说明书(英文)

INSTRUCTION OF SAF（PROJECT NO.1949）TYPE：14144AZ/2315SHANGHAI BLOWER WORKS CO.LTDFEB,2011CATALOGUE1、 INSTRUCTION1.1、 GENERAL1.2、 DATA SHEET & PERFORMANCE CURVE1.3、 INTRODUCTION OF FAN STRUCTURE1.3.1、IMPELLER1.3.2、MAIN SHAFT1.3.3、BEARING 1.3.4、COUPLING1.3.5、CASING 1.3.6、INLET CONE1.3.7、INLET VANE CONTROL1.3.8、SEALING1.3.9、SILENCER2、 INSTALLATION3、 COMMISSIONING AND OPERATION3.1、PREPARATION BEFORE COMMISSIONING3.2、COMMISSIONING OF TRANSMISSION MECHANISM3.3、TRIAL RUN 3.4、EMERGENCY SHUT DOWN4、 MAINTENANCE4.1、MAINTENANCE DURING OPERATION4.2、MAINTENANCE DURING A TEMPORARY STOP4.3、MAINTENANCE DURING A PLANNED STOP4.4、MAINTENANCE OF COMPONENTS4.4.1、MAINTENANCE OF IMPELLER AND SHAFT4.4.2、MAINTENANCE OF BEARING4.4.3、MAINTENANCE OF INLET GUIDE DAMPER 4.4.4、MAINTENANCE OF SILENCE4.5、FAILURES AND CAUSES4.5.1、SHORT OF FLOW4.5.2、SHORT OF PRESSURE4.5.3、MOTOR OVERLOADING4.5.4、VIBRATING4.5.5、EXCESSIVE TEMPERATURE RISE ON BEARINGAPPENDIX : PERFORMANCE CURVE1INSTRUCTION1.1 GENERAL This centrifugal fan is manufactured in accordance with the technologies imported from German TLT Company. The type of the fan is 14144AZ/2315 The digit of the type number means: 1414 = ( Blade outlet diameter of impeller / inlet diameter of impeller ) 100 4 -Pneumatic model system Z -The impeller is a double suction impeller 2315 -Inlet diameter of impeller (mm) The fan consists of casing, inlet box, inlet cone, transmission mechanism, -impeller, bearing housing, inlet vane control. The fan is driven by the motor and the type of the motor is YKK800-8, 2400KW and 6.6KV. The inlet vane is controlled by the electric operator and the type of the operator supplied by ROTORK is IQM/MOW7R.1.2 DATA SHEET AND PERFORMANCE CURVE The fan is designed on the basis of the parameters provided by customer, the parametr refers to the sheet as follows. The performance curve of the fan refers to Appendix. The fan can reach an operating point specified by adjusting opening angle of inlet vane.Work pointTBBMCRVolume Flow(m3/s)329.82274.85Total Press(Pa)5415.84166Inlet Temprature()147.5132.5Inlet Density (kg/m3)0.8270.827Effect（%）88.778.4Shaft Power(kw)2006.81331Fan Speed(r/min)720Motor Output(kw)2400Motor Speed(r/min)7401.3 INTRODUCTION OF FAN STRUCTURE1.3.1 Impeller The impeller is a double suction style with airfoil blades, it is high efficient. The material of blades, disc and disc cover is 15MnV, they are welded to each other. The ingress of disc cover is made to forge. The impeller and main shaft are connected with a flange structure instead of hub connection. (refers to the figure below), this structure greatly reduced the weight of the impeller. The impeller and the main shaft are fasten by 20 high strength bolts(35CrMoA) which are locked by lock washers, meanwhile the flange shaft shoulder of main shaft can prevent bolts from turn, this connection method is safe and reliable and it can bear a rather large torque. The impeller and the main shaft shall static and dynamic balanced to ensure a stable rotor operation after installed.1.3.2 Main shaft The main shaft is a segment shaft with rolling bearings at both side of which one is connected with the motor through a coupling. The material of the main shaft is 45-1. The shaft has enough stiffness and strength for operating.1.3.3Bearing The type of the bearing is 23140CC/W33/C3 SKF double-row radial spherical-rolling bearing lubricated by lubricant of N46. The bearing housing is cooled by pressed backwater, the cooling tube is G2”, the water volume is 2.4m3/h. Each bearing of the fan equipped with a WRKK2-333 thermal resistance for remote and local monitoring. Three dias of fans use one monitor system.1.3.4CouplingThe type of coupling is YOTcs1250M-011 metal shackle coupling provided by Guangdong Zhongxin Co., Ltd. The hub of fan side has been installed to the main shaft of fan in factory. Other parts should be installed in scene such as the hub of motor side, intermediary shaft, diaphragms and so on. .1.3.5Casing The casing is made of welded Q235A steel plate, and it consists of the fan casing and inlet box. Reinforcing steel were welded on the side board to reinforce the stiffness of the casing and inlet boxes and to prevent the casing and inlet boxes from deformation during transportation, installation and operation. Manholes are opened on the casing and inlet boxes for the purpose of maintenance.1.3.6 Inlet cone The inlet cone is a streamline shape conduit, it is from shrinking to diffusing. The flow can pass through the conduit evenly in a certain speed, improved the flow inside the impeller.1.3.7 Sealing Sealing plate seals are sealed at the inlet boxes where the main shaft projecting out to reduce the flow loss of inlet boxes. The seals here consists of two press plates, one supplementary plate and one sealing plate (rubber plate without asbestos, t4), they are connected by screws (refer to Fig.4). Other flange such as split- flange is sealed -by sealing rope(fibre glass cord, 6). 2 INSTALLATION The fan installation shall be performed strictly in accordance with the procedure below:1） Study this Instruction Book carefully before installation to know the fan structure and its installation steps. Necessary preparation: Check if there are any cracks or defects on the base surface, if the anchor bolts hole can meet technical requirement, if the base are smooth; check if the components of the fan are complete and with no damage on them, and if the rotating direction meets the drawing requirements.2） Pay attention when installing bearing housing: The housing at motor side is a radial-thrust bearing housing while the housing at another side is a radial bearing housing. Take the shaft hole as the basement to find the main shaft levelness, both allowances of axial level deflection and the radial level deflection are 0.05/1000.3） Connecting two parts of bottom casing with bolts before install the bottom casing, welding periphery inside the connecting flange, thus, the rigidity of casing is reinforced and leakage during operation is avoided.4） Paying special attention to confirm the correct position of altitude-direction of the inlet box when installing the bottom inlet box, find the horizontal center line among radial-thrust bearing, radial bearing, bottom casing and bottom inlet box.5） Sleeving the inlet vane control and inlet cone through the main shaft on the rotor in accordance with the general drawing. Pay attention that the inlet vane control has the positive and contrast style. To judge if the inlet vane controls are installed correctly, one important thing is that when the inlet vanes are at a position nearly closed, the prerotating direction is same with the rotating direction of the impeller, otherwise. It will decrease the fan efficiency sharply and cause an unusual vibration. 6） Lift the rotor together with inlet vane and inlet cone. The levelness of the rotor center shall not exceed 0.05/1000. The position of the rolling bearing and the bearing housing is adjusted by adjusting shims. The thinner shim(8mm) is set at the side where the thermometer hole is, and the thicker shims are set at another side. Pay attention to the rotating direction of the impeller.7） After the rotor installed, take the rotor and impeller as a basement. Keep the inlet vane and inlet cone can be assembled with casing and inlet box and readjust the positions of bottom casing and bottom inlet box till the inlet box , inlet vane, inlet cone, and casing can match each other correctly, also, the radial clearance and the axle clearance between inlet cone and impeller shall be kept with the scope specified in the general drawing. The adjustment of the inlet vane is also important, since the inlet vane is a stator part while the main shaft is a rotating part, a certain radial clearance shall be kept between the inner core of inlet vane and the main shaft.8） Install the upper casing, upper inlet boxes and upper bearing housing.9） Install the coupling assembly. (Axial compensating value is 4mm. Radial compensating value is 3.8mm. Angular compensating value is 1 )10） Install the electrical actuator.11） Install the transmission mechanism the length of the link rod can be adjusted in a range by a nut at spherical hinge. By adjusting the length of the link rod, the range 090of inlet vane could match the stroke of the crank of electrical actuator.12） Install the measuring instrument.13） Second grouting in the anchor bolt position.3COMMISSION AND OPERATION3.1Preparation before commission3.1.1Check carefully if all the bolts have been fastened.3.1.2Check if the rotating direction of impeller, inlet damper and motor is correct.3.1.3 Check if there are any sundries left in the casing, inlet boxes and pipes3.1.4 Check if the wire in the instruments are correctly connected.3.2Commission of transmission mechanism3.2.1Close the inlet vane control, then check if the position of the regulating handle is correct, the neighbouring dampers shall contract each other; if the neighbouring dampers cannot contact, it shall be fastened and regulated.3.2.2 The designed direction of the inlet damper is same with rotating direction of the impeller.3.2.3 The length of link rod of transfer motion shall be regulated to ensure the range of the electrical actuator meet a full open and full close range of inlet damper.3.2.4Close the inlet vane before the fan started3.3Trial run 3.3.1The fan shall be started unloaded. Closed the inlet damper and open the valve in the discharge duct to avoid the motor overloaded. The fan shall not run a long time in the condition when the inlet damper closed. If the fan runs well and reaches a rated speed, open the inlet damper gradually till the fan can reach a rated operation point.3.3.2 During the fan operation, pay attention to the bearing temperature. The temperature rises sharply in first hours. And then it becomes stable at a certain temperature value. The bearing temperature rise shall not exceed 40 and the vibrating velocity of mean square root at bearing shall not exceed 4.6mm/s.3.4Emergency shut down as follows3.4.1The fan or motor is abnormal or has an abnormal screaming when the fan started.3.4.2The temperature and vibrating velocity of bearing exceeds the specified value.3.4.3The inlet vane is out of control.3.4.4 The motor is suddenly overloaded.3.4.5 Other unexpected failures which is dangerous to the safety of personal and the unit.4MAINTENANCE To avoid the failures and accidents caused by bad maintenance, and to prevent from the natural failures and accidents caused by fan of motor itself, to develop the functions of the equipment and to prolong working life of the equipment, a correct maintenance work shall be reinforced.4.1Maintenance during operation During operation, readings of all instruments shall be recorded every hour, if a sharp change occurred, the cause shall be found out and cleaned. For the purpose of keeping the fan operating in a good state till its scheduled stoppage, the bearing temperature, cooling water, operating stability and oil seals in bearing housing shall be routine checked.4.2 Maintenance during a temporary stoppage If other equipment of the unit stopped out of the schedule, the fan shall take the chance to have its worn parts checked, mainly the seals and bearings, clear sundries in the impeller and check the wearing condition of blades.4.3Maintenance during scheduled stoppage The maintenance work during scheduled stoppage shall enable the fan operating without failures till next stoppage. Maintenance work below is suggested:1） Check and clear the sundries in the impeller.2） Check the wearing condition of blades.3） Renew the lub oil of the bearings4） Check and replace damaged seals in the fan .5） Check the performance of the coupling.6） Check the wearing state of expansion joints.7） Clean the fan casing , inlet boxes and conduits. Then the fan trial run, if every thing well, the maintenance finished.4.4Maintenance of the fan components4.4.1Maintenance of the fan components When the impeller and main shaft were assembled together, they are dynamic balanced before delivery, this is why we had better not disassemble the impeller from the shaft. If we had to disassemble it for some special reasons, the corresponding positions for both parts shall be marked and restore to their original position after assembly, in this way, the dynamic balance can be maintained. Otherwise, the rotor shall be dynamic balanced again. The rotor needs no special maintenance, check the abrasion of the impeller irregularly and clear all adhesion on blade, these adhesions on the blade will cause a strong vibration during operation. During stoppage of the fan, turn the rotor at least every week by hand for 180to change the permanent loading position of a rotor and to avoid shaft deformation.4.4.2 maintenance of the bearing When maintaining the bearing, disassemble the thermometer first and then disassemble the cover of bearing housing. The lub oil in bearing shall be routine renewed, the first period for renewal is 200 operation hours, then renew the lub oil each year. Check the oil seal when renew the oil.4.4.3Maintenance of inlet vane control Under a normal operating condition, the inlet vane can work for 2 to 3 years without maintenance except ordinary inspection. Joint bearings dont need been removed to clean or add lubrication, which lubricate itself. Rust protection shall be taken to avoid a inlet vane control failure. During a fan stoppage, the vanes shall be turned around regularly to keep the activity of the vanes. The sound insulation is easy to remove and install, which should been paid attention to avoid the adjusting circle and joint bearings of inlet vane.4.5 FAILURES AND CAUSES During fan operation, c