TROUBLE-SHOOTING OF FANS, BLOWERS AND

FLUIDIZERS
The purpose of this report is to include the various failure and their effects on the
fans, blowers and fluidizer. This report does not cover the solutions to the occurred
problems and maintenance strategies to curb future failures.

FANS:
A device used to deliver a quantity of air at a desired pressure.

TYPES OF FAN:
According to shaft and discharge fluid direction it can be categorized as:
1. Positive displacement or Axial Fans
a) Reciprocating fans
b) Rotary fans
c) Propeller fans
2. Radial Fans:
a) Centrifugal fans

BLOWERS:
A blower uses mating helical lobes or screws and is used for the same
purpose as a fan. They are normally moderate- to high-pressure devices.
Blowers are almost identical both physically and functionally to positive
displacement compressors.
Difference between fan and blower lies in their rotating element
configuration and discharge pressure capabilities.

FLUIDIZERS:
Fluidizers are identical to single-stage, screw-type compressors or blowers. They
are designed to provide moderate- to high-pressure transfer of nonabrasive, dry
materials.

FAN TROUBLE-SHOOTING
Generally the failures and problems occurred in fans are categorized as under:
1. MECHANICAL FAILURES
2. ELECTRICAL FAILURES
3. FOUNDATION PROBLEMS

MECHANICAL FAILURES
Bearing noise varying from a 'dry' rumble to a squeal
Insufficient discharge pressure
Insufficient Capacity
High vibration
Short Bearing life

ELECTRICAL FAILURES
Motor trips
Fan won't run
Overheating of windings of motor
Fan runs in alternate direction.

FOUNDATION PROBLEMS
Soft foot
Bearing support structure weakening due to excessive vibration
Lateral flexibility ( related to support structure mass and rigidity) failure

CASE STUDY
TROUBLE SHOOTING IN CENTRIFUGAL OF FANS
MAJOR CAUSES:
The major causes leading to failures in centrifugal fans are:
1. AERODYNAMIC INSTABILITY
When fans are operated outside the control range they tend to become unstable
which cause fan rotor assembly to deflect from centerline
2. PLATE-OUT

Dirt, moisture, and other contaminants tend to adhere to the fans rotating element.
This buildup, called plate-out, increases the mass of the rotor assembly and
decreases its critical speed, the point where the phenomenon referred to as
resonance occurs. If fan actual speed coincide with the resonance speed excessive
vibration occurs leading to catastrophic failure.
3. SPEED CHANGES
4. LATERAL FLEXIBILITY
FAILURE MODES OF CENTRIFUGAL FANS:

PROBLEMS

CAUSES

INSUFFICIENT
DICHARGE PRESSURE

INSUFFICIENT CAPACITY

OVER-HEATED BEARING

SHORT BEARING LIFE

Air leaks in system

Damaged Wheel
Dampers
Incorrect direction of rotation
Total system head greater than
design
Aerodynamics Instability
Air leaks in system
Damaged Wheel
Not adjusted dampers
Incorrect direction of rotation
Total system head greater than
design
Abnormal end thrust
Aerodynamics Instability
Bent shaft
Broken and loose bolts
Damaged wheel
Excessive belt tension
Too much grease in ball bearing
Aerodynamics Instability
Bent shaft
Specific gravity above design

OVER LOAD ON DRIVER

Bearings improperly lubricated

Bent shaft
Over fan capacity
Incorrect direction of rotation

HIGH VIBRATION

Abnormal end thrust

Aerodynamics Instability
Bearings improperly lubricated
Bent shaft
Broken and loose bolts
Damaged Motor
Worn Couplings
Worn Bearings
Unstable foundation
Misalignment
Bent shaft
Misalignment
Total system head greater than
design
Motor improperly wired
Bearings improperly lubricated
Motor improperly wired
Defective stuffing box
Wheel binding on fan housing

POWER DEMAND EXCESSIVE

MOTOR TIPS

MAJOR CAUSES:
PROCESS INSTABILITY
Blowers are very sensitive to variations in their operating envelope
The probability of catastrophic failure to blower components increases in
direct proportion to the amount and speed of the variation in demand or
downstream pressure

START/STOP OPERATIONS

Frequent start/stop operation also have a negative effect on blower reliability

DEMAND VARIATIONS:
Frequent variations in demand greatly accelerate the wear rate of the thrust
bearings in the blower. This can be directly attributed to the constant, instantaneous
axial thrusting caused by variations in the discharge pressure required by the
downstream system.

MECHANICAL FAILURES
The primary failure points include: thrust bearing, timing gears, and rotor
assemblies.