M.

Sc Design Project Report

Analysis of Induced Draft (I.D) Fan

Author
Muhammad Junaid
2015-MS-MED-13

Supervisor
Dr. Muhammad Sajid Kamran

Department of Mechanical Engineering

University of Engineering and Technology, Lahore
 Master of Science
In
Mechanical Design Engineering

Internal Examiner ___________________

Signature /Date

External Examiner ___________________

Signature /Date

Chairman ___________________
Signature /Date

Department of Mechanical Engineering

University of Engineering and Technology Lahore

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 ACKNOWLEDGMENTS

First, I would like to offer my prayers of thankfulness to ALMIGHTY ALLAH for blessing
me and showing me the way to finish this work.

I would like to extend thanks to my parents, my friends, colleagues and classmates, who so
generously contributed to the work presented in this thesis. Special Thanks goes to my Parents
who stayed by my side throughout this period of work.

Special mention goes to my enthusiastic supervisor, Dr. Muhammad Sajid Kamran. My M.Sc
has been an amazing experience and I thank him whole-heartedly for his tremendous academic
support.

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 ABSTRACT

Hardfacing is a technique used to reduce the wear and tear of the metal which is important
factor for calculating the life of material. Hardfacing is a metal working process where harder
or tougher material is applied to a base metal. It increases its wear resistance. This report
describes the wear and tear, stress distribution, area of maximum and minimum stresses and
effect of hardfacing as well as comparison of the different hardfacing materials on the life of
the blades of induced draft fan, an important equipment used in cement industry. Excessive
wear tear and enhanced vibration are common issues. Three different types of hardfacing
electrodes i.e. 7018(ESAB), H67W and Stoody-130(ESAB) having main constituent of Mild
Steel, Chromium Carbide and Tungsten Carbide respectively are analyzed and results are
discussed. Analysis performed in Abaqus showed critical area of wear and how hardfacing
increases the wear resistance of the blade. The effect of these three welding materials on the
blade life and behavior were observed and by comparing their results, it also signifies the
importance of selecting welding electrodes in scope of industrial maintenance to be used for
prolonged life and better results.

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 Table of Contents

ACKNOWLEDGMENTS ..........................................................................................................ii

ABSTRACT............................................................................................................................... iii

Introduction ................................................................................................................................ 1

1.1 Introduction ...................................................................................................................... 1

1.2 Methods of hardfacing ..................................................................................................... 1

1.3 Material of hardfacing...................................................................................................... 2

1.4 Impeller Fan/ Centrifugal Fan.......................................................................................... 2

1.5 Types of Draft .................................................................................................................. 3

1.5.1 Induced Draft ............................................................................................................ 3

1.5.2 Forced Draft .............................................................................................................. 3

1.6 Problems Associated With Induced Fan .......................................................................... 3

1.7 Objectives......................................................................................................................... 4

2 .Literature Review................................................................................................................... 5

3 Methodology ......................................................................................................................... 14

3.1 Fan Selection:................................................................................................................. 14

3.1.1 Drawing................................................................................................................... 14

3.1.2 Physical Model: ...................................................................................................... 15

3.1.3 CAD Model:............................................................................................................ 16

3.2 Material Selection .......................................................................................................... 16

3.3 Governing Equations & Boundary Conditions: ............................................................. 17

3.3.1 Governing equations ............................................................................................... 17

3.4 Solution Procedure ......................................................................................................... 19

3.5 Flow Diagram ................................................................................................................ 21

4 Results & Discussion: ........................................................................................................... 22

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 4.1 Mild Steel:...................................................................................................................... 22

4.2 Chromium Carbide......................................................................................................... 23

4.3 Tungsten Carbide ........................................................................................................... 25

Conclusions .............................................................................................................................. 28

References ................................................................................................................................ 29

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 List of Figures

Figure 3-1: Drawing................................................................................................................. 15

Figure 3-2: Physical Model...................................................................................................... 15
Figure 3-3: CAD Model ........................................................................................................... 16
Figure 3-4: Spring Mass Damper System ................................................................................ 17
Figure 3-5 (a): Meshing ........................................................................................................... 18
Figure 3-6(b). Initial Conditions .............................................................................................. 18
Figure 3-7: Final Conditions .................................................................................................... 19
Figure 4-1: Displacement for Mild Steel ................................................................................. 22
Figure 4-2: Stress Results for Mild Steel ................................................................................. 23
Figure 4-3: Displacement results for Chromium Carbide........................................................ 24
Figure 4-4: Stress Results for Chromium Carbide................................................................... 24
Figure 4-5: Displacement Results for Tungsten Carbide......................................................... 25
Figure 4-6: Stress Results for Tungsten Carbide ..................................................................... 26
Figure 4-7: Comparison of Deformation & Stresses of different welding electrodes ............. 27

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 List of Tables

Table 3-1: Technical Data of Fan ............................................................................................ 14

Table 4-1: Properties of Mild Steel.......................................................................................... 22
Table 4-2. Properties of Chromium Carbide............................................................................ 23
Table 4-3: Properties of Tungsten Carbide .............................................................................. 25

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Introduction

1.1 Introduction

Wear is the predominant factor that control the life of any machine part. Different types
of wear exist but the most typical modes are Abrasion, Impact, Metallic, Heat,
Corrosion etc. Most parts don’t wear due to single mode of wear, such as Impact but
from a combination of modes i.e. impact and abrasion.

Hardfacing is a metalworking process where harder or tougher material is applied to a

base metal. It is welded to the base material, and generally takes the form of specialized
electrodes for arc-welding or filler rod for oxyacetylene and TIG welding.

Hardfacing may be applied to a new part during production to increase its wear
resistance, or it may be used to restore a worn-down surface. Hardfacing by arc welding
is a surfacing operation to extend the service life of industrial components, pre-
emptively on new components, or as part of a maintenance program. The result of
significant savings in machine down time and production costs has meant that this
process has been adopted across many industries such as Steel, Cement, Mining, Petro
chemical, Power, Sugar cane and Food.

1.2 Methods of hardfacing

Hardfacing can be deposited by various welding methods:

 Shielded Metal Arc Welding (SMAW)

 Gas Metal Arc Welding (GMAW)
 Oxy-fuel Welding (OFW)
 Submerged Arc Welding (SAW)
 Electro-slag Welding (ESW)
 Plasma Transferred Arc Welding (PTAW)
 Thermal spraying
 Cold polymer compounds
 Laser Cladding

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Commonly applied materials include cobalt-based alloys (such as stellite), nickel-based
alloys, chromium carbide alloys and NOREM. Hardfacing is sometimes followed by
hot stamping to refinish the part or add color or instructional information to the part.
Foils or films can be used for a metallic look or other protection.

1.3 Material of hardfacing

The problem addressed in this project was that which welding electrode is more
suitable, reliable and gives better results for repair work on the surface of the blade.
When blades get wear and holes are produced on the surface we perform welding on
hit and trail rule and depend upon availability of welding electrode that may be 7018
(ESAB),H67W and stoody-130(ESAB).

The results show the best-suited welding electrode among three of them which gives
more resistance to wear and stresses. These results describe the selection of material
composition of hardfacing to minimize the wear and production of holes on the surface
of the blade and also provide better solution for the problem usually faced while
dealing with induced draft fan in cement industry.

1.4 Impeller Fan/ Centrifugal Fan

A centrifugal fan is a mechanical device for moving air or other gases. The terms
"blower" and "squirrel cage fan" are frequently used as synonyms. These fans increase
the speed and volume of an air stream with the rotating impellers. The centrifugal fan is
one of the most widely used fans. Centrifugal fans are by far the most prevalent type of
fan used in the cement industry today. They are often cheaper than axial fans and
simpler in construction. They are used in transporting gas or materials and in
ventilation. They are also well-suited for industrial processes and air pollution control
systems. In cement industry, different types of fans are used. They may be of differe nt
types, sizes, designs & drafts depending upon the process requirement. The sub-
division of fans on the basis of draft produced are of mainly two types:

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1.5 Types of Draft

1.5.1 Induced Draft

When air or flue gases flow under the effect of a gradually decreasing pressure below
atmospheric pressure. In this case, the system is said to operate under induced draft.
The stacks provide sufficient natural draft to meet the low draft loss needs. In order to
meet higher pressure differentials, the stacks must simultaneously operate with draft
fans.

1.5.2 Forced Draft

When air or flue gases are maintained above atmospheric pressure. Forced draft fan
take air from the surroundings and add it to the system. Force draft is usually used for
cooling purposes.

1.6 Problems Associated With Induced Fan

The purpose of this project was to discuss the problems associated with induced draft
fan used in cement industry. Induced fan is very critical equipment and its smooth
operation is very helpful in maintaining process parameters. Special care is required for
inspection and maintenance. Excessive wear tear rate and enhanced vibration are
common issues. The function of Induced Draft fan in cement industry is to remove hot
gases & provide a path for dust & gases to pass through the electrostatic precipitator.
Hot gases normally having temperature of 250-300 C are sucked at -1800 Pa pressure
from the system(Grate Cooler) & exhausted to the environment after collecting dust
particles by electromagnetic effect produced in electrostatic precipitator by applying
high voltages. Gases and dust particles at high temperature entering the impeller cause
damage to its body. It is common observation that life of the fan is not more than 3
years due to robust conditions as well as different types of stresses produced result in
irregular deformation of the fan which causes vibration. Excess vibration may results
in failure of the system. It is observed that dust particles fill the damaged portion of the
blades which results in unbalancing and cause of vibration. Blades are more subjected
to heat and dust. To minimize this effect usually hardfacing is done on different portions
of the fan especially on the upper face of the blades which is exposed to heat and dust
to increase toughness, strength and minimize the wear tear.

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1.7 Objectives

The objectives of this project are:-

 To analyze the different stresses produced
 Identify the area of maximum & minimum stresses
 To justify the area of hard facing
 Effect of different hardfacing material composition

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2 .Literature Review

This research paper describes different methods of hardfacing, their base materia ls,
weld consumables and the effects of hardfacing on the life and wear resistance. It
categorized the weld consumables into 4 different groups, also grouped the base
materials but the mostly used base material is steel. The paper briefly defines that
hardfacing is the versatile, simplest, economical and easiest way to make equipme nt
more resistant to wear, impact and abrasion. Hardfacing extends the life of the
component which results in cost saving of replacement.[1].

This study investigate the abrasive wear failure of tungsten carbide hardfacing on
continuous digester (CD) blade (carbon steel) in an environment of sulphuric acid
.Comparison being made on the hardness, thickness and microstructural of the
hardfacing between unworn and 3 months old worn blade on few locations around the
blade. The cross sections of the blade revealed non-uniform coverage of the hardfacing
on the blade for both worn and unworn blade. The edge of the blade has the least amount
of hardfacing thickness which with time acts as the point of failure during the wear
process. The hardness obtained from both the unworn and worn samples are around
25% lower from the hardfacing electrode manufacturer’s hardness specificatio n.
Microstructural micrograph analysis of the hardfacing revealed non uniform size
carbide with non-uniform distributed of carbide in the hardfacing layer[2].

The objective of this research paper is to develop the welding procedure for multi-
layered hardfacing on 3.5% chromium cast steel and study wear behavior of hardfacing
deposits. Four different types of welding procedures are adopted by using stainless steel
and martensitic hardfacing electrodes as buffer and hardfacing respectively. Preheating
procedures are also adopted. The study reveals that hardfacing deposits in heat affected
zone showed no cracks and defects but high abrasive wear resistance was obtained
without preheating. This was due to full martensitic structure of hardfacing[3].

This paper is concerned with the effect of elevated temperatures on hardfacing

depending upon the thickness of the steel plate on which hardfacing is done and its
behavior when exposed to impact and heat. The experiment is carried out by performing
longitudinal and lateral deformation analysis of steel plates of different thickness i.e.
7mm, 16mm & 25mm in ANSYS. This research implies that by measurements of

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deformations, it was established that they are the most prominent in hard facing of the
thin plates, when the drastic increase of deformations appear at all the points of the hard
faced layer in both the lateral and longitudinal direction. For thick plates, however, the
increase of deformations in the lateral directions is negligible, while the increase in the
longitudinal direction is more prominent[4].

This research paper in helpful in determining the parameters of the welding and its
effects on the efficiency of hardfacing. The parameters include thickness of the hard-
faced layer, weight, type of electrode used, type of polarity whether positive or negative
type of current i.e. AC or DC voltage and current value suitable for hardfacing. It must
be noted here that good hardfacing results in weight loss of the equipment it means that
good hard-facing is one in which thin overlay hardfacing welding is done with high
abrasive resistance not the thick overlay hardfacing with low abrasive resistance, but
only weight is not the parameter to define the status of hardfacing many other
parameters should also be included like current, polarity, conditions, voltage, buffer
layer, electrode being used. The most widely used electrodes for domestic hardfacing
are ESAB, H 67 W and they give good results[5].

This paper is concerned with the parameters in defining the performance of the
centrifugal fan. Different analysis are done on the impellers of different sizes and blades
profiles. The efficiency of impeller is mainly dependent upon the profile of the blades,
blade angle and many more. This paper gives the comparison among the
aerodynamically available different blade designs. Three dimensional, steady state and
transient flow of the four different blade profiles was generated. Numerical results
showed influence of changing curve length of the blade on performance and noise of
the fan. It was found that flow rates less than 0.4 kg/s the total efficiency increased with
the increased blade lengths, but for the flow rates more than 0.4 kg/s the increasing of
the increase in efficiency[6].

In this paper the failure of shaft of centrifugal fan was investigated. Firstly, the material
composition and mechanical properties of the shaft was examined and found correct
according to the requirements. Ultrasonic analysis was performed to measure the shaft
torsional force enough for the smooth operation. The finite element simulation showed
the stress concentration was remarkable at the shaft shoulder's chamfer , while the
actual radius of the shaft shoulder's chamfer caused more significant stress

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concentration, so the radius the shaft shoulder's chamfer must reasonable and accurate
during the process. It is concluded that the higher stress concentration and torsional
vibration produced micro cracks along the radius of the shaft which resulted in the
failure of the shaft[7].

In this research paper Structural (FEA) analysis is done by using ANSYS 12 software.
Structural analysis includes the fatigue testing of the fan. The fatigue testing on the fan
is done at 705 RPM. The material of the fan is structural steel. Volume and mass of the
fan are 1.45×109 mm3 and 11413 kg. In the fatigue analyses of fan the contours of
fatigue life fatigue damage and fatigue safety factor were plotted while in FEA analys is
certain contours of total deformation and equivalent stress acting on the fan. It is
observed that e maximum deformation takes place at the edges of the aero foil. It is
seen that maximum equivalent stress is acting at the aero foil and contact points which
means that if damage takes place it will start from contact points of the aero foil [8].

In this paper stress distribution analysis of rotor blade is done. The blade is subjected
to centrifugal loading. FEM is adopted and done in ANSYS. The geometry of the blade
is symmetrical, blade is twisted and single blade is considered. The analysis shows at
maximum stress is witnessed on the tip of the blade that is exposed to the centrifuga l
compressive loading [9].

In this work, stresses and natural frequencies of axial flow fan are evaluated. Various
combinations of hub thickness and ring thickness are considered to calculate stresses
and frequencies. It is observed that in case of solid hub the maximum stresses are
induced at root of the blade and if the thickness of the hub reduces the stresses at the
root of the blade increases and natural frequency decreases. Finite element analysis is
done on impeller for investigation of stresses and natural frequency [10].

In this study, two different electrodes were used to examine the effect of microstruc ture
and wear resistance for hard facing deposits. Electrode-1 has less wear as compared to
electrode-2 as the percentage of chromium, carbon and silicon is more in electrode-I.
The factors such as, arc current, arc voltage, welding speed, electrode stick-out and
preheat temperature predominantly influence the weld quality. The abrasion tests were
conducted on a dry sand–rubber wheel abrasion machine as per ASTM G65 standard.
Results revealed that as hardness increases, the loss of wear decreases. The wear surface

7
results were analyzed by scanning electron microscopy results which indicates that the
best abrasion resistance is obtained in microstructures composed of chromium carbide
alloy [11].

This work reports research concerning the behavior of cermet coatings deposited by
high velocity oxy-fuel (HVOF) spraying which are designed to exhibit resistance to
abrasive wear and high-temperature oxidation. It was found that the abrasive wear
resistance of the FeCr–TiC coatings depended on the SHS powder characteristics and
composition which in turn depended upon the reactant proportions. With hard, angular
alumina, the equimolar coating exhibited the lowest wear coefficient whereas with soft,
rounded silica abrasive, the excess Ti coating had the lowest wear coefficient. Such
behavior was rationalized in terms of the coating microstructure. Wear coefficients of
the FeCr–TiC coatings were equivalent or better than the NiCr–Cr3C2 coating sprayed
from blended powder [12].

In this paper high temperature forging tools are highly damaged by wear shearing under
cyclic loading which reduces the life of tools. In real conditions, depending upon the
tool areas, the level of wear can change. The surfaces of tools can be treated by cobalt-
based hard facing using different welding processes. This study focuses on tri-
biological damages of Stellite 21 deposited by MIG process. It is observed that The
Stellite 21 dendritic matrix is able to high plastic deformation and precipitates are
broken up and flow with the matrix [13].

Hot-working processes are carried out in harsh working conditions such as the elevated
temperature, the repeated thermal load, the large mechanical load, etc. The harsh
working conditions of the hot-working process cause the premature failure of hot-
working dies. The hardness of the top surface after the wear experiments is lower tha n
that before the wear experiments when the hard facing thickness is 3 mm. The research
have reports that the highest hardness of the Stellite21 hard-faced specimen is recorded
when the ageing temperature is nearly 800oC and the temperature range of the ageing
treatment of the Co based hard-faced part is 650~1,150oC [14].

In the present study, two different hard facings produced by the plasma transferred arc
process were analyzed and compared to reveal differences between Ni Cr B Si coatings

8
reinforced with standard chromium carbide and chromium-based cermet powders. The
coatings were produced from a mixture of hard phases (Cr3C2 or Cr3C2–Ni) and nickel
based powder with a ratio of 40/60 vol. %. The coatings' thickness was set to 2–2.5 mm
on an austenite substrate. The mechanical properties of the Cr3C2andCr3C2–Ni
reinforced hard facings, the distinctly different micro-structures result in different wear
behaviors of the coatings. The wear rate at 700 °C is lower for the Cr3C2–Ni reinforced
hard facing as compared to the commercially used WC/W2C reinforced NiCrBSi
coating. At the same time the wear resistance of the Cr3C2–Ni reinforced coating shows
high temperature stability up to 700 °C with negligible wear rate growth [15].

Tungsten carbide (WC) hardfacing coating is commonly used to enhance carbon steel
blade performance which works in acidic and abrasive condition during production
process. This paper deals with tungsten carbide (WC) hardfacing microstruc ture
analysis on a carbon steel blade. Mixing of ilmenite ore with sulphuric acid is performed
by the carbon steel blade as part of a production process. Tungsten carbide hardfacing
is deposited on the carbon steel blade to enhance its wear resistance. The carbide
distribution along with elemental composition analysis of the hard-faced carbon steel
blade specimens is examined using Scanning Electron Microscopy (SEM), Energy
Dispersive Spectroscopy (EDS) and X-Ray Diffraction (XRD) respectively.
Microstructure analysis revealed that different sizes of carbides with non-unifo r m
distribution are found around the coating region. The carbide region is contains high
percentage of tungsten (W) meanwhile, non-carbide region rich in tungsten (W) and
iron (Fe) [16].

This study investigate the abrasive wear failure of tungsten carbide hardfacing on
continuous digester (CD) blade (carbon steel) in an environment of sulphuric acid and
ilmenite ore mixture. Comparison being made on the hardness, thickness and
microstructural of the hardfacing between unworn and 3 months old worn blade on few
locations around the blade. The cross sections of the blade revealed non-unifo r m
coverage of the hardfacing on the blade for both worn and unworn blade. The edge of
the blade has the least amount of hardfacing thickness which with time acts as the point
of failure during the wear process. The hardness obtained from both the unworn and
worn samples are around 25% lower from the hardfacing electrode manufacturer's
hardness specification. Microstructural micrograph analysis of the hardfacing revealed

9
non uniform size carbide with non-uniform distributed of carbide in the hardfacing
layer [17].

Supercritical boiler technology was introduced to the power industry in the early
1960’s. Since this time, there have been many innovative boiler design configuratio ns
and features introduced to reduce capital and operating costs, simplify operation and
maintenance, and increase reliability [18].

The boiler draft operation at Callide C Power Station is commonly known as “balanced
draft pulverized fuel (PF) boiler” operation. This is when a mixture of hot and cold
combustion air is forced into the coal pulverizes fuel mills (PF mills) via primary air
(PA) fans. Once the PF mills have ground the coal into PF, a mixture of hot air and PF
is directed to the boiler burners where additional hot combustion air is forced into the
burner via forced draft (FD) fans. After combustion inside the boiler at approximate ly
1400°C, the air and PF turns into gas and must be evacuated by means of induced draft
(ID) fans where the gas is sent to the stack (or chimney) and released to atmosphere .
This balance draft operation is when there is pushing of air and pulling of gas and the
furnace is maintained at near or below atmospheric condition. Hence, describing the
term “balancing of drafts” [19].

Fans in a boiler plant are perhaps the most important of all auxiliary equipment because
they affect boiler performance, auxiliary power consumption and boiler dynamics.
Design factors such as fan margin and fan type have a major role in boiler design and
efficiency. It is important thorough engineering must be sought when selecting boiler
draft fans [20].

Boiler fan is the main power consumption device in thermal power units and the
induced draft fan accounted for the largest proportion. Reducing the energy
consumption rate of induced draft fan is the main path to reduce the power consumptio n
rate of thermal power units. The induce fan driven by small turbine is greatly effective
for reducing the power consumption rate and the supply coal consumption rate in large
thermal power plant. Take 1000 MW power units for example, the selection of steam
source for steam turbine were discussed and economic performance of the unit under
different steam source was compared in this paper. The result shows that compared with

10
the motor driven method, there is about 1.6 g/kWh decrease in supply coal consumptio n
rate driven by the fourth stage extraction steam; whereas there is about 2.5 g/kWh
decrease in supply coal consumption rate driven by the fifth stage extraction steam [21].

Fan margin calculations are the most critical design aspect when selecting correct fan
size. Margins on volume, head, operating and ambient temperatures are included into
fan design conditions for calculating boiler maximum continuous rating (MCR). Boiler
draft fan margins are essential for the following reasons: • Safety margins for pressure
and draft losses through the boiler draft system are vital in ensuring MCR is always
available. • Ambient temperature variation of -5°C to +50°C in the tropics and - 20°C
to +35°C in temperate climates, translates to a variation of approximately 20% in the
specific volume of air. • Unpredictable fouling of surfaces increases pressure head,
particularly with fuels such as coal. • Differences in boiler construction geometry
compared with design calculations due to inaccuracies in manufacturing and
erection[22].

The theory of lubrication and bearing design in rotating machines falls under the
broader context of tribology. The term ‘tribology’, is the science of mechanisms of
friction, lubrication, and wear of interacting surfaces that are in relative motion.
Tribological components are those which carry all the relative movements in rotating
machines and their performance is a critical contribution to reliability and efficie nc y.
These components are the local points where high forces and rapid movements are
transmitted simultaneously. They are also the components most likely to fail because
of the high concentration of energy that is carried at this point during normal operation
and particularly start-up. These components are the mechanical fuses if a machine fails
in service, therefore indicating a failure mode exists [23].

Bearings in heavy rotating machines are divided into two categories: (1) anti-fric tio n
bearings, better known as rolling element bearings and (2) fluid film bearings, more
commonly known as journal bearings or sleeve bearings. Within these two categories,
bearing load on the shaft is categorized by the load direction: radial load, axial load and
combination radial and axial load. The axial load component (also referred to as thrust
load) is in the direction of the shaft axis, while the radial load component is in the
direction normal to the shaft axis [24].

11
Rolling element bearings use a set of rolling elements (either balls or rollers) that roll
in an annular space between two races (see Figure 2.9), known as the inner race and
outer race. The rolling elements are maintained equally spaced via a separator, also
known as cage or retainer. The two broad categories for rolling element bearings are
ball bearings and roller bearings. The most common types of ball bearings are: 1. Deep-
groove ball bearing 2. Self-aligning ball bearing 3. Double-row deep-groove ball
bearing 4. Angular contact ball bearing [25].

Rolling elements bearing are becoming more common in today’s industries mainly due
to precision CNC machining capabilities and advances in material metallurgy. These
bearings offer the following advantages when compared with journal bearings: (1) less
friction at starting and general operation, (2) less sensitive to lubrication interruptio ns,
(3) suitable for high precision applications and (4) more suitable for supporting
combination radial and axial loads. However, the disadvantages are: (1) require more
space in the radial direction and (2) repeated cycle stresses at ball-to-race contact
creates a finite fatigue life [26].

To eliminate the wear problems associated with hydrodynamic bearings, externally

pressurized hydrostatic bearings ensures a complete fluid film separates the two
surfaces at all speeds, including zero speed. This makes hydrostatic bearings well suited
for rotating machines requiring frequent stopping and starting cycles and variable
speed. Another advantage of hydrostatic bearings is their good stiffness to radial loads
due to the constant pressure fluid film between two solid surfaces. This high stiffness
of radial displacement makes this bearing suitable for precision machines, such as
precise machine tools. The disadvantages of hydrostatic bearings when compared with
hydrodynamic bearings are: (1) higher initial cost, (2) requirement for high-press ure
external pump and (3) greater risk of lubrication failure because of failure of external
pump [27].

The Callide C ID fans and electric induction motors utilize both rolling element
bearings and journal bearings. The induction motors use a split sleeve hydrodyna mic
bearing on both drive end (DE) and non-drive end (NDE). This bearing type is ideal for
heavy electric drive applications due to high radial loads, high speeds, simplistic design,
constant speed and infrequent stop and start cycles [28].

12
A lubricant is a gas, liquid, or solid that is used to prevent contact of parts in relative
motion, reducing friction and wear (Mobley 1999, p.55). Lubricants also perform other
important functions such as: machine cooling, rust prevention, preventing the
deposition of solids on close-fitting parts, and power transmission. Lubrication is an
important part in the efficiency and reliability of rotating machines which is under ever
increasing scrutiny in today’s economic climate. Engineers are continuously improving
lubrication systems in an attempt to increase productivity, more cost effective. Correct
lubricant selection and lubrication system design is vital in achieving a cost effective
and reliable machine [29].

As highlighted above, the importance oil selection with the proper additives is crucial
in all lubrication systems. The oil used in Callide C ID fan lubrication system is Shell
Tellus S 46, which is a zinc-free hydraulic oil used for severe conditions. The Shell
Tellus oil range is a ‘top-tier’ anti wear hydraulic oil formulated to provide exceptiona l
performance in hydraulic fluid power transmission subjected to severe duty. One of the
most important performance benefits is long life due to its excellent oxidation
properties, between two to four times that of other anti-wear hydraulic oils. Extended
oil life depends on its ability to resist oxidation due to heat in the presence of air, water
and metal catalysts such as copper. Refer to Table 2.1 for Shell Tellus S 46 oil properties
[30].

13
3 Methodology

3.1 Fan Selection:

The technical data, drawing and real-time picture of the fan selected for project analys is
is hereby mentioned;

Table 3-1: Technical Data of Fan

Parameter Value Unit

Volume 840000 m3 /h

Static Pressure 1800 Pa

Inlet Pressure 1800 Pa

Working Temperature 250 oC

Dust Content 60 Mg/m3

Density 1.23 Kg/Nm3

Atmospheric Pressure 101300 Pa

Fan Rotational Speed 730 rpm

Need Power 685 kW

Motor Power 710 kW

3.1.1 Drawing

Figure 1 shows dimensions of the induced draft fan used in cement industry. It
demonstrates the diameter of the impeller, width and thickness of the blade and
complete arrangement of the blades on the body of the impeller. All measureme nts are
taken in millimeters.

14
 Figure 3-1: Drawing

3.1.2 Physical Model:

Figure 2 shows the real time pictorial view of the complete impeller. This picture was
taken at Gharibwal Cement’s production site. It can be seen that front face of the blade
is hard-faced for prolonged life.

Figure 3-2: Physical Model

15
3.1.3 CAD Model:

Figure 3 shows the CAD model of the impeller simulated in solid works exactly on the
basis of dimesons showed in figure 1 (Drawing) and measurements taken at production
site shown in figure below.

Figure 3-3: CAD Model

3.2 Material Selection

Material selection for hardfacing was well-addressed in this report. Three differe nt
material composition were considered. The welding electrodes 7018(ESAB), H67W
and Stoody-130(ESAB) having main constituent of Mild Steel, Chromium Carbide and
Tungsten Carbide. This report highlighted the effect of these different material
compositions on the surface of fan blade which was composed of mild steel. The
properties of the materials taken as input for analysis were poison ratio, tensile strength
and density.

16
3.3 Governing Equations & Boundary Conditions:

3.3.1 Governing equations

The below-given figure shows the mathematical model of the spring-dashpot- mass
system with an applied external force.

Figure 3-4: Spring Mass Damper System

𝑴𝒙̈ (𝒕) + 𝑩𝒙̇ (𝒕) + 𝑲𝒙(̇ 𝒕) = 𝒇(𝒕) Equation 3-1

Where M is the mass, B is the damping coefficient and K is the spring constant and x
(t) is the horizontal displacement of the mass from equilibrium position.

In structural analysis, direct stiffness matrix is used for comp-automated analysis of

complex structures. Matrix method uses the members' stiffness relations for computing
member forces and displacements in structures. This method is the most common
implementation of Finite Element Method (FEM). In this method, system must be
modeled as set of simpler, idealized elements connected at the nodes. The stiffness
matrix of order 6x6 is given as:

𝒇𝒙𝟏 𝒌𝟏𝟏 𝒌𝟏𝟐 𝒌𝟏𝟑 𝒌𝟏𝟒 𝒌𝟏𝟓 𝒌𝟏𝟔 𝒖𝒙𝟏

𝒇𝒚𝟏 𝒌𝟐𝟏 𝒌𝟐𝟐 𝒌𝟐𝟑 𝒌𝟐𝟒 𝒌𝟐𝟓 𝒌𝟐𝟔 𝒖𝒚𝟏
𝒎𝒛𝟏 𝒌 𝒌𝟑𝟐 𝒌𝟑𝟑 𝒌𝟑𝟒 𝒌𝟑𝟓 𝒌𝟑𝟔 𝜽𝒛𝟏
= 𝟑𝟏
𝒇𝒙𝟐 𝒌𝟒𝟏 𝒌𝟒𝟐 𝒌𝟒𝟑 𝒌𝟒𝟒 𝒌𝟒𝟓 𝒌𝟒𝟔 𝒖𝒙𝟐
𝒇𝒚𝟐 𝒌𝟓𝟏 𝒌𝟓𝟐 𝒌𝟓𝟑 𝒌𝟓𝟒 𝒌𝟓𝟓 𝒌𝟓𝟔 𝒖𝒚𝟐
[𝒎𝒛𝟐] [𝒌𝟔𝟏 𝒌𝟔𝟐 𝒌𝟔𝟑 𝒌𝟔𝟒 𝒌𝟔𝟓 𝒌𝟔𝟔 ] [ 𝜽𝒛𝟐 ]

17
3.3.2 Boundary Conditions:

Figure 3-5 (a): Meshing describes the meshing on the blade of the impeller fan.
Tetrahedral 3D meshing had been performed in Abaqus.

Figure 3-5 (a): Meshing

Figure 3-6(b). Initial Condition shows fixed supports were applied on the sides of the
blade as boundary conditions, small pink arrows show the location where fixed supports
were enforced.

Figure 3-6(b). Initial Conditions

18
Figure 3-7: Final Condition describes the final conditions applied on the front
face/surface of the blade exposed to air pressure in the form of distributed pressure of
0.0018 MPa.

Figure 3-7: Final Conditions

3.4 Solution Procedure

The solution can be divided into three sections given as;

 Geometry of Impeller (SolidWorks)

 Deformation Analysis (Abaqus)
 Stress Analysis (Abaqus)

Geometry of impeller is done in SolidWorks by using different commands like extrude,

loft, extrude cut, circular pattern etc. After sketching, drawing is imported to Abaqus
for analysis. Firstly deformation analysis of the impeller is performed. Structural
analysis is done to identify stresses on blades. Different material compositions are
applied on upper face of blade to analyze the behavior of the equipment.

This analysis describes our objectives of identifying the area of maximum and
minimum stresses as well as the effect of different hardfacing materials on impeller
wear resistance, abrasion and life. Different hardfacing composition provides the
information about the most suitable type of hardfacing material to be used for the long-
lasting effects in the present situation i.e. dust and heat.

19
The techniques applied for performing analysis are given as:

 Material properties
 Tetrahedral meshing
 Applying boundary condition
 Distributed pressure

The body of the blade is considered homogeneous, elastic and linear. Material
properties in all three cases are young’s modulus, Poisson ratio and density.by varying
their values different results has been found. Tetrahedral 3D meshing has been
performed and fixed supports are applied on the blade as boundary conditions and
distributed pressure of 0.0018 MPa is applied at the face of the blade exposed to air
pressure in practical. The area of maximum and minimum deformation (displaceme nt)
and stresses is identified by applying deformation analysis in Abacus. Similarly process
is repeated by changing the material properties of the blade i.e. mild steel, chromium
carbide and tungsten carbide. This variation of material composition gives us the
information that which one is the most suitable in welding a layer of hardfacing on the
surface of the blade and which welding electrode should be consumed to get better
results.

20
3.5 Flow Diagram
Start

Deformation produced
Area of max & min stresses
Area of hard facing
Different material compositions

Solid works
Sketching of impeller blade
Geometry exported to Abaqus
for Analysis

Abaqus
Structural Analysis
Deformation Analysis
Von-Misses Stress Analysis

Repeating procedure by
applying different material
Compositions of hardfacing i.e.
Mild steel, Chromium carbide

Results
Mild steel
Chromium carbide
Tungsten Carbide

End

21
4 Results & Discussion:
4.1 Mild Steel:
The mechanical properties of mild steel required for analysis are given in Table 4-1:
Properties of Mild Steel.

Table 4-1: Properties of Mild Steel

Material Young Modulus Poisson Ratio Density

Mild Steel 210 GPa 0.30 7850 Kg/m3

Considering Mild Steel as the material for the fan blade, applying the properties shown
above and applying Pressure of 0.0018 MPa. Figure 4-1: Displacement for Mild Steel
shows displacement and value of maximum displacement is +0.000119 mm.

Displacement (mm)
0.000119
0.000109
0.000099
0.000089
0.000079
0.000069
0.000059
0.000049
0.000039
0.000029
0.000019
0.000009

Figure 4-1: Displacement for Mild Steel

Figure 4-2: Stress Results for Mild Steel showed distribution of stresses on the surface
of the blade and also defines the area of minimum and maximum stresses that shows us
stresses to the maximum value of 0.0515 MPa. The welding electrode normally use for
Mild Steel 7018(ESAB).

22
 σ, Stress (MPa)
0.0515
0.0475
0.0434
0.0394
0.0353
0.0313
0.0273
0.0232
0.0192
0.0151
0.0111
0.0070

Figure 4-2: Stress Results for Mild Steel

4.2 Chromium Carbide

The mechanical properties of chromium carbide required for analysis are given in
Table 4-2. Properties of Chromium Carbide.

Table 4-2. Properties of Chromium Carbide

Material Young Modulus Poisson Ratio Density

Chromium Carbide 373.13 G Pa 0.20 6700 Kg/m3

Considering layer of Chromium Carbide hard faced on the surface of fan blade,
applying the properties shown above and applying Pressure of 0.0018 MPa. Figure 4-3:
Displacement results for Chromium Carbide shows displacement and value of
maximum displacement is +0.000068 mm.

23
 Displacement (mm)
0.000068
0.000062
0.000057
0.000051
0.000045
0.000039
0.000032
0.000028
0.000022
0.000017
0.000011
0.000005
0.000000

Figure 4-3: Displacement results for Chromium Carbide

Figure 4-4: Stress Results for Chromium Carbidgives distribution of stresses on the
surface of the blade and also defines the area of minimum and maximum.

σ, Stress (MPa)
0.0562
0.0518
0.0473
0.0429
0.0384
0.0340
0.0296
0.0251
0.0207
0.0162
0.0118
0.0074

Figure 4-4: Stress Results for Chromium Carbide

24
4.3 Tungsten Carbide
The mechanical properties of tungsten carbide required for analysis are given in Table
4-3: Properties of Tungsten Carbide.

Table 4-3: Properties of Tungsten Carbide

Material Young Modulus Poisson Ratio Density

Tungsten Carbide 600 G Pa 0.22 15100 kg/m3

Considering layer of Tungsten Carbide hard faced on the surface of fan blade, applying
the properties shown above and applying Pressure of 0.0018 MPa. Figure 4-5:
Displacement Results for Tungsten Carbide shows displacement and value of
maximum displacement is 0.000042 mm.

Displacement (mm)
0.000042
0.000039
0.000035
0.000032
0.000028
0.000024
0.000021
0.000017
0.000014
0.000010
0.000007
0.000003

Figure 4-5: Displacement Results for Tungsten Carbide

Figure 4-6: Stress Results for Tungsten Carbides distribution of stresses on the surface
of the blade and also defines the area of minimum and maximum stresses that shows us
stresses to the maximum value of 0.0554 MPa. The welding electrode normally use for
Tungsten Carbide is Stoody-130 (ESAB).

25
 σ, Stress (MPa)
0.0554
0.0511
0.0467
0.0423
0.0379
0.0336
0.0292
0.0248
0.0204
0.0161
0.0117
0.0073

Figure 4-6: Stress Results for Tungsten Carbide

Results shows that tungsten carbide layer welded on the fan blade gives much better
resistance to displacement and stresses produced on the surface of the blade due to the
pressure faced by the surface of the blade.it is more convenient and reliable to use
welding electrode Stoody-130(ESAB) for Welding on the surface of blade as it gives
better results than chromium carbide and mild steel. Chromium carbide is better than
mild steel but shows less reliable behavior than tungsten carbide .The area of Stress
distribution in all three cases is alike therefore maximum stresses occur at the weakest
point and proper welding should be done at that specific point.

26
 Deformation Stress

0.14

0.118
0.12

0.1

0.08
0.068

0.06 0.0515
0.0426
0.04

0.02
0.0052 0.0055

0
Mild Steel Chromium Carbide Tungsten Carbide

Figure 4-7: Comparison of Deformation & Stresses of different welding electrodes

27
 Conclusions

Induced draft fan is very critical equipment and its failure results in breakdown of the
whole process. In cement industry fan is subjected to heat and dust which increase the
rate of wear & tear. Extra care should be taken, regular inspection and maintenance is
required to keep the operation smooth. Hard facing is done to make it more resistant to
wear. Normally hard facing of chromium carbide is done on the upper face of the blade.
The aim of this project is to analyze the area of maximum stresses and effect of heat on
the impeller. It will be helpful in finding the most efficient material composition of hard
facing to make it more reliable and long lasting. Different hard facing techniques,
material compositions, effective areas of hard facing and problems associated with
centrifugal ID fans were reviewed and a suitable solution to the problems is required
depending upon the conditions and requirements of the ID fan taken as our project’s
main focus. It will help us in maintenance of the fan on regular basis and will definite ly
improve the quality of the actions taken during maintenance as well as reduce the time
of maintenance to make the equipment more reliable and maintenance free. The
Structural Analysis is done by considering mild steel, Chromium Carbide and Tungste n
Carbide and Results Show that Welding of tungsten carbide has more life and reliability
that chromium carbide and mild steel therefore it is suggested to use Stoody-
130(ESAB) for welding purpose whenever needed.

28
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