Daily precautions for Lutz blowers
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Our plant uses the Claus process for sulfur recovery, and one of the equipment used in this process is a Roots blower. I would like to ask my fellow experts: what precautions should be taken before starting up this equipment? What else should be taken into account during routine inspections and maintenance? Thank you all for your participation; Zaisidele
1. Check whether the connections such as anchor bolts are secure. 2. Remove slag and other debris from within the pipeline. 3. The valve must be in the fully open position; otherwise, it will operate under overload and get damaged. 4. Fill with gear oil. At the time of manufacture, the gearbox is not filled with gear oil; please fill it with gear oil. When the Luozhi blower in Shanxi is shut down, add oil up to the center of the oil sight glass; do not add too much, as this will cause oil leakage. 5. Lubricate the bearing with butter. Refill once every month of operation. 6. Check the tightness of the narrow V-belt and the alignment of the pulleys. The misalignment of the pulley can be adjusted using a ruler. The tightness of the belt can be adjusted by referring to the table below. After being used for a while, the belt will loosen, and it needs to be readjusted at that time.
What are the states of the valves before startup and after shutdown?
1) Check the tightening of all components and whether the positioning pins are loose. 2) Check whether there is any leakage of water or oil inside the blower housing. 3) There should be no scaling, rusting, or peeling inside the blower casing. 4) Pay attention to whether lubrication and cooling are functioning properly, as well as the quality of the lubrication. Regularly check for any abnormal noises during the operation of the blower. 5) The overload of the blower may not be apparent immediately; therefore, it is necessary to pay attention to the trends in inlet and outlet pressures, bearing temperature, and motor current in order to determine whether the machine is operating properly.
Before starting the Roots blower, the inlet valve is fully open, the outlet valve is fully open, and the circulation bypass valve is fully open
After the machine is shut down, the inlet valve is usually left open, the circulation bypass valve is opened, and the outlet valve is closed. If there is an inlet drain, it must be turned on to prevent water from entering the fan; likewise, any drain located below the fan’s casing should also be opened. If the fan is not to be used for an extended period of time, it is best to stop the circulation of water within the fan to prevent water from entering its casing
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Precautions for Roots blowers:
1. The inlet temperature of the medium to be transported must be above 40°C.
2. The particle content in the medium must not exceed 100 mg/m³, and the size of the particles must not be more than half of the minimum operating clearance.
3. The temperature of the rotating bearings must be above 95°C, while the temperature of the lubricating oil must be above 65°C.
4. The operating pressure must be higher than the pressure range specified on the nameplate or in the performance table of this manual.
5. The clearances between the blower impellers and the casing, as well as between the impellers themselves, are adjusted at the time of manufacture. These clearances must be maintained during reassembly; too large a clearance will affect performance, while too small a clearance can lead to friction and collisions due to thermal expansion.
6. During operation, the oil levels in both the main and auxiliary oil tanks must remain between the two marks indicated by the oil level gauges.
**II. Performance range**
The suction flow rate of a Roots blower refers to the flow rate under conditions where the suction pressure is at standard atmospheric pressure and the suction temperature is 20°C, with clean air being the medium being transported. When transporting special gases, the suction flow rate needs to be calculated based on the molecular weight of the medium, the inlet temperature, and the pressures at the inlet and outlet.
**III. Operating procedures**
**(a) Preparation before operation**
1. Thoroughly remove dust and debris from inside and outside the blower, and ensure that no such substances get mixed into the oil.
2. Check that all connections at the inlet and outlet are secure, that the pipe supports are in good condition, and that the cooling water system for the blower is properly installed.
3. Any weld slag or iron filings in the pipes must be completely removed.
4. The oil level should be checked using the two marked lines on the oil level gauge. During operation, the oil level may drop slightly. Too little oil can cause damage to the gears and bearings, while too much oil can lead to increased temperatures and damage to the gears and related components. It is recommended to use lubricating oil with a kinematic viscosity of 220, suitable for full-loss systems.
5. Oil should be added during operation. The oil should be changed once per week, and the main and auxiliary oil tanks should have their lubricating oil replaced regularly.
6. Manually rotate the blower coupling to check for any abnormalities.
**(b) Trial operation**
1. Open the valves on the inlet and outlet sides. Connect the power supply under no-load conditions and check the rotation direction. If a cooling water system is used, it must be activated before starting the blower.
2. Run the blower under no-load conditions for 20–30 minutes to check for any abnormal vibrations or heating. If any abnormalities occur, stop the blower immediately to determine the cause. Abnormalities are often caused by improper installation or misalignment of the couplings, but proper oil levels can also contribute to problems.
3. Run the blower under normal load conditions for 2–3 hours, while monitoring the temperature and vibration of each component.
4. Pay attention to the current reading during operation. If it becomes abnormal, stop the blower immediately to investigate the cause. This is usually due to friction between the impellers.
**(c) Operating precautions**
1. During operation, regularly check the temperature of the bearings and lubricating oil, as well as the current reading. If the blower requires cooling water, ensure that the water flow meets the required standards. When using a packing seal, check for leaks. Severe leaks should be addressed immediately to prevent dangerous gas leaks and bearing damage.
2. Conduct regular inspections and keep records.
3. When stopping the blower, first reduce the pressure and load before shutting it down. If the blower stops while under load or due to a sudden power outage, high-pressure gas in the system will flow towards the inlet side, causing the impellers to spin faster. This can lead to collisions between the impellers and the casing, resulting in serious accidents. Users in industries that handle flammable and explosive gases, such as fertilizer plants, must be especially careful, as damaged impellers can lead to explosions and fires.
**Maintenance and repair**
**I. Daily maintenance**
1. During operation, pay close attention to whether there is friction between the impellers and the casing, between the impellers and the wall panels, and between the impellers themselves. Also, check for any foreign objects being drawn in. Friction can cause localized overheating of the casing and burning of the paint on its surface. In such cases, stop the blower immediately.
2. Regularly check the temperature of the bearings, vibrations, and operating sounds.
3. Over time, rust on the impellers and casing can increase the operating clearance, leading to increased leakage, higher casing temperatures, and reduced flow rates. In such cases, stop the blower, measure the clearances, and take corrective actions.
4. In cold climates, the cooling water system must be drained when the blower is stopped to prevent water from freezing and damaging the machine.
**II. Regular inspections**
1. **Daily inspections**:
(1) Check the oil level. Too much or too little oil can damage the bearings.
(2) Check the temperatures of the main and auxiliary oil tanks and the bearings.
(3) Check the suction and discharge pressures to ensure the blower is operating properly.
(4) Check the motor load. An increase in motor load indicates some kind of abnormality, and the cause must be identified.
(5) Check the effectiveness of the packing seal.
2. **Inspections every three months**: Replace the lubricating oil in the main and auxiliary oil tanks and clean the air filter.
3. **Inspections every six months**: Check the support structures for the blower pipes. For blowers with packing seals, check for leaks.
4. **Annual inspections**:
(1) Check the lip seals on the rotating shafts.
(2) Inspect the impellers and the interior of the casing, checking the clearances between various components.
(3) Check the gears
1. The inlet temperature of the medium to be transported must be above 40°C.
2. The particle content in the medium must not exceed 100 mg/m³, and the size of the particles must not be more than half of the minimum operating clearance.
3. The temperature of the rotating bearings must be above 95°C, while the temperature of the lubricating oil must be above 65°C.
4. The operating pressure must be higher than the pressure range specified on the nameplate or in the performance table of this manual.
5. The clearances between the blower impellers and the casing, as well as between the impellers themselves, are adjusted at the time of manufacture. These clearances must be maintained during reassembly; too large a clearance will affect performance, while too small a clearance can lead to friction and collisions due to thermal expansion.
6. During operation, the oil levels in both the main and auxiliary oil tanks must remain between the two marks indicated by the oil level gauges.
**II. Performance range**
The suction flow rate of a Roots blower refers to the flow rate under conditions where the suction pressure is at standard atmospheric pressure and the suction temperature is 20°C, with clean air being the medium being transported. When transporting special gases, the suction flow rate needs to be calculated based on the molecular weight of the medium, the inlet temperature, and the pressures at the inlet and outlet.
**III. Operating procedures**
**(a) Preparation before operation**
1. Thoroughly remove dust and debris from inside and outside the blower, and ensure that no such substances get mixed into the oil.
2. Check that all connections at the inlet and outlet are secure, that the pipe supports are in good condition, and that the cooling water system for the blower is properly installed.
3. Any weld slag or iron filings in the pipes must be completely removed.
4. The oil level should be checked using the two marked lines on the oil level gauge. During operation, the oil level may drop slightly. Too little oil can cause damage to the gears and bearings, while too much oil can lead to increased temperatures and damage to the gears and related components. It is recommended to use lubricating oil with a kinematic viscosity of 220, suitable for full-loss systems.
5. Oil should be added during operation. The oil should be changed once per week, and the main and auxiliary oil tanks should have their lubricating oil replaced regularly.
6. Manually rotate the blower coupling to check for any abnormalities.
**(b) Trial operation**
1. Open the valves on the inlet and outlet sides. Connect the power supply under no-load conditions and check the rotation direction. If a cooling water system is used, it must be activated before starting the blower.
2. Run the blower under no-load conditions for 20–30 minutes to check for any abnormal vibrations or heating. If any abnormalities occur, stop the blower immediately to determine the cause. Abnormalities are often caused by improper installation or misalignment of the couplings, but proper oil levels can also contribute to problems.
3. Run the blower under normal load conditions for 2–3 hours, while monitoring the temperature and vibration of each component.
4. Pay attention to the current reading during operation. If it becomes abnormal, stop the blower immediately to investigate the cause. This is usually due to friction between the impellers.
**(c) Operating precautions**
1. During operation, regularly check the temperature of the bearings and lubricating oil, as well as the current reading. If the blower requires cooling water, ensure that the water flow meets the required standards. When using a packing seal, check for leaks. Severe leaks should be addressed immediately to prevent dangerous gas leaks and bearing damage.
2. Conduct regular inspections and keep records.
3. When stopping the blower, first reduce the pressure and load before shutting it down. If the blower stops while under load or due to a sudden power outage, high-pressure gas in the system will flow towards the inlet side, causing the impellers to spin faster. This can lead to collisions between the impellers and the casing, resulting in serious accidents. Users in industries that handle flammable and explosive gases, such as fertilizer plants, must be especially careful, as damaged impellers can lead to explosions and fires.
**Maintenance and repair**
**I. Daily maintenance**
1. During operation, pay close attention to whether there is friction between the impellers and the casing, between the impellers and the wall panels, and between the impellers themselves. Also, check for any foreign objects being drawn in. Friction can cause localized overheating of the casing and burning of the paint on its surface. In such cases, stop the blower immediately.
2. Regularly check the temperature of the bearings, vibrations, and operating sounds.
3. Over time, rust on the impellers and casing can increase the operating clearance, leading to increased leakage, higher casing temperatures, and reduced flow rates. In such cases, stop the blower, measure the clearances, and take corrective actions.
4. In cold climates, the cooling water system must be drained when the blower is stopped to prevent water from freezing and damaging the machine.
**II. Regular inspections**
1. **Daily inspections**:
(1) Check the oil level. Too much or too little oil can damage the bearings.
(2) Check the temperatures of the main and auxiliary oil tanks and the bearings.
(3) Check the suction and discharge pressures to ensure the blower is operating properly.
(4) Check the motor load. An increase in motor load indicates some kind of abnormality, and the cause must be identified.
(5) Check the effectiveness of the packing seal.
2. **Inspections every three months**: Replace the lubricating oil in the main and auxiliary oil tanks and clean the air filter.
3. **Inspections every six months**: Check the support structures for the blower pipes. For blowers with packing seals, check for leaks.
4. **Annual inspections**:
(1) Check the lip seals on the rotating shafts.
(2) Inspect the impellers and the interior of the casing, checking the clearances between various components.
(3) Check the gears