Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3
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Transcript of Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3
Simdean Envirotec Ltd. 1
Operation and Maintenance Manual for Simdean Air Extraction System
Client: Amey Cespa (WM) Ltd , Waterbeach MBT, Cambs
Your Ref.: PO.1000000230 and Amey Cespa Sub-contract Order Waterbeach MBT Air Handling Works
Our Ref.: Job No. JB 1164-13
Date: December 2013
Issue No: Draft
Unit 2, Shrewley Farm Five Ways Road
Hatton, Warwicks CV35 7AT Tel : +44(0)1926 840233 Fax : +44(0)1926 840237
Simdean Envirotec Ltd. 2
Index Section 1................ Introduction & Certificate of
Conformity Section 2 ................ Safety Section 3 ................ Description Section 4 ................ Installation Section 5 ................ Operating Instructions Section 6 ................ Maintenance Instructions Section 7 ………….. Control System Section 8 ............... Drawings Section 9 ................ Control system listing Section 10............... Proprietary Equipment
Simdean Envirotec Ltd. 3
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 +44 (0)1477)537553 +44 (0)1926 840233
Fax +44 (0)1926 840237
Mobile Telephone +44 (0)7831 807238
Email : [email protected]
Simdean Envirotec Ltd. 4
Certificate of Conformity
Simdean Envirotec Ltd herby certify that the equipment detailed and referred to in
this Operating & Maintenance Manual are either proprietary equipment or products
produced within our factory.
The equipment where applicable is in conformity with the following standards.
All equipment where applicable complies with the Low voltage directive 73/23/EC,
EMC Directive 89/336/EC and Machinery Directive 89/392/EEC (Amended
98/37/EEC) and is CE marked
Any extract ductwork has been designed manufactured and installed in accordance
with HVCA DW154 guidelines
We thus certify that the equipment has been designed, supplied, installed and
commissioned in conformity with the requirements of the contract between Simdean
Envirotec Ltd and Amey Cespa (WM) Ltd
Simdean Envirotec Ltd. 5
Section 2
Safety
As with all items of Process Plant, care must be taken when carrying out all
Maintenance and Operational procedures
There are two main areas of potential danger to personnel when operating or
maintaining the odour control systems. To ensure complete safety it is important these
safety instructions are read and fully understood.
Mechanical
The only moving parts capable of being accessed within the air extraction system are
the extract fans. It is important that when carrying out any maintenance procedures on
the plant that the system fans are electrically isolated and that the motors cannot be
switched on accidentally.
.
Electrical
The system fans installed on the system are fitted with 415V 3 ph motors. The
control panel is located to the exhaust and as such the exhaust fan motor are both
fitted with a local isolator . When working on either of the system fans it is essential
that the isolator is switched off and locked to avoid any accidental switching of the
isolator thus allowing the motors to become live.
The damper actuators are powered at 240 V any work to be performed on these
actuators should be performed with the actuators isolated from the electrical supply
All other electrical items on the odour control systems are supplied with a voltage of
equal to or less than 110V. Although this reduced voltage is used on the plant, we
would stress that no electrical work on the system is undertaken without the control
panel being isolated from the mains supply unless the person performing the work is a
suitably qualified electrician.
Simdean Envirotec Ltd. 6
Section 3
Odour control systems Description
General
A layout drawing of the equipment is contained within Section 8 of this Operating &
Maintenance Manual
Materials of Construction
In general the majority of the extract ducting within the building is constructed from
polypropylene sheet. External to the building the interconnecting ducting between the
major items of plant are constructed from GRP clad Celmar (fabric backed
Polypropylene sheet).
The system exhaust fan is constructed with all contact parts manufactured from
stainless steel sheet. The use of unprotected ferrous metals has been minimized to
ensure corrosion of the system is reduced to a minimum.
Control
Control of the overall system is effected by a relatively simple PLC controller and
HMI screen linked to a pair of ABB inverter for speed control of the exhaust fans and
pressure and velocity sensors for monitoring of the process variables. The operating
and maintenance manual for the control system and the inverter drive are contained in
separate sections to this manual with the Control system in Section 7 and the inverter
drive details contained within Section 9
Simdean Envirotec Ltd. 7
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:-
Control Panel layout
HMI Screen
Simdean Envirotec Ltd. 8
Either of the fan speeds can be altered by changing the value of the fan speed Hz. On
touching the value in the boxes 2 & 3 a keyboard will pop up and the “new” value can
be entered . Once this has been entered the return or enter key must be pressed, the
Keyboard will disappear and the new value will appear in the boxes 2 and /or 3. The
values shown in red are the actual speed the fan are running. These are read from the
actual inverters and as such are read only values and cannot be altered.
The design values for the total flowrate through the system is as follows:-
Central corridor Extract Air Flowrate 100, 000 m3/h
Additional Extract Air Flowrate 55,000 m3/h
Simdean Envirotec Ltd. 9
Section 5
Operating Instructions
The simple operation of the odour control system is at present controlled as per the
details listed in section 4 of this O&M manual
Pressure drop
The pressure level on the inlet to the fans are measured using a simple pressure sensor
located external to the building adjacent to the access stairs on the discharge end of
the composting hall,
The sensors used are CMR Controls Ltd P sensors and these indicate the indicate the
static pressure within the extract ductwork at 2 locations viz:-
Inlet to the Main central corridor extract fan
Inlet to additional exhaust fan
In addition to the pressure sensors monitoring there are a further 2 – off sensors linked
to veloprobes. The veloprobes are Stainless Steel are duct velocity sensors which have
been designed to be installed in any duct. The Velo Probes work in conjunction with
the CMR V-Sensor. As a complete system, the Velo Probes and V-Sensor generate a
linear velocity pressure measurement and provide a signal output which is a linear
volume flow. The probes are manufactured to measure by CMR. The veloprobes are
installed in the ductwork between the Technium scrubbers and the biofilters and also
between the Henze scrubber and the biofilter inlets
The operating and Maintenance manuals for the Veloprobes , P sensors and V
sensors are Section 9 of this manual
Section 6
Maintenance
In general the air extraction system is relatively maintenance free. However, to keep
the system running efficiently it is vital that the other proprietary items of equipment
are regularly inspected and serviced. Where appropriate we include the operating and
Simdean Envirotec Ltd. 10
maintenance manuals for the particular proprietary equipment. These are included in
Section 9 of this manual.
In general terms we would make the following observations
Ducting
Should be inspected regularly for damage and leakage with particular attention
being given to damage of the ductwork at high level within the section of the
ductwork within the buildings. The condition of the extract grilles should be
examined on a monthly basis to check for any blockage via particulates in the
air stream.
System Exhaust fans
The extract fan are central to the operation of the odour control plant and
should be regularly inspected and serviced. Please refer to the Operating and
Maintenance manual supplied within Section 9 of this manual.
General Maintenance Schedules
The table shown below details the preventative maintenance schedules for the overall
plant. For detailed maintenance instructions consult the appropriate proprietary
equipment maintenance manuals
Equipment Daily Monthly 3 Monthly Annually
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
Simdean Envirotec Ltd. 11
System set points
Section 7
Control System
In general the overall control of the system is performed by the PLC controller and
HMI screen using an ABB inverter. A separate operating and maintenance manual
for the automatic control system is included below. However in the event of the
control system failure it is possible to operate the exhaust fan manually.
The exhaust fans can be operated in the manual mode as follows
It is essential that this is only preformed by a qualified electrician
Power down the control panel and open the main door with isolator
Open the panel door containing the inverters
Shut the main door and switch the isolator back on :-
Manual mode control
Exhaust fans
.
The inverter control panel is fitted with a BOP (basic operating panel) for the
inverter. Whilst the detailed operating and maintenance instructions for the drives are
given in section 8 of the inverter manual instructions for changing the speed of the
fans via the inverter drive control panel mode are shown below:-
Refer to DriveIT
low Voltage AC drives User’s 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
Simdean Envirotec Ltd. 12
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
Simdean Envirotec Ltd. 13
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
Simdean Envirotec Ltd. 14
Section 8
Drawings
Control Panel Wiring Diagram
Simdean Envirotec Ltd. 15
Control Panel Wiring Diagram
for Amey Cespa Waterbeach MBT
JB 1164-13
Draft
December 2013
Unit 2, Shrewley Farm Five Ways Road
Hatton, Warwicks CV35 7AT Tel : +44(0)1926 840233 Fax : +44(0)1926 840237
Simdean Envirotec Ltd. 16
Simdean Envirotec Ltd. 17
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Simdean Envirotec Ltd. 27
Section 9
Control System
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Waterbeach 051213 / Waterbeach_plc1 [CPU 1214C DC/DC/Rly] /Program blocksMain [OB1]Main PropertiesGeneralName Main Number 1Type OB.ProgramCycle Language LADInformationTitle "Main Program Sweep (Cycle)" AuthorComment FamilyVersion 0.1 User-defined ID
Name Data type Offset CommentTemp
Network 1: First scan, system run
MOVE
MOVE
"FirstScan"%M5.0%M5.0
0
"Main FanControl SpeedRef"
%QW4%QW4
0
"Small FanControl SpeedRef"
%QW16%QW16
ENIN
ENO
OUT1
ENIN
ENO
OUT1
Symbol Address Type Comment"Main Fan ControlSpeed Ref"
%QW4 Word
"Small Fan ControlSpeed Ref"
%QW16 Word
"FirstScan" %M5.0 Bool
Network 2: Safety relay checking
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S
R
"Estop healthy"%I0.2%I0.2
"System Healthy"%M0.2%M0.2
"Estop healthy"%I0.2%I0.2
"System Healthy"%M0.2%M0.2
Symbol Address Type Comment"Estop healthy" %I0.2 Bool"System Healthy" %M0.2 Bool
Network 3: System Start and stop from HMI or Manual
S
R
"start button"%I0.0%I0.0
"System Healthy"%M0.2%M0.2
"System run"%M0.3%M0.3
"stop button"%I0.1%I0.1
"System run"%M0.3%M0.3
"System Healthy"%M0.2%M0.2
Symbol Address Type Comment"System Healthy" %M0.2 Bool"start button" %I0.0 Bool"System run" %M0.3 Bool"stop button" %I0.1 Bool
Network 4: First Scan network to set Inverter
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Network 4: First Scan network to set Inverter (1.1 / 2.1)
TONTime
MOVE
MOVE
MOVE
MOVE
TONTime
TPTime
1
"System run"%M0.3%M0.3
"start on delaytimer"
%DB2%DB2
T#5S ...
"fan controlword init"
%M0.0%M0.0
"fan controlword init"
%M0.0%M0.0
16#0476
"Main FanControl Word"
%QW2%QW2
16#0476
"Small FanControl Word"
%QW14%QW14
"fan controlword init"
%M0.0%M0.0
16#047F
"Main FanControl Word"
%QW2%QW2
16#047F
"Small FanControl Word"
%QW14%QW14
"fan controlword init"
%M0.0%M0.0
"PID StateDelay Timer"
%DB3%DB3
T#2S ...
"PID StatePulse timer"
%DB4%DB4
T#300MS ...
INPT
QET
Time
ENIN
ENO
OUT1
ENIN
ENO
OUT1
ENIN
ENO
OUT1
ENIN
ENO
OUT1
INPT
QET
Time
INPT
QET
Time
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Network 4: First Scan network to set Inverter (2.1 / 2.1)1.1 ( Page1 - 3)
MOVE
MOVE
13 "Main_Fan_
Inverter_PID".sRet.i_Mode
3 "Small_Fan_Inverter_PID".sRet.i_Mode
ENIN
ENO
OUT1
ENIN
ENO
OUT1
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Symbol Address Type Comment"Main Fan ControlWord"
%QW2 Word
"Small Fan ControlWord"
%QW14 Word
"fan control word init" %M0.0 Bool"start on delay timer" %DB2 IEC_Timer"PID State Delay Tim‐er"
%DB3 IEC_Timer
"PID State Pulse timer" %DB4 IEC_Timer"Main_Fan_Inver‐ter_PID"
%DB6 Block_FB
"Main_Fan_Inver‐ter_PID".sRet.i_Mode
Int set to change status (0=Inactive;1=SUT;2=TIR;3=Automatic;4=Hand)
"Small_Fan_Inver‐ter_PID"
%DB5 Block_FB
"Small_Fan_Inver‐ter_PID".sRet.i_Mode
Int set to change status (0=Inactive;1=SUT;2=TIR;3=Automatic;4=Hand)
"System run" %M0.3 Bool
Network 5:
"System run"%M0.3%M0.3
"AutoMan switch"%M0.4%M0.4
"Auto run"%M0.5%M0.5
"System run"%M0.3%M0.3
"AutoMan switch"%M0.4%M0.4
"Man Run"%M0.6%M0.6
Symbol Address Type Comment"System run" %M0.3 Bool"AutoMan switch" %M0.4 Bool"Auto run" %M0.5 Bool"Man Run" %M0.6 Bool
Network 6: Man control of fan speed
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MULInt
MOVE
MOVE
MULInt
"Man Run"%M0.6%M0.6
"Man fan1"%MW30%MW30
40"man fan 3"%MW18%MW18
"Man Run"%M0.6%M0.6
"man fan 3"%MW18%MW18
"Main FanControl SpeedRef"
%QW4%QW4
"Man Run"%M0.6%M0.6
"man fan 4"%MW20%MW20
"Small FanControl SpeedRef"
%QW16%QW16
"Man Run"%M0.6%M0.6
"Man Fan 2"%MW34%MW34
40"man fan 4"%MW20%MW20
EN
IN1IN2
ENO
OUT
Int
EN
IN
ENO
OUT1
EN
IN
ENO
OUT1
EN
IN1IN2
ENO
OUT
Int
Symbol Address Type Comment"Main Fan ControlSpeed Ref"
%QW4 Word
"Small Fan ControlSpeed Ref"
%QW16 Word
"Man Run" %M0.6 Bool"Man fan1" %MW30 Word"Man Fan 2" %MW34 Word"man fan 3" %MW18 Word"man fan 4" %MW20 Int
Network 7: Pressure and Velocity conversions
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Network 7: Pressure and Velocity conversions (1.1 / 2.1)
NORM_XtoInt Real
NORM_XtoInt Real
NORM_XtoInt Real
NORM_XtoInt Real
MULAuto (Real)
MULAuto (Real)
4
3
2
10
"Pressuresensor smallfan inlet"
%IW96%IW96
27648
"Psmallfan"%MD36%MD36
0
"Pressuresensor mainfan inlet"
%IW100%IW100
27648
"Pmainlfan"%MD44%MD44
0
"Velocity sensorcontrol small
fan"
%IW98%IW98
27648
"Vsmallfan"%MD52%MD52
0
"Velocity sensorcontrol main
fan"
%IW102%IW102
27648
"Vmainfan"%MD60%MD60
"Small_fan_velocity"
%MD56%MD56
4071.0
"Small_fan_volume"
%MD68%MD68
"Main_fan_velocity"
%MD64%MD64
7238.0
"Main_fan_volume"
%MD72%MD72
ENMIN
VALUEMAX
ENO
OUT
toInt Real
ENMIN
VALUEMAX
ENO
OUT
toInt Real
ENMIN
VALUEMAX
ENO
OUT
toInt Real
ENMIN
VALUEMAX
ENO
OUT
toInt Real
EN
IN1IN2
ENO
OUT
Auto (Real)
EN
IN1IN2
ENO
OUT
Auto (Real)
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Network 7: Pressure and Velocity conversions (2.1 / 2.1)1.1 ( Page1 - 7)
SCALE_XtoReal Real
SCALE_XtoReal Real
SCALE_XtoReal Real
SCALE_XtoReal Real
MULAuto (Real)
4
3
2
10.0
"Psmallfan"%MD36%MD36
2500.0
"Small_fan_inlet_Pressure"
%MD40%MD40
0.0
"Pmainlfan"%MD44%MD44
2500.0
"Main_fan_inlet_Pressure"
%MD48%MD48
0.0
"Vsmallfan"%MD52%MD52
20.4
"Small_fan_velocity"
%MD56%MD56
0.0
"Vmainfan"%MD60%MD60
20.4
"Main_fan_velocity"
%MD64%MD64
7238.0
ENMIN
VALUEMAX
ENO
OUT
toReal Real
ENMIN
VALUEMAX
ENO
OUT
toReal Real
ENMIN
VALUEMAX
ENO
OUT
toReal Real
ENMIN
VALUEMAX
ENO
OUT
toReal Real
IN2
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Symbol Address Type Comment"Pressure sensor smallfan inlet"
%IW96 Word
"Psmallfan" %MD36 Real"Small_fan_inlet_Pres‐sure"
%MD40 Real
"Pressure sensor mainfan inlet"
%IW100 Word
"Pmainlfan" %MD44 Real"Main_fan_inlet_Pres‐sure"
%MD48 Real
"Velocity sensor con‐trol small fan"
%IW98 Word
"Vsmallfan" %MD52 Real"Small_fan_velocity" %MD56 Real"Velocity sensor con‐trol main fan"
%IW102 Word
"Vmainfan" %MD60 Real"Main_fan_velocity" %MD64 Real"Small_fan_volume" %MD68 Real"Main_fan_volume" %MD72 Real
Network 8: Fan speed reading
CONVtoInt Real
DIVAuto (Real)
CONVtoInt Real
DIVAuto (Real)
"Small fanactual control
speed"
%IW16%IW16"small_fan_speed"
%MD76%MD76"small_fan_
speed"
%MD76%MD76
400.0
"small_fan_Hz"%MD80%MD80
"Main fanactual control
speed"
%IW4%IW4"main_fan_speed"
%MD84%MD84"main_fan_
speed"
%MD84%MD84
400.0
"main_fan_Hz"%MD88%MD88
EN
IN
ENO
OUT
toInt Real
EN
IN1IN2
ENO
OUT
Auto (Real)
EN
IN
ENO
OUT
toInt Real
EN
IN1IN2
ENO
OUT
Auto (Real)
Symbol Address Type Comment"Small fan actual con‐trol speed"
%IW16 Word
"small_fan_speed" %MD76 Real"small_fan_Hz" %MD80 Real"Main fan actual con‐trol speed"
%IW4 Word
"main_fan_speed" %MD84 Real"main_fan_Hz" %MD88 Real
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ScreensScreen_1Hardcopy of Screen_1
GeneralName Screen_1 Background color 109, 109, 109Grid color 182, 182, 182 Number 1Template TooltipLayersActive layer 0
Layer_0 CheckedLayer_1 CheckedLayer_2 CheckedLayer_3 CheckedLayer_4 CheckedLayer_5 CheckedLayer_6 CheckedLayer_7 CheckedLayer_8 CheckedLayer_9 CheckedLayer_10 CheckedLayer_11 CheckedLayer_12 CheckedLayer_13 CheckedLayer_14 CheckedLayer_15 CheckedLayer_16 CheckedLayer_17 CheckedLayer_18 CheckedLayer_19 CheckedLayer_20 CheckedLayer_21 CheckedLayer_22 Checked
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Layer_23 CheckedLayer_24 CheckedLayer_25 CheckedLayer_26 CheckedLayer_27 CheckedLayer_28 CheckedLayer_29 CheckedLayer_30 CheckedLayer_31 Checked
Switch_1
Type SwitchGeneralLabel text Switch Mode Switch with textValue status ON 1 Process valueText OFF Manual Text ON AutoAppearanceBackground color 72, 72, 72 Foreground color 255, 0, 31Design3D border style Checked Focus color 145, 182, 227LayoutFit to size Unchecked Height 42X position 47 Y position 15Width 114TextFont Tahoma, 12px, style=Bold Horizontal align‐
mentCentered
Vertical alignment MiddleLimitsColor for High limitviolated
255, 109, 118 Color for Low limitviolated
255, 218, 44
MiscellaneousTooltip Layer 0 - Layer_0Name Switch_1SecurityAuthorization Allow operator con‐
trolChecked
Dynamizations\Tag connectionProperty name Process value Tag AutoMan switch
Text field_1
Type Text fieldGeneralText Set Main Fan speed HzAppearanceBackground color 145, 145, 145 Background fill pat‐
ternTransparent
Border color 0, 0, 0 3D border style UncheckedBorder width 1 Line style NoneForeground color 218, 218, 218
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Simdean Envirotec Ltd. 28
Section 10
Proprietary equipment
Operating & Maintenance
Instructions for Belt Driven Fans
SSTTOOCCKKBBRRIIDDGGEE AAIIRRCCOO
FF..SS..SS LLttdd
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 @
Newton Moor Ind. Est., Newton, Hyde, Cheshire SK14 4LD Tel: 0161 303 3229 Fax: 0161 350 1980
(o/seas replace 0161 with ++4461) Web site: www.stockbridge-airco.com
INSTALLATION, OPERATING & MAINTENANCE
INSTRUCTIONS FOR CENTRIFUGAL FANS
Covering: Intended use Initial inspection Long term storage Installation and application In service procedures & routine maintenance *Read these instructions first. *Use the correct tools. *Always check that relevant mandatory & voluntary safety practices are observed. *Ensure that guards are fitted before operating equipment. *Rotate fans regularly if they stand idle for long periods.
*Isolate and disconnect electricity supply before servicing or any other work is carried out on the unit. *If in doubt contact Stockbridge Airco Ltd Service Dept.
To maintain warranty all service & maintenance work must be arranged via STOCKBRIDGE AIRCO FSS LTD!
SSTTOOCCKKBBRRIIDDGGEE AAIIRRCCOO FF..SS..SS LLttdd
CAUTION: All necessary steps have been taken to ensure, as far as is practical, that fans are designed and manufactured to be safe when used properly. These instructions are however, general and it is important that the user observes all statutory plant and other safety requirements. It is further assumed that the fans will be installed and used by appropriately qualified, experienced and competent people, for whom these instructions have been written.
STOCKBRIDGE AIRCO FAN(S) MUST BE INSTALLED IN ACCORDANCE WITH OUR OPERATING AND MAINTENANCE INSTRUCTIONS.
IN THE ABSENCE OF ANY VIBRATION MEASUREMENT AND VIBRATION TRIP SWITCHES, THE FAN UNIT MUST BE INSPECTED, ON A REGULAR
BASIS, AND VIBRATION READINGS TAKEN TO WARN OF ANY POTENTIAL FAILURE (SEE ATTACHMENT A FOR DETAILS). THIS IS
ONLY NECESSARY IF THE VIBRATION EQUIPMENT IS NOT PERMANENTLY IN OPERATION & BEING MONITORED BY A SAFETY
TRIP SYSTEM. ONUS IS PLACED ON THE OPERATORS & USERS OF THE EQUIPMENT
THAT NO FOREIGN BODIES, OTHER THAN THOSE THE FAN IS INTENDED TO HANDLE OR COME INTO CONTACT WITH, WILL ENTER
THE SYSTEM.
Intended use All Airco fans are specifically designed to operate as fully ducted units, inlet & outlet, unless otherwise stated. Units supplied for use as open inlet and/or discharge will be supplied with appropriate guards in place. Under NO circumstances should a unit be used for any other purpose other than that for which it was originally intended without prior consultation and approval in writing from Stockbridge Airco Ltd. Any work undertaken to modify any aspect of the unit, including purposes of use, must not take place without prior consultation and written approval from Stockbridge Airco FSS Ltd, failure to do so will render any warranty, guarantee and CE marking (if applicable) invalid. NOTES Use only Stockbridge Airco spares to maintain warranty.
If in doubt please contact our Service Department.
1) Inspection on delivery 1.1 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. 1.2 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 Always store the right way up. 2.2 Protect bearings against ingress of moisture, heat, dirt or other foreign materials. 2.3 Protect exposed metal parts against atmospheric corrosion and rust. 2.4 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 Position the fan on site and tighten all fasteners. 5.2 Wire up the motor according to manufacturer’s instructions. Adjust starter overload trips
accordingly. 5.3 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 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 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 Don’t forget that where a fan system is not functioning properly there may be more than one cause. Look for all possible causes and eliminate systematically. Fan system malfunction may show up as one or more of the following. Insufficient air flow Too much air flow High power consumption Bad starting Air surging, noise or vibration
Insufficient air flow At correct operating speed this is usually accompanied by reduced power consumption on centrifugal fans, especially on those having forward curved or radial tipped blades. Power consumption is less affected on centrifugal fans having backward curved blades and can, in some cases of unusual application, be slightly increased. This can also be the case with some axial fans. Action list. 1) Check running of rotation. A centrifugal fan running backwards will Still blow some air through
the system. A suggestion : Only a few mm of shaft is ever exposed, drop one end of a ruler onto it, a kick to one side will indicate direction of rotation.
2) Check impeller handing. 3) Check running speed. 4a) Choose a straight section of ducting, where disturbance from upstream conditions is likely to be minimal, preferably upstream of the fan, and traverse by pilot tube to determine the actual volume. 4b) Measure total pressure on the inlet side and static pressure on the outlet as appropriate. The algebraic difference is the fan static pressure. 4c) Check 4a and 4b against design data. 4) If 4a is LOW and 4b is EQUAL TO OR GREATER THAN design pressure the main fault
probably lies in the system away from the fan beyond the test points. Explore sections of the system to identify points of excessive loss. This can be done y taking static or total pressure measurements at strategic points in the system.
Apart from inaccurate estimation of normal losses excessive losses may arise from: 5.1) Badly adjusted dampers. 5.2) Two or more bends, obstructions or changes of section in close proximity. 5.3) An inlet or outlet grille or guard of excessive density, e.g. due to air flow contraction through
sharp openings a punched or expanded metal guard over an opening may have an effective free area 30% or more below its measured free area.
5.4) An overloaded filter. 5.5) An accumulation of foreign matter. 5.6) Air swirl.
5.7) Air swirl followed by a contraction. (Very bad) 5.8) Less than a 2.5D length of straight duct at the fan discharge. Action for elimination of 5.6 & 5.7 – fit anti swirl device. 6) If both 4a and 4b are low the main fault probably lies in the fan or its immediate connections though system faults may also contribute. Having made checks 1,2 and 3 proceed with further checks as follows: 7) Check for foreign matter in impeller. 8) Check flexible connections or jointing at fan inlet and outlet to see that there is no intrusion in the airway. 9) Is leakage or recirculation between test points and fan causing reduced effective flow. (Inc. leakage at test holes) 10) Swirl at fan inlet in same direction as rotation will cause reduced air flow and pressure. 11) Adverse factors at inlet e.g. bend or offset 12) Adverse factors at outlet e.g. sudden expansion, bend or other obstruction which does not permit recovery of flow distribution to a normal pattern. 13) Is the fan rated for the density of air gas it is handling? A fan rated for handling cold air at sea level will develop reduced pressure at altitude or if handling hot gas.
Too much air flow At correct operating speed this causes excessive power consumption on forward curved centrifugal fans. Power consumption is also high on radial tipped centrifugal fans but it is not affected on most backward curved centrifugal fans. Power may be slightly reduced on some axial fans. Action list: 1) Check impeller handing. A backward curved or inclined impeller (centrifugal) of the wrong hand
running as forward curved will give too much air and take excessive power. 2) Choose a straight section of ducting where disturbance from upstream conditions is likely to be
minimal and traverse by pilot tube to determine the actual air flow. Compare this with the design volume rating. The degree of excessive volume may provide a clue to the cause, e.g. up to about 10% above design rating may indicate over estimation of system resistance. A significantly higher disparity may indicate a major system fault.
3) Dampers or registers not set correctly or system components not installed. 4) Air leakage beyond test point. 5) Bypass damper not fully closed. 6) Over estimation of system resistance. Slow down fan or close dampers until required duty is achieved.
Power consumption high May occur with any of the following: 1) A centrifugal fan having forward curved, radial or nearly radial tipped blades handling too
much air. 2) A centrifugal fan having backward curved blades running in the wrong direction or wrong
hand impeller running correctly. 3) Swirl at fan inlet in the opposite direction to fan rotation. 4) Single phasing on a 3phase motor. (A supply fault) 5) Any A.C. motor running below its design speed due to a winding or starting fault, or low
supply voltage.
Bad starting May arise due to one of the causes in previous section – but may also arise from: 1) Low supply voltage 2) Starting voltage tappings too low on auto-transformer starter. 3) Wrong type of fuses fitted. 4) A motor fault. 5) Failure to take full account of inertia of fan and drive components in motor selection. 6) Wrong capacitor value. With all centrifugal fans closing the system dampers until full speed has been achieved can reduce the starting load.
Air surging, noise or vibration. Air surging results from instability of flow and may arise from various causes, among which are the following: 1) Hunting of fans in parallel operation. 2) An obstruction or bad connection at fan inlet creating unstable air entry (e.g. reversed vortex
condition). 3) Alternate break away and re-attachment of flow to walls of a diverging airway.
Noise Noise arises to some degree from practically every fan but is only a problem when its level is unacceptable. It may be generated as air noise, mechanical noise or electrical hum or a combination of all three. While air noise can be aggravated by some obstruction in close proximity to the inlet or outlet of the fan it most commonly results from unsuitable selection of the fan. This latter condition can only be cured by substituting a quieter fan (usually larger diameter lower speed) or by applying sound attenuating techniques.
Mechanical Noise Mechanical noise can arise from moving parts touching, faulty or wrongly selected bearings, panel vibration etc. Causes are usually self-evident but a stethoscope can be very useful in checking noise from bearings or motors.
Electrical Noise
Electrical noise can arise from eccentricity between rotor and stator, porosity or faults in rotor castings, vibration if winding etc. It is nearly always present to some extent. Certain types and sizes of single-phase 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
Poor >4.5 >7.1
Velocity
(mm/sec) RMS
Plan for attention as soon as possible
Requires attention urgently
TABLE 1.1
Volume control devices
Inlet dampers These can be fitted in the ductwork and should be at least 6 equivalent diameters from the inlet. Parallel blade dampers may, however, be used in an inlet box and should be installed with the blades in parallel with the fan shaft so that when closing they create swirl in the direction of fan rotation producing a similar effect to inlet vane control.
Inlet vane control To maintain a fair degree of fan efficiency at reduced airflow conditions, this form of control is used on the fan inlet itself. When partially closed it creates a spin in the same direction as the impeller rotation, which reduces the pressure/volume characteristic of the fan. When it is intended to use this type of control Stockbridge Airco should approve it.
Outlet dampers It is generally recommended that, where outlet dampers are required, the opposed blade damper should be utilised. Both parallel and opposed blade dampers are suitable for fitting to the fan outlet although 2 diameters of duct between the fan outlet and damper is preferred, provided the effect of the damper on the flow pattern in the subsequent system is appreciated.
Operating & Maintenance
Instructions for Belt Driven Fans
SSTTOOCCKKBBRRIIDDGGEE AAIIRRCCOO
FF..SS..SS LLttdd
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
@
1
Newton Moor Ind. Est., Newton, Hyde, Cheshire SK14 4LD
Tel: 0161 303 3229 Fax: 0161 350 1980 (o/seas replace 0161 with ++4461)
Web site: www.stockbridge-airco.com
INSTALLATION, OPERATING & MAINTENANCE
INSTRUCTIONS FOR CENTRIFUGAL & AXIAL FANS
Covering:
Intended use
Initial inspection
Long term storage
Installation and application
In service procedures & routine maintenance
*Read these instructions first.
*Use the correct tools.
*Always check that relevant mandatory & voluntary safety
practices are observed.
*Ensure that guards are fitted before operating equipment.
*Rotate fans regularly if they stand idle for long periods.
*Isolate and disconnect electricity supply before servicing or
any other work is carried out on the unit.
*If in doubt contact Stockbridge Airco FSS Ltd Service Dept.
To maintain warranty all service & maintenance work must be
arranged via STOCKBRIDGE AIRCO FSS LTD!
SSTTOOCCKKBBRRIIDDGGEE AAIIRRCCOO
FF..SS..SS LLttdd
2
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.
3
Intended use
All Airco fans are specifically designed to operate as fully ducted
units, inlet & outlet, unless otherwise stated.
Units supplied for use as open inlet and/or discharge will be supplied
with appropriate guards in place.
Under NO circumstances should a unit be used for any other purpose
other than that for which it was originally intended without prior
consultation and approval in writing from Stockbridge Airco FSS
Ltd.
Any work undertaken to modify any aspect of the unit, including
purposes of use, must not take place without prior consultation and
written approval from Stockbridge Airco Ltd, failure to do so will
render any warranty, guarantee and CE marking (if applicable)
invalid.
NOTES Use only Stockbridge Airco spares to maintain warranty. SEALANT USED ON FANS – High Velocity Duct Sealant 40-113
Manufacturer – Bostik Findley Ltd (Stafford UK)
If in doubt please contact our Service
Department.
4
1) Inspection on delivery
1.1 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.
1.2 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 Always store the right way up.
2.2 Protect bearings against ingress of moisture, heat, dirt or other foreign materials.
2.3 Protect exposed metal parts against atmospheric corrosion and rust.
2.4 Cover all openings to prevent loose materials entering the fan case or interfering with the
impeller.
2.5 Take the tension out of the fan belts.
2.6 Turn fan and motor slowly, check that they rotate freely at least once per week, this should help
prevent “brinelling” of the races.
2.7 Do not store near vibrating machinery or bearings may suffer damage of the same kind.
2.8 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
5) Fitting the Fan
5.1 Position the fan on site and tighten all fasteners.
5.2 Wire up the motor according to manufacturer’s instructions. Adjust starter overload trips
accordingly.
5.3 When fitting the fan unit ensure that there is adequate air space around the motor end cowl for
cooling.
5.4 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.
6
Trouble shooting
Don’t forget that where a fan system is not functioning properly there may be more than one cause.
Look for all possible causes and eliminate systematically.
Fan system malfunction may show up as one or more of the following.
Insufficient air flow
Too much air flow
High power consumption
Bad starting
Air surging, noise or vibration
Insufficient air flow
At correct operating speed this is usually accompanied by reduced power consumption on centrifugal
fans, especially on those having forward curved or radial tipped blades. Power consumption is less
affected on centrifugal fans having backward curved blades and can, in some cases of unusual
application, be slightly increased. This can also be the case with some axial fans.
Action list.
1) Check running of rotation. A centrifugal fan running backwards will Still blow some air through the
system.
A suggestion : Only a few mm of shaft is ever exposed, drop one end of a ruler onto it, a kick to one
side will indicate direction of rotation.
2) Check impeller handing.
3) Check running speed and that belts are not slipping.
4a) Choose a straight section of ducting, where disturbance from upstream conditions is likely to be
minimal, preferably upstream of the fan, and traverse by pilot tube to determine the actual
volume.
4b) Measure total pressure on the inlet side and static pressure on the outlet as appropriate. The
algebraic difference is the fan static pressure.
4c) Check 4a and 4b against design data.
4) If 4a is LOW and 4b is EQUAL TO OR GREATER THAN design pressure the main fault probably
lies in the system away from the fan beyond the test points. Explore sections of the system to
identify points of excessive loss. This can be done y taking static or total pressure measurements at
strategic points in the system.
Apart from inaccurate estimation of normal losses excessive losses may arise from:
5.1) Badly adjusted dampers.
5.2) Two or more bends, obstructions or changes of section in close proximity.
5.3) An inlet or outlet grille or guard of excessive density, e.g. due to air flow contraction through
sharp openings a punched or expanded metal guard over an opening may have an effective free
area 30% or more below its measured free area.
5.4) An overloaded filter.
5.5) An accumulation of foreign matter.
5.6) Air swirl.
5.7) Air swirl followed by a contraction. (Very bad)
5.8) Less than a 2.5D length of straight duct at the fan discharge.
Action for elimination of 5.6 & 5.7 – fit anti swirl device.
7
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:
7) Check for foreign matter in impeller.
8) Check flexible connections or jointing at fan inlet and outlet to see that there is no intrusion in
the airway.
9) Is leakage or recirculation between test points and fan causing reduced effective flow. (Inc.
leakage at test holes)
10) Swirl at fan inlet in same direction as rotation will cause reduced air flow and pressure.
11) Adverse factors at inlet e.g. bend or offset
12) Adverse factors at outlet e.g. sudden expansion, bend or other obstruction which does not permit
recovery of flow distribution to a normal pattern.
13) Is the fan rated for the density of air gas it is handling? A fan rated for handling cold air at sea
level will develop reduced pressure at altitude or if handling hot gas.
Too much air flow
At correct operating speed this causes excessive power consumption on forward curved centrifugal
fans. Power consumption is also high on radial tipped centrifugal fans but it is not affected on most
backward curved centrifugal fans. Power may be slightly reduced on some axial fans.
Action list:
1) Check impeller handing. A backward curved or inclined impeller (centrifugal) of the wrong hand
running as forward curved will give too much air and take excessive power.
2) Fan speed too high? (Pulleys wrong size or interchanged).
3) Choose a straight section of ducting where disturbance from upstream conditions is likely to be
minimal and traverse by pilot tube to determine the actual air flow. Compare this with the design
volume rating. The degree of excessive volume may provide a clue to the cause, e.g. up to about
10% above design rating may indicate over estimation of system resistance. A significantly higher
disparity may indicate a major system fault.
4) Dampers or registers not set correctly or system components not installed.
5) Air leakage beyond test point.
6) Bypass damper not fully closed.
7) Over estimation of system resistance. Slow down fan or close dampers until required duty is
achieved.
8
Power consumption high
May occur with any of the following:
1) A centrifugal fan having forward curved, radial or nearly radial tipped blades handling too
much air.
2) A centrifugal fan having backward curved blades running in the wrong direction or wrong hand
impeller running correctly.
3) Swirl at fan inlet in the opposite direction to fan rotation.
4) A fine pitch axial fan operating against excessive back pressure.
5) Single phasing on a 3phase motor. (A supply fault)
6) Any A.C. motor running below its design speed due to a winding or starting fault, or low supply
voltage.
Bad starting
May arise due to one of the causes in previous section – but may also arise from:
1) Low supply voltage
2) Starting voltage tappings too low on auto-transformer starter.
3) Wrong type of fuses fitted.
4) A motor fault.
5) Failure to take full account of inertia of fan and drive components in motor selection.
6) Wrong capacitor value.
With all centrifugal fans closing the system dampers until full speed has been achieved can reduce the
starting load. This does not apply to axial fans.
Air surging, noise or vibration.
Air surging results from instability of flow and may arise from various causes, among which are the
following:
1) An axial fan operating far back on its characteristic in “stall”.
2) Most other fan types operating near zero volume condition.
3) Hunting of fans in parallel operation.
4) An obstruction or bad connection at fan inlet creating unstable air entry (e.g. reversed vortex
condition).
5) Alternate break away and re-attachment of flow to walls of a diverging airway.
Noise
Noise arises to some degree from practically every fan but is only a problem when its level is
unacceptable. It may be generated as air noise, mechanical noise or electrical hum or a combination of
all three. While air noise can be aggravated by some obstruction in close proximity to the inlet or outlet
of the fan it most commonly results from unsuitable selection of the fan. This latter condition can only
be cured by substituting a quieter fan (usually larger diameter lower speed) or by applying sound
attenuating techniques.
9
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 single-
phase 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
Poor >4.5 >7.1
Velocity
(mm/sec) RMS
Plan for attention as soon as possible
Requires attention urgently
TABLE 1.1
10
Volume control devices
Inlet dampers
These can be fitted in the ductwork and should be at least 6 equivalent diameters from the inlet. Parallel
blade dampers may, however, be used in an inlet box and should be installed with the blades in parallel
with the fan shaft so that when closing they create swirl in the direction of fan rotation producing a
similar effect to inlet vane control.
Inlet vane control
To maintain a fair degree of fan efficiency at reduced airflow conditions, this form of control is used on
the fan inlet itself. When partially closed it creates a spin in the same direction as the impeller rotation,
which reduces the pressure/volume characteristic of the fan. When it is intended to use this type of
control Stockbridge Airco should approve it.
Outlet dampers
It is generally recommended that, where outlet dampers are required, the opposed blade damper should
be utilised. Both parallel and opposed blade dampers are suitable for fitting to the fan outlet although 2
diameters of duct between the fan outlet and damper is preferred, provided the effect of the damper on
the flow pattern in the subsequent system is appreciated.
11
Fenner belt tension guide
The belt will be tensioned correctly when the applied force (Newtons), deflects the belt at its mid-point
by a distance D, calculated from:
D mm = 16 x pulley centre span (m)
Force N to deflect belt 16mm/span
Belt tension indicator
To mid centre distance
(16mm deflection/1metre span)
Belt type Small pulley dia mm Force/Newton
SPZ 59 - 95 13 - 20
100 - 140 20 - 25
SPA 80 - 132 25 - 35
140 - 200 35 - 45
SPB 112 - 224 45 - 65
236 - 315 65 - 85
SPC 224 - 355 85 - 115
375 - 560 115 - 150
DIAGRAM 1.1
TABLE 1.2