Centrifugal Fans Using Vibration Analysis To Detect Problems

CENTRIFUGAL FANS USING VIBRATION ANALYSIS TO DETECT PROBLEMS
PRINCIPLES OF OPERATION: Centrifugal fans are one of the most versatile and widely used pieces of rotating mechanical equipment found today. The fan is an essential part of all heating, air conditioning, air handling and ventilation systems. Fans are used in automobiles, homes, offices, industry and many other applications. The most common use of centrifugal fans is to move air and gases for air handling or ventilation systems. The basic principal of operation for a centrifugal fan is that a shaft mounted rotating wheel (impeller) inside a scroll type housing imparts energy to the air stream or gas being moved by the fan. Centrifugal fans utilize centrifugal force (thus their name) to increase the velocity of the air as it passes between the fan wheel blades and exits at the tip of the fan wheel. This action converts mechanical energy (shaft torque) into kinetic energy by acceleration of the air stream to a higher velocity (velocity pressure) and potential energy (static pressure). Fans are velocity generators for the air being moved. FAN PERFORMANCE: Fans follow basic laws of performance. These are useful in determining the effect of changes to the operating parameters and can help determine the cause of operational problems. These basic laws apply to any type of fan or fan system. 1. The air volume varies directly as the fan wheel (impeller) rotating speed. 2. The pressure (static, velocity and total) varies as the square of the fan wheel (impeller) speed. 3. The power required (horsepower) varies as the cube of the fan wheel (impeller) speed. 4. At constant speed and capacity, the pressure and power vary directly as the density of the air moved (lbs per cubic foot). 5. At constant pressure, the speed, capacity and power vary inversely as the square root of the density of the air. 6. For a constant weight of air: a. The speed, capacity, and pressure vary inversely with the density of the air. b. The horsepower varies inversely with the square of the density. DETECTING FAN PROBLEMS USING VIBRATION ANALYSIS: Fans are subjected to operational forces generated by their operating speed, static pressures and system arrangement. These operational forces cause forced vibration and may originate from the rotating parts themselves. Unbalanced fan wheels and drive sheaves are examples of forces that cause force and couple unbalance. Axial load on fan bearings is generated primarily by the negative static pressure at the inlet of the fan wheel. The relationship between a fans operating conditions (flow quantity, pressure, speed and arrangement) generate forces that cause vibration and problems that reduce the expected life of the bearings and fan components.
Copyright 2014 Technical Associates of Charlotte, P.C. www.technicalassociates.net
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SUMMARY OF COMMON FAN VIBRATION PROBLEMS: (Detected Using Vibration Analysis) 1. Unbalance of Overhung Fan Rotating Parts (Fan Wheel or Drive Sheave): Overhung Rotor Unbalance will cause high 1X RPM in both the axial and radial directions. Axial readings tend to be in-phase and steady, whereas radial phase readings might be unsteady. Overhung rotors have both force and couple unbalance, each of which will likely require correction. Thus, correction weights will most always have to be placed in 2 planes to counteract both force and couple unbalance. 2. Unbalance of Center-Hung Fan Wheel: Force Unbalance will be in-phase and steady. Amplitude due to unbalance will increase by the square of speed (a 3X speed increase = 9X higher vibration). 1X RPM is always present and normally dominates the spectrum. This can be corrected by placement of only one balance correction weight in one plane at the Rotor center of gravity (CG). Approximately 0 phase difference should exist between outboard and inboard horizontal, as well as between the outboard and inboard vertical direction. 3. Belt Drive Problems and Drive Misalignment: Sheave misalignment is a very common problem with belt-driven fans. When it is present, the vibration at fan speed is typically the highest vibration peak in spectra taken on the motor. It can be confirmed by measuring phase in the axial direction at fan speed. Misalignment will cause phase differences at or approaching 180 between the motor and fan inboard bearings (closest to the pulleys) with phase comparisons made at fan speed. 4. Fan Stall Condition: This unstable condition can cause the ductwork to vibrate excessively and produce a howling sound. In many cases subsynchronous frequencies will occur at approximately 66%-75% of the fan RPM that will oscillate in amplitude and will produce subsynchronous sidebands around 1X blade pass frequency (where blade pass frequency = #blades X RPM). 5. Fan Surge Condition: Surge is a condition resulting from improper fan selection or operation and is recognized by the whoosh sound as air surges back through the fan. The frequency is subsynchronous typically at 33%-50% of fan running speed. 6. Fan Bent Shaft Condition: Bent shaft problems cause high axial vibration with axial phase differences tending towards 180 on the same rotor. Dominant vibration normally occurs at 1X RPM if bent near shaft center, but at 2X RPM if bent near the coupling. Dial indicators can be used to confirm a bent shaft. 7. Misalignment Condition: Fan shaft misalignment is a condition typically found in direct drive overhung fans. Misalignment is a condition where the centerlines of two (2) connected shafts typically at the coupling do not coincide. Parallel misalignment is a condition where the shaft
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centerlines are parallel, but not aligned. The radial vibration spectra will show 2X RPM higher than 1X and a 3X higher than normal. Axial 1X and 2X will be low with 180 out of phase across the coupling in the radial and axial direction. Angular misalignment will show high axial 1X and some 2X and 3X RPM 180 out of phase axial across the coupling. 8. Belt Wear: Belt wear can be detected by the presence of frequencies not only at Belt RPM, but also at multiples of belt RPM (harmonics). Typically, when belt wear is present, the peak at 2X belt RPM will exceed the peak at 1X belt RPM. If belt wear is significant, it will usually produce many harmonics of belt speed. Note that belt speed will always be lower than either the motor or fan speed (RPM). 9. Fan Bearing Problems: Peaks (with harmonics) at nonsynchronous frequencies is a symptom of rolling element bearing wear. Short bearing life for fans is typically the result of poor bearing selection for the application, such as excessive loads, poor lubrication or high temperatures. If the model number and manufacturer of the bearings are known, then the specific fault frequencies for the outer race, inner race, rolling elements and cage can be determined. These fault frequencies for such bearings are found within tables of most predictive maintenance (PdM) software today. 10. Air Flow and Air Turbulence Problems: Fans will normally have a peak in the spectrum at blade pass or vane pass frequency. Increased amplitude of the peak indicates the possibility of clearance problems at the discharge of the scroll or flow restrictions causing high discharge pressure. Severe flow turbulence will generate subsynchronous peaks and a raised noise floor. This article is intended to be a summary of common fan problems that vibration analysis can detect and identify. Formal vibration analysis training and balancing training from an organization like Technical Associates of Charlotte can provide an analyst with valuable information and understanding of fan problems detected by vibration analysis. Specialized vibration training courses such as time waveform analysis can also be beneficial. In addition, most training service providers offer vibration analysis certification through a written examination as confirmation of the students comprehension of the course material and the basics for detecting common fan problems using vibration analysis. James David Kesler Sales/Operations Manager Technical Associates of Charlotte 1230 West Morehead St., Suite 400 Charlotte, NC 28208
Copyright 2014 Technical Associates of Charlotte, P.C. www.technicalassociates.net
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CENTRIFUGAL FANS USING VIBRATION ANALYSIS TO DETECT PROBLEMS

Copyright 2014 Technical Associates of Charlotte, P.C. www.technicalassociates.net