Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

75
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

description

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Transcript of Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

Page 1: 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

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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

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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]

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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

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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Section 8

Drawings

Control Panel Wiring Diagram

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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

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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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Softkey_F1

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Layer_23 CheckedLayer_24 CheckedLayer_25 CheckedLayer_26 CheckedLayer_27 CheckedLayer_28 CheckedLayer_29 CheckedLayer_30 CheckedLayer_31 Checked

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Dynamizations\Tag connectionProperty name Process value Tag Small_fan_velocity

I/O field_2

Type I/O fieldGeneralDisplay format Decimal Field length 4

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ternSolid

Border color 0, 0, 0 3D border style UncheckedLine style Solid Foreground color 36, 36, 36UnitCharacteristicsHidden input UncheckedLayoutBottom margin 2 Fit to size UncheckedHeight 23 X position 16Left margin 5 Right margin 2Y position 86 Top margin 2Width 96TextFont Tahoma, 9px, style=Bold Horizontal align‐

mentLeft

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Text field_1

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mentLeft

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FlashingFlashing NoneMiscellaneousLayer 0 - Layer_0 Name Text field_4

Softkey_F1

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Dynamizations\EventEvent name Press key

Function list\ActivateScreen

Screen name Screen_1 Object number 0

Softkey_F2

Type Function keyGeneralAuthorization Global assignment UncheckedLED tag Bit in the LED tag 0Graphic

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Page 52: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

Simdean Envirotec Ltd. 28

Section 10

Proprietary equipment

Page 53: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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 @

Page 54: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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

Page 55: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 56: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 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 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.

Page 57: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 58: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 59: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 60: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 61: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 62: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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

Page 63: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 64: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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

@

Page 65: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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

Page 66: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 67: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 68: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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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.

Page 69: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 70: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 71: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 72: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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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.

Page 73: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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

Page 74: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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.

Page 75: Amey Cespa Waterbeach Air Extraction System OM Manual Rev 3

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