Understanding fan vibration and imbalance

Key concepts Detecting imbalance early reduces damage and lowers repair costs. Imbalance and
vibration are not the same. Dirt, temperature, and loose fits can cause imbalance. Fans play a key role
in most manufacturing processes by recirculating air, ventilating hazardous gases, and cooling
machinery.

Key concepts

Detecting imbalance early reduces damage and lowers repair costs

Imbalance and vibration are not the same

Dirt, temperature, and loose fits can cause imbalance.
Fans play a key role in most manufacturing processes by
recirculating air, ventilating hazardous gases, and cooling
machinery. One problem that can develop in all of these
applications is imbalance. Since imbalance is a potentially
dangerous condition and can result in breakdowns and costly
plant shutdowns, it is imperative that plant engineers
understand what it is, how to detect it, what causes it, and
how it can be addressed.

Detecting imbalance early can save large amounts of money.

The less damage, the less the cost of repair. In some cases,
imbalance results from an improper manufacturing process.

It is important to clarify the difference between "imbalance"

and "vibration." A fan rotor generally consists of a welded,
riveted, or cast fan impeller mounted on a shaft. Even if the
manufacturer takes care in locating blades and weighing
component parts, the weight center is separated from the axis
of rotation. This difference between the weight center and
axis of rotation is referred to as "imbalance."

Imbalance is not a function of rotational speed and therefore

can be assessed and measured when the fan is not in
operation. Imbalance can be quantified by multiplying the
weight of the fan rotor by the radial distance between the
weight center and axis of rotation (Fig. 1).

Vibration occurs during fan operation and may have many

causes, one of which could be imbalance. Other causes of
vibration include mechanical looseness, coupling
misalignment, defective bearings, insufficient flatness of
bearing mounting surfaces, rotor cracks, driver vibration, and
V-belt slippage.

<table ID = 'id3456082-20-table' CELLSPACING = '1'

CELLPADDING = '1' WIDTH = '95%' BORDER = '1'><tr ID =
'id3456092-20-tr'><td ID = 'id3456094-20-td'>

</td></tr><tbody ID = 'id3507744-52-tbody'><tr ID =
'id3456106-24-tr'><td ID = 'id3456108-24-td'> Fig. 1. A rotor
with the center of mass off slightly from the axis of
rotation creats imbalance. </td></tr></tbody></table>

How to calculate imbalance:

Imbalance = Weightweight offset

Where: Weight, oz

Imbalance = 300 lb16 oz/lb x 0.0052 in.

Buildup on blades

Imbalance may be the result of a manufacturing process or

operating conditions. For example, many fan rotors are used
on wet scrubber systems where wet and sticky particulate
matter sometimes passes through and adheres to the
surfaces of the fan impeller. Usually this buildup of particulate
matter is evenly distributed over all surfaces and the resulting
imbalance is minimal. However, if a piece of the built-up
material flies off due to centrifugal force, then significant
imbalance can occur.

In some cases, backward-curved fan blades have proven

effective in controlling buildup, particularly on preheater ID
fans in the cement industry, where buildup can be a regular
problem. The design of the backward-curved fan must be
carefully selected. If there is too much curvature of the blade,
buildup can develop in the hollow pocket on the backside.
Backward-curved fan designs are available with steeply
sloped blades preventing this sort of buildup.

Temperature differential

Another common cause of imbalance is nonuniform

temperature. If a fan rotor is left at rest during an outage, a
differential temperature may develop between the top and
bottom of the housing (Fig. 2). A similar, though less
pronounced, temperature differential may develop in the
shaft, resulting in differential thermal expansion. Bowing can
result from as little as a 1-deg F temperature difference
between the top and bottom of the shaft (Fig. 3).

<table ID = 'id3456607-52-table' CELLSPACING = '1'

CELLPADDING = '1' WIDTH = '95%' BORDER = '1'><tr ID =
'id3456617-52-tr'><td ID = 'id3456619-52-td'>

</td></tr><tbody ID = 'id3503510-74-tbody'><tr ID =
'id3456626-55-tr'><td ID = 'id3456628-55-td'> Fig. 2. A
difference in temperature between the top and bottom of
a fan housing during outage or shutdown can be
significant. </td></tr></tbody></table>
Bowing in the shaft causes vibration on startup. The vibration
is quite high at first and then decreases slowly as rotor
temperature becomes uniform. If correction weights are
applied during startup, then vibration is minimal during
startup, but quite severe once the temperature differential is
corrected. The solution is an auxiliary drive that rotates the
fan rotor slowly during shutdown periods, ensuring uniform
fan temperature.

Dirt or fluid in hollow blades

Imbalance may also occur because of the accumulation of

dirt or fluid inside hollow sections of rotor blades. Some
centrifugal fans have hollow airfoil blades, which offer
maximum efficiency in clean operating conditions. However,
during extended operation in wet or dirty environments,
pinholes can develop in the blade skins and dirt or fluid builds
up in one or more of the blades. Since the accumulated
material shifts in the hollow blade during each start, the fan
rotor is nearly impossible to balance. Solid blade shapes
(backward-curved, backward-inclined or radial-blade fan
designs) are usually selected for centrifugal fans in extremely
dirty or wet environments.

<table ID = 'id3456663-68-table' CELLSPACING = '1'

CELLPADDING = '1' WIDTH = '95%' BORDER = '.5'><tr ID =
'id3456673-68-tr'><td ID = 'id3456675-68-td'>

</td></tr><tbody ID = 'id3513608-87-tbody'><tr ID =
'id3456687-72-tr'><td ID = 'id3456690-72-td'> Fig. 3. Bowing
in a shaft can result from just a 1-deg F temperature
difference between the top and bottom of the
shaft. </td></tr></tbody></table>

Loose hub-to-shaft fit

During initial start-up, the fan hub may be securely held in

place by setscrews. After a period of time, however, the
setscrews may loosen due to fretting or corrosion. This
loosening of the setscrews allows the hub and fan impeller to
become displaced relative to the axis of rotation. The result is
extreme imbalance. For this reason, hub-to-shaft connections
with an interference fit or some type of tapered bushing are
usually preferred to setscrews.

Where there is rapid temperature change, the fan impeller

and hub may heat up faster than the shaft, which could cause
looseness in the hub-to-shaft fit and imbalance. In such
cases, an extreme interference fit or an integral hub/shaft
arrangement is preferred.

Tolerances for vibration

Tolerances for vibration vary widely according to industry and
application. The Air Movement and Control Association Intl.,
Inc.'s (AMCA) Standard 204, Balance Quality and Vibration
Levels for Fans ," recognizes five different fan application
categories (BV-1, BV-2, BV-3, BV-4, and BV-5) for the
required balancing grade during manufacturing of the fan
(see table). These balance categories are ordered from a less
sensitive group (HVAC) to the most sensitive fans, which
include those for petrochemical processes and computer chip
manufacturing. (Note the table describes fans not only with
regard to their application, but also their driver.)

The table also shows the appropriate balance quality grade

for each of the fan application categories. These values vary
from balance quality grade G-16 (least stringent requirement)
to balance quality grade G-1.0 (most stringent requirement).

What do these balance grades actually mean? Take balance

grade G-2.5, for example. Given a rotor operating in free
space without bearings or any support system, the expected
vibration velocity for this rotor balanced to grade G-2.5 is
approximately 0.1 in./sec. Each balance quality grade refers
to the expected vibration velocity in free space measured in
in./sec.

Assessing vibrationin real applications

How do these measurements in free space relate to actual

applications? What are the real expected values when the
rotor is supported by a bearing system? What are the
acceptable vibration levels?

Since a bearing system offers some degree of stiffness,

vibration levels are generally lower when the bearing system
is included. Consider an extreme case with a relatively light
rotor supported by a massive bearing system. In this case,
the force of imbalance generated as the unit rotates is
probably not significant enough to cause much movement in
the bearing housing and structural supports. Such a system is
said to have low vibration sensitivity.
A stiff-support system with low vibration sensitivity can make
it difficult to monitor the health of the machine using the
bearing housing as the point of reference. It would be
possible for rotor cracks to cause great centrifugal force
without significant vibration registering in the bearing housing.
In other words, in a stiff-support system there is stable
operation, but with a false sense of security. Catastrophic
failure could occur without any prior warning.

How can the health of a fan be effectively monitored? One

solution is a proximity probe, which is applicable in sleeve-
type bearing installations. A proximity probe reaches down
through the bearing housing and into the bearing liner where
it directly measures the radial movement of the shaft. High
levels of vibration can be detected before any damage
occurs. Proximity probes are not practical with roller bearings.
Vibration can be measured effectively on the housing instead.

Occasionally, it may be necessary to mount a fan on

structural steel instead of a concrete foundation at grade
level. In such applications, guard against the possibility of a
correspondence in vibration frequency of fan excitation and
the natural frequency of the steel supports.

When the vibration frequency of the two correspond, the total

vibration amplitude is significantly higher than it would be if
the fan were mounted on a concrete foundation at grade
level. A system such as this has high vibration sensitivity.
Very small changes in the residual imbalance of the rotor
cause very large responses in the vibration levels.

When fans are mounted directly on structural steel platforms,

the potential for a natural frequency excitation exists. A
flexible fan mounting provides one solution to this problem.

A flexible mounting consists of a rigid sub-base under the fan,

often filled with concrete, and supported by a spring isolation
system. For most applications, static deflection of the spring
isolators should be on the order of 1 in.

Since most fans operate at 880 rpm or higher, the natural

frequency of the spring isolation system would be sufficiently
removed from the operating speed of the fan to ensure
minimal transmission of energy. The fan housing should be
mechanically separated from the inlet and discharge
ductwork so it is free to float on the spring isolation system.

The result of the flexible mounting system is lower stiffness

for the bearing housing and bearing pedestal. As a result,
slightly higher vibration levels, as measured on the bearing
housing, can be tolerated for flexible-mounted systems than
for rigid-mounted systems.

Those in charge of industrial fans must be vigilant. Regular

maintenance and inspection of fans prevent costly shutdowns
and catastrophic failures, which could result in injury or
damage to other equipment. Most balance and vibration
problems can be detected by a fan service professional.
Many balance and vibration problems can be corrected
through adjustments or repairs. In general, repairing fans as
opposed to buying replacements is highly economical and
efficient. The sooner the problem is detected, the lower the
cost of repair or correction.

Edited by Joseph L. Foszcz, Senior Editor, 630-320-

7135, jfoszcz@cahners.com

Information for this article came from AMCA Standard 204,

"Balance Quality and Vibration Levels for Fans." For a
complete copy of the standard, contact the Air Movement and
Control Association Intl., Inc., 30 W. University Dr., Arlington
Heights, IL 6000 4-1893; 847-394-0150; fax 847-253-0088.
The association's web site is amca.org.

More info

The authors are available to answer questions about fan

vibration and imbalance. They can be reached at 724-452-
6121.
How to calculate imbalance

Imbalance = Weight weight offset

Where: Weight, oz Offset, in.

Imbalance = 300 lb 16 oz/lb x 0.0052 in. = 25-oz-in.

Application categories and required balancing grade*

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CELLPADDING = '2' BORDER = '1'><tr ID = 'id3434978-9-tr'
STYLE = 'background-color: #EEEEEE'><td ID = 'id3434983-
9-td' CLASS = 'COPY'> Application </td><td ID =
'id3434990-11-td' CLASS = 'COPY'> Examples </td><td ID =
'id3434996-13-td' CLASS = 'COPY'> Driver power limits,
kW (hp) </td><td ID = 'id3433998-15-td' CLASS =
'COPY'> Fan application category, BV </td><td ID =
'id3434004-17-td' CLASS = 'COPY'> Balance quality grade
for rigid rotors/impeller </td></tr><tbody ID = 'id3434013-
21-tbody'><tr ID = 'id3434015-21-tr'><td ID = 'id3434018-21-
td' CLASS = 'COPY'>HVAC</td><td ID = 'id3434023-22-td'
CLASS = 'COPY'>Building ventilation and air
conditioning</td><td ID = 'id3434029-23-td' CLASS =
'COPY'>& 3.7 (5.0) > 3.7 (5.0)</td><td ID = 'id3434035-24-td'
CLASS = 'COPY'>BV-2 BV-3</td><td ID = 'id3434041-25-td'
CLASS = 'COPY'>G 16 G 6.3</td></tr><tr ID = 'id3434403-
27-tr'><td ID = 'id3434405-27-td' CLASS = 'COPY'>Industrial
processes power generation</td><td ID = 'id3434410-28-td'
CLASS = 'COPY'>Baghouse, scrubber, conveying, boilers,
combustion air, pollution control</td><td ID = 'id3434416-29-
td' CLASS = 'COPY'>& 300 (400) > 300 (400)</td><td ID =
'id3434422-30-td' CLASS = 'COPY'>BV-3 BV-4</td><td ID =
'id3434428-31-td' CLASS = 'COPY'>G 6.3 G 2.5</td></tr><tr
ID = 'id3434434-33-tr'><td ID = 'id3434436-33-td' CLASS =
'COPY'>Petrochemical processes</td><td ID = 'id3434442-
34-td' CLASS = 'COPY'>Hazardous gases, process
fans</td><td ID = 'id3434448-35-td' CLASS = 'COPY'>& 37
(50) > 37 (50)</td><td ID = 'id3434453-36-td' CLASS =
'COPY'>BV-3 BV-4</td><td ID = 'id3434459-37-td' CLASS =
'COPY'>G 6.3 G 2.5</td></tr><tr ID = 'id3434466-39-tr'><td
ID = 'id3434468-39-td' CLASS = 'COPY'>Computer chip
manufacturer</td><td ID = 'id3434474-40-td' CLASS =
'COPY'>Clean room</td><td ID = 'id3434479-41-td' CLASS =
'COPY'>Any</td><td ID = 'id3434485-42-td' CLASS =
'COPY'>BV-5</td><td ID = 'id3434490-43-td' CLASS =
'COPY'>G 1.0</td></tr><tr ID = 'id3434497-45-tr'><td ID =
'id3434499-45-td' CLASS = 'COPY'>* Information adapted
from AMCA Standard 204, "Balance Quality and Vibration
Levels for Fans."</td></tr></tbody></table>

Reasons for imbalance

Buildup of particulate matter on fan blades or in hollow fan

blades

Differential temperatures between the top and bottom of the

fan housing

Accumulations of dirt and particulate matter

Loose hub-to-shaft fit

Improper or makeshift balancing procedures