MM M02 1

Project Dwg. No: P101-25-1701.
03-W017
Forced Draft Fan

MECHANICAL MAINTENANCE MANUAL
PT PAITON ENERGY
PAITON EXPANSION PROJECT
Forced Draft Fan Maintenance

Manual No. MM-M02.01
Revision 003
Note
This mechanical maintenance manual is intended to provide the Paiton Expansion Project
mechanical maintenance personnel with the basic understanding required to perform preventive,
routine, corrective and overhaul maintenance activities on the subject equipment.
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy
Industries, Ltd. and Paiton Expansion Project.
Forced
Draft
Fans
Be sure to read this manual.

Contents
Safety
General
Specifications
Preventive Maintenance
Disassembly and Reassembly
Corrective Maintenance
Recommended Lubrication
Appendixes
Contents
Contents
Revision Record i
Important Informationii
Warranty v
Limitation of Liabilityvii
Copyright viii
Personnel to whom the Manual is Directed ix
Contact Address x
Abbreviations xi
List of Vendor Manuals xiv
Arrangement of the System Maintenance Manualxv
Chapter1
Safety ____________________________
1.1
Feature of Forced Draft Fan Safety 1-1
1.2
Warnings Description 1-2

1.2.1
Definitions of Serious Injury, Minor Injury, Serious

Damage to Property, and Minor Damage to Property 1-3
1.2.2
Symbol 1-4
1.2.3
Hazard Warning Label 1-5
1.2.4
Hazard Area 1-7
1.3
Risk Assessment Standard 1-8
1.4
Safety Measures 1-10

1.4.1
Work Permit System (Lockout/Tagout) 1-10
1.4.2
General Cautions on Personnel in Working Area 1-11
1.4.2.1 Cautions against Rotating Equipment 1-11

1.4.2.2 Cautions against High Voltage Section 1-11
1.4.2.3 Cautions against High Temperature Sections 1-12
1.4.2.4 Cautions for Steam Leak in the Plant 1-13
1.4.2.5 Cautions against Oil/Coal Leak in the Plant 1-13
1.4.2.6 Cautions against Chemicals 1-14
1.4.2.7 Cautions against Combustible Materials/Storage Areas 1-14
1.4.2.8 Cautions against Lack of Oxygen 1-15
Rev.003
1.4.2.10Cautions against Sharp Objects 1-16
MM-M02.01
1.4.2.9 Cautions against Lifting Heavy Object 1-16
1.4.2.12Cautions using Crane 1-17
1.4.2.11Cautions using Fork Lift 1-16

1.4.2.13Disposal 1-18
Forced Draft Fan
Mitsubishi
Contents
Chapter1
1.5
Safety (Continued from previous page)

Emergency Measure 1-19
1.5.1
Evacuation in an Emergency 1-19
1.5.1.1 Evacuation Route 1-19

1.5.1.2 Evacuation of Disabled persons who cannot move
by themselves 1-19
1.5.1.3 Evacuation from Power House 1-20
Rev.003
Fire Accident 1-21
1.5.3
Earthquake 1-22
1.5.4
Explosion Accident 1-22
1.6
Qualification and Training 1-23
Chapter2
General ___________________________
2.1
Purpose 2-1
2.2
References 2-1
2.3
Overview of the FDF 2-2
2.4
Components 2-7
2.4.1
Casing 2-7
2.4.2
Rotor 2-9
2.4.3
Moving Blade Regulating Mechanism 2-10
2.4.4
Main Bearing Assembly 2-11
2.4.5
Control/Lubricating Oil System 2-11
2.4.6
Coupling 2-12
Chapter3
Specifications _____________________
Chapter4
Preventive Maintenance _____________
4.1
Prerequisites 4-1
4.2
MM-M02.01
1.5.2
4.3
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4.1.1
Scheduling 4-1
4.1.2
Departmental Interface/Notification 4-2
4.1.3
Isolation of Equipment 4-2
4.1.4
Safety Precautions 4-2
Routine Maintenance 4-3

4.2.1
Preparation 4-3
4.2.2
Inspection and Maintenance 4-4
Annual Outage Maintenance 4-10

4.3.1
Preparation 4-10
4.3.2
Inspection and Maintenance 4-11
Contents
Disassembly and Reassembly ________
5.1
FDF Disassembly and Reassembly 5-1
5.2
Rotor Disassembly and Reassembly 5-18
5.3
Bearing Disassembly and Reassembly 5-27
5.4
Moving Blade Regulating Mechanism Linkage

Disassembly and Reassembly 5-33
5.5
Coupling Disassembly and Reassembly 5-38
Chapter6
Corrective Maintenance _____________
6.1
Prerequisites 6-1
6.2
Preparation 6-2
6.3
Troubleshooting 6-2
Chapter7
Recommended Lubrication __________
MM-M02.01
Rev.003
Chapter5
Forced Draft Fan

Mitsubishi
Contents
Appendixes
Appendix A
Torque Chart A-1
Appendix B
Spare Parts B-1
Appendix C
Special Tools C-1
Appendix D
Coupling Alignment D-1
Appendix E
Applicable Vendor Drawings E-1
Appendix F
MV Packing Insertion F-1
Appendix G
Applicable Vendor Manuals G-1
Appendix H
Part List H-1
Appendix I
Moving Blade Paint Data Sheet I-1
MM-M02.01
Rev.003
List of Figures
Figure1-1
Types of Hazard Warning Label 1-6
Figure 1-2
FDF Mapping for Hazard Areas 1-9
Figure 2-1
Air & Flue Gas P & I D 2-3
Figure 2-2
FD Fan Outline 2-4
Figure 2-3
FD Fan Sectional View 2-5
Figure 2-4
FD Fan Cutaway View 2-6
Figure 2-5
FDF Casing Assembly 2-13
Figure 2-6
Rotor Assembly 2-14
Figure 2-7
Moving Blade Regulating Mechanism Assembly 2-15
Figure 2-8-1
Linkage Mechanism Assembly 2-16
Figure 2-8-2
Blade Sticking Detector 2-17
Figure 2-9
Bearing Box Assembly 2-18
Figure 2-10
FDF Lube and Control Oil P & I D 2-19
Figure 2-11
Intermediate Shaft and Coupling Assembly 2-20
Figure 3-1
Performance Curve 3-4
Figure 4-1
FDF Clearance Details 4-18
Figure 5-1A
Overhaul Plan for FDF 1/2 5-15
Figure 5-1B
Overhaul Plan for FDF 2/2 5-16
Figure 5-2
Supporting Procedure for FDF Rotor 5-17
Figure 5-3
MB Hydraulic Mechanism Exploded View 5-24
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Contents
List of Figures
MB Mechanism Exploded View 5-25
Figure 5-5
Supporting Procedure for Rotor Disassembly

& Reassembly 5-26
Figure 5-6
Bearing Box Exploded View 5-31
Figure 5-7
Supporting Procedure for Bearing Removal 5-32
Figure 5-8
MB Regulating Linkage Mechanism Exploded View 5-37
Figure 5-9
Centering Tool Assembly for Intermediate Shaft 5-41
Figure E-1
Forced Draft Fan Outline Drawing E-2
Figure E-2
Forced Draft Fan Sectional Drawing E-3
Figure E-3
FDF Lubricant & Control Oil Unit P & ID E-4
Figure E-4
FDF-A Lubricant & Control Oil System Unit

Assembly 1/2E-5
Figure E-5
FDF-A Lubricant & Control Oil Unit

Assembly 2/2E-6
Figure E-6
FDF-B Lubricant & Control Oil Unit

Assembly 1/2E-7
Figure E-7
FDF-B Lubricant & Control Oil Unit

Assembly 2/2E-8
Figure F-1
MV Packing Insertion F-2
Figure F-2
MV Packing Material & DimensionF-3
MM-M02.01
Rev.003
Figure 5-4
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Contents
List of Tables
Risk Assessment Standard 1-8
Table 3-1
Forced Draft Fan 3-1
Table 3-2
Forced Draft Fan-Motor 3-2
Table 3-3
FDF Control Oil Unit 3-3
Table 4-1
Routine Maintenance Checklist 4-7
Table 4-2
Annual Outage Maintenance Checklist 4-14
Table 6-1
Troubleshooting Forced Draft Fan 6-3
Table 7-1
FD Fan Recommended Lubrication 7-1
Table A-1
Torque Chart A-1
Table B-1
Recommended List of Strategic Spare Parts

(Off-Shore) B-2
Table C-1
FD Fan Special Tools C-2
Table H-1
Part List (1 of 8) H-2
Table H-2
Table H-3
Table H-4
Part List (4 of 8)H-11
Table H-5
Table H-6
Table H-7
Table H-8
Table I-1
Moving Blade Paint Data Sheet (1 of 2) I-2
Table I-2
Moving Blade Paint Data Sheet (2 of 2) I-3
MM-M02.01
Rev.003
Table 1-1
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Revision Record
Revision Issue
Date
Date Revised
Pages
Inserted
2-11, 2-13,
2-18
Revised in accordance with design

progress.
26. May. 2011
26. May. 2011
2-14 ~ 2-16
Revised in accordance with

Drawing review sheet
26. May. 2011
26. May. 2011
2-17
Added drawing of blade sticking

detector in accordance with
drawing review sheet
(PE-MHIN-PEHO-T-11025)
26. May. 2011
26. May. 2011
3-4
Added performance curve in

accordance with drawing review
sheet (PE-MHIN-PEHO-T-11025)
26. May. 2011
26. May. 2011
4-18,
4-14~4-18

progress.
26. May. 2011
26. May. 2011
5-28
Corrected an error.
26. May. 2011
26. May. 2011
Appendix B
Revised updated status
26. May. 2011
26. May. 2011
F-3
Revised in accordance with

drawing review sheet
(PE-MHIN-PEHO-T-11025)
26. May. 2011
26. May. 2011
Appendix-H
Added the part list.
26. May. 2011
26. May. 2011
4-14
G-19~G-21
G-28, G-29
Added the comments in

27.Feb. 2012
27.Feb. 2012
3-1, 4-5, 4-14,

4-18, 6-3

accordance with design progress.
27.Feb. 2012
27.Feb. 2012
E-4
Revised the updated status.
27.Feb. 2012
27.Feb. 2012
2-5
Appendix I

27.Feb. 2012
27.Feb. 2012
4-8, G-16

progress.
27.Feb. 2012
27.Feb. 2012
G-120~G-128
Added Line Filter manual in

accordance with design progress.
27.Feb. 2012
27.Feb. 2012
Rev.003
Description of Revision
5-9, 5-13

accordance with NCR
(MBK-N-NCR-0047).
23. March.2012
23. March.2012
MM-M02.01
Page Number
E-4
Revised updated status.
23. March.2012
23. March.2012
Forced Draft Fan

Mitsubishi
Important Information
Purpose of the Plant Usage
This plant is designed to generate electric power of 815 MW by the steam turbine
generator.
The plant is used for the electric power generation purpose that supports stable and
reliable electric power supply to the power grid and supplying steam for auxiliary
equipment in the power station.
General
1.
To satisfy the purpose mentioned above, the following points must be strictly
observed.
a)
The operation, maintenance and inspection of the Forced Draft Fan

must be performed by the persons who have basic technical knowledge
and have been trained concerning the hazard of the Forced Draft Fan
and the avoidance of the hazard.
b)
The operators and maintainers must read and understand these

manuals before starting the operation, maintenance or inspection.
It is often experienced that serious damages to the equipment or
personnel have occurred by the unexpected action of operators or
maintainers who do not understand well about the equipment.
c)
The modification or change of operational specification must be

performed under MHI supervision or as per the written acceptances of
MHI.
The modification or change of specification causes not only a decline in
performance but also a decline in safety for operation of the equipment.
The customer is requested to discuss with MHI about any planned
modification or changes before the work actually starts.
MM-M02.01
Rev.003
The address for MHI to be contacted is shown in this chapter.

2.
The operation and maintenance must be performed according to the

applicable laws and regulations at the location of the power station.
3.
Disposal from the power station must be treated to satisfy the local
regulations.
4.
The copyright of software, drawings and other documents provided by MHI

at all times, is still reserved by MHI.
Forced Draft Fan

Mitsubishi
ii
5.
Use or copying of the whole or part of any information provided by MHI for
any purpose other than operation and maintenance of this plant without
written consent is strictly prohibited.
Important General Notice for Safety

1.
The operator and maintainer must have knowledge about the equipment to
maintain good operating condition and to avoid danger when using the
equipment and systems.
2.
The protection measures must satisfy all of the operational functions.
3.
The safety activity must be planned systematically as a Safety and Health

management system and operate continuously.
The Safety and Health management system must include the following
points,
a) Instruction for the use and the maintenance of the personal protective
equipment issued to operators and maintainers
b) The establishment of a work management organization to make clear
the operation directives and work procedures
c) Implementation of training for operator and maintainer
4.
The customer must train the operators and maintainers to act actively and to
prevent the occurrence of an accident by using their knowledge of the power
plant.
5.
The customer must make the operators and maintainers understand that the
most important purpose of safety control is to protect all personnel from
accidents and also to maintain operation of the plant without troubles.
6.
To prevent accidents involving personnel and equipment, it is necessary to

observe the notices of this manual and to keep the correct operation
according to the description provided in this manual.
If the notices are not observed, the following dangers could occur to the
operators or to the maintainers.
Rev.003
7.
a)
Risk of a fatal accident
b)
Danger to lose his health and fitness
c)
Danger of damage to the equipment
MHI can not forecast all possible dangers existing in the plant such as
danger due to human error and/or dangers caused by the operating
environment.
MM-M02.01
As this manual and the alert label cannot cover all of the dangers, the
operators and maintainers have to pay their full attention to all general safety
notices.
Forced Draft Fan

Mitsubishi
iii
8.
MHI can not be responsible for damages and injury caused by neglecting the
notices in this manual, and other necessary general notices.
Instruction of this Manual

This manual is provided for people familiar with the use of English. If some
person not familiar with English is going to operate the plant, the Customer
must train him specially.
2.
The warning labels are to be expressed in the English language.
3.
This manual contains optional matters.
4.
Some figures in this manual include internal parts of the equipment which
may not be obvious, when looking at the completed equipment drawing.
5.
MHI may change the content of this manual without notice.
6.
This manual is intended for the use by the operators and maintainers and it
must be accessible to them at all times.
7.
If the Customer needs more detailed information, please contact MHI local
office or MHIs official agent.
MM-M02.01
Rev.003
1.
Forced Draft Fan

Mitsubishi
iv
Warranty
The provisions set forth in this section are in addition to all liability and
warranty disclaimers and limitations set forth in the Contract, whether arising
under law or from course of performance, course of dealing, or usage of trade.
Nothing in these provisions shall constitute or be deemed to constitute any

additional liability undertaking or warranty, express or implied, with respect to
the Plant. All capitalized terms used, but not defined in this Warranty
Limitations section shall have the respective meanings ascribed to them in the
Contract.
The Contract Warranties are subject to the construction, installation and

Commissioning works having been performed in full compliance with the
requirements stated in (a) the Contract, (b) all manuals provided by MHI,
including this manual, (c) all applicable rules, regulations and laws prevailing
in the location where the Plant has been installed and will operate, and (d) any
other instructions, if any, provided by MHI (collectively, Rules and
Requirements). The Contract Warranties will NOT cover any accidents,
partial or total failure of the Plant, losses or damages to personnel or property
(including, without limitation, the Plants components, parts, systems and
other equipment), or any other liability (collectively, Accidents and Damages)
in the case of any breach of the stated Rules and Requirements.
For the detailed terms and conditions of the warranty concerning the Works
and Project, refer to the Contract.
In addition to the foregoing, the Contract Warranties will NOT cover any of the
following Accidents and Damages:
Accidents and Damages caused by any deviation from the Rules and
Requirements;
MM-M02.01
Rev.003
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Mitsubishi
Accidents and Damages caused by the modification or re-installation of the

Plant after the original installation, or caused by operation of the Plant for a
purpose other than that for which it is designed;
Accidents and Damages caused by natural disasters or accidents during

transfer or related handling;
Accidents and Damages occurring after the term of the warranty has expired;
Accidents and Damages due to faulty operation or operation not in

accordance with the Rules and Requirements;
Accidents and Damages due to inappropriate maintenance or servicing

performed by the Customer, its personnel or any other party.
Accidents and Damages caused by any components, parts, systems or other

equipment other than those delivered by MHI;
Accidents and Damages caused by unidentifiable reasons including loss of

the damaged parts which is necessary to pinpoint a cause of the failure;
Accidents and Damages caused by referring to inadequate, or incorrect

references, data or information provided by the Customer;
Accidents and Damages or rust/corrosion due to inadequate handling and/or

storage by the Customer; or
Accidents and Damages due to handling, storage and/ or use of the Plant
under severe conditions or in an environment that does not meet the design
specification conditions.
MM-M02.01
Rev.003
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vi
Limitation of Liability
Use and Disposal
Nothing in this Limitation of Liability section or manual shall constitute or be

deemed to constitute any additional liability undertaking or warranty, express
or implied, with respect to the Plant. All capitalized terms used, but not defined
in this Limitation of Liability section shall have the respective meanings
ascribed to them in the Contract.
The contents of this manual are subject to change without prior notice and
without any obligation or liability to MHI.
For Documents and Safety Training
Use of the Plant must be limited to the use specified by MHI, including without
limitation, use of the Plant in accordance with the Contract, this manual, all
Safety Manuals, all applicable laws and regulations, and any other instructions,
if any, provided by MHI. The Plant components, parts, systems and other
equipment (collectively, Equipment) must be appropriately disposed of in
accordance with the Contract, this manual, all Safety Manuals, all applicable
laws and regulations, and any other instructions, if any, provided by MHI.
For Damage to the Plant
MM-M02.01
Rev.003
The Customers personnel must read, understand and abide by all documents
provided by MHI, including without limitation, the operation and maintenance
manuals, safety manuals, and instruction manuals (collectively, Safety
Manuals) and must have received all required and/or necessary safety
training prior to the start of their work. Persons who have not received such
safety training are not permitted to work on the installed Plant. This initial
training, however, is merely the minimum requirements prior to allowing any
personnel to work on the installed Plant. The Customer must, on a continual
and regular schedule, give up-to-date training to its personnel on safety
requirements, provide testing or other methods to confirm their understanding
of the safety training, and confirm that they have the physical and mental
capability to perform their respective roles. The Customers obligation for
safety training and personnel supervision is an ongoing obligation and must
be continuously performed and kept current throughout the operation of the
Plant. Accidents, partial or total failure of the Plant, damage to personnel or
property, loss, injuries, and other liability (collectively, Liability) caused by
inadequate safety training or the Customers personnels failure to abide by
the documents provided by MHI are expressly excluded from the coverage of
any warranty provided by MHI and are the sole and exclusive responsibility of
the Customer.
Forced Draft Fan

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vii
MHI will NOT be liable for any Liability caused by modification or changes
made in Plant-related documents (including any Safety Manual) by anyone
other than MHI.
For Damage to the Plant

Accidents may occur by use of Equipment that is acquired from anyone other
than MHI or anyone not appointed by MHI to modify or repair this Plant. The
Customer shall not be permitted to modify or repair the Plant or change
Equipment of the Plant without MHIs prior written approval, under any
circumstance.
MHI will NOT be liable for any Liability resulting from any abuse, misuse,
misapplication of the Equipment supplied by MHI.
MHI will NOT be liable for any Liability caused by an act by the Customer in
violation of the Contract, this manual, any applicable law or regulation, or any
Safety Manual or any other instruction provided by MHI, including without
limitation, a change of the installation environment or the removal and
installation of any Equipment in a location different to that originally selected
by MHI.
MHI will NOT be liable for any Liability caused by a defect, imperfection, or
fault, in material or Equipment that was used during a repair, even when such
a repair was performed by or under an instruction given by MHI.
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
viii
Copyright
COPYRIGHT 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS RESERVED.
ANY REPRODUCTION IS EXPRESSLY PROHIBITED.
All of the content contained in this manual is protected by Japanese, International
and/or United States copyright laws.
All copyright, trade secrets, and other proprietary and intellectual property rights in
the documents provided by Mitsubishi Heavy Industries, Ltd. (MHI) (including
safety-and-instruction manuals) are at all times owned and reserved by MHI. Subject
to your compliance with the restrictions set forth below, MHI grants to you a limited,
non-exclusive license in the copyright for the sole purpose of allowing you to use,
operate, maintain and inspect the Plant.
Use, copying, other reproduction of the whole or part of the documents provided by
MHI (including safety-and-instruction manuals) for any purpose other than the
purpose described above without MHIs prior written consent is strictly prohibited.
The act of rewriting, translating, modifying, revising, creating electronic copies,

uploading, selling, sublicensing, or otherwise disclosing the whole or part of the
manuals is strictly prohibited.
Except as specifically set forth above, no right, title or license to the documents
provided by MHI, whether arising from contract, implication, and estoppel or
otherwise, is being granted or otherwise transferred.
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
ix
Personnel to whom the

Manual is directed
This Manual was prepared for all personnel who will participate in the operation
and maintenance of the plant, and other related mechanical plant and equipment
installed.
In this Manual, MHI classifies personnel into the following two classes based on
their ability, experience and their attitude to the safety of personnel, and the plant
installed.
Only the personnel recognized by the Customer as trained personnel are allowed
to perform the operation and maintenance specified in the manuals.
Maintainers and Operators are required to have read and understood the contents
of the safety, operation, and maintenance manuals and sufficiently understand the
work procedures before actually starting their tasks.
Operator
Operators following the instructions of their supervisor or the Shift Charge

Engineer are permitted to handle materials to be used in the operation of the plant.
Operators are allowed to turn on the power supply, startup equipment, open up or
remove covers or panels on receipt of an instruction or authorization from their
superior.
Operators are permitted access to emergency stop devices following instructions
given by their superior when dangerous or hazardous situations are recognized.
Maintainer
MM-M02.01
Rev.003
Maintainers are permitted to perform maintenance on the plant. They will also
perform troubleshooting routine and periodical inspections of the installed
equipment. The maintainer will also work under the supervision of MHIs
supervisors during on-the-job training and annual maintenance and overhaul work
if MHIs supervisors are requested to witness periodical inspections, etc.
Maintainers MUST have attended the training programme initially provided by MHI
and subsequently by the Customer, and they must have obtained the necessary
knowledge and maintenance skills to understand the characteristics of their tasks
before actually starting their work.
Forced Draft Fan

Mitsubishi
Contact Address
For any question or any clarification required, please do not hesitate to contact MHI
through the following address (es).
For Support before Operation:

MITSUBISHI HEAVY INDUSTRIES, Ltd.
Nagasaki Shipyard & Machinery Works
MM-M02.01
Rev.003
1-1, Akunoura Machi, Nagasaki 850-063
Forced Draft Fan

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xi
Abbreviations
Abb.
Expanded Form
Abb.
Expanded Form
American Society for Testing and

Materials
FDF
Forced Draft Fan
BMCR
Boiler Maximum Continuous

Rating
MB
Moving Blade
CCW
Counter-Clock Wise
NDE
Non-Drive End
CCCW
Closed Circuit Cooling Water
NOL
Normal Oil Level
DE
Drive End
PPE
Personal Protective Equipment
DP
Differential Pressure
DTI
Dial Test Indicator
MM-M02.01
Rev.003
ASTM
Forced Draft Fan

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xii
List of Vendor Manuals

Description
Manufacturer
Handling Manual of Lubrication Oil

Unit for FD Fan
Daikin Hydraulic Engineering Co. Ltd.

Japan
Handling Manual of Pleated Type

Accumulator
Nippon Accumulator Co., Ltd.

Japan
MM-M02.01
Rev.003
Item No.
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xiii
Arrangement of the System

Maintenance Manual
This manual is arranged as follows.
Chapter 1
Explains health and safety issues during installation, operation, maintenance,
disassembly and reassembly of the FDF.
Chapter 2
Describes the construction, purpose, and function of the FDF and the associated
parts.
Chapter 3
Describes the FDF parts, using the relevant Data Sheets.
Chapter 4
Describes the Preventive, Routine, and Outage Maintenance.
Chapter 5
Describes the disassembly and reassembly procedures, necessary to obtain access
to internal parts for inspection and repair during FDF overhaul.
Chapter 6
Describes the corrective maintenance procedures to be followed to investigate,
identify and remedy defects occurring during operation.
Rev.003
Describes the lubricants and its frequency and quantity of applications.
MM-M02.01
Chapter 7
Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/ Documents
Forced Draft Fan

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xiv
Chapter 1
Safety
C h a p t er
1 S af et y
1.1
Feature of Forced Draft Fan Safety

The function of the Forced Draft Fan is to supply combustion air to the steam
generator. Hence this is very critical equipment for uninterrupted power
generation.
The FDF is an axial fan with a rotor (moving) blade pitch control mechanism for
controlling the air flow and is fitted with aluminum blades. Absolute care must be
taken during maintenance of these fans and also cleanliness of the fan internal
is very important. If not, the fan blades will be damaged by the foreign particles
and will lead to the reduction of boiler load or stoppage of generation due to non
availability of the fan.
Like any other critical rotating equipment, this fan also has many clearances
with close tolerance. Utmost care is to be taken to maintain these values as per
this manual. Incorrect clearances can either lead to the damage of the fan or
hamper the performance of the equipment.
For the proper functioning of the bearings and also for the control of the blade
pitch, the FDF is provided with an oil system. Any oil leak and foreign particles in
the system is not only dangerous to the equipment but it also can cause the
area around the fan to be slippery leading to the fall of operating personnel. Oil
leakage and foreign particles also can lead to a fire.
Considering the above fact, a constant monitoring of the fan and its oil unit is
necessary.
During normal conditions, all the standard safety precautions are to be followed.
MM-M02.01
Rev.003
During outage maintenance, proper safety procedures are to be followed by the

operating personnel who will purge all systems before issuing a Permit to Work
to the Maintenance Staff.
Forced Draft Fan

Mitsubishi
1-1
Chapter 1
1.2
Safety
Warnings Description
Safety of personnel working in the power plant is the most important matter. And
all kinds of consideration to avoid dangerous conditions are studied and applied
to the design of the power plant. However, certain risks are unavoidable due to
the nature of the plant.
This manual classifies the severity and hazard level of such risks by two
categories, DANGER and CAUTION. Read and understand the indications
thoroughly before operation or maintenance of the plant.
The contents of wordings, DANGER and CAUTION are described as follows;
Kinds
Meaning of Warnings
DANGER indicates an imminently hazardous situation
during use of the Forced Draft Fan, which, if not avoided,
could result in death or serious injury, or serious
damage to the property or environment.
CAUTION indicates a potentially hazardous situation
CAUTION
during use of the Forced Draft Fan, which, if not avoided,

may result in minor injury or minor damage to the
property or environment.
This manual also uses the following indicators in addition to the hazard level
indications described so far.
Kinds
Meaning of Warnings
IMPORTANT describes the particular information or
items that personnel must know during operation and
IMPORTANT
maintenance of the Forced Draft Fan, and that, if not

heeded, may result in an accident of an in-assessable
hazard level.
NOTICE describes useful information and tips for
operation and maintenance of the Forced Draft Fan.
MM-M02.01
Rev.003
Notice
Forced Draft Fan

Mitsubishi
1-2
Chapter 1
Safety
1.2.1 Definitions of Serious Injury, Minor Injury,

Serious Damage to Property, and Minor Damage to
Property
Serious Injury
This term describes injuries, which leave after effects such as loss of
eye sight, permanent disability, bone fracture or breakage, gas
inhalation, asphyxiation, electric shock, hospitalization or prolonged
hospital visits for treatment.
Minor Injury
This term describes injuries, which do not require hospitalization or
prolonged attention at a hospital (injuries other than the serious
injuries described above).
Serious Damage to Property

This term describes damages, which require a suspension of
productive activity for one day or more due to restoration of the
damaged property.
Minor Damage to Property
MM-M02.01
Rev.003
This term describes damage, which does not require any suspension
of productive activity due to restoration of the damaged property.
Forced Draft Fan

Mitsubishi
1-3
Chapter 1
Safety
1.2.2 Symbol
In this manual, the following symbols are added for easy understanding
of the contents of warnings and are found next to DANGER,
CAUTION and other indications.
These symbols are in compliance with ISO 3684.
Symbol
Description
This symbol indicates the possible presence of high voltage, and
warns of a hazard which may result in system shock, burn or
death by electric shock if safety precautions are neglected or the
system is handled incorrectly.
This symbol indicates a movable section that is inside a safety
cover or is exposed.
Movable parts may inflict laceration or bone fracture to body parts
such as a hand by pinching the hand and/or clothing.
This symbol indicates the presence of parts the surface of which
could be hot, and may cause a burn if handled incorrectly.
This symbol indicates that care should be taken where you place
your feet when moving around the area.
Risk of injury by tripping is present near this symbol due to
factors such as a location with an unstable surface, or
obstructions such as scaffolding, temporary pipe lines, or other
protrusions.
This symbol indicates the possible presence of gas (es) harmful
or asphyxiant to personnel.
Be sure to ventilate fully before work commences.
This symbol indicates caution against the handling of a heavy
object or working in an abnormal position.
Do not work in an abnormal posture which may damage your back
or waist.
This symbol indicates prohibited items or actions during the
MM-M02.01
Rev.003
operation and maintenance of the Forced Draft Fan.
Forced Draft Fan

Mitsubishi
1-4
Chapter 1
1.2.2
Safety
Symbols (Continued from previous page)
Symbol
Description
This symbol indicates that personnel must not touch since the
surface is hot.
Do NOT enter any area where this symbol is displayed.
This symbol indicates that the entry of personnel is prohibited.

Do NOT enter any area where this symbol is displayed.
This symbol indicates that physical contact is prohibited.

Do NOT touch or enter a location or enclosure where this symbol
is displayed.
This symbol indicates that the stated items or actions in the
warning notices relative to operation and maintenance of the
Forced Draft Fan are mandatory.
This symbol indicates a movable section that is inside a safety
cover or exposed.
Do NOT touch any equipment where this symbol is displayed.
1.2.3 Hazard Warning Label

Hazard warning labels are applied where potential hazards are present
during operation and maintenance activities.
Hazard warning labels will be in appropriate sizes and colors that will
catch the eye and the attention of personnel. They also have symbols
that show the hazard types, in addition to the descriptions of warning
contents.
IMPORTANT
Personnel are requested to confirm the location of, and to read, and
thoroughly understand the contents of all hazard warning labels
applied to this Forced Draft Fan. If any of the hazard warning labels
Rev.003
peel off/wear out or become unreadable, install a new label in the
MM-M02.01
original location without delay.
Forced Draft Fan

Mitsubishi
1-5
Chapter 1
WARNING
Safety
DO NOT COME
NEAR TO SHAFT
EXPOSED ZONE
WHEN IN
OPERATION
PINCH POINT
STEEP
DROP
DO NOT
ENTER
DO NOT
TOUCH
DO NOT
TOUCH
MM-M02.01
Rev.003
TB0001_A
FIGURE 1-1
Forced Draft Fan
Mitsubishi
TYPES OF HAZARD WARNING LABELS
1-6
Chapter 1
1.2.4
Safety
Hazard Area
IMPORTANT
Only trained maintainers or operators are allowed to enter the
maintenance work area. Entry to the area by personnel untrained
could cause not only injury but also serious damage to the Forced
MM-M02.01
Rev.003
Draft Fan.
Forced Draft Fan

Mitsubishi
1-7
Chapter 1
1.3
Safety
Risk Assessment Standard

As prepared by the Design Section as per MIL STD822D.
TABLE 1-1
RISK ASSESSMENT STANDARD

Detailed Description of Impact on each Object
Category
Safety
Catastrophic
II
Critical
III
Marginal
VI
Negligible
- Unit shutdown (unit cannot be

operated)
- More than 4 days for repairing
- Unit shutdown (can not be
operated)
- Within 3 days for repairing
- Unit shutdown (can not be
operated)
- Can be repaired by Customer
TABLE 1-1
- Death
- Harmful gas, coal or oil leakage

- High pressure and temperature
material leakage such as steam,
water, air and gas, oil, coal etc.
- Low oxygen
- Serious Injury
- Same as the above
- Minor Injury
(with
hospitalization)
- Minor Injury
(without
hospitalization)
- Same as the above

- High temperature surface
- High elevation or unstable
- Not harmful and high pressure
& temperature leakage
-Mechanical protected
Description
Category
Detailed
(A)
Frequent
Repeating occurrence
1 time / 1 or 2 months
(B)
Probable
Known to occur, or, it has happened
1 time / 1 year
(C)
Occasional
Could occur
1 time / 5 years
(D)
Remote
Not likely to occur
1 time / 10 years
(E)
Improbable
Practically Impossible
1 or 2 times / total life
TABLE 1-1
Hazard
Categories
Frequency
of Occurrence
Rev.003
Environment
RISK ASSESSMENT STANDARD (CONTINUED)
Definition
MM-M02.01
Health
RISK ASSESSMENT STANDARD (CONTINUED)

I
II
III
VI
Catastrophic
Critical
Marginal
Negligible
(A)
Frequent
13
(B)
Probable
16
(C)
Occasional
11
18
(D)
Remote
10
14
19
(E)
Improbable
12
15
17
20
Forced Draft Fan

Mitsubishi
1-8
Chapter 1
Safety
DANGER ZONE
(Contains the high temperature
& high pressure medium such
as steam, water, air and gas,
coal, oil etc)
MM-M02.01
Rev.003
WORKING FLOOR
MPTD-3-0536
Forced Draft Fan

Mitsubishi
FIGURE 1-2
FDF MAPPING FOR HAZARDOUS AREAS

1-9
Chapter 1
1.4
Safety
Safety Measures
1.4.1 Work Permit System (Lockout / Tagout)
Work permit system is applied when equipment is shutdown for
maintenance work, to complete the maintenance work under a safe
condition. The outline of the work permit system is as follows:
(1)
The Maintenance Engineer applies for the work permit clearly

indicating the content of the maintenance work that he wants to
do, and submits it to the Shift Charge Engineer.
(2)
The Shift Charge Engineer passes the work permit form to the
operator to study and decide the isolation method from the line in
operation on the mechanical and electrical view point and then
report to the Shift Charge Engineer with his comments on the
hazard conditions for the work.
(3)
The Shift Charge Engineer gives work permit number and

prepares necessary tags to show the work permit number and
the situation of isolation by valves and power supply. He will then
instruct the operators to set the isolation condition following the
work permit form.
(4)
The operators will open the breaker and set the valves to the
specified condition, they will drain and vent the equipment to be
worked on, and the breaker and the valves are then locked. The
operators return the work permit to the Shift Charge Engineer.
(5)
The Shift Charge Engineer checks the isolation and will issue the
signed work permit to the Maintenance Engineer, or his
representative.
(6)
The Maintenance Engineer orders the start of the maintenance

work to the personnel nominated.
(7)
The Maintenance Engineer or his representative will then return

the signed work permit to the Shift Charge Engineer after making
sure the maintenance work is completed.
(8)
The Shift Charge Engineer will then send operators to release the
locks and return to the original situation.
(9)
The operators check the situation and report that the system is
now back to the normal condition when signing off the work
permit.
Rev.003
(10) The Shift Charge Engineer makes sure that the work under the
permit is completed and files details in the log book.
MM-M02.01
The work permit system is to clarify responsibility for the works on each
step and to ensure that the work is performed safely.
Forced Draft Fan

Mitsubishi
1-10
Chapter 1
Safety
1.4.2 General Cautions on Personnel in Working Area

1.4.2.1
Cautions against Rotating Equipment

All couplings on rotating machines are covered by the
coupling cover but whole parts of the shaft are not fully
covered. It is recommended that the following warning is
observed strictly.
Do not approach or operate the equipment where protective

covers have been removed. Get additional supervisor
assistance.
Make sure that the breaker for the motor is opened when you
are required to remove the cover.
Care must be taken of the exposed rotating parts especially

in the area between the casing , the coupling and moving
blades.
All shafting, coupling and other rotating parts must be

guarded in order to prevent accidental contact.
1.4.2.2
Cautions against Electrical Equipment
MM-M02.01
Rev.003
The electrical equipment covered under this section

includes all the concerned plant equipment and the
maintenance tools like grinders, lamps, welding equipment
etc. though live parts of the plant equipment or
maintenance tools are insulated; be sure to observe the
following cautions. Failure to observe them may cause
fatal accidents, personal injuries and damage to the
electrical equipment.
Forced Draft Fan

Mitsubishi
Always, confirm that power supply is disconnected at the

up-stream side of power supply system and it is locked
according to the Work Permit.
Do not remove or open panels or doors labeled with high

voltage live part warning label not included in the Work
Permit.
Ensure the proper earthing is provided for all electrically

operated tools and equipment used for maintenance works.
When using lamps for internal inspection, ensure that a low

voltage system (24volts) is available.
Make sure that no materials or Parts remain in the Panel or

terminal box before closing them finally.
1-11
Chapter 1
1.4.2.3
Safety
Cautions against High Temperature Sections

Various equipment and pipelines contain high temperature
steam or water in the plant, and most are insulated on their
surface.
There are also several hot spots in the wide area of the
Plant where some specified equipment and pipe lines are
not insulated, and as the temperature is quite high, you
could get burned.
Please observe the following cautions to avoid burn injury.
CAUTION
Wear suitable working wear including gloves, to avoid direct
contact to hot spots in the plant.
Clinkers in the boiler bottom are often very hot inside even
though they look cool on the outer surface.
Always wear gloves in this situation.
Level gauges of pressure vessels including connecting pipes

are not insulated to cool down the steam to drain.
Sampling piping is not insulated to cool down the steam to a

suitable temperature for the analyzer except in the places
located close to the working area for personnel.
All exhaust pipes of the safety valves and the exhaust pipe of
the boiler flush pipe are not insulated.
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
1-12
Chapter 1
1.4.2.4
Safety
Cautions for Steam Leak in the Plant

The steam leak especially from high temperature steam
may cause serious injury to the personnel and it must be
repaired at an early stage of the leakage. The following
pre-cautions must be followed to find leakage at an early
stage.
Water drips may occur at the insulated parts such as the

connected parts of the lagging. The leaking point can be
found by removing insulation partially using great care.
As you approach the leakage, the water will change to visible

steam. It is now too dangerous to remove the insulation.
Leakage of the superheated steam only makes whistling

noise without generating white steam. It is very dangerous to
approach the noise area.
Contact the Charge Engineer to obtain a Permit to Work

before repairing the damage.
Be well aware of the steam. The steam could leak from the
water system containing water at 100C or higher even if it is
a low pressure type water system.
High temperature drain or steam could leak from the flush

pipe during start-up.
If not avoided, the steam or vapor can enter the inside of your
working wear through the small gap between the body and
the clothing.
1.4.2.5 Caution against Oil / Coal Leak in the Plant
Oil / Coal leakage is very dangerous. It is a potential fire

hazard.
Rev.003
Any oil spillage must be reported to the Shift Charge

Engineer.
MM-M02.01
CAUTION
Oil leaks make the area slippery and people are advised to
move around these areas carefully.
Forced Draft Fan

Mitsubishi
1-13
Chapter 1
1.4.2.6
Safety
Cautions against Chemicals

Pay attention to the items listed below to prevent any
accident related to the chemicals in the plant.
IMPORTANT
Precaution against chemicals:
Operate chemical injection systems by strictly following the

instruction of the chemist. The operator must use suitable
protective tools.
Disposal:
Observe the rules and regulation of the installation site.
Material safety data sheet (hereafter MSDS):
Always understand the content of applicable MSDS in

advance, and observe the notified instructions when
handling.
Emergency response:
Solution against emergency must be thoroughly instructed to

all personnel involved so that the fullest measures can be
taken against any situation.
1.4.2.7
Cautions against Combustible Materials/

Storage Areas
MM-M02.01
Rev.003
IMPORTANT
Forced Draft Fan

Mitsubishi
Storage containers must be clearly marked to indicate the

content.
Bunding must be provided for bulk tanks.
Suitable fire protection must be provided for each area.
Do not store bulk combustible materials on the site.
Small quantities of combustible materials must be stored in

fire resistant cupboards.
Combustible materials must be segregated from other

equipment.
1-14
Chapter 1
1.4.2.7
Safety
Cautions against Combustible Materials /

Storage Areas (Continued)
IMPORTANT
Leakage of gasoline has the risk of fire. Maximum storage

quantity of gasoline outside of the dispensing pump is five
liters.
Emergency response:
Personnel directly involved in combustible materials MUST be

properly trained and thoroughly instructed. Other personnel
in the vicinity must be aware of the dangers and take
precautions in all situations.
1.4.2.8
Cautions against Lack of Oxygen
Check that the oxygen content in the equipment vessel or in

the confined space is between 18~22% before entering, and
ensure sufficient ventilation.
Continue monitoring oxygen and ventilation during

inspection.
It is recommended that you do not enter the equipment,

vessel or confined space alone but if the situation demands
that you must enter, take the necessary preventive safety
measure provided, breathing system etc, and find a partner
who will wait for your return at the point of entry, keeping in
verbal contact throughout.
Make complete arrangements for rescue.
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
1-15
Chapter 1
1.4.2.9
Safety
Cautions against Lifting Heavy Object

Be careful during the removal/installation of any
equipment during maintenance.
CAUTION
Do NOT attempt to move or lift equipment in an abnormal
posture. ALWAYS install/remove equipment, using a forklift or

a crane. A normal lift without mechanical aid should be
handled by using two or more persons.
Failure to observe the above may cause injury due to dropped
equipment, back or waist injury or damage to the equipment.
1.4.2.10 Caution against Sharp Objects
CAUTION
Use leather gloves when handling parts with sharp edges.
1.4.2.11 Cautions using Fork Lift
CAUTION
Do NOT permit anyone to stand below any item being lifted
under any circumstance.

Failure to observe this may cause fatal accidents.
When using a forklift, ALWAYS lift the objects parallel to the
ground while considering the center of gravity.

Otherwise, lifted objects may fall and serious damage could
occur.
A forklift is often used to transfer small machines. Check fork
MM-M02.01
Rev.003
insertion position for the forklift prior to use. Be careful, as

marks which indicate the fork insertion positions are
sometimes hidden by wraps or packing materials.
Forced Draft Fan

Mitsubishi
1-16
Chapter 1
Safety
1.4.2.12 Cautions using Crane
CAUTION
A crane is often used to transfer heavy parts. Check for any
possible risks which could occur during hoisting and
transportation before operating the crane.
Check of the equipment:
Check the crane, the crane hook and all related items before
use. Use wire ropes which can withstand the weight of the parts
multiplied by a safety factor.
Inspect the shackles, eyebolts, jigs and wire ropes provided for
the hoisting work prior to the actual hoisting.

Perform periodical inspection (dye penetrant test) of hoisting
tools at least once a year.

Rigging / Slinging work:
Only authorized personnel can perform slinging work and
operation of the crane.

Work area:
Before hoisting, secure a working area around the part to be
lifted and prohibit the entry of unrelated personnel.
Hoisting method:
Hoist the part parallel to the ground while paying attention to
the center of gravity.

Do NOT permit any person to stand under the part being lifted.
Pay attention to and ensure that all persons are clear of the
equipment being lifted.

Hoisting point:
Do NOT hoist any parts from a position other than the specified
hoisting points.
Unpacking:
Do NOT unpack any part until it is located in the designated
location.
Rev.003
Protection of machine:
MM-M02.01
Avoid any impact to the unpacked parts.
Forced Draft Fan

Mitsubishi
1-17
Chapter 1
1.4.2.13
a)
Safety
Disposal
Water disposal including oily drain
The water is disposed to the plant drain system. The water
must be carefully disposed according to the materials
contained in the water. The water drain system is
separated into three categories that are rain water,
chemical water and oily water.
The waste waters are treated and then discharged into the
public drain system.
b)
Chemical disposal
Chemicals must be handled following the instruction of the
MSDS and disposed to the chemical drain system.
c)
Solid disposal made by maintenance work
MM-M02.01
Rev.003
For disposal from the site, observe the local legal

regulations.
Forced Draft Fan

Mitsubishi
1-18
Chapter 1
1.5
Safety
Emergency Measure
1.5.1 Evacuation on Emergency Case
1.5.1.1
Evacuation Route
Following items are considered on design and installation
of emergency evacuation.
IMPORTANT
Each building installed in the plant is provided with at least two
exits. A clear indication of the exits can be seen from anywhere

in the building as the exit sign is illuminated using the
emergency power supply.
Evacuation routes are indicated on each floor of the building,
directing personnel to the exits.

Keep the evacuation routes completely free from materials and
tools.
1.5.1.2
Evacuation of Disabled Persons Who Cannot

Move by Themselves
The following are necessary items, prepared for emergency
evacuation.
IMPORTANT
It is recommended to keep a stretcher available for
emergencies at the places selected as being secure at the

safety meeting.
If you find this kind of accident, inform the rescue team, and
MM-M02.01
Rev.003
attempt to bring the collapsed person to the first aid station.
Forced Draft Fan

Mitsubishi
1-19
Chapter 1
1.5.1.3
Safety
Evacuation from Power House

Following are guidance for the evacuation from the power
house.
IMPORTANT
An evacuation place for personnel to gather in after evacuation
from the power house in an emergency must be predetermined

and explained beforehand in the emergency training.
Evacuation directive must be given by the responsible person
such as Shift Charge Engineer, and all personnel must be

alerted in the power house repeatedly with an available
broadcast facility.
All people working in the power house must stop their work
immediately and leave the power house to the gathering place.

When evacuated to the evacuation place, make sure
MM-M02.01
Rev.003
that there is no one missing.
Forced Draft Fan

Mitsubishi
1-20
Chapter 1
Safety
1.5.2 Fire Accident
IMPORTANT
Clearly show the location of fire alarm push button and fire
extinguisher to make everybody take the first step at fire

protection.
Inform everyone concerned that a fire has now started if you
discover a fire.
Start fire fighting using the fire extinguisher located near the
fire site.
The operators must check the plant is ready for trip, and wait
for order from the responsible person.

The operator and other personnel must transfer the fire fighting
to the fire fighting team when they arrive at the fire site and the
operators must wait for instruction from the Shift Charge
Engineer. All other personnel must immediately start
evacuation.
If unit trip is decided, the operator must trip the plant manually.
The operators must evacuate from the power house according
to the instruction of the responsible person immediately after

shutdown of the unit.
If the fire is extinguished successfully, the operators should
return to the power house as required by the Shift Charge

Engineer and start inspection of the equipment for restart of the
unit.
Based on the inspection, the responsible person should decide
whether to operate the unit again or shutdown for repairing.

After the inspection or repair, and then checking the equipment
MM-M02.01
Rev.003
and/or system, start up the unit again.
Forced Draft Fan

Mitsubishi
1-21
Chapter 1
Safety
1.5.3 Earthquake
In the case of an earthquake, the shift charge engineer or operator
must judge whether the unit trip is necessary according to the intensity
of the earthquake, and immediately trip the unit manually. If the unit is
tripped, all equipment must be carefully checked on its operation status
and tripped if abnormal phenomena are found.
In the local area, mechanical and/or thermal shocks may be given to
the equipment, piping, instruments and electrical panels. Be sure to
observe the following when completing the inspection.
Check that the lubricating oil pump is running. Bearings of the
equipment will be damaged if lubricating oil is not supplied.

Check the piping and equipment for steam and water leakage. The
steam or high temperature water leakage may cause serious

injury to the personnel and it must be repaired at an early stage of
the leakage.
Check the pulverizers and /or coal silos for signs of a fire. If a coal
fire does start, make sure that CO2 fire fighting system is properly
operated.
Check the position of boiler seismic stopper. Since the boiler
seismic stopper must be anchored at the original position, boiler

cannot be re-started if the slippage is found. If the stopper is not
at the original position, please contact MHI.
CAUTION
Check the piping and equipment for breaking and the dropping of
insulation. Since the exposure of hot surface may cause burn

injury, it must be repaired by a maintainer fully dressed in his
personnel protective equipment.
1.5.4 Explosion Accident
Rev.003
Do not use a fire in a hazardous area where the combustibles
MM-M02.01
(hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or
handled. Use of a fire in a hazardous area could cause serious
injury to personnel and serious damage to equipment due to an
explosion.
Forced Draft Fan

Mitsubishi
1-22
Chapter 1
1.6
Safety
Qualification and Training

The system must be operated only by authorized operators & maintenance
supervisors.
The customer shall authorize all operators and maintainers, who are involved in
the operation and maintenance of this plant, either by the training course given
by Mitsubishi, or by the customers own personnel assessment.
Operator and maintainer training course (both classroom training and On Job
Training (OJT)) will be provided by Mitsubishi before the handing over of this
plant. The customer must train and assess new operators and maintainers who
join after the turn-over according to his own procedure and standard, (Mitsubishi
training course may still be available if required).
Operator and Maintainer can read and fully understand the description of
this manual.
Operator and Maintainer can understand the related P & ID, logic diagram.
Operator and Maintainer know the location of the system equipment

including pipe routes, valves and instruments.
Operator and Maintainer have fundamental knowledge of the function of

each equipment.
Operator can operate the equipment and the system manually at local
stations.
Operator can operate the system remotely using the DCS system.
Operator can respond suitably for any kind of alarm.
Operator knows the location of emergency exit on the power house and is
available to provide first aid treatment.
Operator knows emergency communication system operation.
Operator and Maintainer, following the Charge Engineers instruction are

aware of the isolation method for mechanical, electrical and instrumental
equipment being prepared for safe maintenance while the unit is in
operation.
Maintainer must also be able to handle the maintenance tools provided by

the owner and those supplied by the manufacturer.
MM-M02.01
Rev.003
As a minimum, operator and maintainer must satisfy the following:
Forced Draft Fan

Mitsubishi
1-23
Chapter 2
General
C h a p t er
2 General
2.1
Purpose
The purpose of this maintenance manual is to provide specific information to the
PAITON III Power Plant maintenance personnel regarding the maintenance of
the FD Fans. Although this document will convey a good knowledge and
direction regarding maintenance of the FD Fans, it is recommended that in the
event of a problem not covered in the document the person responsible should
seek assistance or instruction from the manufacturer.
References
a)
Air & Flue Gas System Flow Diagram

MHI Dwg No. 0C058-97000-2161-1A
Project Dwg No. P101-51-3-00-10-B049
b)
Forced Draft Fan Lubricant And Control Oil System P& ID

MHI Dwg No. N29-10M-7091
Project Dwg No. P101-51-3-BB-BG-W004
c)
Forced Draft Fan Particular Study

MHI Dwg No. 0C058-97000-2161-1A
Project Dwg No. P101-18-1701.03-B007
d)
Forced Draft Fan Outline Drawing

MHI Dwg No. 0C058 - N29-10P-2385
e)
Forced Draft Fan Sectional Drawing

MHI Dwg No. 0C058-N29-10M-7092
f)
Overhaul Plan For Forced Draft Fan

MHI Dwg No. 0C058-P97000-3371
Project Dwg No. G101-57-3-05-00-E029
MM-M02.01 Rev.003
2.2
Forced Draft Fan

Mitsubishi
2-1
Chapter 2
2.3
General
Overview of the FDF

Refer to Figures 2-1, 2-2, 2-3, 2-4 and 2-10.
The Forced Draft Fan (FDF) is an essential equipment / auxiliary for the supply
of combustion air to the steam generator.
Each unit of Paiton Power Project is equipped with two FD fans. Each fan
supplies 50% of the combustion air required at the Boiler Maximum Continuous
Rating (BMCR) condition.
The fan design parameters are based on air temperature of 25.5C and an air
density of 1.1665 kg/m at the fan inlet. The fan supplies combustion air to the
boiler at a static pressure of 480 mmH2O (Gauge) as shown in Figure 2-1 and
Figure 2-2.
The FDF is a single stage axial fan with rotor moving blade pitch control. It is
driven by a single speed 13.2 kV motor at a rated speed of 980 rpm. Looking
from the motor NDE side, the direction of rotation of the fan is CW.
The fan suction casing is bolted to the air inlet structure above the fan and is
supported by a steel framework. The inlet structure consists of sections bolted
together at the flanges. The top section is the air intake section and it is provided
with a wire netting of stainless steel to prevent the ingress of foreign material.
The suction silencer suction section along with the acoustic insulation on inside
of the casing is designed to reduce the air intake noise to 85 dB (A) at 1 m
distance from the equipment. The lower section is curved to direct the air into
the impeller casing.
The fans are located outside of the Generation Building at ground level. The fan
and the motor are suitably supported on the four reinforced concrete
foundations as shown in the Figure 2-2.
A hydraulic mechanism regulates the pitch of the moving blades on the rotor
which rotates at the design speed as shown in Figure 2-3.
MM-M02.01 Rev.003
Refer to Figure 2-10. An oil unit supplies the necessary high pressure control oil
required to change the pitch of the moving blades during fan operation. Oil
obtained from a connection before the control oil filter, is used at a reduced
pressure, to lubricate the fan bearings. Cooling water from the Closed Circuit
Cooling Water (CCCW) System is used to cool the lubricating oil flowing through
the cooler.
Forced Draft Fan

Mitsubishi
2-2
General
MM-M02.01
Rev.003
Chapter 2
FIGURE 2-1
Forced Draft Fan
Mitsubishi
AIR & FLUE GAS P & I D
2-3
LOCAL PANEL
Chapter 2
General
OIL UNIT
ACCUMULATOR
BLADE DRIVE UNIT

E
TRURTH N
NO
N
PLANT
NORTH
CW
FDF 3A
CL OF BOILER
CW
A-A
FLOW
FLOW
FDF 3B
FLOW
SUCTION SILENCER
SUCTION SILENCER
FLOW
KEY PLAN
FAN SPECIFICATION
FAN TYPE
MOTOR
A
FAN
FLOW
FAN FLOW RATE
Rev.003
m /min/FAN
FAN INLET TOTAL PRESS.
-50
mmH2O(Gauge)
FAN OUTLET STATIC PRESS.
480
mmH2O(Gauge)
FLUID TEMP. AT FAN INLET
25.5
FAN SPEED
980
FLUID DENSITY
RATED MOTOR OUTPUT
MM-M02.01
AXIAL FAN
21000
1.1665
2500
C
rpm
kg/m3
kW
MANHOLE
MPTD-3-0002
FIGURE 2-2
Forced Draft Fan
Mitsubishi
FD FAN OUTLINE
2-4
Chapter 2
ITEM
50
54
52
51
CL OF M/B
1
2
FLOW
MOTOR SIDE
12
33 31
MOVING BLADE
ROTOR
TEFLON RING
CRANK ARM
CRANK ARM
SERVO CYLINDER
SERVO CYLINDER COVER
SLIDING PIECE FOR CRANK ARM
SLIDING PIECE FOR CRANK ARM (WITH PIN)
10
SIDE RING OF ACTUATOR DISK

NUT FOR MOVING BLADE SHAFT
12
MOVING BLADE SUPPORT BEARING
19 18
13
INTERMEDIATE SHAFT
14
COUPLING SPACER
15
PISTON
16
PISTON RING
17
NUT FOR PISTON
18
MV-PACKING
19
PLATE FOR MV-PACKING
20
SLEEVE
21
COUPLING
22
NUT
23
BEARING BOX
24
RADIAL BEARING
25
THRUST BEARING
26
BEARING BOX COVER
27
SPHERICAL KEY
28
SLEEVE FOR BRG.
29
PILOT SLEEVE
30
PILOT VALVE
31
COVER
32
OIL COVER FOR PILOT LEAK
33
CONTROL OIL INNER PIPINGS
50
SUCTION CASING
51
IMPELLER CASING
52
REAR CASING
53
DIFFUSER
54
BAND FOR CASING
27
23
14
21 22
13
ROTATION
11
17 15 16
9
DESCRIPTION
11
10
30 32 29 7
CL OF SUCTION
53
26 28
26
24 25
MM-M02.01
Rev.003
20
General
MPTD-3-0025
FIGURE 2-3
Forced Draft Fan
Mitsubishi
FD FAN SECTIONAL VIEW
2-5
General
MM-M02.01
Rev.003
Chapter 2
FIGURE 2-4
Forced Draft Fan
Mitsubishi
FD FAN CUTAWAY VIEW
2-6
Chapter 2
2.4
General
Components
Each FDF consists of the following components:
Casing
Rotor assembly
Moving blade regulating mechanism
Main bearing assembly
Coupling
Control/lubricating oil system
2.4.1
Casing
Refer to Figure 2-5.
The fan casing consists of the following sections:
suction silencer casing
impeller casing
rear casing
diffuser casing
The suction silencer consists of an expansion joint, sound deadening

part, wire netting part and roof are bolted and seal welded. The suction
silencer components are bolted and seal welded. Sound proofing
insulation is provided on the internal surface of the suction casing. A
blind drain pipe is provided for bottom of suction casing. For
maintenance purpose a manhole is provided at the bottom of the
suction casing lower part.
The fan drive shaft penetrates the suction casing to connect with the
electric drive motor installed outside the fan casing. The suction casing
shape changes from rectangular to circular, in the direction of the flow.
The impeller, rear and diffuser casing sections are provided with inner
casings concentric to the horizontal axis of the fan and are supported
on the outer casings with support plates. A band for casing is provided
around the flanged joint of the rear casing and the diffuser.
MM-M02.01 Rev.003
Sound proofing insulation is provided for each outer casings. For the
suction casing sound proofing insulation is done internally. Ladder is
provided on both the impeller and rear outer casing for outage
maintenance.
The casing shape is specially designed to provide a streamline flow of
air to the moving blades.
Forced Draft Fan
Mitsubishi
2-7
Chapter 2
General
All the flanged joints of the casing are provided with Neoprene rubber
as a gasket. The casing shape is specially designed to provide a
streamline flow of air to the moving blades. From the rectangular inlet
connection, the air flows horizontally over the rotating blades.
Air from the atmosphere is drawn through the wire netting into the
suction casing through a silencer. It is directed towards the moving
blades via a 90-degree bend. The air flows through the annular space
between the inner casings and the outer casings.
The diffuser is connected to the discharge duct through an expansion
joint.
Oil line is routed through the inner casing bottom side to the oil unit.
Instrument tapping points are provided on the suction casing to
facilitate the measurement of static pressure.
Impeller casing
The impeller casing houses of the following:
rotor assembly
bearing assembly
The circular impeller casing gradually reduces in diameter in the

direction of the flow. A tubular inner casing, installed within the impeller
casing, houses the bearing assembly. The moving blades occupy the
annular space between the tubular inner casing and the impeller outer
casing. The impeller casing is horizontally split to ease maintenance
activities.
The annular inner circumferential surface of the impeller casing outer
side which along the circumference of the tip circle of the moving
blades is machined surface.
The upper half of the impeller casing is bolted to the lower half for easy
removal during maintenance.
Rear casing
MM-M02.01 Rev.003
The rear casing is of uniform diameter and is located between the

impeller casing at the upstream side and the diffuser at the
downstream side. The impeller casing and the rear casing are axially
split, enabling maintenance access to the rotor wheel and the
components of the moving blade regulating mechanism.
The rear casing facilitates the routing of the moving blades operating
shaft. The control oil supply and return lines to the moving blade
operating mechanism are also routed through the rear casing.
Forced Draft Fan
Mitsubishi
2-8
Chapter 2
General
The rear casing is provided with an inner casing to protect the moving
blade regulating mechanism components from damage. The rear inner
casing is supported by the stationary blades around the circumference.
A manhole is provided on the inner casing for inspection and
maintenance of the moving blade regulating mechanism.
Diffusser
The diffuser is installed downstream of the rear casing and is

connected to the discharge duct through an expansion joint. The
diffuser section gradually increases in cross-sectional area, recovering
the kinetic energy imparted by the moving blade.
The diffuser is provided with an inner casing and is supported by plate
at two locations. A manhole door is provided on the diffuser inner
casing for the entry of personnel from the discharge duct and to
carryout any inspection and maintenance of the moving blade
regulating mechanism.
2.4.2 Rotor
The rotor is a forged component welded to a solid shaft. The rotor is
supported on the shaft at one point within the bearing box by
anti-friction bearings. The motor side and fan side of the bearing box
covers are provided with labyrinth seals to prevent oil leaks.
The DE side of the shaft is fitted with a sleeve for facilitating installation
of bearings on the shaft. The coupling half is keyed and shrink fitted to
the rotor shaft end at the DE side and locked with a nut.
The rotor is comprised of moving blades, the blade shafts and blade
regulating mechanism. The blade shafts are supported by the moving
blade support bearing and nuts. The moving blade support bearings
are of the sealed type.
The piston applied as blade pitch regulating servo cylinder piston is
located on the rotor boss. The piston is fixed by means of a sleeve and
parallel pin on one side and a nut on the other side. The servo cylinder
moves axially over the piston while both parts are rotating. The axial
movement of the servo cylinder is converted into rotary movement of
the blades by a crank arm connecting the moving blade shaft.
MM-M02.01 Rev.003
The moving blades, made of forged aluminum, are of light weight. The
moving blades have a laminar flow blade profile, high efficiency and a
good performance characteristic.
Provision is made on the rotor for the addition of weights required for
the dynamic balancing of the fan.
Forced Draft Fan
Mitsubishi
2-9
Chapter 2
General
2.4.3 Moving Blade Regulating Mechanism

Refer to Figures 2-7 and 2-8-1, 2-8-2.
The moving blade regulating mechanism regulates the blade pitch
even while the fan operates at the rated speed. The moving blade
regulating mechanism consists of the fixed piston mounted on the boss
of the rotor shaft, the movable servo cylinder and the pilot valve.
The servo cylinder and the piston rotate at the same speed as the rotor
and cylinder alone is free to move axially. The cylinder cover secured to
the servo cylinder has the necessary holes for the supply and return of
the control oil which moves the cylinder.
The pilot valve can move axially only and is located inside a sleeve
secured to the inside of a servo cylinder. This pilot valve moves in and
out to allow the flow of control oil as necessary to operate the moving
blades.
Control inner pipe (flexible hoses) on the pilot valve head enable the
flow of supply and return, control oil and leakage oil through the drain
cover.
A pneumatically operated control drive located outside of the fan casing
enables the operation of the pilot valve through a linkage mechanism.
The linkage mechanism is so arranged that a 90 rotation of the control
drive unit link rotates the moving blades through an angle of 40 to
+14. A moving blade sticking detector is provided on the linkage
between the control drive unit outside of the fan casing to detect any
excessive load for operation of the blades.
MM-M02.01 Rev.003
The servo cylinder is a compact modular design and it is easy to

overhaul. The ratio of input to output is one, yielding a good response
characteristic.
Forced Draft Fan

Mitsubishi
2-10
Chapter 2
General
2.4.4 Main Bearing Assembly

The bearing box is supported on the inner casing of the impeller casing.
The rotor can be overhung with one bearing box. The bearing box
contains an antifriction cylindrical roller bearing at the fan end and two
ball bearings at the motor end. The cylindrical roller bearing absorbs
the radial load and the ball bearings absorb the thrust load generated
by the fan work.
End covers fitted on either side of the bearing box are provided with oil
baffles or labyrinth seals to prevent lubricating oil leakage along the
shaft from the bearing box.
Lubricating oil is supplied to the bearing box through an oil supply line
and distributed to bearings through internal holes on the bearing. An oil
bath is provided in the bearing box by means of suitable protrusions in
the lower half bearing box to match roller or ball of bearings. The
lubricating oil for the bearings is supplied from a forced lubricating oil
system, an external oil unit.
2.4.5 Control / Lubricating Oil System

Refer to Figures 2-10.
The control/lubricating oil system consists of:
one 400 liter capacity oil tank
2 x 100% control oil pump, one in operations, one in standby
control oil pump suction strainer
control oil pump discharge strainers
lube oil duplex strainers
lubricating oil cooler
one return oil strainer
an accumulator (control oil)
MM-M02.01 Rev.003
The oil pumps mounted on the top of the reservoir draw oil from the
reservoir through two dedicated individual suction strainers. The oil is
then filtered by two 100% capacity oil filters and supplied as control oil
at about 5.39~5.88 MPa for the blade regulating mechanism. An oil
accumulator (pre-charge N2 pressure at 1.4MPa) installed on the
control oil supply line absorbs minor pressure fluctuations.
Forced Draft Fan

Mitsubishi
2-11
Chapter 2
General
Pressure reducing valves reduce the pressure of the control oil to about
0.15~0.18 MPa and supply lubricating oil to the fan bearings. The
return control oil from the blade regulating mechanism is also directed
to the lubricating oil supply line. The oil cooler receives cooling water
from the CCCW System to cool the lubricating oil before admitting it to
the bearing box.
The oil reservoir is provided with a return oil filter to collect debris in the
return oil.
For further details, please refer to the Vendors manual, Appendix F.
2.4.6 Coupling
The fan rotor is coupled to the drive motor with a rigid coupling.
MM-M02.01 Rev.003
The coupling consists of one intermediate shaft, two hubs (motor side
and fan side), a spacer (motor side), reamer bolts and nuts.
Forced Draft Fan

Mitsubishi
2-12
General
MM-M02.01
Rev.003
Chapter 2
FIGURE 2-5
Forced Draft Fan
Mitsubishi
FDF CASING ASSEMBLY
2-13
General
MM-M02.01
Rev.003
Chapter 2
FIGURE 2-6
Forced Draft Fan
Mitsubishi
ROTOR ASSEMBLY
2-14
General
MM-M02.01
Rev.003
Chapter 2
FIGURE 2-7
Forced Draft Fan
Mitsubishi
MOVING BLADE REGULATING MECHANISM ASSEMBLY

2-15
General
MM-M02.01
Rev.003
Chapter 2
FIGURE 2-8-1
Forced Draft Fan
Mitsubishi
LINKAGE MECHANISM ASSEMBLY
2-16
General
MM-M02.01
Rev.003
Chapter 2
FIGURE 2-8-2
Forced Draft Fan
Mitsubishi
BLADE STICKING DETECTOR
2-17
MOTOR SIDE
Chapter 2
ITEM
29
16 17
F
34
33
28
33 34
31
MOTOR SIDE
23
18
10
19
32
28
DET.G
E-E
22
C
L OF BEARING
36
T
GAS
37
VEN
35
OIL SUPPLY
OF BEARING
D-D
B
9
MOTOR SIDE
37
26
F-F
41 42
39
26
30
5
ROTATION
D
SEAT FOR
VIBROMETER
T
RO
N
IO
AT
25
OIL LEVEL
OIL LEVEL
2
E
40
E
38
37
DESCRIPTION
BEARING BOX (UPPER)
BEARING BOX (LOWER)
STOPPER
PLATE FOR BEARING KEEP
ADJUSTING RING (UPPER)
ADJUSTING RING (LOWER)
STOPPER BOLT
PIPE FOR RETURN OIL
ECCENTRIC BUSH
10
O-RING
11
12
SEAL PACKING
ADJUSTING LINER
13
ADJUSTING LINER
14
ADJUSTING LINER
15
ADJUSTING LINER
16
BOLT
17
WASHER
18
SPECIAL BOLT
19
FLAT BAR
20
BOLT
21
WASHER
22
90 ELBOW
23
TAPER PIN
24
SEAT FOR THERMOMETER
General
25
PARALLEL PIN
26
BEARING KEEP
27
OIL BATH DRAIN PLUG
28
THRUST BEARING
29
RADIAL BEARING
30
SLEEVE
31
O-RING
32
O-RING
33
BEARING INNER SPACER
34
BEARING OUTER SPACER
35
BOLT
36
PARALLEL PIN
37
SPHERICAL KEY
38
OIL BAFFLE ASS'Y (COUPLING SIDE)
39
OIL BAFFLE ASS'Y (ROTOR SIDE)
40
SHAFT
41
BOLT
42
WASHER
MM-M02.01
Rev.003
B-B
C
C-C
12 13 14 15
B
11
A-A
OIL RETURN
OF BEARING
20 21
27
24
27
MPTD-3-0037
FIGURE 2-9
Forced Draft Fan
Mitsubishi
BEARING BOX ASSEMBLY
2-18
Chapter-2
FT
FT
FT
PT
TE
2~4
General
FDF SUCTION
SILENCER
TI
TE
25A
10A
65A
15A
15A
20A
15A
15A
20A
25A
PI
40A
40A
DPI
PT
FT
XE
PS
LUBRICATING OIL RETURN
BLADE STICKING DETECTOR
20A
PILOT
LEAK OIL
20A
ZS
2
OIL SEAL
LEAK OIL
ZS
U-SEAL
LS
LI
U-SEAL
CONTROL OIL LEAK OIL
20A
20A
25A
40A
25A
PS
1
FOR MAINTENANCE
PS
6
PS
5
PS
4
65A
PS
2
LOCAL PANEL
20A
PS
3
LUBRICATING OIL SUPPLY
A-1
FOR MAINTENANCE
25A
ZS
1
CONTROL OIL SUPPLY
DU-1
CONTROL OIL RETURN
40A
F-4
PI
2
PI
1
F-6
PI
4
03HLB01AC1
C-1
WATER DRAIN
P
AIR BREATHER
TI
1
M
P 03HLB01AP202
P-2
(03HLB01AP204)
LS
1
PI
5
TI
3
OIL SUPPLY PLUG
F-1
LI
1
T-1
03HLB01BB101
(03HLB01BB102)
F-3
50A
50A
40A
MM-M02.01
Rev.003
OIL UNIT
SET POINT
5.39 ~ 5.88 MPa
0.15 ~ 0.18 MPa
RANGE
0~15MPa
0~15MPa
0~15MPa
0~1.0MPa
0~1.0MPa
0~0.4MPa
SYMBOL
PI-1
PI-2
PI-3
PI-4
PI-5
PI-6
03HLB01CP211
(03HLB01CP221)
03HLB01CP212
(03HLB01CP222)
03HLB01CP213
(03HLB01CP223)
03HLB01CP214
(03HLB01CP224)
03HLB01CP215
(03HLB01CP225)
03HLB01CP216
(03HLB01CP226)
CONTROL OIL PRESS. NORMAL INTERLOCK
03HLB01CT311
(03HLB01CT321)
03HLB01CT312
(03HLB01CT322)
03HLB01CT313
(03HLB01CT323)
03HLB01CT314
(03HLB01CT324)
FDF LUBRICATING OIL COOLER INLET

FDF LUBRICATING OIL COOLER OUTLET
COOLING WATER INLET
OIL TANK
03HLB01CT011
(03HLB01CT021)
03HLB01CT001
(03HLB01CT051)
03HLB01CT002
(03HLB01CT052)
03HLB01CT003
(03HLB01CT0530
BEARING OIL TEMPERATURE HIGH ALARM

FDF 3A/3B SUCTION AIR TEMP.-A
FDF 3A/3B SUCTION AIR TEMP.-B
FDF 3A/3B SUCTION AIR TEMP.-C
03HLB01CY011
(03HLB01CY021)
BEARING VIBRATION HIGH ALARM
03HLB01CG211
(03HLB01CG221)
03HLB01CG212
(03HLB01CG222)
BLADE ANGLE 0% POSITION INTERLOCK

BLADE STICKING ALARM
FULL CLOSE ON
ZS-1
ZS-2
03HLB01CG211
(03HLB01CG221)
03HLB01CG212
(03HLB01CG222)
OIL TANK LEVEL LOW ALARM
MIN. OIL LEVEL LOWER

THAN 50mm (122 ) ON
LS-1
03HLB01CL311
(03HLB01CL321)
OIL TANK LEVEL
MAX. OIL LEVEL 400

MIN. OIL LEVEL 170
LI-1
03HLB01CF101
(03HLB01CF151)
03HLB01CF102
(03HLB01CF152)
03HLB01CF103
(03HLB01CF153)
FDF 3A/3B AIR FLOW-A

FDF 3A/3B AIR FLOW-B
FDF 3A/3B AIR FLOW-C
03HLB01CP101
(03HLB01CP151)
FDF 3A/3B SUCTION PRESS.
CONTROL OIL PRESS. LOW TRIP

LUBRICATING OIL PRESS. NORMAL INTERLOCK
LUBRICATING OIL PRESS. LOW TRIP
0~10MPa
P>
= 4.90 MPa ON
0~10MPa
P<
= 4.41 MPa ON
< 1.96 MPa ON
0~10MPa
P=
> 0.13 MPa ON 0.02~0.2MPa
P=
< 0.12 MPa ON 0.02~0.2MPa
P=
< 0.08 MPa ON 0.02~0.2MPa
P=
PS-1
PS-2
PS-3
PS-4
PS-5
PS-6
0~100 C
0~100 C
0~100 C
0~100 C
TI-1
TI-2
TI-3
TI-4
T>
= 70 C ON
0~150 C
TE-1
TE-2
TE-3
TE-4
V>
l ON
= 105um
0~300um(P-P)
l
XE-1
EQUIPMENTS LIST
SYMBOL
TI
4
F-2
03HLB01CP311
(03HLB01CP321)
03HLB01CP312
(03HLB01CP322)
03HLB01CP313
(03HLB01CP323)
03HLB01CP314
(03HLB01CP324)
03HLB01CP315
(03HLB01CP325)
03HLB01CP316
(03HLB01CP326)
DESCRIPTION
FDF CONTROL OIL PUMP 3 A1/B1 OUTLET
FDF CONTROL OIL PUMP 3 A2/B2 OUTLET
CONTROL OIL SUPPLY PRESS.
FDF LUBRICATING OIL COOLER INLET
FDF LUBRICATING OIL COOLER OUTLET
LUBRICATING OIL SUPPLY PRESS.
TI
2
OIL DRAIN
03HLB01AP201
(03HLB01AP203)
P-1
20A
PI
6
F-5
65A
25A
PI
3
40A
25A
25A
THERMOMETER
(LOCAL)
THERMOCOUPLE
PRESSURE GAUGE
(LOCAL)
DIFFERENTIAL PRESSURE GAUGE
PRESSURE TRANSMITTER
DIFFERENTIAL PRESSURE TRANSMITTER
VIBRATION METER
PRESS. SWITCH
LIMIT SWITCH
LEVEL SWITCH
LEVEL GAUGE
GLOBE VALVE
GLOBE VALVE (NORMALLY CLOSED)
REGULATING VALVE
SAFETY VALVE
3-WAY VALVE
STOP CHECK VALVE
BUTTERFLY VALVE
NEEDLE VALVE
REDUCER
SIGHT FLOW
STRAINER
OIL COOLER
ORIFICE
ACCUMULATOR
CHECK DAMPER
FLANGE
EXPANSION JOINT
FLEXIBLE HOSE
CAP
OIL LINE
DRAIN LINE
COOLING WATER LINE
AIR LINE
CAPILLARY
ELECTRIC SIGNAL
AIR SIGNAL
PRESSURE GAUGE
MOTOR
INSTRUMENTS LIST
PRESSURE SWITCH
FDF
EXPLANATION OF SYMBOL
DESCRIPTION
INSTRUMENT(FIELD MOUNTED)
LOCAL PANEL MOUNTED INSTRUMENT
THERMOMETER
SYMBOL
THERMO
COUPLE
03HLB01AN101
(03HLB01AN102)
LEVEL LEVEL LIMIT

GAUGE SWITCH SWITCH
15A
TE
1
15A
03HLB01BS101
(03HLB01BS102)
XE
1
P-1
P-2
F-1
F-2
F-3
F-4
F-5
F-6
C-1
A-1
T-1
DU-1
DESCRIPTION
FDF CONTROL OIL PUMP 3 A1/B1
FDF CONTROL OIL PUMP 3 A2/B2
RETURN OIL STRAINER
LUBRICATING OIL DOUPLEX STRAINER

FDF LUBRICATING OIL COOLER
ACCUMULATOR
OIL TANK
DRIVE UNIT
FORCED DRAFT FAN
FDF MOTOR
REMARKS
7.85 MPax 34.5 /min
AC 416 V x 50 Hz
7.5 kW x 6P
100 mesh
150 mesh
150 mesh
20u
l
20u
l
200 mesh
3 TON/Hr
60
400
Torque 102 N-m
21000 m3/minx480 mmH2O
2500kW x 6P
COOLING WATER
FIGURE 2-10
FDF LUBE AND CONTROL OIL P & I D
MPTD-3-0026
Forced Draft Fan

Mitsubishi
2-19
Chapter 2
ITEM
1
2
3
4
5
6
7
General
DESCRIPTION
MOTOR COUPLING
SPACER
REAMER BOLTS
REAMER BOLTS
NUT
WIRE
INTERMEDIATE SHAFT
A-A
FAN SIDE
MOTOR SIDE
PUT MATCH MARKS
PUT MATCH MARKS
MM-M02.01 Rev.003
MPTD-4-0036
FIGURE 2-11
Forced Draft Fan

Mitsubishi
INTERMEDIATE SHAFT AND COUPLING ASSEMBLY
2-20
Chapter 3
Specifications
C h a p t er
3 Specifications
TABLE 3-1
FORCED DRAFT FAN
Subject
Specifications
Equipment number
03HLB01AN101
03HLB01AN102
Quantity
Two (2)
Fan
Coupling
Bearing
Manufacturer
MHI
Model
ML-H1-R132/270
Type
Axial Fan, Variable Blade Control
Manufacturer
MHI
Type
Rigid Coupling
Manufacturer
J TEKT
Type
Anti-friction bearing (MHI special type)

Bearing No.
Major material
MM-M02.01
Rev.003
Weight
(approximately)
Forced Draft Fan

Mitsubishi
Basic load rating (kN)

Dynamic
Static
NJ338AF3C3
+DP30-1
987
1260
7338B/1DAD
T/30-1
1170
4220
Casing
Rolled Steel for General Structure
Moving Blade
Forged Aluminum
Rotor Shaft
Carbon Steel for Machine Structural Use
Bearing (Box/Body)
Cast steel
Coupling
Cast steel
Silencer
33.0 t (including expansion joint)
Rotor assembly
3.0 t
Suction Casing
17.0 t (including insulation)
Impeller Casing
Upper Half
2.0 t (included insulation)
Impeller Casing
Lower Half
3.0 t (without insulation)
Rear Casing
Upper Half
1.3t (included insulation)
Rear Casing
Lower Half
Diffuser
3-1
Chapter 3
Specifications
Continued form previous page
TABLE 3-1
FORCED DRAFT FAN
Subject
Specifications
Design Rotating Speed
980 rpm
Blade
14
Performance Characteristics
Direction of Rotation
Clockwise (Viewed from motor side)
Capacity (each fan)
21,000 m3/min
Inlet pressure
-50 mmH2O
Outlet static pressure
480 mmH2O
Fluid
Air
Fluid temperature at inlet
25.5 C
Fluid density (design)
1.1665 kg/m3
TABLE 3-2
FORCED DRAFT FAN - MOTOR
Subject
Specifications
Manufacturer
Hyundai Heavy Industries Co. Ltd.
Type
HRP3 637-68E
Rated Output
2,500 kW
Rated Voltage
13,200 V
Rated Current
133.1 A
Frequency
50 Hz
Poles
Coupling
Direct
Rating
Continuous
Insulation Class
Maximum Ambient Temperature
40 C
Bearing
Split sleeve
Type
14,500 kg
MM-M02.01
Rev.003
Total Weight (approximately)
Forced Draft Fan

Mitsubishi
3-2
Chapter 3
TABLE 3-3
Specifications
FDF CONTROL OIL UNIT
Subject
Oil Specification
Specifications
ISO VG 32
Electric Power
Power
AC 380V, 7.5kW, 1,000rpm
Control Oil Pump
Type
Vane Pump
Quantity
Two (2) sets (1 Normal ; the other for

stand-by)
Capacity
34.5L/min
Working Pressure
7.85 MPa
Type
Totally Enclosed Fan Cooled Type
Quantity
Two (2) sets
Oil Tank
Total Volume
400 l
Oil Cooler
Type
Shell and Tube
Quantity
One (1) set
Water quantity
3.0 Ton/H
Oil Pump Motor
150 mesh
Return Oil Strainer
100 mesh
Lub. Oil Pump Discharge duplex

strainer
200 mesh
Control Oil Pump Discharge Strainer
20
Accumulator
60 l
MM-M02.01
Rev.003
Suction Strainer Control oil system
Forced Draft Fan

Mitsubishi
3-3
Specifications
MM-M02.01
Rev.003
Chapter 3
FIGURE 3-1
Forced Draft Fan

Mitsubishi
PEFORMANCE CURVE
3-4
Chapter 4 Preventive Maintenance
eu
C h a p t er
4 Preventive Maintenance
Preventive maintenance is carried out to avoid or minimize the possibility of failure or
deterioration of equipment performance. This requires a constant effort from
maintenance staff to ensure that the Unit is available on demand.
There are two categories of preventive maintenance, Routine Maintenance and Annual
Outage Maintenance. Routine maintenance helps to reduce the possibility of outage
and hence the downtime of machinery. Annual outage maintenance is required to
maintain the internal components of the installed equipment.
Though vendor/manufacturers recommendations provide a good basis for the
provision of a preventive maintenance schedule, the frequency and other details should
be updated from time to time based on practical experience and actual feedback
gathered through inspection and normal operation of the equipment/plant.
Consideration of these site related specific issues will make the preventive
maintenance more effective.
4.1
Prerequisites
The necessary prerequisites for the preventive maintenance of the FDF are as
follows:
4.1.1 Scheduling
Scheduling is the first activity in the preparation of a preventive
maintenance program. The schedule is to include planning to attend all
operating equipment on a fixed regular basis.
Initially, schedules will be prepared based on vendor/manufacturers
generic instructions, the schedules will, however, be updated
(frequency, nature of inspection, etc.) as site specific data becomes
available.
Rev.003
Preventive maintenance is to be coordinated with other concerned

departments. In the case of a major scheduled outage, maintenance
personnel and other concerned departments should jointly produce a
plan of activities, well in advance, to decide the inspection activities and
other logistics (such as the availability and supply of required
equipment, spare parts, and tools, etc.).
MM-M02.01
The schedule should clearly identify the critical path. Priority is to be

assigned to specific tasks that also involve parallel activities to reduce
the equipment downtime and to complete the work within the
scheduled time.
Forced Draft Fan
Mitsubishi
4-1
4.1.2 Departmental Interface/Notification

Departmental communication is essential and interfacing between
departments is to be maintained to avoid any lack of communication
that may arise and adversely affect routine or annual outage
maintenance work.
Prior to commencing preventive maintenance all concerned persons
(shift supervisor, operators, etc.) are to be made aware of the schedule
and the nature of the activities that are to take place.
If it becomes clear that there is a problem or a conflict of interests in the
schedule (e.g. the maintenance schedule interferes with another
groups work, inter departmental works, sub contractors work etc.), this
is to be resolved by mutual agreement between the parties involved.
4.1.3 Isolation of Equipment

It is important that isolations are agreed and valid clearances and work
permits are obtained before any maintenance work is performed. The
isolation boundaries of the particular equipment to be taken under
maintenance are to be clearly identified.
In the case of an electrical isolation the power supply shall be
disconnected and/or the fuses removed. In the case of a mechanical
isolation, the valves or other mechanical means of isolation, at the
isolation boundaries are to be closed and if possible locked closed. The
system within the isolation boundaries is to be vented and
depressurized.
4.1.4 Safety Precautions

Before the commencement of any maintenance work, the person in
charge of the work site is to perform a risk assessment and method
statement for the safe execution of the job scope activities, described
within the work permit.
Risk assessment includes identifying, recognizing and understanding
the potential hazards associated with the work. The method statement
is to illustrate the safe working practices in accordance with the safety
manual and the manufacturers instruction manual to prevent personal
injury and/or equipment damage.
Rev.003
Prior to the commencement of actual work, the person carrying out the
work is to make a safety check based on the above method statement
and also use his own judgment to ensure that the equipment and the
prevailing working conditions are safe.
MM-M02.01
During maintenance work, every employee should follow the safe

working procedures detailed in the method statement.
Forced Draft Fan
Mitsubishi
4-2
4.2
Routine Maintenance
The purpose of routine maintenance is the implementation of the preventive
maintenance program on a day-to-day basis through a planned and correctly
executed inspection.
The routine maintenance activities are very important in that if they are properly
carried out, they will enhance equipment reliability. As a result, good routine
maintenance activities may help in cost reduction in the long run through the
minimization of equipment downtime.
Cleaning is an important and necessary maintenance activity to prevent the
ingress of foreign material. Other major points are as follows: (Summarized
major routine activities are also shown in Table 4-1).
4.2.1 Preparation
a)
Spare parts, Tools and Equipment

It is important to prepare the necessary parts, tools and
equipment before commencing actual work. Routine
maintenance generally requires a standard mechanical toolkit,
consumables, cleaning materials, etc.
Any shortages of these items will affect the maintenance activity
and may delay the schedule. Personal Protective Equipment
(PPE) is necessary for maintenance staff at all times.
Maintenance work area must be barricaded showing the
necessary warning signs.
Upon completion of work, all tools and equipment should be
serviced and stored correctly to ensure availability for further use.
b)
Documentation
Documentation is an important part of any maintenance duty. All
findings should be noted on a comprehensive log sheet, reporting
all aspects of the equipment observed during the routine
inspection.
The data recorded in these documents will be useful in
determining the root cause of equipment failure found during
annual outage/corrective maintenance work.
MM-M02.01
Rev.003
Any abnormalities, if observed, are to be immediately

communicated to the concerned department/personnel for
rectification and are to be detailed in the report and the value
recorded every time.
Forced Draft Fan

Mitsubishi
4-3
4.2.2 Inspection and Maintenance
Take care near rotating machinery, hands, feet, and clothing

can be drawn into machinery. Always check that all guards
are in place before starting any rotating machinery.
No open flames or other source of ignition permitted in fan

area.
Dont come closer around the suction silencer inlet less than
2 m.
CAUTION
Dont open the manhole when fan is running.
Check that instruction is clear when fan is running.
Dont climb on casing when fan is running.
a)
Rotor Assembly
The rotor assembly, consisting of the rotor, the moving blades
and the rotor shaft, etc. is to be monitored for vibration. Vibration
may be generated by several factors. Possible causes of
vibration are an imbalance of the rotor resulting from erosion or
damage to the rotor by foreign materials, or by dust adhering to
the impeller blades.
Another possible cause of vibration could be shaft misalignment.
If the vibration is observed to have increased, but is still within the
limit of 105 m without any other abnormality noticed, the
equipment may continue to be operated under close supervision.
If vibration alarm announced, look over the vibration and incase
of vibration increasing, stop the fan immediately. As well as
vibration, another area that deserves attention is the identification
of any abnormal noise. Any abnormal noise generated should be
investigated to identify the source. If the noise comes from the
flange joints, e.g. high noise created by air leakage from the
packing, operation may be continued, as it has no direct impact
on possible fan failure or operation.
MM-M02.01
Rev.003
However, if any abnormality is observed at the coupling, the

equipment is to be shutdown immediately for rectification of the
problem.
Forced Draft Fan

Mitsubishi
4-4
b)
Bearings
Bearing problems generally result from lubricating oil starvation
and/or excessive vibration. Emphasis is to be given to check the
equipment operating parameters, (e.g. oil supply, oil temperature,
bearing temperature and oil tank levels).
The temperature of the returning lubrication oil from the bearing
is alarm value of 70C. Correct oil flow is to be verified through
the lubricating oil return line oil flow indicator.
Lack of cooling water flow, fouling of oil cooler tubes, presence of
dirt in the lubricating oil, deteriorated bearings may also lead to
an increase in bearing operating temperature.
Entering foreign materials leads to bearing damage. Using
un-recommend oil leads to a poor bearing performance.
c)
Moving Blade Regulating Mechanism

The moving blade regulating mechanism is to be monitored for
smooth operation. Visual inspection of the linkage mechanism is
to be carried out for looseness of pins and links.
Operational availability of blade sticking detector is to be ensured.
If there is any sign of linkage mechanism sticking, the cause
should be eliminated at the earliest opportunity depending upon
the severity of the problem. See Chapter 6 Corrective
maintenance for reference.
CAUTION
Dont come closer to drive unit and moving blade sticking
detector.
d)
Fan Casing
The fan casing is to be checked for leakage. Erosion, abrasion or
cracking may occur in the casing during fan operation. In the
event of air leakage through any part of the casing, external patch
welding work may be undertaken as a temporary measure and
the event should be recorded for inclusion in the annual overhaul
program.
Rev.003
e)
Control/Lubricating Oil System
MM-M02.01
The oil pump is to be monitored for smooth operation, seal

leakage and vibration. Any apparent problem is to be immediately
resolved.
Forced Draft Fan

Mitsubishi
4-5
The condition of the control oil / lube oil filter is to be monitored.

When there is a high differential pressure across a filter the stand
by filter should be placed in service and the defective filter,
should be cleaned or replaced immediately to be an effective
standby.
It is most important to follow the lubricating oil requirements such
as, the frequency of replacement of the lubricating oil as per the
manufacturers instruction or based on the analysis result
received from the laboratory.
Regular visual inspection of the oil condition is recommended,
(e.g. if the color of the oil becomes green/white, it signifies that
water ingress has taken place. Alternately, if the oil gradually
becomes dark, it implies that either overheating or debris/dirt
mixing has taken place).
The tank oil level is to be monitored at frequent intervals. The
system is to be observed for any oil leakage if a gradual decrease
in oil level is noticed.
The oil flow through the return line flow indicator is to be
monitored regularly. If there is an abnormal decrease or increase
in return oil flow, the cause is to be investigated and rectified.
If oil leakage is found, inspect the oil level gauge every time. And
repair them after reducing oil pressure, if it is possible to stop the
fan.
CAUTION
If oil leakage is found, take care not to come close the

leakage point because workers can get oil in the eyes.
Dont go up on the piping not to damage the piping.

The temperature of oil in the tank should be observed on a
routine basis. The temperature should be below 70C.
For further details, please refer to the vendors manual in
Appendix F.
f)
Coupling
MM-M02.01
Rev.003
The fan coupling is to be monitored for any abnormal noise.

Noise would be heard from the coupling if there is any looseness
of the coupling bolts or coupling. Noise is also generated if the
coupling misalignment is beyond permissible limits or if the
coupling rubs the coupling guard.
Forced Draft Fan

Mitsubishi
4-6
TABLE 4-1
No.
Description
Main Bearing
ROUTINE MAINTENANCE CHECKLIST
Major Check Item
Check Method
Check Reference
Vibration
Permanent
instruments
Less than 105 m
Temperature
Permanent
instruments
Not exceeding 70C
Action to be Taken
(if beyond acceptable limit)
Remarks
Recommended
Maintenance
Frequency
Shut down and check for bearing damage and the

rotor assembly for unbalance.
Check and clean the moving blades for any
deposits.
Check and adjust alignment.
Daily
Check for any foreign materials in the lubricating oil

Rotate the rotor assembly by hand and observe for
any rubbing noise.
Replace bearings if the vibration is not decreased
after field balancing.
2
Moving Blade
Regulating
Mechanism
MM-M02.01
Rev.003
Coupling
Casing
Forced Draft Fan

Mitsubishi
Abnormal noise
Audible
No abnormal noise.
Check and replace coupling bolts, etc., if damaged

and then re-check alignment.
Rubbing contact
with the coupling
guard
Visual and
audible
No contact between
the coupling and
coupling guard.
Adjust coupling guard clearance.
Control oil pump

discharge strainer
Visual
Not Clogged
Replace the clogged filter.
Smooth operation
Permanent
instrument
No alarm
Visual and
audible
No apparent air
leakage
Check for any air

leakage
Beware of rotating part

during maintenance
Daily
Daily
Permanent
instruments
Rectify defective regulating mechanism and linkage
mechanism after shut-down if FDF cannot be
controlled.
Tighten bolts or patch weld after shutdown.
Daily
Daily
4-7
Continued from previous page

TABLE 4-1
No.
Description
Lubricating oil
system
Major Check Item Check Method
Oil pressure
Permanent
instrument
Check Reference
Lube oil supply is 0.15

to 0.18 MPa.
Action to be Taken
Remarks
Recommended
Maintenance
Frequency
Check the lube oil pump discharge pressure and by For more details, Please refer
sight glass.
to Vendors Manual.
Check the oil flow into the bearing, pressure control
valve.
Check oil temperature.
Check Oil flow.
MM-M02.01
Rev.003
Check the operation of the stand by pump.

Oil pump bearing
temperature
Touch/ Portable No appreciable

thermometer
temperature rise
Check the cause of temperature rise.
Oil pump shaft oil

leak
Visual
No leak
Replace oil seal
Oil pump shaft

rotating condition
Visual
Audible
No abnormal noise
No abnormal trembling
Investigate and take action to normalize the

condition such as exchange of bearings.
Oil strainer
Permanent
instrument
Not clogged
Color indicator on the
top of the strainer is not
red (replacement) , but
green (normal)
Change over the stand by control oil pump line and

replace the clogged up strainer. (Control oil pump
discharge strainer)
(Control oil discharge

strainer)
Forced Draft Fan

Mitsubishi
Daily
Change over the stand-by strainer and clean the

blocked filter in maintenance filter (lubricating oil
duplex strainer).
4-8
Continued from previous page

TABLE 4-1
No.
Description
Lubricating oil
system (Cont)
Major Check Item Check Method
Oil strainer
Permanent
instrument
Check Reference
Diff. press. Less than

0.1 MPa
(Lubricating oil duplex
strainer)
Level gauge
Oil tank
Oil temperature
Rev.003
Oil cooler water

flow
Action to be Taken
Recommended
Maintenance
Frequency
Change over the stand by control oil pump line and

replace the clogged up strainer. (Control oil pump
discharge strainer)
Change over the stand-by strainer and clean the
blocked filter in maintenance filter (lubricating oil
duplex strainer).
Visual
No leak
Exchange of O-ring
Further tightening
Permanent
instrument
Normal Oil Level
Investigate and top up the oil level.
Permanent
instruments
Not to exceed 70C.
Investigate and take action to reduce the

temperature
Visual,
Rated flow
Investigate and normalize the flow.
Daily
Repair of any leakage of water into the system.
Further details, please refer to

Daily
Vendors manual.
Permanent
Instrument
Visual
Remarks
No leak of water or oil
Further tightening
MM-M02.01
Exchange of packing.
Visual,
Permanent
Instrument
Forced Draft Fan

Mitsubishi
Oil temp. of oil cooler

outlet is not to exceed
70C.
Cooling water check

Disassembly & clean up of cooler.
4-9
Chapter 4
4.3
Annual Outage Maintenance

The purpose of annual outage maintenance is the implementation of a
preventive maintenance program on a yearly basis through a planned and
correctly executed maintenance work program accompanying necessary
inspections. The annual outage maintenance activities are very important in the
sense that if properly undertaken these enhance the life and reliability of
equipment.
Major activities related to annual outage maintenance are as follows:
(Summarized major activities for annual outage maintenance are also shown in
Table 4-2).
4.3.1 Preparation
a)
Parts, Tools and Equipment

Refer to Subsection 4.2.1 a) Spare Parts, Tools and Equipment.
In addition, it will be necessary to identify and request the
provision of any spare part requirements.
Annual outage will, in certain cases, require the use of material
handling equipment.
Unused spare parts are to be returned for correct storage and
used spare parts are to be replenished.
b)
Documentation
Refer to Subsection 4.2.1 b), Documentation.
Records are to be maintained to record information regarding the
spares and consumables used. These records will be used for
future reference and spare parts replenishment.
MM-M02.01
Rev.003
On completion of annual outage maintenance work, the

equipment is to be monitored for correct operation and
maintenance data logging. This will help to determine the correct
intervals of preventive maintenance activities to ensure optimum
plant availability. The correct recording of findings during
inspection will build a valuable document for future reference.
Forced Draft Fan

Mitsubishi
4-10
Chapter 4
4.3.2 Inspection and Maintenance

a)
Rotor Assembly
The rotor assembly is to be checked for erosion, and for the
adhesion of dust that could have occurred during normal
operation of the equipment, either of which could induce severe
rotor imbalance resulting in excessive vibration of the rotating
assembly, and could cause serious equipment damage.
The occurrence of wear and cracking is to be further checked
through a non-destructive testing procedure (e.g. dye penetrant
test, etc.).
The rotor clearances with the respective stationary parts are to
be checked against the tolerances as indicated in Figure 4-1,
FDF Clearance Details. After thorough inspection, if any part is
found to be worn beyond the acceptable limits as specified in the
annual outage maintenance check list table (Table 4-2), the
respective part is to be replaced.
The moving blades are to be operated for full opening and closing
positions to ensure that all moving blades move in unison. The
support bearing of any sticking blade is to be inspected and
replaced if found defective.
The grooves /bosses on the rotor shaft corresponding to the
bearing box oil baffle assemblies on both motor side and fan side
are to be inspected for damage or wear. Minor damage can be
corrected with an oilstone.
b)
Bearings
Replace the fan bearings if they surpass the recommended
replacement period or if they show indications of wear during
operation.
Operation with damaged bearings can have serious
consequences in that it may induce excessive vibration and
bearing temperature problems that may cause subsequent
damage to the shaft.
Rev.003
To maintain the bearings in good condition the lubricating oil in

the tank is to be analyzed for oil properties in a laboratory at
frequent intervals and replaced in its entirety when there is
deterioration in oil quality.
MM-M02.01
Prior to disassembly, the bearing box is to be inspected for any

trace of oil leakage through the shaft. After disassembly, check
the clearance between the oil baffle assemblies and the rotor
shaft.
Forced Draft Fan
Mitsubishi
4-11
Chapter 4
Any damage to the grooves of the rotor shaft and the

corresponding oil baffle assembly on the bearing box end covers
is also to be checked.
Check the tightness of the bearing box fixing bolts. A loose
bearing box may induce vibration which could damage the fan
internals.
c)
Moving Blade Regulating Mechanism

Prior to dismantling, the moving blade regulating mechanism is to
be inspected for any trace of oil leakage from the hydraulic
cylinder and pilot valve head that might have occurred during
normal operation.
The inner surface of the hydraulic cylinder and the outer surface
of the piston are to be checked for any damage, pitting or scratch.
Minor damage can be polished with an oilstone under MHI
supervision. The piston rings and the hydraulic cylinder packings
are to be inspected for damage and replaced with new if found
defective.
The flexible oil hoses connecting the pilot valve are to be
inspected for ageing, damage or cracks. Defective hoses are to
be replaced with new.
Correct tightening of the bolts and nuts for the linkage assembly
and the greasing of the various moving parts is to be performed.
On completion of the maintenance work the linkage assembly is
to be checked for smooth operation with the power cylinder. The
90 movement of the power cylinder lever is to be adjusted for the
moving blade operation range of 40 to + 14.
d)
Casing
The fan casing is to be inspected internally to check for erosion,
wear and cracks, and any previously reported defects are to be
investigated and repaired by patch-welding.
However, if wear or erosion occurs repeatedly in any particular
area, the welding of a wear plate in position should be considered
as a solution to the problem. Checks for corrosion are to be
performed at this time.
MM-M02.01
Rev.003
Any corrosion encountered is to be removed and the resultant

bare metal treated. Any accumulation of debris is to be collected
and removed.
Forced Draft Fan

Mitsubishi
4-12
Chapter 4
e)
Control / Lubricating Oil System

The oil pump components such as casing, gears, bearings, oil
seals, fasteners, etc. are to be inspected for any damage and the
defective components replaced with new.
The control oil filters are to be inspected for any deformation or
damage. If there is any damage to filters, they must be replaced.
The accumulator bladder is to be inspected for ageing, cracks or
rupture. A defective bladder is to be replaced with new. The
pre-charge pressure of the oil accumulator is to be checked and
pressure readjusted using nitrogen gas. A falling pre-charge
pressure is to be investigated and the defective components
replaced.
The lubricating oil cooler is to be inspected for tube damage or
blockage. Hydraulic testing of the cooler is to be conducted and
any leaking tube is to be plugged. Replace the tube bundle set
with a new one if the cooler performance deteriorates after
plugging several tubes.
For further details, please refer to the vendors manual in
Appendix F.
f)
Coupling
MM-M02.01
Rev.003
Coupling alignment checks are to be conducted carefully both

before dismantling and after reassembly, (refer to Appendix D).
Check the coupling bolts, hubs and spacer for damage or wear.
Defective components are to be replaced with new. Check and
confirm the security of the hubs on the respective shafts.
Forced Draft Fan

Mitsubishi
4-13
TABLE 4-2
No.
1
Description
Rotor
1
(inc. shaft* )
Moving
Blades
Major Check
Item
Check
Method
Check
Reference
ANNUAL OUTAGE MAINTENANCE CHECK LIST

Action to be Taken
(if beyond
acceptable limit)
Remarks
Wear, cracks
Visual
No appreciable
wear
No crack
Replace the rotor

Every rotor overhaul
assembly
(4 years)
Repair and rebalance *1 every bearing
overhaul (every 8
years) (if have
spares), 4 years (if
have not spares)
Inner casing
and seal
clearances
Measurement
Clearances are
within specified
criteria (Refer to
Figure 4-1)
Adjust clearance by
adjusting of bearing
box position (using by
shim plate, etc)
Outer casing
clearances
Measurement
Clearances are
within specified
criteria (Refer to
Fig 4-1)
Adjust clearance
Wear, crack
Visual*1,
Measurement
*2
PT check*2
Wear less than

10%
Replace the blades
Inspection Date
Inspector
Results
Every casing overhaul

(4 years)
Adjusting clearance
carried after checking
of correct rotor
assembling.
Blades are to be
replaced as a set.
*1. Every inner
inspection (2 years)
*2. Every rotor
overhaul (4 years)
No crack
Moving Blade Replacement

Bearing
Visual
Not loose (in

caulked
condition)
Tighten the blade

fixing bolts and caulk
N/A
N/A
Replace

(every four years)
MM-M02.01
Rev.003
Axial
movement
Forced Draft Fan

Mitsubishi
4-14
(Continued from previous page)
TABLE 4-2
No.
3
Coupling
Major Check
Item
Check
Method
Check
Reference
Action to be Taken
(if beyond
acceptable limit)
Visual
No defective
parts
Alignment
Measurement
Refer to Appendix Realign within

D
specified criteria
Every coupling
overhaul (4 years)
Rubbing with
the coupling
guard
Visual and
Audible
No contact
between the
coupling and
coupling guard
Adjust the coupling

guard position
Every coupling
overhaul (4 years)
Main Bearing
N/A
N/A
N/A
Replace
Clearance check is
carried out when
replace the bearing.
Recommended to
replace bearing every
8 years (if have
spares), 4 years (if
have not spares)
Bearing box
Seal clearance Measurement

measurement
Clearance are
within specified
criteria (Refer to
Figure 4-1)
Replace

(every 4 years)
Casing
Wear, Cracks
Visual,
Measurement
No appreciable
wear
Repair the casing
Casing to blade
clearance should not
exceed tolerance
limits
Debris
Visual
No debris
Remove debris and

clean the fan casing
inside
Every inner
inspections (2 years)
Inspection Date
Inspector
Results
Every coupling
overhaul (4 years)
MM-M02.01
Replace or repair
Remarks
Deformation,
crack and
damage
Rev.003
Description
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Mitsubishi
4-15
(Continued from previous page)
TABLE 4-2
No.
Major Check
Item
Check
Method
Moving Blade Pilot valve and Measurement

Regulating
sleeve
Mechanism
clearances
Check
Reference
Action to be Taken
(if beyond acceptable
limit)
Remarks
Clearances are Replace the pilot valve

within specified and sleeve
criteria (Refer to
Figure 4-1)
Recommended to
replace Cylinder, Pilot
valve & Sleeve every
8 years. (if have spare
parts, 6 years if have
not spares)
Wear of servo Measurement

cylinder,
sleeve
Clearance are
Replace
within specified
criteria (Refer to
Figure 4-1)

(4 years)
Oil leakage
Visual
No oil leakage
Replace the O-rings

and MV-packing
Every inner inspection

(2 years)
Moving blade
operation
Visual
Smooth
operation
Replace defective
components
Moving blade
adjustment
Visual,
Measurement
Adjust blades
position from
-40 to +14
Adjust connecting rod

length
Corresponding
control drive range is
0 to 100 (0 to 90)
(4 years)
Replacement N/A
of consumable
parts
N/A
Replace

(4 years)
Refer to Appendix H.
Replacement N/A
of consumable
parts (oil hose)
N/A
Replace
Every inner inspection

(2 years)
Refer to Appendix H.
Inspection Date
Inspector
Results
MM-M02.01
Rev.003
Description
Forced Draft Fan

Mitsubishi
4-16
(Continued from previous page
TABLE 4-2
No.
Description
Major Check
Item
Grease up
Linkage
mechanism
Check
Method
Check
Reference

Action to be Taken
(if beyond acceptable
limit)
N/A
N/A
N/A
Every year
Replacement
of consumable N/A
parts
N/A
Replace
Every casing overhaul (4

years)
Refer to Appendix H
No appreciable
Repair the silencer
wear
Silencer
Wear crack
Visual
Control/
Lubricating
Oil System
Oil condition*1
Visual
Replace oil
every annual
outage
maintenance.
N/A
Wear or
damage of oil
pump
3
components*
Visual
No wear or
damage
Replace defective
components
Damage of
control oil
filters*2
Visual
No damage
Replace filter
Accumulator
2
bladder*
Visual
Pressure
gauge
No ageing,
cracks or
damage
Replace bladder
Oil cooler
3
leakage*
Visual
Hydraulic test
No leak
Plug the leaking parts

(packing and O-rings)
Oil cooler
protecting
2
zincs*
Measurement
Their length is
below 1/4
1/3 of the
original length
or not
Replace new one
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
Remarks
Inspection Date
Inspector
Results
Drop of silencer wall

leads to rotor damage.
Every inner inspection (2
years)
For further details, please
refer to Vendors manual.
*1 Interval is every 1
year.
*2 Interval is every 2
years.
*3 Interval Is every 4
years.
4-17
MM-M02.01
Rev.003
Chapter 4
FIGURE 4-1
Forced Draft Fan
Mitsubishi
FDF CLEARANCE DETAILS
4-18
Chapter 5
C h a p t er
5 Disassembly and Reassembly

Disassembly and reassembly are the activities to be conducted when internal parts of
the equipment are required to be accessed. An important part of the activities is the
preparatory work. This should identify the manpower, spare parts and tools that may be
required during the maintenance work. A shortfall of any of these may affect the
schedule and the operational status of the plant.
The major parts of the FDF are the casing, blade pitch control mechanism, bearing and
the blade assembly. Except for the bearing replacement all other disassembly and
reassembly of the FDF parts can be done in site. The rotor removal to a lay down area
is necessary when the bearings are to be replaced as this work is possible only with
shaft in vertical position. The following sections describe the details of disassembly and
reassembly of various parts.
The major steps associated with disassembly and assembly are as follows:
Note
MHI recommends that disassembly and reassembly of FDF is carried out
under MHI supervision only.
5.1
FDF Disassembly and Reassembly

a)
Preparation
MM-M02.01
Rev.003
If FDF disassembly becomes necessary, all associated equipment is to be

mechanically and electrically isolated and an authorized clearance and
work permit shall be in place at the location prior to the commencement of
work. The following points are also to be considered when preparing for
disassembly and assembly:
Forced Draft Fan

Mitsubishi
Have all necessary drawings (assembly drawings, sectional drawings,

spare part details, etc.) and documents (log sheets, field record book,
etc.) ready prior to start of work.
Prepare the necessary handling facilities (e.g. cranes, chain blocks

jacks and supports, etc.) to remove and store the various parts of the
equipment.
Co-ordinate with the I&C Department to remove all the attached

instrumentation such as vibration pick ups, thermocouples and
impulse piping before starting disassembly work.
Move the moving blades to fully closed position before stopping the oil
pumps.
5-1
Chapter 5
Ensure that the electrical breaker must be switched off & locked at
both locations & the key must be retained by the Charge Engineer.
Special tools are listed in Appendix C.
b)
Disassembly
CAUTION
When separating joints and flanges use jacking bolts and
wooden mallets. Never apply force with hammers, chisels or
screwdrivers.
All data is to be recorded during disassembly. During disassembly, make
match marks on adjoining parts for easy identification during reassembly.
The disassembly procedure is described as follows:
Upper Casing Removal:

Check O content inside before entering the fan compartment.

O content should always be >20%.
CAUTION
Use the safety belt when entering inside the casing through
the manhole.
Take precaution against falling.
MM-M02.01
Rev.003
When working inside of the fan, a colleague should be

stationed at the entry point to provide assistance when
required.
Forced Draft Fan

Mitsubishi
Move the moving blades to a fully close position before starting

disassembly of the FDF. Take care not to be close to moving blade
when direction is changing.
Remove the insulation of the flange section of upper halves of the

impeller casing (17) and rear casing (19).
Remove the band for casing (26) provided between rear and diffuser
(upper part only) casings.
5-2
Chapter 5
Remove vertical joint bolts (8) between suction casing (28) and
impeller casing (17) (upper part only).
Remove the horizontal flange bolts and nuts (9, 2&12, 1&11)
connecting upper and lower half of the rear casing (19) (outer side)
and impeller casing (17) (outer side).
Enter the discharge duct through a duct manhole.
Enter the diffuser inner from the manhole diffuser inner casing (29).
Remove the manhole cover for rear casings (22). Please note that
the two halves of the rear inner casing do not have a bolted joint and
have only metal to metal contact.
Enter the suction casing through the suction casing manhole (30).
10 Remove the bolt (16) connection with the impeller inner casing and
intermediate shaft cover. Slide the impeller shaft cover (23) towards
the motor side.
11 Remove the horizontal joint of the impeller inner casing.
12 Thus both the rear and impeller casings can be lifted together. If to be
removed separately, remove the vertical joint bolts and nuts between
the outer impeller casing and the rear casing also.
13 Lift the outer casing along with the connected inner casing.
CAUTION
Rigging and transportation of equipment must be carried out
by authorized persons. Care is to be taken while equipment
weight and center of gravity is to be considered.
CAUTION
Ensure that the moving blades are in the fully closed position.
Removal of rear casing inner casing with moving blades in the
open position leads to damage of the moving blades.
Special care is to be taken when lifting the casing to

prevent damage to the moving blades.
Special care is to be taken when moving blade operates.
MM-M02.01
Rev.003
CAUTION
Forced Draft Fan

Mitsubishi
5-3
Chapter 5
Take care not to drop the part to be lifted while rigging. If the
part drops on equipment the part as well as the equipment will
get damaged.
Dont stand or walk under a lifted object. If the object falls, it

could lead to a fatal or a severe injury.
CAUTION
While rigging, never stand or sit on the object to be lifted.
CAUTION
Rise the upper casing more than 1.8m above from the moving
blade to avoid contact.
14 Clean the inside of the fan casing before disassembly, to prevent the
entry of any foreign material into the bearing box and the servo
cylinder.
Oil Lines Removal:

CAUTION
Remove the oil connections only after depressurizing the system
to atmospheric pressure.
Rev.003
15 Remove the connecting pin (5 of Figure 2-8) and disconnect the pilot
valve (30) of Figure 2-3 from the control drive linkage (For details of
linkage assembly refer to Figure 2-8).
MM-M02.01
16 Remove the control oil inner pipings (flexible hoses) (33) from the pilot
valve (30) of control oil supply, control oil return, pilot leak and oil leak
line.
17 Cover the openings of oil lines immediately with cloth to prevent the
entry of dust.
Forced Draft Fan
Mitsubishi
5-4
Chapter 5
Pilot Valve Removal:

Refer to Figures 2-7 and 5-3.
18 Remove the oil cover for pilot leak (40) from the pilot valve by
withdrawing machine screw (37) and washer (32).
19 Remove the bolts and washer (24 & 31) of cover (10).
20 Slowly withdraw the pilot valve (1) together with the joint (14), the
bearing (6), the scroll (5) and the cover (10).
21 Provide temporary covers for the opening of the servo cylinder cover
(39).
Note
If pilot valve disassembly is to be done follow the steps
below, pilot valve disassemble is carried out at the clean
place (work shop etc.) carefully.
The pilot valve (1) dismantling is done in the following steps:
(i)
Remove the retaining rings (27) on either side of the

scroll (5). Slide the pilot valve (1) with the scroll (5) and
bearing (6).
(ii)
Remove the retaining ring (28) and the bearing (6) from
the scroll (5).
(iii)
Remove the set screw (35) and then the scroll. Remove
the spring pin (34) from the pilot valve shaft.
(iv)
Remove the cover (10) with oil seal (7) and floating ring
(9) from the pilot valve (1).
(v)
Remove the retaining rings (8 & 29) on either side of

cover.
(vi)
Remove the floating ring (9) and oil seal (7) and O ring
(56).
(vii) Remove the bolts (25) and spring washer (33). Discard the
packing (15).
Rev.003
Note :
MM-M02.01
Pilot parts shall be kept in the oil bath after disassembly.
Forced Draft Fan

Mitsubishi
5-5
Chapter 5
Coupling Removal:
Refer to Figure 2-5, 2-11, 5-2 and 5-9.
22 Remove the drive side coupling cover assembly (24 of Figure 2-5).
23 Fix the supporting tools with the impeller inner casing and suction
casing to support the intermediate shaft as shown in Figure 5-9.
24 Install the support bar (turn buckle, washer, plate) to the rotor not to
fall the rotor from the casing and be damage as shown in Figure 5.2.
25 Remove and secure the wire ( 6 of Figure 2-11).
26 Remove the reamer bolts (3 of Figure 2-11) and nuts (5 of Figure
2-11) on the rotor side of the coupling to decouple the fan from the
intermediate shaft.
27 If motor removal is necessary for annual outage maintenance,
remove the bolts (4 of Figure 2-11) and nuts (5 of Figure 2-11) on the
motor side of the coupling to decouple motor from the intermediate
shaft.
Note
As per the design, the intermediate shaft cover can slide
inside the suction inner casing. This arrangement will
provide sufficient space for fixing the intermediate shaft
centering special tool at the fan side impeller inner casing
bottom half. Similarly on the motor side of the intermediate
shaft sufficient space is available for fixing the centering
tool on the suction inner casing bottom half after removal of
coupling cover.
Rotor Assembly & Bearing Removal:

28 Disconnect and remove the lubricating oil supply pipe from the
bearing box upper, and cover the openings immediately with clean
clothes to prevent the entry of foreign material.
29 Drain the oil from the bearing box by removing the oil bath drain plug
(27) and reinstall the plug in position.
30 Remove the temperature measuring instrument and vibration pickups
from the bearing box assembly.
Rev.003
31 Install eye bolts in the threaded holes provided on the bearing box
and the rotor.
MM-M02.01
32 Connect the appropriate lifting gear to the lugs provided on the

bearing box and the rotor wheel.
Forced Draft Fan

Mitsubishi
5-6
Chapter 5
33 Remove the bolts (16 and 35), Remove the taper pins (23) in position
and parallel pin (36).
34 Remove the bearing box upper half (1) and oil baffle assembly (38 &
39) upper half.
35 Adjust the slings to facilitate the vertical lifting of the combined rotor
and the bearing assembly.
36 After removing the rotor and bearing assembly, cover the lower half of
the bearing box by a sheet and plate.
Note
To prevent the plate from moving, secure using a wire.
Note
Please note that the bearing box is assembled in two halves.
The removal of the bearing box lower half may be judiciously
decided. If the bearing box removal is necessary, the taper
pins need not be removed from its position on the lower half.
Please note that the taper pins are spot welded to the
eccentric bush (9) which is inserted and caulked to the base.
The rotor is normally removed by removing the upper half of
the bearing box as described in this section.
CAUTION
Special care is to be taken when lifting the rotor assembly with
blades to prevent damage to the moving blades and the bearing
box.
CAUTION
Dont sit or stand on a rotor being removed.
Dont go near a rotor being lifted.
MM-M02.01
Rev.003
37 Slowly lift up the rotor assembly with the bearing and transport it to
the lay down area.
Forced Draft Fan

Mitsubishi
5-7
Chapter 5
c)
Reassembly
The reassembly procedure is carried out in the reverse sequence to that
for disassembling. Install all parts in the same positions they were
removed from, referring to the match marks and checking that the
clearances are maintained as specified in Figure 4-1. All contact surfaces
are to be cleaned before starting reassembly and all gaskets are to be
replaced.
Note
Before the installing of the rotor assembly, oil flushing is
finished.
If disassembly of rotor has been performed, ensure that the rotor is

reassembled and ready for installation as per section 5.2.
If disassembly of the bearing box has been performed, ensure that

the bearing is reassembled and ready for installation as per section
5.3.
Visually inspect the fan casings to ensure that they are clean and free
of foreign material before rotor installation.
Lift the rotor assembly slightly to ensure that the load is correctly
balanced.
Take care not to drop the lifted object while rigging. If the
lifting part falls, it will damage the stationary equipment.
Never stand under an object being lifted. This could cause a

fatal or a severe injury.
CAUTION
Rev.003
CAUTION
MM-M02.01
Ensure that the moving blades are in the fully closed position.
Special care is to be taken when lowering the casing to

prevent damage to the moving blades, and bearings.
Forced Draft Fan

Mitsubishi
5-8
Chapter 5
Refer to Figures 2-9.

5
Transport the rotor assembly with the bearing, blades and servo
cylinder to the fan casing.
Using a suitable lifting device lower the assembly slowly into the
casing.
Take care of the proper seating of the bearing on its assigned support.
Install the support bar (turn buckle, washer, plate) to the rotor, not to
fall the rotor from the casing as shown in Figure 5-2.
Remove the lifting equipment.
CAUTION
Dont sit or stand on a rotor being removed.
10 Install the upper half of bearing box and oil baffle assembly (38&39).
Note
Install the bolt (35) and parallel pin (36) before installing
bearing box cover to bearing box. If you dont keep this
assembling process, it leads to oil leakage.
11 Check the bearing clearances between the shaft and bearing box
cover (radial & axial) with those specified in Figure 4-1.
12 Accordingly, fix the spherical keys (37) with shims (45) Figure 5-6 to
the bearing keep (26), for adjusting the clearances specified in Figure
4-1.
13 Fix the bearing body stopper (3).
14 Measure and check the tolerances between the bearing box and the
spherical key which is top side specified in Figure 4-1.
15 Install the bearing box taper pins (23) and parallel pin (36) in its
original place on the upper half of bearing box and install bolts (16 &
35).
16 Tighten the fixing bolts (16&17) to the required torque.
Rev.003
17 Replace the consumable parts (packing etc.) and install all the
bearing box oil supply lines.
MM-M02.01
18 Install the vibration monitors and the temperature measuring elements

on to the bearing box.
19 Reassemble the coupling as per section 5.5 and remove the rotor
support bar and coupling support.
Forced Draft Fan
Mitsubishi
5-9
Chapter 5
CAUTION
Be careful not to place your finger between the upper and the
lower casings during reassembly.
CAUTION
Ensure the moving blade full close position before the
installing the casing.
20 Measure the radial clearance of the impeller with the outer casings the
impeller and the rear inner casing.
21 Adjust the inner casings to achieve the clearance as indicated in
Figure 4-1.
CAUTION
Not enough adjusting of clearance leads to contact of rotation
parts and stationary parts.
After completing maintenance in the oil lines of the bearing
box/oil unit, do complete oil flushing using eye protection.
Note
If pilot valve disassembly is done, it is reassembled as
follows, pilot valve reassemble is carried out at the clean
place (work shop, etc.) carefully.
The pilot valve (1) reassembly is done in the following steps:
(i) Reassemble the pilot valve with the bearing (6), scroll (5),
cover (10) in the reverse order to disassembly. Note before
reassembly replaced the consumable parts ( oil seal (7),
floating ring (9), bearing (6), O ring and retaining ring.)
Rev.003
(ii) Install the cover (10) with oil seal (7) and floating ring (9)
to the pilot valve (1)
MM-M02.01
(iii) Install the scroll (5) with the spring pin (34) and the set
screw (35). Note before the installing the scroll, set the
retaining ring (27) of joint side (14).
Forced Draft Fan

Mitsubishi
5-10
Chapter 5
(iv) Install the retaining rings (27) on the either side of the
scroll (5).
(v) Install the retaining rings (28) and the bearing (6).
(vi) Provide packing (15) onto the pilot valve head, install the
joint (14) and secure it with spring washers (33) and bolts
(25).
Refer to Figure 20-7 and 5-3
22 Remove the temporary cover provided for the opening of the servo
cylinder cover (39).
CAUTION
Installing the pilot to the rotor should be carried out in the
casing.
23 Smear lubricating oil over the pilot valve assembly and slowly insert
the pilot valve assembly on the servo cylinder cover (39).
24 Tighten the bolts (24) with washers (31).
25 Install the oil cover for pilot leak (40) and secure it with spring washer
(32) and screw (37).
26 Connect the control oil inner piping (Figure 2-3 (33)) to the pilot valve
(1) to the control oil supply, control oil return, pilot leak, oil leak line.
Oil Lines Reassembly and Fan Normalization:

CAUTION
Wear the eye protection in oil line assembly working.
Special care is to be taken with oil hose, do not bend.
Rev.003
27 Start the oil pump, operate the moving blades

28 Check for the correct lubricating oil flow.
MM-M02.01
29 Check and confirm that the system is free from any control and
lubricating oil leakage.
Forced Draft Fan

Mitsubishi
5-11
Chapter 5
30 Ensure the moving blade stroke from 0% to 100% (from - 40 to +

14) as per the procedure described below.
(i)
Start the oil pump and check that the oil pressure is between 1.0
and 1.5 MPa.
(ii) Locate the reference moving blade manually at the - 40 position

stamped on the rotor.
(iii) Move slowly the pilot valve by manual to the +14 position, and
ensure the moving blade stroking smoothly.
(iv) Return the pilot valve by manual to the - 40 position stamped on
the rotor.
Note
Ensuring of moving blade stroking may carried out before
rotor installing (after rotor reassembly) by using N2 gas.
CAUTION
Before the moving blade operates, check that the support bar
(refer figure 5-2) is removed from the rotor.
Be careful when adjusting the moving blade. It could result in
the breaking of the equipment.
Special care is to be taken when the moving blade operate.
(Like pinching in the moving blade)
31 After ensuring the moving blade stroke, readjust that control oil
pressure is between 5.39 MPa and 5.88 MPa.
32 Connect the linkage mechanism to the pilot valve joint (14).
33 Adjust and calibrate the moving blade stroke from 0% to 100% (from 40 to + 14) as per the procedure described below.
(i)
Start the oil pump and check that the oil pressure is between 1.0
5.39 MPa and 5.88 MPa..
MM-M02.01
Rev.003
(ii) Operate the control drive locally from 0% to 100% and ensure
that the moving blade pitch indicator is moved form fully closed
positions to fully open positions and stamped on the rotor is
moved from - 40 to + 14. Adjust the linkage mechanism if
required.
Forced Draft Fan

Mitsubishi
5-12
Chapter 5
(iii) Operate the control drive from the DCS from 0% to 100% to
confirm that the moving blade pitch angle is in requirement with
the DCS indication. Adjust the linkage mechanism if required.
(iv) Record the angle of stamped on the rotor and moving blade pitch
indicator on side of outer casing for every 20% DCS demand.
CAUTION
Be careful when adjusting the moving blade. It could result in
the breaking of the equipment.
Special care is to be taken when the moving blade operate.
(Like pinching in the moving blade)

34 Install the upper halves of the impeller casing (17) and rear casings
(19) by using a special tool (guide tool).
Note
Check no oil leakage from the bearing box etc. before installing the
upper halves of casings.
35 Measure the impeller axial clearance at the upper half of the rear and
impeller inner casings.
36 Measure the radial clearance between the blades and the rear inner
casing in the open position as indicated in Figure 4-1.
37 Grind the rear inner casing to achieve a clearance within the tolerance,
if required.
CAUTION
Dont operate the moving blade while installing the casing.
Do not machine the moving blades to achieve the required

clearance.
38 Adjust the inner casings to achieve clearance as indicated in Figure
4-1.
Rev.003
CAUTION
MM-M02.01
Not enough adjusting of clearance leads to contact of rotation

parts and stationary parts.
Forced Draft Fan

Mitsubishi
5-13
Chapter 5
39 Install the joint bolts (1 & 11, 2 & 12, 9, 10 & 13) as required for the
casings (horizontal and vertical) and tighten them after achieving the
required tolerances.
40 Slide the intermediate shaft cover (23) to the rotor side and install the
bolts (16) and spring washer (14).
41 Install the drive side coupling cover assy (24).
42 Install the band for casing (26) provided over the rear upper casing.
CAUTION
Before entering through a manhole inside the casing,
establish a temporary platform/grating.
43 Replace or renew the insulation around the casing joints.
CAUTION
Keep a sufficient distance while fixing the upper and lower
casing. If you are trapped between the casings, it could result
in a fatal or a serious injury.
44 After a final inspection inside the casings, close all the manhole (22,
29 and 30 of Figure 2-5).
CAUTION
Before closing the manholes/access doors to the FDF, an
inspection must be carried out to ensure that no material has
been left inside. If some thing remains in the fan, it could lead
to serious fan damage.
Before you close the manhole, check that all persons have
left.
MM-M02.01
Rev.003
45 Return the fan into service.
Forced Draft Fan

Mitsubishi
5-14
Chapter-5
L
10400
610 1890
E
TRU TH N
R
NO
2860
690825
600
3000
PLANT
NORTH
3B
2100
700
700
11001000
NOTES :
11001000
600
1300
BOILER FRONT
1. THIS DRAWING SHOWS THE DISASSEMBLY PROCEDURE.

PLEASE REFER TO EACH EQUIPMENT O&M FOR DETAIL.
1200
FLOOR(FL+7500)
MOTORIZED
GEARED
TROLLEY
CHAIN BLOCK
20ton
MONORAIL
L
10400
5900
690 3810
2. OVERHAUL BY THIS DRAWING MAKES FAN(A) AND

FAN(B) SYMMETRICAL TO BOILER CENTER.
8200
4500
min.
1380
10400
3040
2860
A2
1550
A3
1A
BCP
FL+9400
MSL+14400
UPPER
CASING
18ton
2870
A1
FL+3600
MSL+8600
OIL UNIT
A4
4. PARTS WEIGHT
UPPER CASING
ROTOR
AIR HOUSING
MOTOR
12400
CARRIER
(SUPPLIED BY
OWNER)
10000
8800
18800
15t TRUCK
(SUPPLIED BY
OWNER)
UPPER CASING
18ton
CARRIER
(SUPPLIED BY
OWNER)
3B
SUBMERSIBLE SCRUBBER CONVEYOR
SECTION A-A
97000-3015 : GENERAL ARRANGEMENT

(SIDE VIEW)
A3 A4
D3 D4
10000
OVERHAUL OF UPPER CASING

A5
MOTOR
13.2ton
A1 A2
FORCED DRAFT
FAN 3A
3470 1860
3810
3040
FLAME DETECTOR & FURNACE

TV CAMERA COOLING AIR FAN(AC)
LOCAL
PANEL
SILENCER
OIL UNIT
MOTORIZED
HOIST
15ton
FLAME DETECTOR & FURNACE

TV CAMERA COOLING AIR FAN(DC)
LOCAL
PANEL
8800
OIL UNIT
FORCED DRAFT
FAN 3B
C2
UPPER CASING
18ton
A1
3470
1860
B1 B2
4500
B3 B4
8200
SECTION B-B
600
C3
7A
1000
C4
MONORAIL FOR MOTOR

BOS FL+9400(I-450x175)
5900
10400
10000
ROTOR
5ton
AIR HOUSING
1.3ton
A2
FL+3600
MSL+8600
18800
R8000
MOTORIZED
GEARED
TROLLEY
CHAIN BLOCK
20ton
MAX.
4420
1500
min.
1380
5A
FL+9400
MSL+14400
min
1650
3000
3000
FURNACE
3000
C1
Rev.003
2860
B
R8000
8800
690
18800
D1 D2
BOILER
MM-M02.01
: 3.3ton
: 3ton
: 1.3ton
: 13.2ton
5. REFERENCE DWG. No.

1FL(FL+0)
-
5A
3B
600
3. OVERHAUL PROCEDURE
UPPER CASING (REF. TO SECTION A-A,B-B)
1) LIFT UP THE UPPER CASING FROM THE
POSITION A1 TO A2 WITH MOTORIZED
GEARED TROLLEY.
2) MOVE THE UPPER CASING FROM THE
POSITION A2 TO A3 AND TURN IT.
3) PUT DOWN THE UPPER CASING ON THE
CARRIER FROM THE POSITION A3 TO A4 .
4) MOVE THE UPPER CASING FROM THE
POSITION A5 TO TEMPORARY STORAGE AREA.
690
10t TRUCK
(SUPPLIED BY
825 OWNER)
3810
3040
2860
MONORAIL FOR ROTOR

BOS FL+9400(I-450x175)
PLAN
MPTD-3-0040-1
Forced Draft Fan

Mitsubishi
FIGURE 5-1A
OVERHAUL PLAN FOR FDF 1/2
5-15
Chapter-5
690
3810
3040
2860
NOTES :
MOTORIZED
GEARED
TROLLEY
CHAIN BLOCK
20ton
1800
B1
B4
MOTORIZED
HOIST
15ton
FL+3600
MSL+8600
3. OVERHAUL PROCEDURE
ROTOR (REF. TO SECTION A-A)
1) LIFT UP THE ROTOR FROM THE POSITION
POSITION B1 TO B2 WITH MOTORIZED
GEARED TROLLEY.
2) MOVE THE ROTOR FROM THE POSITION
B2 TO B3 .
3) PUT DOWN THE ROTOR ON THE TRUCK FROM
THE POSITION B3 TO B4 .
min.
1380
MOTORIZED
GEARED
TROLLEY
CHAIN BLOCK
20ton
A2
UPPER CASING
18ton
MAX.
4420
B2
B3
FL+9400
MSL+14400
min
1650
FL+9400
MSL+14400
2620
ROTOR
5ton
TEMPORARY
RACK
(SUPPLIED BY
OWNER)
2. OVERHAUL BY THIS DRAWING MAKES FAN(A) AND

FAN(B) SYMMETRICAL TO BOILER CENTER.
min.
1380
MONORAIL
1. THIS DRAWING SHOWS THE DISASSEMBLY PROCEDURE.

PLEASE REFER TO EACH EQUIPMENT O&M FOR DETAIL.
SILENCER
A1
FL+3600
MSL+8600
AIR HOUSING (REF. TO SECTION C-C)

1) LIFT UP THE AIR HOUSING FROM THE
POSITION C1 TO C2 WITH MOTORIZED HOIST.
2) MOVE THE AIR HOUSING FROM THE
POSITION C2 TO C3 AND TURN IT.
3) PUT DOWN THE AIR HOUSING ON THE
TRUCK FROM THE POSITION C3 TO C4 .
OIL UNIT
3470
10t TRUCK
(SUPPLIED BY
OWNER)
10000
8800
1860
4500
5900
18800
10400
3B
5A
8200
MOTOR (REF. TO SECTION B-B,C-C)

1) LIFT UP THE MOTOR FROM THE POSITION
POSITION D1 TO D2 WITH MOTORIZED HOIST.
2) MOVE THE MOTOR FROM THE POSITION
D2 TO D3 .
3) PUT DOWN THE MOTOR ON THE TRUCK FROM
THE POSITION D3 TO D4 .
SECTION A-A
SECTION B-B
OVERHAUL OF ROTOR
4. PARTS WEIGHT
UPPER CASING
ROTOR
AIR HOUSING
MOTOR
MONORAIL
MOTORIZED
HOIST
15ton
MOTORIZED
HOIST
15ton
SILENCER
: 3.3ton
: 3ton
: 1.3ton
: 13.2ton
5. REFERENCE DWG. No.

1FL(FL+0)
-
SILENCER

(SIDE VIEW)
min.
1650
MOTOR
13.2ton
D3
C1
D2
1000
950
3200
C2
C3
AIR
HOUSING
1.3ton
FL+9400
MSL+14400
FL+3600
MSL+8600
D1
C4
MONORAIL
3150
min.
1650
FL+9400
MSL+14400
FL+3600
MSL+8600
D4
10t TRUCK
(SUPPLIED BY
OWNER)
10000
15t TRUCK
(SUPPLIED BY
OWNER)
8800
18800
8800
18800
5A
3B
10000
5A
3B
SECTION C-C
OVERHAUL OF AIR HOUSING
OVERHAUL OF MOTOR
MM-M02.01
Rev.003
SECTION C-C
MPTD-3-0040-2
Forced Draft Fan

Mitsubishi
FIGURE 5-1B
OVERHAUL PLAN FOR FDF 2/2
5-16
Chapter-5
ITEM
1
2
3
DESCRIPTION
SUPPORT BAR
TAPERED WASHER
CENTERING TOOL ASSY
NOTE:
TAKE CARE OF SETTING DIRECTION OF TAPERED WASHER
CL OF M/B
3
2
MM-M02.01
Rev.003
A-A
MPTD-3-1195
FIGURE 5-2
Forced Draft Fan
Mitsubishi
SUPPORTING PROCEDURE OF FDF ROTOR
5-17
Chapter 5
5.2
Rotor Disassembly and Reassembly

a)
Preparation
If the removal of the moving blades and the hydraulic cylinder in FDF rotor
becomes necessary, all associated equipment is to be mechanically and
electrically isolated and an authorized work permit and valid isolation
certificate shall be in place prior to the commencement of the work. The
outer casings are to be removed and FDF rotor is disassembled as per
section along with blades, bearing and hydraulic cylinder as per section
5.1. The following points are also to be considered while preparing for
disassembly and reassembly of FDF rotor:
Have all necessary drawings and documents (log sheets, field record
book, etc.) ready prior to the start of work.

equipment.
CAUTION
Wear safety glasses to protect your eyes during the inspection /
maintenance.
CAUTION
Always use the Personnel Protective Equipment (PPE) during
maintenance.
Note
Ensure that the rotor is set on the maintenance stand. See Figure
5-5.
b)
Disassembly
Rev.003
All data is to be recorded during the disassembly of each part. During

disassembly, make match marks on the adjoining parts for reference
during the reassembly. The disassembly procedure is described as
follows after the disassembly of the FD fan as described under the section
5.1.
MM-M02.01
Disassembly of Moving Blades and Hydraulic Cylinder:

Refer to Figures 2-6, and 5-4.
1
Forced Draft Fan
Mitsubishi
Match mark the blades with their installed locations.
5-18
Chapter 5
Note
Figure 5-4 shows the exploded view of the rotor consisting of
blades, crank arm and sliding piece for crank arm.
Remove the set screw (22) and the U-nut (23) and then unscrew the
nut for blade support (4) by using a special tool (spanner) for nut for
M/B and place it down inside the rotor.
Lightly tap and remove the moving blade support bearing (36) and
place it inside the rotor wheel above the nut for blade support (4).
Slowly pull the moving blade (1) with the Teflon ring (15).
Refer to Figures 2-7 and 5-3

5
Remove the bolts (26) and then remove the servo cylinder cover
assembly (39) with pilot sleeve (2).
Remove the bolts (22) and washer (30), and pull up the pilot sleeve
(2) with blade (4) and cover (3).
Note
The pilot sleeve shall be kept in the oil bath together with pilot
valve.
The sleeve (2) dismantling is done in the following steps:

(i)
Remove the cover (3) by unscrewing the bolts (23).
(ii) Remove the blade (4) by unscrewing the screw (36). Remove the
washer (32).
8
Discard the O-rings (16~21).
Remove the set screws (48) and then unscrew the nut for piston (43)
(using special tool) from the fan shaft.
10 Remove the piston (42) with the help of special tools (draw out tool,
guide bar & nut). Dismantle the piston rings (46) from the piston.
Refer to Figures 2-6 & 5-4.
11 Remove the fixing bolts (20) and the side ring of actuator disk (6) from
the rotor (8).
Rev.003
12 Remove the crank arm (2) as an assembly outwards from the rotor (8)
after removing the retaining ring (28).
MM-M02.01
13 Remove the bush (17) from the rotor (8).
Forced Draft Fan

Mitsubishi
5-19
Chapter 5
14 Remove the sliding piece with its bush inside (37) from crank arm (2)
after releasing the retaining ring (29). The exceptional one number
sliding piece for crank arm (with pin) (38) and its bushes (18) are also
removed easily after removing the retaining ring (28).
Refer to Figure 2-7 and 5-3
15 Withdraw the servo cylinder (52) axially. Unscrew the set screw (55)
and then remove the bush (54) from the cylinder assembly.
16 Remove the hexagon socket head bolt (49) and then the plate for MV
packing (41). Discard the packing (45).
17 Remove the parallel pin (50) and then pull out the sleeve (44). Discard
the O-ring (51). (if replace the sleeve)
Note
In the case of disassembly and replacement of the sleeve (44) for
its wearing, apply heat to its.
c)
Reassembly
of disassembly. Install all parts in the same positions they were removed
from, referring to the match marks and checking that the clearances are
maintained as specified in Figure 4-1, FDF Clearance Details. All removed
gaskets and O-rings are to be discarded and replaced with new ones.
Reassembly of Moving Blades and Servo Cylinder:

Refer to Figures 2-7, and 5-3.
1
Insert the O-ring (51) and then the sleeve (44) onto the fan shaft and
secure it with the parallel pin (50).
Insert the bush (54) inside the servo cylinder (52) and fix it to the
cylinder with the set screw (55)..
Insert the servo cylinder assembly (52) onto the sleeve (44).
Apply grease to the lip of the MV-packing (45), then insert the
MV-packing into the slot ensuring that the lip is facing towards the
piston by using special tools (guide ring, tightening plate, inset ring,
guide bar & nut).
Note
Rev.003
Be sure to assemble the MV-Packing in the direction indicated

in the drawing. If assembled in reverse direction, it may cause oil
MM-M02.01
leakage. Additional details on MV-packing insertion are provided

in Appendix F.
Forced Draft Fan

Mitsubishi
5-20
Chapter 5
Note
Use the MV-packing insert tool supplied as a special tool for the
installation of MV-packing.
Note
Ensure that the plate for MV packing (41) does not protrude from
the servo cylinder face.
Install and gradually tighten the plate for MV packing (41) to the servo
cylinder (52) by bolts (49).
Install the retaining ring (47) after final tightening of the plate for MV
packing (41).
Note
Control match marks of moving blades and rotor. Apply specified
torque on each bolt using torque wrench. Apply lubricant to the
threads and seating surfaces when tightening the bolts.
CAUTION
Do not use lubricants containing Molybdenum Base such as
Molycoat.
If a moving blade is sticking after re-assembly, confirm the
clearance and check for any crack.
7
Install bush for crank arm (17) on the rotor (8). The seam of this bush
is to be located at 45 towards motor side and with respect to the
direction of rotation of the rotor.
Install all the 13 numbers of the crank arms (2) onto the inner side
holes in the rotor (8). Lock the crank arms with the retaining ring (28).
Install all the 13 numbers of sliding pieces for crank arm (37) and
secure them in the position with the crank arm (2) by retaining ring
(29). The oil less bush for sliding piece (41) is to be located on center
line and 180 opposite to the direction of rotation of rotor.
MM-M02.01
Rev.003
10 Install the crank arm (3) on the rotor (8). Lock the crank arms for
blade shaft with the retaining ring (28). Install sliding piece for crank
arm (with pin) (38) in the hole of the servo cylinder (35).
Forced Draft Fan

Mitsubishi
5-21
Chapter 5
Note
Install the moving blade such that the leading edge of the moving
blade is toward the suction casing and the trailing edge toward the
rear casing.

11 Install the Teflon ring (15) onto the top of the holes in the outer
periphery in the rotor (8).
12 Insert the moving blade with (1) through the holes in the outer
periphery of rotor (8) into the involute spline hole of the crank arm
(2/3).
Note
Moving blade weight measurement should be carried out. Decide
the blade arrangement by calculating the balancing by blade
weights. Allowable unbalance is to be adjusted during a balancing
procedure by additional weights.
13 While inserting the blade in the rotor (8), install the moving blade
support bearing (36) along with the nut for moving blade shaft (4)
through the bottom side of the outer periphery holes in the rotor (8)
before locating the moving blade bottom into the spline hole of crank
arm (2/3) .
14 Ensure the position of the moving blades shaft end on the spline hole
in the crank arm (3).
15 Secure the moving blade support bearing (36) with the nut for moving
blade shaft (4) by using a special tool (spanner).
CAUTION
Do not machine the moving blades to achieve the required
clearance.
16 While tightening the nut for moving blade shaft (4), ensure that
moving blades are free to rotate by hand.
Rev.003
17 Follow the same procedure to install the remaining moving blades.

MM-M02.01
18 Replace the piston rings (46) on the piston, if they were removed
during disassembly, then insert the piston (42) through the rotor shaft
by using the special tool and locate it butting to the sleeve (44).
Forced Draft Fan

Mitsubishi
5-22
Chapter 5
19 Install the nut for piston (43) and secure it by using special tool
(spanner) and set screws (48).
20 Install the side ring of actuator disk (6) such that the hole matches the
pin of the sliding piece with pin (38).
21 Tighten the bolts (20) to the specified torque as per Appendix A.
22 Install the sleeve (57) onto the inside surface of the servo cylinder
cover (39) if removed during disassembly and secure it by set screw
(58).
23 Reassemble the pilot sleeve (2) with blade (4) and the cover (3) after
replacing the defective parts and the O-ring (17).
24 Install new O-rings (18 & 19) in their respective slots in the sleeve (57)
and install the sleeve assembly onto the servo cylinder cover (39) and
secure it with bolts and washers (22&30).
25 Install and tighten the set screw (22) and the U-nut (23) to the
required torque as per Appendix A.
26 Install the servo cylinder cover (39) on to the servo cylinder (52) with
bolts (26).
27 Check the 0% position of moving blade angle and cylinder position.
28 Verify that the blade root clearance is within the specified tolerance.
Adjust the axial clearance of the moving blade, if necessary.
29 Ensure that the balance weights (32) are in their original locations on
the rotor wheel and the screws (33) are not loose.
Note
Ensure the moving blade stroke by using N2 gas etc, if possible.
After ensuring the moving blade stroking, pilot valve shall be kept
MM-M02.01
Rev.003
in the oil bath till installing the rotor to the casing.
Forced Draft Fan

Mitsubishi
5-23
Chapter-5
ITEM
PILOT VALVE
PILOT SLEEVE
COVER
SCROLL
7
8
OIL SEAL
RETAINING RING
FLOATING RING
COVER
PLUG
10
13
18
19
20
O RING
O RING
BOLT
24
25
27
28
29
31
RETAINING RING
WASHER
SPRING WASHER
33
SET SCREW
36
PARALLEL PIN
CYLINDER COVER
DRAIN COVER
43
45
MM-M02.01
Rev.003
54
55
FIGURE 5-3
Forced Draft Fan
Mitsubishi
MB HYDRAULIC MECHANISM - EXPLODED VIEW
5-24
Chapter-5
MM-M02.01
Rev.003
FIGURE 5-4
Forced Draft Fan
Mitsubishi
MB MECHANISM EXPLODED VIEW
5-25
Chapter 5
APPROX. 72kg
APPROX. 20kg
2
1
CL OF M/B
MAINTENANCE STAND
MM-M02.01
Rev.003
MPTD-4-1194
FIGURE 5-5 SUPPORTING PROCEDURE FOR ROTOR DISASSEMBLY & REASSEMBLY
Forced Draft Fan

Mitsubishi
5-26
Chapter 5
5.3
Bearing Disassembly and Reassembly

a)
Preparation
If bearing disassembly becomes necessary, all associated equipment is to
be mechanically and electrically isolated and an authorized work permit
and valid isolation certificate is to be in place prior to the commencement
of work. The outer casings are to be removed and rotor is shifted to lay
down area. Please refer to section 5.1 for the details. The following points
are also to be considered when preparing for disassembly and
reassembly:

equipment.
Remove all instrumentation such as vibration pick ups and

thermometers before starting the disassembly work.
Prepare a suitable fixture to support the rotor assembly vertically

when carrying out the disassembly and reassembly of the bearings.
CAUTION
Be careful not to put your finger in between the upper and the
lower halves during reassembly.
CAUTION
Always ensure that the wire slings, shackles, eyebolts and lifting
gear are certified to the Safe Working Load (SWL).
CAUTION
MM-M02.01
Rev.003
Do not stand under a lifted object. This could lead to a fatal / or a

severe injury.
Forced Draft Fan

Mitsubishi
5-27
Chapter 5
b)
Disassembly
The disassembly of the bearing box shall be carried out after the removal
of the moving blades to prevent any damage to the blades during handling.
If the servo cylinder does not require any disassembly, take due care to
position the pilot valve clear off the ground while supporting the rotor
assembly vertically.
during reassembly. The disassembly procedure is described as follows:
Note
Protect the openings on the rotor with proper covers to prevent the
entry of dust.
CAUTION
Rigging and transportation of equipment must be carried out by
authorized persons. Care is to be taken where equipment weight
and center of gravity is to be considered.
CAUTION
After the maintenance of oil lines of the bearing box/oil unit,
ensure that oil flushing of the lines is carried out to remove any
entrapped foreign matters.
1
Support the rotor assembly vertically (Refer Figure 5-7).
CAUTION
Special care is to be taken to prevent the outer race of radial
bearing and the bush from falling.
2
Remove the set screw (24) and nut (14).
Remove the driving coupling half. (Need with burner)
Rev.003
CAUTION
MM-M02.01
If remove the driving coupling half, apply with burner (propane

gas)
Forced Draft Fan

Mitsubishi
5-28
Chapter 5
Remove the sleeve for bearing (13).

5
Match mark the plate for bearing keep (4) with the bearing keep (26)
and remove the 90o elbow (22) with the connecting pipe from the
plate.
Loosen and remove the bolts (20) and washers (21) securing the
plate for bearing keep (4) with bearing body. Carefully hold the plate
to avoid its fall. Also the adjusting ring bottom half (6) may fall from its
position along with the plate for bearing keep. Carefully remove the
adjusting ring bottom half.
Remove the upper half of the adjusting ring (5) from the outer race of
the radial bearing by removing the stopper bolt (7).
Slide the plate for the bearing keep (4) down the shaft. This plate can
be removed only after removal of the bearings.
Using a puller if required to remove the bearing keep (26) with its
spherical keys (37) and shims from the bearing assembly. Remove
the O-rings (10) from inside the bearing keep.
10 Remove both the thrust ball bearings (28) and the outer spacers (34)
with O-rings (32). Discard the O-rings. Use puller and heat as
required.
11 The inner spacers (33) for the above bearings are secured.
12 Remove the radial bearing (29) at the fan side. Use puller and heat as
required.
13 The plate for bearing keep (4) can be withdrawn now from the shaft
(40).
c)
Reassembly
for disassembly. Install all parts in the same positions they were removed
maintained as specified in Figure 4-1, Clearance Drawing for FDF. The
used gaskets and O-rings are to be discarded and replaced with new
ones.
Rev.003

Clean the bearing seating surfaces on the rotor. Minor surface
corrections shall be carried out using an oilstone.
MM-M02.01
Forced Draft Fan

Mitsubishi
5-29
Chapter 5
Note
The reassembly of the bearings and the coupling hub on the
rotor are to be carried out in the vertical position.
Insert the plate for bearing keep (4) on to the shaft (40).
Install the fan side radial bearing (with rollers and outer race) onto the
inner race.
Heat the inner race of the radial bearing (29) in an oil bath to about
100C until the inner race diameter increases by 0.1 mm.
Transfer the inner race of radial bearing (29) from the oil bath or oven
and install it on the rotor so that the inner race abuts the step provided
on the rotor.
A weight or pressure should be applied to the inner race to ensure it

remains in contact with the step on the rotor as it cools.
Include the bearing inner spacer (33) and outer spacer (34)on to the
radial bearing.
Insert the O-rings (32) on to the spacer outer.
Follow the heating procedure explained in Step 4.
10 Heat the thrust bearing (28) and insert it onto the rotor so that it abuts
firmly onto the inner spacer and then on to the roller bearing.
11 After the ball bearing has cooled to ambient temperature, insert the
next set of inner spacer (33) into the outer spacer (34).
12 Insert O-rings (32) on to the outer spacer.
13 Follow the same heating procedure to install the motor side thrust ball
bearing (28).
14 Fix the upper adjusting ring (5) on to the outer race of the radial
bearing (29).
Note
Adjustable rings must be adjusted so as to maintain 0-0.05mm
axial clearance between the bearing box, bearing box cover
and adjusting ring. Bearing must be closely fitted to the
bearing box.
15 Place a new O-ring (31) on the bearing keep (26).

Rev.003
16 Insert the bearing keep (26) onto the set of bearings.
MM-M02.01
17 Locate the plate for bearing keep (4) in its position matching the
marks provided during disassembly. Along with the plate locate the
lower adjusting ring (6) also.
Forced Draft Fan

Mitsubishi
5-30
Chapter-5
35
29
44
43
32
Rev.003
MM-M02.01
MPTD-3-0473
FIGURE 5-6
Forced Draft Fan
Mitsubishi
BEARING BOX - EXPLODED VIEW
5-31
Chapter 5

NUT
COUPLING
KEY
SLEEVE OF BEARING
O RING
THRUST BEARING (DE)

BEARING INNER SPACER
O RING
O RING
THRUST BEARING
BEARING OUTER SPACER
O RING
O RING
RADIAL BEARING (NDE)
SET SCREW
ROTOR
MM-M02.01
Rev.003
ROTOR STAND
MPTD-4-0554
FIGURE 5-7 SUPPORTNG PROCEDURE FOR BEARING REMOVAL

Forced Draft Fan
Mitsubishi
5-32
Chapter 5
5.4
Moving Blade Regulating Mechanism Linkage Disassembly

and Reassembly
a)
Preparation
Movable blade regulating mechanism linkage is not normally included in
overhaul maintenance but if it should ever be necessary, the procedure is
as follows. All associated equipment is to be mechanically and electrically
isolated and an authorized work permit and valid isolation certificate shall
be in place prior to the commencement of work. The outer casings are to
be removed. Please refer to section 5.1 for the details. The following
points are also to be considered while preparing for disassembly and
reassembly:
Prepare the necessary handling facilities (e.g. chain blocks, slings,

etc.) to remove and store the various parts of the equipment.
Dont replace parts in a running unit. Also, when replacing a

new component, be careful the replacement does not fall on the
impeller wheel assembly.
Prepare a temporary platform / grating to work on the defective

cylinder during maintenance.
Dont move the drive unit. Special care is to be taken when

replacing the parts.
b)
Disassembly
MM-M02.01
Rev.003

during the reassembly. The disassembly procedure is described as
follows:
Forced Draft Fan
Mitsubishi
5-33
Chapter 5
Remove the split pins (19), pins (5) and nuts (11), thus disconnecting
the linkage assembly both from the pilot valve end and the control
drive unit. Remove the spherical bearings (6) and lever (1). While
removing the pin from the lever, take care not to drop the spherical
bearing (6) or the lever (1).
Note
If control drive unit is to be removed from the foundation during
disassembly, loosen the bolts on the stand on the control drive .
For disassembly and reassembly of the control drive, please refer
to the respective I&C vendor manual.
Remove the bolt (36), the bush (39) and the U nut and split pin
(37&38) thus disconnecting the power cylinder unit from the linkage
mechanism. While removing the connections on the lever (31) arrest
the detective cylinder assembly so that it does not fall of and cause
damage or injury to persons.
Remove the taper pin (21&22), U-nuts (24&25) and set screws
(18&26).
Remove the levers (30&31) from the operating shaft (28) and remove
the piece (4).
Remove the spring pin (23) and the pointer (29).
Remove the dust cover (32).
Remove the bolts (9), washers (12) and nuts (13); loosen set screws
(34) on both ends.
Remove the sleeve (33). Remove the ball bearing units (7&8) secured
to the operating shaft support (42).
Remove the taper pin (20), bolts (10) and nuts (11).
10 Remove the stand for scale plate (2) together with scale plate (3) from
the operating shaft support (42).
11 Withdraw the operating shaft (28) axially from outside the rear casing
(40).
c)
Reassembly
MM-M02.01
Rev.003

maintained as specified.
Forced Draft Fan

Mitsubishi
5-34
Chapter 5

1
Clean the operating shaft (28) and insert it through the operating shaft
support (42) from outside rear casing.
Locate the shaft in the same position as it occupied before

disassembly.
Locate the scale plate stand (2) on the operating shaft support (42)
flange with taper pin (20).
Secure the scale plate stand (2) by bolts (10) and washers (15).
Pack the ball bearing units (7&8) at both ends with lubricating grease
and insert it through the operating shaft (28).
Install the sleeve (33) with set screw (34) on both ends of the shaft
inside the bearings.
Secure the ball bearing units (7&8) to the operating shaft support (42)
flange with bolts (9), washers (12), (13).
Install the dust protective cover (32).
Install the scale pointer (29) and secure it to the operating shaft by the
spring pin (23).
10 Insert the piece (4) then insert the lever (30) onto the operating shaft
(28) from inside the rear inner casing (41).
11 Install the taper pin (21) and the U-nut (24).
12 Set the lever (30) in line with the pilot valve axis.
13 Install and tighten the set screws (18) after finalizing the lever
position.
14 Install the spherical bearings (6) into the apertures provided on the
lever (1),
15 Install the lever (1) and secure it with pins (5) and nuts (11) on both
ends of the lever.
16 Insert the split pins (19).
17 Insert the lever (31) onto the operating shaft (28) from outside the rear
housing.
Rev.003
18 Install the taper pin (22) and the U-nut (25).
MM-M02.01
19 Set the lever (31) in line with the actuator lever axis.
20 Install and tighten the set screw (26) after finalizing the lever position.
Forced Draft Fan

Mitsubishi
5-35
Chapter 5
21 Connect the lever (31) to the actuator linkage assembly by installing

the bolt (36), nut (37) and split pin (38).
22 Ensure the direction of detective cylinder assembly (27) as shown in
the Figure 5-8 before connecting the lever (31).
23 Start the control oil pump and check the blade operation from 0% to
100% by manually operating the actuator carefully.
24 Carryout any minor adjustments by altering the length of the lever (31)
and/or the blade sticking detector linkage assembly to achieve the full
range of blade operation.
25 Loosen the spring pin (23) and adjust the pointer (29) to match the
blade position of 0% to 100%.
MM-M02.01
Rev.003
26 Tighten the spring pin after final adjustment.
Forced Draft Fan

Mitsubishi
5-36
Chapter-5
ITEM
10
13
16
17
38
20
MM-M02.01
Rev.003
27
FIGURE 5-8
Forced Draft Fan
Mitsubishi
MB REGULATING LINKAGE MECHANISM EXPLODED VIEW

5-37
Chapter 5
5.5
Coupling Disassembly and Reassembly

a)
Preparation
If FDF coupling disassembly becomes necessary, all associated
equipment is to be mechanically and electrically isolated and an
authorized work permit and valid isolation certificate is to be in place prior
to the commencement of work. The outer casings are to be removed.
Please refer to section 5.1 for the details. The following points are also to
be considered when preparing for disassembly and reassembly:
b)
book, etc.) ready prior to the start of the work.
Prepare the necessary handling facilities (e.g. chain blocks, slings,

etc.) to remove and store the various parts of the equipment.
Disassembly
during reassembly. The disassembly procedure is described as follows:
1
Thoroughly clean the surrounding area and the suction casing before
commencement of the work.
Refer to Figure 2-5 and proceed as follows

2
Remove the coupling cover (24) provided outside of the suction

casing at the drive end.
Enter through the suction inner casing manhole (30) and slide the
intermediate shaft cover (23) from the suction inner casing side (28).
Refer to Figure 2-11 and proceed as follows;

4
Support the intermediate shaft (7 of Figure 2-11) suitably using the

supporting tools on both ends as shown in Figure 5-9.
Note
As per the design, the intermediate shaft cover can slide
inside the suction inner casing. This arrangement will provide
sufficient space for fixing the intermediate shaft supporting
special tool at the fan side. Further, the suction inner casing is
supported by the suction casing. After removing the coupling
Rev.003
cover the second supporting tool can be fixed on the other

end of the intermediate shaft towards the motor side.
MM-M02.01
24 Remove the coupling reamer bolts (4) and nuts (5) from the coupling
flange at the motor side securing the motor coupling (1) and the
coupling spacer (2).
Forced Draft Fan
Mitsubishi
5-38
Chapter 5
Note
Leave one coupling reamer bolt and nut in position (preferably at
the bottom hole) to prevent the spacer from falling during
removal. Loosen this bolt and nut to provide a gap for the removal
of the element and the washers.
c)
Gently tap and rotate the spacer (2) with respect to the remaining
coupling bolt.
Support the coupling spacer (2) suitably and remove the last coupling
bolt (3) and nut (5) from the coupling between the coupling spacer (2)
and the intermediate shaft (7).
Remove all the reamer bolts and nuts from the fan rotor coupling
flange.
If further disassembly is required, i.e. removal of coupling hub, use

the special tool to withdraw the hub from the shaft.
Reassembly
MM-M02.01
Rev.003

maintained as specified. Refer to Figures 2-11 and 4-1.
Forced Draft Fan

Mitsubishi
Ensure that intermediate shaft (7 of Figure2-11) is supported by

supporting tool.
Check the shaft and the internal surface of the hub and remove any
scratches or blemishes on the surface.
Check the shaft key and the key ways to ensure that the surfaces are
smooth.
Insert the key into the shaft key way and then into the hub key way to
confirm the fit.
Measure the outside diameter of the shaft and the bore of the hub,
and record these values.
Clean the shaft and the hub. Insert the key into shaft key way. Heat
the hub in an oil bath to approximately 100C and fit the hub onto the
shaft.
Fix the reamer bolts (3&4 of Figure 2-11) on the fan side coupling.
Verify run out by rotation of the fan shaft. After the verification tighten
the coupling bolts and nuts to the specified torque.
Remove the intermediate shaft supporting tool on the fan side.
5-39
Chapter 5
Check the intermediate shaft level by placing a spirit level on the fan
side of the intermediate shaft machined surface.
10 Check that the intermediate shaft to motor shaft coupling alignment is

within the specified criteria (refer to Appendix D).
11 Make preparations for fixing the coupling reamer bolts (3 & 4 of Figure
2-11) with spacer (2 of Figure 2-11) on the motor side. Tighten the
coupling bolts and nuts to the specified torque.
12 Remove the intermediate shaft supporting tool on motor sides.
13 Install the intermediate shaft cover on the fan side and the coupling
cover on the motor side.
MM-M02.01
Rev.003
14 Remove the tools and tackles from inside the suction casing.
Forced Draft Fan

Mitsubishi
5-40
Chapter 5
IMPELLER CASING(INNER)
INTERMDIATE
SHAFT COVER
SLIDE
MOTOR SIDE
INTERMEDIATE SHAFT
CL OF FAN
50
20
180
(
2
B
10
B-B
6
A-A
ITEM
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
JOINT
ADJUSTABLE BOLT
PIN
BEARING
RETAINING RING
BOLT,NUT
BOLT
SUPPORTING PLATE
SUPPORTING PLATE
SUPPORTING PLATE
MM-M02.01
Rev.003
MPTD-4-0556
FIGURE 5-9
Forced Draft Fan
Mitsubishi
CENTERING TOOL ASSEMBLY FOR INTERMEDIATE SHAFT
5-41
Chapter-6
C h a p t er
6 Corrective Maintenance
Corrective maintenance is the repair or replacement work undertaken for sudden failure of
any part or component of the equipment. Though a well planned preventive maintenance
program tries to minimize the probability of occurrence of sudden failure of equipment,
provision for attending these unscheduled maintenance requirements is to be made.
Corrective maintenance work is to be given priority depending on the seriousness of the
problem faced and the impact on plant operations. The schedule for repair of any
equipment should be carefully planned to keep outage time to a minimum.
During such repair or replacement work, an inspection is to be carefully conducted to
determine why the equipment or component has failed. Good corrective maintenance
requires, not only the quick restoration of the failed equipment back into service but also
demands every effort to identify and record the root cause of the failure. The inspection
results can be of significant help in exploring the exact reason for the failure. The findings,
along with possible rectification proposals, are to be used as a feedback to update the
preventive maintenance procedures.
6.1
Prerequisites
The necessary prerequisites for the corrective maintenance of the FDF are as
follows:
a)
Scheduling
Unlike preventive maintenance, scheduling activity only starts after failure of
the equipment. Depending on the severity of the problem, the importance of
the service provided by the failed equipment and availability of manpower to
attend to the problem, a contingency schedule is to be prepared to solve the
problem at the earliest opportunity. The schedule should clearly indicate the
critical path activity and assign the priority for different parallel activities.
Finally, once the schedule is agreed, strict adherence to it is to be maintained
to ensure timely completion of the maintenance activity.
b)
Departmental Interface/Notification
Refer to Section 4.1.2, Departmental Interface/Notification.
Isolation of Equipment
Refer to Section 4.1.3, Isolation of Equipment.
d)
MM-M02.01
Rev.003
c)
Safety Precautions
Refer to Section 4.1.4, Safety Precautions.
Forced Draft Fan

Mitsubishi
6-1
Chapter-6
6.2
Preparation
a)
Parts, Tools and Equipment

Refer to Subsection 4.2.1 a), Parts, Tools and Equipment.
b)
Documentation
Refer to Subsection 4.2.1 b), Documentation.
6.3
Troubleshooting
MM-M02.01
Rev.003
This section provides information about carrying out troubleshooting and servicing
for the FDF, pertaining to mechanical maintenance staff. Tables of Faults, Possible
Causes and Remedies have been provided to assist in troubleshooting by qualified
users. If any new kind of problem is encountered which is not listed in the following
table, contact the manufacturer for assistance.
Forced Draft Fan

Mitsubishi
6-2
Chapter-6
TABLE 6-1
Fault
Vibration
TROUBLESHOOTING FORCED DRAFT FAN

Possible Cause
Remedy
Lubricating oil supply flow/pressure low
Check oil flow in sight glass/adjust

pressure control valve setting
Bearing damaged
Replace bearings
Unbalance of rotor wheel and rotor shaft

due to attached foreign material or
misalignment
Perform field balancing
Bearing fixing bolts loose
Tighten the fixing bolts
Coupling deformation
Replace the damaged coupling

components and realign the fan and
motor
Inadequate lube oil flow
Check oil flow/pressure
Excessive oil temperature
Check and adjust cooling water supply

Clean the oil cooler
Ingress of debris
Check and rectify the cause for debris

ingress
Suction starvation of the lube oil pump
Changeover to the standby pump. Check

the suction filter
Foreign material inside the fan

casing/duct
Check and remove as necessary

material
Air leakage from the shaft seal or casing

flanged joints or cracks developed in
casing/ducting
Check for wear/cracking and repair

Check and replace gasket, if necessary
Contact of rotating parts with stationary

parts
Stop the fan and carry out internal

inspection to check the clearances
Damage of hydraulic cylinder parts
Repair or replace the damaged parts.

(Take record of difference in routine or
annual outage maintenance.)
Seizure of moving blade support bearing
Replace support bearing
Misalignment of linkage/levers
Correct & adjust the alignment
Failure of oil pump
Repair or replace
Malfunction of relief valve
Readjust or replace relief valve
Strainer plugged
Clean or replace strainer
Excessive pilot valve clearance
Replace pilot valve to have proper

clearance
Control/lubricating oil
pressure high
Malfunction of relief valve
Readjust or replace relief valve
leakage
O-ring failure in pilot valve
Replace O-rings
Excessive lube oil flow
Check and adjust oil flow
Excessive labyrinth seal clearance
Adjust seal clearance
Bearing temperature
high
Abnormal noise
Moving blade sticking
MM-M02.01
Rev.003
pressure low
Forced Draft Fan

Mitsubishi
6-3
Chapter-7
Recommended Lubrication
C h a p t er
7 R ec om m e nde d L ubr i cat i on

FD FAN RECOMMENDED LUBRICATION
MM-M02.01
Rev.003
TABLE 7-1
Forced Draft Fan

Mitsubishi
7-1
Appendix A
A p p en d i x
A Torque Chart
TABLE A-1
Description
TORQUE CHART
Bolt size
Quantity
Torque
Remarks
Bolt (for operating plate)
M16
16
147 N-m
Bolt (for cylinder cover assembly)
M16
12
147 N-m
Set screws and U nut (nut for M/B

shaft)
M10
14
21 N-m
Note: Perform the following steps in sequence:

Apply lubricants to the threads and seating surfaces when tightening bolts.
Do not use lubricant containing molybdenum when tightening bolts.
Tighten bolts in sequence art 120o intervals.
In the first stage, evenly tighten with 30% of the specified torque.
In the second stage, evenly tighten with 70% of the specified torque.
In the third stage, tighten with the specified torque.
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
A-1
Appendix B
A p p en d i x
MM-M02.01
Rev.003
B Spare Parts
Forced Draft Fan

Mitsubishi
B-1
Appendix B
RECOMMENDED LIST OF STRATEGIC SPARE PARTS (OFF SHORE, ONE YEAR)
MM-M02.01
Rev.003
TABLE B-1
Forced Draft Fan

Mitsubishi
B-2
Appendix B
RECOMMENDED LIST OF STRATEGIC SPARE PARTS (OFF SHORE, STRATEGIC)
MM-M02.01
Rev.003
TABLE B-2
Forced Draft Fan

Mitsubishi
B-3
Appendix C
A p p en d i x
MM-M02.01
Rev.003
C Special Tools
Forced Draft Fan

Mitsubishi
C-1
Appendix C
TABLE C-1
Eqt. ID *
(Note 1)
PJ No.
RG
RG
RG
RG
03HLB01AN1
03HLB01AN1
03HLB01AN1
03HLB01AN1
Tool ID
1-1
1-2
1-3
1-4
Special Tool Name/

Description
SUPPORTING TOOL
SUPPORTING TOOL
SUPPORTING TOOL
JOINT BAR
ASSEMBLY
Name of Eqt. for

which special
tools used
FDF
FDF
FDF
FDF
Suppliers
ID No. (Note 2)
B07100-0002001-001
B07100-0002001-002
B07100-0002001-003
B07100-0002001-004
FDF SPECIAL TOOL LIST (1 OF 7)

Total Qty.
Supplied for
Plant
2 SET
2 SET
2 SET
10 SET
Purpose
FOR
INTERMEDIATE
SHAFT
FOR
INTERMEDIATE
SHAFT
FOR
INTERMEDIATE
SHAFT
FOR
SUPPORTING
TOOL
Ref. Instruction /
Doc/DwgsNote # 3
N29-10M-7093
N29-10M-7093
N29-10M-7093
N29-10M-7093
Outline View &

Dimensions (Note # 4)
Weight
Remarks
11.5 kg
ASSEMBLING PARTS
- ADJUSTING BOLTS:
M30 (2PC)
SPECIAL TOOLS SHALL BE
USED UNDER MHI
SUPERVISION
5.3 kg
ASSEMBLING PARTS
- ADJUSTING BOLTS:
M30 (1PC)
USED UNDER MHI
SUPERVISION
27.8 kg
ASSEMBLING PARTS
- ADJUSTING BOLTS:
M30 (2PC)
USED UNDER MHI
SUPERVISION
1.13 kg
ASSEMBLING PARTS
- PIN : 5 PCS
- BEARING: NAST 15R
(5 PC)
- RETAINING RING:15
(5PC)
USED UNDER MHI
SUPERVISION
RG
03HLB01AN1
1-5
BOLT NUT M16x45
FDF
B07100-0002001-005
12 SET
FOR
SUPPORTING
TOOL
N29-10M-7093
0.141 kg

USED UNDER MHI
SUPERVISION
RG
03HLB01AN1
1-6
BOLT M12x55
FDF
B07100-0002001-006
FOR
SUPPORTING
TOOL
N29-10M-7093
0.068 kg

USED UNDER MHI
SUPERVISION
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
C-2
Appendix C
TABLE C-1
Eqt. ID *
(Note 1)
PJ No.
RG
RG
03HLB01AN1
03HLB01AN1
Tool ID
3-1
Special Tool Name/

Description
SPANNER
INSERT PIECE
Name of Eqt. for

which special
tools used
Suppliers
ID No. (Note 2)
FDF
B07100-0002002-001
FDF
B07100-0002003-001

Total Qty.
Supplied for
Plant
Purpose
1 SET
FOR M/B
FASTENING
NUT
FOR MOVING
BLADE ARM
BUSH
FOR MOVING
BLADE ARM
BUSH
Ref. Instruction /
Doc/DwgsNote # 3
Outline View &

Weight
Remarks
1.1 kg

USED UNDER MHI
SUPERVISION
1.06 kg

USED UNDER MHI
SUPERVISION
0.48 kg

USED UNDER MHI
SUPERVISION
N29-10M-7093
RG
03HLB01AN1
3-2
PLATE
FDF
RG
10
03HLB01AN1
3-3
BOLT
FDF
B07100-0002003-003
FOR MOVING
BLADE ARM
BUSH
0.10 kg

USED UNDER MHI
SUPERVISION
RG
11
03HLB01AN1
3-4
WIRE BAND
FDF
B07100-0002003-004
2 SET
FOR MOVING
BLADE ARM
BUSH
0.05 kg

USED UNDER MHI
SUPERVISION
RG
12
03HLB01AN1
4-1
GUIDE RING
FDF
B07100-0002004-001
FOR MV
PACKING
N29-10M-7093
2.7 kg

USED UNDER MHI
SUPERVISION
MM-M02.01
Rev.003
B07100-0002003-002
Forced Draft Fan

Mitsubishi
C-3
Appendix C
TABLE C-1
Eqt. ID *
(Note 1)
PJ No.
RG
Tool ID
Special Tool Name/

Description
Name of Eqt. for

which special
tools used
Suppliers
ID No. (Note 2)
13
03HLB01AN1
4-2
TIGHTENING PLATE
FDF
B07100-0002004-002

Total Qty.
Supplied for
Plant
Purpose
FOR MV
PACKING
Ref. Instruction /
Doc/DwgsNote # 3
Outline View &

Weight
Remarks
N29-10M-7093
2.4kg

USED UNDER MHI
SUPERVISION
RG
14
03HLB01AN1
4-3
INSERT RING
FDF
B07100-0002004-003
FOR MV
PACKING
N29-10M-7093
3.4kg

USED UNDER MHI
SUPERVISION
RG
15
03HLB01AN1
4-4
GUIDE BAR & NUT

M10
FDF
B07100-0002004-004
3 SET
FOR MV
PACKING
N29-10M-7093
3.65 kg

USED UNDER MHI
SUPERVISION
RG
16
03HLB01AN1
SPANNER
FDF
B07100-0002005-001
1 SET
FOR NUT OF
PISTON
N29-10M-7093
3.0 kg

USED UNDER MHI
SUPERVISION
RG
17
03HLB01AN1
6-1
DRAW OUT TOOL
FDF
B07100-0002006-001
1 SET
FOR PISTON
N29-10M-7093
3.8 kg

USED UNDER MHI
SUPERVISION
6-2
GUIDE BAR &

NUTM16
FDF
B07100-0002006-002
0.26 kg

USED UNDER MHI
SUPERVISION
RG
18
03HLB01AN1
2 SET
FOR PISTON
N29-10M-7093
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
C-4
Appendix C
TABLE C-1
Eqt. ID *
(Note 1)
PJ No.
RG
Tool ID
Special Tool Name/

Description
Name of Eqt. for

which special
tools used
Suppliers
ID No. (Note 2)
13
03HLB01AN1
4-2
TIGHTENING PLATE
FDF
B07100-0002004-002

Total Qty.
Supplied for
Plant
Purpose
FOR MV
PACKING
Ref. Instruction /
Doc/DwgsNote # 3
Outline View &

Weight
Remarks
N29-10M-7093
2.4kg

USED UNDER MHI
SUPERVISION
RG
14
03HLB01AN1
4-3
INSERT RING
FDF
B07100-0002004-003
FOR MV
PACKING
N29-10M-7093
3.4kg

USED UNDER MHI
SUPERVISION
RG
15
03HLB01AN1
4-4
GUIDE BAR & NUT

M10
FDF
B07100-0002004-004
3 SET
FOR MV
PACKING
N29-10M-7093
3.65kg

USED UNDER MHI
SUPERVISION
RG
16
03HLB01AN1
SPANNER
FDF
B07100-0002005-005
1 SET
FOR NUT OF
PISTON
N29-10M-7093
3.0kg

USED UNDER MHI
SUPERVISION
RG
17
03HLB01AN1
6-1
DRAW OUT TOOL
FDF
B07100-0002006-001
1 SET
FOR PISTON
N29-10M-7093
3.8kg

USED UNDER MHI
SUPERVISION
6-2
GUIDE BAR &

NUTM16
FDF
B07100-0002006-002
0.26kg

USED UNDER MHI
SUPERVISION
RG
18
03HLB01AN1
2 SET
FOR PISTON
N29-10M-7093
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
C-5
Appendix C
TABLE C-1
Eqt. ID *
(Note 1)
PJ No.
RG
Tool ID
Special Tool Name/

Description
Name of Eqt. for

which special
tools used
Suppliers
ID No. (Note 2)
FOR BOLT
19
03HLB01AN1
SOCKET WRENCH
FDF
B07100-0002007-001
Total Qty.
Supplied for
Plant
Purpose
Ref. Instruction /
Doc/DwgsNote # 3
Outline View &

Weight
Remarks
N29-10M-7093
1.74kg

USED UNDER MHI
SUPERVISION
RG
20
03HLB01AN1
8-1
SPECIAL EYE BOLT
FDF
B07100-0002008-001
FOR ROTOR
2.8kg

USED UNDER MHI
SUPERVISION
RG
21
03HLB01AN1
8-2
SPECIAL EYE BOLT
FDF
B07100-0002008-002
FOR ROTOR
1.2kg

USED UNDER MHI
SUPERVISION
RG
22
03HLB01AN1
9-1
GUIDE TOOL
FDF
B07100-0002009-001
FOR CASING
2.59kg

USED UNDER MHI
SUPERVISION
RG
23
03HLB01AN1
9-2
NUT M20
FDF
B07100-0002009-002
12
FOR CASING
0.059kg

USED UNDER MHI
SUPERVISION
5500 QLE-N
MM-M02.01
Rev.003
RG
24
03HLB01AN1
10
TORQUE WRENCH
FDF
B07100-0002010-001
1 SET
FOR BOLT
5.2 Kg

USED UNDER MHI
SUPERVISION
MPD-4-0579
Forced Draft Fan

Mitsubishi
C-6
Appendix C
TABLE C-1
Eqt. ID *
(Note 1)
PJ No.
RG
Tool ID
Special Tool Name/

Description
25
03HLB01AN1
11
MAINTENANCE
STAND
Name of Eqt. for

which special
tools used
Suppliers
ID No. (Note 2)

Total Qty.
Supplied for
Plant
Purpose
FDF
B07100-0002011-001
1 SET
FOR ROTOR
ASSEMBLY
Ref. Instruction /
Doc/DwgsNote # 3
Outline View &

Weight
Remarks
N29-10M-7093
353kg

USED UNDER MHI
SUPERVISION
RG
26
03HLB01AN1
12-1
TURN BUCKLE
FDF
B07100-0002012-001
6 SET
ROTOR
SUPPORT
N29-10M-7093
3.75kg
RG
27
03HLB01AN1
12-2
PLATE
FDF
B07100-0002012-002
ROTOR
SUPPORT
N29-10M-7093
0.06kg
ROTOR
SUPPORT
N29-10M-7093
0.15kg
ROTOR
SUPPORT
0.48kg
RG
28
03HLB01AN1
12-3
WASHER
FDF
B07100-0002012-003
RG
29
03HLB01AN1
13-1
GAS CHARGING
3-WAY VALVE
(M3-G02)
FDF
B07100-0002013-001
MHI INTERNAL REMARKS.

THESE TOOLS ARE
SUPPLIED WITH CASING
ASSEMBLY. AFTER FDF
INSTALLATION. THESE
TOOLS MUST BE STORED
WITH OTHER SPECIAL
TOOLS IN THE TOOL BOX,
TO USE THESE TOOLS IN
ASSEMBLING AND
DISASSEMBLING OF THE
OVERHAUL.
USED UNDER MHI
SUPERVISION.

USED UNDER MHI
SUPERVISION
STORE IN THE TOOL BOX

FOR ACCUMULATOR.
RG
30
03HLB01AN1
13-2
HOSE (H210-L02)
FDF
B07100-0002013-002
FOR
ACCUMULATOR
0.64kg

USED UNDER MHI
SUPERVISION
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
C-7
Appendix C
TABLE C-1
Eqt. ID *
(Note 1)
PJ No.
RG
31
03HLB01AN1
Tool ID
13-3
Special Tool Name/

Description
PRESSURE GAUGE
Name of Eqt. for

which special
tools used
FDF
Suppliers
ID No. (Note 2)
B07100-0002013-003

Total Qty.
Supplied for
Plant
Purpose
FOR
ACCUMULATOR
Ref. Instruction /
Doc/DwgsNote # 3
Outline View &

Weight
Remarks

FOR ACCUMULATOR.
-
0.18kg

USED UNDER MHI
SUPERVISION

FOR ACCUMULATOR.
RG
32
03HLB01AN1
13-4
ADAPTOR (AD-23)
FDF
B07100-0002013-004
FOR
ACCUMULATOR
0.18kg
RG
33
03HLB01AN1
13-5
CAP NUT WRENCH

(TWH81)
FDF
B07100-0002013-005
FOR
ACCUMULATOR
1.4kg

USED UNDER MHI
SUPERVISION
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
C-8
Appendix D
A p p en d i x
D Coupling Alignment
The following basic alignment procedure is suitable for most motor to driven machine couplings,
however, for certain types of coupling reference should be made to the manufacturers
instructions.
Peripheral Alignment
(Using a Dial Test Indicator (DTI)).
Match mark the coupling halves.
With both match marks at the top:

Check DTI reading at zero.
Turn both shafts 90, check DTI reading at 90.
Turn both shafts a further 90, check DTI reading at 180.
Turn both shafts a further 90, check DTI reading at 270.
Turn both shafts to zero, recheck DTI reading at zero.
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
D-1
Appendix D
Axial Alignment
An inside micrometer or a tapered gap gauge can be used dependent upon the size of the gap
between the coupling faces. This example uses an inside micrometer.
Ensure both match marks at the top:
1
With shafts stationary, measure a, b, c, d.
Turn both shafts 180 (match marks at the bottom).
With shafts stationary, measure c, d, a, b.
From the readings obtained, adjustments can be made to the liners (shims) installed under the
feet of the driving/driven equipment. Allowable tolerances are as follows:
Flexible Couplings
Rigid Couplings
Peripheral
0.05 mm
Peripheral
0.05 mm
Axial
0.05 mm
Axial
0.05 mm
However, the Flexible Coupling supplier, Daido Precision Industries Ltd, have mentioned the
following specific installation acceptance criteria:
MM-M02.01
Rev.003
Form Flex Coupling
Forced Draft Fan

Mitsubishi
Maximum End Float:
3.1 mm (0.10)
Maximum Lateral Misalignment:
31.8 mm (0.50)
D-2
Appendix E
A p p en d i x
MM-M02.01
Rev.003
E Applicable Vendor Drawings
Forced Draft Fans

Mitsubishi
E-1
MM-M02.01
Rev.003
Appendix E
MPTD-3-0474
Forced Draft Fan

Mitsubishi
FIGURE E-1
FORCED DRAFT FAN OUTLINE DRAWING
E-2
MM-M02.01
Rev.003
Appendix E
MPTD-3-0475
Forced Draft Fans

Mitsubishi
FIGURE E-2
FORCED DRAFT FAN SECTIONAL DRAWING
E-3
MM-M02.01
Rev.003
Appendix E
MPTD-3-0477
Forced Draft Fan

Mitsubishi
FIGURE E-3
FDF LUBRICANT & CONTROL OIL SYSTEM P & ID
E-4
MM-M02.01
Rev.003
Appendix E
MPTD-3-0477
Forced Draft Fan

Mitsubishi
FIGURE E-4
FDF-A LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 1/2
E-5
MM-M02.01
Rev.003
Appendix E
MPTD-3-1198
Forced Draft Fan

Mitsubishi
FIGURE E-5
FDF-A LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 2/2
E-6
MM-M02.01
Rev.003
Appendix E
MPTD-3-1199
Forced Draft Fan

Mitsubishi
FIGURE E-6
FDF-B LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 1/2
E-7
MM-M02.01
Rev.003
Appendix E
MPTD-3-1200
Forced Draft Fan

Mitsubishi
FIGURE E-7
FDF-B LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 2/2
E-8
Appendix F
A p p en d i x
MM-M02.01
Rev.003
F MV PACKING INSERTION
Forced Draft Fan

Mitsubishi
F-1
Appendix F
BOLT
HYDRAULIC CYLINDER
RETAINING RING
1
TO REPLACE THE MV PACKING,
REMOVE THE BOLT, THE RETAINING
RING AND THE STOPPER PLATE.
REMOVE THE OLD PACKING.
MV PACKING
STOPPER PLATE FOR MV PACKING
INSERT THE GUIDE BARS AND

THE GUIDE CYLINDER.
INSERT THE INNER ADAPTER,

INSERT THE MV PACKING,
INSERT THE RUBBER PACKING,
LOCATE THE INSERT RING.
GUIDE BAR
GUIDE BAR
GUIDE CYLINDER
INSERT RING
RUBBER PACKING
INNER ADAPTER
MV PACKING
LOCATE THE TEMPORARY

STOPPER PLATE EVENLY TIGHTEN
THE NUTS. GENTLY PUSH THE
INSERT RING AND THE PACKING
RINGS INTO THE HYDRAULIC
CYLINDER.
WHEN PACKINGS ARE INSERTED

REMOVE THE TEMPORARY
STOPPER PLATE, THE GUIDE BAR
AND THE INSERT RING, INSERT THE
OUTER ADAPTER, THE ORIGINAL
STOPPER PLATE, THE RETAINING
RING, AND THE BOLTS, TIGHTEN
THE BOLTS.
BOLT
STOPPER PLATE
HYDRAULIC CYLINDER
RETAINING RING
STOPPER PLATE
MM-M02.01
Rev.003
RUBBER PACKING
OUTER ADAPTER
NOTE:
SPECIAL TOOLS FOR THIS PROCEDURE ITEM
ARE IN SPECIAL TOOLS LIST, APPENDIX C.
RUBBER PACKING
INNER ADAPTER
MV PACKING
MPTD-4-1196
FIGURE F-1
Forced Draft Fan
Mitsubishi
MV PACKING INSERTION
F-2
MM-M02.01
Rev.003
Appendix F
FIGURE F-2
Forced Draft Fan

Mitsubishi
MV PACKING MATERIAL & DIMENSION
F-3
Appendix G
A p p en d i x
G APPLICABLE VENDOR MANUALS

Description
Manufacturer
Handling Manual of Lubrication Oil

Unit for FD Fan
Daikin Hydraulic Engineering Co. Ltd.

Japan
Handling Manual of Pleated Type

Accumulator
Nippon Accumulator Co., Ltd.

Japan
MM-M02.01
Rev.003
Item No.
Forced Draft Fan

Mitsubishi
G-1
Appendix G
APPENDIX G-1
HANDLING MANUAL
OF
LUBRICATION OIL UNIT FOR FD FAN
Rev.003
VENDOR:
DAIKIN HYDRAULIC ENGINEERING CO., LTD.
MM-M02.01
JAPAN
Forced Draft Fan

Mitsubishi
G-2
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-3
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-4
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-5
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-6
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-7
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-8
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-9
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-10
Appendix G
MM-M02.01
Rev.003
Forced Draft Fan

Mitsubishi
G-11
Appendix G
MM-M02.01
Rev.003
10
Forced Draft Fan

Mitsubishi
G-12
Appendix G
MM-M02.01
Rev.003
11
Forced Draft Fan

Mitsubishi
G-13
Appendix G
MM-M02.01
Rev.003
12
Forced Draft Fan

Mitsubishi
G-14
Appendix G
MM-M02.01
Rev.003
13
Forced Draft Fan

Mitsubishi
G-15
Appendix G
MM-M02.01
Rev.003
14
Forced Draft Fan

Mitsubishi
G-16
Appendix G
MM-M02.01
Rev.003
15
Forced Draft Fan

Mitsubishi
G-17
Appendix G
MM-M02.01
Rev.003
16
Forced Draft Fan

Mitsubishi
G-18
Appendix G
MM-M02.01
Rev.003
17
Forced Draft Fan

Mitsubishi
G-19
Appendix G
MM-M02.01
Rev.003
18
Forced Draft Fan

Mitsubishi
G-20
Appendix G
MM-M02.01
Rev.003
19
Forced Draft Fan

Mitsubishi
G-21
Appendix G
MM-M02.01
Rev.003
20
Forced Draft Fan

Mitsubishi
G-22
Appendix G
MM-M02.01
Rev.003
21
Forced Draft Fan

Mitsubishi
G-23
Appendix G
MM-M02.01
Rev.003
22
Forced Draft Fan

Mitsubishi
G-24
Appendix G
MM-M02.01
Rev.003
23
Forced Draft Fan

Mitsubishi
G-25
Appendix G
MM-M02.01
Rev.003
24
Forced Draft Fan

Mitsubishi
G-26
Appendix G
MM-M02.01
Rev.003
25
Forced Draft Fan

Mitsubishi
G-27
Appendix G
MM-M02.01
Rev.003
26
Forced Draft Fan

Mitsubishi
G-28
Appendix G
MM-M02.01
Rev.003
27
Forced Draft Fan

Mitsubishi
G-29
Appendix G
MM-M02.01
Rev.003
28
Forced Draft Fan

Mitsubishi
G-30
Appendix G
MM-M02.01
Rev.003
29
Forced Draft Fan

Mitsubishi
G-31
Appendix G
MM-M02.01
Rev.003
30
Forced Draft Fan

Mitsubishi
G-32
Appendix G
MM-M02.01
Rev.003
31
Forced Draft Fan

Mitsubishi
G-33
Appendix G
MM-M02.01
Rev.003
32
Forced Draft Fan

Mitsubishi
G-34
Appendix G
MM-M02.01
Rev.003
33
Forced Draft Fan

Mitsubishi
G-35
Appendix G
MM-M02.01
Rev.003
34
Forced Draft Fan

Mitsubishi
G-36
Appendix G
MM-M02.01
Rev.003
35
Forced Draft Fan

Mitsubishi
G-37
Appendix G
MM-M02.01
Rev.003
36
Forced Draft Fan

Mitsubishi
G-38
Appendix G
MM-M02.01
Rev.003
37
Forced Draft Fan

Mitsubishi
G-39
Appendix G
MM-M02.01
Rev.003
38
Forced Draft Fan

Mitsubishi
G-40
Appendix G
MM-M02.01
Rev.003
39
Forced Draft Fan

Mitsubishi
G-41
Appendix G
MM-M02.01
Rev.003
40
Forced Draft Fan

Mitsubishi
G-42
Appendix G
MM-M02.01
Rev.003
41
Forced Draft Fan

Mitsubishi
G-43
Appendix G
MM-M02.01
Rev.003
42
Forced Draft Fan

Mitsubishi
G-44
Appendix G
MM-M02.01
Rev.003
43
Forced Draft Fan

Mitsubishi
G-45
Appendix G
MM-M02.01
Rev.003
44
Forced Draft Fan

Mitsubishi
G-46
Appendix G
MM-M02.01
Rev.003
45
Forced Draft Fan

Mitsubishi
G-47
Appendix G
MM-M02.01
Rev.003
46
Forced Draft Fan

Mitsubishi
G-48
Appendix G
MM-M02.01
Rev.003
47
Forced Draft Fan

Mitsubishi
G-49
Appendix G
MM-M02.01
Rev.003
48
Forced Draft Fan

Mitsubishi
G-50
Appendix G
MM-M02.01
Rev.003
49
Forced Draft Fan

Mitsubishi
G-51
Appendix G
MM-M02.01
Rev.003
50
Forced Draft Fan

Mitsubishi
G-52
Appendix G
MM-M02.01
Rev.003
51
Forced Draft Fan

Mitsubishi
G-53
Appendix G
MM-M02.01
Rev.003
52
Forced Draft Fan

Mitsubishi
G-54
Appendix G
MM-M02.01
Rev.003
53
Forced Draft Fan

Mitsubishi
G-55
Appendix G
MM-M02.01
Rev.003
54
Forced Draft Fan

Mitsubishi
G-56
Appendix G
MM-M02.01
Rev.003
55
Forced Draft Fan

Mitsubishi
G-57
Appendix G
MM-M02.01
Rev.003
56
Forced Draft Fan

Mitsubishi
G-58
Appendix G
MM-M02.01
Rev.003
57
Forced Draft Fan

Mitsubishi
G-59
Appendix G
MM-M02.01
Rev.003
58
Forced Draft Fan

Mitsubishi
G-60
Appendix G
MM-M02.01
Rev.003
59
Forced Draft Fan

Mitsubishi
G-61
Appendix G
MM-M02.01
Rev.003
60
Forced Draft Fan

Mitsubishi
G-62
Appendix G
MM-M02.01
Rev.003
61
Forced Draft Fan

Mitsubishi
G-63
Appendix G
MM-M02.01
Rev.003
62
Forced Draft Fan

Mitsubishi
G-64
Appendix G
MM-M02.01
Rev.003
63
Forced Draft Fan

Mitsubishi
G-65
Appendix G
MM-M02.01
Rev.003
64
Forced Draft Fan

Mitsubishi
G-66
Appendix G
MM-M02.01
Rev.003
65
Forced Draft Fan

Mitsubishi
G-67
Appendix G
MM-M02.01
Rev.003
66
Forced Draft Fan

Mitsubishi
G-68
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-69
Appendix G
MM-M02.01
Rev.003
68
Forced Draft Fan

Mitsubishi
G-70
Appendix G
MM-M02.01
Rev.003
69
Forced Draft Fan

Mitsubishi
G-71
Appendix G
MM-M02.01
Rev.003
70
Forced Draft Fan

Mitsubishi
G-72
Appendix G
MM-M02.01
Rev.003
71
Forced Draft Fan

Mitsubishi
G-73
Appendix G
MM-M02.01
Rev.003
72
Forced Draft Fan

Mitsubishi
G-74
Appendix G
MM-M02.01
Rev.003
73
Forced Draft Fan

Mitsubishi
G-75
Appendix G
MM-M02.01
Rev.003
74
Forced Draft Fan

Mitsubishi
G-76
Appendix G
MM-M02.01
Rev.003
75
Forced Draft Fan

Mitsubishi
G-77
Appendix G
MM-M02.01
Rev.003
76
Forced Draft Fan

Mitsubishi
G-78
Appendix G
MM-M02.01
Rev.003
77
Forced Draft Fan

Mitsubishi
G-79
Appendix G
MM-M02.01
Rev.003
78
Forced Draft Fan

Mitsubishi
G-80
Appendix G
MM-M02.01
Rev.003
79
Forced Draft Fan

Mitsubishi
G-81
Appendix G
MM-M02.01
Rev.003
80
Forced Draft Fan

Mitsubishi
G-82
Appendix G
MM-M02.01
Rev.003
81
Forced Draft Fan

Mitsubishi
G-83
Appendix G
MM-M02.01
Rev.003
82
Forced Draft Fan

Mitsubishi
G-84
Appendix G
MM-M02.01
Rev.003
83
Forced Draft Fan

Mitsubishi
G-85
Appendix G
MM-M02.01
Rev.003
84
Forced Draft Fan

Mitsubishi
G-86
Appendix G
MM-M02.01
Rev.003
85
Forced Draft Fan

Mitsubishi
G-87
Appendix G
MM-M02.01
Rev.003
86
Forced Draft Fan

Mitsubishi
G-88
Appendix G
MM-M02.01
Rev.003
87
Forced Draft Fan

Mitsubishi
G-89
Appendix G
MM-M02.01
Rev.003
88
Forced Draft Fan

Mitsubishi
G-90
Appendix G
MM-M02.01
Rev.003
89
Forced Draft Fan

Mitsubishi
G-91
Appendix G
MM-M02.01
Rev.003
90
Forced Draft Fan

Mitsubishi
G-92
Appendix G
MM-M02.01
Rev.003
91
Forced Draft Fan

Mitsubishi
G-93
Appendix G
MM-M02.01
Rev.003
92
Forced Draft Fan

Mitsubishi
G-94
Appendix G
APPENDIX G-2
HANDLING MANUAL
OF
Rev.003
PLEATED BLADDER TYPE ACCUMULATOR
MM-M02.01
VENDOR:
NIPPON ACCUMULATOR CO., LTD.
Forced Draft Fan

Mitsubishi
G-95
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-96
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-97
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-98
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-99
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-100
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-101
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-102
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-103
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-104
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-105
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-106
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-107
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-108
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-109
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-110
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-111
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-112
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-113
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-114
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-115
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-116
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-117
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-118
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-119
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-120
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-121
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-122
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-123
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-124
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-125
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-126
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-127
MM-M02.01
Rev.003
Appendix G
Forced Draft Fan

Mitsubishi
G-128
Appendix H
A p p en d i x
MM-M02.01
Rev.003
H PART LIST
Forced Draft Fan

Mitsubishi
H-1
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-2
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-3
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-4
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-5
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-6
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-7
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-8
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-9
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-10
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-11
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-12
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-13
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-14
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-15
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-16
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-17
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-18
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-19
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-20
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-21
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-22
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-23
MM-M02.01
Rev.003
Appendix H
Forced Draft Fan

Mitsubishi
H-24
Appendix I
A p p en d i x
MM-M02.01
Rev.003
Moving Blade
Paint Data Sheet
Forced Draft Fan

Mitsubishi
I-1
MM-M02.01
Rev.003
Appendix I
TABLE I-1
Forced Draft Fan
Mitsubishi
MOVING BLADE PAINT DATA SHEET (1 of 2)
I-2
MM-M02.01
Rev.003
Appendix I
TABLE I-2
Forced Draft Fan
Mitsubishi
MOVING BLADE PAINT DATA SHEET (2 of 2)
I-3

MM M02 1

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Project Dwg. No: P101-25-1701.

Forced Draft Fan

Forced Draft Fan Maintenance

Be sure to read this manual.

Disassembly and Reassembly

Feature of Forced Draft Fan Safety 1-1

Warnings Description 1-2

Definitions of Serious Injury, Minor Injury, Serious

Hazard Warning Label 1-5

Hazard Area 1-7

Risk Assessment Standard 1-8

Safety Measures 1-10

Work Permit System (Lockout/Tagout) 1-10

General Cautions on Personnel in Working Area 1-11

1.4.2.1 Cautions against Rotating Equipment 1-11

1.4.2.10Cautions against Sharp Objects 1-16

1.4.2.9 Cautions against Lifting Heavy Object 1-16

1.4.2.12Cautions using Crane 1-17

1.4.2.11Cautions using Fork Lift 1-16

Safety (Continued from previous page)

Evacuation in an Emergency 1-19

1.5.1.1 Evacuation Route 1-19

Fire Accident 1-21

Explosion Accident 1-22

Qualification and Training 1-23

Overview of the FDF 2-2

Moving Blade Regulating Mechanism 2-10

Main Bearing Assembly 2-11

Control/Lubricating Oil System 2-11

Preventive Maintenance _____________

Forced Draft Fan

Departmental Interface/Notification 4-2

Isolation of Equipment 4-2

Safety Precautions 4-2

Routine Maintenance 4-3

Inspection and Maintenance 4-4

Annual Outage Maintenance 4-10

Inspection and Maintenance 4-11

Disassembly and Reassembly ________

FDF Disassembly and Reassembly 5-1

Rotor Disassembly and Reassembly 5-18

Bearing Disassembly and Reassembly 5-27

Moving Blade Regulating Mechanism Linkage

Coupling Disassembly and Reassembly 5-38

Corrective Maintenance _____________

Recommended Lubrication __________

Forced Draft Fan

Torque Chart A-1

Spare Parts B-1

Special Tools C-1

Coupling Alignment D-1

Applicable Vendor Drawings E-1

MV Packing Insertion F-1

Applicable Vendor Manuals G-1

Part List H-1

Moving Blade Paint Data Sheet I-1

Types of Hazard Warning Label 1-6

FDF Mapping for Hazard Areas 1-9

Air & Flue Gas P & I D 2-3

FD Fan Outline 2-4

FD Fan Sectional View 2-5

FD Fan Cutaway View 2-6

FDF Casing Assembly 2-13