installation,operation and maintenance manual … btnp single suction multi stage centrifugal blower...

MODEL BTnP Installation,Operation and Maintenance Manual

SINGLE SUCTION MULTI STAGE CENTRIFUGAL BLOWER

MODEL BTnP SINGLE SUCTION MULTI STAGE CENTRIFUGAL BLOWER

Installation,Operation and Maintenance Manual

TABLE OF CONTENTS

Safety Precautions (MAPEW_STDFB199802)Exemption ClausesGeneral Safety Precautions Important Warning ItemsAttaching position for warning labels (SAMPLE)

Chapter 1 Introduction (MAPEP_STDFB199802)

Chapter 2 Disassembly and Assembly (MAPED_STDFDBSBBJ200408)2.1 Disassembly and maintenance2.1.1 Checking before starting the work2.1.2 Confirmation before disassembly2.1.3 Disassembly procedure2.2 Assembly2.2.1 Bearing assembly2.2.2 Mounting the coupling2.2.3 Mounting the rotaring member2.2.4 Confirming the assembly tolerence2.2.5 Assembling the casing2.2.6 Alignment adjustment2.2.7 Accessory assembly

Chapter 3 Operation (MAPEO_STDF199802) 3.1 Operating Notes3.2 Items to be confirmed before operation3.3 Preparation for start up3.4 Start up3.5 Notes for operation3.6 Stop

Chapter 4 Maintenance and Inspection (MAPEM_STDF199802)4.1 Storage and Curings4.2 Inspection4.2.1 Daily inspection

III

IIIIVV

1

2222388899

101011

12121314161920

21212222



TABLE OF CONTENTS

4.2.2　Periodic inspection4.2.3　Replace the parts4.2.4　Maintenance and inspection procedure4.3　 Lubricating oil4.3.1　Lubricating oil control 4.3.2　Lubricating oil to be used4.4　 Adjustment

Chapter 5　Trouble shooting (MAPET_STDF199802) 5.1　 Vibration 5.1.1　Countermeasures of vibration5.2　 Bearing temperature rise5.2.1　Bearing temperature rise 5.2.2　Causes for bearing temperature rise and measures to be taken 5.3　 Performance degradation 5.3.1　Performance degradation 5.3.2　Causes for degraded performances and countermeasures 5.4　 Blower troubles and its causes

Chapter 6　Guarantee and Service (MAPEG_STDFB199802) 6.1　Guarantee period 6.2　Scope of guarantee 6.3　Our guarantee is not applicable to 6.4　Our guarantee is applicable to

22 22 23 26 26 26 26

27 27 27 31 31 31 32 32 32 34

35 35 35 35 35


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• •

Be sure to completely read this Manual and other accompanying documents before installation, operation, maintenance or inspection of this pump and to use this pump properly. Read all about the knowledge, safety information and precautions concerning the equipment prior to using it. In this Manual, precautions have been classified into "DANGER", "WARNING", "CAUTION", and "NOTICE".

• •

Even an item indicated by "CAUTION" has the possibility of causing a serious result depending on the situa-tion. You have to strictly observe the precautionary messages since they all explain important matters. General safety precautions for this product will be explained after the next paragraph and should be observed, together with the above.

! DANGERThis indicates an urgent and dangerous situation that could result in a personal serious injury or loss of life unless it is avoided. This will be used only for an extremely dangerous situation.

! WARNINGThis indicates a dangerous situation that may result in a serious injury or loss of life unless it is avoided.

! CAUTION This indicates a dangerous situation that may result in a slight injury or an injury of intermediate degree unless it is avoided.

NOTICEThis indicates a message related to the safety of persons or the protection of equipments (loss of property)

Safety Precautions (MAPEW_STDFB199802)

Ⅰ


- -


We are unable to take the responsibility for any incongruence created due to inobservance of the items described in the Operation Manual.

Exemption Clauses

Ⅱ


- -


The precautions to be strictly observed when operating the fan (blower) are listed below. These precautions must be strictly observed. Perform the following pre-starting checks: Check that all safety guards are mounted correctly and securely. Check that all alarm contacts operate correctly under the previously set conditions. Check that the gas detector operates correctly. Keep the power of the gas detector turned on to perform checks during operation. Do not put hands or objects into the safety guards during operation. If the shaft seals are of the type that require purging, continually provide nitrogen gas or air purging. For a fan (blower) that handles hot gas, keep hands away from the exposed parts of the operating during or immediately after operation. When checking the fan (blower) in their stopped condition, strictly observe the following safety precautions: Before starting checks, make sure that the motor is turned off. Also, provide appropriate marking or labeling so that the motor is inadvertently turned on. If the fan (blower) handles gas other than air, check for safety by performing inert gas replacements before disassembling the casing. If the fan (blower) handles potentially flammable gas, do not use fire nearby. If it becomes absolutely necessary to use fire, check for gas and see that the intended work can be performed safely. Do not modify the fan (blower) itself and do not disturb the preset conditions of related units. Please contact us if modification associated with changes in operating specifications is required. If the warning labels attached to the product become detached or damaged, reorder them from our Head Office sales department.

General Safety Precautions

Ⅲ

1. 1) a) b) c) 2) 3) 4) 5) 2. 1) 2) 3) 3. 4.


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! WARNINGDo not operate the product if the safety guards for sections such as couplingsguard and heat slinger guard are removed. Contact with the couplings, shaft,heat slinger, pulleys, or V-belts, causes serious bodily injury.The safety guards must be remounted before operating the product.If the safety guards are to be removed, turn the motor off and provide appropri-ate marking or labeling so that the motor is inadvertently turned back on. Serious bodily injury will result if the product is started abruptly.For a fan (blower) that handles poisonous gas or potentially flammable gas, ifshaft sealing uses a purging gas, supply of the purging gas must be continued, irrespective of whether the product is turned on or off. If the purging gas is turned off, the gas sprouting from the casing may cause poisoning or fire.For a fan (blower) that handles hot gas, keep hands away from the exposedparts of the casing. Burns may be caused.

Before starting the fan (blower), carefully read the operating manual and relateddocuments and operate the product correctly.

Before starting the fan (blower), record its installed status, its centered status,unit setting conditions, and the lubricated status of the bearings and auxiliaryequipment.The sections that require oil lubrication, the inner surfaces and outer surfaces(spherical seats) of the sliding bearings, and the insides of the bearing boxes are coated with a corrosioninhibiting oil. Before operating the product, disas-semblethe upper bearing box and remove the corrosion-inhibiting oil using a thinner.When reassembling the upper bearing box, apply a liquid gasket (such as ThreeBond #1212) to the upper and lower mating flanges.

! CAUTION

NOTICE

Important Warning Items

Ⅳ

• • • •

•

• • •


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Attaching position for warning labels (SAMPLE)

Ⅴ

NP.80101

NP.80102 NP.80107


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This manual is intended for the user of the fan (blower) to thoroughly understand their correct usage. After in-factory stringent product inspection, the fan (blower) has undergone our withstand pressure tests and operational tests with in-factory testing equipment in accordance with JIS-B8330 (fan), JIS-B8340(blower) to verify that specifications on the operational status, performance, etc. of the product are satisfied and that the required standards are passed. The fan (blower) must be correctly serviced and operated to provide their excellent performance. Mis-handling causes trouble in addition to preventing satisfactory performance from being achievable. Always operate the product within the limits laid down in this manual, and avoid applying an overload. Also, perform correct maintenance and checks and undertake all possible preventive measures against accidents. If an operational failure or other trouble occurs, please contact us giving the following information: Information contained the specifications plate of the fan (blower) ; (that is, type, pressure, capacity, speed, built, and serial number) Information concerning the trouble (please give us the furthest possible detailed information about the status existing before and after the trouble occurred) See the end of this manual for the listing of contact addresses.

Chapter 1 Introduction (MAPEP_STDFB199802)

1) 2) 3) 4) a) b)

1


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1.1 Checking before starting the work

Prepare the required disassembly tools and measuring tools.

Confirm the disassembly and assembly procedure.

Prepare the required replacement parts.

repare the small parts kit, rotating member support base, and bearing protectors such as rags and vinyl.

1.2 Confirmation before disassembly

During operation (Record the operating conditions before disassembly.)

Measure and record the bearing vibration before disassembly.

Check if gas leaks from the casing.

Check the bearing for noise.

Check the casing internal noise.

2.1 Disassembly and maintenance

Chapter 2 Disassembly and Assembly (MAPED_STDFDBSBBJ200408)

! WARNINGBefore starting disassembly, make sure that if the product is driven by motor, thepower of the motor is turned off.When lifting the product, check its weight and the angle of lifting.Check your footing for safety.

• • •

! WARNINGIf the fan (blower) handles gas other than air, perform inert gas replacements and see that the replacements are completed.

•

! CAUTIONAsk us or a specialized service company for part replacement or repair. Wrongmaintenance may cause trouble or accidents.

•

! CAUTIONThoroughly understand the construction of the fan (blower) and use the correctprocedures

•

2. 1) 2) 3) 4) 2. 1) a) b) c) d)

2


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When stop

Visually observe the appearance.

Record the coupling misalignment.

Check if there is any contact between the rotating member and stationary member.

Check if lubricating oil is oozing or not. Also check the bearing housing for contamination.

Make sure that anchor bolt (installation bolt) is tightened.

When gas other than air must be handled, make sure that gas replacement must have been completed.

Check the parts for separation identification and matching marks.

When disassembly is required due to accident, take a photograph of internal conditions.

1.3 Disassembly procedure

Remove the safety guard.

Remove the connection link between the damper or suction vane proper and operating equipment.

Remove the expansion joint of the suction and discharge cones, or the connection with the silencer, and the piezometer.

Disconnect the damper or suction vane proper from the casing.

Disengage the coupling between the blower and drive unit.

For JIS flange type couplingLoosen the nut of the coupling bolt and remove all the coupling bolts.

For gear couplingLoosen the nut of the installation bolt and remove all the installation bolts. Care should be taken not to damage the O-ring.


2) a) b) c) d) e) f) g) h) 2. 1) 2) 3) 4) 5) a) b)

3


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For disk couplingLoosen the nut of the spacer installation bolt and remove all the installation bolts. Then draw out the element.

Disconnect the suction cone installation bolt, and remove the suction cone.

For the split type casing, remove the installation bolt of the flange by lifting the upper casing in the vertical direction.(Use the external drawing to confirm the height required for disassembly.)

Apply cloth so that shaft will not be damaged, and apply the wire protected with rubber.

Disassemble the bearing housing and bearing.

Remove the mounting bolts and knock pins from the base. Lift the shaft/bearing box assembly together with the rotating member.


c) 6) 7) 8) 9)

①

②

4


- -


Lift the rotating member and remove it. In this case, lift it slowly, and keep it in the vertical and horizontal directions. Remove the rotating member provided with the coupling and bearing (with bearing housing in the case of integral bearing). Place the disconnected rotating member on an adequate support base. Protect the bearing housing and bearing, for example, by covering it with cloth. How to disconnect the coupling The coupling is shrink-fitted on the shaft. Heat the coupling hub in a short time to give clearance, and draw it out all at once.

Use a gas burner to heat the coupling. Provide glass cloth protection to other parts than the coupling so that the flame from the burner does not come into contact with the coupling. Set a coupling pullout tool to the end of the shaft. Heat the periphery of the coupling uniformly with the gas burner. Heating the coupling, tighten the jack bolt of the pullout tool, and when the coupling begins moving out, remove it by hand.


10) 11) 12) 13) 14)

a) b) c) d) e)

5

In this case, heat the periphery of the hub in a short time.If heated for a long time, heat will be conveyed to the shaft, and clearance may not occur. The appropriate heating temperature will be 100 degrees Celsius.

NOTICE• •


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How to remove the bearing (bearing housing)

Remove the setscrews from the water flinger and offset it horizontally. Unbolt the cover and offset it horizontally. Remove the lock washer from the bearing nut, then remove the nut, and remove the bearing. (The bearing must be removed using a suitable guide and taking care not to damage the fitting section between the bearing and the shaft. See the figure.)



①

②

③

15)

6

Do not use the removed bearing again.NOTICE •


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How to remove the impeller Do not disconnect the impeller in principle.



16)

7

When the impeller must be removed, be sure to contact our company, and follow the instruction of the personnel in charge.NOTICE

•


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2.1 Bearing assembly

For assembly, follow the reverse of the disassembly step.

The bearing is close-fitted on the shaft.

2.2 Mounting the coupling

Heat the bearing to 80 to 110 degrees Celsius and mount it in position.

Immediately after mounting the bearing, attach the lock nut, and bring the stepped portion of the shaft in close contact with the bearing end. Replace consumables such as shape proof washer, felt ring and gasket by new ones. Insert the tongue of the shake proof washer into the shaft groove, and tighten the nut. Clean inside the bearing and bearing housing. For grease lubrication, mount the bearing; then apply grease to the bearing, taking care not to allow entry of foreign substances.

The coupling is close-fitted. Mount it by heating the coupling hub.

2.2 Assembly


2. 1) 2)

2.

3)

4) 5) 6) 7) 8)

1)

8

At the time of bearing assembly, never apply lubricating agent containing molyb-denum disulfide (MORICOTE/DOWCORNING or its equivalent).NOTICE

•

To facilitate next disassembly, apply the lubricating agent containing molybdenum disulfide (MORICOTE/DOWCORNING or its equivalent) to the shaft coupling joint section.

NOTICE•

Do not use the burner to heat it. Be sure to use the bearing heater or oil heatingoil.To prevent the bearing hardness from reducing, do not heat it in excess of 110 degrees Celsius. If the heating temperature is too high, the bearing service life will reduce.

NOTICE• •


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Insert the coupling on the blower side up to the stepped portion of the shaft. If there is no stepped portion, adjust the shaft end to the coupling hub end.

The shaft end and coupling hub end must be matched with each other on the drive unit side.

2.3 Mounting the rotating member

Mount the rotating member according to the reverse of the disassembly step.

2.4 Confirming the assembly tolerance

Measure the shaft horizontality.Measure on the shaft close to the bearing housing on the thrust side.

Measure the bearing housing inclination.

Where "D" indicates the diameter of the dial gauge needle turning on the bearing housing end face (mm).



2)

3) 2. 2. 1)

2)

9

Heating must be made uniformly. Heating temperature should not exceed 130 degrees Celsius.NOTICE

•

The base horizontality must not exceed 0.1mm to 1m.NOTICE •

The bearing housing inclination must not exceed 0.07/100 × D mm.NOTICE •


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Adjust the inclination by inserting the shim liner between the bearing housing and base.

2.5 Assembling the casing

Apply gaskets to the upper and lower matching faces of the casing and other matching faces, and tighten them.Set the upper casing position by the knock pin.

2.6 Alignment adjustment

Using the blower side coupling as a reference, make alignment with the coupling on the drive unitside.

To correct misalignment, use the dial gauge to measure four points (top, bottom, right and left) on the periphery of the coupling.

To adjust the parallelism of the coupling, measure four points (top, bottom, right and left) with a thickness gauge.

To correct misalignment and parallelism, insert shim liners between the drive unit and base.

When measuring misalignment, take into account the runout on the periphery of the coupling and the dead weight of the dial gauge.

The tolerances of parallelism, face-to-face dimension and misalignment differ according to the type and structure of the coupling.

Check the type of the coupling, and make adjustment according to the alignment record given on the following page.

3) 2. 1) 2) 2. 1) 2) 3) 4) 5) 6) 7)

10


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2.7 Accessory assembly

Assemble the accessories. (Assemble such accessories as safety guard.)

The coupling bolt must be installed after independent operation of the drive unit.


11

2. 1) 2)


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It is desirable that the fan (blower) be operated in the vicinity of its design flow rate. It may however become absolutely necessary to operate the fan (blower) at low flow rate. If this is the case, the characteristics of the fan (blower) must be thoroughly understood before operating it.

If the fan (blower) handles a hot gas or a gas significantly differing from air in terms of densityWhen the fan (blower) is started using normal-temperature air, overloaded operation may continue until the required temperature or density has been reached. Therefore, reduce the degree of opening of the dampers or suction vanes or operate the fan (blower) in the bypass operation, blow-off operation, or deceleration operation.

If the fan (blower) is to be operated at low flow rateIf the fan (blower) is to be operated at low flow rate, surging or rotational stalling may occur and increasethe vibration of the casing, bearings, or ducting, or the low-frequency noise level. Extended operation under these states causes damage to the casing, bearings, or ducting, cracking of the foundation concrete, or other trouble. Therefore, increase the flow rate by either increasing the degree of opening of the dampers or suction vanes or combining air restriction with bypass operation or blowoff operation.

3.1 Operating Notes

Chapter 3 Operation (MAPEO_STDF199802)

■

■

12

Do not to operate the fan more than three minutes when it blows inadequately, otherwise the inside temperature of the fan rises, and it shall cause mal-functionand damages at the fan.Do not operate the blower in its surging region. Increases in vibration cause trouble.Operate the blower at loads exceeding the rated output of the driving motor. 　Continued overloading causes trouble.

NOTICE• • •


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Before starting the operation, check the following when the equipment is started for the first time after installing the blower, after a long-time disuse or after disassembly and maintenance. Start independent operation of the drive unit, and make sure that there is no problem in rotational direction or vibration.

Turn power off after checking. Reconnect the coupling between the driving motor and the fan (blower).

Check the blower operation sequence. Assembly Make sure that all bolts are tightened firmly. Make sure that coupling bolts are tightened firmly. Check that there are proper clearances between the rotating member and stationary member (suction cone and impeller, impeller and casing, and shaft and casing shaft through hole).

Make sure that the safety guard is correctly installed. When the suction and discharge cones are provided with expansion joints, they must be installed properly due consideration given to thermal expansion.


3.2 Items to be con�rmed before operation

13

1)

a) b)

2) 3) a) b) c)

4) 5)

Check to see that oil pipe, shaft sealing pipe and coolant pipe are flushed.Check the casing interior, air suction cone, suction/discharge pipe connectionsand the area surrounding the fan. Make sure that parts, tools and other remnants are not left behind.

NOTICE• •

Loosen the shipping bolts for transport and installation.NOTICE •

• ! WARNINGIf the fan (blower) is driven by motor, the terminal box cover must be kept mountedto avoid the danger of electric shock.

• ! WARNINGIf the fan (blower) is driven by motor, check that the power of the motor is turnedoff.


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For oil bath lubricated bearing, prepare the specified level of lubricating oil plus 20% allowance. Supply oil to the level specified by the oil level gauge of the bearing housing. Oil level shall be kept between the red line on the gauge.

Supply the specified amount of lubricating oil to the position indicated in the lubricating oil list.

Do not use low quality lubricating oil.

For forced lubrication, the bearing housing is filled with a proper amount of grease at the time of shipment. When the equipment is operated after a long-time storage, following the steps given in the long-term storage procedure.

For the auxiliary equipment using hydraulic oil and pneumatic air, use the attached measuring instruments to make sure that hydraulic oil and pneumatic air meet the specified requirements.Check that the operating links and small pipes are connected, and start independent operation to make sure that there is no problem.

Check the auxiliary equipment for the following items:

G.O. motor and control motor :

Make sure that the open/close direction of the damper or suction vane is correct.

Check that all operations are smooth, and the damper or suction vane operations are correct without any problem.

Lubrication unit : Make sure that hydraulic pressure, oil temperature, pressure, temperature and volume of the coolant, and oil supply and discharge meet the specified requirements.


3.3 Preparation for startup

1) a) b)

c)

d)

2)

3)

4)

a)

•

•

b)

14

Too high an oil level causes oil leakage.NOTICE •


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Turning unit : Engagement and disengagement of the clutch must be performed correctly. Speed change gear : The hydraulic multiple disk clutch type speed change gear and fluid coupling must permit specified speed control. Preparation for startup must have been completed. Shaft seal (carbon ring seal, mechanical seal, etc.) : The specified volume and pressure of seal gas must be ensured.

Feed the specified coolant when a water-cooled bearing housing is used. Check the type of the bearing housing according to the appended Installation Drawing (external view) and Bearing unit Drawing. In principle, keep the suction damper (or suction vane) or discharge damper fully closed. Make sure that preparation has been completed for the operation of the main power supply, auxiliary equip-ment power circuit, valve of the main pipe and auxiliary equipment. Feed the drive unit in the jog mode, and check for rotational direction, internal contact and abnormal noise.


c) d) e)

5) 6) 7) 8)

15

To check setting parameters at safety devices in order to avoid any mal-factionwhich shall cause any damage at bearings.NOTICE

•

If any abnormality occurs, examine and remove the cause of the abnormality.Continued operation of abnormal fan (blower) causes trouble.NOTICE

•

• ! WARNINGInsufficiencies in the amount and pressure of sealing gas cause the internal gasto leak from the fan (blower) and create a dangerous situation in the presence ofpoisonous gases or potentially flammable gases.


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Star t up the equipment while checking plant safety. Operate necessary auxiliary equipment (Forced lubricating unit) and make sure that the starting conditions for the fan (blower) are established. (See appendix 5."Operation block chart") Star t the fan (blower). Simultaneously with startup, check for internal contact, abnormal noise and vibration. In the case of the sliding bearing, check the oil ring for rotation.

In the case of the sliding bearing, check the oil ring for rotation.(Remove the oil cover and check it by visual observation.)

If rotation is not smooth or horizontal unusual vibration is observed, these imply that the oil ring is deformedor that the oil ring or the wall of the bearing groove has rotation- obstructing flaws or is not smooth or flat. Therefore, check for these defects and if any is found, remove the cause(s).

After the specified speed has been reached, gradually open the suction valve or discharge valve.In this case, ensure that the surge area will be passed through in the shortest possible time.The current value will undergo drastic change in the surge area. Observing the ammeter, open the suction damper (or suction vane) or discharge damper quickly.

After startup, check for bearing vibration, bearing temperature and noise every 5 to 10 minutes until bearing temperature is stabilized. Make sure that there is no abnormal temperature rise.



3.4 Startup

1) 2) 3) 4)

■

5)

6)

16

To stop the machine immediately and start investigation of causes when any abnormal condition appears.NOTICE

•

Do not increase the temperature of gas rapidly when it reaches over 100℃. Theratio of the rise in the temperature of gas shall be 50℃ per hour (not exceed100℃ per hour).Abrupt increases in temperature can cause increased vibration or collision accidents since the differences in the degree of thermal expansion between rotating parts result in imbalance.

NOTICE• •

• ! WARNINGDuring operation, keep hands away from all rotating parts such as the shaft, heat slinger, coupling, and V-belts. Contact causes serious injury.


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For a fan (blower) that handles a hot gas, if the starting temperature of the fan (blower) is lower than the gas temperature, increased shaft output may cause overloaded operation. Reduce the degree of opening of the dampers or suction vanes to operate the fan (blower) in that case. Operation with reduced damper or suction vane angle, however, may cause surging or rotational stalling. In that case, either combine air restriction with bypass operation or blow-off operation or reduce the revolutions. The parts will exhibit the following elongation due to thermal expansion. Rotating member The shaft elongates in the axial direction, starting from the bearing on the thrust side. Casing, etc. Thermal elongation in the axial direction and the direction perpendicular to it will occur over the sliding plate, starting from the fixed point in the following sketch. Thermal elongation in the vertical direction will occur, starting from the casing installation surface. Make sure that, in the process of temperature rise, elongation due to thermal expansion proceeds in the anticipated direction.

When operation is restarted after a long-time stopping (2 to 3 hours or more) in handling high temperature gas, imbalance and shaft bending may be caused by differences in cooling speeds of various parts of the rotating member. This requires turning before startup.



■

a)

b)

7)

17

The improper heat expansion (restriction of heat expansion) at shafts and casings shall make them touch and grind, and it may cause unusual vibration, improper temperature increase at bearings, etc.When this phenomenon observed, to stop increasing the gas temperature, andto check any parts fused, except pre-fixed sections.

NOTICE•

To make "Turning" before re-start of fan(blower) absolutely because it becomes to cause of vibration increase, bearing damage, foundation damage & contact accident if operation continues at condition of shaft bending or un-balance.To ensure that temperature of various parts of the rotating member is kept almost constant, slightly open the suction damper (suction vane) or discharge damper.Feed high temperature gas and turn the rotating member; then start the operation.

NOTICE• •


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Turning procedure

Make 1 + 1/4 rotations at an interval of 10 minutes manually (using the coupling part, etc.). Make this adjustment until misalignment on the periphery of the coupling on the blower side is reduced below 1/10mm in terms of the reading of the dial gauge. Turning motor operate it for about 10 minutes when the turning device is used.


1) 2)

18

Notes on turningIf the opening of the suction damper valve or discharge valve is excessive during turning, rotation may be reversed by flow of air. Gradually open the damper or suction vane so that rotation will not be reversed.

NOTICE•


- -

It is recommended to record the pressure, air volume, current value, bearing temperature, bearing vibration, etc. at specified intervals. During operation, check around the blower on a periodic basis. According to the appended "Check List during Operation", carry out inspection, measurement and record of various parts. If the results are out of the specified range, make adjustment according to "Chapter 5. Maintenance and Inspection". If any problem has been found out during the operation, it is necessary to take measures to prevent a trouble in advance. After stopping the blower or conducting more intensive supervision, find out the cause of the problem. Conspicuous surging may occur in the area of the characteristics curve exhibiting right-hand rise.



3.5 Notes for operation

1) 2) 3) 4)

19

Not to operate the fan under " Surging Region ".Under " Surging Region ", vibration shall increase and may cause any trouble atthe fan.This may damage the impeller or duct etc.

NOTICE•


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For normal stop, gradually close the suction damper (or suction vane) or discharge damper from the fully closed state, thereby preventing reverse flow of gas. Then stop the drive unit. If coolant is likely to freeze, keep water warm even after stopping, or remove water completely.

3.6 Stop

1) 2)

20

To carry out emergency stop in the event of an accident, stop the drive unit andcompletely close the suction damper (or suction vane) or discharge damper atthe same time.

NOTICE•

• ! WARNINGTo ensure safety, do not remove the safety guard until the fan (blower) is stopped completely.


- -


Remove rust and clean the equipment on a periodic basis. Put the cover on it to ensure that dust will not enter. Turn the rotating member on a periodic basis (about once a month) to prevent the bearing from becoming rusty, or from sticking due to dust. (If there is a turning device , operate it on a periodic basis.) Lock the handle to prevent the main valve from opening or closing. If long-term storage is specified, follow the instruction given in the separate "Long-term Storage Procedure".

4.1 Storage and Curings

Chapter 4 Maintenance and Inspection(MAPEM_STDF199802)

21

1) 2) 3) 4)


- -


2.1 Daily inspection

Inspect the bearing temperature, bearing vibration, bearing noise, and internal noise of the casing.

Record the bearing temperature and bearing vibration at monthly intervals so that the results can be com-pared with satisfactory conditions immediately after installation.If bearing temperature and bearing vibration tend to increase, reduce the inspection intervals, thereby preventing accident.

Vibration toleranceSee the appended "Bearing Vibration Evaluation Criteria".

Bearing temperature toleranceSee the appended "Check List during Operation".

Current value (when the motor is used)Keep the current value below the rated current value of the motor.

2.2 Periodic inspection

The frequency of fan (blower) overhauling depends on the type of gas to be handled, the operating condi-tions, the type of material to be used, and other factors. However, overhauling the fan (blower) at least once for every two years is recommended.

Conduct inspection according to 5.2.4 "Maintenance and Inspection Procedure" to be discussed later.For disassembly and maintenance during inspection, see 3.1 "Disassembly and Maintenance" to be discussed earlier.

2.3 Replace the parts

The parts to be replaced during disassembly and maintenance are listed below.

4.2 Inspection

Chapter 4 Maintenance and Inspection (MAPEM_STDF199802)

4.

1) 2) 3) 4. 4.

22

• ! WARNINGBe careful not to get your body caught at the rotating member of the fan (blower)during operation.


- -


Consumable partsBall (rolling) bearing: Spring washer and liquid packing (Three Bond #1212)Grease lubrication: Felt ringOil bath lubrication: GasketsSliding bearing: Gaskets, liquid packing (Three Bond #1212) andfelt ring (if used)CouplingJIS flange type: Rubber ringGear type: O-ringsDisc type (FORMFLEX): Nylon nut for coupling boltCasing gasket: Liquid packing (Three Bond #1212)

Bearings

The recommended replacement criteria for the bearings are shown below.Ball rolling bearing: At least once for every two to three years, or 1/2 or less of the calculatedlifeSliding bearing: At least 1.5 times the required clearance (refer to the Factory InspectionRecord)Clearance between shaft and bearing inside diameterClearance between bearing box spherical seat and bearing spherical outline

2.4 Maintenance and inspection procedure


23

1) a) • • b) c) • • • d) 2) a) b) • • 4.

Inspection item Maintenance/inspection method Measures

1. Impeller 1) Check for dust deposition.

2) Check for wear and corrosion.

3) Check the welded portion for any problem.

4) Check for clearance with suction cone (in axial direc-

tion and direction perpendicular to it).

1) Cleaning

2) Repair and balance adjustment

3) Repair and balance adjustment

4) Correction

2. Shaft 1) Check if the key is loosened.

2) Check for bending, damage and dent.

3) Check the casing through hole for contact.

4) Check if the nut and washer are fatigued or not.

1) Replace the key.

2) Correction and replacement

3) Installation adjustment

4) Tighten them.


- -



24


3. Bearing and

bearing housing

1) Replace the entire lubricating oil.

2) Check the bearing and bearing housing interior for

rust.

3) Check if the bolt is loosened.

4) Anti-friction bearing ：

a) Check the inner race, outer race, ball and roller

for color, damage and sliding scratch.

b) Manually turn the rotating member and check for

noise.

5) Sliding bearing ：

a) Check the metal for damage and dent.

b) Bearing clearance

Measure the clearance between journal portion

and bearing using a plumb line. Measure the

clearance in the thrust direction by a searcher.

1) Remove old oil and clear the interi-

or.

2) Clean or replace the bearing.

3) Tighten the bolt.

4)

a) Clean and check them by visu-

al observation, then evaluate

them.

b) Replace the anti-friction bear-

ing if there is any problem.

5)

a) Clean and check them by visu-

al observation, then evaluate

them.

b) Replace the white metal lining

(depending on tolerance).

4. Coupling 1) For JIS �ange type

a) Check for centering.

b) Check the coupling bolt rubber bushing for defor-

mation and wear.

c) Check if the nut is loosened.

2) For gear type

a) Check for centering.

b) Check lubricating oil for contamination and vol-

ume.

c) Check the tooth surface for deformation and

wear

d) Check if the nut is loosened.

e) Check the O-ring for deformation and damage.

f) Check oil leakage.

3) For disk type

a) Check the centering.

b) Check the element.

c) Check if the nut is loosened.

1)

a) Adjust it.

b) Replace it.

c) Tighten it.

2)

a) Adjust it.

b) Replace all oil.

c) Replace it.

d) Tighten it.

e) Replace it.

f) Replace the O-ring to maintain

sealing.

3)

a) Adjust it.

b) Replace it.

c) Tighten it.

5. Casing 1) Check for corrosion and wear.


3) Check the shaft seal packing and labyrinth for any

defect.

4) Check contact with the rotary members such as im-

peller and shaft.

5) Check the interior for entry o� oreign substances.

6) Check the connection duct for any problem.

1) Repair it.

2) Tighten it.

3) Repair or replace them.

4) Adjust it.

5) Clean and remove them.

6) Correct it.


- -



25


6. Base 1) Check if the bolt is loosened.

2) Check if the nut for anchor bolt is loosened.

3) Check for corrosion.

1) Tighten it.

2) Tighten it.

3) Repair.

7. Suction vane

and valve

(suction and dis-

charge)

1) Check for corrosion and wear.

2) Check if sliding portions stick.

3) Check that sliding portions are lubricated.


1) Repair or replace it.

2) Clean it.

3) Supply lubricating oil.

4) Tighten it.

8. Around the foun-

dation

1) Check if the nut for anchor bolt is loosened.

2) Check the concrete for cracks and deterioration.

3) Check if the concrete (gro ut)below the base is sepa-

rated or not.

4) Check the horizontal adjustment liner for displace-

ment.

1) Tighten it.

2) Repair.

3) Repair it.

4) Readjust it.


- -

3.1 Lubricating oil control

Lubricating oil is most important for fan (blower) operation and maintenance. Blower durabilityand parts replacement intervals greatly depend on lubricating oil quality under the same conditions.

Lubricating oil used in the test operation must be replaced with new one within three months.

Lubricating oil must be replaced with sufficient care taken not to allow entry of foreign substances.

Entry of foreign substances in lubricating oil may cause damage, wear and seizure of the bearing,possibly resulting in a serious accident.Extreme care must be taken to prevent this.

3.2 Lubricating oil to be used

Use the lubricating oil specified in the appended "Lubricating Oil List".

Use of lubricating oil of different brand may given an adverse effect to bearing service lifeand bearing temperature. Before using it, check lubrication performances with the lubricatingoil manufacturer.

For supply of lubricating oil and replacement intervals, see the appended "Lubricating Oil List".

When replacing lubricating oil, check and maintain the bearing at the same time.For adjustment of the clearance between the impeller and suction cone (axial direction and the directionperpendicular to it) and the clearance between the shaft and casing shaft through hole and coupling align-ment accompanying the maintenance and inspection, see "Assembly" in 3.2 to be discussed earlier.

For adjustment of the clearance between the impeller and suction cone (axial direction and the direction perpendicular to it) and the clearance between the shaft and casing shaft through hole and coupling alignment accompanying the maintenance and inspection, see "Assembly" in 3.2 to be discussed earlier.



4.3 Lubricating oil

4.4 Adjustment

4. 1) 2) 3) 4. 1) 2) 3) 4)

26


- -

5.1 Vibration

Chapter 5 Trouble shooting (MAPET_STDF199802)


1.1 Countermeasures of vibration

If causes were found on preceding Section 6.1.2 "Locating the sources of vibration" should be taken.The following describes the causes for each category:

General causes Speci�c causes Measures

sesuac lacinahceM

1. Imbalance of rotating member 1) Uneven wear and corrosion of

the rotating member

2) Uneven dust deposition on

the rotating member

3) Deposition o� oreign sub-

stances on the rotating mem-

ber

4) Partial damage of the rotating

member

5) Wear by dust

1) Repair the worn or corroded

position.

2) Clean it.

3) Clean it.

4) 、5) Repair damaged por-

tions, and adjust the balance

or replace the rotating mem-

ber.

2. Contact between the rotating

member and stationary mem-

ber

1) Deposition of dust between

the rotating member and sta-

tionary member

2) Bearing wear and damage

1) Disassemble and clean it.

2) Anti-friction bearing: Replace

the bearing.

Sliding bearing: Replace the

white metal lining.

3. Coupling

1) JIS �ange type

Coupling bolt failure

1) Wear and deformation of rub-

ber bushing

1) Replace it.

2) Gear coupling

Gear face failure

1) Uneven contact of gear face

2) Wear of gear face

3) Increase in gap

1) 、2) 、3) Replace them.

3) Disk type

Element failure

1) Deformed or worn element 1) Replace the element.

4. Misalignment 1) Bearing wear

2) Shaft bend

3) Foundation deformation

1) Anti-friction bearing: Replace

or repair the bearing.

Sliding bearing: Replace the

white metal lining.

2) Repair or replace with a new

shaft.

3) Repair

5. Shaft de�ection 1) Shaft bend 1) Repair or replace

27

5. 1)


- -



If the cause is not clear, check according to the following steps:

Drive unit independent operationRemove the coupling locking bolts.

When the drive unit independently shows vibration, use shim liners to adjust the drive unit installationface clearance, and tighten the bolts and nuts, then restart the operation.

When vibration is reduced according to the above step �, the rotating member may be unbalancedor drive unit shaft is bent.

Measure the vibration at the drive unit shaft end (or coupling periphery). If any bend isdetected, contact the drive unit manufacturer.

General causes Speci�c causes Measures

sesuac ciluardyH

1. Surging 1) Operation in the low �ow

range due to insu�cient re-

striction by damper or suction

vane

1) Adjust the opening of the

damper or suction vane so

that operation will be per-

formed in the area of the char-

acteristics curve exhibiting a

downward slope to the right

2. Pipe 1) Pipe vibration 1) Pipe reinforcement

3. Others 1) Eddy current o� uid

2) Organ pipe oscillation of duct

1) Control the eddy current.

2) Reinforce the duct or change

the structure.

sesuac lamrehT

1. Thermal distortion 1) Unbalanced rotating member

2) Thermal bending of the shaft

1) Turning or reduction of tem-

perature rise speed

2) Turning or reduction of tem-

perature rise speed

2. Mechanical cause due to ther-

mal expansion of equipment

1) Contact between the rotating

member and stationary mem-

ber due to thermal expansion

of the connected duct

2) Misalignment due to thermal

expansion

3) Sliding failure of the casing

1) Installation of expansion joint

2) 、3) Re-alignment with consid-

eration given to thermal expan-

sion

tinu evird ot eud sesuaC

1. Power supply 1) Unbalanced power voltage 1) Check the power supply of

each phase and take appropri-

ate actions.

2. Starter 1) The starting resistor is inad-

equate (for winding type).

1) Check and adjust it.

3. Stream volume (for steam tur-

bine)

1) Unstable stream volume 1) Check and adjust it.

28

2)

a)

①

②

③


- -



If no bend is found out, the rotating member is unbalanced. The balance must be adjusted. When no cause is found on the drive unit side: Check for alignment. Make adjustment if alignment fails to meet the tolerance. Check for the squareness between the shaft and bearing. If the squareness fails to meet the tolerance, correct it. When the anti-friction bearing is used, check for bearing noise, or use a test instrument to perform diagnosis. If any problem is found out, replace the bearing. When the sliding bearing is used, check the metal and its washers. If any problem is found out, repair the bearing. Shaft bend Disconnect the coupling and measure the shaft bend. When the bend is 3/100mm (6/100mm on dial gauge reading ) or less, adjust the balance. If a bend of 3/100mm or more is detected, a new shaft must be manufactured. When the casing must be disassembled for adjustment: In principle, internal inspection and cleaning are possible without disassembling the casing. Check the impeller for wear, corrosion, and deposition of dust and foreign substances. Cleaning must be made thoroughly.

29

④

b)

①

②

③

④

⑤

⑥

⑦

c)

①

②


- -



If cleaning is insufficient, imbalance may remain without being corrected. If the bearing vibration has exceeded the tolerance after operation, adjust the balance.

30

③


- -



2.1 Bearing temperature rise

It is often said that the bearing temperature measured on the bearing housing must not exceed "ambient temperature + 40 degrees Celsius or less". However, it depends on the measuring position, ambient temperature, the relationship with coolant temperature, and viscosity of the lubricating oil; it cannot be determined unilaterally. It is recommended to determine the permissible temperature according to the lubrication method, mesuring method and ambient conditions, without sticking to the principle of "ambient temperature + 40 degrees Celsius".

It can be said generally that seizure does not occur easily even at a high temperature if temperature is stable. Sufficient care must be taken of the relationship between oil temperature and bearing temperature, and a sudden rise of bearing temperature.

If there is a sudden rise of stabilized temperature, care must be taken even if the absolute value of temperature is small. It will be necessary to check to find out the causes.

2.2 Causes for bearing temperature rise and measures to be taken

5.2 Bearing temperature rise

31

5.

5. 1) 2) 3)


- -



3.1 Performance degradation

Generally, the performances of the blower are gradually degraded by changes of the operationconditions and long-time continuous operation. The performance degradation due to long-timeoperation must be repaired at the time of periodic inspection and repair.

3.2 Causes for degraded performances and countermeasures

5.3 Performance degradation

32

5.

5.

Causes Measures

esir erutarepmet gnirae

B

1. Coolant

1) Coolant feed interruption

2) Coolant temperature rise

1) Immediately take actions to permit coolant feed.

2) Increase the coolant volume (below the speci�ed pres-

sure), or install a cooling device.

2. Lubricating oil

1) Deterioration o� ubricating oil

2) Water mixed into lubricating oil

3) Impurities mixed into lubricating oil

4) Insu�cient volume o� ubricating oil

5) Excessive volume o� ubricating oil

1) Clean the bearing portion, and replace the lubricating

oil.


oil.


oil.

4) Add an adequate volume o� ubricating oil.

5) Remove the volume o� ubricating oil to get the proper

level.

3. Misalignment Re-adjustment

4. Bearing damage and wear Anti-friction bearing: Replace it with a new one.

Sliding bearing: Repla ce the white metal lining.

5. Shaft bend Correct the bend or replace the shaft with a new one.

6. When caused by vibration Take the measures against vibration.

7. Lubrication unit trouble

1) Oil pump failure

2) Drop of oil level in the tank

3) Clogged oil strainer

4) Reduced oil cooler capacity

5) Operation error of oil piping system valves

1) Disassemble and clean the oil pump, or replace it.

2) Supply new oil.

3) Clean it by switching.

4) Increase the volume of coolant and clean inside the

tube.

5) Adjust the position and apply hand lock.


- -



33

Causes Measures

noitadarged ecnamrofre

P

1. Reduction of speed (power supply, frequen-

cy, steam volume, pressure)

Use the measuring instruments to check it.

2. Damper opening error Adjust the opening to get the speci�ed air vol-

ume.

3. Impeller damage increased by due to deposi-

tion of dust, wear and corrosion

Disassemble, inspect and clean it.

Replace the impeller when it is much worn.

4. Measuring instrument failure Test and correct them.

5. Increased resistance due to leakage of the

casing and duct and deposition of dust

Disassemble, inspect and clean them.

6. Reduced speci�c gravity of gas Check it by a speci�c gravity meter or through

gas analysis.

7. Changes in gas temperature Check it.


- -


The table below shows the blower's general troubles and causes.

5.4 Blower troubles and its causes


34

Trouble No. ＡＢＣＤＥＦＧＨＩＪＫ

.oN esua

C

Trouble/symptom　

　Cause

noit

arbiv

des

aerc

nI

esion lamronb

A

esir erutarepmet gnirae

B

putrats ta daolrevO

noitarepo gnirud daolrevO

erusserp dna etar wolf ni segnahC

egnahc daoL

raew rellep

mI

noisorroc rellepmI

dn

eb tf

ah

S

nois

orroc tf

ah

S

１ Impeller wear ○ ○

２ Impeller corrosion ○ ○

３ Increase of dust volume ○ ○ ○

４ Dust deposited on impeller ○

５ Imbalance ○

６ Shaft bend ○ ○

７ Misalignment ○

８ Insu�cient lubrication ○ ○

９ Bearing damage and wear ○ ○ ○ ○ ○ ○

10 Entry of dust into bearing ○ ○

11 Excessive thrust bearing clearance ○ ○ ○

12 Contact ○ ○ ○ ○ ○ ○ ○

13JIS �ange type coupling:

Rubber bushing wear○

14Gear coupling:

Tooth face wear○

15Disk coupling:

Element deformation○

16 Insu�cient foundation rigidity ○

17 Installation failure ○

18 Drain ○ ○

19 Uneven contact of packing seal ○ ○ ○

20 Damper opening error ○ ○ ○ ○ ○

21 Surging ○ ○ ○ ○

22 Pressure higher than speci�ed level ○

23Entry o� oreign substances from the

suction and discharge cones○ ○ ○

24 Reduction o� nlet gas temperature ○ ○

25 Abnormal rise o� nlet gas temperature ○ ○ ○

26 Impact of sucked gas components ○ ○ ○ ○

27 Vibration by �uid ○ ○

28 Unbalanced power supply ○ ○ ○ ○ ○

29 Instrument trouble ○ ○ ○ ○ ○ ○


- -


Contact the supplier you purchased the product from or our company if repair or inspection services are necessary for your fan or blower. In the presence of any abnormalities in your fan or blower, stop its operation immediately and carry out troubleshooting procedure. (Refer to Chapter 6 "Trouble shooting.") In the case of malfunctions, please report to the supplier the items listed on the fan or blower's nameplate (particularly, our serial number and type) and the state of malfunctions (abnormalities). Any other information would also be helpful, if available.

One year from the date of delivery.

During the guarantee period, we supply repair parts and dispatch repair service men free of charge for any damage that has occurred during your correct use due to our design or production errors. However, our guarantee does not cover any other expenses.

Malfunctions resulting from incorrect operation, use or storage by the customer.Malfunctions or damage after the expiration of the guaranty period.Malfunctions due to repair or remodelling not performed by our company or our affiliated servicecomapnies.Problems resulting from any applications not stipulated in the contract with us.Malfunctions due to fires, acts of God, natural calamities or other force of majeure.　Problems resulting from the use of any parts that do not meet our specifications.Consumables, packings(*1), sealats(*2), sliding parts(*3), etc.

Under the conditions of the guarantee, we are only responsible for the mending, repair or replacement of defective parts or the supply of replacement parts. The guarantee does not require us to compensate for any secondary losses.

(*1) O-rings, gaskets, etc. (*2) Oil seals, mechanical seals etc. (*3) Bearings

6.1 Guarantee period

6.2 Scope of guarantee

6.3 Our guarantee is not applicable to

6.4 Our guarantee is applicable to

35

• • • • • • •

Chapter 6 Guarantee and Service (MAPEG_STDFB199802)


- -


List of warning labels (MAPEL_STDFB199802)

Ｎｏ. ＮＡＭＥ　ＯＦ　ＰＡＲＴＯＵＴ　ＬＩＮＥＭＡＴＥＲＩＡＬＲＥＭＡＲＫＳ

１ Warning label Aluminum foil NPE80101

２ Warning label Aluminum foil NPE80102

３ Warning label Aluminum foil NPE80107

４

５

REMARKS

36


- -


37

MODEL BTnPSINGLE SUCTION MULTI STAGE CENTRIFUGAL BLOWER

- -


Contacts

•

•

•

38

Head office

5-1, OMORI-KITA 1-CHOME, OTA-KU, TOKYO 143-8558, JAPAN

OVERSEAS TRADING SECT., INDUSTRIAL BUSINESS DEPT.

TELEPHONE : ＋81-3-3298-5123

TELEFAX : ＋81-3-3298-5146

Mishima plant

3-27, MIYOSHI-CHO, MISHIMA-SHI, SHIZUOKA 411-8560, JAPAN

INSPECTION & TEST SECT., QUALITY ASSURANCE DEPT.

TELEPHONE : ＋81-55-975-7900 TELEFAX : ＋81-55-975-5785

Aerodynamics Machinery Designing Group

TELEPHONE : ＋81-55-975-8053

TELEFAX : ＋81-55-975-8867

If you have any uncertain points or questions concerning the handing of the product, please call our branch

office, sales office or Business Division of the Head office nearest to you.

We look forward to your continued patronage.

installation,operation and maintenance manual … btnp single suction multi stage centrifugal blower...

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