Main factor to be consider in the fan during Operation & Maintenance other than routine Check

High gas temperature Fan Operation & Erosion or Wear and corrosion maintenance Vibration

The fan should not operate over above the maximum design temperature. If so Material strength Material yield strength, as well as creep and rupture strength, properties drop dramatically with slight increase in temperature. Thermal expansion

With high temperature, loosening of hub in shaft may occur. Resulting vibration and movement of the rotor on the shaft. Thermal Fatigue Fast rate of temperature change may cause premature rotor failure because of Thermal fatigue.

Gas Temperature Effect

High Temperature corrosion Sulfidation and carburization may occur and form surface pitting, embrittlement corrosion of weld material. Rotor inlet seal

Required more clearance to take care expansion or it will damage the inlet cone and rotor.
Expansion Joints Expansion Joints are essential for high temperature fan and it should be provided Adequate

General Procedure
Shaft cooling and Seal Gland cooling is required for fan operating at higher temperature (> 650 deg C). While heating or cooling we have to maintained 40 Deg C per hour rate. In Emergency Shutdown, it is important that the fan should be rotated at 40 rpm rate until the gas temperature decreases to 100 Deg C. Other wise it will lead to permanent distortion of the shaft.

Erosion (Wear) is a major problem in induced draft fans while handling dust mixture gas.

High dust loading combined with high inlet velocities can result in dangerous Break downs
To avoid Erosion wear liners will help, but while selecting the system the following points should be considered to minimize the problem. Reduce the particulate (dust) flow rate Reduce the average particle size Install high efficiency dust collector to separate the dust from air stream.

Cause of Erosion

 Reduce the gas (with dust) velocity at fan inlet. The kinetic energy (KE) generated over the particles is square of the velocity. For reducing the fan inlet velocity we have to select lower speed fan and larger diameter fan

We can select Double inlet fan instead of single inlet fan to reduce the fan inlet velocity.
For clean air application, we can use Mild steel material. For dusty air we have to use hard facing impeller. Bolting type wear liner is not safe for high speed and long operating hours fans. Some Hard facing electrode for fan Chequred pattern hard facing will not solve full L&T CPE-063 Diffusion -Abroloy 3000D wear problem. Advani Weld arc SV-6 Wear Resist XL-CC 60

Vibration is a periodic back-and-forth motion of a machine or Machine parts. Vibration is a destructive force that leads to the premature failure of rotating machinery. Vibration will degrade weaker machine components until the eventual collapse of the mechanical system. Usually, the first casualties are machine parts like bearings, couplings and mechanical seals If allowed to progress to extreme levels, bearing housings and pedestals, shafts, foundations, and virtually every connecting member to the machine is go to severe damage.

Vibration

If the part responsible for the vibration can withstand greater loads than associated machine components, it could lead to premature failure of these components with little damage to the offending part. For example, gears and couplings can usually withstand greater loads than their support bearings. Vibration is accurately defined by all these common terms: swinging back-and-forth, oscillating, unbalanced, vibrating and shaking. Vibration occurs when a machine or machine component moves from its neutral position or normal position of rest to a lower and upper extreme limit of travel.

Vibrations fall into two categories, free and forced

Free vibrations occur when the system is disturbed momentarily and then allowed to move without restriction. Forced vibrations occur if a system is continuously driven by an external agency The cause of vibrations must be due to force, Which change its direction or its strength. So each case the vibration has different characteristics.

Vibration Terminology
Vibration Frequency Is Number of cycle happened for a particular time.
1 Cycle Displacement

Time Vibration Displacement Is the total distance traveled Expressed in CPM by the vibration part from one Cycle per minute) extreme limit to other limit 1 Hz = 1 CPS = 60CPM (Peak-Peak displacement)

Peak velocity

Vibration Velocity Is the peak speed of parts displacement, which is high at neutral point.

Expressed in Microns (0.001 mm)

Expressed in mm/sec

Vibration Terminology
Vibration Acceleration During vibration the weight reach zero velocity at peak point and again accelerate the speed after turning the direction is Vibration acceleration. Phase Phase is defined as the position of a vibration part at a given instant with reference to a fixed point or another vibrating part.
Peak Acceleration

Expressed in g ie 9.81 m/sec2

Expressed in Degree i.e. 0 deg to 360 deg

Phase = 0 90 Deg Deg Phase = 180 Deg

Displacement !, Velocity !, or Acceleration ! Which parameter should we use to monitor the fan health ? Displacement (D) , Velocity (V) , and Acceleration (g) are directly related one to each other along with Frequency.
Velocitypeak = 52.3 * Displacement
Peak

* Frequency * 10 1000
4

gpeak = 5.6 * Displacement

Peak

* Frequency * 10 1000

In practical we can directly measure the velocity and acceleration, so the above formula is shown to explain the relation.

When a sheet metal is bent repeatedly front and Back the folding area fail in to fatigue and break Increasing the amount of the bending (Displacement) the sheet is more likely to fail
Increasing the rate of bending (Frequency) the sheet is quicker to fail So the failure severity of sheet metal is depends on amount of displacement and rate of frequency.

Like that Vibration severity is a function of Displacement and Frequency i.e. Velocity
Velocity in mm/sec is the Overall Indicator of Machinery Health.

Vibration measurement should be taken in rotor support bearing in three position. Axial Inline with shaft Radial (H) Horizontal Perpendicular to shaft Radial (V ) Vertical Perpendicular to shaft
The velocity measured in bearing is show the combination of vibration level of different parts, like shaft, bearing, Housing, pedestal and foundation. Also it may be the combination of different cause.

Vibration Amplitude Vibration frequency is a measure of how often a machine or machine component oscillates. Vibration amplitude is a measure of how much or how far it travels back-and-forth.
The distance traveled, or vibration amplitude can be measured as a Peak, Peak to Peak or RMS value. Peak (Pk) amplitude measures the amount of travel from the neutral position to the upper extreme limit of travel or from the neutral position to the lower extreme limit of travel. Peak-to-Peak (Pk-Pk) amplitude is the total amount of travel from the upper extreme limit of travel to the lower extreme limit of travel.

RMS amplitude is Root Mean Square of peak value.

RMS amplitude measures the amount of travel from the neutral position to 70.7% of the extreme limit.

RMS = 0.707 * Peak

or

Peak = 1.414 *RMS

The Vibration may be cause for the following reason.

Unbalance Misalignment Bent shaft Mechanical Looseness

Defective Bearings Rubbing

Electrical defects

Dynamic air force

Foundation and soil

Chennai 720KHz

Toone The If Locate level station of the Pitch fault pitch and or or Which Speed speed Station is of not music match We will it Vary will have affect for to tune Karnatic Quality individual or of Western music. frequency or Pop and Identify the Station Which create the fault. All rhythms and Pitch match to the Desired level, We get a good Music Like that to Machine If Machine one Locate part parts the parts faulty faulty Vibrate Vibrate the part, vibration different to We a desired have frequency. level Velocity to analyze thewill machine the So Increase each displacement health machine condition with havedifferent some is OK. limits for safe vibration frequency.

Trichy 936KHz

Madurai 1050KHz

Nellai 1150KHz

The Safest level of Vibration in Terms of Velocity is < 6 mm /Sec for All Fans.
The Vibration severity level for Fans 0 2.5 mm/sec Excellent 2.5 6.0 mm/sec Good 6.0 - 12.5 mm /sec Alarm More than 12 .5 mm/sec Shutdown To locate the fault we have to use Frequency filter analyzer with Oscilloscope or Recorder. We have to Set different frequency and find out the Displacement for each frequency. Once it will be recorded the cause of fault can be identified

Unbalance Frequency Direction = 1 X RPM

= Horizontal or Vertical

Misalignment = Shaft to bearing, Drive Coupling Frequency Direction = 2 X RPM Usually; = Axial 3 X RPM rare

Looseness = Bearing clearance, Rotor to shaft, bolts

Frequency
Direction

= 2 X RPM
= Vertical

Loose V-Belts Frequency Direction = 1 X RPM

= Horizontal or Vertical

Bad antifriction bearing Frequency Direction = 6 to 10 0 X RPM (Related to number of Balls) = Horizontal or Vertical

Aerodynamic force
Frequency Direction = No of Impeller blades X RPM = Horizontal or Vertical

Electrical Defects = Uneven air gap, Open/Shorted windings Broken or Loose bar, Unbalanced three phase supply Frequency = 1 X RPM Immediately disappears after switch off Direction = Horizontal or Vertical

Worn out Gear

Frequency = No of teeth X RPM Direction = Horizontal or Vertical Vibration due critical speed will increase at the speed match to critical speed and decrease at lower or higher RPM.

Case-1 Machine Health is Good Condition

Here all the vibration Signature is below limit

Case-2 Unbalance

Vertical & Horizontal vibration Signature is above limit

Case-3
Misalignment and Looseness

Vertical & Horizontal at 2k is high and axial in 1k and 2k is high

Case-4
Damaged Bearings parts

Vertical & Horizontal at 10k is high

Critical Speed
Every Material has a natural Frequency at which it like to Vibrate and resonance. The natural frequency of most musical instruments like Drum, Bell , Violin are give various musical notes. There are two things, which affect the natural frequency the Stiffness (Spring constant) and the Weight ( Mass) In all rotating part the resonance will occurs at a particular speed is called Critical speed (i.e. it matching its natural frequency. So the stiffness and weight of the machine is decide the critical speed of the machine.

Critical Speed = lateral natural frequency assuming shaft is Rigidly supported (Normally 1.4 times of operating speed)
Design Resonant Speed = lateral natural frequency Including Stiffness effects of bearing housing, Steel pedestal and base frame. (Normally 1.25 times of operating speed)

Installed Resonant Speed = lateral natural frequency Including Stiffness effects of foundation & soil.

Unbalance is one of the leading causes of vibration in rotating machinery. Unbalance is simply an unequal distribution of rotor weight along the shaft axis. Unbalance imposes high dynamic loads on support bearings due to the centrifugal forces generated during rotation. The true measure of unbalance is expressed in terms of Oz-in or gram-cm.

FC = 0.11 x (RPM 1000)2 x Gram-Cm

FC = Centrifugal force in Kg 0.11 = Constant to convert gram-cm to Kg 1000 = Constant to determine the square factor

TYPES OF UNBALANCE 1. Static 2. Couple 3. Dynamic Static The shaft center line is shifted parallel to the Principal axis. It Can be balanced in a Single Plane, usually at the rotor center of gravity

Couple The central principal axis intersects the shaft centerline at the rotor center of gravity. An equal amount of force applied to both ends of the rotor, acting in opposite directions It must be balanced in two Planes, usually at the ends of the rotor

Dynamic The combination of static and couple unbalance forces usually induce a central principal axis that is offset from the shaft centerline and the rotor CG. It must be balanced in two Planes, usually at the ends of the rotor

In site Balancing
There are three method of balancing which can be done at site . Static Balancing method Three point method Dynamic Balancing with analyzer

Static Balancing Mark a point at bottom of rotor and rotate certain revaluation and leave it. The rotor should stop without any force.
After stopping note the marked point, if the mark is again bottom the unbalance mass is at bottom. Confirm the point one or two repeat action. If the mark is not at bottom again mark second point at bottom repeat the action. After confirm the point add a trial weight at 180 Deg (Top) from the point and repeat the action. By increase or degrease the weight balance the wheel.

Three Point Balancing

Reading Take Displacement reading(D1) at 1st - D1 = 150 Micron full speed. Draw a circle with Trial Wt (TW) = 280 gram radius of Displacement Reading 2nd - D2 = 100 micron Mark three point in circle and 3rd - D3 = 200 Micron Wheel approximately at 120 Deg. th 4 - D4 = 280 Micron Weld Trial Weight at point A and run the fan at full speed. Take Displacement reading and draw a circle at point A Remove trial weight and weld at point B and run the fan at full speed. Take Displacement reading and draw a circle at point B Remove trial weight and weld at point B and run the fan at full speed. Take Displacement reading and draw a circle at point B

Three Point Balancing

Mark point D at intersection of three circles. Distance (L) = 133.35 Angle = 42 Deg Draw a line from First circle center to Point D and measure length Draw a line from center to point A and measure the angle The Correction weight (CW) required
A
D

CW = TW (D1/L)
= 280* (150 / 133.35) = 315 Grams Remove trial weight and weld the correct wt 315 gram at point angled to 42 Deg in clock wise direction.
C