15 TPH FBC Boiler Manual

M /s.
SKM ANIMAL FEEDS AND

CET HAR VE SSELS LIMITED FOODS (INDIA) LIMITED.
1 X 15 TPH FBC BOILER(BH112)
TABLE OF CONTENTS
SL. NO. DESCRIPTION PAGE NO.
I. GENERAL
CONTRACT DATA SHEET 003
GENERAL DESCRIPTION OF BOILER 004
TECHNICAL WRITE-UP FOR BOILER COMPONENTS 007
PRINCIPLE OF FLUIDISED BED COMBUSTION 014
WATER QUALITY REQUIREMENT 018
METHOD OF WATER ANALYSIS 030
BOILER OPERATING INSTRUCTIONS 051
PROCEDURE FOR HYDROSTATIC TESTING 092
PROCEDURE FOR SLOW FIRING 095
PROCEDURE FOR ALKALI BOILOUT 098
PROCEDURE FOR STEAM BLOWING 102
OPERATION ON LOW LOADS 106
TROUBLE SHOOTING CHART 108
DO’S AND DONT’S 116
INSPECTION AND MAINTENANCE SCHEDULE 119
PRESERVATION OF BOILER 124
II. SCHEDULE
VALVES 129
LUBRICATION 133
https://boilersinfo.com
GENERAL
CONTRACT DATA SHEET
CUSTOMER M/S. SKM ANIMAL FEEDS AND FOODS (INDIA) LIMITED
LOCATION MODAKURICHI, ERODE (DIST.), TAMIL NADU.
BOILER TYPE BI-DRUM WATER TUBE BOILER (FBC)
CAPACITY 15 TPH (FROM & AT 100°C)
PRESSURE 17.5 KSC (g)
TEMPERATURE SATURATED
FUEL FIRING DOB
FEEDER TYPE POCKET FEEDER
TYPE OF FIRING FLUIDISED BED COMBUSTION
BED SIZE 3900 X 1800 MM
FURNACE EXPANDED BED HEIGHT 727 MM
HEAT INPUT (Kcal/hr) 10351438
HEATING SURFACE AREA (M²)
BANK TUBE ASSY. 309.00
HEATING BED COIL ASSY. 62.00

SURFACE
WATER WALL ASSY. 151.20
TOTAL 522.20
SIZE SET RELIEVING
LOCATION QTY. (NB) / PRESSURE CAPACITY OF END CONN.
(Nos) ORIFICE (Kg/cm²) VALVE (Kg/hr)
SAFETY STEAM 2 50 / 80 I) 18.00 i) 9713 FLANGED
VALVE DRUM ‘K’ ii) 18.25 ii) 9840 ANSI B16.5
300# / 150#
GENERAL DESCRIPTION OF BOILER
GENERAL DESCRIPTION OF BOILER
The "CETHAR FLUIDIX" is a fluidised bed boiler with the following features.
a) Compartmentalised combustion chamber

b) Under bed fuel feeding system
c) Bi-drum water tube type.
The boiler is designed for DEOILED BRAN (DOB) as main fuel with capacity of 15 TPH
at MCR. The outlet steam parameters are 17.5 KSC(g) pressure and SATURATED
steam temperature.
AIR SYSTEM:
This system starts with FD fan to supply the required combustion air and impart energy
for fluidisation. FD fan is a centrifugal type, direct coupled fan. Ambient air from fan outlet
is heated in air heater and heated air is distributed evenly to combustion chamber
through compartmentalised air box. A part of combustion air is tapped from air heater
outlet and further pressurised by a PA fan for pneumatic fuel feeding. PA fan is also of
centrifugal type, direct coupled fan. Air flow is measured using aerofoil meter.
COMBUSTION CHAMBER:
The distributor plate is the heart of FBC system. It is made up of carbon steel base plate
with air nozzles to distribute the fluidising air from air box uniformly over the entire bed.
Bed coils are immersed in the bed to maintain the bed temperature of 850-900°C by
absorbing the heat through them. Sufficient free board volume is available above the
bed to ensure complete combustion of fuel.
FUEL AND ASH HANDLING SYSTEM:
The fuel from bunker is fed pneumatically into the bed by pocket feeder and mixing
nozzles located below the bunker. The speed of fuel flow can be adjusted from the control
panel.
The ash generated is collected at bed, bank, air heater, feed water heater, spark
arrestor for MDC and bag filter zones.
FLUE GAS SYSTEM:
The hot flue gas generated from the combustion chamber is cooled by, passing through
waterwall, bank tubes, airheater, feed water heater, spark arrestor for MDC and Bag
filter. Balance draft is maintained by FD and ID fans. Flue gas is passed through a high
efficiency MDC and bag filter before lifting it to the atmosphere through the chimney.
The bag filter shall have bypass ducting arrangement to pass flue gas during servicing of
Bag filter.
WATER AND STEAM CIRCUIT:
The feed water at 30°C is fed to the boiler feed pump where it is pressurised to the
required boiler pressure. The feed water from feed pump is fed to steam drum. From
steam drum the water passes through the bank tubes to mud drum. While passing
through the bank tubes the water is heated up by the flue gas passing over the tubes. The
hot water enters into the bed coils, through downcomers and further heated up. The
steam water mixture then rises through the water wall panel tubes and enters into the
steam drum through riser tubes.
TECHNICAL WRITE-UP FOR THE
BOILER COMPONENTS
TECHNICAL WRITE UP FOR THE BOILER COMPONENTS
FLUIDISED BED COMBUSTION .
In a typical fluidized bed combustor, solid, together with inert material - for example
sand, silica, alumina or ash are kept suspended through the action of primary air
distributed through the air nozzles.
Turbulence is promoted by fluidisation making the entire mass of solids behave much like
a fluid. Improved mixing generates heat at a substantially lower and more uniformly
distributed temperature.
While it is essential that temperature of bed should be at least equal to ignition

temperature of fuel, it must never be allowed to approach adiabatic combustion
temperature to avoid melting of ash.
This is achieved by extracting heat from the bed through heat transfer tubes immersed in
the bed. Almost, all Atmospheric Bubbling FluidIsed Bed Combustion Boilers (AFBC) use
the bed evaporator (Bed coil) tubes as the mode of extracting heat from the bed to
maintain the bed temperature.
The Boiler components are categorised as Pressure and Non – Pressure Parts as
mentioned below.
1.0 BOILER PRESSURE PARTS
The complete system of boiler pressure parts covers
- Steam drum / Mud drum.
- Bank tubes
- Water wall system.

-
- Bed tube sections.
- Economiser
Together with all required headers, integral piping, interconnecting piping and
supports.
The complete system of pressure parts tubing, piping and headers will be of
ERW or seamless construction as applicable.
1.1 STEAM DRUM / MUD DRUM
The steam drum / mud drum shall be of fusion welded construction. Liberally
sized with high efficiency of internals. The drums will be provided with 2 nos.
manhole doors, to open inwards. Steam drum is provided with screen box
separators with screen type dryers as drum internals.
Suitable nozzles with flanges of adequate thickness will be provided in the drum
to mount the valves and fittings. Provision for blow down will be given in the mud
drum. Liberally sized down comers and risers are provided.
The thickness on the drum is arrived based on the requirements as specified

under IBR 1950 with latest amendments. The drums are provided with
ellipsoidal dished ends.
1.2 BANK TUBES
The bank tubes are of ERW. Tubes connecting to the drums shall enter readily on
both ends of the bank tubes are expanded into the steam and mud drums.
The bank tubes are designed with multi pass arrangement and the average flue
gas velocity is kept at optimum, considering the life of bank tubes.
1.3 FURNACE - WATER WALL SYSTEM
The furnace is of natural circulation, balanced draft design suitable for

firing the fuels specified. The complete furnace section, including the fluid bed
and water wall section are fabricated with welded wall type panel construction.
Necessary supporting / suspension systems are provided for the complete
system - for free expansion of components when unit is in operation.
1.4 BED COIL SECTION
The bed is provided with three nos. of compartments with individual air control
system for reliable and continuous operation of Fluidised bed steam generator
at continuous MCR load.
Water circulation in the bed tubes is kept optimum to ensure longer tube life.
Access door are provided at suitable elevation on any sides of the bed on the
walls, for easy access to the bed section, for any inspection and maintenance.
2.0 NON - PRESSURE PARTS.
2.1 BUNKER AND FUEL FEEDING SYSTEM
Boiler is equipped with fluid bed combustor consisting of complete system of

fuel transportation from the bunker to the fluidized bed.
Bunker is sized with proper valley angle for the better flowability of the fuel. The
bunker bottom portion is divided into required no. of hoppers corresponding to
the number of compartment in the Air box. The outlet of each bunker is connected
with pocket feeders. From Pocket feeder to the mixing nozzle the fuel will be
taken by dividing chutes, and it will be sent into the furnace using high pressure air
from Primary air fan. Feeder units will be so spaced and arranged that, individual
units are well accessible for inspection, repair and maintenance as required.
2.2 FUEL DISTRIBUTING SYSTEM
The Primary fuels from the feeding points will be pneumatically transported
through IS 1239 fuel feed pipes to the fluidised bed. Forced air flow to each of the
bed compartments can independently controlled by suitable means. A manually
operated damper is provided in the air ducting to each bed section. There are 8
nos. of feeding points and are located in the bed for uniform fuel distribution.
Fluidised Bed Proper: The Fluidised Bed system will be of the proven design
capable of continuous reliable operation and firing the fuel specified with wide
turndown range. The nozzle design will permit effective fluidisation at lower loads
with shutting down of some compartments. Fluidising nozzles will have suitably
sized stem portion extending from the bed plate to the furnace side. Besides the
design and arrangement of fuel feeding, air supply to the bed, their controls, will
ensure achieving complete combustion efficiency, avoiding problems of
slagging and clinker formation.
The design and arrangement of the bed sections are such that it will be possible
to isolate any bed section from fuel feed side, and primary air feed side, as and
when required for operational requirements.
The bed air nozzles are of SS trip / MS body material and shall be fixed on to the
bed plate by threading from the bottom side.
3.0 TUBULAR AIR HEATERS
Air heater of multitubular recuperative type is provided at the downstream of

bank tubes with gas flow through the tubes and air flow over the tubes.
The air heater tubes are of mild steel construction. The air heater is complete with
all casing, supporting structures, ducting systems etc.
4.0 FANS - DRAUGHT SYSTEM
The boiler is equipped with each one no. of 100% MCR FD fan, ID fan and PA
fan.
The fans supplied are complete with coupling, base plates etc. All control
vanes/dampers are provided with complete and connecting mechanism etc., All
the Fan impellers are dynamically balanced. Forced draft fan are provided with
grease lubrication.
5.0 DUCTING SYSTEM
All ducts are of Mild steel suitably stiffened and reinforced on the outside and
designed to withstand the pressures encountered.
The ducting system is complete with all required expansion joints, mating
flanges, dampers, supports, access doors, platforms, insulation etc. All ducts are
of welded construction.
6.0 REFRACTORY, INSULATION, CLADDING
All other piping, air ducts, flue ducts, etc., are provided with insulating system of
adequate thickness.
7.0 BOILER STRUCTURES
The boiler is provided with all required base frame, steel work of sufficient height,
with required foundation bolts, etc. The steel supporting structure for boiler,
bank tubes and airheater are from the firing floor, which is RCC.
The required structural columns, frame work for the ducting and piping,
equipment, stair cases up to boiler drum level, are provided with stairs and
walkways. The steam drum ends are provided with independent local
platform.
In addition, pipe supports, duct supports, etc., are provided for the complete
system.
8.0 AIR SYSTEM
The air from the Forced draught fan will pass through Airheater to Air box. The
combustion air will assist the combustion as well as the fluidisation. In the
proposed under bed feeding system a small quantity of air which is tapped
from the combustion air, will be boosted by a primary air fan and will be
used to transport the fuel pneumatically to the furnace.
FLUIDISED BED COMBUSTION
FLUIDISED BED COMBUSTION
FLUIDISED BED
When air or gas is passed through an inert bed of solid particles such as sand
supported on a fine mesh or grid, the air initially will seek a path of least resistance and
pass upward through the sand. With further increase in the velocity, the air bubbes
through the bed and the particles attain a state of high turblence. Under such
conditions, the bed assumes the appearance of a fluid and exhibits the properties
associated with a fluid and hence the name “Fluidised Bed”.
MECHANISM OF FLUIDISED BED COMBUSTION
If the sand, in a fluidized state, is heated to the ignition temperature of the fuel
and the fuel is injected continuously into the bed, the fuel will burn rapidly and the
bed attains a uniform temperature due to effective mixing. This, in short is fluidized
bed combustion.
While it is essential that temperature of bed should be atleast equal to ignition

temperature of fuel and it should never be allowed to approach ash fusion
temperature (1050°C TO 1150°C) to avoid melting of ash. This is achieved by
extracting heat from the bed by conductive and convective heat transfer through
tubes immersed in the bed.
If velocity is too low, fluidization will not occur and if the gas velocity becomes too
high, the particles will be entrained in the gas stream and lost. Hence to sustain
stable operation of the bed, it must be ensured that gas velocity is maintained
between minimum fluidization velocity and particle entrainment velocity.
ADVANTAGES OF FBC BOILERS
1. Considerable reduction in boiler size is possible due to high heat transfer

rate over a small heat transfer area immersed in the bed.
2. Low combustion temperature of the order of 750°C - 900°C facilities burning

of coal with low ash fusion temperature, prevents NOx formation, reduces
high temperature corrosion and erosion, and minimises accumulation of
harmful deposits due to low volatilization of alkali components.
3. High sulphur coals can be burnt efficiency without much generation of Sox
by feeding limisestone continuously with the fuel.
4. The unit can be designed to burn a variety of fuels including low grade coals like
floatation slimes and washery rejects without much sacrifice in operation
efficiency, because only about 1% by wt. of carbon content in the bed can
sustain the fluidized bed combustion.
5. High turbulence of the bed facilities quick start-up and shut down.
6. Full automation of start-up and operation using simple reliable equipment is

possible.
7. Inherent high thermal storage characteristics can easily absorb fluctuations in

fuel feed rate.
8. There is reduced possibility of formation of local hot spots on heat transfer

surfaces.
9. Though having comparatively low efficiency, fluidized bed coal fired boilers offer
the following distinct advantages over pulverized coal fired boilers, especially
when using low rank coals:-
i) High thermal inertia helps to overcome the problems of flame stability.

It eliminates the necessity of supplementary oil firing to prevent
extinction of flame when moisture and ash content of coal are high.
ii) The formation of sticky deposits on the fire side of the tubes because of
lowering of ash fusion temperature by sodium components in ash is
avoided due to low bed temperature.
iii) Lower coal crushing cost due to higher particle size.
10. Efficiency of 80% and above can be achieved.
WATER QUALITY REQUIREMENT
WATER QUALITY REQUIREMENT FOR BI-DRUM BOILERS
FEED WATER:
DRUM OPERATING PRESSURE (Kg/cm² (g) UPTO 20
HARDNESS ppm max. 1.0
pH AT 25°C --- --- 8.8 - 9.2
OXYGEN ppm max. 0.02
TOTAL IRON ppm max. 0.05
TOTAL COPPER ppm max. 0.01
SiO2 ppm max. 1.0
CONDUCTIVITY AT 25°C µs/cm max. 10.0
HYDRAZINE RESIDUAL ppm ---- ---
BOILER WATER
DRUM OPERATING PRESSURE (Kg/cm² (g) UPTO 20
pH AT 25°C --- --- 10.0 – 10.5
PHOSPHATE RESIDUAL ppm --- 10 – 40
TOTAL DISSOLVED SOLIDS ppm max. 2000
SPECIFIC ELECTRICAL CONDUCTIVITY AT 25°C µs/cm max. 4000
SILICA ppm max. 25.0
SODIUM SULPHATE AS NA2 SO3 ppm -- 20 – 40
WATER TREATMENT
I. SOURCES OF WATER:
Water can be generally classified as:
a. Surface water.
b. Ground water
a. SURFACE WATER
Surface water comes from streams, ponds, lakes and reservoirs.
b. GROUND WATER
Ground water comes from wells, mines and springs.
II. IMPURITIES IN WATER:

Impurities in water can be classified into:
a) Suspended solids.
b) Dissolved solids.
c) Dissolved gases.
a) SUSPENDED SOLIDS :
Clay, silt, Organic matter and micro organisms.
b) DISSOLVED SOLIDS.
Calcium Salts Calcium carbonate, calcium bicarbonate, calcium

sulphate, calcium chloride and calcium nitrate.
Magnesium salts Magnesium carbonate, Magnesium bicarbonate,
Magnesium sulphate, Magnesium chloride and
Magnesium nitrate.
Sodium salts Sodium carbonate, Sodium bicarbonate, Sodium
sulphate, Sodium chloride and Sodium nitrate.
Miscellaneous :
Dissolved solids : Silica, Iron, Aluminium & Manganese.
Hardness forming salts:

Hardness is only due to calcium and magnesium salts.
Carbonate Hardness : (Temporary hardness)
- Calcium Bicarbonate
- magnesium Bicarbonate
Non-carbonate Hardness : (Permanent hardness)
- Calcium sulphate
- Calcium chloride
- Calcium Nitrate
- Magnesium sulphate
- Magnesium chloride
- Magnesium Nitrate
Silica : Presence of silica in water also gives rise to hard deposits which are as
bed as scales.
Alkalinity :
Alkalinity is due to presence of
- Bicarbonates
- Carbonates
- Hydroxides
‘M’ Alkalinity represents Total Alkalinity.
‘P’ Alkalinity represents Partial Alkalinity.
Total Hardness : H
Total Alkalinity : M
a) When H>M Both carbonate and non-carbonate hardness are present

H-M Non carbonate hardness (NCH)
b) When H=M Only carbonate hardness is present.
c) When M>H Only carbonate hardness is present.

M-H Sodium bicarbonate.
c) DISSOLVED GASES :
Oxygen, Carbon-di-oxide and Hydrogen sulphide.
III. EFFECTS OF IMPURITIES:
A. DISSOLVED SOLIDS AND SUSPENDED SOLIDS:

They give rise to scaling and deposition in a given system. They also accelerate
corrosion.
B. ORGANIC MATTER:
This has a greater effect on scale deposition than on corrosion. However, the
effect of micro organisms on both deposition and corrosion can be major and
must not be overlooked.
C. DISSOLVED GASES:
They invariably influence the corrosion rate.
IV. TREATMENT:
Water is purified by
- External treatment
- Internal treatment.
EXTERNAL TREATMENT:
- Clarifiers : For precipitating colloids and setting suspended matter.

- Filtration : To remove suspended matter.
- Remove of hardness : Cold Lime soda process.
Hot Lime soda process.
Ion Exchange process.
- Removal of dissolved : Determineralization by Ion Exchange process.
Solids Desalination.
Electrodialysis.
Reverse Osmosis.
INTERNAL TREATMENT:
A. For Boiler Water Treatment:
Water is internally conditioned by the use of chemicals. Chemicals are added

to water for the following purposes.
1. Internal softening.
2. Oxygen scavenging.
3. Alkalinity Building.
4. Sludge conditioning.
5. Anti foaming.
1. INTERNAL SOFTENING:
The residual hardness in the feed water should be treated to bring it down to zero.
If allowed to concentrate, scales would begin to form. Hardness is taken care of
by providing a phosphate treatment. The principle behind it is as follows:
Calcium is allowed to react with phosphate and is converted into calcium

phosphate which is easily removed by blow down. Phosphate reserves of 30
ppm to 40 ppm is provided in the boiler water.
2. OXYGEN SCAVENGING
Corrosion would be rampant if oxygen in feed water is not removed. This can
affect the pre-boiler, boiler and condensate line sections. The removal of
oxygen therefore is a must.
The concentration of oxygen is dependent on temperatures. Oxygen content is

lesser at higher temperatures. Oxygen in water is removed by addition of
sodium sulphite. Sodium sulphite reacts with oxygen to form sodium sulphite.
We should necessarily provide reserves of sulphite (around 30 ppm) for
exigencies. Catalysed sulphite should be used.
Hydrazine hydrate can also be used for removal of oxygen. But the speed of
reaction is much lesser with hydrazine. Further, it is toxic in nature. However,
hydrazine is effective in reducing oxides of copper and iron and is more
effective in preventing deposition of corrosion products in feed lines, etc.
Hydrazine also helps in removing old corrosion products from boiler internals
and helps to maintain a uniform Fe3O4 layer on internal boiler surfaces.
Reserves of 0.1 to 0.2 ppm of hydrazine should be maintained.
3. ALKALINITY:
Alkalinity is necessary for the following reasons :
a. To prevent Magnesium to Magnesium Hydroxide sludge which is easily

removed by blow down. If Magnesium is allowed to react with phosphate
Magnesium phosphate, a thick slimy sludge will be formed, which is as bad
as a scale. Therefore OH alkalinity is provided whereby Magnesium
preferably reacts with it to form Magnesium hydroxide.
b. To minimize solubility of iron.
c. It keeps silica in solution. i.e, it reacts with silica and forms a complex
silicate compound which will remain in solution and will precipitate.
NOTE : Excess alkalinity should be avoided as it will give rise to

caustic embrittlement.
4. SLUDGE CONDITIONING:
Sludge conditioning is a must and must be provided in boiler water. The

sludge that is formed should be kept in suspension so that it is removed
easily during blow down. If the sludge is not conditioned, it would deposit on
the tubes and drums. This will serve as nuclear for scale formation.
Sludge conditioning can be achieved by the use of chemical sludge
conditioners.
5. ANTIFOAMING:
Foaming is said to occur when the steam space in the boiler is partially
filled with unbroken steam bubbles. Foaming is caused by impurities in the
water preventing the free escape of steam as it rises to the surface or by
and oily scum on the surface on the water. This surface scum may be
caused by oil, organic matter or any suspended matter in the water.
Remedy :
1. To provide an anti foaming agent.

2. Provide enough blow down to avoid excessive concentration of salts.
3. Treatment and filtration of the water to remove solid impurities.
Priming :
Priming is carrying over of water slugs with the steam. The causes are the same as
that of foaming. But it may occur even with perfectly pure feed water itself.
a. The steam space is too small.

b. If the boiler is operated way above its normal capacity.
c. If the water level is carried too high.
Remedy :
1. To avoid priming, all main stop valves on boilers and steam lines should be
opened very slowly and water in the boiler should not be carried above its
normal level.
2. Boiler design should be corrected to increase the steam space.
Summary :
01. Internal Softening Provide phosphate treatment to take care of

residual hardness.
(Provide 20-40 ppm of phosphate reserves)
Avoid high PO4
02. Oxygen Scavenging Introduce an oxygen scavenger like catalysed
sodium sulphite to remove completely dissolved
oxygen. Provide 20-30 ppm of sulphite reserves.
03. Alkalinity Provide 200 ppm of OH Alkalinity in boiler water.
04. Sludge conditioning Sludge should be conditioned with the help of a
sludge conditioner.
05. Antifoam Antifoam should be incorporated in the chemical
treatment to take care of foaming.
06. Suspended Solids Guard against mud, silt, oil, process contaminants,
etc. Provide filteration for raw water if necessary.
07. Blow down Control blow down properly to keep sludge
accumulation under control and to avoid excessive
TDS concentration.
CONVERSION TABLE FOR SPECIFIC CONDUCTANCE TO TDS AT 25°C (11°F)
uS TDS uS TDS uS TDS
5 3 300 188 2200 1485
10 6 350 218 2400 1647
15 8 400 251 2600 1795
20 11 450 284 2800 1950
25 14 500 320 3000 2085
30 17 550 347 3200 2200
35 20 600 376 3400 2395
40 23 650 402 3600 2530
50 26 700 428 3800 2685
60 35 750 462 4000 2855
70 40 800 495 4200 3010
80 47 850 530 4400 3180
90 53 900 564 4600 3335
100 59 960 623 4800 3505
110 64 1000 660 5000 3675
170 104 1300 858 8000 6115
180 110 1400 923 8500 6600
190 116 1500 975 9000 7045
200 121 1600 1000 9500 7525
220 136 1700 1145 10000 7857
240 148 1800 1195 12000 9850
260 160 1900 1205 14000 11805
280 173 2000 1315 16000 11900
BASED ON CONDUCTANCE OF SODIUM SULPHATE SOLUTIONS
OXYGEN CONTENT AT VARIOUS TEMPERATURES
Oxygen Oxygen
Temperature Temperature content Temperature Temperature content
°F °C ppm °F °C ppm
135 57.2 4.9 185 85.0 2.4
145 62.8 4.4 190 87.8 2.0
155 68.3 3.9 ----- ----- -----
165 73.9 3.6 200 93.3 1.1
175 79.4 3.0 205 96.1 0.7
180 82.2 2.6 210 98.9 0.3
Deaerator
pressure Temperature °F
Psi
212 205 197 188 178 164 148 133 118
0
218 212 204 195 186 175 162 149 134
2
227 221 215 208 200 191 180 169 159
5
237 227 221 215 208 200 190 181 170
7
239 235 230 224 218 211 204 196 185
10
Max. Oxygen 0 0.7 1.4 2.2 2.9 3.6 4.3 5.0 5.7
content (ppm)
WATER TREATMENT SUPPLIER ADDRESS’S
M/S. ANCO INDIA CHEMICALS (P) LTD,

PLOT NO. 1/1A, U.R. NAGAR EXTENSION,
JAWAHARLAL NEHRU ROAD,
ANNA NAGAR WEST EXTENSION,
CHENNAI – 600 101.
M/S. AQUA CONTROLS & SYSTEMS

2/33, D-TYPE SIDCO NAGAR,
VILLIVAKKAM,
CHENNAI – 600 049.
M/S. EFFIMAX ENGINEERS,

PLOT NO. : 5107, IST FLOOR,
12TH MAIN ROAD,
ANNA NAGAR,
CHENNAI – 600 040.
M/S. ION EXCHANGE (INDIA) LTD,

‘ION HOUSE’,
42, B.N. REDDY ROAD,
T. NAGAR,
CHENNAI – 600 017.
M/S. SURAJ CLEAR WATER SYSTEMS,

12, IIIRD STREET,
THIRUMURTHY NAGAR,
NUNGAMBAKKAM,
CHENNAI – 600 034.
METHODS OF WATER ANALYSIS
CONTENTS
1. SAMPLE COLLECTION - PRECAUTIONS
2. USE OF INSTRUMENTS – GENERAL INSTRUCTIONS.
3. DETERMINATION OF HARDNESS
4. DETERMINATION OF P & M ALKALINITY
5. DETERMINATION OF SULPHITE
6. DETERMINATION OF DISSOLVED OXYGEN MORE THAN 0.1 PPM
7. DETERMINATION OF TOTAL DISSOLVED SOLIDS.
8. DETERMINATION OF OIL
9. DETERMINATION OF pH
10. DETERMINATION OF TOTAL SILICA
11. DETERMINATION OF ORTHOPHOSPHATE

SAMPLE COLLECTION - PRECAUTIONS
Proper sampling procedure is equally important as the actual investigation to ensure

reliable measurements.
As a matter of principle, water for testing should be sampled by the actual person
responsible for the examination or atleast by someone familiar with the plant and
suitably instructed.
Sampling lines are to be kept continuously flowing. Sampling and cooling water lines
should be free from choking and sampling lines to be purged for about 30 minutes
everyday as a routine and whenever choking is suspected. To avoid contamination of
cooled samples, they are to be collected in dust-free atmosphere. Cooling water
contamination of samples is to be prevented. The sampling rate should be of not less
than 25 kg/hr and sample temperature shall not exceed about 40°C. The container
used for collecting samples should be made of polythene or polyethylene. Before
collecting samples, rinse the container atleast 3 times. After collecting the samples,
rinse the stopper and tightly close the container.
USE OF INSTRUMENTS - GENERAL INSTRUCTIONS
SPECTROPHOTOMETER
The following instructions shall be followed to ensure the accuracy of spectrometric

determinations.
1. The spectrophotometer used for colorimetric determinations is to be calibrated

atleast once in six months.
2. The temperatures of both sample solution and calibration solution shall be

nearly equal to each other. (Preferably within the range 20°C to 25°C). To
obtain this temperature, the sample shall be externally cooled with ice.
3. Same optical cell is to be used for calibration and measurement.
4. For the determination of the various constituents, individual graphs are to be

prepared with standard solutions.
5. The straight line portion of the curve which represents linearity only is to be
used.
6. Solutions of higher concentrations are to be diluted suitably so that the

concentrations can be measured within the linear portion of the graph.
7. Supplier’s other operation instructions shall also be followed.
OTHER INSTRUMENTS
The general operating instructions supplied along with instruments shall be followed.
DETERMINATION OF HARDNESS
I. INTRODUCTION
1. TOTAL HARDNESS
Calcium and magnesium ions in water are sequestered by the addition of sodium
ethylene diamine tetra acetate. The end point of the reaction is detected by means
of an indicator, chrome-black Tat an optimum pH of 10.0 – 10.4 which has a wine
red colour in the presence of calcium and magnesium and a blue colour when
they are sequestered.
2. CALCIUM HARDNESS
Calcium ions in water are sequestered by addition of EDTA. The end point of the
reaction is detected by means of an indicator, murexide which is dark purple in the
absence of calcium but which with calcium forms a light salmon red complex.
The optimum pH range is about 10.4.
II. PROCEDURE
1. TOTAL HARDNESS
a. Pipette 50 ml of the sample into a white procelin casserole. If

necessary adjust to pH7 – 10 kg using ammonium hydroxide of HCL.
b. Add 0.5 ml of buffer solution and mix by stirring. (The pH of this

solution should be between 10 – 10.2)
c. Add approximately 0.2 gms of dry chrome black T indicator to
produce the required depth of colour. The titration with EDTA should
proceed immediately upon addition of the chrome black T.
d. If hardness is present the solution will turn red. Standard EDTA

solution is added slowly with continuous stirring until the end point is
read which is pure blue colour with no reddish tinge remaining.
Further addition of EDTA will produce no further colour change.
2. CALCIUM HARDNESS
a. Pipette 50 ml of the sample into a white porcelain casserole.
b. Add 2 ml of 4% NaOH solution and stir. (The pH of this solution

should be above 10.4)
c. Add approximately 0.2 gms of calcium (Murexide indicator).
d. Add standard EDTA solution slowly with continuous stirring until the
colour changes from salmon pink to orchid purple.
CALCULATION
1. Total hardness (as ppm CaCO3) = ml std EDTA soln x 20

2. Calcium hardness (as ppm CaCO3) = ml std EDTA soln x 20
3. Magnesium hardness (as ppm CaCO3) = Total hardness (as ppm CaCO3)
minus calcium hardness (as ppm CaCO3)
III. REAGENTS
1. Standard calcium chloride solution (1 ml equals 1 mg CaCO3)
Dissolve 1.00000 gm of reagent grade calcium carbonate containing less than

0.04% MG (dry at 110°C for one hour) in 10 ml 1:1 Hydrochloric acid, without
spattering, dilute exactly to one litre and transfer to a clean dry glass
stoppered bottle for storage (or use a commercially prepared standard).
2. Buffer solution
350 ml ammonium hydroxide (conc.) + 54 gms ammonium chloride + 20 ml

magnesium complex solutions are mixed and made up to one litre with distilled
water. Magnesium complex solution is prepared as follows. 4.1 gm of MgO
(analar) is mixed with 37.2 gms of EDTA and dissolved in 410 ml of warned
distilled water.
3. Calcium Indicator
Murexide : Grind 0.2 gm ammonium purpurate (murexide) with 100 gms of

sodium chloride to 40 to 50 mesh size.
4. Chrome Black T Indicator
Grind 0.2 gms of chrome black T powder with 80 gms of powered Nacl and store
in a dark chloride bottle.
5. Standard EDTA solution
Weight 4.0 gms of di sodium di hydrogen EDTA di hydrate and dissolve it in 800
ml water. Adjust to pH 10.5 with 5% NaOH. To standardize, pipette 25 ml of
standard Cacl2 solution (prepared above) and add ammonium hydroxide (1 : 4)
solution to obtain to obtain a pH of 10 to 10.4 add 0.2 gms of chrome-black T
indicator. Titrate with EDTA solution according to the procedure above. This
EDTA solution should be equivalent to more than 1 mg of CaCO3 per ml. Let V =
the volume of standard EDTA solution required to titrate 25 ml of standard
CaCl2 solution. Then 25 ml CaCl2 / V (times volume of EDTA to be diluted) =
volume to which EDTA must be diluted.
Using volumetric pipettes and / or burettes make the required dilution, mix well and
restandardize as a check. The use of a factor is also satisfactory. This
solution should be stored in polyethylene bottles and restandardized monthly.
6. Sodium hydroxide solution (4%)
Dissolve 4.0 gms of NaOH in water and dilute to 100 ml.
IV. GLASS WARES
1. Titration apparatus outfit, consisting of automatic – zeroing 10 ml burette with

reservoir bottle.
2. 50 ml measuring cylinder – 1 No.
3. White porcelain casserole with a glass stirrer.
4. Stop cock lubricant.

DETERMINATION OF P&M ALKALINITY
THEORY OF TEST
This test is based on the determination of the alkaline content of a sample by titration
with a standard acid solution. In this measurement, the end points are taken of
change in the colour of organic indicators phenolphthalein (approx. pH 8.3) and
methyl orange (approx. pH 4.3) represent definite points to which the alkalinity of
the sample has been reduced by the addition of the standard acid solution.
APPARATUS REQUIRED
1 Burette, automatic, 25 ml or ordinary

1 Casserole, porcelain 250 ml
1 Cylinder, graduated, 50 ml
1 Stirring rod, glass.
CHEMICALS REQUIRED
Sulphuric acid, N/50

Phenolphthalein indicator
Methyl orange indicator
Methyl purple indicator
PROCEDURE FOR TEST
Measure a clear 50 ml sample of water in the graduate and transfer to the

casserole. Add 4 or 5 drops of phenolphthalein indicator. If the sample is an
alkaline water, such as usually is the case with the boiler water, it will turn red. If
the sample is a raw or natural water, it usually will remain colourless, Add the
standard N/50 sulphuric acid from the burette drop by drop to the sample in the
casserole, stirring constantly until the point is reached where on drop removes the
last trace of red colour and the sample becomes colourless. Stop and record the total
number of ml to this point as the P reading.
Add 4 drops of methyl orange indicator (if no red colour developes on the addition of
the phenolphthalein indicator to the original sample, the titration may be started with
the methyl orange indicator at this point). Continue adding the acid drop by drop
until one drop changes the colour from a yellow to a salmon-pink. Record the final
burette reading as the M reading. This is a more difficult end point and some practice
may be required. The general tendency is to add too much acid. If too much acid is
added, the sample will change from a salmon-pink to definite red. Record the titration
to P point and the total titration to the M point as the P and M readings respectively.
(Note that the M reading will always be greater then the P reading in as much as the
P reading is included in the M reading.)
CALCULATION OF RESULTS
FORMULA
1000
ppm alkalinity as Ca CO3 = ml N/50 sulphuric acid x --------------
ml sample
Using a 50 ml sample, the phenolphthalein alkalinity in parts per million as CaCO3 is

equal to the ml of N/50 sulphuric acid required for the P reading multiplied by 20. The
methyl orange alkalinity is equal to the ml of N/50 sulphuric acid required for the M
reading multiplied by 20.
LIMITATION OF TEST
It is preferable to express the results of the alkalinity determination in terms of P and

M alkalinity as above. However, results are sometimes calculated in terms of
bicarbonate, carbonate and hydrate on the assumption that titration to the P and point
is equivalent to all the hydrate and one half the carbonate alkalinity and that the
titration to M is equivalent to the total alkalinity. Many factors such as the presence of
phosphate silica, organic and other buffers affect this titration and the calculation of
the form of alkalinity present may be in error. Under normal circumstances in plant
control, expression of results as P and M alkalinity is entirely satisfactory and is to be
preferred from the standpoint of simplicity.
DETERMINATION OF SULPHITE
This method is designed primarily for the routine control of boiler feed waters subject
to sulphite treatment. Reductants like sulphite and certain heavy metal ions react
similarly to sulphite. Copper catalyzes the oxidation of sulphite on exposure to air
especially at warm temperatures.
REAGENTS
Standard Potassium Lodate Titrant

Dissolve 0.566 g KIO3 dried at 120°C and 0.5 g NaHCO3 in distilled water and
dilute to 100 ml. The equivalent of this titrant is 1.0 mg Na2SO3 per 1.00 ml.
Potassium iodide solution 50 g per litre. Dissolve 50 mg of iodate free Kl and 0.5 g of
sodium bicarbonate (NaHCO3) in freshly boiled and cooled water and dilute to one
litre.
Starch indicator.
Hydrochloric Acid 1 + 1
PROCEDURE
Place 10 ml 1 + 1 HCL in a 250 ml flask. Rapidly add 100 ml sample submerging the
pipette tip below the acid surface to minimize air exposure. After adding 1 ml starch
indicator solution and 5 ml Kl solution titrate with standard KlO3 titrant to the first
appearance of a persistent blue colour. Determine the blank titration by carrying 100
ml distilled water through the complete procedure.
SO3 milligrams per litre = (a-b) x 6.35

Na2SO3 milligrams per litre = (a-b) x 10
Where A = milliliters of titration for sample
B = milliliters of titration for blank.
APPARATUS REQUIRED
1. 250 CC Erlenmeyer flask

2. 10 CC pipette (for 1 : 1 HCL)
3. 100 ml pipette (for the sample to be measured)
4. 1 ml pipette (for starch indicator)
5. 5 ml pipette (for Kl solutin)
6. 50 ml burette (for KlO3 titrant)
DETERMINATION OF DISSOLVED OXYGEN IN INDUSTRIAL

WATERS CONTAINING MORE THAN 0.10 PPM
I. SAMPLING
It is important to use air tight connections in all apparatus used for sampling
and testing. When sampling hot water a water cooled coil should be
introduced into the sampling line. A convenient arrangement for sampling
for feed water is shown in the figure. The sample itself should be taken in a
500 ml winkler flask containing a few glass beads, as shown in figure and
water should flow through for atleast 10 minutes before taking the actual
sample so as to displace all traces of air. Care must be taken to see that air
bubbles do not form around the stopper of the winkler flask while sampling.
II. REAGENTS REQUIRED
1. Manganous chloride
Dissolve 400 gm of Manganous chloride (AR) in one litre.
2. Alkaline iodine
Dissolve 600 gm of Potassium Hydroxide and 140 gm of Potassium iodide

in one litre of water.
3. N / 100 Sodium thiosulphate
Dissolve 2.482 gm of AR sodium thiosulphate (Na2S2O3 5H2O) in water

and make up to one litre. Add about 1 gm of AR sodium carbonate to
preserve the solution.
4. Sulphuric Acid 1 : 1
Add 250 ml of conc. Sulphuric acid to 250 ml of water. Cool and store.
III. PROCEDURE
By means of the funnel fitted to the Winkler’s flask add 2 ml of the

manganous chloride solution and then add 2 ml of the alkaline iodide
solution. Mix allow to stand for 10 minutes and then add 2 ml of 1 : 1 H2SO4.
Take 250 ml of the sample and titrate the liberated iodine with N/100
thiosulphate solution using starch as indicator. Millilitre of N/100 thiosulphate
used for 250 ml sample x 0.224 = ml of oxygen / litre 1 ml of oxygen / litre
= 1.430 mg / litre.
IV. GLASSWARES
1. Winkler’ flask arrangement as shown in the figure.

2. 2 ml pipette.
3. Burette 50 ml – 1 No.
DETERMINATION OF EVAPORATION (T.D.S.) IGNITION RESIDUES
AND VOLATILE MATTER
a) Evaporation residues at 105°C apparatus required.
1, 200 CC. capacity platinum evaporation dish.

2. 100 CC. 200 CC. pipettes to measure water to be tested.
3. Water bath.
4. Drying over.
5. Dessicator.
6. Ignition furnace.
PROCEDURE
100 CC or possible a greater quantity of the water to be tested (filter if

suspended solids are present – estimate separately suspended solids
content) is evaporated in a platinum dish on a water bath until it is dry after
which it is dried down to constant weight in a drying over at 105°C. It is
weighed after cooling in the dessicator.
b) Determining the ignition residues
The evaporation residue determined at 105°C as described above is ignited

in an ignition furnace at 600 ±25°C until constant weight. Cool in the
dessicator and weigh. Constant weight shall be considered as attained when
the change in weight of the dish plus residue shall be not more than 0.5 mg
between two successive operations involving heating, cooling in a
dessicator and weighing.
c) Determining the volatile matter
Record the loss in weight in the previous determination as weight of volatile

dissolved matter.
CALCULATIONS
Total dissolved solids ppm A/W x 1000
Ignition residue ppm B/W x 1000
(A – B)
Volatile matter ppm ---------- x 1000
W
Where,
A = mg of dissolved matter.
B = mg of ignition residue
(A-B) = mg of volatile matter
W = (CC) weight of sample used.
DETERMINATION OF OIL INDUSTRIAL WATERS CHLOROFORM –
EXTRACTABLE MATTER
THEORY OF TEST
This test determines the substances which are extractable by chloroform and is not
a test specific for oil. Heavy oils, fats and certain other organic compounds will be
measured by the test. Following evaporation to dryness of the chloroform extract,
the residue is weighed.
CHEMICALS REQUIRED
Hydrochloric acid (1 : 9)
Chloroform, redistilled
PROCEDURE FOR TEST
Procedure for collecting the sample – collect approximately 900 ml of sample in a

glass container such as a wide-mouth, 1000 ml Erlenmeyer flask. The sample
should be collected directly in the flask and not transferred from another container.
Glass stoppers or caps covered with aluminum foil should be used. The flask
should be weighed prior to collection of the sample.
Procedure for Determination – Weigh the flask and its contents to the nearest 1
gram and obtain the weight of the sample by difference. Withdraw a few drops of
the sample, determine pH and adjust to between pH 3.0 and 4.0 by hydrochloric
acid (1 : 9).
Add 100 ml of chloroform to the flask and agitate by means of shaking machine or
mechanical stirrer for 15 minutes. After separation, transfer the chloroform layer by
a glass siphon to a 500 ml separate funnel. No lubricant should be used on the
funnel stopcock. Add 50 ml of chloroform to the flask and repeat agitation for 15
minutes. Then transfer this second portion of chloroform to the separate funnel.
Draw off the chloroform layer through a dry, fat-and-oil-free filter paper into a 250 ml
breaker. It there is suspended matter at the interface, leave about 2 ml of the
chloroform layer the funnel. Add 20 ml portion of fresh chloroform directly to the
funnel shake and then withdraw the chloroform, using it as a wash for the filter.
Evaporate the chloroform on a boiling water bath to about 20 ml then transfer
quantitatively to a weighted platinum or silica evaporating dish. If the source of the
water sample was at or above 212°F. Continue evaporation to dryness on the
boiling water bath. If the sample was from a source below 212°F, again reduce
the volume to about 20 ml on the boiling water and then continue evaporation at
room temperature. Weigh until constant weight is obtained.
CALCULATION OF RESULTS
Chloroform – extractable matter ppm =

1000
weight increase of evaporating dish, mg x --------------
ml sample
LIMITATIONS OF TEST
With proper technique, an accuracy of 1.0 ppm or 2% which ever is greater can
be obtained. The method does not determine lighter hydrocarbons which volatilize
under the test conditions. Substances other then oil are included as chloroform
extractable matter. While this procedure is based on ASTM method D1178 -54T,
that method should be consulted if it is desired to conduct the test in exact
conformity to ASTM – standards.
APPRATUS REQUIRED
1. A well-equipped laboratory
2. Wide mouth 1000 ml Erlenmeyer flask.
3. Balance capable of weighing upto 1 kg with an accuracy of ± 1 gm.
4. pH meter.
5. 100 ml measuring cylinder.
6. Shaker or mechanical stirrer.
7. 500 ml separating funnel
8. Glass syphon
9. Oil free filter paper
10. 250 ml beaker.
11. Funnel with filter stand.
12. Water path suitable for heating (thermostat)
13. Platinum or silica evaporation dish.
DETERMINATION OF pH VALVE
INTRODUCTION
As a yard stick for the concentration of hydrogen ions, the pH value gives an
indication of the percentage reaction (alkalinity or acidity) of the water and hence
its aggressivity. The pH value is the negative logarithm to the base 10 of the
hydrogen ion concentration, expressed as gram ions per litre.
The pH value of a given solution depends on the temperature and as a rule it is

quoted for 20°C. At this temperature the pH value ranges from 0 to about 14.
Water with pH=7 has a neutral reaction, while there is an acid reaction at pH<7
and a basic reaction at pH>7.
APPARATUS REQUIRED
1. A pH meter with associated glass and reference electrodes.

2. Buffer table of kwown pH.
ELECTROMETRIC DETERMINATION OF pH VALUE
With the electrometric method, the pH value is determined from the potential
difference between the measuring electrodes immersed in the liquid under test and
a reference electrode of known potential for testing water electrode assemblies
comprising a glass electrodes and a calomel reference electrode are suited.
pH meter is to be operated in accordance with the instruction supplied with it, by

its manufacturer. To ensure accurate measurements, air must be prevented from
getting to the sample, since pH value may be strongly influenced by atmospheric
contaminants.
Where water is very pure and the pH value and electrical conductivity are being
determined simultaneously, make sure that the pH electrodes are inserted AFTER
the conductivity electrodes if the measuring points are connected in series.
ELECTRODE TREATMENT
New glass electrodes and those that have been stored dry shall be conditioned and
maintained as recommended by the manufacturer. If the assembly is in intermittent
use, keep the immersed ends of the electrodes in water between measurements.
For prolonged storage, glass electrodes may be allowed to become dry, but the
junction and filling openings of reference electrodes should be capped to reduce
evaporation.
STANDARDISATION OF ASSEMBLY
Turn on the instruments, allow it to warm up and bring it to electrical balance in

accordance with the manufacturer’s instructions. Wash the glass and reference
electrodes and the sample cap by means of a flowing stream of distilled water from
a wash bottle. Note the temperature of the test solutions and adjust the
temperature dial of the meter to correspond. Select the two reference buffer
solutions, the pHs values of which are close to the anticipated pH of the test
solution. (Buffer solutions can be prepared from the buffer tablets following
manufacturer’s instructions). Warm or cool these reference solutions as necessary
to match within 2°C the temperature of the unknown. Fill the sample cup with the
first reference buffer solution, and immerse the electrodes. Engage the operating
button, turn the range switch if present to the proper position and rotate the
assymmetry potential knob until the reading of the dial corresponds to the known
pH of the reference buffer solution. Repeat the above procedure until two
successive instrument readings are obtained, without changing the setting of the
assymmetry potential knob. Care should be taken to see that the level of the KCI
solution in the reference electrode must always be kept within that of the measured
solution. To reduce the effects of thermal and electrical hysteresis, the
temperature of electrodes, reference buffer solutions and wash water should be
kept as close to that of the unknown sample as possible.
Wash the electrodes and sample cum three times with water. Place the second
reference buffer solutions in the sample cup and measure pH by simply reading the
dial. Do not change the setting of assymmetry potential knob.
The assembly shall be judged to be operated satisfactorily if the pH reading

obtained for the second reference buffer solution agrees with its assigned pH value
with in 0.05 unit. In long series of measurements, supplement initial and final
standardisations by interim checks.
Wash the electrodes by means of a flowing stream from a wash bottle. Place the
water sample in a clean glass beaker. Measure the temperature. Insert the
electrode and measure pH as before.
INSTRUCTIONS
pH meter should be checked for its performance using buffer tablets atleast once a
shift.
DETERMINATIONS OF TOTAL SILICA IN HIGH PURITY WATER
INTRODUCTION
Some boiler stations using ion exchange columns of preboiler water purification
have noticed silica concentrations building up in the units and at the same time a
soluble silica analysis on water coming from the ion exchange column showed no
silica. Analysis for colloidal silica on these same samples showed that the silica
was present as a colloidal particle. This technique has been developed as an
analytical procedure to accurately determine trace concentrations of silica where all
or a part is present in colloidal form. Total silica is determined
spectrophotometrically after solubilization by the pressurized bomb method. (Paar
oxygen bomb).
PROCEDURE
1. Accurately measure 50 ml or a suitable aliquot of the sample into a platinum

cup.
2. Add 1 ml of 0.2 N NaOH and close the cup with a platinum cover.
3. Place the closed cup in a paar oxygen bomb containing 100 ml of deionized
water and completely assemble the bomb.
4. Nitrogen is added to obtain 30 pounds pressure and let out five times to
completely, flush out oxygen in the bomb to prevent bomb corrosion.
5. Pressurize the bomb with nitrogen to 45 psig (maintained for specified

period) and place in an oven at 190°C for 8 hours. The oven should be
placed in a hood since all gaskets in the bomb are made of Teflon.
6. Remove the bomb from the oven, cool and remove the sample from the
platinum cup. Silica is determined spectrophotometerically by using the
applicable high or low range method.
CALCULATION
1. See silica curve for the spectrophotometer used.

2. Colloidal silica (ppm) = Total silica (ppm) - soluble silica (ppm)
APPARATUS REQUIRED
1. 25 ml – Pipette
2. 50 ml – Pipette for suitable aliquot sample.
4. Platinum cup with cover.
5. Oxygen bomb.
6. 1 ml Pipette (for 0.2 N NaOH solution)
7. 10 ml – Pipette (for deionized water)
8. Nitrogen cylinder with pressure regulator opener etc.
9. AIR OVEN to be capable of giving a temp, of 190°C for 12 hours
continuously.
10. Spectrophotometer at 815 nm.
DETERMINATIONS OF ORTHOPHOSPHATE INDUSTRIAL WATER

ASTM : D515-68
INTRODUCTION
This method is applicable to the routine determination of orthophosphate in the

2 – 25 ppm PO4 range in industrial water and is based on the photometric
measurement of the yellow colour of the molybdo vanadophosphoric acid
produced. The colour intensity is proportional to the orthophosphate concentration
in the sample. Highly coloured water such as tannin treated boiler water and high
concentration of ferric iron interfere thus requiring preliminary treatment to remove
these materials.
PROCEDURE
1. To a 125 ml Erlemeyer flask, using a pipette or volumetric flask, add 50 ml. of

the clear sample or a liquit there of diluted to 50 ml. with deionized water. The
sample must be free of suspended matter to avoid arroneous high results.
Filtration using what man no. 42 filter paper has been found to be satisfactory
in most cases.
2. Add, using a graduate, 25 ml of ammonium vanadomolybdate solution and mix

well by swirling.
3. Allow 10 minutes for colour development and read within 30 minutes on the
spectrophotometer at 400 mm.
4. Reagent blank and atleast two phosphate standards should be run along with
samples.
CALIBRATION AND STANDARDIZATION
1. Prepare a series of standards to cover the range 0-25 mg/litre (ppm) and
prepare calibration curve.
REAGENTS
1. Ammonium vanadomolybdate solution – Dissove 40 grams of ammonium

molybdate – tetrahydrate (NH4)6MO7O244H2O) in 400 ml. of water. Dissolve
1.0 gram of ammonium metavanadate in 300 ml of water and add 200 ml
concentrated nitric acid (SP. GR. 1.42). Add the first solution to the second
solution mix well, and dilute to 1 litre with water in a volumetric flask.
2. Phosphate standard solution (1 ml = 1 mg PO4) – Dissolve 1.433 grams of oven

dried (4 hours at 105°C )C.P. potassium dihydrogen phosphate (KH2PO4) in
water and dilute volumetrically to one litre.
APPARATUS REQUIRED
1. 125 ml Erlenmeyer flask.
25 ml – Pipette for suitable aliquot sample.
10 ml – Pipette
3. Filter stand with funnel, 42 what man filter paper etc.
4. 25 ml – Pipette (for ammonium vanadomolybdate solution)
5. Spectrophotometer at 40 nm.
BOILER OPERATING INSTRUCTIONS
BOILER OPERATING INSTRUCTIONS
01. STARTING OF ALL INDIVIDUAL EQUIPMENTS
02. STARTING OF BOILER FEED PUMPS
03. DP STUDY
04. BED MATERIAL, CHARCOAL & KEROSENE REQUIREMENT
05. BOILER LIGHT UP
06. NORMAL OPERATION
07. NORMAL SHUT DOWN TO COLD
08. NORMAL SHUT DOWN TO HOT STAND BY
09. HOT RESTART

STARTING OF ALL INDIVIDUAL
EQUIPMENTS
STARTING OF ALL INDIVIDUAL EQUIPMENT
GENERAL
The boiler is provided with interlocks for safe and reliable operation and none of these
should be bypassed.
The sequence of starting of the equipments is as follows:
* Check water level gauge for water in Drum.
01. Start the ID fan.

02. Start the PA fan.
03. Start the FD fan.
04. Start the Fuel feeders.
Similarly while switching off, reverse sequence must be followed.
The individual equipment can be started through DCS or from Local Push Button
(LPB). Switch on the power supply to the motor control centre (MCC) panel. The
fuses of individual motor controls shall be checked for continuity. Three phase supply
of 415 V / 11000 V 50 Hz with allowable percentage of variation shall be ensured
before switching on the equipment.
STARTING OF BOILER FEED PUMPS
GENERAL
Ensure that the suction valve is open and water is available in the deaerator storage
tank. Also ensure that, the discharge valve or the feed control valve including the
bypass valve is closed. Then start the feed pump. Do not close the suction valve, when
the pump is running. The auto recirculation valve to be opened automatically at the
time of starting the pump and the same will be after crossing the pump min. flow. After
that outlet valve is to be opened immediately. Do not run the feed pumps without suction
filter. During normal running of boiler the pump can be started / stopped with discharge
valve open, since the feed line is under pressurised condition.
DP STUDY
DP STUDY
DP study must be carried out individually for all compartments. In simple terms, DP
study is nothing but finding out the pressure drop across distributor plate at different air
flows. Follow the steps given below.
DP study shall be done separately for each compartment. Hence close the FD, PA
dampers of the compartments which are not being studied.
Switch on ID fan, PA fan and then FD fan. Open the suction damper of FD fan and set 10
mm air flow in Aerofoil meter. Measure the air box pressure and gas plenum pressure (ID
fan damper is to be adjusted to maintain a gas plenum pressure of -5 mmwc at all
conditions).
Suppose,
FD air flow = 10 mmwc across Aerofoil meter
Air box pressure = 75 mmwc
Gas plenum pressure = -5 mmwc
The pressure drop across DP at 10 mm air flow = 75 + 5 mmwc
= 80 mmwc
Thus, the pressure drop across DP can be found out 20, 30, 40, 50, 75, 100 & 125 of air
flow.
* The pressure drop values should be found out for other compartment too.
* The pressure drop values shall be compared. For the same air flow, if there is
a deviation of more than 5 mm between compartments, then it becomes
necessary to check the following.
* The manometer readings may be incorrect. Check for leakage in the pressure
tapping locations or Aero foil meter and air box.
* Check for leakage in the impulse lines to manometer/ Draft indicator.
* Check for leakage between fuel feed pipe and air box.
* Check for broken air nozzles.
* The pressure drop values found in DP study, shall be recorded for

future use. The pressure drop values measured in DP study are used to
find out the bed height when the boiler is in running condition i.e. at a
particular air flow. Also it is used to establish the practical pressure drop
across the aero foil meter at the MCR air flow. If the DP drop is subracted
from the total drop across the bed and DP, then bed height can be arrived at.
The pressure drop values taken shall be recorded on the following tables for future
reference.
DP STUDY READINGS
COMPARTMENT – I
PRESSURE DROP ACROSS DISTRIBUTOR

SL. FD AIR FLOW (MM) GAS PLENUM PLATE (AIR BOX PRESSURE – GAS
NO. PRESSURE (MM) PLENUM PRESSURE)
01
02
03
04
05
06
07
08
COMPARTMENT – II

01
02
03
04
05
06
07
08
DP STUDY READINGS
COMPARTMENT – III

01
02
03
04
05
06
07
08
COMPARTMENT – IV

01
02
03
04
05
06
07
08
BED MATERIAL, CHARCOAL & KEROSENE
REQUIREMENT
BED MATERIAL, CHARCOAL, KEROSENE REQUIREMENT
BED MATERIAL REQUIREMENT:
Quantity of bed material per startup : 2350 Kgs.
Quantity of Bed material to be stocked : 23500 Kgs. (For 10 Startups)
BED MATERIAL SPECIFICATION:
Maximum particle size : 2.36 mm
Particles to pass through sieve No. : 8
Minimum particle size : 0.85 mm
Particles to stay on sieve No. : 20
Particle density : 2000 Kg/m3
Bulk density : 1000 to 1100 Kg/m3
Chemical composition
Alumina : 45% to 35%
Silica : 55% to 65%
Fusion temperature : 1400°C (Min.)
(Bed material shall be from Crushed refractory bricks or from sieved ash).
CHARCOAL REQUIREMENT:
Quantity of charcoal per startup : 150 Kgs.
Quantity of charcoal to be stocked : 1500 Kgs. (For 10 Startups)
CHARCOAL SPECIFICATION:
Charcoal size : 15 to 25 mm LUMPS
Calorific value : 6600 Kcal/Kg.

(Charcoal should be sundried)
KEROSENE:
Quantity of kerosene per startup : 10 Litres.
Quantity of kerosene to be stocked : 100 Litres. (For 10 Startups)

USE OF BED MATERIAL
The bed material plays a vital role in the fluidised bed combustion process. The bed
material is inert and does not undergo any chemical change. The size of the bed
material is so selected to meet the fluidisation requirements. The bed material once
heated serves like an ignitor for the incoming fuel. The normal bed height when
defluidised is maintained in the range of 300 mm to 400 mm. The bed material also acts
as the carrier of heat between the burnt and the heat transfer surface.
PROCUREMENT OF BED MATERIAL
The bed material shall be procured from refractory supplier. Alternatively, the bed
material can be purchased from the user of a coal fired fluidised bed boiler. The ash
drained from the fluidised bed can be screened and used as bed material.
IMPORTANCE OF BED MATERIAL QUALITY AND QUANTITY
1. Before programming for a light up, it is necessary that the recommended quantity
of bed material is procured according to the specifications. The bed material is to
be stocked atleast for 10 start ups.
2. If the bed materials is procured from a refractory supplier, ensure only refractory
bricks are crushed to make bed material. Mix up of insulation bricks is not
allowed.
3. The fusion temperature of the bed material has to be above 1400°C. If the fusion
temperature is lower, clinkering will occur in the bed.
4. It is important that the bed material is procured according to the size

recommended. Oversize particles do not fluidise well and fine powder will fly away.
Also the fine powder puts off charcoal fire while start up. (Because fine bed
material quickly transfer heat to the bed coils).
5. In a coal fired boiler, the ash produced from coal partly accumulates in the bed
and the same is drained to maintain a constant recommended bed height in the
fluidised bed. This ash drained from the bed can also be screened and the
screened ash can be used as bed material. In an agro fuel fired boiler, the bed
material will not be generated and hence bed material has to be procured for daily
consumption.
6. A coal fired fluidised bed in operation contain good amount of fines and coarse
particles. Which are due to varying coal particle size on crushing. Hence for
every light up (except hot restart) fresh bed material is to be used. This is
essential for a smooth and quick start up.
7. When the bed material is procured from a refractory supplier, the size of the
bed material is to be specified up mentioning the upper sieve no. 8 and lower
sieve no. 20. The material has to pass through sieve no. 8 and to stay on sieve
no. 20.
USE AND IMPORTANCE OF CHARCOAL:
1. Charcoal is required for lighting up of the boiler. A fixed quantity of charcoal is burnt
in the fluidised bed to raise the bed temperature in the start up compartment.
Once the bed temperature is raised further fuel is fed to establish combustion of
fuel in the fluidised bed.
2. Charcoal is selected as the start up fuel, mainly, because of its high heat content ,
rapid burning characteristics and low ignition temperature.
3. Good quality charcoal is a must for easy light up. Ensure charcoal is dry and not
already burnt. Heavier charcoal is an indication of good quality. Tamarind wood
charcoal is the best because it burns for more time and the calorific value is
about 6600 kcal/kg.
4. Charcoal should be dry for rapid burning. Wet charcoal should not be used in
any case. Ensure the charcoal in stock is also dry.
5. The charcoal should not contain powder or bigger lumps. The charcoal shall be
sized to 15 - 25 mm. Fine charcoal burns easily and does not contribute much for
heating the bed. Bigger lumps would cause clinker formation as the lumps do not
easily fluidise.
BED MATERIAL FILLING:
* The bed material can be filled by entering the furnace. For start up purpose, the
bed height shall be 200 - 225 mm above the air nozzle top level in the start up
compartment.
* The bed material below the nozzle level remains static all the time. This is not to
be counted as the bed height.
* Uniform spreading can be done by admitting fluidising air through the bed. The
air should be sufficient enough to fluidise bed.
* The bed height can be measured physically after putting off the air flow.
* Alternatively the bed height can be found out by pressure drop across the
fluidised bed.
Let us assume,
For 100 mm fluidising air flow the distributor plate pressure drop is found to be 150 mm.
Let gas plenum pressure = -10 mmwc
Let air box pressure drop across the fluidised bed = 484 mmwc
The pressure drop across the fluidized bed and the distributor plate = 491 mmwc
The pressure drop across the distributor plate is 121 mmwc as found in DP study.
The pressure drop across the bed = 491 - 121.
= 270 mmwc
Since the bulk density of the bed material is 1000 kg/m^3, the pressure drop across the
bed in mm is the bed height in mm.
Though the normal operating bed height is 300 - 550 mm, initial bed material filling is
done only upto 200-225 mm. This low bed height reduces the charcoal requirement for
start up purpose. Also low bed height helps in raising the boiler pressure slowly.
In the case of compartmental start up the bed material shall be filled as explained below:
Fill the bed material to a height of 300 mm in all compartments. Fluidise all the
compartments together provided the fan motor amperes are below the limits. If not
possible, fluidise two compartments together for levelling. Then the next compartment
can be fluidised separately. The start up compartment is to be fluidised separately.
When this is done a portion of the bed material spills to the adjacent compartment and
forms a mount along the edge of the compartment. Further bed material is to be added
to the start up compartment so that the bed height of 200 - 225 mm is maintained.
BOILER LIGHT-UP
04. BOILER LIGHT-UP:
The lighting up of the boiler is to be done with the help of charcoal and kerosene. The
light up is to be done only for a single compartment. After stabilising with a single
compartment fire is transferred to other compartments as per the procedure explained
separately.
PREPARATIONS:
01. Inspect the boiler prior to starting and check the following.
- All access doors are closed.

- All personnel cleared.
- All foreign materials are removed from furnace and pressure parts.
- Starting equipment and interlocks are in position.
- Boiler is filled with DM water above the low level limit.
02. Check the following equipments for adequate lubrication and readiness for service.
- Fans and drives.

- Feed pumps and drives.
- Fuel feeders and controllers.
03. Check dry fuel (0-6) mm is available in the bunker, the gates below the bunker
are open and fuel is available at feeder inlet.
04. Check the instrument air is available at the required pressure (of 7 kg/cm2) for
instrumentation and control.
05. Check the following valves in the Boiler drum are closed.
- Feed control valve and its bypass valve.

- Blow down valve.
- Main steam stop valve.
- Drain valves of water level gauge.
06. Check the following valves are kept open.

- Air vent on top of drum.
- Water level gauge, pressure gauge and level transmitter / isolation valves.
- Valves before and after the feed control valve in the feed line.
- Valves on the feed line connecting to the feed pumps in operation.
07. Check the bed material is filled in the furnace and fluidisation study is
complete.
BOILER FILLING:
Before starting the filling up, keep the vent on the drum open and close the blow down
and drain valves. The filling up is done by running the feed pumps but the rate of flow is
controlled by means of feed control valve. During the filling up check the operation of
blow down valve and drain valves and then close them. The boiler is filled up
completely till water comes through the drum vent and is drained to bring the water level
to low level alarm limit.
FLUIDISATION STUDY:
* During the fluidisation studies, except for large compartments the fuel
transport air need not be introduced as it would disturb the bed.
* Observe the fluidisation of the start up compartment by varying the air flow
gradually. Mark the position of dampers when the bed material begins to
fluidise. In the case of pneumatically operated dampers, note the input signal
"PSI" from the manual loaders.
* The on set fluidisation may also be observed by plotting the bed pressure drop
against the air flow.
* Set the air flow at 5 mm P.
* Measure the air box pressure, P1 mm wc
* Add the gas plenum pressure P2 to P1 (P1+(P2)) is the pressure drop across
the distributor plate and bed.
* Substact P3 mmwc, which is the pressure drop across DP alone which is
measured in DP study. i.e., (P1 + (P2)) - P3 would be the pressure drop across
the bed.
* The pressure drop across the bed is thus obtained for various air flows. The
readings may be plotted in a graph as shown.
* The air flow at which fluidisation starts is noted. This value is to be maintained
for the purpose of mixing at the time of startup.
* Once the fluidisation study is completed, the fans shall be switched off and boiler
shall be taken for light up.
The boiler light up is done using charcoal and kerosene as explained below.
* A fixed quantity of dry charcoal is spread uniformly over the start up compartment.
* A fixed quantity of Kerosene mixed charcoal is spread uniformly over the dry
charcoal layer.
* The fire is initiated using swab.
* Further by proper air flow control, fire can be spread and the heat released by
charcoal is utilised to heat the bed material to a temperature above the ignition
temperature of the fuel.
* In the process of preheating bed material the required fluidisation velocity is

maintained in the bed by suitably opening the FD fan inlet damper.
* Further the fuel feed rate is adjusted to maintain a bed temperature of 800°C to
850°C.
* The charcoal of size below 15 mm shall not be accounted for the above quantity.
* Keep the ID fan damper open at the time of lighting up. This would reduce the
possibility of furnaces puff.
* Initiate the fire bushing number of swabs. Throw the swabs in such a way that
the fire spreads uniformly over the entire furnace. If the spreading of the fire is
non uniform sprinkle some kerosene choked charcoal and throw it to the
locations where fire is not there. Unless the fire is more or less present over the
entire surface, it is advised not to proceed with the light up. Unless the top
layer or charcoal gets ignited, further charcoal would not get ignited.
BED TEMPERATURE AND AIR FLOW CONTROL
The thermocouples are located in such a way that they are well utilised for start up.
The top level bed thermocouple is located at a height to read the temperature just at the
burning charcoal layer. The bottom level thermocouple is located to read the bed material
temperature at a height of 100 mm from nozzle level.
After the introduction of fire, top level thermocouple temperature will go up. It is
very important to increase the air flow gradually in order to increase the top level
temperature to 800°C. At first the ID fan damper opening alone allows some leakage
air. Further opening of FD fan damper will add some more air to increase the bed
temperature. Now close ID fan and FD fan inlet dampers. Start ID fan then FD fan. Open
ID fan and FD fan inlet dampers step by step to increase the top level temperature to
800°C to 850°C. Till this period the bottom level thermocouple would not have
shown increase in temperature. Once the top level temperature reaches 800 - 850°C,
the burning top layer of charcoal shall be mixed with rest of the bed. The mixing is
done by increasing the air flow so as to fluidise the bed. The mixing air flow should not
be higher than that of the air flow established during the fluidisation study. For this
purpose the markings made on damper positions shall be used.If the mixing is done at
higher airflow, the burning charcoal will spill into the adjacent compartment. More than
the loss of charcoal in the start up compartment, the bed height will reduce in start up
compartment. This would lead to defluidisation as the air would tend to bypass at bed
heights lower than 100 mm.
The duration of mixing shall be between 20 - 30 seconds. During the mixing process,
the top level temperature would start reducing. At the same time, bottom level
temperature would begin to rise.
Soon after the mixing is completed the air flow is brought to a minimum. Open the man
hole door and visually ensure through mixing has been done. If top layer charcoal
has not been disturbed at some places, mixing shall be carried out once again.
After ensuring thorough mixing, the air flow shall be brought down to minimum and
then shall be increased in steps. The airflow shall be increased gradually so as to
raise the bed temperature. The airflow shall be brought up at MCR airflow in process of
raising bed temperature above 600°C.
Once the bed temperature shoots above 600°C, the fuel transport lines are to be
dechoked and fuel flow shall be established.
* Switch on the New PA fan.
* Open the fuel transport air dampers of the start up compartment.
* Check the suction at the mixing nozzle. If suction is not available, open the
respective bottom drain gates of fuel pipes to dechoke, if any. After the choking
of fuel feed pipe is cleared close the gates.
* In the case of larger compartments it is advisable to initiate minimum airflow

in fuel pipe lines just before mixing process to avoid choking of the fuel lines.
* Adjust the PA fan suction damper, to maintain the header pressure in between
700 to 900 mm of wc.
Initiate the fuel flow by switching on the fuel feeders. The fuel flow shall be kept
minimum at the beginning. At the time of fuel feed initiation, the charcoal might not
have burnt fully. Hence it is most important to initiate fuel feed gradually.
Excess fuel feed will increase the bed temperature uncontrollably. Though the
bed temperature can be controlled by increasing the air flow, it is advisable to take care at
the time of fuel feed initiation. Stabilise the start up compartment operation with a bed
temperature of 850°C and with the MCR air flow.
* On the waterside watch the drum level. If the level goes down switch on feed
pump and regulate the feed control valve. ON/OFF operation of feed pump
should be avoided to the extent possible. If the feed pump is auto operated,
keep the selector switch in auto mode. Here again regulatethe feed control valve
to avoid frequent start/stop of the pump.
* Close the drum vents at 2 kg/cm² pressure if the boiler is provided with
superheater. This is done so that superheater coils are cooled better by more
steam flow through them. Ensure the vents, start up vents, drains are open
in superheater lines. The condensate in superheater coils and main steam pipe
should have been removed earlier. In the case of non drainable sections of
superheater coils it is possible that condensate leads to water hammer.
* In cases of powercut during start up after the mixing it will not be possible to
access how much charcoal is burnt out. It is advised to cool throughly and drain
the bed material in start up compartment and do a fresh light up.
* However, if the powercut had occurred before mixing one may attempt to light up
as below:
* Sprinkle Kerosene soaked charcoal through man hole evenly over the start up
compartment. The charcoal quantity shall be the same as that for light up.
* Throw swabs and light up.
* Follow the same procedure as discussed in a regular light up.
* If the powercut occurs after mixing and provided the duration is also short, it
may be possible to ligh up.
* Fluidise the bed minimally. Check the bed temperature. If the bed temperature is
more than 400°C add dry charcoal to the bed. The charcoal should be thrown
uniformly over the entire bed. Observe the rise in temperature. If there is no
improvement in bed temperature it is better to cool the bed. Never allow the bed
to be static in this method. If the bed is static, clinker formation will start.
START-UP PARAMETERS:
Bed height : 300 mm from Distributor plate

Bed material size : 0.85 - 2.38 mm.
Before firing Charcoal (Dry) : Kg.
Charcoal kerosene
mixed : Kg.
PA header pressure : mmwc

Before mixing Mixing temperature : 850°C
Mixing air flow : mmwc
Bed temp. before

fuel feed : Min. 600°C
Fluidising airflow : mmwc
After mixing PA header pressure : mmwc
Feeder rpm
COMPARTMENTAL TRANSFER:
The start up with one compartment is recommended for the following reasons.
01. Gradual loading of pressure parts.

02. Reduction of Charcoal for start up.
03. Load variation.
The compartment transfer means activating a static (cold) compartment of the
furnace adjacent to the activated compartment. This is done just by admitting the
fluidising air to the compartment to be activated and mixing the cold material with hot
material of the operating compartment. Before activating a static compartment, the
airflow in the fluidising compartment shall be increased to 120% of the MCR air flow,
and the fuel feed rate shall be correspondingly increased to maintain the bed temperature
at 900°C.
Now open the compartment air damper of the adjacent compartment which is to be
activated. The cold bed material in this compartment would begin to mix up with that
of hot bed material in the operating compartment. The bed temperature in new
compartment would begin to rise.
The bed temperature in operating compartment will begin to drop. Once this temperature
reaches 750°C slump the new compartment by closing the air damper.
The bed temperature of the operating compartment shall be once again brought up to
900°C before another attempt is made.
By following the process of mixing the bed material of the compartment to be

activated with that of the operating compartment, on one or many attempts, the
activation can be completed. The bed temperature of the new compartment shall be
brought to atleast 600°C before fuel feeding is commenced.
The primary air lines in the new compartment shall be opened and the fuel feeding can
be commenced and the bed temperature shall be brought to 800°C with MCR fluidising air
flow condition. Care shall be taken not to drop the temperature of operating
compartment below 600°C in the process of activating adjacent compartment.
If by mistake, the temperature of the operating compartment drops below 600°C, it

becomes necessary to raise the temperature using charcoal. The charcoal should be
sprayed over the entire compartment. Charcoal should be mixed with the bed keeping
the bed minimally fluidised. The charcoal if burns under static condition, the chance of
clinkering is high.
NORMAL OPERATION
05. NORMAL OPERATION
LOAD CONTROL:
The steam generation needs to be matched with that of demand to avoid venting of
steam. If the steam drawn from the boiler is less compared to steam generated then the
pressure would rise and thus resulting in lifting of safety valve. Frequent lifting of safety
valve will damage the safety valve seat. Steam generation can be varied by slumping
compartments or by varying the fluidisation air flow or by varying the bed temperature
or by varying the bed height.
Load variation of 70% to 100% may be obtained by varying the bed temperature. The
bed temperature can be reduced upto 700°C and can be increased to 900°C based on
demand. For this purpose the fuel fed rate needs to be varied. Further turndown is
also possible by reducing the fluidisation airflow but not to the extent of defluidisation of
the bed. In such cases the air flow through primary air lines should never be reduced.
Only the fluidising airflow should be reduced. Further load control is done by slumping
the compartments. The compartments can be slumped only from either ends of the
bed. In case of two compartments any compartment may be slumped. In case of
three compartments only first or third compartment is to be slumped, before the middle
compartment is slumped.
Slumping of the compartment is to be done as explained here. Bring down the fuel
rate to minimum and switch off the feeder. Wait till the bottom bed temperature comes
around 850°C, and then close the fluidising air damper of the compartment. Then close
the fuel transport air line dampers. When the fluidising air through a compartment is
cut off, the air through the other compartments would increase. This air flow shall be
adjusted by throttling inlet damper of FD fan. Further draft in the furnace shall be
adjusted by throtting of ID fan inlet damper.
Reactivation of a compartment shall be done in the following sequence. Open the fuel
transport airline valves first and ensure the required air pressure is available in the PA fan
header. If the line is choked, choke shall be removed by using the drain gates, of the
fuel transport lines. Then open the fluidising air damper and set the FD fan inlet damper
for the required MCR airflow. If the bed temperature is above 600°C fuel feed shall be
initiated and the bed temperature shall be brought to the required operating
temperature.
In case the temperature of the bed is less than 600°C immediately after fluidisation, the
compartment shall be started in the manner explained in the compartment transfer
method. The load control is graphically depicted in figure 2 for the furnace with three
compartments.
During one compartment operation, the bed height can not be increased as the bed
is not contained on one side. This is applicable to some extent to two compartments
operation also maximum variation is possible in all compartments operation as the bed
is totally contained in all four sides by the furnace water wall.
DYNAMICS IN FLUIDISED BED:
The height of the fluidised bed needs to be increased after the activation of all
compartments in order to meet the steam demand. In the case of coal firing, the bed
height automatically increases due to generation of ash from coal burning. The ash
which is retained in the bed, if not drained, will accumulate to an extend that the air flow
through the bed starts coming down below the MCR airflow. The height of bed is not to
be allowed to increase beyond the recommended bed height which is about 300 mm to
400 mm. The bed height is indirectly measured by means of air box pressure as
explained in the earlier sections. Other than the purpose of maintaining required bed
height, the bed drain gates are to be operated for removing higher size particles.
When there are deviations from the specified fuel feed size, ie., minus 6 mm, the higher
size particles would begin to settle down at the air nozzle level. Similarly when agro fuel is
used stones ingress with fuel would lead to setting of stones.
The bed drain is to be operated frequently to drain the higher size particles. If the drain
is not operated frequently the fluidisation will be upset causing clinker formation. In
the case of fuels (Agrowaste) which do not generated bed ash, bed material requires to
be added frequently in order to compensate for loss of bed material by attrition and
subsequent elutriation. Hence sufficient stock of bed material is to be maintained.
ASH REMOVAL:
The ash should be drained from all collection points. Failure to remove the ash will result
in choking of flue gas path.
BOILER TRIPPING DUE TO POWER CUT:
In case of boiler tripping due to power cut or for any other reason, immediately close
the inlet dampers of the FD fan and ID fan. In the event of power availability and if the
boiler is required to be started immediately switch on the fans. Establish the MCR air flow
and start fuel feeding. Otherwise if the boiler is to be boxed up, close the main steam
stop valve. Close the compartment dampers also. The boiler can be restarted as
explained in the further chapters. (Write up on hot restart).
INGRESS OF FOREIGN MATTER IN FUEL:
Ingress of cotton waste, waste cloth, coconut shell, mango seed etc., will block the fuel
flow from the chute into the feeder. This is indicated by the drop in bed temperature
(provided the feed rate of the feeder is not increased).
The above mentioned problems can be eliminated if a screen is provided in the fuel
handling system. Feeder tripping due to foreign material is a great nuisance and at times
it may lead to boiler shut down. In case of coal, it becomes necessary to provide a
magnetic separator to separate out the tramp iron from the coal. This not only protects
the crusher, but also prevents to damage to the feeder.At times it may so happen that the
foreign matter may block the fuel transport line. When there is no airflow in the fuel
transport line, the bed material from the bed enters the fuel feed nozzle and leads to
choking of the line. The choking should be removed by slumping the bed and by opening
the drain gates. Also the foreign matter should be removed from the mixing nozzle
opening the plug of the mixing nozzle.
NORMAL OPERATING PARAMETERS (STABILISED CONDITION)
Air box pressure :
(Drain the bed if the pressure is high) :
Fluidising air flow :
Primary air header pressure :
Bed temperature :
Feeder rpm / vibratory feeder setting :
Furnace gas plenum pressure :
Blowdown every : hrs.

NORMAL SHUT DOWN TO COLD
06. NORMAL SHUT DOWN TO COLD:
Reduce the fuel feed rate and slow the feeders to empty before stopping them. Maintain
the same air flow to cool bed faster. If the steam is not drawn from the boiler, open the
airvent to reduce pressure. If it is not necessary to enter the boiler for maintenance,
slow rate of pressure and temperature decay is desirable switch off the fans after the
bed has cooled down to 500°C. Switching off the fans should be in the order of FD and
ID fans. If it is desirable to accelerate the cooling process in order to permit entry into the
unit for maintenance, the fans could be continued to run at the same flow rate until
temperature reaches 100°C. During the process maintain normal water level in the boiler.
After the bed temperature reached 100°C open the blowdown valve and drain the
boiler. (The boiler water temperature must be reduced atleast 90°C before draining).
Drain the bed material. This can be done by opening the gates below the drain points
collect this bed material, sieve and reuse for subsequent light ups.
NORMAL SHUT DOWN TO HOT STANDBY
07. NORMAL SHUT DOWN TO HOT STAND BY
If the boiler has to be shut for a relatively short period (minimum of 2 hours) follow the
procedure given below.
01. Switch of the fuel feeder, FD, PA & ID fans instantaneously. The PA line dampers
and fluidising air dampers need not be closed. But FD & ID fans dampers must be
closed.
02. Do not reduce the boiler pressure in line with unit load reduction. When the
desired pressure at which the boiler is to be held is reached after the boiler is off
the line, the boiler may be up by closing the main steam valve.
03. Keep the water level in sight in the gauge glass and add make up rate as
required.
HOT RESTART
08. HOT RESTART
After a shut down for a brief period, follow the steps given below to re-start the unit.
01. Open the air vent. Check fluidising air damper and PA damper are "OPEN".
02. Keeping the ID and FD fan dampers in the closed position.
03. Start ID, FD and PA fans in quick succession.
04. Start the fuel feeders with minimum speed.
05. Gradually open ID and FD fan dampers to maintain air flow D.P. of 30 mm and
gas plenum pressure of 10 mm.
06. Increase the speed of fuel feeders and watch the bed temperature.
07. If the bed temperature is slowly increasing then increase fuel feed and air flow in
line with load requirement.
08. If the bed temperature is not increasing, stop the fuel feeders.
09. If the bed temperature is below 600°C throw charcoal through access door, till
temperature reaches 600°C. This has to be carefully done. This may be required
if more than one hour has lapsed after shutting down.
10. If the bed temperature is less than 300°C, cool the bed and start the boiler
following "normal startup from cold" procedure.
PROCEDURE FOR
HYDROSTATIC TESTING
PROCEDURE FOR HYDROSTATIC TESTING
The system components have been hydrostatically tested to (1-1/2) times the design
pressure in the factory. However, the complete system, along with all interconnecting
piping should be hydrostatically tested before start-up to comply with code
requirements and to check for leaks that might have resulted during shipping and
handling. The boiler and process lines must be completely vented in order to fill them
with water.
The following is a recommended procedure for hydrostatic testing:
1. Open the steam drum vent valve and close steam outlet valve.
2. The boiler safety valve stubs are plugged with end plates and sent as a dummied
stub. Hence this end plate have to be cut and removed after hydrotest and the
safety valves are to be buttwelded.
3. For subsequent hydro test if any and for every annual hydro testing gag the safety
valves in accordance with safety valve manufacturer's recommendations. In lieu of
gagging, the safety valves may be removed and replaced with test plugs or blind
plates.
4. Isolate pressure switches, gauge glasses or control components which are

not intended to be subjected to a hydrostatic test.
5. Fill the system with treated water in accordance with recommended CVPL's water
quality. The temperature of water used shall not be less than 20°C and greater than
50°C.
6. Once the system is filled and the pressure is approximately 1 kg/cm², close all vents.
The pressure may then be increased gradually to the test pressure requirement of
the local steam boiler inspecting agency. Do not subject any pressure part to more
than 1-1/2 times the design pressure rating of the component.
7. Examine the system for any leaks. If no leaks are visible, hold the system in a
pressurised static condition for a period of 1/2 hour to satisfy the code requirements.
8. After that the pressure shall be reduced to maximum allowable working pressure
and maintained for sufficient time to permit close visual inspection for leakage of
pressure parts.
9. Upon completion of the test, release pressure slowly through a small drain valve.
Then fully open the vents and drains when the pressure drops to 1 Kg/cm2(g).
Particular care must be given to make sure that parts not normally containing water
during operation are drained free of water. The system should be drained fully after
hydrostatic testing to prevent freezing, if the unit is installed in a cold weather area,
and to minimize corrosion of the metal surfaces.
10. If temporary handhole or manhole gaskets were used for the test, they should be
replaced with regular service gaskets before reading the unit for operation. Gaskets
should never be reused. Replace gauge glass if necessary and make sure that the
gauge cocks are open. Remove all blanks or gags from safety valves and install
safety valves, if removed.
PROCEDURE FOR SLOW FIRING
PROCEDURE FOR SLOW FIRING
REFRACTORY DRY OUT:
After the refractory works are finished, the refractory work must be subjected to proper
curing and initial heating. These two procedures must be strictly carried out. Otherwise,
cracks may occur on the refractory surface. These procedures are explained below.
CURING FOR CASTABLE REFRACTORY:
All the castable are hydraulic setting and need the presence of moisture for setting
process, so it is necessary to ensure that the castable does not dry out to exposure or
due to heat produced within the mass. It should not be allowed to dry during first 24
hours after it has been placed.
Moist condition has to be maintained by covering the castable with wet gunny sacks
or by frequent sprinkling of fine mist of cold water on all exposed surfaces. Sprinkling
should be started after the castable has set partially. It is generally advisable to spray
water on dense castables every 45 minutes for hours.
INITIAL HEATING FOR CASTABLE REFRACTORY:
Proper attention should be given during initial heat up of castables, as they have
considerably lower permeability when compared to brick. It is more difficult for the
water to passthrough the castable and escape as the refractory is heated more rapidly.
So due to this, high pressure steam is developed inside the brick and this ruptures the
lining.
Rapid heating also causes the hot face to dry up and heat up while the rest of castables
is still comparatively cool. This will lead to expansion of hot face and hence develops a
crack on cold face.
SLOW FIRING PROCEDURE :
Following are to be done before slow firing is started:
a) All the coal nozzles and air nozzles must be fully covered with bed materials.
b) No fans should be operated for the heating purpose. Firing should be done only by
natural draught. For this all dampers should be kept open.
c) Sufficient sized fire wood required has to be stocked for the dry out.
The following heat and curing schedule is recommended:
01. Heat gradually up to 110°C and hold at this temperature for six hours.
02. Then raise the temperature at the rate of 10°C per hour up to 550°C and hold at
this temperature for six hours.
03. After this, the furnace can be cooled naturally.
Slow firing can be done by burning sized waste wood in the furnace on the bed
material. The fuel required shall be computed as if the boiler would be operated
to generate 20% MCR load. The sized wood can be fed in the furnace through
the manhole.
PROCEDURE FOR ALKALI BOILOUT
PROCEDURE FOR ALKALI BOILOUT
1. Check boiler erection work is completed with all assemblies, valves, fittings and
necessary instrumentation.
2. Boiler auxiliaries such as fans, feed pumps should have been trial run and made
ready for operation.
3. Check boiler instrumentation and control panel are ready for regular operation. But
the following instruments are to be isolated for alkali boilout.
I) Flow, pressure and level transmitters.

ii) Pressure switches.
4. Ensure steam drum internals have been fixed in position.
5. Check all the refractory and insulation work are completed.
6. Check all scaffolding, temporary supports, debris are cleared.
7. Ensure slow firing is done as per the slow firing procedure.
8. Check suitable fire fighting equipments such as Co2 or foam type fire
extinguishers, sand buckets, etc, are available at suitable convenient places.
9. Check boiler chemical feeding system is ready for operation.
10. Check sufficient quantity of chemicals are available. Based on the water
volume of the boiler the chemicals required can be estimated. If water volume of
the boiler is Q M^3 each chemicals required will be 4 x Q kgs. The same quantity of
chemicals will be required for each boil out.
11. For alkali boilout sodium carbonate and trisodium phosphate are used.
12. Prepare 20% concentrated solution of the chemicals separately in a
drum and the solution is charged in to the boiler through the nozzles (either
auxiliary steam top nozzle or Air vent nozzle) in to the shell/drum manually by
means of funnel.
13. After the addition of chemicals in to the required quantity, the nozzles are covered
with the cover flange and fill up water to the normal operating level.
14. Light up the boiler and raise the steam pressure is gradually to 5 ata as per
standard operating procedure and maintain the pressure for minimum period of 12
hours.
15. Tighten all glands and flange joints.
16. Raise the firing rate to achieve a boiler loading of nearly of the normal loading rate
of the boiler.
17. Samples to be taken every two hours and analysis is to be carried to determine
the following:
a) Ph value
b) Alkalinity
c) Phosphate
d) Oil
e) Silica
18. Ensure the pre-commissioning activities are carried out as per the commissioning
check list.
19. Ensure the alkali Boilout is carried out in 3 stages and fresh chemicals are
changed before each stage.
20. Ensure the pressure is maintained in the boiler for each stage alkali boilout as
follows:
DURATION
I stage - 5 kg/cm sq. - 12 hours.
II stage - 7 kg/cm sq. - 12 hours.
III stage - 10 kg/cm sq. - 12 hours.

(Ensure the pressure of the boiler is raised gradually for alkali boilout).
21. Each stage of boiling can be terminated when the content of oil in the boiler
water maintains a steady value. However final reading of oil should be less than 5
ppm.
22. After termination of boilout procedure, shut down the boiler and allow the unit to
cool down gradually.
23. Drain the boiler after the drum pressure reaches atmospheric pressure. Water jets
shall be used to clean the headers.
24. After complete draining of boiler, clean the complete unit by filling the water and
drain it for atleast one time.
The handhole pipes of all headers preferably at bottom most point to be cut and
inspected for any foreign materials availability and to be cleaned.
25. After inspection and cleaning reweld the end caps and hydro test the boiler to
working pressure.
26. Now the boiler is ready for steam blowing.

PROCEDURE FOR STEAM BLOWING
PROCEDURE FOR STEAM BLOWING
STEAM BLOWING
Steam blowing is an established practice for the purpose of physically removing any
substance which remain deposited in the superheater and associated pipe lines. These
substances are mainly scales and loose minerals that might have been entrapped
during manufacture, storage and erection at site.
PRINCIPLE
The principle of steam blowing is to give thermal shock and dislodge the scales.
These scales will be subsequently driven out by the dynamic velocity of the expanding
steam. Before starting the boiler for steam blowing the following points are to be
ensured:
1. Alkali boilout is completed.
2. All the instruments calibration are completed and safety interlocks are in line, except
water level interlock which is to be isolated temporarily.
3. NRV and flow nozzle should not be fitted initially and thermowell in steam line is to
be removed.
4. All the spring hangers in steam line are loaded properly.
5. Temporary steam line is erected and anchored properly for steam blowing.
6. Target plate fixing arrangement to be kept ready.
7. Required target plates are to be machined and kept ready to fix when required.
Target plates shall be of aluminium material.
PROCEDURE :
The method of steam blowing is as below :
1. Operate with one compartment and raise the boiler pressure above 35 kg/cm^2. The
bed temperature shall be maintained at about 800-950°C.
2. Quickly open the main steam stop valve (or the temporary blowing valves if
provided). In order to maintain the flow to atmosphere the main steam stop valve is to
be kept open till the steam pressure drops down close to 16 kg/cm².
3. Slowly reduce the firing rate and slump the boiler. The main steam stop valve
shall be closed when the boiler pressure reaches 16 kg/cm²
.
4. After one hour, the boiler shall be restarted with one compartment and the bed
temperature shall be maintained at about 800 - 950°C'.
The steam blowing shall be once again started when the pressure reaches 35
kg/cm². By the above procedure, the scale adhering to the contours get cracked
due to temperature difference and get removed to subsequent blows.
* SCHEME OF BLOWING
Temporary discharge piping which lead the steam to the atmosphere shall be welded
downstream of main steam line must be properly supported and anchored.
OPERATIONAL PRECAUTIONS
1. Normally the steam blowing operation is the first occasion to fire the unit at
significant rate. The unit must be brought up much slower while all equipments are
checked and expansion movements are monitored closely.
2. During blowing, water level in drum gauge glass may fluctuate very widely.
Feed regulating station must be checked for proper remote operation. Sufficient
quantity of D.M water availability muse be ensured.
3. Flue gas temperature at the inlet of convection superheater must be restricted to

450°C.
4. Temporary discharge piping which should be atleast equal to the diameter of piping to
which it is connected must be well supported to withstand reaction forces during steam
blowing.
5. Discharge piping should be so diverted that personnel and equipments are not
endangered. The area should be cordoned off.
6. After three free blows, target plate can be fixed.
7. Based on target plate condition as recommended by the turbine supplier blow can
be continued or terminated.
8. During blowing sufficient time duration should be given between blows to attain
better thermal shock to discharge the scale and other deposits in pressure parts and
steam line.
9. After clearing the steam blowing, boiler to be stopped and steam line to be cooled
to complete the welding of NRV and flow nozzle and thermowell fixing in main steam
line.
10. Temporary steam line to be removed and permanent line to be connected with TG.
11. After completion of the job, the boiler is ready for safety valve floating.
OPERATION ON LOW LOADS
OPERATION ON LOW LOADS
The boiler should not be operated at low loads continuously for long time. If the boiler
is run continuously at low loads (<60% MCR load) then due to low quantity of steam
flow through the super heater, the super heater tubes may fail. To protect the super
heater tube from failure, the boiler should be run at higher loads (>60% load) only and
the excess steam over the utilised steam shall be vented continuously through start-up
vent.
TROUBLE SHOOTING CHART
TROUBLE SHOOTING CHART
DURING START UP
Sl.NO. TROUBLE CAUSES REMEDY
01. Start up failures. Improper Bed material size. Bed material size has to be between 0.85 mm and 2.36 mm.
Improper charcoal size. Charcoal size should be 15-25 mm.
Poor Quality of charcoal. Charcoal shall be dry for good quality.
Insufficient Qty. of charcoal. Qty. of charcoal shall be 20 kg. per m2 area of bed and kerosene
soaked charcoal shall be 10 kg. per m2 area of bed.
Insufficient bed height. Bed height should be 200 mm above the air nozzle.
Excess bed height. Bed height should be 200 mm above the air nozzle.
Improper spreading of charcoal. Uniform spreading of charcoal shall be ensured.
Improper spreading of fire over the Swab fire initiated should be even. If not throw kerosene soaked
top layer of kerosene soaked charcoal at such locations where fire is not present.
charcoal.
Wrong bed temperature indication. Thermocouples are to be checked using swab fire before starting
Improper mixing. Mixing should be done with the predetermined air flow level
(Just above MFC level)
Improper fuel feeding. Fuel is to be fed only after the bed temperature reaches 600°C.
P.A. Line choking. Minimum airflow in fuel transport line is to be maintained till the
start of fuel feed. Before fuel feed, increase airflow to MCR air flow
Dechoking of the lines is possible by opening the line flap damper
fully and by opening the corresponding drain gates in the airbox.
02. Clinker formation High bed temperature over the entire Charcoal Quantity shall be as per recommendations.
during start up bed. This is due to excess charcoal
over the entire (or) due to excess fuel feed before High bed temperature can be reduced by controlling fuel feed and
bed. charcoal combustion is complete. by increasing the air flow.
(or) incomplete mixing.
Give the required mixing air flow.
Warning: Air flow should be slightly more than MCR level.

Otherwise all hot material would go to the adjacent compartment.
Low fluidisation velocity after mixing. Air flow level can be increased. (MCR air flow level)
Wrong temperature indication. Checking the thermocouple with swab fire before starting.
Excess fuel feeding. Fuel feeding should be gradually increased after ensuring that the
fuel is catching fire.
03. Localised Clinker Localised vigorous static burning of Before mixing clinkers may form due to delay in mixing.
Formation charcoal before and after mixing :
After mixing, clinkers form due to inadequate mixing (i.e. less mixing
air flow or less duration of mixing)
After proper mixing, clinkers may form if the air flow is not brought to
MCR level.
DURING COMPARTMENTAL TRANSFER (FROM COLD CONDITION)

01. Fire extinguishing Improper method of activation. The bed temperature of operating compartment drops because of
in operating cold bed material in activated compartment mixing with hot bed
compartments. material of operating compartment.
Attempting for compartment Slump the activated compartment as soon as the bed temperature
transfer in one to two trials. in operating compartment drops below 750°C. Further attempt
should be made only after bringing the bed temperature of the
operating compartment to 900°C with 120% MCR air flow.
02. Clinker formation Insufficient air flow. After compartmental transfer, the air flow should be once again
in Operation brought to MCR condition in operating compartment.
compartment.
Excess fuel feed. After tranferning, the fuel feed rate in operating compartment needs
to be reduced.
03. Bed temperature a. Inadequate air flow for disturbing Increase the airflow momentarily if the fan capacity is available and
not rising in the cold bed material. provided the bed temperature in operating compartment is not low.
activated
compartment. Alternatively, momentarily close the FD damper of the operating
compartment.
Long operation with single compartment results in excess bed

material ash accumulation in the compartment adjacent to the
operating comparment. Drain the bed if necessary.
04. Clinker formation Insufficient air flow static bed This can be avoided by maintaining the bed fluidising before fuel
in activated promotes vigorous burning of fuel at feed. To disturb the clinker formation momentary mixing may be
compartment. several locations and thus clinkers adopted at times.
form.
Excess fuel feed before the bed Fuel should not be fed before bed temperature rises to fuel ignition
temperature rises to fuel ignition temperature (600°C for coal; 300°C for husk) . Sudden bed
temperature. Otherwise, fuel temperature rise could be controlled by increasing the air flow or by
accumulated leads to sudden bed activating the adjacent cold compartment.
temperature rise.
05. Bed temperature Excess fuel feeding when the bed Fuel feeding should be gradually increased, when bed temperature
dropping in temperature around 600°C is 500° - 600°C.
activated quenches the fire.
compartment.
Operating at less air flow condition Air flow should be sufficient. MCR air flow is required.
leads to CO formation and less heat
release and thus bed temperature
remains low.
06. PA line choking

Failure to set fuel transport air flow Minimum air heater pressure of 700 mmwc is required to be set to
before attempting activation. prevent PA line choking. The header pressure should be increased
to MCR condition before fuel feed.
DURING CONTINUOUS OPERATION
01. Bed temperature Insufficient fuel feed rate. Sufficient fuel feed rate is required.
dropping.
Excess fuel Sufficient fuel feed rate is required.
Excess air flow. Sufficient air flow is required (MCR air flow)
Fuel line choking.
- Due to wetness of fuel. Wet fuel should be avoided.
- Due to entry of foreign materials. To avoid the entry of foreign materials a vibratory screen (or)
magnetic separator can be provided in the fuel handling system.
Fuel not being fed from feeder.
- Due to high moisture in the fuel, To avoid this, high moisture fuel should not be used.
fuel would adhere in the pocket
feeders blade, so no fuel would be
fed.
Excess bed height causes less Bed should be drained once in every shift. (Maintain air box
fluidisation. pressure below 425 mm of wc).
Thermocouple is in loose contact. Thermocouple to be corrected.
Bed height is less than 175 mm. Bed height should be increased.
02. High bed More fuel feed rate. Fuel feed rate has to be reduced.
temperature.
Less air flow. Air flow has to be increased slightly (upto MCR air flow level)
Excess feeding of fuel from feeder. Rotor requires replacement.

One of the causes may be, broken
pocket feeder blades. Due to this
more fuel would be fed.
03. Clinker High bed temperature due to excess Decreasing the fuel feed rate (or) air flow may be slightly increased.
formation. fuel feeding.
Low fluidisation velocity. Air flow can be slightly increased.

- leads to static burning at places.
Bigger size fuel. Bigger size fuel could be avoided. So correct size fuel could be used
(Below 6 mm).
Bigger size fuel would burn partially.

So partially burnt fuel would settle in
the bed. Sometimes bed
temperature would shootup
suddenly. This may cause clinker
formation.
Bed draining not done - due to this To avoid this bed should be drained once for every shift. (Maintain
bed height would increase. So, there air box pressure below 425 mm of wc).
would be defluidisation.
Erratic disturbance in fuel feeding. Erentual disturbance fuel feed leads to reduction in bed temperature
- may be due to foreign particles, and thus velocity and the fuel feed is restored if be necessary to
tripping the feeder or choking the increase the air flow momentarily.
mixing nozzle.
04. PA line choking. Foreign material choking the mixing This can be avoided by providing vibratory screen or magnetic
nozzle. seperator in fuel handling system.
05. Backflow of air Fuel line choking due to one of the Choking is to be removed..
thro’ bunker gate. above causes.
06. Back firing. ID fan damper has been opened ID fan damper has to be slightly opened. (maintain furnace pressure
sufficiently. of minimum - 10 mm of wc).
Insufficient air pressure to lift power Sufficient air pressure is to be supplied (pressure 3.5 to 5 kg/cm2 for
cylinder. power cylinder action).
Ash accumulation in hoppers above Ash should be removed periodically.

various drain points.
- This would reduce ID fan suction.
07. Steam production Improper parameters. Proper parameters should be followed.

is less.
DO’S AND DONT’S
DO’S AND DONT’S
Sl.NO. DO’S DONT’S
01. ECONOMISER Run the boiler with continuous running of the feed Don’t run the boiler with frequent switching ON
pump. & OFF of the feed pump.
02. FEED PUMP Keep the isolation valves at spare feed pump ----
open.
03. LEVEL TRANSMITTER Blow down should be given once, daily for level Don’t stat the boiler, if the liquid level limitter is
transmitter lines. not functioning for high level, low level and trip
level.
04. WATER LEVEL GAUGE Give frequent blow downs of water level gauge to Don’t run the boiler, if the water level gauges
free from blockages at both top and bottom are not showing the same water level.
points.
05. FUEL OVER SIZE Allow 10% of 8 - 10 mm size fuel. Don’t start the boiler if the fuel size is more
than 6 mm ( 8 - 10 mm, over size upto 10%
accepted ).
06. ASH DRAIN POINT During boiler operation check whether there is Don’t open the ash drain gates frequently.
(other than bed drain suction in all the ash drain points.
points)
07. FEED WATER & Analyse the feed water and boiler water daily. Don’t run the boiler if the water quality is not as
BOILER WATER per the specifications given in the manual.
Sl.NO. DO’S DONT’S
08. RELAY SETTING Set the relay in full load amps of the motor. Don’t start the fans before setting the relay
(MOTORS) amps.
09. GAS PLENUM Maintain the gas plenum pressure at minus 5 --------
PRESSURE mmwc.
10. THREE PHASE SUPPLY Check the continuity of fuses. Don’t bypass the fuses with direct wire
connection.
11. CONTINUOUS BACK Ensure that ash chutes and ducts are clean from Don’t run the boiler with continuous back fire.
FIRE ash accumulation.
12. PART LOAD BOILER Change the compartments every shift. Do not run a particular compartment alone
OPERATION continuousl.
INSPECTION AND
MAINTENANCE SCHEDULE
INSPECTION AND MAINTENANCE SCHEDULE
EQUIPMENT NO. POINTS TO BE CHECKED FREQUENCY REMARKS
FD SYSTEM
FD fans & Motors 1. Check whether motor bearing temperature is Daily One set of motor bearings is to be
normal. kept as spare.
2. Check whether the motor current is normal. Daily (For coupled fans, one set of fan
bearings is to be kept as spare)
3. Check whether the vibration level and sound level is Daily
normal.
Airfoil meter 1. Ensure that the draught connections are not leaky. Weekly.
2. Ensure that the manometer water is clean. Weekly.
Air box draft / mano 1. Ensure that the draft connections are not leaky. Weekly.
meter / Draft gauge
2. Ensure that the manometer water is clean if a Weekly.
manomer is provided.
Air box 1. Ensure that all the nozzles are in good condition. At every shut 50 nozzles are to be maintained
down. as spare.
2. Ensure that the nozzles are free from plugging by At every shut Use compressed air for cleaning.
coal powder. down.
3. Ensure that the nozzles are free from plugging by If furnace Use compressed air for cleaning.
refractory. refractory work
was done.
4. Clear the sieved bed material from each Once in three

compartment in the air box. months/in case
of air nozzle
breakage.
ID SYSTEM
ID fan & Motor 1. Check the bearing temperature of the fan and Daily One set of motor and fan bearings
motor is to be maintained as spare.
2. Check whether the motor current is normal. Daily
3. Check whether the vibration and sound level is Daily.

normal.
ID fan impeller 1. Check for erosion / damage. Once in six Keep a spare ID fan impeller
months. expected life 1 year.
PA SYSTEM
PA fan & Motor 1. Check motor bearing temperature. Daily One set of motor and fan bearings
are to be maintained as spare.
2. Check whether the motor current is normal. Daily
3. Check whether the vibration level and sound level Daily.

is normal.
Fuel feed nozzle 1. Inspect the fuel nozzle cap for any damage. Everyshutdown Keep 4 nos. of fuel nozzles as
spare for replacement.
2. Inspect the supporting lugs of coal nozzle cap. Everyshutdown
FUEL FEEDING SYSTEM
Feeders & Drive 1. Check the any damage in the feeder due to foreign Weekly
material.
2. Chain lubrication. Weekly
3. Gear box Lubrication oil level. Weekly
4. Change gear box oil, on contamination. Weekly
FEED WATER SYSTEM
Feed pumps 1. Check the operation of spare pump. Daily Refer O & M Manual.
2. Replace the gland packing. If leaking. Keep spare gland packings.
3. Check for abnormal vibration and sound. Daily Keep spare gland packings.
4. Check for suction strainer choking. Daily
Feed water 1. Check for Hardness, pH, O2, oil content and TDS in Daily Compare with recommendation
feed water. given and take corrective
measures.
FURNACE
Bed thermocouple. 1. Ensure that all the thermocouple compensating When 40 m length of compensating
cables are in good condition and the end thermocouple cable is to be kept as spare.
connections are not loose. shows above
1200°C.
2. Replace the thermocouple if burnt. During the Keep 4 nos. of spare bed
immediate thermocouples at stock.
next shut down
Refractory wall 1. Repair the cracks in the refractory wall. During the Keep required castable refractory
immediate and binding mortar in stock.
next shut
down.
Water level gauge 1. Check the water level gauge function by giving a Keep spare glasses and washers
blowdown. Every shift. for both water level gauges.
BOILER SYSTEM
Boiler water 1. Check Alkalinity, pH, Residual SO4 residual Every shift Compare with recommendation
phosphate and TDS. given and take corrective actions.
2. Follow blowdown schedule to bring TDS to limits. Every shift
1. Blow the steam through safety valve by hand Every one

Safety valves popping with the lever to avoid seat seizure. month
ASH REMOVAL SYSTEM
Ash hoppers 1. Ensure that ash is being removed and ash flows out Every shift.
freely.
Bed coil headers. 1. Inspect and remove sludge accumulation in the bed Every year.
coil header.
Blowdown the water through header drain valve At every shut

after the fire is put off, but with the boiler under a down.
pressure of min. 5 kg/cm2.
Valves in feed water, 1. Inspect for gland leakages and tighten the gland Weekly.
boiler water systems, nuts.
steam line
2. Replace the gland packings. Every year / on
major leakage
PRESERVATION OF BOILERS
PRESERVATION OF BOILERS
INTRODUCTION
Atmospheric corrosion of ferric materials proceeds rapidly in the presence of oxygen and
moisture. The oxides produced are objectionable and can be transported to critical heat
transfer areas. Also, through the wall, pit type corrosion can occur. In today’s boilers
with their numerous complex circuits and bends, it is usually impossible to completely dry
a boiler in preparation for storage. Draining all circuits (if drainable) while hot may
temporarily dry the surfaces; however, unless dry air can be continuously circulated
to eliminate all the water vapour from the unit, recondensation will again result in moist
conditions. For this reason, wet lay-up normally offers the most positive method of
protection for components in modern boilers.
LAY-UP METHOD
This method employs filling up the boiler with treated water and keeping the unit
pressurized to 5 Kg /cm²(g) feed pump may be used for this purpose. Water
conforming to recommended specification furnished in earlier section, is to be used
for filling.
However, a better method of preserving of boiler would be to have nitrogen blanketting.

In this method the boiler is filled with water treated for pH and O2 and sealed with
nitrogen at a pressure of 0.35 atg to avoid air ingress.
Figure shows the general arrangement of the rig up required for nitrogen blanketting.
Nitrogen cylinders can be employed for this purpose. The nitrogen supply can be
connected to the drum vent and superheater vent.
WET METHOD
If the boiler is likely to be out of service for more than a few days, but may be needed for
steaming at short notice, all parts, including the economizer and superheater should be
completely filled with correctly conditioned water. Non-drainable superheaters should be
filled only with condensate quality water treated with volatile chemicals such as hydrazine
or ammonia. It is most important that pockets of air are not allowed to remain in the
boiler and that there should be no leakage.
When completely filling the boiler with water, sufficient sodium sulphite or hydrazine
should be added to combine with the dissolved oxygen and leave an excess of 100
mg/ 1 to 200 mg/1 of sodium sulphite as Na2 SO3 or hydrazine as N2H4. In addition,
alkali should be added to ensure that a pH value of 10.0 to 11.5 is maintained.
Distribution of these chemicals throughout the bulk of the water should be ensured
by filling with a premixed solution, by use of a circulating pump or by heating the
boiler when partially filled and then topping up with conditioned water.
It is recommended that the aircock on the drum or shell should be connected to a

surge tank located at a higher level. This compensates for any volumetric change
and ensures a positive pressure thus preventing admission of oxygen to the unit. This
tank should be covered and kept dosed with oxygen scavenger and alkali. Alternatively,
pressure on the system should be maintained by using a small pump.
The oxygen scavenger reserve and the pH value or alkalinity should be checked regularly
and additional treatment chemicals added, as necessary and distributed to maintain
the treatment levels within the recommended range. Any additional water added to
the boiler should contain the appropriate quantities of treatment chemicals.
When required for service the boiler should be drained down to normal working
level before firing. Phosphate or other conditioning reserves should be re-established
as soon as possible.
This method of storage is recommended only if there is no likelihood of frost damage

occuring. Wet storage is not recommended for periods of longer than 2 or 3 months
unless the treated water is circulated regularly in all parts of the boiler including the
economizer and superheater. Wet storage tends to promote condensation of
atmosphere moisture and hence corrosion in the flue gas side. Where this proves
trouble some dry storage is to be preferred.
SCHEDULES
VALVES SCHEDULE
LUBRICATION SCHEDULE
LUBRICATION SCHEDULE
BRAND NAME / SPECN. OF INITIAL FIRST SUBSEQUENT

SL. ITEM MAKE ITEM PARTS PARTS TYPE OF LUBRICANT FILLING FILLING FILLING
No. DESCRIPTION QTY. TO BE QTY. LUBRICANT QUANTITY (RUNNING (RUNNING
(Nos) LUBRICATED (Nos) IOCL MAKE HP MAKE (PER ITEM) HOURS) HOURS)
01. FD FAN CVL 1 BEARING 2 GREASE SERVOGEM EP-2 --- 0.33 Kg. 1100 1100
02. ID FAN CVL 1 BEARING 2 GREASE SERVOGEM EP-2 --- 0.80 Kg. 2000 2000
03. PA FAN CVL 1 BEARING 2 GREASE SERVOGEM EP-2 --- 0.23 Kg. 1500 1500
04. FEED PUMP GRUNDFOS 2 BEARING 2 OIL SERVOPRIME-46(OR) ENKLO 46 1.25 Kgs. 300 8000
SERVOSYSTEM- 46
05. GEAR BOX ELECON 3 GEAR UNIT 2 OIL SERVOMESH-SP320 ENKLO-320 1.8 Ltrs. 250 3000
06. GEARED MOTOR POWER 1 GEAR UNIT 1 OIL HP - 90 EP - 90 2.7 Ltr. 10,000 2 TO 3 YEARS
BUILD
BEARING 2 GREASE SERVOGEM-2 LITHON 2 0.3 Kg. 150 ONCE IN A
WEEK
07. MOTORS CROMPTON 6 BEARING 2 GREASE SERVOGEM-2 LITHON 2 0.5 Kg 300 1200
IOCL -- INDIAN OIL CORPORATION LTD. HP - HINDUSTAN PETROLEUM

M /s. SKM ANIMAL FEEDS AND
CET HAR VE SSELS LIMITED
FOODS (INDIA) LIMITED.
TABLE OF CONTENTS
III. BOILER MOUNTINGS:
WATER LEVEL GAUGE 003
LIQUID LEVEL LIMITTER 010
SAFETY VALVE 017
BLOW DOWN VALVES 025
IV. BOILER AUXILIARIES:
FAN 031
FEED PUMP 068

BOILER MOUNTINGS
DATA SHEET
WATER LEVEL GAUGE
DESCRIPTION SPECIFICATION
GENERAL DATA:
MAKE M/S. LEVCON INSTRUMENTS PVT. LTD.
QUANTITY 2 NOS.
APPLICATION STEAM DRUM
TAG NO. LG201 & LG202
TYPE TRANSPARENT
CENTRE TO CENTRE DISTANCE 450 MM
MINIMUM VISIBILITY 320 MM
END CONNECTION 25 NB, FLANGED ANSI B16.5, 300# RF
GAUGE GLASS BORO-SILICATE MOULDED
IBR T.C. IN FORM III-C PROVIDED
OPERATING DATA:
WORKING PRESSURE 18.25 Ksc (g)
HYDRO TEST PRESSURE 27.38 Ksc (g)
WORKING TEMPERATURE SATURATED
SUPPLIER’S ADDRESS:
M/S. LEVCON INSTRUMENTS PVT. LTD,

6TH FLOOR, “RAJKAMAL”,
13, CAMAC STREET,
KOLKATA - 700 017.
DATA SHEET
LIQUID LEVEL LIMITTER
GENERAL DATA:
QUANTITY 1 NO.
APPLICATION FOR STEAM DRUM
TAG NO. LLL201
MEDIUM STEAM / WATER
CENTRE TO CENTRE DISTANCE 450 MM
SWITCHING RANGE 250 MM
END CONNECTION 25 NB, FLANGED, ANSI B16.5, 300#
NO. OF CONTACTS PER CARRIAGE 1 SPDT, 1 NO + 1 NC
CURRENT RATING 5 AMPS, 230 V AC
NO. OF SET POINTS 3
SET POINTS HIGH LOW LOW LOW
77.77% 33.33% 22.22%
OPERATING DATA:
MAX. WORKING TEMPERATURE SATURATED
13, CAMAC STREET,
KOLKATA - 700 017.
DATA SHEET
SAFETY VALVE
DESCRIPTION UNIT SPECIFICATION
GENERAL:
MAKE -- M/S DARLING MUESCO (INDIA) PVT.LIMITED
QUANTITY -- 2 NOS.
TYPE -- SPRING LOADED
NOZZLE & DISC -- SS 410 STELLITED
BONNET TYPE -- OPENED
LIFTING LEVER -- PLAIN
BODY & BONNET MATERIAL -- SA216 GR. WCB
SPRING MATERIAL -- C.S SPRING STEEL CD PLATED
OPERATING DATA: DRUM - I DRUM - II
TAG NO. -- PSV-201 PSV-202
MODEL NO. -- SVC-500 SVC-500
MEDIUM -- SATURATED STEAM SATURATED STEAM
SET PRESSURE Kscg 18.00 18.25
TEMPERATURE °C SATURATED SATURATED
ACTUAL RELEAVING CAPACITY Kg/hr 9713 9840
BLOW DOWN PERCENTAGE % 5.0 5.0
SIZING CODE -- IBR IBR
VALVE INLET / OUTLET SIZE MM 50 / 80 50 / 80
ORIFICE -- K K
END CONNECTION INLET -- FLANGED, ANSI B16.5, 300# RF
END CONNECTION OUTLET -- FLANGED, ANSI B16.5, 150# RF
M/S DARLING MUESCO (INDIA) PVT.LIMITED
PLOT NO.97 A, PHASE-I, G.I.D.C.,
VATVA,
AHMEDABAD - 382445
DATA SHEET
BLOW DOWN VALVE
GENERAL DATA:
QUANTITY 1 NO.
APPLICATION INTERMITTENT BLOWDOWN LINE
TAG NO. BDV201
TYPE RACK & PINION OPERATED
SIZE 40 NB
END CONNECTION FLANGED, ANSI B16.5
RATING 300#
OPERATING DATA:
MEDIUM BOILER SATURATED WATER
WORKING TEMPERATURE SATURATED

13, CAMAC STREET,
KOLKATA - 700 017.
BOILER AUXILIARIES
DATA SHEET
FANS
GENERAL DATA:
MAKE M/S. CETHAR VESSELS LIMITED.
APPLICATION FD FAN ID FAN PA FAN

QUANTITY 1 NO. 1 NO. 1 NO.
TYPE CENTRIFUGAL CENTRIFUGAL CENTRIFUGAL
MEDIUM AMBIENT AIR FLUE GAS HOT AIR
FLOW 5.05 M3/SEC. 8.30 M3/SEC. 1.8 M3/SEC.
PRESSURE 700 MMWC 450 MMWC 700 MMWC
TEMPERATURE 40°C 170°C 199°C
TYPE OF DRIVE DIRECT COUPLED DIRECT COUPLED DIRECT COUPLED
SPEED 1500-1480 RPM 1480 RPM 2900 RPM
(RATED) (RATED)
CASING ORIENTATION ACW-10 CW-2 CW-3
MOTOR RATING 55 KW 75 KW 22 KW
MOTOR FRAME SIZE ND 250M ND 280S ND 180M
MOTOR MAKE CROMPTON CROMPTON CROMPTON
BEARING 22217 EK/C3 22219 EK/C3 22215 EK/C3
BEARING MAKE SKF SKF SKF
COUPLING 109Z – BIBBY 110Z– BIBBY 104Z– BIBBY
RESILENT RESILENT RESILENT
PLUMMER BLOCK SNH 517 TG SNH 519 TG SNH 515 TG
LOCATING RING ---- FRB 15/170 FRB 13/130
ADAPTER SLEEVE H317 H319 H315
DOUBLE LIP SEAL TSNA 517G TSNA 519G TSNA 515G
LUBRICATION GREASE GREASE GREASE
SERVOGEM EP-2 SERVOGEM EP-2 SERVOGEM EP-2

M/s. CETHAR VESSELS LIMITED,
No. 4, DINDIGUL ROAD,
TRICHY - 620 001.
OPERATION AND
MAINTENANCE MANUAL
FOR INDUSTRIAL FANS
4, DINDIGUL ROAD, TIRUCHIRAPALLI - 620 001. INDIA.

TEL : 91 - 431 – 2484000
FAX : 91 - 431 – 2481079
e-mail : [email protected]
-1-
FAN OPERATION AND MAINTENANCE MANUAL
SL. NO CONTENTS
1.0 DETAILS OF FAN
2.0. DESCRIPTION OF COMPONENTS
2.1 CASING
2.2 IMPELLER
2.3 SHAFT
2.4 BEARINGS
2.5 COUPLINGS
2.6 PULLEY & BELT ARRANGEMENT
2.7 PLUMMER BLOCK / MOTOR SUPPORT PEDESTAL
2.8 IGV AND MULTIFLAP DAMPER
2.9 SEALING
2.10 COOLING DISC
3.0 STORAGE & INSTALLATION
3.1 STORAGE OF FAN
3.2 ERECTION OF STATIC CASING PARTS
3.3 INSTALLATION OF BEARINGS
3.4 ERECTION OF SHAFT & IMPELLER ASSEMBLY
3.5 ERECTION OF MOTOR / BEARING PEDESTAL ON FOUNDATION
3.6 INSTALLATION OF MOTOR
-2-
SL. NO CONTENTS
4.0 FAN OPERATION
4.1 GENERAL
4.2 CHECK POINTS BEFORE TRIAL RUN
4.3 LUBRICATION
4.4 STARTING THE FAN
4.5 CHECK POINTS DURING TRIAL RUN
4.6 CONTINUOUS OPERATION
4.7 SERVICE CHECK LIST
4.8 STOPPING SEQUENCE
4.9 TROUBLES & REMEDIES
4.10 MAINTENANCE OF FANS
5.0 DATA SHEETS
5.1 BEARING CLEARANCE RADIAL & EXPANSION
5.2 COUPLING ALIGNMENT DETAILS
5.3 SHAFT AND BEARING ALIGNMENT
5.4 VIBRATION LEVEL RECORDS
5.5 TRIAL RUNNING DETAILS
5.6 CHECK SHEET
-3-
1.0 DETAILS OF FAN
Centrifugal fans are being used to handle cold air / hot air / hot flue gas
without abrasive dust. These fans are used as Forced Draught, Induced
Draught, Primary Air as booster fan, seal air fan, ash / fuel conveying
line fans and other various applications.
The air / gas enters the impeller auxiliary from the IGV / multi flap
damper in the guided controlled way and passing through the blade
passage leaves the impeller through the spiral casing. In the casing, the
area increases gradually, so the part of the kinetic energy of fluid is
converted into static pressure. The fan is controlled by IGV / multi flap
dampers or by speed drive. The fan is driven by a motor / Turbine.
-4-
2.0 DESCRIPTION OF COMPONENTS
The fan consists of the following major parts.
2.1 CASING
The spiral casing assembly is a fabricated component. It is having

opening in the front side of the casing (or split along the shaft axis)
for installation / removal of the impeller. The casing consists of two
stiffened side walls with a spiral scroll and it is supported at bottom or at
side according to the construction. The single / double suction boxes are
also fitted to side walls of the casing. The suction box helps in
accelerating the flow to the impeller.
2.2 IMPELLER
Impeller is a welded structure, consists of back center plate, shroud

plate and blades. The impeller is fitted to hub having the machined
bore or it is bolted to flange which is welded to the shaft depending on its
construction. The impeller assembly is dynamically balanced in the
works and balancing weights are welded to counter unbalance,
created during manufacturing. The handling of the impeller is very
important since it is a critical part of the fan.
2.3 SHAFT
The shaft is turned from solid or fabricated from hollow and solid
combination and it is supported between two bearings. The positions
where hub and bearings are to be fitted are machined to close
tolerances.
2.4 BEARINGS
Grease lubricated spherical roller bearings take charge of supporting the

fan shaft.
These are bearings with cylindrical bore.
-5-
The bearing housing is split horizontally. The upper members are
screwed to the lower members. Two asymmetrically arranged
tensioning pins each will prevent incorrect assembly of the housing
elements. Feet on the lower members of the housing serve for
screw connection to the supporting structure.
The shaft passage ways on the bearing housings are provided with
talcum soaked felt seals, which prevent penetration of dirt in to the
inside of the housing.
Grease cups are arranged on the upper housing members for normal
relubrication.
One floating bearing and one fixed bearing are located on each side
of the fan shaft.
The spherical roller bearing on the floating bearing side will be installed
into the bearing housing so as to under go axial displacements in the
housing bore wherever a change is occurring in the length of the
shaft.
On fixed bearing side, where axial forces have to be accommodated,

the spherical roller bearing will be fixed in the housing by appropriate
rings.
2.5 COUPLING
The fan shaft is connected to the motor through a coupling viz.,

spring grid or tyre - type coupling, which are generally used. In case
where the rotor is very heavy the fan moment of inertia becomes
huge, a hydraulic coupling, whose output speed can be varied
steplessly by means of a scoop tube is used.
-6-
2.6 PULLEY & BELT ARRANGEMENT
The fan shaft is connected to motor shaft through pulley and belt
arrangement to have lower / higher speed than motor.
2.7 PLUMMER BLOCK / MOTOR SUPPORT PEDESTAL
A shallow fabricated base of M.S. construction carries the bearing / shaft

assembly and the driving motor. In case of impeller supported in
between bearings, the non-located bearing is supported by a separate
frame. The fan casing is supported independently and have provision
for thermal expansion while handling hot air / gas.
2.8 IGV AND MULTIFLAP DAMPER
The damper assembly consists of a outer shell, damper flaps with

individual shaft and bearings. The damper will be radial vane type or single
flap butterfly type. The shafts are connected by levers and links to the
actuator. In case of double inlet fans both the dampers are connected to a
common shaft and operated using a single actuator.
2.9 SEALING
a. SHAFT SEALING
To avoid air leak at the shaft passageway, it is sealed using

soft material viz., brass, gasket.
b. IMPELLER SUCTION SEALING
It is provided between impeller suction nozzle and casing

suction cone.
2.10 COOLING DISC
To reduce the temperature rise in the bearing cooling disc is

provided nearer to it.
-7-
3.0 STORAGE & INSTALLATION
3.1 STORAGE OF FAN
GENERAL
As soon as received, the different parts of the equipment should be

placed in clean and dry covered premises.
LONG TERM STORAGE
Storage for a period of three years must be ensured in the best possible
condition, basically protected from dampness so as to avoid oxidization
of the different parts of the fan unit.
The mechanical parts with machined surfaces are coated with anti-
corrosion varnish. In the case of prolonged storage, before putting into
service, the equipment shall be inspected periodically and the
machined parts shall be protected from time to time using a protective
coating in case of need.
They will be stored in sufficiently large premises, thus providing space

for inspection and easy maintenance of the equipment stored.
Moreover, the storage premises will protect the equipment from sudden
change in temperature, dust, foreign matter, etc.
The impeller and bearing assembly should be rotated at a very low

r. p. m. (rotation by hand) for about thirty minutes, once a week.
STORAGE OF BEARINGS
As a general rule, the bearings are given a rust prevention treatment in

the works before being packed. The can be preserved for several years,
in their original packing, on a condition that the relative humidity in the
storage premises is not over 60%. A higher degree of relative humidity,
upto 75% is however permissible for short term storage.
-8-
TRANSPORT
The fans are despatched in dismantled condition with proper packing.
Handle all fan parts carefully during transport. Avoid damaging damper
control unit and rotor by careless installation or by chains of lifting
devices.
Pay particular attention to impeller, bearing housings and bearings.

They should not be dropped on the floor or should not be
mishandled.
INSPECTION
When packages are received at site, check all parts with the help of the
packing list and drawing. If necessary, make a list of the missing parts
(in case of shortage) and initiate action for replacement, insurance
etc.
Check for any damage occurred to the parts during transit. In

consultation with the manufacturer, take steps to repair the damages,
if any.
3.2 ERECTION OF STATIC CASING PARTS
INSTALLATION PROCEDURE
PRELIMINARY ACTION
a. Ensure that civil work is correct to drawing and that holding

down bolt pockets are clean and positioned to accommodate fan
casing assembly.
b. Using an optional level or water level, transfer a ‘bench mark’ on

to the plinth which will be used for setting the casing to the
correct height above Ordnance Datum.
-9-
c. Using a steel measure, mark into the plinth top surface, the
longitudinal center line of the fan shaft and the transverse center
line of the casing.
d. Identify the correct casing and ensure that the inlet and outlet
flanges have correct orientation.
e. Clean the casing to expose the original, works, shaft and bearing
centre line markings. These should be reinforced for clarity.
f. The fan casing will be arranged such that a minimum number of

pieces will need to be omitted to facilitate the installation or
removal of the shaft / impeller / assembly for maintenance
purposes.
g. The items required to form the reminder or lower casing must be

identified and moved to the work area. The inlet box(es) should be
installed first, and where these are in close proximity to the
plinths and access is limited, lagging should be applied prior to
installation (where applicable).
INSTALLATION
The casing sections must be assembled in accordance with the general

arrangement drawing and should be mounted on steel packers placed at
each side of the holding down bolts. The correct flange jointing material
must be used ensuring that gaps do not occur at junctions. The casing
flange joint bolts should remain untightended to allow flexibility during
leveling and further assembly.
Initial alignment of the casing must be carried out ensuring correct radial
and axial location, with respect to fan-shaft and located bearing centre
lines.
The casing assembly must not proceed further until the shaft / Impeller /
Assembly and if applicable Inlet Guide Vane installation has been
completed.
- 10 -
Secure the holding down bolts into the plinth in accordance with the set
procedure. Where the procedure required bolts to be held in square
pockets cast into a plinth by filling the pockets with a grouting mixture,
the grout must completely fill the pocket and be trowelled level to
facilitate the positioning of steel packers.
INSTALLATION (TOP HALF)
The final casing sections can now be installed and positional checks
made. When final alignment is complete the casing joint securing bolts can
be tightened.
Secure the suction cone to the inlet ducts and centralize to the rotor seal
in accordance with the arrangement drawings, taking care to ensure that
the expansion clearance has been set correctly.
Fit the casing-to-shaft seal in accordance with the appropriate drawing.
The holding down bolts can now be tightened down to required torque,
making sure that adequate packing material has been placed at each
side of the bolts.
INSPECTION
Final examination must be made to ensure that all flange bolts are
securely tightened and that joint sealing is effective. The clearance
between the suction cone and impeller seal must be checked and
recorded.
The suction and discharge flanges must be inspected for correct

orientation and position.
3.3 INSTALLATION OF BEARING
PRE-ASSEMBLY CHECKING
As the bearings are finished to high precision, thorough inspection and

checking on the following points are essential prior to assembly.
- 11 -
a. On opening the packing of bearings, the same shall be thoroughly
checked for dirt or other foreign matter and if found, same shall be
carefully washed off with petrol. The new bearings should not be
washed unless and until it is necessary.
b. The shaft shall be checked for damage due to transport and

handling. Particularly the surfaces where the bearings are to be
mounted should be checked for rusting, scoring etc. Rust, if found,
should be removed by rust remover. Heavy pittings on bearing
surfaces of shaft is not acceptable.
Localized scorings could be removed using oil stone.
If the shaft is found to have a bend, the same should not be used for
assembly.
c. Plummer blocks although made by precision matching to the given

specifications, a thorough checking is essential to make sure against
any defects in the bearing seating surfaces or dirt inclusion which can
possibly result from handling, transportation etc. The flaw, if any, is to be
carefully removed with the use of an oil stone or fine emery paper and the
dirt to be thoroughly washed off and cleaned.
d. Bearing to be mounted shall be taken out of the original protective

packing only immediately before mounting.
e. The mounting and dismounting tools and necessary jigs must be

of proper dimension and simple design so that they do not cause
any mechanical damage to the bearings.
Keep the rotor assembly on the floor by proper support.
GENERAL INSTRUCTIONS
a. Never apply direct blows to the bearing. Always use a length of

tubing or similar tool-otherwise the ring may crack, the cage may
become damaged, or metal fragments may break off and cause damage
when the bearing is put into operation.
- 12 -
b. Small bearing may be mounted with the aid of a mounting dolly or a
length of tubing. The tube should be clean and have no burrs.
Place the tool against the inner ring and apply blows, evenly distributed
around its end face, with an ordinary hammer (hammers with head or other
soft metal heads are unsuitables as fragments can easily break off and
enter the bearing). Ensure that the bearing does not skew on the shaft.
c. Never apply force to the outer ring when mounting a bearing on a shaft.
The raceways and rolling elements can easily be damaged and the
bearing life reduced considerably as a consequence.
d. If the shaft has external or internal threads, they may be utilized

when mounting the bearing.
e. If a mechanical or hydraulic press is available, this can be used for

mounting small and medium sized bearings. Use a mounting dolly
or a clean piece of tubing between the press and the inner ring.
f. Large bearings are easier to mount if they are first heated to a

temperature of 80°C to 90°C above ambient temperature. However, the
bearing should never be allowed to reach a temperature above +120°C.
One method is to use an oil bath. The oil should be clean and have a
flash point above +250°C. Clean a suitable receptacle and pour in
sufficient oil to completely cover the bearing. The bearing should not be
in direct contact with the base of the receptacle but should be placed
on a suitable platform to avoid local heating. Heat the bath on an
electric hot plate, gas flame, or similar equipment.
A bearing should never be heated using a naked flame.
g. Put on clean protective gloves or use clean rags to hold the hot
bearing drain off any oil which may be left in the outer ring and wipe
the bearing bore push the bearing quickly into position.
h. Press the bearing hard against the abutment face until it has cooled
sufficiently so that the inner ring fits well to the shoulder.
- 13 -
MOUNTING OF BEARING
I. BEARING
a) The inner ring of bearings is always mounted with an interference fit

usually on shaft. The original radial internal clearance of the bearing
is gradually reduced as the bearing is driven up. Thus reduction in
clearance is a measure of the degree of interference.
b) Before mounting, remove the rust inhibiting compound from the bearing
bore only. Please the bearing on the shaft and screw on the lock nut.
Drive the bearing up the sleeve by tightening the lock nut.
c) Before spherical roller bearings are mounted on shaft, the radial

internal clearance should be measured using a feeler gauge. Stand
the bearing on the work bench and rotate the inner ring a few times
to allow the rollers to assume their correct positions, before inserting the
blade of the feeler gauge between the upper most roller and the outer ring
raceway. Use a thin blade to start with and increase the thickness
gradually until the blade can be just be inserted. The measured
clearance should be the same for both rows of rollers.
d) Check the reduction in clearance frequently during the driving-up

process. Measure between the lowest roller and the outer ring raceway.
The adjacent table contains guideline values for the reduction in radial
internal clearance and axial drive-up for spherical roller bearings.
Heavy loads, high speeds, or large differences in temperature between
inner and outer rings (inner ring hotter than outer) mean that a
relatively large residual radial internal clearance is required. In such
cases a bearing having larger initial radial internal clearance than
normal, i.e, C3 or C4 is generally used and mounted using the
maximum reduction clearance. If the outer ring is hotter than the inner, a
bearing having less initial radial internal clearance than normal is
generally used.
e) Remove the lock nut after the drive-up has been completed and place the
locking washer in position. Screw on the lock nut again and tighten it.
Bend down a suitable tab of the locking washer so that it engages in on
of the slots in the lock nut. Measure the residual clearance again to
see that it is unchanged.
- 14 -
II. INTERFERENCE FIT IN THE HOUSING
a) Lightly smear the bearing seating with oil use a mounting dolly or a
clean piece of tubing, but place it against the outer ring race. Ensure
that the bearing does not skew in the housing. A mechanical or
hydraulic press may also be used as advantage. Otherwise the rules
for mounting bearings with an interference fit on shafts are valid
when the bearings is to have an interference fit in the housing.
b) It may sometimes be necessary to heat the housing in order to mount

the bearing. Normally, a small rise in temperature will be sufficient
because the interference is rarely tight. An electric lamp, a heating
tool, hot oil or a naked flame may be used to heat the housing. If a
naked flame is used, great care must be exercised otherwise the housing
may crack or disort.
Check the dimension of bearing seating after heating and do not

forget to wipe the seating clean before mounting the bearing. Press
the bearing hard against the abutment face until the housing has
cooled sufficiently for the bearing to have an interference fit.
III. TEST RUNNING AND REPORT
It is during the very first period of operation after starting up that any
mounting errors can be corrected. Keep a check on bearing
behavior immediately after starting up.
If there is the slightest doubt as to bearing performance, the machine

should be stopped and the bearing arrangement checked.
Mounting data, such as the date, the full designation of the bearing,
results of dimensional checks, bearing radial internal clearance
before and after mounting, the lubricant used, etc., should be
noted in report form. A maintenance schedule should be
attached to the report giving details of relubrication, inspection
routines, operating temperature etc., if this is done, a good record
of the bearing will be obtained and any future replacement can be
planned well in advance.
- 15 -
3.4 ERECTION OF SHAFT AND IMPELLER ASSEMBLY
PRELIMINARY ACTION
a) Check the centre line of casing, shaft axis and impeller axis.
b) Position bearing pedestals and bolt with base frame.
c) Check the levels, height and centre to centre of bearing pedestal.
d) Identify the shaft and impeller ensuring that both bear the same
works order number and that the impeller is of the correct handling.
NOTE: TOP SURFACE LEVEL OF BEARING PEDESTAL SHOULD BE CHECKED BY

MASTER LEVEL. PERMISSIBLE DEVIATION IS 1 DIVISION OF MASTER
LEVEL HAVING ACCURACY 0.02 MM / METER. THIS LEVEL SHOULD BE
OBTAINED BY ADDING OR REMOVING STEEL PACKERS IN BETWEEN
BASE FRAME AND FOUNDATION.
INSTALLATION
Ensure that sound access roads and hard standing are prepared,
adequate to support the assembly, transporter and the mobile crane.
Assemble the bearings in shaft as per the “assembly procedure of

plummer block and bearing”.
Before lifting into position it may be necessary to fit the suction cone
into the impeller seal (on larger fans the suction cone should be fitted at
works). This is achieved by placing the cone over the shaft end and
moving it towards the impeller as far as the transport cradle will permit.
ALIGNMENT
To facilitate rotor alignment, the face of the shaft half coupling

should be vertical. This is achieved by raising the outboard bearing
until the shaft is level at the inboard bearing journal when measured
with an engineer’s spirit level.
Drop a plumb line set through the centre of the drive coupling to
ensure that the shaft lies over the centre line of the base frame.
- 16 -
With a straight edge and steel measure, check the distance / square
ness off the coupling face to the motor holding down bolt holes on
both sides of the centre line. If correction of square ness is required
this can be achieved by moving the outboard bearing.
When the foregoing checks have been completed and recorded, the
outboard bearing must be positioned to obtain the correct axial
expansion clearances.
INSPECTION
Complete the shaft location inspection record sheet.
3.5 ERECTION OF MOTOR / BEARING PEDESTAL ON FOUNDATION
PRELIMINARY ACTION
Ensure conformity with the civil arrangement drawing.
NOTE : Make sure that non-shrinkage type grout materials are

used. Allow to dry long enough.
Check the holding down bolt pockets are in the correct position,
of adequate depth and size to allow bolts to hang vertical and
that no debris remains in the pockets.
The surface area where steel packers are placed must be sound
and flat ensuring good contact between the matting surfaces.
INSTALLATION PROCEDURE
a) Using a optical level or water level, transfer a ‘bench-mark’ on to the

plinth which will be used for setting the pedestal to the correct height
above ordnance Datum.
b) Using a steel measure, mark into the plinth top surface, the
longitudinal centre line of the fan shaft and the transverse centre line of
the located bearing.
- 17 -
c) Clean the pedestal to expose the original, works, shaft and bearing
centre line markings. These should be reinforced for clarity,
d) Insert the pedestal / holding down bolts into the respective pockets and
lower the pedestal into position on adequate number of temporary
packers placed beneath the pedestal for leveling.
e) Fit the holding down bolts and nuts along with lock-nuts ensuring that
sufficient thread protrudes to facilitate further adjustment (approx. 15 mm).
f) Using a straight edge and steel measure adjust the pedestal to the
correct height, and level to within ±1.5 mm.
g) Align the pedestal centre lines with the plinth centre lines using piano wire
as a datum reference. When the inboard and outboard pedestal are
separate components, further measurements must be made to ensure
precise relative alignment and location.
h) Secure the holding down bolts in accordance with the set procedure.
Where the procedure required bolts to be held in square pockets cast
into a plinth by filling the pocket with a grouting mixture, the grout must
completely fill the pocket and be trowelled level to facilitate the
positioning of steel packers.
FINAL LEVELING
Steel packers must be placed between the pedestal underside and the
plinth surface to give adequate support. This is best achieved by placing
on either side of the holding down bolts and also at any other point where
load is being supported.
Tighten bolts to specified torque.
Using suitable optical or water level, check the height of each machined
pad on the pedestal top surface. One pad, local to the located bearing,
should be taken as the reference pad and the height of the remaining pads
should be corrected by adjusting the thickness of the steel packer units
satisfactory level state has been achieved.
- 18 -
BEARING PEDESTALS
The bearing support pedestals should be positioned on the pedestal,

after final alignment inspection, in accordance with the appropriate
drawing. All machined foot pads should be cleaned and lightly oiled and
the grillage support pads wiped clean before positioning the
pedestals.
INSPECTION
Final inspection must be recorded on the correct inspection sheet and

witnessed by all the concerned personnel.
3.6 INSTALLATION OF MOTOR
PRELIMINARY ACTION
a) Identify the correct motor ensuring that the bearings and cooling fan
are arranged for the appropriate rotation.
b) Remove protective coating from the motor feet and the drive coupling
faces and lightly oil the machined surfaces.
ERECTION
a) Lift the motor on to the base and position approximately.
b) Where bearings of the sleeve or friction type are used, remove the bearing
top halves, examine the bearings and remove any temporary restraints
which have been fitted for transit.
c) Where the bearings are of the non-located type, move the rotor axially to
coincide with the marked magnetic running centre. Where no mark exists
the manufacturer must be consulted.
ALIGNMENT
Alignment must be carried out in accordance with drive coupling

assembly and alignment.
- 19 -
4.0 FAN OPERATION
4.1 GENERAL
The ready-to-operate condition of the fans is established only when the

work and tests described under “MAINTENANCE” are completed and have
been entered into protocols.
Fan operation comprises of the following phases :
a) Check points prior to starting the fan.

b) Starting the fan.
c) Continuous operation of the fan.
The work to be performed under point 4.2 until start-up of the machines has
to be done in a chronological order which is not interrupted. When
interruption is absolutely necessary, the checks and tests have to be
repeated.
The “CHECKS” under points 4.2, 4.3, 4.4, 4.5 & 4.6 have to be made
and entered into protocols upon each and every start-up. Conformations to
this effects have to be entered into the check list.
4.2 CHECK POINTS BEFORE TRIAL RUN
01. Check up the fixation of the bearing housings and electric motor.
02. Check up the coupling is correctly tightened.
03. Check up the fixation of the whole fan assembly on the base frame.
04. Check that the connecting flanges between the fan and ducting are
good, and proper packing is provided.
05. Check that the different components of the control system are
correctly connected.
06. Check that the inlet damper is fully closed.
07. Check that linkage between actuator and damper.
08. Check that no foreign object has been left any where in side the fan.
09. Check that no water stays in the bottom of the casing and inlet box.
10. Check the inspection door on the casing and inlet box are correctly
shut.
- 20 -
11. Check that the rotor can turn freely without rubbing with any as it is
noted in the individual document.
12. Check that the bearings have been correctly filled with oil as it is
noted in the individual document.
13. If some time has elapsed between the erection and the start up of
the fan, it is advisable to recheck the alignment to ensure that no
setting of foundations has occurred sufficient to cause fouling. This
may be checked by turning the impeller by hand or momentary
operation of the fan motor starter.
14. If an auxiliary lubrication system is incorporated check that oil is
being returned via the drains before starting the fan.
15. When the fan is being started up (after a shut down for inspection or
maintenance) the casing and duct (if fitted) should be checked for
the presence of loose tools, nuts or bolts which might cause damage
to the fan.
16. Check proper clearances in the expansion joints at the entry and
exit if the same is provided.
17. Ensure proper functioning of “Emergency off” switch.
18. Ensure the provision of all protections / interlocks for fan and
motor.
19. Check proper earthing of motor body.
4.3 LUBRICATION
a) Check type of lubrication Grease

b) Check type of lubricant Servogem – EP2
GREASE LUBRICATION
Fill the space between the balls or rollers with a grease which is suitable for
the operating conditions. The free space around the bearing should
normally be between a third and half – filled with grease if the bearing is to
operate at very high speeds, the quantity of grease in the free space
should be just less than one third or, where the bearing is to operate at very
slow speeds, the free space may be completely filled with grease.
LUBRICATION INTERVAL
Normally six months, to be changed as and when required.
- 21 -
4.4 STARTING THE FAN
The fan shall be started with closed control unit in order to avoid over
loading of the driving motor.
For safety reasons no persons should stay in the coupling and rotor zone
during the start-up procedure.
The control unit shall be opened after operating speed has been reached.
Operation with closed control unit should not be continued for too long a
time, because the fan would then be heated to an excessive extent.
People responsible for the starting must always stay nearest as possible to
the emergency stop switch.
During the acceleration phase, that there is no abnormal noise.
4.5 CHECK POINTS DURING TRIAL RUN
a) Check bearing vibration level. The vibration levels indicated in below are
in full accordance with the standard VDI 2056.
Velocity in mm/sec. (RMS)
Good : ≤ 1.8
Satisfactory : ≤ 4.5
Unsatisfactory : ≤ 11.2
Alarm level : 7.1
Trip level : 11.2
b) Check that the bearings temperature is good.
Normally, this temperature first raises and then decreases and stabilizes
at particular temperature.
SET THE ALARM POINT AT 90°C.

SET THE TRIPPING POINT AT 100°C.
c) Check up the noise of the bearing housings. This can be heard by

applying an ear against the handle of a screw driver, the tip of which is
applied against the bearing.
- 22 -
d) If everything seems to be good, let the fan be running for five to six hours.
e) After this trial, check that all nuts are correctly tightened.
4.6 CONTINUOUS OPERATION
a) Fan running shall be steady and free from trouble. Steady running and
noise produced by running shall carefully be observed during the initial
operating hours.
b) The bearing temperatures shall be supervised until constant temperature

has been established after some hours.
c) When unsteady running is observed or the bearing temperatures are rising

permanently and exceed 90°C, the fan shall be shut down for finding and
eliminating the cause.
4.7 SERVICE CHECK LIST
During continuous operation of the fan, the various operating data may be
recorded at regular intervals of time. A typical format is suggested in this
manual. Apart from these, the following shall be recorded at convenient
timers.
a) Vibration levels.
b) Water flow.
4.8 STOPPING SEQUENCE
a) Gradually decrease the load on the fan to minimum.
b) Close the discharge damper and switch off the motor.
c) Where a fan is handling hot gases it should not be allowed to come to rest
with the shaft and impeller subjected to high gas temperature. When
shutting down, the fan should be kept running until the gas temperature is
below 120°C, or in the case where the hot gases have been isolated the
impeller should be kept running until it has dissipated its heat and has a
surface temperature not exceeding 120°C.
- 23 -
4.9. OPERATIONAL TROUBLES, REMEDIES
TROUBLE CAUSE REPAIRS
4.9.1 High bearing Bearing damages Replace bearing.

temperature (fatigue)
Bearing clearance too Install with correct clearance.
small.
Lubrication failure. Add lubricant and check for leakage.
4.9.2 Unquiet Bearing clearance too Check bearings. If required replace
running large. them (Check also motor bearing if
required). Possibly measure sound
conducted through solids.
Mechanical rubbing Check all gaps between stationary
rotating parts.
Unbalance due to Remove deposits.
deposits at rotor.
Unbalance due to wear Replace or repair the impeller and
on blades. dynamically balance.
Misalignment. Check alignment realign.
4.9.3 Vibration Deposit on Impeller In most cases deposit will be
heaviest on backs of blades. This
must be removed and the impeller
thoroughly cleaned with a wire
brush.
Misalignment of fan Correct the alignment.
and driving unit.
Abrasion of Impeller. Impeller wear may cause out of
balance, even though wear is not
sufficiently severe to justify
replacement or repairs. Re-balance
impeller in position.
- 24 -
TROUBLE CAUSE REPAIRS
Impeller damaged in Rectify any obvious damage and re-

transit or erection. balance impeller in position. If badly
damaged return impeller to our
works.
Bent shaft. Shaft should be replaced.
Slack H.D. Bolts in Tighten all H.D. bolts and check
bearings, base plates alignment.
or pedestals.
Inferior concrete Renew concrete or grouting with a
foundations or stronger mixture of good quality
grouting. material. Make sure plinth is
feathered into concrete floor or
supporting steel work.
Weak structural Reinforce supporting structure with
additional members, suitably tied to
existing members. Experience has
proved that bolted structures are
less satisfactory than riveted. If
structure is bolted, holes should be
reamed and fitted bolts with locking
washer used.
NOTE : The recommended maximum “out of balance” running, measured as
an R.M.S. velocity at the fan shaft bearings, is 5.5 mm/sec. It is
recommended that the fan is tripped and steps taken to improve
the condition if the “out of balance” reaches 10 mm/sec.
- 25 -
4.10 MAINTENANCE OF THE FANS
BETWEEN PLANNED SHUT DOWNS
Every 8 operating hours Routine recording in accordance with check sheets.
See also point “Check during operation”.
Every 2000 operating hours or at lease once in every six months :
Check the impeller erosion.
Check and dampers condition.
Retighten all fixing bolts.
Check the balancing weights condition in impeller and shaft.
Every 4000 operating hours or at least once in a year.
Check the lube oil system, service it and change the oil as recommended.
Check the wear in the impeller, if excessive wear is noticed change the
impeller in consultation with manufacturer.
Check for freeness of expansion joints at suction and delivery.
DURING PLANNED SHUT DOWNS
It is recommended to effect overhauls every 8000 to 10000 operating hours

(at least once in two years). It is also suggested to get the assistance of the
manufacturer to carry out such overhauls.
Check the impeller for soot deposition and wear. Clean the impeller.
If erosion is found excessive, change the impeller in consultation with

manufacturer.
Check wear on fan casing, stiffening pipes, rods etc.
Check the condition of damper flaps. Repair in case of small dampers and
replace, if required.
- 26 -
MAINTENANCE AND LUBRICATION OF BEARING
Rolling bearings must be lubricated to prevent inter-metallic contact between

in rolling elements, raceways and cage and also to protect the bearing
against corrosion and wear.
Rolling bearings may be lubricated with grease or oil lubricant properties

deteriorate with time as a result of mechanical working and edging.
Additionally, all lubricants become contaminated in service and must
therefore be replenished or changed from time to time.
RELUBRICATION INTERVAL
The period during which a grease lubricated bearing will function

satisfactorily without relubrication is dependent on the bearing type, size,
speed, operating temperature and the grease used. The relubrication
intervals (hours of operation) is based on the use of an age-resistant
average quality grease and is valid for bearing temperatures of +70°C
measured on the outer ring. The intervals should be halved for every 15°C
increase above +70°C, but the maximum permissible operating temperature
for the grease should obviously not be exceeded.
The amount of grease needed for relubrication can be obtained from G =

0.005 DB
Where,
G = Grease quantity, g
D = Bearing outside diameter , mm
B = Total bearing width, mm
CHECKING NOISE LEVEL
a) Grinding Noise :
Inadequate lubrication (surface rubbing directly against one another).
b) Whistling:
Improper lubrication (grade or quantity).
- 27 -
c) Clear noise at regular intervals :
Imprints in race of outer ring because of abnormal vibration.
d) Intermittent noise :
Rolling part deteriorated or damaged.
e) Cracking Noise :
Presence of foreign particles.
f) Whinning or high pitch Noise :
Axial thrust from motor.
- 28 -
5.1 BEARING CLEARANCE RADIAL & EXPANSION
Reduction in Axial drive - upMin. permissible

Bearing bore radial residual clearance
diameter Taper 1 : 12
internal Taper 1 : 30 other mounting
d on diameter
clearance on diameter bearings with initial
clearance
Over incl. Min. Max. Min. Max. Min. Max. Normal C3 C4
MM MM MM MM MM
30 40 0.020 0.025 0.35 0.40 ---- ---- 0.015 0.025 0.040
40 50 0.025 0.030 0.40 0.45 ---- ---- 0.020 0.030 0.050
50 65 0.030 0.040 0.45 0.60 ---- ---- 0.025 0.035 0.055
65 80 0.040 0.050 0.60 0.75 ---- ---- 0.025 0.040 0.070

80 100 0.045 0.060 0.70 0.90 1.75 2.25 0.035 0.050 0.080
100 120 0.050 0.070 0.75 1.10 1.90 2.75 0.050 0.065 0.100
120 140 0.065 0.090 1.10 1.40 2.75 3.50 0.555 0.080 0.110
140 160 0.075 0.100 1.20 1.60 3.00 4.00 0.055 0.090 0.130
160 180 0.080 0.110 1.30 1.70 3.25 4.25 0.060 0.100 0.150
180 200 0.090 0.130 1.40 2.00 3.50 5.00 0.070 0.100 0.160
200 225 0.100 0.140 1.60 2.20 4.00 5.50 0.080 0.120 0.180
225 250 0.110 0.150 1.70 2.40 4.25 6.00 0.090 0.130 0.200
250 280 0.120 0.170 1.90 2.70 4.75 6.75 0.100 0.140 0.220
280 315 0.130 0.190 2.00 3.00 5.00 7.50 0.110 0.150 0.240
315 355 0.150 0.210 2.40 3.30 6.00 8.25 0.120 0.170 0.260
355 400 0.170 0.230 2.60 3.60 6.50 9.00 0.130 0.190 0.290
400 450 0.200 0.260 3.10 4.00 7.75 10.00 0.130 0.200 0.310
450 500 0.210 0.280 3.30 4.40 8.25 11.00 0.160 0.230 0.350
500 560 0.240 0.320 3.70 5.00 9.25 12.50 0.170 0.250 0.360
560 630 0.260 0.350 4.00 5.40 10.00 13.50 0.200 0.290 0.410
630 710 0.300 0.400 4.60 6.20 11.50 15.50 0.210 0.310 0.450
710 800 0.340 0.450 5.30 7.00 13.30 17.50 0.230 0.350 0.510
800 900 0.370 0.500 5.70 7.80 14.30 19.50 0.270 0.390 0.570
800 1000 0.410 0.550 6.30 8.50 15.80 21.00 0.300 0.430 0.640
1000 1120 0.450 0.600 6.80 9.00 17.00 23.00 0.320 0.480 0.700
1120 1250 0.490 0.650 7.40 9.80 18.50 25.00 0.340 0.540 0.770
- 29 -
- 30 -
- 31 -
5.3 SHAFT AND BEARING ALIGNMENT
The arrangement is as follows :
a) Located or thrust bearing showing equal clearance on each side of

bearing bush.
b) Motor shaft on true running centre.
c) Coupling.
d) Expansion clearance on non-located bearing.
e) Clock gauge fixed to fan half coupling.
Procedure for checking coupling alignment :
a) Take face and peripheral readings on motor half coupling by rotating both
an and motor shaft.
b) The alignment is correct when the readings taken fall within the following
figures.
c) Coupling faces parallel to 0.001.
d) When the two shafts are rotated, the deflection to the clock gauge should
not be greater than 0.002.
- 32 -
5.4 VIBRATION AMPLITUDE
(PEAK – PEAK IN MICRONS)
I.
H V A
FIXED BEARING
FREE BEARING
LOAD :
MOTOR COUPLING END BEARING
MOTOR FREE END BEARING
II.
H V A
FIXED BEARING
FREE BEARING
LOAD :
III.
H V A
FIXED BEARING
FREE BEARING
LOAD :
CHECKED BY :
- 33 -
5.5 TRIAL RUNNING DETAILS
TRIAL RUNNING DATA
OPERATION REMARKS & MEASURED

VALUES
a) ASSEMBLY CHECK LIST
- Tightening of grouting bolts :
b) STATIC PARTS
- Positioning of the shaped inlet :
- Tightening of fixing bolts on the ducts :
- Tightening of the fixing bolts on static parts :
- Closing of the inspection door :
ROTOR
- Shaft alignment :
- Tightening of fixing bolts Impeller / shaft :
- Expansion clearance on the free bearing :
- Alignment of the coupling :
CHECK UP BEFORE STARTING UP

LUBRICATION
- Bearings lubrication :
- 34 -
UTILITIES
- Connection to the electric circuit :
- Connection to the control system :
DRIVES
- Rotation of the motor :
CHECK UP DURING RUNNING
- Abnormal noise :
- Vibration level during the acceleration phase :
- Free bearing :
- Fixed bearing :
- After 2 – 3 hours :
- Free bearing :
- Fixed bearing :
- Vibration level after stabilization of the

bearing temperature :
- Free bearing :
- Fixed bearing :
- 35 -
CHECK SHEET
OPERATIONAL PARAMETER
Ambient Temp : °C Starting time : Sec. Started at : hrs
Medium Temp : °C Deceleration time : min. Stopped at : hrs
No-Load current : Amp.

Sl. Time Ambient Fan bearing Motor bearing Motor
No. Temp. temperature °C temperature °C
Hour °C Free brg. Fixed brg. Driving End Non-Driving Current Voltage %
End Amps Volts Load
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Checked by : Fan :
Date : Site :
- 36 -
DATA SHEET
FEED PUMP
GENERAL DATA:
MAKE M/S. GRUNDFOS PUMPS INDIA PVT. LTD.
QUANTITY 2 NOS
MODEL NO CR 20-17
RATED RESULTED
FLOW 21 m3/hr 19 m3/hr
HEAD 203 Mwc 215 Mwc
TEMPERATURE 105°C
SPEED OF THE PUMP 2934 RPM
TYPE OF SHAFT SEAL HQQE
SHUT OFF HEAD 255 MWC
METHOD OF STARTING DOL / STAR DELTA
MATERIAL OF CONSTRUCTION
PUMP HOUSING CAST IRON
EN-JL1030 DIN W-Nr
A48-30-B ASTM
IMPELLER STAINLESS STEEL
1.4301 DIN W-Nr
304 AISI
INSTALLATION
MAX. AMBIENT TEMPERATURE 50 DEG C
MAX. PRESSURE AT STATED TEMP. 25 / 120 BAR / DEG C
STANDARD PIPE CONNECTION DIN
SIZE, PIPE CONNECTION DN50
MATERIAL CLASS F
PRESSURE STAGE, PIPE CONN. PN 25
FLANGE SIZE OF MOTOR FF300
LIQUID TEMPERATURE RANGE -20 TO 120 DEG C

... 2 ...
DATA SHEET
FEED PUMP
ELECTRIC MOTOR
MOTOR TYPE 160L
EFFICIENCY CLASS 1
NUMBER OF POLES 2
MOTOR CAPACITY 18.5 KW
MAINS FREQUENCY 50 HZ
RATED VOLTAGE 3 X 380 - 415 D / 660 - 690 Y V
RATED CURRENT 31.5 / 18.4 AMPS
STARTING CURRENT 700%
COS PHI-POWER FACTOR 0, 92
RATED SPEED 2940 RPM
ENCLOURE CLASS (IEC 34-5) IP 55
INSULATION CLASS (IEC 85) F
M/s. GRUNDFOS PUMPS INDIA PVT. LTD,
NO. 118, OLD MAHABALIPURAM ROAD,
OKKIAM THORAIPAKKAM,
CHENNAI - 600 096.
M /s. SKM ANIMAL FEEDS AND
CET HAR VE SSELS LIMITED
FOODS (INDIA) LIMITED.
TABLE OF CONTENTS
V. FUEL FEEDING SYSTEM:
VARIABLE FREQUENCY DRIVE 003
GEAR BOX 006
VI. BAG FILTER 033
VII. OTHERS:
GEARED MOTOR 114
LIST OF MOTORS 125

FUEL FEEDING SYSTEM
DATA SHEET
VARIABLE FREQUENCY DRIVE

GENERAL DATA:
MAKE M/S. ABB LIMITED.
QUANTITY 3 NOS
APPLICATION TO CONTROL THE SPEED OF POCKET FEEDER MOTORS
MOTOR CAPACITY 1.5 KW / 1440 RPM
SPEED VARIATION RANGE 10 TO 100%
MODEL NO. ACS550-01-06A9-4
INPUT VOLTAGE 415 V ±10%
INPUT FREQUENCY 50 Hz ±5%
AMBIENT TEMPERATURE 50°C
MOTOR CONNECTION
OUTPUT VOLTAGE 0 TO U in
LOAD CHARACTERISTIC CONSTANT TORQUE VARIABLE POWER
CONTROL CHARACTERISTIC
CONTROL METHOD OPEN LOOP SENSORLESS CURRENT VECTOR METHOD.
INPUT PROTECTION MCCB
RADIO (V/HZ) PROGRAMMABLE (THROUGH FRONT PANEL KEY PAD)
PROTECTION FUNCTION
OVER CURRENT PROTECTION TRIP LIMIT 4 * ICT (SELECTABLE)
OVER VOLTAGE Un=415 V, TRIP LIMIT = 1.35 * Un
UNDER VOLTAGE 1.65 * Un
EARTH FAULT PROTECTS THE CONVERTOR IN CASE OF EARTH FAULT IN
MOTOR OR MOTOR CABLE
INPUT PHASE SUPERVISION TRIPS IF ANY OF THE INPUT PHASE MISSING
OUTPUT PHASE SUPERVISION TRIPS IF ANY OF THE OUTPUT PHASE MISSING
MOTOR OVERLOAD PROVIDED
PROTECTION
MOTOR STALL PROTECTION PROVIDED
UNIT OVER TEMPERATURE PROVIDED
SHORT CIRCUIT PROTECTION PROVIDED

DATA SHEET
VARIABLE FREQUENCY DRIVE

CONTROLS CONNECTIONS AVAILABLE INSIDE THE DRIVE:
ANALOG VOLTAGE INPUT 0 TO +10 V
ANALOG CURRENT INPUT 4 TO 20 MA DC
DIGITAL INPUTS POSITIVE OR NEGATIVE CONTROL LOGIC
RELAY OUTPUT MAX. CLOSING VOLTAGE 300 V DC, 250 V AC.
MAX. CONTINUOUS CURRENT : 2 AMPS
ANALOG CURRENT OUTPUT 4 TO 20 mA DC (SPEED FEED BACK TO PANEL)
ENVIRONMENTAL CONDITION
AMBIENT OPERATING -10°C TO 50°C
AMBIENT STORING -40°C TO 60°C
RELATIVE HUMIDITY LESS THAN 95% NO CONDENSATION ALLOWED
VIBRATION OPERATION Mx AMPLITUDE 3 MM IN FREQUENCY RANGE
2 TO 9 HZ, MAX.
ACCELERATION AMPL 0.5 g IN FREQUENCY RANGE AT 9 TO 200 HZ
SHOCK OPERATING MAX., 8G 11 MS STORING
TRANSPORT MAX. ,15G 11 MS
DRIVE ENCLOSURE CLASS IP 20
PANEL ENCLOSURE IP 41
DRIVE ENCLOSURE PLASTIC COATED HOT DIP GALVANISED (1500/MM) STEEL
SHEET
M/s. ABB LIMITED,
“CENTURY PLAZA”, 3RD FLOOR, 3C, 3D & 3F,
561 - 562, MOUNT ROAD, TEYNAMPET,
CHENNAI - 600 018
CLICK HERE TO OPEN THE MANUAL
DATA SHEET
GEAR BOX
GENERAL DATA:
MAKE M/S. ELECON ENGINEERING COMPANY LTD.
QUANTITY 3 NOS.
APPLICATION FOR FUEL FEEDING SYSTEM
MODEL 3 NU
TYPE WORM AND WORM WHEEL
INPUT CAPACITY 1.5 KW
INPUT SPEED 1440 RPM
GEAR RATIO 50 : 1
MOUNTING FOOT MOUNTED
PRIME MOVER MOTOR (FOR VFD)
DUTY CYCLE CONTINUOUS
ROTATION REVERSING
ORIENTATION RIGHT (VIEWED FROM MOTOR END)
M/S ELECON ENGINEERING COMPANY LTD,
553, MOUNT ROAD, III FLOOR,
TEYNAMPET,
CHENNAI - 600 018.
WORM REDUCTION GEAR UNITS
WORM REDUCTION GEAR UNITS
FVM/SFV
FSM/SFU
SMM/SSM
INSTALLATION,
OPERATION NU/SNU
AND
MAINTANANCE NU/SNU DOUBLE
MANUAL
REDUCTION
FIM/SFO
COOLING
TOWER
GEAR UNIT
Always a step ahead in technology
Manual No. : 06/G/IM/4/02
TABLE OF CONTENTS
INTRODUCTION 1
INSTALLATION 1
TRANSPORTATION 1
HAND CHANGING 2
INSTRUCTION FOR CONVERSION OF NU/SNU TYPE GEAR UNITS IN TO VARIOUS MOUNTING POSITIONS 3
X Ð FOR OUTPUT SHAFT VERTICAL UPWARD 4
Y Ð FOR OUTPUT SHAFT VERTICAL DOWNWARD 4
THIS MOUNTING IS POSSIBLE 5
FOUNDATION 5
COUPLING AND SYSTEM ALIGNMENT 5
SAFETY PRECAUTION 6
LUBRICATION 6
RECOMMENDED LUBRICANT - ISO VG 320 7
POLYGLYCOL BASED SYNTHETIC LUBRICANT 8
OIL LEVEL MONITORING 9
WORM/WORM WHEEL REPLACEMENT INSTRUCTIONS 9
METHOD OF ADJUSTMENT. 9
ALLOWANCES FOR DEFLECTION AND OIL ENTRY GAP 10
BEARING ASSEMBLY 11
OIL SEAL MOUNTING 11
SHIPPING SPECIFICATIONS AND OIL CAPACITIES 11
SHIPPING SPECIFICATIONS AND OIL CAPACITIES FOR SNU/SFU/SFO/SFV/SSM 12
SHIPPING SPECIFICATIONS AND OIL CAPACITIES FOR DOUBLE REDUCTION WORM GEARS 14
ELECON SPEED REDUCERS TROUBLE-SHOOTING GUIDE 15
SECTIONAL ARRANGEMENT FOR SNU GEARS 16
PART NOS. FOR SNU - U, O, V, GEAR UNITS 17
SECTIONAL ARRANGEMENT FOR SFU GEARS 18
PART NOS. FOR SFU GEAR UNITS 19
PRODUCT SAFETY INFORMATION 20
1) INTRODUCTION
Thank you for choosing ELECON gear box, the value
leader among reputed gear manufacturers in India. We
sincerely request you to go through this operation and
maintenance manual, before you start using this product.
This manual is designed carefully covering all important
aspects and features of the gear box.
To obtain warranty service or paid after sales services for
our product, contact EMTICI Engineering Limited office
nearest to you. An address/telephone/fax/e-mail list of
EMTICI offices is provided on the back cover of the manual.
The proper working of a gear unit depends on careful
installation, correct grade of lubricant and good working
conditions. Hence, it is most important to see that the
installation of the gear unit is done according to the
instructions given in this manual to ensure proper working
of the gear unit, and to ensure a long and trouble free
service.
2) INSTALLATION
ELECON worm reduction gear units are supplied in
completely assembled condition without oil. The shaft ends
are coated with anti-corrosive agents which are to be
removed only by suitable solvents. In no case, shafts
should be scraped on field.
2.1) TRANSPORTATION
The gear units should be lifted by making the use of the
eyebolts or integrally cast lugs. These are designed for the
weight of the gear units only and no accessories should be
lifted alongwith the gear units. In no case shaft ends should
be used for handling the units. NU/SNU models, vertical
gear units should be lifted by using eye bolts fitted on the
gear units. The complete method of lifting is shown in the
figures a, b and c. Not to lift the gear unit as shown in fig.
d & e.
1
2.2) Hand Changing.
5"
(a) 1 to 3" NU/SNU
8
This is achieved easily and quickly by just replacing the cap from one end to the other end of the worm shaft as shown
in Fig. 1 & Fig. 2.
Figure 1 Figure 2
(b) NU/SNU models 3.54" to 10.5" and in all other types of gear units just replace the fan and fan cowl from one end and
fix on other end. This is shown in Fig. 3 & Fig. 4. It is not necessary to dismantle the gear unit in any way.
Figure 3 Figure 4
2
2.3. INSTRUCTION FOR CONVERSION of NU/SNU type gear units in to various mounting positions.
The gear unit is supplied in NU-U / SNU-U B
Fig. 5a v¬z Figure 5b s[ vg];fz NU-U / SNU-U Sglr[
assembled condition (i.e. underdriven mounting
position) as shown in figures 5a & 5b. ;[ ;+rfL,t L:yLtF 5æsfz ;[ h]0f c]vf 5æL[ ¢t Lsif hftf c{ p
The gear unit can be quickly converted from glr[ sl Lnxf ;[ ;+rfL,t L:yLt sf Luiz v,uVv,u L:yLt
underdriven mounting position to other mounting d¨ aælnz I,u4 vfÂ., ,[j, .LG0s[8z4 v¬z 0fig[ I,u s[
positions by re-arranging the interchangeable Breather
:y,f+tz ;[ an,f hf ;stf c{ p jL8"s, 5æ:yfg sl L:yLt
plug, Oil level indicator, Drain plug and by fixing
additional base for vertical mounting. s[ L,i[ vLtLz=t a[; sf 5æimu Lsif hftf c{ p
D
2.3.1 NU-U → NU-O / SNU-U → SNU-O 1 5æ:yf5g L:yLt sm an,g[ s[ L,i[ glr[ nl c]? LjLw sf
2 NU & 3 NU Figure 5a
3" 1" 4
1. For gear units 1 , 2
4 4 , & 3" NU/SNU tilt vg];z6 sz¨ p
the unit upside down as shown in figure 6a. B
!∏ Luiz 2sd s[ P5z s[ efu sm glr[ P,L8i[ p
3"
Each gear unit from 4" NU/SNU onward is sup- ic LjLw s[j, 1 4 , 2 1" v¬z 3" NU/SNU Luiz
4
plied with a kit containing two detachable feet 2sd s[ L,i[ nl c{ p SFig. 6aF
and screws. Fix these feet on top of the gear 5æTi[s 4" NU/SNU v¬z P5z jf,[ Luiz 2sd s[ ;fy
unit with screws, as shown in figure 6b and the 2s Ls8 nl hftl c{p Lh;d¨ nm 5f”j v¬z :§} cmt[ c{ p .g
unit can be turned upside down. 5f”j sm Fig. 6b d¨ Lnbfi[ c]? tzls[ ;[ ,uf.i[ v¬z :§}
D L
2. Replace breather plug (B) and drain plug (D), ;[ s; nlLhi[p va Luiz s[ P5zl efu sm glr[ P,L8i[ p
keeping oil level indicator (L) in the same posi- 4 NU onward Figure 5b
tion. @∏ aælnz I,u (B) v¬z 0fig[ I,u (D) s[ :y, sf j{sL<5s P5imu
3. Fill oil inside the gear unit upto the mid point of
sz¨4 v¬z vfÂ., ,[j, .LG0s[8z (L) sm iyfjt zb¨ p
B
oil level indicator (L). E #∏ Luiz 2sd d¨ vfÂ., ,[j, .LG0s[8z (L) s[ dNi ts t[, ez¨p
4. The gear unit is ready for NU-O/SNU-O position $∏ va Luiz 2sd NU-O/SNU-O 5LzL:yLt s[ L,2 t{ifz
as shown in (figure 6a & 6c) c{ p SFig. 6a v¬z 6cF
Screws Feet B
L
D L
Figure 6a
Figure 6b Figure 6c
D
3
3-ELECON ENG.
Fin Proof Dt. 30-5-02
NU-V (X) X – FOR OUTPUT SHAFT VERTICAL UPWARD
2.3.2 · NU-U SNU-V
SNU-U NU-V (Y) Y – FOR OUTPUT SHAFT VERTICAL DOWNWARD
SNU-V
1. Tilt the gear unit so that the !∏ v5[L£t 5LzL:yLt d¨ Luiz 2sd sm .; tzc
output shaft is vertically upward 5,L8i[ Ls P;sf vfP85]8 xfo8 P5z if
(X) or downward (Y) as per your Base
glr[ sl vmz cm hfi p
requirement. Screws
2. A kit contains a base, screws

@∏ Luiz 2sd s[ ;fy 2s Ls8 Lnif uif c{
and plug supplied with gear unit. Lh;d¨ 2s a[;4 :§} v¬z I,u c{ p a[; sm
Fix this base to the gear unit Fig. 7 s[ vg];fz ,uf.i[ v¬z :§} ;[ s;
as shown in figure 7 and tighten nlLhi[ h{;f Ls Fig. 8 d¨ Lnbfif uif c{ p
the screws as shown in figure
8. The gear unit is now ready va vf5sf Luiz 2sd NU-V/SNU-V L:yLt
with base for NU-V/SNU-V d¨ 5æ:yfL5t szg[ s[ L,i[ t{ifz c{ p
mounting. Figure 7 Figure 8
#∏ vfÂ., ,[j, .LG0s[8z v¬z 0fig[ I,u sf
3. Replace the oil level indicator :y,f+tz sz¨ p Fig. 9 s[ vg];fz4 aælnz I,u
(L), drain plug (D) and the
sm an,t[ ;di 2<am (E) Lgsf, n¨ p
breather plug (B). Remove elbow B
(E) while replacing the breather $∏ Luiz 2sd d¨ vfÂ., ,[j, .LG0s[8z s[ dWi
plug, as shown in figure 9. ts t[, ez n¨ p
4. Fill oil inside the gear unit upto %∏ Luiz 2sd NU-V(X)/NU-V(Y) sl 5LzL:yLt
the mid point of oil level indica- L
tor. D d¨ t{ifz c{ p Fig. 9 d¨ nLx"t4 Luiz 2sd
NU-V(Y) sl 5LzL:yLt d¨ c{ p
5. The gear unit is ready for NU-V Figure 9
G SNU df[0, d[+ el .; tzc ;[ 5æif[u sz[+ p
(X)/NU-V (Y) position. Figure 9
shows the gear unit in NU-V (Y) &∏ a[; ;f.0 sl uæl;Lg5, ;[ vfÂ., afcz g
position. Similarly in SNU model.
Lgs,[ .;L,2 a[; ;f.0 sl uæl;Lg5, sm
6. Replace grease nipple by plug Lgsf, sz I,u ,uf.i[ p ic Fig. 9 d¨
on base side as shown in figure
9 to avoid oil leakage from grease
Lnbfif uif c{ p
nipple (G).
4
4-ELECON ENG.
2.3.3 This mounting is possible only for B
!∏ v5[L£t 5LzL:yLt d¨ Luiz 2sd sm .; tzc 5,L8i[ Ls
1"
1 3", 2", 2 and 3" NU/SNU .;sf .g5]8 xfo8 La,s], P5z sl tzo if glr[ sl
4 4 tzo cm hfi p
1. Tilt the gear unit so that the input shaft is @∏ vfP85]8 sjz s[ ;el :§} Lgsf, n¨ v¬z sjz sm .;
L
vertically upward or downward as per your tzc 3]df.i[ Ls jc Fig. 10 s[ vg];fz vfÂ., ,[j,
requirement.
.LG0s[8z sl ;dLkLth n]zl P5z 45° 5z vf hfi[p
2. Remove all the screws of the output cover
#∏ 0fig[ I,u (D) v¬z aælnz I,u (B) sf :y,f+tz sz¨p h{;f
and rotate the cover in such a way that the Figure 10
oil level indicator position comes to 45° above Ls Fig.10 d¨ nxf"if uif c{4 aælnz I,u sm an,t[ ;di
the horizontal axis as shown in fig. 10 2<am (E) Lgsf, n¨ v¬z iyfLrt L:yLt d¨ ,uf2[ p
3. Replace the drain plug (D) and breather plug $∏ Luiz 2sd sm ;dLkLth 5LzL:yLt d¨ vLtLz=t 5f”j s[
(B) and fix it to the appropriate position as P5z ,ufif hf ;stf c{p i[ vLtLz=t 5f”j df+u[ hfg[ 5z
shown in fig. 10 P5,Aw cØ p
4. The gear unit can be mounted horizontally by %∏ va Luiz 2sd NU-H(X)/NU-V(Y) 5LzL:yLt s[ L,i[
using additional support which is supplied on t{ifz c{ p
request.
5. The gear unit is ready for NU-H (X)/NU-H(Y)
position
2.4 FOUNDATION
Correct installation of the gear system is essential to achieve good performance. The gear unit must be rigidly connected to the
foundation which must also be rigid and have a flat mounting surface. If the foundation on base plate structure is incorrectly designed
or constructed, shaft misalignment, vibration, bearing damage and even shaft or housing breakage can result.
The best practice is to install the gear box on rigid concrete foundations, however, in some applications the gear boxes are required
to be mounted on machining structure especially in cement and chemical plants.
While the gear unit is installed on structural foundation, care should be taken that gear unit is mounted on a combined base plate
with driving motor and sufficient areas should be there to properly align the input and output couplings. Packing should be placed so
that support is given in the plane of coupling face.
2.5 COUPLING AND SYSTEM ALIGNMENT
In order to minimize wear, vibration and coupling problem, it is must that the accurate alignment between coupling hubs on connected
shafts is essentially achieved.
5
5-ELECON ENG.
2.5.1. Ensure correct gap between two coupling halves.
2.5.2. Angularity error should be corrected by using feeler gauge shown in figure
11 and arriving at a constant gap measures every 90 deg. of rotation of the
A
coupling halves simultaneously.
D B
Difference between clearances measured at opposite positions should be less
than 0.25mm/100 mm outside diameter of coupling.
C
Figure 11 2.5.3. Eccentricity error can be corrected by using straight edge, as shown in figure
12 when both coupling halves have the same outside diameters.
If not a straight edge, should be used in conjunction with feeler gauge to half the
difference in diameter. Here also checking should be done every 90 deg. while
mounting both coupling halves simultaneously.
A
2.5.4 SAFETY PRECAUTION.

D B
The client should protect the coupling, rotating shaft extensions etc. with safety
guards.
C
3. LUBRICATION
Gear units are supplied in completely assembled condition without oil and must be Figure 12
filled with the correct grade of lubricant to the correct level. Reliability, efficiency and
wear free operation mainly depend on lubricant use. Over-filling of lubricant results
in over heating and leakage.
6
RECOMMENDED LUBRICANT - ISO VG 320
MINERAL OIL
BRAND GRADE
International Brands
British Petroleum CS 320 or GR-XP320
Castrol Alpha Zn 320 or Alpha Sp 320 or Tribol 110/320 IGQA
Caltex Meropa 320
Esso Teresso 320 or Spartan 320
Fuchs Renolin CKC 320
Mobil Oil Co. Mobil DTE Oil AA or Mobilgear 632

Shell Co Vitera Oil 320 or Omela 320
Kluber Kluber oil GEM 1Ð320
Indian Brands
Bharat Petroleum Cabol 320
Fuchs Renolin CKC 320
Castrol Alpha Zn 320 or Alpha Sp-320 or Tribol
Gulf Gulf harmony 320 or Gulf EP 320
Hindustan Petroleum ENklo 320 or Parthan EP 320

Indian Oil Servomesh SP 320 or Servosystem 320 or Servomesh EE320
Veedol Avalon 320

Kluber Kluber oil GEM 1Ð320
7
Recommended Grease : For low speed of operations. Below 50 RPM, splash lubrication is not sufficient and bearings are required
to be grease packed.
Brand Grade
Castrol EPL 2
Indian Oil Servogem EP 2
Hindustan Petroleum HP LITHON EP 2
POLYGLYCOL BASED SYNTHETIC LUBRICANT

USE OF POLYGLYCOL BASED SYNTHETIC LUBRICANT IS ALSO ADVISABLE TO IMPROVE THE TRANSMITTING CAPACITY (RATING) OF GEAR UNITS MIN
20% AS COMPARED WITH USE OF MINERAL OIL AT SAME WORKING TEMPERATURE. THIS GEAR OIL SHOWS EXCELLENT NON AGEING STABILITY WITH
FAVOURABLE INFLUENCE ON EFFICIENCY.
Approved Synthetic Lubricants

Brand Grade
Castrol Tribol 800-220

Fuchs Renolin PG 220
Kluber Klubersynth GH 6Ð220
Special Note : Synthetic Lubricants must not be mixed with any other type of oil. The gear unit must be flushed while changing
to or from this lubricant.
¥ First change of oil should be made after 500 hours of operation.
¥ Subsequent oil change must be made after every 3000 hours of operation. The interval should not exceed 12 months.
Cleanliness of oil is of prime importance and it is imperative to flush the gear unit with flushing oil before refilling. Fluid
is to be drained off completely before filling the fresh oil.
Oil of two different manufacturers should not be mixed in any case even though they may be of equivalent grade.
The unit is ready to be put into operation So it's not needed to make any adjustment in the assembly.
¥ Maximum rise in oil temperature 93¡ C under full load with ambient temperature 35¡ C
8
3.1. OIL LEVEL MONITORING
All units are supplied with a filler plug (which also acts as a breather) at the top of the unit. In most cases, there is an oil level indicator
(Knob type) screwed to the gear unit and also oil level indicator (glass tube inserted in the pipe) provided at the side of the gear unit.
1) The oil is to be filled up during stationary position to the center in case of the knob type oil level indicator / on to the mark
given on the glass tube.
2) The oil level should be examined periodically and should not fall below the level.
3) The gear unit is to be stopped before you check the oil level position. If required, the required amount of oil should be filled
again.
4) It is essential to ensure that the breather plug hole is kept clear at all times. This may lead to oil leakage and the inhalation
of foreign matter through the oil seal, which could cause the inability of the gear unit to ventilate freely.
Especially in lower ratios 5:1 to 10:1, the filler cum breather plug is to be mounted opposite to the direction of rotation to
prevent oil leakage from breather.
4. WORM/WORM WHEEL REPLACEMENT INSTRUCTIONS

In order to obtain the best performance from a pair of worm gears, it is essential, when mounting them in the gear unit, they should
be adjusted correctly.
Given below are some notes on assembly for all worm gear mounting that will be of particular use to users of ELECON worm gear
units.
4.1. METHOD OF ADJUSTMENT.

The Worm wheel should be mounted approximately to the center with the worm and after coating the worm threads with a Prussian
blue or similar compound, the gear should be turned by hand to produce a tooth marking on the wheel. If the marking is not as
desired, the wheel should be adjusted sideways until a correct marking is obtained as shown in fig. 13.
Worm
Worm rotation
Entering
rotation Leaving
Entering side
Leaving side
side
side
figure 13 figure 14
(CORRECT) (INCORRECT)
9
This sketch represents a typical shaft assembly after the hand of
assembly has been changed, i.e. a gap between flange and case on
one side and a gap between gap spigot and bearing on the other side.
Gap taken up by shims here Gap taken up by shims here

on removal of metal from on removal of metal from
Figure 15 spigot face.
spigot face.
The gap observed between cover and gear case face is to be covered by using required set of aluminum shims and accordingly the
adjustment to be made for correct positioning of the wheel as shown in fig.15, Moreover rotate the wheel in both direction of rotation
and to consider both of the driving faces of the teeth and to get a contact as shown in figure 16.
This figure shows that correct leaving side contact on both faces of a worm wheel, which is desirable
'A' 'B' when the gears are required to run in both direction of rotation.
Driving face for
worm rotation 'B'
4.2. ALLOWANCES FOR DEFLECTION AND OIL ENTRY GAP
Driving face for

Elecon worm gears are manufactured in such a manner so as to allow for deflection and to give an entry
worm rotation 'A' gap for the lubricants on the entering side on the wheel teeth. This is done by producing the gears with
a "leaving side" contact as shown in figure 13. This contact obviously leaves an entry gap for the oil
and moreover when the wheel deflects under load, the contact tends to become more central which still
leaving some entry gap.
A driving face contact as shown in figure 14 is the worst possible condition under which a pair of worm
gears can be run, since there is no entry gap for the oil and moreover, any deflection will aggravate the
Figure 16 trouble further.
A gear mounted in this manner may cause a temperature rise in the oil as much as 20 percent higher than the correctly mounted
gear as shown in figure 13. The remedy is to make the wheel (by means of adjustment provided in the design) to the left until contact
similar to that in figure 13 is obtained. This is to be done by trial and error and by movement of wheel to the left will cause the contact
to move to the right.
4.3. BEARING ASSEMBLY
All worm gear units where the worm shaft and wheel shaft are supported on taper roller bearings. The covers are provided for location
and fitting purpose. This is shown in Fig. 15 and proper adjustment is to be carried out by using shims.
4.4 OIL SEAL MOUNTING
When a gear unit has been dismantled, it is advisable to replace the old oil seal to a new oil seal and this should be done carefully
to avoid the damage of the sealing lip of seal. If a special fitting accessory is not available it is advisable to use a piece of thin
card or a plastic sheet round the shaft to cover keyways and sharp edges, then apply a grease on the lip and slide the seal over it.
5. SHIPPING SPECIFICATIONS AND OIL CAPACITIES
The approximate oil quantities and weight of the various worm gear unit types and sizes are given in the following tables. However,
these are only indicative and actual oil filling should be up to the center where plug type oil level indicator used and upto maximum
marking level for oil level indicator.
3 4 5 6 7 8 9 10.5 12 14 17
Net Weight 35 70 90 130 175 210 295 450 640 900 1300
FSM/FSS Gross Weight 50 90 110 165 220 275 365 595 900 1150 1750
Oil Capacity 2.5 3.5 4.5 6.5 9 11 15 20 25 36 60
Net Weight 32 65 95 135 185 223 320 480 660 940 1380
FIM Gross Weight 50 86 120 170 228 300 390 610 920 1180 1800
Oil Capacity 3.3 4 5 7 8.5 12 17 22 27 38 95
Net Weight 40 55 70 125 170 240 295 440 630 870 1575
FVM/FSV Gross Weight 50 75 90 160 210 265 350 560 845 1120 2000
Oil Capacity 1.5 2.25 3 4.5 5 8 11 20 29 43 105
Net Weight 145 210 290 430 780 1280
Gross Weight 195 259 354 500 940 1540
SMM/SMWR Approx. Oil A 7 10 14 21 24 28
Capacity in ltrs B 7 10 13 18 22 25
For Diff.Mounting C 5 8 11 20 26 28
Positions D/ E 8 12 15 21 23 30
* Weight in Kg.
¥ Capacity in ltrs.
11
5.2 SHIPPING SPECIFICATIONS AND OIL CAPACITIES FOR SNU/SFU/SFO/SFV/SSM
AVERAGE WEIGHT IN KILOGRAMS
GEAR SIZE 1 5/8 1 1/4 2 2 1/4 3 3.54 4 5 6 7 8 9 10.5
GEAR TYPE NET GR NET GR NET GR NET GR NET GR NET GR NET GR NET GR NET GR NET GR NET GR NET GR NET GR
SNU-U 7 8.5 8 10.5 12 23 14 25 32 60 40 65 65 95 95 125 152 190 180 230 220 270 319 385 460 585
SNU-O 7 8.5 8 10.5 12 23 14 25 32 60 40 65 72 102 105 135 165 204 195 265 237 305 336 400 480 600
SNU-V 7.3 9 8.5 11.5 14 24 15 25 37 67 43 68 73 103 105 135 166 205 200 270 250 315 348 430 481 610
SNU-SM ... ... ... ... 15 28 16 28 35 65 41 66 64 80 110 140 157 170 200 270 252 316 330 415 465 590
APPROXIMATE OIL CAPACITY FOR SNU GEAR UNIT IN LITRES
SNU-U 0.3 0.4 0.6 0.7 2.2 2.1 2.5 4 5 9.5 11 16 21
SNU-O 1.4 0.5 0.7 0.8 2 3.8 5.1 8 13.5 18 19 41 45
SNU-V 0.3 0.4 0.6 0.7 2 3.5 4.0 5.7 8.5 18 20 25 26
APPROXIMATE OIL CAPACITY FOR SNU-SM GEAR UNIT DIFFERENT MOUNTING POSITION IN LITRES
A .... .... 0.6 0.7 1.3 4 5 7 10 18 19 41 45
B .... .... 0.6 0.7 2.1 2.5 2.5 4 6 9.5 11 16 21
C .... .... 0.6 0.7 1.7 2.5 2.5 4.7 8.8 18 20 25 26
DE .... .... 0.7 0.8 2.6 3 3 8 11.6 19 20 25 26
12
10 12 14 17
Net Weight 450 580 885 1260

SFU Gross Weight 595 900 1140 1700
Oil capacity 20 25 36 60
Net weight 480 660 940 1380
SFO Gross Weight 610 920 1180 1800
Net weight 440 660 870 1575
SFV Gross Weight 560 845 1120 2000
Net Weight ... 780 1280
Gross Weight ... 940 1540
SSM Approx. Oil A ... 24 28
Capacity B ... 22 25
For Diff.Mounting C ... 26 28
Positions D/E ... 23 30
First change of oil should be made after 500 hrs. of operation.

Subsequent oil changed must be made after every 3000 hours of operation. The interval should not exceed
12 months.
* Weight in kg.
* Capacity in ltrs.
13
5.3 SHIPPING SPECIFICATIONS AND OIL CAPACITIES FOR DOUBLE REDUCTION WORM GEARS.
SIZE 21/4/40 21/4/50 3/60 3/70 4/80 4/90 5/105 5/120 6/140
NU-UD/FSMD
Net Weight kg. 79 109 184 200 270 350 530 720 1100
Gross Weight kg. 110 130 220 240 320 410 615 950 1190
Approx. Oil 1st Stage 0.7 0.7 2.2 2.5 3.5 3.5 4.5 4.5 6.5
Capacity
Ltrs. 2nd Stage 2.5 4 5 9 11 15 20 25 36
NU-OD/FIMD
Net Weight kg. 86 119 195 210 290 385 550 745 1070
Gross Weight kg. 125 150 250 250 340 440 630 958 1220
Approx. Oil 1st Stage 0.8 0.8 2 2 3.5 3.5 4.5 4.5 6.5
Capacity
Ltrs. 2nd Stage 4.1 8 13.5 14.5 15.5 17 22 27 38
NU-VD/FVMD
Net Weight kg. 87 119 195 205 300 350 520 720 1000
Gross Weight kg. 110 150 250 260 360 410 615 950 1090
Approx. Oil 1st Stage 0.7 0.7 2.2 2.2 3.5 3.5 4.5 4.5 6.5
Capacity
Ltrs. 2nd Stage 3.10 5.7 8.5 9.9 10 11 20 29 43
14
ELECON SPEED REDUCERS TROUBLE-SHOOTING GUIDE
Our worm gear units are designed to run satisfactorily for the service life of more than 26,000 hours depending upon their
proper installation, operation and maintenance. When malfunction does occur, the source of trouble can be easily traced. Special skills
or abilities are not required in case of corrections or repairs is needed. As a guide to continuous good performance the following
information will prove useful :
Problem Cause Remedy
Reducer is over heated * Over load * Check the actual loading
* Lubricant is more or less than required * Fill oil to specified level
* Incorrect grade of Iubricant * Use oil of correct grade
* Oil seal damaged * Replace the oil seal
Reducer buzzes * Gear damaged * Correct gears
* Bearing damaged * Replace the bearing
* Inadequate lubricant * Supply with more oil
* Foreign matter enters the reducer * Remove it and change the oil
Unusual vibration * Foreign matter * Remove it and change the oil
* Bearings damaged / worn out * Replace the bearing
* Bolts loosened * Tighten the bolts
Leakage of oil * Oil seal damaged * Replace
* Packing damaged * Replace
* Drain plug loosened * Tighten the drain plug
Input/output shafts do * Bearing damaged * Replace
not work * A solid foreign matter in gearing * Remove it and clean the inside & fill fresh lubricant
Note : The information given here is for users guidance. It will enable them to obtain satisfactory performance of the gear box.
However, in case of doubt, the users are advised not to do any guess-work or take chance but to consult Elecon.
Materials used for construction of Worm gears
No. DESCRIPTION MATERIAL USED No. DESCRIPTION MATERIAL USED
1 WORM SHAFT Up to 100mm O/D 20MnCr 5 4 OUTPUT SHAFT Ck60N
Above 100mm O/D En Ð 353 5 BEARINGS ANTIFRICTION (Taper Roller Bearings)
2 WORM WHEEL PHOSPHOR BRONZE (Pb2ÐC) 6 OIL SEALS RADIAL
3 GEAR CASE CAST IRON
The material specified above is only for standard Worm gear units. For special application depending on criticality of load conditions,
Elecon Design office suggests special material and can be offered with additional price.
15
16
PART NOS. FOR SNU - U, O, V, GEAR UNITS
PART DESCRIPTION QTY/GB CODE NO. PART DESCRIPTION QTY/GB CODE NO.
NO. NO.
1 GEAR CASE 1 54 KEY ON EXTENSION LENGTH 1

2 BREATHER PLUG 1 55 HEX. SOCKET SCREW 8
3 DRAIN PLUG 4 56 BASE 1
4
5
NYLON WASHER
OIL LEVEL INDICATOR
1
1
58 PLUG
]
FOR "V"
(IN PLACE OF GREASE NIPPLE) MOUNTING 1
6 M/F ELBOW WITH CHECK NUT 1
7 SEALING CAP 1
9 NAME PLATE 1 EXTRA ROLLER BRG. ASSLY
10 RIVET 4
11 STRAIGHT GREASE NIPPLE 2 41 SLOW SPEED SHAFT 1
Ð FOR "O"
12
13
FEET
HEX. HEAD SCREW ] MOUNTING
2
4
61
62
DISTANCE PIECE
DISTANCE RING
1
1
21 WORM SHFT 1 63 CYLINDRICAL ROLLER BEARING 1
22 TAPER ROLLER BRG. 2 64 EXTERNAL CIRCLIP 1
23 WORM SHFT OPEN COVER 2
24 OIL SEAL 2
25 SHIMS 1SET
26 HEX. HEAD SCREW 12
28 FAN 1
29 HEX. SCOKET GRUB SCREW 1
30 KEY FOR FAN 1
31 FAN COWL 1
33 KEY ON EXTENSION LENGTH 1
41 SLOW SPEED SHAFT 1
42 WORM WHEEL 1
43 KEY FOR WORM WHEEL 1
44 DISTANCE PIECE 2
45 TAPER ROLLER BEARING 2
46 BEARING HOUSING 2
48 BLANK COVER 1
49 OPEN COVER 1
50 SHIMS 1SET
52 OIL SEAL 1
53 BAFFLE PLATE 2
17
18
PART NOS. FOR SFU GEAR UNITS
G/B SIZES : 10", 12", 14" & 17"
PART NO. DESCRIPTION QTY/GB CODE NO. PART NO. DESCRIPTION QTY/GB CODE NO.
1 GEAR CASE 1 52 HEXAGON HEAD SCREW 12

2 SPRING DOWEL SLEEVE 2 53 KEY ON EXTN. SIDE 1
3 HEXAGON HEAD BOLT 4
4 SPRING WASHER 4 EXTRA ROLLER BEARING
5 HEXAGON HEAD SCREW 4
6 SPRING WASHER 4 55 SLOW SPEED SHAFT 1
7 OIL SCRAPER 2 56 CYLIDRICAL ROLLER BEARING 1
8 HEXOGON HEAD SCREW 4 57 EXTERNAL CIRCLIP 1
9 FILTER PUG 1 58 DISTANCE RIECE 1
10 'L' TYPE OIL LEVEL INDICATOR 1 59 DISTANCE RING 1
11 DRAIN PLUG 1
12 NYLON WASHER 1
13 PLUG 1
14 LABEL 1
15 NAME PLATE 1
16 HAMMER DRIVE RIVETS 4
21 WORM SHAFT 1
22 OIL THROWER 2
25 SHIMS 1SET
26 WORM SHAFT OPEN COVER 2
27 OIL SEAL 2
29 KEY 1
30 FAN 1
31 HEXAGON SOCKET GRUB SCREW 1
32 FAN COWL 1
34 SPRING WASHER 3
35 KEY ON EXTN. SIDE 1
41 SLOW SPEED SHAFT 1
42 KEY 1
43 WORM WHELL 1
45 DISTANCE PIECE 2
48 SHIMS 1SET
49 S. S. SHAFT BLANK COVER 1
50 S. S. SHAFT OPEN COVER 1
51 OIL SEAL 1
19
PRODUCT SAFETY INFORMATION
General ELECON gear units will operate safely provided that they are selected, installed, used and
maintained properly. As with any equipment that consists of rotating shafts and transmitting power,
adequate guarding is necessary to eliminate the possibility of physical contact with rotating shafts or
coupling.
Potential Hazards The following points should be noted and brought to attention to the persons involved in the
installation, use and maintenance of equipment.
1. For lifting of gear unit, eye-bolts or lifting points (on larger units) should be used.
2. Check the grade and quantity of lubrication before commissioning. Read and carry out all instructions on lubricant
plate and in the installation and maintenance manual literature.
3. Installation must be performed in accordance with the manufacturer's instructions and be undertaken by suitably
qualified personnel.
4. Ensure the proper maintenance of gear boxes in operation. USE ONLY ELECON Spares for gear boxes.
5. The oil level should be examined periodically, if required the oil should be filled again.
6. The operating speeds, transmitting powers, generated torques or the external loads must exceed the design values.
7. The driving and the driven equipment must be selected to ensure that the complete installation of the machinery will
perform satisfactorily e.g. avoiding system critical speeds, system torsion vibration etc.
20
NOTES FROM CLIENT :
21
NOTES FROM CLIENT :
22
CUSTOMER'S FEEDBACK
ELECON CONTACT
HEAD OFFICE
Elecon Engineering Company Ltd. Phone :
Anand Sojitra Road Gear Division : 91-2692-36513, 36516, 36469
Vallabh Vidyanagar - 388 120 MHE Division : 91-2692-37016, 37017, 36521, 36590
Gujarat Fax :
India. Gear Division : 91-2692-36527
MHE Division : 91-2692-36457
E-mail :
Gear Division : [email protected]
: [email protected]
Name :
Designation :
Company :
Primary Business :
Address :
Phone # :
Fax # :
E-mail Address :
Web Page :
23
For any service requirements. Please contact our office with complete name plate details
SELLING AGENT
EMTICI ENGINEERING LTD.,
REGISTERED OFFICE
Anand - Sojitra road, Vallabh Vidyanagar 388 120 Gujarat, India. Phone : +91(2692) 230168, 31125 Fax : +91-2692-236508
AHMEDABAD ASANSOL BANGALORE

Ph. No. : +91-79-6406683,84,85,86 Phone : +91-341-205901, 202038, 211726 Phone : +91-80-2260219, 2281834, 2250082
Fax No. : +91-79-6401363 Fax : +91-341-202038 Fax : +91-80-2281834
E-mail : [email protected] E-Mail : [email protected] E-Mail : [email protected]
BILASPUR KOLKATA CHENNAI
Phone : +91-7752-47347, 28922, 24122 Phone : +91-33-4761861, 4760876, Phone : +91-44-4349237, 4349497,
Fax : +91-7752-23188 4760904, 4760926 4349643, 4322455
E-Mail : [email protected] Fax : +91-33-4761831 Fax : +91-44-4349643
E-Mail : [email protected] E-mail : [email protected]
DHANBAD
Phone : +91-326-306283, 302320 JAMSHEDPUR MUMBAI
Fax : +91-326-302320 Phone : +91-657-428138, 435382 Phone : +91-22-22821315, 22820725,
E-Mail : [email protected] Fax : +91-657-428015 22821365, 22870792, 22815693
E-Mail : [email protected] Fax : +91-22-22870791
NEW DELHI
NAGPUR E-Mail : [email protected]
Phone : +91-11-3414339,
3414341, 3414069, 3414634 Phone : +91-712-540771, 531601 SECUNDERABAD
Fax : +91-11-3709046 Fax : +91-712-531450 Phone : +91-40-7844748, 7845250, 7846984
E-Mail : [email protected] E-Mail : [email protected]
Fax : +91-40-7848317
ELECON SINGAPORE PTE. LTD. PUNE E-Mail : [email protected]
Phone : 65-227-8258, 65-227-8425 Phone : +91-20-4330646
INTERNATIONAL BUSINESS DIVISION
Fax : 65-227-8942 Fax: +91-20-4330646
Phone : +91(11) 3414339,40,41 (D) 3709047
E-mail: [email protected] Email : [email protected]
Fax : +91(11) 3709046
E-mail: [email protected].
Manufacturer by:
ELECON ENGINEERING COMPANY LTD.
POST BOX # 6, VALLABH VIDYANAGAR - 388120, GUJARAT, INDIA.
MHE DIVN. : Tel. : +91 (2692) 237016, 236590, Fax : + 91(2692) 236457 E-Mail : [email protected]
GEAR DIVN. : Tel.: +91-2692-236469, 236513, 236516 Fax : 91-2692-236559 E-Mail : [email protected]
Web Site : http://www.elecon.com
Always a step ahead in technology

DATA SHEET
BAG FILTER
GENERAL DATA:
MAKE M/S. BATLIBOI ENVIRONMENTAL
ENGINEERING LIMITED
QUANTITY 1 NO
APPLICATION FLY ASH COLLECTION
FUEL DOB
MEDIUM FLUE GAS
TYPE REVERSE PULSE JET (ONLINE CLEANING)
NUMBER OF FIELD 1
GAS VOLUME (M3/SEC.) 6.95 (25020 AM3/hr)
GAS TEMPERATURE
NORMAL / MAXIMUM / MINIMUM (°C) 170 / 180 / 160
INLET DUST CONCENTRATION (gms/NM3) 13.73
OUTLET DUST CONCENTRATION (mg/NM3) LESS THAN 150
GUARANTEE PRESSURE DROP ACROSS THE BAGS
DURING INITIAL START UP 125 MMWC
MAX. PRESSURE DROP DURING OPERATION 150 MMWC
GROUND CLEARANCE BELOW HOPPER (mts) 1200 MM
COMPERSSED AIR QTY REQUIRED 40 Nm^3/hr
PRESSURE RANGE 5 - 6 Ksc(g)
QUALITY CLEAN AND DRY AIR.
AIR TO CLOTH RATIO 1.3 M^3/min/m^2
FILTERING AREA 319 M²
BAG DETAILS
SIZE (DIA X LENGTH) 152 X 3965 MM
MATERIAL RYTON
QUANTITY (NOS) 169 NOS.

DATA SHEET
BAG FILTER
FLUE GAS COMPOSITION (APPROX)
- CO2 (%) 15.54
- H20 (%) 13.34
- O2 (%) 3.61
- N2 (%) 67.41
- S02 (%) 0
PARTICLE SIZE DISTRIBUTION 69% - ABOVE 14.5 MICRONS
31% - LESS THAN 14.5 MICRONS
CONSTRUCTIONAL DETAILS
TOP PLENUM
MATERIAL MILD STEEL
THICKNESS (MM) 3.15
MID CASING
MATERIAL MILD STEEL
THICKNESS (MM) 3.15
HOPPER
MATERIAL MILD STEEL
THICKNESS (MM) 3.15
TUBE SHEET
MATERIAL MILD STEEL
THICKNESS (MM) 5
PULSING VALVES
QUANTITY 13 NOS
SIZE 40 NB
POWER SUPPLY 220 V AC SINGLE PHASE

DATA SHEET
BAG FILTER
TIMER
QUANTITY 1 NO.
TYPE SOLID STATE SEQUENTIAL
PULSE DURATION (MILLI SECONDS) 20 TO 200
INTERVAL 1.5 TO 60 SECONDS
POWER SUPPLY 220 VAC SINGLE PHASE
DIFFERENTIAL PRESSURE SWITCH
TYPE DIAPHRAM SEALED PISTON ACTUATED
PRESSURE RANGE 25 TO 250 MMWC
POWER SUPPLY 220 VAC SINGLE PHASE
M/S. BATLIBOI ENVIRONMENTAL ENGINEERING LIMITED,
BATLIBOI HOUSE,
GOVNDI (W) ,
MUMBAI – 400 043.
OPERATION AND MAINTENANCE INSTRUCTIONS
FOR CLASSIC SERIES
PRESSURE / DIFFERENTIAL PRESSURE SWITCHES
SWITZER INSTRUMENT LIMITED

CHENNAI – 600 098
INDIA
SWITZER Pressure or Differential Pressure Switch is OPERATION
a simple electro mechanical device operating on basic
principles of Levers and opposing forces. Three
Pressure Switch : Models 201, 203, 281, 204, 208,
essential elements, various combinations of which
209 and 021 & 023
form the basics for presenting hundreds of variants to
suit a variety of industrial applications. They are :
Process pressure when applied to the sensing element
creates a force which overcomes that of a pre-
1. sensing element either of bellows or diaphragm
tensioned spring, and in turn moves a balancing arm to
(metallic or elastomeric)
effect a minimal movement required to actuate a
microswitch (es).
2. a stable spring to determine the range set point
and
Refer table below for sensing element type and
material.
3. a snap-acting microswitch available in a wide
variety.
Instrument On-off
Sensor & Material
Model Differential
Mounting / Connections / Precautions
Bellows
1. Position gaskets correctly while covers are fixed. 201 Phosphor Bronze / Fixed
Cover mounting screws must be tight. 316LSS / Monel
2. Properly seal the electrical entries and cables with Bellows

203 Phosphor Bronze / Adjustable
correct cable gland, weatherproof or flameproof as 316LSS / Monel
required. If in doubt, consult factory.
281 Bellows
3. Process pressure should not exceed stated (Dual Phosphor Bronze / Fixed
maximum working pressure. Setpoint) 316LSS / Monel
204
4. Connected electrical load should not exceed (High Static
Metallic Diaphragm
Fixed
declared maximum electrical capacity BOTH in 316SS / Monel/Hast’l C
Pressure)
amperes and volts.
Metallic Diaphragm
208 Fixed
5. Do not establish pressure connections by 316SS / Monel/Hast’l C
rotating the housing. Hold hexagon of the
sensor pressure connector with suitable 209
spanner and tighten. (Food Grade Metallic Diaphragm
Fixed
/ Hygenic 316LSS
Service)
6. Mount the instrument firmly and rigidly either
directly on the pressure piping or on a vibration 021
Elastomer Diaphragm
free wall, panel or pipe stanchion. (Draft &
Nitrile/ EPDM / Viton / Fixed
Compound
Silicone
Ranges)
7. If outdoor installation is envisaged provide
sufficient protection against aggressiveness of air, 023
dust, very low or very high temperature, solar Elastomer Diaphragm
(Draft &
Nitrile/ EPDM / Viton /
radiation, water penetration etc. This is essential Compound
Silicone
Adjustable
even for weatherproof instruments. Ranges)
8. If process temperature is higher than the

permissible maximum temperature, it can be
Differential Pressure switch : Models 301,303, 381,
brought down at the instrument end by employing
304, 384, 306, 386, 310, 313, GN 310
a longer pressure piping. Ask factory for piping
nomogram.
When pressures from two different sources in a process
are connected across the sensing diaphragm, metallic
9. A condensate coil or Pig tail should be used
or elastomeric, the pressure difference creates a force
invariably for steam service.
which when overcomes that of a pre-tensioned spring,
moves a balancing arm to effect the minimal movement
10. Ensure that suitable dampener / snubber is used
required to actuate a microswitch(es).
in rapidly fluctuating pressure lines.
High and low pressures are applied on either side of Switching point should preferably lie in the mid 50% of
the specially contoured diaphragm and this design the adjustable range span.
feature straight away eliminates the errors due to the
difference in area, a common problem present in twin Markings provided on the range scale are for guidance
element pressure differential switches. only. To set switching points precisely use a master
Pressure Gauge.
In models 301/ 4, 303, 381/ 4, 306, 386 and GN 310, a
unique motion transfer assembly is used, which is The switching point can be set, either for fall in pressure
sensitive to minute movements of the diaphragm but or rise in pressure by rotating the Range Adjusting screw.
immune to the application of very high static pressure
except in 310, 313 & GN 310. Remove the instrument cover. Unscrew and remove the
lock plate, which prevents the movement of the Range
In models 310 & 313, the task of transferring the screw.
resultant movement of the diaphragm is achieved by
employing an additional sealing diaphragm above the Now proceed with the setting of the switching points as
low pressure chamber. below:

material. 2) Fixed ON-OFF Differential Models :
Instrument On-off
Sensor & Material
Model Differential
a) Rotate the range adjustment screw clockwise to
Metallic Diaphragm increase the switching point. Rotating anti-clockwise
301 Fixed
316L SS will decrease the switching point.
303 Metallic Diaphragm Adjustable

b) After setting, re-fix the locking device back in position
316L SS to prevent unauthorised adjustment of the set point.
304 c) The center screw and the striker screw are precisely
(High Static Diaphragm Fixed
Pressure) 316L SS adjusted and factory-set using Loctite. Alteration of
centre screw height will disturb the contact
381 established between the sensor and the balance
(Dual Diaphragm Fixed beam. Disturbance of stricker screw will result in
Setpoint) 316L SS microswitch not acting or set-point shift. Ref. Fig 1.
384 RANGE ADJUSTER
(Dual Setpoint, Diaphragm Fixed
High Static 316L SS
Pressure)
MICRO SWITCH
306 CENTER SCREW
(Economy Diaphragm Fixed
Version) Nitrile STRICKER SCREW
386
(Dual Setpoint, Diaphragm Fixed bar
Economy Nitrile
Version )
310, GN 310 Diaphragm

Neoprene / EPDM / Fixed
(Low Ranges)
Silicone
313 Diaphragm Neoprene Adjustable

/ EPDM / Silicone
FORCE FROM PROCESS PR.
Setting of Switching points :

FIG.1 Fixed ON-OFF Differential Model
1) Set-up :
Models 281 & 381/4 provide an independently adjustable
A pressure source and a master gauge of accuracy high and low set point facility. A single sensing element
better than 0.5% is required to set the actuating point. actuates two different balance arms through a floating
In the case of Differential Pressure switches connect arm. See Fig.2. Two sets of range springs, range scales,
the pressure source to the high pressure port and balance arms and micro switches are independently
leave the low pressure port vented to atmosphere. operated.
HI ST.PT.
SPRING
RANGE ADJUSTER
LO ST.PT.
SPRING
MICRO SWITCH
CENTER SCREW
STRICKER SCREW
NYLOCK NUT
DIFFL. ADJUSTER
bar
AUX. SPRING
DIFFL. SPRING SEAT
FORCE FROM PROCESS
FIG. 2 Operating principle of dual set pt. version FIG.4 Wide Band Adj. Differential Mechanism
Both the range springs are clearly marked for high and a) In adjustable differential model set the lower switching
low functions. First set the low range spring and adjust point first. Release the aux. spring to be free by lifting
the desired value for the actuation of the microswitch. up the nyloc nut and the diffl. Adjuster. Using the
The high range spring should then be adjusted range adjuster set the lower switching point. Then load
similarly to the desired high set point. Ensure that the the aux. spring by turning in the Diffl. Adjuster to set the
correct micro switch is monitored while settings are upper switching point.
done. Refer Fig.3.
b) Adjusting the differential adjuster will shift only the
upper switching point i.e. the switching pressure
difference (on-off differential) alone changes. A
RANGE SPRING
clockwise rotation will increase upper switching point
RANGE SPRING HI PR. and anti-clockwise rotation will decrease it.
LO PR.
MICRO SWITCH
STRICKER SCREW
c) The upper switching point should not exceed the
BAL. BEAM
maximum range value.
BAL. BEAM-HI PR.
LO PR.
FLOATING CROSS
BEAM d) After setting the differential, tighten the Nyloc nut to
lock the differential adjuster to prevent loosening during
operation.
FORCE FROM PROCESS
Precaution :
FIG.3 Side-view of Mechanical Frame S.A.
of Dual set-point version
The switch actuating screw on the balancing arm is
critically adjusted. Disturbance of this would result in not
3) Adjustable ON-OFF Differential Models :
achieving the desired result while ON-OFF differential
adjustments are made. If accidentally disturbed, to reset
On-Off differential value can be adjusted for a wider
the micro switch for correct operation adjust the height of
value from about 10 to 15% of the span to a maximum
the striker screw such that the balancing arm is not in
of 60% as specified against each range. The minimum
contact with the auxiliary spring seat at the time of switch
value will vary with different switch combinations. This
de-actuation. Refer Fig.5. This alone will ensure
facility is achieved by an auxiliary spring brought into
unloaded condition of the auxiliary spring during de-
action when the switch actuating plate moves up before
actuation. For actuation of the microswitch, the balance
it operates the micro switch. Adjustment of the tension
beam has to lift the aux. spring seat which is pre-loaded
of the spring decides the pressure difference between
with the desired value of wide band On-Point. Refer
the on point and off point. Refer Fig. 4.
Fig.6.
MICRO SWITCH
Notes :
AUX. SPRING
DIFFL SPRING SEAT 1) In the instruments with 2 SPDT switches for DPDT
action, the synchronization of actuation is achieved
within practical limits. The switches are
0.5/0.8mm GAP synchronized as per customer preference either on
falling or on rising pressure. If no preference is
indicated, synchronization is done on fall in pressure
at factory.
2) Do not exceed the rated maximum working pressure.

Over pressure beyond the specified value will
FIG.5 Switch at off position – permanently damage the sensing element leading to
Aux Spring load not acting replacement.
MICRO SWITCH MAINTENANCE
AUX. SPRING
DIFFL SPRING SEAT Instruments are so designed with rugged components

that they seldom require maintenance. Occasional
cleaning of the moving parts, checking of the
microswitch(s) and ensuring firm electrical contacts at
the terminals will provide a long trouble-free
performance.
In the case of diaphragm operated instruments, do not

attempt dismantling the sensing diaphragm as it would
permanently disturb the factory settings. Special jigs are
FIG.6 Switch at on position –
needed for reassembly and hence replacement is not
Aux Spring load acting
recommended at the user end. However, cleaning of
the diaphragm chamber can be performed by flushing
with a cleaning fluid, which is compatible with the
diaphragm and its housing material.
#0404 IM-PS&DPS-REV.1
SWITZER INSTRUMENT LIMITED Works :

127 SIDCO ESTATE, CHENNAI 600 098
Sales / Head office : Ph : 044-26242244/55/3355, Fax : 044-26248849
9 South Boag Road, T Nagar, Chennai 600 017 E-mail : [email protected]
Ph : 044-24340999/3958/4321, Fax :044-24347887 Website : www.switzerinstrument.com
OPERATION AND MAINTENANCE INSTRUCTIONS
FOR CLASSIC SERIES
PRESSURE / DIFFERENTIAL PRESSURE SWITCHES
SWITZER INSTRUMENT LIMITED

CHENNAI – 600 098
INDIA
SWITZER Pressure or Differential Pressure Switch is OPERATION
a simple electro mechanical device operating on basic
principles of Levers and opposing forces. Three
Pressure Switch : Models 201, 203, 281, 204, 208,
essential elements, various combinations of which
209 and 021 & 023
form the basics for presenting hundreds of variants to
suit a variety of industrial applications. They are :
Process pressure when applied to the sensing element
creates a force which overcomes that of a pre-
1. sensing element either of bellows or diaphragm
tensioned spring, and in turn moves a balancing arm to
(metallic or elastomeric)
effect a minimal movement required to actuate a
microswitch (es).
2. a stable spring to determine the range set point
and
material.
3. a snap-acting microswitch available in a wide
variety.
Instrument On-off
Sensor & Material
Model Differential
Mounting / Connections / Precautions
Bellows
1. Position gaskets correctly while covers are fixed. 201 Phosphor Bronze / Fixed
Cover mounting screws must be tight. 316LSS / Monel
2. Properly seal the electrical entries and cables with Bellows

203 Phosphor Bronze / Adjustable
correct cable gland, weatherproof or flameproof as 316LSS / Monel
required. If in doubt, consult factory.
281 Bellows
3. Process pressure should not exceed stated (Dual Phosphor Bronze / Fixed
maximum working pressure. Setpoint) 316LSS / Monel
204
4. Connected electrical load should not exceed (High Static
Metallic Diaphragm
Fixed
declared maximum electrical capacity BOTH in 316SS / Monel/Hast’l C
Pressure)
amperes and volts.
Metallic Diaphragm
208 Fixed
5. Do not establish pressure connections by 316SS / Monel/Hast’l C
rotating the housing. Hold hexagon of the
sensor pressure connector with suitable 209
spanner and tighten. (Food Grade Metallic Diaphragm
Fixed
/ Hygenic 316LSS
Service)
6. Mount the instrument firmly and rigidly either
directly on the pressure piping or on a vibration 021
Elastomer Diaphragm
free wall, panel or pipe stanchion. (Draft &
Nitrile/ EPDM / Viton / Fixed
Compound
Silicone
Ranges)
7. If outdoor installation is envisaged provide
sufficient protection against aggressiveness of air, 023
dust, very low or very high temperature, solar Elastomer Diaphragm
(Draft &
Nitrile/ EPDM / Viton /
radiation, water penetration etc. This is essential Compound
Silicone
Adjustable
even for weatherproof instruments. Ranges)
8. If process temperature is higher than the

permissible maximum temperature, it can be
Differential Pressure switch : Models 301,303, 381,
brought down at the instrument end by employing
304, 384, 306, 386, 310, 313, GN 310
a longer pressure piping. Ask factory for piping
nomogram.
When pressures from two different sources in a process
are connected across the sensing diaphragm, metallic
9. A condensate coil or Pig tail should be used
or elastomeric, the pressure difference creates a force
invariably for steam service.
which when overcomes that of a pre-tensioned spring,
moves a balancing arm to effect the minimal movement
10. Ensure that suitable dampener / snubber is used
required to actuate a microswitch(es).
in rapidly fluctuating pressure lines.
High and low pressures are applied on either side of Switching point should preferably lie in the mid 50% of
the specially contoured diaphragm and this design the adjustable range span.
feature straight away eliminates the errors due to the
difference in area, a common problem present in twin Markings provided on the range scale are for guidance
element pressure differential switches. only. To set switching points precisely use a master
Pressure Gauge.
In models 301/ 4, 303, 381/ 4, 306, 386 and GN 310, a
unique motion transfer assembly is used, which is The switching point can be set, either for fall in pressure
sensitive to minute movements of the diaphragm but or rise in pressure by rotating the Range Adjusting screw.
immune to the application of very high static pressure
except in 310, 313 & GN 310. Remove the instrument cover. Unscrew and remove the
lock plate, which prevents the movement of the Range
In models 310 & 313, the task of transferring the screw.
resultant movement of the diaphragm is achieved by
employing an additional sealing diaphragm above the Now proceed with the setting of the switching points as
low pressure chamber. below:

material. 2) Fixed ON-OFF Differential Models :
Instrument On-off
Sensor & Material
Model Differential
a) Rotate the range adjustment screw clockwise to
Metallic Diaphragm increase the switching point. Rotating anti-clockwise
301 Fixed
316L SS will decrease the switching point.
303 Metallic Diaphragm Adjustable

b) After setting, re-fix the locking device back in position
316L SS to prevent unauthorised adjustment of the set point.
304 c) The center screw and the striker screw are precisely
(High Static Diaphragm Fixed
Pressure) 316L SS adjusted and factory-set using Loctite. Alteration of
centre screw height will disturb the contact
381 established between the sensor and the balance
(Dual Diaphragm Fixed beam. Disturbance of stricker screw will result in
Setpoint) 316L SS microswitch not acting or set-point shift. Ref. Fig 1.
384 RANGE ADJUSTER
(Dual Setpoint, Diaphragm Fixed
High Static 316L SS
Pressure)
MICRO SWITCH
306 CENTER SCREW
(Economy Diaphragm Fixed
Version) Nitrile STRICKER SCREW
386
(Dual Setpoint, Diaphragm Fixed bar
Economy Nitrile
Version )
310, GN 310 Diaphragm

Neoprene / EPDM / Fixed
(Low Ranges)
Silicone
313 Diaphragm Neoprene Adjustable

/ EPDM / Silicone
FORCE FROM PROCESS PR.
Setting of Switching points :

FIG.1 Fixed ON-OFF Differential Model
1) Set-up :
Models 281 & 381/4 provide an independently adjustable
A pressure source and a master gauge of accuracy high and low set point facility. A single sensing element
better than 0.5% is required to set the actuating point. actuates two different balance arms through a floating
In the case of Differential Pressure switches connect arm. See Fig.2. Two sets of range springs, range scales,
the pressure source to the high pressure port and balance arms and micro switches are independently
leave the low pressure port vented to atmosphere. operated.
HI ST.PT.
SPRING
RANGE ADJUSTER
LO ST.PT.
SPRING
MICRO SWITCH
CENTER SCREW
STRICKER SCREW
NYLOCK NUT
DIFFL. ADJUSTER
bar
AUX. SPRING
DIFFL. SPRING SEAT
FORCE FROM PROCESS
FIG. 2 Operating principle of dual set pt. version FIG.4 Wide Band Adj. Differential Mechanism
Both the range springs are clearly marked for high and a) In adjustable differential model set the lower switching
low functions. First set the low range spring and adjust point first. Release the aux. spring to be free by lifting
the desired value for the actuation of the microswitch. up the nyloc nut and the diffl. Adjuster. Using the
The high range spring should then be adjusted range adjuster set the lower switching point. Then load
similarly to the desired high set point. Ensure that the the aux. spring by turning in the Diffl. Adjuster to set the
correct micro switch is monitored while settings are upper switching point.
done. Refer Fig.3.
b) Adjusting the differential adjuster will shift only the
upper switching point i.e. the switching pressure
difference (on-off differential) alone changes. A
RANGE SPRING
clockwise rotation will increase upper switching point
RANGE SPRING HI PR. and anti-clockwise rotation will decrease it.
LO PR.
MICRO SWITCH
STRICKER SCREW
c) The upper switching point should not exceed the
BAL. BEAM
maximum range value.
BAL. BEAM-HI PR.
LO PR.
FLOATING CROSS
BEAM d) After setting the differential, tighten the Nyloc nut to
lock the differential adjuster to prevent loosening during
operation.
FORCE FROM PROCESS
Precaution :
FIG.3 Side-view of Mechanical Frame S.A.
of Dual set-point version
The switch actuating screw on the balancing arm is
critically adjusted. Disturbance of this would result in not
3) Adjustable ON-OFF Differential Models :
achieving the desired result while ON-OFF differential
adjustments are made. If accidentally disturbed, to reset
On-Off differential value can be adjusted for a wider
the micro switch for correct operation adjust the height of
value from about 10 to 15% of the span to a maximum
the striker screw such that the balancing arm is not in
of 60% as specified against each range. The minimum
contact with the auxiliary spring seat at the time of switch
value will vary with different switch combinations. This
de-actuation. Refer Fig.5. This alone will ensure
facility is achieved by an auxiliary spring brought into
unloaded condition of the auxiliary spring during de-
action when the switch actuating plate moves up before
actuation. For actuation of the microswitch, the balance
it operates the micro switch. Adjustment of the tension
beam has to lift the aux. spring seat which is pre-loaded
of the spring decides the pressure difference between
with the desired value of wide band On-Point. Refer
the on point and off point. Refer Fig. 4.
Fig.6.
MICRO SWITCH
Notes :
AUX. SPRING
DIFFL SPRING SEAT 1) In the instruments with 2 SPDT switches for DPDT
action, the synchronization of actuation is achieved
within practical limits. The switches are
0.5/0.8mm GAP synchronized as per customer preference either on
falling or on rising pressure. If no preference is
indicated, synchronization is done on fall in pressure
at factory.
2) Do not exceed the rated maximum working pressure.

Over pressure beyond the specified value will
FIG.5 Switch at off position – permanently damage the sensing element leading to
Aux Spring load not acting replacement.
MICRO SWITCH MAINTENANCE
AUX. SPRING
DIFFL SPRING SEAT Instruments are so designed with rugged components

that they seldom require maintenance. Occasional
cleaning of the moving parts, checking of the
microswitch(s) and ensuring firm electrical contacts at
the terminals will provide a long trouble-free
performance.
In the case of diaphragm operated instruments, do not

attempt dismantling the sensing diaphragm as it would
permanently disturb the factory settings. Special jigs are
FIG.6 Switch at on position –
needed for reassembly and hence replacement is not
Aux Spring load acting
recommended at the user end. However, cleaning of
the diaphragm chamber can be performed by flushing
with a cleaning fluid, which is compatible with the
diaphragm and its housing material.
#0404 IM-PS&DPS-REV.1
SWITZER INSTRUMENT LIMITED Works :

127 SIDCO ESTATE, CHENNAI 600 098
Sales / Head office : Ph : 044-26242244/55/3355, Fax : 044-26248849
9 South Boag Road, T Nagar, Chennai 600 017 E-mail : [email protected]
Ph : 044-24340999/3958/4321, Fax :044-24347887 Website : www.switzerinstrument.com
OTHERS
DATA SHEET
GEARED MOTOR
GENERAL DATA:
MAKE M/S. POWER BUILD ELECON GEARS LTD
QUANTITY 1 NO.
MODEL NO. AMC50S
TYPE OF MOTOR SQUIRREL CAGE
MOTOR RATING 0.37 KW
OUTPUT SPEED 30.5 RPM
TYPE OF MOUNTING FOOT MOUNTED
AMBIENT TEMPERATURE 50°C
VOLTAGE & COMBINED VARIATION ±10%
FREQUENCY VARIATION ±5%
ENCLOSURE TEFC S1
DEGREE OF PROTECTION IP 55
INSULATION CLASS ‘F’
POWER SUPPLY 415 V, 3 PHASE, 50 HZ
TYPE OF STARTING DOL
DUTY CONTINUOUS
LOCATION OUTDOOR
M/S POWER BUILD ELECON GEARS LTD,
NO. 553, MOUNT ROAD, 3RD FLOOR,
EAST COAST CENTRE, TEYNAMPET,
CHENNAI - 600 018.
DATA SHEET
LIST OF MOTORS
GENERAL DATA:
MAKE M/s. CROMPTON GREAVES LIMITED.
TYPE SQUIRREL CAGE INDUCTION MOTOR
POWER SUPPLY 415 V ± 10%, 3 PHASE, 50 HZ, ± 5% AC
TEMPERATURE 45°C
ENCLOSURE TEFC
PROTECTION IP 55
INSULATION CLASS “F”
DUTY CONTINUOUS
TYPE OF MOUNTING HORIZONTAL FOOT MOUNTED
APPLICATIONS
FULL LOAD
DESCRIPTION QTY. CAPACITY SPEED CURRENT FRAME NO. OF TYPE OF
(NOS) (KW) (RPM) (AMPS) SIZE POLES CONN.
FD FAN 1 55 1480 92.0 ND 250M 4 STAR-DELTA
ID FAN 1 75 1480 123.0 ND 280S 4 STAR-DELTA
PA FAN 1 22 2980 41.0 ND 180M 2 STAR-DELTA
POCKET 3 1.5 1500 3.2 ND 90L 4 V.F.D.
FEEDER
M/s. CROMPTON GREAVES LIMITED,
POST BOX NO.3316, NO.3-A
M.G.R. SALAI, NUNGAMPAKKAM,
CHENNAI - 600 034.
- ~ ---
CUSTOMERSAFETY INSTRUCTIONS&
INSTALLATIONCHECKLIST
GUARANTEEOF SATISFACTION
This motor is guaranteed to be free of any

manufacturing defect.
CAUTION: 0
We undertake to repair or replace this motor at
our option or any part thereof, which we are
satisfied was originally defective in material or
workmanship, provided that the motor or its
part/s is returned, freight paid to our nearest LIFTING
branch/dealer within 12 months from the date
1. Use all lifting facilities provided - Both lifting points if fitted
of purchase by the first user.
or single lifting point if fitted. Do not use any other part of
We cannot, however, accept responsibility if the motor for lifting.
the motor is found to be repaired by persons Note Maximum handtift is 20Kg below shoulder, but
ot~er than those authorised by us to carry out above ground ieveL
such repairs. Guarantee does not cover
Vertical lifting - Prevent uncontrolled rotation of the motor.
consequential damage/defects of any nature.
not lift other equipments with motor lifting points only.
This guarantee excludes every condition or
warranty whether statutory or otherwise
whatsoever not herein expressly set out.
MAXIMUM WEIGHTS (Unpacked)
NOTE: Toavail the guarantee facility,thiscard
must be produced at the time of lodging
complaints along with the purchase documents,
bearing the motor reference number.
l
o
~ r;lcrompton
~Greaves
.. , , ' -- ~-
CUSTOMERSAFETY INSTRUCTIONS&
INSTAllATION CHECKLIST
GUARANTEEOF SATISFACTION
This motor is guaranteed

manufacturing defect.
to be free of any CAUTION: 0
We undertake to repair or replace this motor at
our option or any part thereof, which we are
satisfied was originally defective in material or
workmanship, provided that the motor or its
part/s is returned, freight paid to our nearest LIFTING
branch/deaier within 12 months from the date
1, Useall liftingfacilitiesprovided - Bothliftingpointsif fitted
of purchase by the first user,
or single lifting point if fitted. Do not use any other part of
We cannot, however, accept responsibility if the motor for lifting,
the motor is found to be repaired by persons Note Maximum handlift is 20Kg below shoulder, but
other than those authorised by us to carry out above ground ievel.
such repairs. Guarantee does not cover
2. Vertical lifting - Prevent uncontrolled rotation of the motor,
consequential damage/defects of any nature.
not lift other equipments with motor lifting points only,
This guarantee excludes every condition or
warranty whether statutory or otherwise
WEIGHTS (Unpacked)
whatsoever not herein expressiy set out.
NOTE: Toavail the guarantee facility,thiscard
must be produced at the time of lodging
complaints along with the purchase documents,
bearing the motor reference number,
1~ICrompton
~Greaves
L-
INSPECTION @
ON RECEIPT:
1. Make surethe right motor isreceived,

PRE-INSTALLATION CHECKS: A
Ensure TICKWHEN CHECKED
Check for transitdamage.
case in
STORAGE:
0
Ensuremotors are stored in a place with ambient
range of -20°Cto +45°C.
2. Storemotorsunder shade and not in D
3. Ensure that the storedmotordoesnot receiveanyharmful
vibration.
Ensureno water drips on motor and no water logging
under the motor.
INSTALLATION- MECHANICAL: e D
~ heatersif fitted. level mounting surface. Clean mounting
foot/flange & shaft of the motor.
all pluas originally provided are 2, Check mounting plane. Add shimsIf D
necessary(Maxm, change of indicator
reading - 0.075mmwithmountingbolts
loose & tight - while checking mounting
surface w.r.t. motor foot/flange.
Check for any misalignmentin motor & D
Check driveshaft.(Approx.TIR- 0.050m)
resistance. While mounting use appropriate fasteners
If lessthan & tightening torques.
10 MOhm, dry 5. Checkall the gaskets,sealants& guards D
are correctly fitted.
Verify belt tension, D
~ - --
INSTALLATION- ELECTRICAL: A
1. Ensurepower supply system is grounded. 0
OPERATION:
e
FREE RUNNING BEFORE COUPLING TO LOAD:
2. Ensure proper earthing. 0
3. Check insulation resistance of all windings 0 1. Ensure supply voltage as per nameplate & 0
withSOOV dc megger. If< 10 Mohm, dry balanced in all three phases. (Maxm. allowable
out as per procedure given in IS: 900. unbalance i.e. Maxm. deviation from average
4. Ensure the equipment is fused and 0 is 1%)For more unbalance, reduce the output
isolated correctly. by derating factor from the graph.
5. Ensure all the covers are fitted and 0 1.0
interior of terminal box is clean & free of
cable residues.
) 0.9
111
6. Seal unused cable entries. 0
0.8 ,,'. ';, . ' '," . "
0.7 .
0 1 2 3 4 5
% VOLTAGEUNBALANCE
CONNECTIONS: 0 2. Check three phase currentsat No Load

( Free Shaft) & tally with the Test Certificate
0
1. Check connection diagram and ensure 0 at the back cover of this book,
correct terminalarrangement. Note: The currents willbe more ifthe voltage
2. Ensureall the connections are tight and clean. . 0 is more. They willbe less ifthe voltage is less.
3. Ensure air clearance between live & live to 0 The increase & decrease willnot be in linear
earth> 10 mm. proportion with voltage,
0 r 0
4. Check driven equipment is free. 3. No abnormal noise. (Use a screwdriver as a
5. Check rotation, uncoupled. 0 medium to hear.)
6. Ensure rating of fuse, setting of protecting 0 4, Bearing not heating up abnormally. 0
devices are correct. 5. Check direction of rotation. Ifspecific, 0
Recommended protections: (Frame 280 & above 2 pole motors may be
Overload, Single Phasing, Under Voltage, fitted with unidirectional fan.)
Earth Fault. 6. Check vibration. (Vibration level on the 0
7. Ensure space heater (if provided) is off 0 mounting structure immediately below the
while starting the motor. motor should be within 30%of horizontal
vibration level at the bearing housing)
L --- .-- - ...
RUNNING ON LOAD
Ensurerated voltage at the motor
PROBLEMS: @
terminalduringstartupand check starting
time withindesignedlimit.(Anynormal
application, the time requiredwillnot be
morethan 5 sec.at DOL Forhighinertia
load the startingtime is
designisreqUire
& reducedvoltage st
longerthan that~in~~~
D
Greavesin case of doubt,
2. EnsureFullLoadCurrentsare balance in all MAINtENANCE:
phases(Maxm.unbalance 8%corresponding
to 1%unbalanceof voltage)and the value is carrying out maintenance
withinNameplateData, In case of pulsating Ensure that the motor is isolated.
load we recomendthe maximumcurrentto
2. Refer to supplier, if in doubt.
be withinNameplatevalue.
3. No abnormalvibration,(If change in
vibrationlevelisobserved,check alignment SPAREPARTS:
'-
again prefereblyin hot condition.) While ordering Spare Parts,aiways quote Machine Number
4. No abnormalnoise,
and Reference number which will be found on the Nameplate.
5. Check maxm.air inlettemperature=
Ambienttemperaturementionedon Nameplate Please use only genuine spares.
6. No abnormalheatingup.
Totalpermissibletemperatureincluding
ambientfor ClassBrated motorsare HAZARDOUSAREAS: 0
approximatelyas follows:
By Thermometer: At Eyebolt:90DC
At B Cover: 80OC
On Sliprin Surface:90°C
Checkthe temperatureafter 4-5hoursof
operation.when it isstabllised.
Checkno sparkingisappearingon the
slipringin case of SlipringMotor.
-- ---~
PINIONS,
PULLEYS AND COUPLINGS
OPERATING& MAINTENANCETIPS
~se tlexible coupling, For rigid couplings refer to
(ALSO REFER IS : 900 -1992) CROMPTONGREAVES.
Use dynamically balanced (with half key) Pully I
CROMPTONGREAVESMotors have been designed, ~ouplings.lpinions.(Motor Rotorsare balanceq.wit~ halt
rnariufactureqanq tested to a high standard.of excellence, Key)
Motorsconformto relevantIndianstandardsas given on the
name plate, Forbelt drive mount belt nearestto motor bearings.Belts
~ho~lqnQtbeJootight,
Thesemotors<;:Ire sQundind~sigryanqrobl,1$tincori~truc¥tion
and willgive satisfactoryserllicewith correct installationand Uset.'Julleydiarneter
and CblJplingI pt1l£ey
bore asfollows:
normal routine maintenance. \
PYJ.,LEYDIMENSIONS (mm)
SITE TOLERANCEON BORE DIA-OF
Check for proper ventilation. TEFCMotors should be PULEY& COUPLING(H-7)
provided with at lea~t gap between fan cover and
nearest barrier. FRAf\.1E MIN MAX FACE
DIA WImH NOMINAL TOLERANCE
InstallDPMotorsat a clean dry place.
160 150 177 30 to 50 + 0,0
Check for ambient conditions, if special treatment on
180 180 203 + 0,025
motor is provided for adverseambient 187 280 50 to 80 + 0.0
200
Ensurepassages in-between ribs in TEFCMotors are 225 197 330 + 0.030
properly cleaned. 250 228 380 80 to 120 + 0;0
280 375 380 + 0:035
FOUNDATION 315 400 380
355 SOO 400
Thefoundation.bft.~emotor$~olJrdbe,pref$mbbt of cQncJ~te, t
or structuralsteel. and must be sufficientlyrigid to minimize
vibrationsand to maintain alignment between the motor
.andthe load. Normallya mixtureof four parts of stone and
two parts of sand and one part of cement by volume is
suitable.
L- -- --
STARTING
Squirrel Cage Motors are suitable for DOL StarIDelta or Auto lubricated Roller and Ball Bearings are already
Transformer Starting. with right quantity of grease.
for 2 starts in one hour, unless it is fresh grease in the bearing;

higher number of starts. Quantity of grease to be filled in bearing
In case of SlipringStarters, ensure the current and voltage (in gms,) = Bearing bore dia.
of the starter are same as specified on the motor name Fill 1/3rd of bearing
plate (RV & RA)
2 of Mis. IOCL or MP2 of
MIXINGOFDIFFERENT
PREVENTIVEMAINTENANCE:
Motor should be kept
moisture. Care should
not
//
----- ----
SLiPRING/BRUSHGEAR LT MOTORS DNiSION
A.fJ/2, MIDC, Ahmednagar 414111.
SizEj ef
brushes en the Slipringmeters are as belew - Tel.: 0241, - 2777372, 74, 75, 76, 78. Grams' CROMGRE Fax. 0241 - 2777508.
FR~E a X t Xr BRANCHES:
'~
160-180 12,5 X 16 X 20/24 t - Thickness NORTHERN REGION:
a - Axialwidth New Delhi . Vandana,11,TolstoyMarg,NewDelhi110001.Tel.:3721536/37. ~
200-250 16 X 20 X 30 Jaipur Church Road, P.O. Box 173, Jaipur. Tel.: 376919, 376307.
280-315 20 X 40 X 28 r - Radialwidth* Jalandhar

lucknow
SO, Mahavir Marg, Jalandhar 144 001. Tel.. 59467, 59478.
Speed Building, 2nd Floor, 3 Shahajahan lucknow 226 001. Tel.: 239443, 239345.
WESTERN REGION:
(',Radidl Mumbai . KanjurMarg (East),Mumbai400042. Tel.: 5782451.
Ahmedabad: 909, Sakar II, Near Ellis Bridge Police Station, Ahmedabad. Tel.: 6581729.
length), Bareda : 10A Kalpana Apartments, Vrundavan Society, Near Gom Water Tank, Golri,
IfSlipringsurface is net smooth, smoothen with fine glass Pone
Baroda 390 01.5. Tel.: 330819.
Surya Bhavan, 5th Floor, 1181, Fergusson College Road, Pone 411005.
paper (DONOTUSEEMERY
CLOTH), Tel.: 5535675, 9665.
i3rusMs should;,be free.in holde.r.reco.,r:pmended brush Indore 103 B,ApolloTradeCenlre,2B, RajagarhKolhi,Mumbai-Agra

Indore. Tel.: 498269, 498276.
Rd., ~
(:>ressu~eis O,2,KG/SQiqr~,,;; (t )(0) j Nagpur 3 West High Court Road, lal Bahadur Shastn Chowk, Dharampelh, Nagpur 440 010. ~
Tel.: 530537.
Ensure that Slipring and'Brushes are free from all and Dust.
Blowout carbon dust from SJiprings and brushes EASTERNREGION:
Koikata : 50. Chowringhee Road, Kolkata 700 071. Tel.: 2829681. 84.
periodically, Bhubaneshwar: Red Cross Bhavan, Sachivalaya Marg, Bhubaneshwar 751 007. Tel.: 531429.
Use brush grade M15Eof Assam Carbon or BE22of Electro I
Carbonium, I SOUTHERNREGION:
I Chennai . No.3-A, Kodambakkam High Road, P.O. Box 3316, Nungambakkam,
For new brushesproperbradfn~is.to.oe'done,«Jth sand t Chennai 600 034. Tel.: 8257375.
Bangalore Milhra Towers, 1s1 Floor, No. 10/4, Kasturba Road, Bangalore 560 001. Tel.: 2273686.
paper. so that curvatures of brushes and slipl'lhg are Coimbatore Krishna Towers, IVFloor (E), P.O. Box 6329, 1087, E Avavashi Rd.,
perfectly matched. Coimbatore. 841 037. Tel.. 495334.
Cachin Cherupushpam Building, 5th Floor, 330.fJ, Shanumugham Road.
Emakulam, Cochin 682 031. Tel.: 370860.
NOTE: Secunderabad: 4th FlOor,Minarva House, 94, Saroiini Devi Road,Secunderabad 500 003.
Tel.: 7847270.
SERVICECENTRES
New Delhi . 27, Rani Jhansi Road, New Delhi 110055. Phone: 7516993, 7532349.
Kolkata : 17111A,'Acharya" J. C. Bose Road, Kolkala 700 014. Phone: 2441557.
Mumbai : Mathuradas MillsCompound, Next 10 Milton, lower Patel, Mumbai 400 013.
Tel.: 4922572, 4947950.
Chennai 3 A, Kodambakkam High Rd., Nungambakkam, Chennai 600034. Tel.: 8274610.

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SKM ANIMAL FEEDS AND

SL. NO. DESCRIPTION PAGE NO.

CONTRACT DATA SHEET 003

GENERAL DESCRIPTION OF BOILER 004

TECHNICAL WRITE-UP FOR BOILER COMPONENTS 007

PRINCIPLE OF FLUIDISED BED COMBUSTION 014

WATER QUALITY REQUIREMENT 018

METHOD OF WATER ANALYSIS 030

BOILER OPERATING INSTRUCTIONS 051

PROCEDURE FOR HYDROSTATIC TESTING 092

PROCEDURE FOR SLOW FIRING 095

PROCEDURE FOR ALKALI BOILOUT 098

PROCEDURE FOR STEAM BLOWING 102

OPERATION ON LOW LOADS 106

TROUBLE SHOOTING CHART 108

DO’S AND DONT’S 116

INSPECTION AND MAINTENANCE SCHEDULE 119

PRESERVATION OF BOILER 124

LOCATION MODAKURICHI, ERODE (DIST.), TAMIL NADU.

BOILER TYPE BI-DRUM WATER TUBE BOILER (FBC)

CAPACITY 15 TPH (FROM & AT 100°C)

PRESSURE 17.5 KSC (g)

FUEL FIRING DOB

FEEDER TYPE POCKET FEEDER

TYPE OF FIRING FLUIDISED BED COMBUSTION

BED SIZE 3900 X 1800 MM

FURNACE EXPANDED BED HEIGHT 727 MM

HEAT INPUT (Kcal/hr) 10351438

HEATING SURFACE AREA (M²)

BANK TUBE ASSY. 309.00

HEATING BED COIL ASSY. 62.00

SIZE SET RELIEVING

LOCATION QTY. (NB) / PRESSURE CAPACITY OF END CONN.

(Nos) ORIFICE (Kg/cm²) VALVE (Kg/hr)

SAFETY STEAM 2 50 / 80 I) 18.00 i) 9713 FLANGED

VALVE DRUM ‘K’ ii) 18.25 ii) 9840 ANSI B16.5

a) Compartmentalised combustion chamber

FUEL AND ASH HANDLING SYSTEM:

WATER AND STEAM CIRCUIT:

FLUIDISED BED COMBUSTION .

While it is essential that temperature of bed should be at least equal to ignition

1.0 BOILER PRESSURE PARTS

The complete system of boiler pressure parts covers

- Steam drum / Mud drum.

- Water wall system.

1.1 STEAM DRUM / MUD DRUM

The thickness on the drum is arrived based on the requirements as specified

1.2 BANK TUBES

1.3 FURNACE - WATER WALL SYSTEM

The furnace is of natural circulation, balanced draft design suitable for

2.1 BUNKER AND FUEL FEEDING SYSTEM

Boiler is equipped with fluid bed combustor consisting of complete system of

2.2 FUEL DISTRIBUTING SYSTEM

Air heater of multitubular recuperative type is provided at the downstream of

4.0 FANS - DRAUGHT SYSTEM

5.0 DUCTING SYSTEM

6.0 REFRACTORY, INSULATION, CLADDING