Forced Draft and Induced Draft Fan
Forced Draft and Induced Draft Fan
Forced Draft and Induced Draft Fan
Maintenance Guide
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Forced Draft and Induced Draft Fan Maintenance Guide, EPRI, Palo Alto, CA: 2004. 1009651.
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REPORT SUMMARY
A continuous flow of air and combustible gases in fossil power plants is required to supply the
correct amount of combustion air and to remove the gaseous combustion products. This flow,
which passes through ducts, the boiler, heat exchangers, and flues and stacks, is created and
sustained by stacks and/or fans. In fossil stations, supply air fans are often referred to as forced
draft (FD) fans and are used to push air through the combustion air supply system into the
furnace. Some stations also use fans to move the gaseous combustion products through heat
exchanger surfaces to the stack. These are often referred to as induced draft (ID) fans.
Background
Reliability of this equipment is important to plant efficiency and availability, and maintenance of
these components becomes an important task for plant personnel. This issue ranked Number 1 in
the 2003 FMAC Maintenance Issues Survey and, because of this, FMAC plans to begin a project
to produce a guide that will address many of the common problems that members are facing with
this equipment. Maintenance issues that are most often cited include bearing and alignment
problems, lubrication, vibration problems (resulting from improper balancing or buildup of
deposits), and erosion and wear of blades from entrained particles. Also reported are problems
with dampers, particularly on flow control dampers.
Objectives
• To provide information on axial and centrifugal fans used for boiler draft service
• To assist fossil power plant maintenance personnel in troubleshooting and maintaining fans
• To provide routine and preventive maintenance guidance to assist in improving the reliability
of fans
Approach
In cooperation with interested FMAC members, a task group of utility engineers, equipment
suppliers, and industry experts was formed. This group identified key design and maintenance
issues facing plant personnel and provided input that was used in the preparation of the guidance
set forth in this report. Experience-proven practices and techniques were identified during this
effort and are summarized here for use by all power plant personnel.
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Results
This guide provides the user with an understanding of FD and ID fans, including elemental
component descriptions, common materials of construction, and typical applications. The scope
of the guide includes common applications and criteria for selection, failure modes and
troubleshooting guidance, condition monitoring and predictive maintenance techniques,
preventive maintenance strategies, recommendations on fan repair and inspection techniques,
and good installation practices, including “how to” information on important steps.
EPRI Perspective
The information contained in this guide represents a significant collection of technical
information, including techniques and good practices, related to the maintenance, monitoring,
and troubleshooting of this important piece of plant equipment. Industry knowledge from recent
experiences and improvements has been included in this report. Assembly of this information
provides a single point of reference for power plant personnel, both now and in the future.
Through the use of this guide, EPRI members should be able to significantly improve and
optimize their existing plant predictive, preventive, and corrective maintenance programs related
to this equipment. This will help members achieve increased reliability and availability at a
decreased cost.
Keywords
Plant maintenance
Plant operations
FD and ID fans
Fossil
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ACKNOWLEDGMENTS
FMAC would like to acknowledge the following individuals for their contributions during the
development of this report.
FMAC also acknowledges the following organizations for permitting the generous use of figures
and various materials from their literature and in-house resources and for reviewing and
providing valuable comments on this document.
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CONTENTS
1 INTRODUCTION ....................................................................................................................1-1
1.1 Purpose ...........................................................................................................................1-1
1.2 Organization ....................................................................................................................1-1
1.3 Key Points .......................................................................................................................1-2
3 TECHNICAL DESCRIPTION..................................................................................................3-1
3.1 Introduction .....................................................................................................................3-1
3.2 Fan Applications..............................................................................................................3-3
3.2.1 Induced Draft Fans ..................................................................................................3-3
3.2.2 Forced Draft Fans....................................................................................................3-3
3.2.3 Balanced Draft.........................................................................................................3-4
3.2.4 Cold Primary Air Fans .............................................................................................3-5
3.2.5 Hot Primary Air Fans ...............................................................................................3-5
3.2.6 Gas Recirculation Fans ...........................................................................................3-6
3.2.7 Number of Fans.......................................................................................................3-6
3.3 Fan Types .......................................................................................................................3-7
3.3.1 Centrifugal Fans ......................................................................................................3-7
3.3.2 Axial Fans..............................................................................................................3-13
3.4 Fan Drives .....................................................................................................................3-15
3.5 Fan Controls..................................................................................................................3-16
3.5.1 Centrifugal Fan Controls........................................................................................3-16
3.5.1.1 Inlet Vanes .....................................................................................................3-16
3.5.1.2 Inlet Dampers ................................................................................................3-17
3.5.1.3 Two-Speed Motors.........................................................................................3-18
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5 TROUBLESHOOTING ...........................................................................................................5-1
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7 MAINTENANCE .....................................................................................................................7-1
7.1 Developing a Preventive Maintenance Program .............................................................7-2
7.2 Basic Rules for Conducting Maintenance .......................................................................7-3
7.3 Periodic Maintenance Recommendations.......................................................................7-3
7.4 Component Maintenance ................................................................................................7-5
7.4.1 Bearings ..................................................................................................................7-6
7.4.1.2 Routine Maintenance Recommendations ........................................................7-7
7.4.1.2 Bearing Overhaul .............................................................................................7-8
7.4.2 Lubrication System ................................................................................................7-10
7.4.2.1 Routine Maintenance .....................................................................................7-10
7.4.2.2 Circulating Lube Oil System Overhaul ...........................................................7-10
7.4.3 Couplings...............................................................................................................7-12
7.4.3.1 Routine Maintenance Recommendations ......................................................7-12
7.4.3.2 Coupling Overhaul .........................................................................................7-13
7.4.3.3 Coupling Alignment........................................................................................7-14
7.4.4 Variable Inlet Vanes and Control Dampers ...........................................................7-15
7.4.4.1 Routine Maintenance .....................................................................................7-15
7.4.4.2 Inlet Vane Overhaul .......................................................................................7-15
7.4.5 Centrifugal Fan Wheels .........................................................................................7-16
7.4.5.1 Centrifugal Fan Wheel NDE...........................................................................7-18
7.4.5.2 Blades ............................................................................................................7-18
7.4.5.3 Center Plate/Side Plate .................................................................................7-21
7.4.6 Shaft ......................................................................................................................7-21
7.4.7 Hubs ......................................................................................................................7-22
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10 SAFETY..............................................................................................................................10-1
10.1 Rotating Equipment.....................................................................................................10-1
10.2 Confined Space...........................................................................................................10-1
10.3 Burn Hazards ..............................................................................................................10-1
10.4 Electrical......................................................................................................................10-1
10.5 Operation Testing........................................................................................................10-2
10.6 Cleaning Operations....................................................................................................10-2
10.7 Fan Movement ............................................................................................................10-2
11 TRAINING...........................................................................................................................11-1
12 REFERENCES ...................................................................................................................12-1
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LIST OF FIGURES
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Figure A-6 Orientation of an Articulated Yoke Probe to Produce Flux Lines at Right
Angles ............................................................................................................................. A-16
Figure A-7 Indications Are Consecutively Numbered and Circled .......................................... A-19
Figure A-8 Marking Multiple Indications.................................................................................. A-19
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LIST OF TABLES
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1
INTRODUCTION
Fired steam generators (that is, boilers) require large draft fans to move air into the furnace and
to remove the combustion products. Draft fans are primary auxiliaries that support boiler
operation for all types of fuel and firing methods. Draft fans are typically used in four principal
applications: forced draft (FD), primary air (PA), induced draft (ID), and gas recirculation (GR).
Other applications include booster fans and mill exhausters. This guide addresses FD and ID
fans, which are the largest and most common applications. The maintenance recommendations
for these fans are easily adapted for most other draft fan applications.
1.1 Purpose
This FD and ID fan maintenance guide provides information on axial and centrifugal fans used
for boiler draft service and is intended to assist fossil power plant maintenance personnel in
troubleshooting and maintaining fans. A discussion of fan characteristics and components that
serves as a reference for understanding the basics of fan performance and mechanical
construction is provided. Routine and preventive maintenance guidance is provided to aid in
improving the reliability of fans. A troubleshooting guide assists in diagnosing problems that
have been encountered in various fan failure reports. Data for this guide were obtained from
direct experience in fossil plants, industry surveys on failure reports, vendor input, and reviews
of plant literature and industry documentation.
1.2 Organization
Section 3 provides technical description, basic discussion of fan performance characteristics, and
the mechanical components.
Section 4 provides an analysis of failure modes and effects as well as failure data.
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Introduction
Appendix B provides a list of all the key points indicated in the guide.
Throughout this guide, key information is summarized in “Key Points.” Key Points are bold-
lettered boxes that succinctly restate information covered in detail in the surrounding text,
making the key points easier to locate.
The primary intent of a Key Point is to emphasize information that will allow individuals to take
action for the benefit of their plant. The information included in these Key Points was selected
by Fossil Maintenance Applications Center (FMAC) personnel, the consultants, and utility
personnel that prepared this guide.
The Key Points are organized according to three categories: Operation and Maintenance (O&M)
Costs, Technical, and Human Performance. Each category has an identifying icon, as shown
below, to draw attention to it when quickly reviewing the guide.
Appendix B contains a listing of all of the key points in each category. The listing restates each
key point and provides reference to its location in the body of the report. By reviewing this
listing, users of this guide can determine whether they have taken advantage of key information
that the writers of the guide believe would benefit their plants.
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Introduction
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2
GLOSSARY OF TERMS
FD Forced draft
GR Gas recirculating
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Glossary of Terms
hp Horsepower
ID Induced draft
PA Primary air
PM Preventive maintenance
UT Ultrasonic test
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Glossary of Terms
VT Visual test
WG Water gauge
1 hp = 746 W
1 lb = 0.45 kg
1 lb/ft3 = 16 kg/m3
1 in. = 25.4 mm
1 ft = 0.3 m
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TECHNICAL DESCRIPTION
3.1 Introduction
A fan is a device that produces a flow of gas by the movement of a surface. As used in this
guide, a fan is defined as a turbo machine with a rotating impeller enclosed in a casing.
Fans are similar to compressors; the difference is that fans create a flow of gas whereas
compressors increase the pressure of the gas. To increase a flow, fans must increase the pressure
of the gas and compressors must create a flow. In the past, there were specific criteria defining
the difference between fans and compressors. For example, the 1946 edition of ASME PTC-11,
“Performance Test Code for Fans,” defines a fan as providing a compression ratio of 1.1 or a
density change of 7%. ISO 5801 defines the upper limit of fans as a pressure increase of 120
inches Wg (30 kPa). ASME PTC-10, “Performance Test Code on Compressors and Exhausters,”
states that compressors are usually intended to produce considerable density change. The choice
of whether a device is a fan or a compressor is not regulated or standardized.
In addition, the fan selected must be adequate for the required duty with regard to air volume,
static pressure, horsepower, and noise. Discussion of these topics follows.
Figure 3-1 is a typical schematic of air and gas flow through a boiler.
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Technical Description
Figure 3-1
Boiler Air Flow Schematic
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Technical Description
ID fans move the combustion flue gas through the boiler, air heater, and precipitator or the
baghouse, scrubber, and chimney to the atmosphere. They are a major component of a fossil-
fired plant and typically consume approximately 2% of the gross electrical output.
ID fans have the largest design margins of any major equipment in a fossil-fueled power plant.
The margins are typically 15% on flow, 30% on head, and 25°F on temperature. The large
margins are intended to allow for the following:
• Uncertainty in determining system requirements
• Allowance for wear
• Operating flexibility
• Allowance for pluggage and leakage
• Air infiltration
Even with these large margins, it is not uncommon for the ID fans to be the limiting factor on the
output of a coal-fired unit. ID fans are included in the top 25 causes of fossil plant outages and
are responsible for approximately 2% of the total outages of fossil-fired units.
The temperature of gas to be handled by the ID fan is based on the calculated unit performance at
maximum boiler load. Temperature affects fan performance, and thus, a margin on temperature
should be included to allow for variations in operation.
FD fans provide combustion air for boilers. The FD fan inlet is open to the atmosphere and
discharges through air preheating coils, an air heater into the boiler windbox, and finally through
the burners into the furnace.
In pulverized coal-fired boilers, approximately one-third of the combustion air is PA that is used
to transport the pulverized coal to the burners. Some boiler designs use PA fans, which may take
suction from the atmosphere and operate in parallel with the FD fans or may take suction from
the FD fan discharge and operate in series with the FD fans. The PA fan application is similar to
the FD fan; therefore, the description, problem area, and maintenance requirements described for
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Technical Description
FD fans are essentially the same for PA fans. Other boiler designs use mill exhausters that take
the air and pulverized coal mixture from the mill outlet and transport the mixture to the burners.
Because of the erosive nature of the pulverizer coal-air mixture, mill exhausters have a very
different application than the FD, ID, or PA fans and are not addressed in this guide.
For pressurized units without ID fans, the FD fan is sized for the entire system to the stack or to
the pollution control system.
FD fans for coal-fired plants rank close behind ID fans as the cause of outages. The causes of FD
fan failures are similar to those for ID fans. The FD fans for a coal-fired plant consume
approximately 0.7% of the gross electrical output.
The design margins on FD fans are typically smaller than the margins on ID fans but still larger
than on other major equipment. Margins of 15% on flow and 30% on head at the maximum
expected ambient temperature are common.
FD fans are normally equipped with sound trunks (inlet boxes) for noise attenuation. When
specifying FD fans, pressure loss through the silencers (if they are provided) must be taken into
consideration. An alternative method of noise attenuation is using a fan room. This involves the
use of open inlet FD fans located in a specially designed room with acoustical baffles for air
entry.
The balanced draft system uses both an FD fan system and an ID fan system to move air through
the boiler.
FD fans on a balanced draft boiler must have the necessary volume output of air required for
combustion, plus air heater losses and discharge pressure high enough to equal the total
resistance of air ducts, air heater, burners, and any other resistance between fan discharge and the
furnace.
ID fans in a balanced draft boiler move the gaseous products of combustion over convection
heating surfaces, pollution control system(s), plus the gas passages between the furnace and
stack.
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Technical Description
The weight of gas to be handled by the ID fan is the sum of the following:
• Theoretical air for combustion
• Excess air required at burner
• Infiltration
• Leakage air-to-gas through the air heater
The draft to be provided by the fan is determined by losses through the following boiler
components:
• Furnace
• Boiler and superheater
• Economizer
• Selective catalytic reduction (SCR)
• Air heater
• Precipitator or baghouse
• Ductwork
• Flue gas desulfurization system (scrubber)
• Stack
For fan design, safety margins are added to the net weight requirement, net draft requirement,
and gas temperature.
Cold primary air fans take ambient air and discharge it through the air heater, where the air is
heated up to 650ºF (the actual temperature depends on the moisture content of the coal), and then
into the pulverizers—where it is used to dry, heat, and convey the pulverized coal to the burners.
This system is used on large boilers where fans are installed in parallel in order to service a bank
of pulverizers.
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Technical Description
The volume requirements of the gas recirculating fan are determined by the amount of
recirculation necessary to obtain the required steam temperature. Maximum flow can occur at
either full boiler load or some reduced boiler load point, depending on boiler design. The gas
recirculation fan must be sized so its pressure capability will always exceed the pressure
differential developed by the boiler; otherwise, backflow of high-temperature furnace gas will
result through the fan, with serious consequences.
Radial tip blade fans (see Figure 3-6) can be applied for gas recirculation duty, but the straight
blade fan may be needed where high concentrations of fly ash will be encountered, depending on
the ash properties. Inlet dampers are the principal means of accomplishing volume control.
One of the major design decisions for a fan system is the number of fans. The factors to be
considered in selecting the number of fans are initial cost, operation and maintenance (O&M)
costs, flexibility of operation, and reliability.
When evaluating initial cost, the cost of motors, ductwork, insulation, control equipment,
electrical equipment, and foundations must be considered in addition to the cost of the fans. The
fewest number of fans usually results in the lowest initial cost.
Operating cost usually decreases as the number of fans increases. Fans usually have their highest
efficiency near their design points. At lower loads, some of the fans can be shut off in a system
with more fans. The remaining fans will then operate closer to their design points and, therefore,
more efficiently. An important parameter for evaluating operating cost is the projected loading
schedule for the generating unit. The variation in operating cost with the number of fans will be
less for a unit that operates at or near full load most of the time than for a unit that operates at
lower loads. Maintenance cost increases as the number of fans increases.
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Technical Description
It is difficult to assign cost values to the differences in reliability and flexibility of operation with
different numbers of fans. It is also difficult to assign a cost value to plant arrangement. Plant
arrangements can be improved by reducing the number of fans. For these reasons, the selection
of the number of fans is not a straightforward economic evaluation.
In addition to the factors discussed above, practical aspects should also be considered. For
centrifugal fans, because of fan size limitations, the maximum unit size for which two ID fans
can be used is approximately 700 MW. The same number of FD and ID fans is usually selected
to simplify operation of the fans.
The trend in the power industry has been to use two FD and two ID fans up to approximately 700
MW. Above this size, it is not practical to build ID fans that are large enough to use two fans. In
recent years, this concept has been challenged, and units with one FD and one ID fan have been
built up to a limit of 500 MW. Obviously, the cost for one fan and motor is less than for two, but
the bulk of the savings comes from the reduced number of ducts as well as capital costs.
The number of ID fans can have an effect on unit availability. Many owners believe that two fans
will provide better availability than one. However, with two fans, the probability of a fan failure
is roughly twice that for one fan, but the impact of a failure is approximately one-half. Thus, the
equivalent availability is about the same. There is not a large enough database of boilers with
single FD and ID fans to verify this probability, but statistical studies (using the NERC-GADS
database) of boiler feed pumps verify this theory. A boiler with one full-size boiler feed pump
has more full forced outages than units with two 50% capacity pumps but fewer forced deratings.
The overall equivalent availability of one full-size feed pump is slightly higher than two half-size
pumps.
On large units with four ID fans, the unit will probably be capable of operating at full load with
three fans under normal operating conditions. Thus, the unit will essentially have an installed
spare, which should result in improved availability.
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Technical Description
Figure 3-2
Section of a Centrifugal Fan
(Courtesy of Howden Buffalo, Inc.)
Figures 3-3 and 3-4 illustrate the cross-sectional view of various parts of a typical centrifugal
fan.
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Technical Description
Figure 3-3
Cross-Section View of a Centrifugal Fan
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Technical Description
Figure 3-4
Centrifugal Fan Components and Accessories
(Courtesy of Howden Buffalo, Inc.)
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Figure 3-5
Typical Rotor with Forward Curved Blades for a Centrifugal Fan
(Courtesy of Howden Buffalo, Inc.)
Centrifugal fans are available with the following various blade profiles, as shown in Figure 3-6:
• Airfoil backward inclined
• Flat bladed backward inclined
• Radial tip
• Straight radial
• Forward curved
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Technical Description
Figure 3-6
Wheel Blade Types and Rotation (Viewed from the Drive End)
In most power plant applications where the fans will handle clean air or clean gas, the highly
efficient backward inclined airfoils are the preferred design. In an application where the fan is
subject to erosion due to heavy dust loading, a straight radial type fan provides erosion
resistance, but at the expense of efficiency.
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Technical Description
The airfoil centrifugal fan is the most frequently applied fan for forced draft duty because of its
inherently high efficiency, low noise, stable performance, and steep rising pressure curve. These
features ensure good operation, particularly when fans are operating in parallel. Forced draft
service tends to be a good application for axial fans. The parts of a typical centrifugal fan rotor
are shown in Figure 3-7.
Figure 3-7
Centrifugal Fan Rotor Components
Axial fans produce movement of air along their axis or in an axial direction. Axial fans are
offered in single- and two-stage models. They are available with fixed-pitch and variable-pitch
blading. The variable-pitch fan is more sophisticated and efficient than the fixed-pitch fan.
Figures 3-8 and 3-9 illustrate sectional views through a two-stage axial fan. Air or gas enters
through a single inlet box where it makes a 90-degree turn through straightening vanes, passes
through the impellers, and exits through the diffuser section.
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Technical Description
Figure 3-8
Two-Stage Axial Fan Assembly
Figure 3-9
Two-Stage Axial Fan Impeller
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Technical Description
Where higher pressures are necessary, two-stage fans may be required. Two-stage fans are
offered for large-capacity induced draft service. A brief description of each of the main
components of the axial fan follows.
Rotor Hub. The rotor hub is the major component of an axial fan. The hub serves as the
retaining ring for the blades and their bearings and as the housing and protective cover for the
blade-actuating mechanism.
Blade Shaft Bearings. Blade shaft bearings are used to transfer the centrifugal force from the
blades to the fan hub.
Main Shaft and Main Shaft Bearings. In the axial fan, the main shaft does not carry large loads
over long spans between bearings as in a centrifugal fan. The rotating masses are low, and the
bearings are located close to the rotor. The shafts, therefore, are small in diameter and relatively
inexpensive in comparison to the large-diameter, long, forged steel shafts required for centrifugal
fans.
Blades. Various materials are used for axial fan blades. For forced draft service, relatively
inexpensive cast aluminum blades are generally used. For induced draft service, where high wear
resistance is required, ductile iron, cast steel, cast steel with hardened surfaces, or forged
aluminum blades with stainless steel inserts are available. Blade material selection is influenced
by the blade velocity and the size and hardness of the dust particles.
In induced draft service, if the fans are operated for long periods with precipitators performing at
low efficiencies, excessive blade wear will occur no matter what blade material is used. This is
true for either type of fan. In the axial fan, however, a worn set of blades can be replaced in a few
shifts. In the centrifugal fan, days of welding and balancing may be required to repair the fan.
Axial flow fans are more complicated than centrifugal fans but have the advantage, in most
cases, of higher efficiency over a wider load range.
Electric motors are normally used for fan drives because they are less expensive and more
efficient than any other type of drive. For fans of more than a few horsepower, squirrel-cage
induction motors are more widely used. This type of motor is relatively inexpensive, reliable,
and highly efficient over a wide load range. It is frequently used in large sizes with a hydraulic
coupling for variable-speed installations.
Two-speed ac electric motors can be used in conjunction with inlet vanes to obtain slightly
higher efficiencies at lower loads. This arrangement has a higher initial cost and is less reliable
than a single-speed motor and inlet vanes. Variable-speed motors are the optimum type of drive
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Technical Description
for centrifugal fans. They allow the fan to operate near its peak efficiency over the entire load
range; controllability is good, and fan erosion is substantially reduced at lower speeds. Recent
developments in variable-speed motors make them an excellent choice for centrifugal fans,
although the high initial cost of variable-speed motors is not justified in all applications.
Steam turbines have higher initial and maintenance costs and are less reliable but do provide a
variable-speed drive. Steam turbines are not competitive with electric motors for fan drives.
As the load on a boiler varies, the pressure and flow requirements from the fans in the system
vary. The most widely used methods to control centrifugal fans are by means of inlet vanes and
variable-speed drives.
Inlet vanes introduce a swirl to the flow entering a fan. This changes the angle of attack between
the flow and the fan blade and effectively changes the fan characteristics. Inlet vane control has a
low initial cost, is a simple method of control, and is very common for ID fans. Figure 3-10 is an
illustration of an inlet vane control assembly. The major disadvantage of inlet vanes is poor
efficiency at lower loads. Inlet vanes are subject to erosion if ash concentrations are high. The
vane linkage and bearings can bind or become damaged if they are located in the gas stream.
Therefore, these components should be located outside the fan inlet housing, where inspection
and maintenance can be performed without entering the fan. The duct connections at the fan inlet
or outlet should be flexible to isolate the fan from duct expansion and vibration. The duct should
be separately anchored and not supported by the fan.
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Technical Description
Figure 3-10
Inlet Vane Control Assembly
Inlet vane control is more efficient than inlet damper control because inlet vanes use part of the
pressure head loss to accelerate the incoming gas in the direction of wheel rotation.
Inlet dampers control air flow by introducing a swirl in the flow and pressure drop. Inlet dampers
have a low initial cost, are simple, and are not as prone to erosion as inlet vanes. The control
linkage on inlet dampers is simpler than that for inlet vanes and can be located completely
outside the duct. However, system pressure pulsations are more common with inlet dampers than
inlet vanes. Inlet dampers can create vortices in the inlet boxes or around the fan shaft. The
biggest disadvantage of inlet dampers is their low efficiency at low loads.
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Technical Description
The fan selection with two-speed motors is the same as with inlet vane control or inlet damper
control. The fans for two-speed motors are often sized so that the fan can operate on low speed at
full load and at normal operating temperature. The high speed provides the design margin.
Operators at some plants with two-speed ID fan motors do not change the motor speed while the
unit is operating. This is usually based on their past experience, when the unit has tripped
because of furnace pressure excursions that occur when speeds are changed. This problem can be
overcome by a careful design of the control system and requires a review of the damper or vane
control response, the allowable furnace pressure limits, and the time it takes for the motor to
change speed.
Fluid drive is a method of varying the fan speed for flow control. The fan selection is essentially
the same as the inlet damper alternative, except that a fluid drive is located between the motor
and the fan to control the fan speed. Inlet dampers are typically used in addition to the fluid drive
to increase the speed of response to avoid furnace pressure excursions during transients. The use
of the dampers for control during normal operation is typical but can be eliminated in most
installations. Using speed control with the dampers full open can result in a significant power
savings (200 hp on a 6000-hp fan) with only minor modifications.
Speed control allows the fan to operate near peak efficiency over the entire load range. However,
the fluid drive has a maximum efficiency of approximately 95%, and it decreases at lower
speeds. The combined efficiency of the fan and fluid drive is slightly lower than inlet vane
control at full load, but it is higher at lower loads. The major disadvantage of a fluid drive is the
high initial cost, which is approximately the same as that of the fan.
Fluid drive control provides better overall efficiency than inlet vane configuration. To optimize
system performance for a fluid drive system, the operator should perform the following:
1. Start the motor under a no-load condition (that is, ensure that the fluid coupling is empty and
the inlet vane or damper is closed). This will limit the inertia acceleration load on the motor
by accelerating the inertia of the fan to its running speed at a controllable rate.
2. Verify that all shut-off dampers (that is, non-control dampers) are fully open before startup to
prevent pressure head losses.
3. Do not use louver dampers or inlet vanes as flow control devices to throttle the fan output
volume in a system that was backfitted with a fluid drive. This will cause energy losses. The
control system should be tuned to allow a variable-speed drive to have control with the
dampers in the fully open position for a given flow range.
4. Watch for control or mechanical problems that could cause the system to hunt from one point
to another.
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Variable-speed motors are directly connected to the fan. The speed of the motor is continuously
variable from approximately 10% up to the full speed. Synchronous or induction motors can be
used with variable frequency drives, and the frequency of the power to the motor is controlled by
an electronic system. The incoming ac power is converted to adjustable voltage dc power by a
thyristor. The adjustable dc power is connected to an inverter, which converts it to an adjustable
ac power output.
Speed control is the optimum method of controlling centrifugal fans. The system resistance for
ID service, and most FD fan service, is essentially a square curve. Because fan efficiency is
essentially constant over similar flow-head squared curves, a variable-speed fan can operate near
its best efficiency over the entire load range. Also, the control is stable down to essentially zero
flow. Fans with variable-speed motors do not require a turning gear because the main motor can
operate at the turning gear speed for extended periods.
Turbine-driven ID fans have been studied by architect-engineers and turbine manufacturers, but
very few have been installed. The advantage of turbine-driven fans is the improved plant heat
rate. Based on previous studies, the capital cost of turbine-driven fans is considerably more than
the cost for centrifugal fans with variable-speed motors.
In most cases, turbine-driven ID fans do not result in a fuel cost savings over ID fans with
variable-speed motors. The efficiency of a turbine drive is typically 81%, which is less than the
main turbine efficiency of 88%. For a motor-driven fan, the efficiencies of the main generator
(98%), transmission (98%), and motor (95%) result in an overall efficiency approximately the
same as that of turbine-driven fans.
The National Fire Protection Association (NFPA) standards for explosion prevention require that
a master fuel trip shall not trip the fans. To meet this requirement, an auxiliary steam source,
such as a cross connection to a second unit or an auxiliary boiler on continuous standby, would
be required with turbine-driven fans. The costs for this auxiliary source would have to be added
to the estimated costs above.
Turbine drives are less reliable than motor drives. Because the availability of variable-speed
motors—including the associated electrical equipment—is higher than that of turbine drives,
turbine drives are not recommended for ID fans.
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Axial flow fans can be controlled by using variable-pitch blades, inlet vanes, or variable-speed
drives.
In a variable-pitch axial fan, blade adjustment levers are located within the hub and are actuated
hydraulically. Variable-pitch axial fans respond quickly and smoothly to system demand
changes. Variable-speed axial fans are not normally used because variable-pitch axial fans are
lower in cost and achieve similar efficiency.
Axial fans can be controlled by varying the blade pitch or speed or by using variable inlet vanes.
Either varying the blade pitch or using variable inlet vanes controls the flow by operating on the
same principle as do variable inlet vanes on a centrifugal fan. Varying the blade pitch is more
efficient than using variable inlet vanes because the flow resistance of the vanes is absent.
Variable-pitch blades can provide efficiency as high as that of variable-speed control over most
of the load range for a lower initial cost. Variable-pitch blades are the most common method of
control; variable inlet vanes are used occasionally, and variable-speed control is rare. Figure 3-11
shows the components of a variable-pitch axial fan.
Figure 3-11
Variable-Pitch Axial Fan Components
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The most common blade actuation system for variable-pitch axial fans is a hydraulic system with
a rotating union between the rotating and stationary parts. A critical design area of variable-pitch
axial fans is the blade thrust bearings. These bearings experience very little movement and loads
in excess of 100,000 pounds. Also, the shaft rotation acts as a centrifuge that separates particles
out of the bearing lubricant and separates the lubricant if it is a mixture of elements of different
densities. Ball bearings are accepted as the best type of bearing for this application.
The impeller blade adjustment system is made up of a stationary servomechanism, rotating seal,
and rotating piston rod. Alignment between the servomechanism and rotating piston rod is
maintained by antifriction-type bearings. This unit provides a transition between the non-rotating
regulating levers and the rotating piston rod; and the servomechanism’s pilot valve transforms a
mechanical input signal from the regulating lever to a hydraulic signal. This hydraulic signal, in
turn, is received by the hydraulic cylinder in the rotor assembly.
The impeller blade adjustment system provides interface between the lever assembly and the
rotor assembly. The impeller blade adjustment system receives its input signals from the boiler
control system through an electric actuator (located outside the axial fan housing) and the
hydraulic supply system. A clevis arm provides a mechanical link between the lever and the
servo. Lever motion is translated into the clevis arm moving axially. The clevis arm’s motion
causes three oil ports inside the servo to close or open in a specific sequence in order to allow oil
to flow to or from the hydraulic supply system. Oil movement determines which side of the
hydraulic cylinder is under pressure, ultimately resulting in movement of the blades to an
ordered position.
In some applications, a combined lube oil/hydraulic supply system is used to provide oil that
both lubricates main fan bearings and provides pressurized hydraulic oil to serve as the working
medium to vary the blade pitch.
Basic components of the hydraulic oil system include primary and secondary pumps, heat
exchangers (either air- or water-cooled type), reservoir, instrumentation (such as pressure
switches, temperature switches, gauges, and alarms), supportive piping, and isolation valves.
It is possible to have fixed pitch blades with an axial fan and control the fan using a variable-
speed drive. Although the arrangement would be slightly more efficient at low flow rates than a
variable-pitch blade axial flow fan, the cost would be higher. Variable-speed axial flow fans are
therefore rarely used in boiler draft applications.
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This alternative has fixed blades and variable inlet vanes. The inlet vanes change the angle of
attachment between the flow and the blades, similar to the effect of inlet vanes on a centrifugal
fan. The design is less complicated than the variable-pitch blade design but is also considerably
less efficient. Fixed blade axial fans have most of the disadvantages of variable-pitch blade axial
fans without the advantage of high efficiency.
All the bearings (that is, main shaft bearings and blade bearings) in an axial flow fan are inside a
fairing inside the fan. For an ID fan or any other hot air or gas service, an external cooling fan is
used to provide cool, clean air to pressurize and cool the main shaft bearings and vibration
probes.
3.6.1 Bearings
Two general types of bearings used in draft fan applications are rolling contact and sliding
contact. Both types, depending on the application, can be designed to support axial or radial
loads.
Both centrifugal and axial fans can use either ball or roller bearings; however, ball and roller
bearings are more common on axial fans. Sliding contact bearings are more common on
centrifugal fans. Ball and roller bearings consist of four major components:
• Outer race
• Inner race
• Rolling elements
• Spacer for the rolling elements
A sliding contact type bearing known as a journal or sleeve bearing is used extensively on
centrifugal draft fans and some axial fans. This type of bearing is made up of four parts: journal,
upper and lower sleeves, and (where required) thrust collars and oil rings. A journal bearing can
be further categorized as a fixed or floating type, depending on whether the axial movement of
the shaft is allowed. Fixed bearings can have either one or two thrust collars. Floating-type
bearings are used to allow for thermal growth in center-hung fans and are installed at the
opposite end of the fan motor. A typical sleeve bearing is shown in Figure 3-12.
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Figure 3-12
Sleeve Bearing Components
Various techniques are used to provide oil to fan and motor bearings. Static lubrication in which
each bearing has a fixed supply of oil in their sumps is very common. This method is simple and
very cost-effective; however, it relies on operator vigilance to detect low oil levels or poor oil
quality. Use of temperature sensors to provide remote warning to the control room operators, in
case of a hot bearing, offers added protection for this method. A gear pump attached to the input
shaft of the driver is a second method used to provide lube oil to fan and motor bearings. A third
method, the use of fluid drives to supply oil to the bearings, is also used on some fans. A fourth
method involves the use of a dedicated circulating lube oil system.
Two variations of this system involve the use of a forced lubricating oil system in which oil is
supplied to the bearings under pressure. The second variation involves the use of a circulating oil
system, which supplies oil to the bearing sump; oil rings then move the oil to the bearing surface.
The latter variation is the one used most often.
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Turning gears are sometimes installed with ID or gas recirculating fans where exposure to high-
temperature flue gas (while the fan is idle) could result in warping or thermal growth of fan
internals. Once a fan is stopped and the inlet and outlet dampers are closed, a fixed volume of hot
flue gases remains inside the fan housing. As these hot gases cool down, a natural temperature
gradient forms. Consequently, the fan rotor cools unevenly. The result is thermal distortion,
which causes the fan shaft to bow upwards in the center. It is interesting to note that many
mistakenly believe that the shaft sags under the weight of the wheel.
A thermally distorted fan wheel will cause vibration when the fan is restarted because the fan is
out of balance due to the distortion. Power stations may choose any one of three solutions to
resolve vibration caused by thermal growth. One approach involves starting the fan and
accepting the accompanying vibrations. Over a period of time, the fan rotor geometry is restored
as a consequence of the rotor becoming evenly heated once again. The second approach involves
the operator’s initiating a series of start-stop cycles to allow the fan wheel temperature to balance
out. As with the first approach, high vibration becomes an accepted condition. This, however, in
addition to exposing the fans to low cycle stresses, makes this option even less attractive. The
third approach involves the installation of a turning gear. A turning gear consists of a small
motor, a reduction gear, and an overrunning clutch. The turning gear is used to keep the fan rotor
turning at a slow speed (approximately 60 to 90 rpm) when the fan is hot but not operating. This
provides an optimum solution to prevent thermal distortion.
The design speed of the turning gear is critical. Most centrifugal fans have sleeve bearings that
have a minimum speed. Below the minimum speed, the oil film between the journal and the
sleeve is not adequate to prevent metal-to-metal contact, and the bearing will be damaged. The
turning gear should be designed to operate above the minimum bearing speed (usually 60 to 90
rpm). The bearing manufacturer should be consulted to determine the minimum speed.
Because boiler draft fans are among the highest auxiliary power consumers in the plant, the
performance of the fans is important for efficient plant performance. Deficiencies in fan
performance can cause a load limitation on plant output. In many coal-fired plants, the ID fans
are the limiting factor on plant electrical output. Although the ID fans may be the apparent cause
of a load limit, in many cases the root cause is high air heater leakage, air heater pluggage, high
gas temperatures, precipitator infiltration, or something similar.
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As with most other turbo machinery, the performance of fans is best illustrated by a curve of
pressure versus flow. Fan curves are usually plotted as pressure in inches of water gauge ("Wg)
versus volumetric flow in actual cubic feet per minute (acfm). Note that most curves are labeled
as cfm, where it is understood that cfm is acfm. Because fan performance depends on inlet
density, the fan curve should specify the density. Some European fan suppliers plot curves in
head—in feet (meters) of fluid (rather than pressure, in inches of water)—versus volumetric
flow. These curves are essentially independent of inlet density, similar to a centrifugal pump
curve that is plotted as head versus volumetric flow.
Figure 3-13 charts the performance field for a typical centrifugal fan with inlet vane control. It is
a customary design practice to specify a test block condition (which contains flow) and head
margin above the expected operating requirements at full unit load. Both centrifugal and axial
fans must be capable of meeting conditions well beyond the expected conditions at full plant
operating load.
When using these curves, care must be taken not to confuse inlet vane position in degrees and
percent open. Fan manufacturers usually present their curves in terms of vane angle, with 90
degrees being the full open position. Many boiler controls identify inlet vane position in terms of
percent open, with 100% being full open. Because control room and actuator position indicators
may not accurately indicate actual vane positions, the actual vane position should be verified.
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Figure 3-13
Typical Centrifugal Fan with Variable Inlet Vanes
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Figure 3-14
Typical Centrifugal Fan with Variable Inlet Vanes and Showing System Curve
Note that at the minimum flow (25% per NFPA), the inlet vanes would need to be less than 15
degrees. The inlet vanes are designed for flow control and not to isolate the fan, and—with the
vanes fully closed—the performance will be approximately the same as with the vanes 15
degrees open. Thus, controllability at this low vane opening may be a problem. Most large
boilers have two 50% capacity FD and ID fans; single-fan operation at low flow rates usually
provides better controllability.
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Figure 3-15 is a typical curve for a centrifugal fan with speed control (applicable to a fluid drive
or a variable frequency drive). The system curve is also shown in this figure. The minimum flow
(25%) is achieved at 200 rpm. A stable speed of 200 rpm could be a problem with a fluid drive
that has a maximum speed of 900 rpm. With variable frequency drives, a minimum speed of 200
rpm should not be a problem.
Figure 3-15
Typical Centrifugal Fan with Speed Control
A centrifugal fan’s most efficient area of operation is near the full-load condition in the test
block area. Because the lines of constant efficiency run approximately perpendicular to the
system resistance line, as load drops, the efficiency of a centrifugal fan also drops rapidly. A
centrifugal fan sized for a test block condition will not operate in its most efficient region under
normal conditions. For a typical centrifugal fan using inlet vane control, efficiency at the test
block condition may be as high as 88% but will be only 70–75% at the 100% unit load condition.
At 50% unit load, fan efficiency may be as low as 25%. A centrifugal fan with a variable-speed
drive operates near its peak efficiency at all loads.
A typical performance field for a variable-pitch axial fan is shown in Figure 3-16. The boiler
resistance curve and test block condition are the same as those used in the previous example for a
centrifugal fan. For axial flow fans, maximum operating efficiencies occur below the stall line,
which represents the maximum capability of the fan. This makes it possible to select a fan that
operates near its optimal efficiency at the expected full-load condition.
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Figure 3-16
Performance Field for Variable-Pitch Axial Flow Fan
Furthermore, for axial fans, the areas of constant efficiency run approximately parallel to the
boiler resistance line. As load decreases, efficiency does not drop off as drastically as it does
with a centrifugal fan. Thus, at 50% load, efficiency may remain as high as 65%—more than
double the efficiency of a centrifugal fan with inlet vane control.
Higher operating efficiencies and the resulting fuel savings are the most significant factors
favoring axial fans.
The fan pressure should be defined on the fan curve. Possible definitions are fan static pressure
(FSP), static pressure rise (SPR), or fan total pressure (FTP). These are defined as follows:
• FSP = SP2 – TP1
• SPR = SP2 – SP1
• FTP = TP2 – TP1
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Where the subscripts 1 and 2 refer to the fan inlet and outlet, SP is static pressure, and TP is total
pressure. Note that fan static pressure is not the same as static pressure rise. These definitions are
illustrated in Figure 3-17.
Figure 3-17
Fan Pressure Definitions
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Fan curves are useful in evaluating actual fan performance, which is usually measured in terms
of pressure rise across the fan and volumetric flow rate. The measured volumetric flow can be
applied directly to the fan curve (assuming that the units are the same). The pressure rise across
the fan must be converted to the density on the fan curve.
Figure 3-18 is an example of correcting the fan performance to the operating conditions. It shows
a typical fan curve based on an inlet density of 0.075 lb/ft3. It also shows an operating point
based on measured data. Due to a temperature difference, the density at the measured point is
0.0696 lb/ft3. Comparing the operating point to the fan curve appears to show that the fan is not
performing as designed. However, correcting the fan curve to the actual density at the operating
point shows that the fan is actually performing better than design.
Figure 3-18
Fan Correction for Inlet Density
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The procedure for correcting a fan curve to the operating density is to correct the fan head as
follows:
ρ2
H 2 = H1 Eq. 3-1
ρ1
Where:
ρ1 = density 1, lb/ft3
ρ2 = density 2, lb/ft3
To convert the fan curve, use Equation 3-1 at several flow rates and plot the new curve. Note that
the volumetric flow rate (cfm) for point 1 and point 2 is the same. A fan is a constant-volume
machine, regardless of density.
• Volume/Pressure Characteristics. As the flow through an axial fan decreases, the output
pressure decreases. The characteristic curve for a centrifugal fan shows an increase in static
pressure as flow decreases. This feature results in the maximum pressure capability of a
centrifugal fan that is substantially higher than that required to satisfy the test block
condition. This higher maximum pressure capability can affect the design pressure of
ductwork, precipitators, and other components in the draft system.
• Erosion/Corrosion. In general, a centrifugal fan has much greater capability to withstand
erosion than axial fans. Protective liners and nose and tip plates are easily applied. Protective
nose pieces and coatings are available for axial fan blades, but generally, axial fans are best
suited for air or clean gas applications.
• Mass and WR2 (moment of inertia). Axial fans weigh less than centrifugal fans and have
fewer massive rotating elements, which reduces foundation mass requirements. The lower
weight results in a lower WR2, which tends to reduce the cost of the drive motor.
• Evaluation. If a decision is made to consider axial fans, bids should be taken for both
centrifugal and axial fans. The final decision can then be based on the results of a
comprehensive economic evaluation.
The costs are lowest for fans with variable-speed motors because inlet vanes are not required.
Axial fans have a higher initial cost. Two-speed and variable-speed motors are considerably
more expensive than constant-speed motors. Axial fans allow a simpler duct arrangement, have
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more moving parts, and require more maintenance than centrifugal fans. Variable-speed
centrifugal fans are the most efficient arrangement, resulting in the lowest auxiliary power
consumption and, therefore, the lowest fuel cost. The appropriate fans should be included based
on an evaluation of the economic parameters. Note that the selection can be affected by the plant
arrangement.
A fan specification should give the fan bidders all of the pertinent information regarding
performance, service, arrangement, and basis of evaluation when required, so that the bidders
can offer the proper fan for the service. The fan’s capability must be specified and must include
rate of mass flow, temperature, elevation, density, pressure at inlet, and pressure at discharge.
Fan capacity is usually rated as a volume rate of flow and is specified in cfm at inlet conditions.
It should be noted that fan performance is based on conditions at the inlet.
The fan must provide the air or gas with sufficient energy to overcome the losses encountered
through the system. The usual method of specifying this energy requirement is to stipulate the
static pressure of the fan in inches of water at a certain volumetric requirement. If fan total
pressure is specified, a clear statement of the fact should also be given to avoid giving the
impression that total static pressure is being specified. In either case, the distribution of pressure
between the inlet and outlet should also be specified.
The fan static pressure is expressed in terms of the sum of the total pressure losses of the system,
the difference between the total pressure at the system exit and the system entrance, and the fan
velocity pressure. Fan velocity pressure (FVP) is defined as the velocity pressure corresponding
to the average velocity through the fan outlet (see Figure 3-17).
Many times, the fan velocity pressure is unknown because the fan has not been selected.
Ignoring FVP builds a margin of safety into the stated pressure requirement.
A good fan test requires test instrumentation and controlled conditions. Data collected from
existing plant instrumentation can be used to identify possible problems but cannot be used to
quantify the magnitude of a performance problem. Plant instrumentation is not accurate enough
to conduct a good fan test.
The codes and standards that specify field performance testing of fans are ASME PTC-11, Fans;
AMCA 203, Field Performance Tests; and AMCA 803, Site Performance Test Standard. These
codes provide guidance on the instruments and methods used to conduct high-quality field
performance tests on fans.
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The actual operating point can be determined from measurements of static pressure at the fan
inlet and outlet and the calculated air or gas flow. The air or gas flow can be calculated from
measurements of oxygen and boiler load. Although these calculations are only approximate, they
are usually adequate for identifying fan performance problems.
Before the actual operating point is compared to the fan design performance, adjustments to
actual operating conditions must be made. Fan performance is affected by inlet vane position
(blade position for variable-pitch axial fans), fan speed, and fan inlet density.
3.11 Operation
The startup of any piece of major equipment requires following specific steps, which can be
divided into two phases:
1. Prestart checks
2. Startup procedures
Prestart checks involve a detailed system walk through to verify that the fan will operate safely.
During prestart checks, the operator should perform the following tasks:
Verify that supportive auxiliary systems and monitoring equipment are operating correctly. For
example, check for adequate lube oil and cooling water, proper temperature range of the lube oil
and cooling water, and proper damper position.
Perform safety-related checks to verify that all DANGER, WARNING, CAUTION, and
DO NOT OPERATE tags have been properly cleared; all safety-related interlocks, alarms, and
similar operational interlocks have been cleared; and all personnel have been cleared from the
fan and ductwork.
Startup procedures should consist of a well-defined sequence of steps that ensure fan safety and
that prevent boiler explosions and implosions. In writing the startup procedures for a draft fan,
the operating engineer should take into account the station’s practices and regulations, the level
of automation, the number of personnel on the shift, and the manufacturer’s recommendations.
The startup procedures, in addition to the controls and interlocks, should follow the requirements
of the current version of NFPA 85 [1].
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The procedure for starting up a draft fan should include the following:
• Sequence of all operator actions required for startup
• Alarm conditions to monitor
• Operating parameters to monitor
• Emergency actions
• Fan control requirements
• Electric motor restrictions
• Requirement for the control of inlet vanes
• Fan outlet dampers requirements
• Individual responsibilities
• Procedures to prevent a stall
Draft fan alarms are either executive or advisory. Executive alarms give operating personnel
audible and visual warnings of a dangerous condition, such as excessive vibration, loss of lube
oil, or a hot bearing. Through safety interlocks, an executive alarm condition may initiate a
shutdown of a fan. The automatic boiler control system would then respond to maintain a safe
condition in the furnace.
Advisory alarms are similar to executive alarms except that operating personnel must initiate the
corrective action. A high differential pressure on the discharge filter of a circulating lube oil
system is an example of an advisory alarm.
The operating parameters that affect the safety of the equipment and personnel should be
monitored.
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Additional parameters and analysis are discussed in the section on condition based monitoring.
The startup procedures should contain cautions and warnings to remind operators of problems
that could develop. In draft fan emergencies where personnel or equipment safety are in danger,
shutting down the fan should be a standard operating procedure.
Before placing control of the fan in the furnace automatic combustion control system, prestart
checks verifying positive control of the fan should be complete. These checks include the
following:
• Verifying that the control damper/inlet guide vane is operating correctly and that local
position indicators agree with the remote indicators located in the control room
• Test operating the fluid drive control (if applicable)
• Verifying that the pitch control (for axial fans only) is operating correctly
• Verifying that the dampers are synchronized (for double inlet fans)
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During startup, it is important not to exceed the electric motor’s duty cycle, especially for an ID
fan being started up with cold air. Frequent starts that exceed the duty for which the motor was
designed form local hot spots or raise the operating temperature above the allowable temperature
rating for the motor insulation. Such a condition could reduce the expected operating life of the
motor or cause a premature failure of the motor’s insulation. Ensuring that the design duty cycle
of a motor is incorporated into a written procedure for starting a draft fan will help in preventing
damage to the motor.
The criteria used to establish the minimum number of starts for a large motor (that is, 500 hp and
greater) are provided in NEMA Standard MG-l, section 20.43:
• Two starts in succession, coasting to rest between starts, with the motor initially at ambient
temperature.
• One start with the motor initially at a temperature not exceeding its rated load operating
temperature.
Specific manufacturer’s requirements for starting operations after a motor has undergone a cycle
of two cold starts and one hot start can be found in the manufacturer’s operating instruction
manual or on the motor’s starting plate. Requirements that should be incorporated include the
following:
• Minimum time the motor must run before it is shut down
• Length of time the motor must be at a standstill before additional starts are attempted
• Maximum operating temperature of the motor windings
• Number of total starts per day that should not be exceeded
Another consideration involves operating the draft fan at or above the motor’s maximum rated
current level. A loss in fan efficiency could cause the motor to be operated above its rating.
According to NEMA Standard MG-l, motors are to be designed to run at a maximum horsepower
and full-load current without exceeding a specified temperature rise. It is normal design practice
for a utility power plant motor to have a design margin of 15% for horsepower for the following
reasons:
• To allow margin for a demand increase from the driven equipment under unusual or
infrequent operating conditions
• To prolong the operating life of the motor in the event of unusual or infrequent operating
conditions
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The life of a motor is originally determined by the effective life of its insulation. The numbers of
starts and operating temperature of the motor directly influence a motor’s operational life. By
operating the motor under normal conditions at less than rated horsepower (and therefore less
than rated maximum current), the motor operating temperature is kept below its maximum
operating temperature.
The startup procedures should specify the position of the inlet and outlet dampers and vanes
during startup. The degree of automation will determine what the operator should do and how the
control system performs. For systems that require the operator to initiate all actions, startup
procedures should address the sequence of opening and closing the dampers and vanes, the time
limits between each step, the requirements for a visual verification of the damper position, and
indications that a vane or damper has failed to open.
Most fan manufacturers recommend starting constant-speed fans with the outlet dampers closed.
A closed outlet damper reduces the starting time and load on the motor. The torque required at
any given speed can be three to four times higher with an open versus closed outlet damper.
Some plants have found that the required torque and startup time for a draft fan system
configured with both inlet vanes and dampers and outlet dampers may not differ significantly if
the outlet dampers are kept open and the inlet control devices are closed. Outlet dampers are
typically high maintenance items—especially on ID fans—and may be required only for startup
and fan isolation during maintenance. Some stations have found outlet dampers unnecessary, but
this depends on the fan design, the motor capabilities, and the design and condition of the inlet
vanes or inlet dampers.
The best practice is to follow the fan manufacturer’s recommendation. If a change in damper
operation is desired, data on startup times and motor current should be collected and discussed
with the fan and motor suppliers.
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The aerodynamic term stall is often used to describe a phenomenon that can occur in an axial
flow fan. Under certain pressure and flow combinations, the gas flow cannot accommodate the
guiding surface of the fan blade, and flow separation occurs. Pronounced separation results in
circulator flow within the fan and a significant reduction in flow through the fan as well as
pressure rise across the fan. An abrupt change in flow and pressure will have an adverse effect on
boiler operation and can cause a unit trip. In addition, stall can damage fan blades.
To prevent a fan stall, operators must understand the fan curves of the fans they are operating.
The startup procedures should describe how to prevent fan stalls. Operators must understand how
they can prevent fan stalls by monitoring the operating values of static pressure, airflow, and
blade position on axial fans. The procedures should show the fan curves and identify points on
the curve that, if exceeded, will stall the fan. The procedures should also describe the following
indications of a fan stall:
• Abnormal flow volume (pulsations) and power consumption (motor amps displaying
abnormal fluctuations)
• High vibration levels
• Failure of the variable-pitch blades to move on command
• Loud, abnormal noise levels
The stall line is usually identified on the performance curve (head versus flow) for axial fans.
The fan control system should monitor the head and flow and give the operator a stall warning so
that the operator can take action before a stall occurs.
The draft fan shutdown procedure should be developed around the safety of personnel and
equipment. There are two types of draft fan shutdown, referred to here as a controlled and
uncontrolled shutdown.
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Technical Description
A controlled shutdown of a fan occurs in a logical and orderly manner. During shutdown,
operators will perform the following:
• Reduce firing rate demands
• Stop the associated fan(s)
• Perform fan post-shutdown-related checks
An uncontrolled shutdown is characterized by a loss of one or more draft fans. An operator error
or a problem that went undetected by the monitoring system could result in an uncontrolled
shutdown. The following conditions could cause an uncontrolled shutdown:
• Control system upsets and/or failures
• High vibration level
• Uncontrolled hot bearing
• Loss of lube oil
• Electrical fire at the motor controller or fan motor
• Fires in ductwork and/or fan housing (GR or PA fan)
• Loss of electrical power
A written procedure for an uncontrolled shutdown of a draft fan should incorporate adequate
measures to ensure boiler safety.
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Technical Description
Boiler safety is addressed through a system of mandatory safety interlocks that protect against an
unstable operating condition. As with any mechanical or electrical system, this safety interlock
system can provide only a limited level of assurance in preventing conditions that might lead to a
boiler explosion or implosion. Two critical factors must be recognized about the reliability of
automatic safety systems:
• The effectiveness of the system depends on how well it is maintained.
• No safety system is 100% reliable.
Written procedures and training on the system requirements and operator responsibilities in the
event of a fan loss provide an additional margin of safety. NFPA 85 [1] discusses conditions
resulting from the loss of a draft fan that may lead to a boiler explosion or implosion. The
following summarizes the required safety system interlock responses from NFPA 85 [1] in the
event of an uncontrolled shutdown of draft fan(s):
• Response to the loss of one draft fan (either one ID or one FD)
– Close dampers of the affected fan unless it is the last FD or ID fan in service.
– If the unit’s automatic safety interlock system is designed to start, stop, or trip ID and FD
fans in pairs, trip the corresponding paired fan; close dampers of these fans unless they
are the last ones in service.
• Response to the loss of all FD or all ID fans:
When two or more fans are brought into parallel operation, the operator must ensure that the
airflow from the fans is balanced. An improper fan paralleling operation can lead to serious
consequences, such as the following:
• High vibration levels, stalled fan(s), airflow pulsations in the ductwork, pressure excursions
to the boiler, or damage to the electric motor.
• Potential for losing both fans. This is particularly serious if the unit loses all of its FD or ID
fans because this may lead to furnace damage and will trip the master fuel valve, resulting in
the loss of the unit.
When paralleling two fans, the operator should observe the following:
• Verify that the second fan to be brought on-line is mechanically ready.
• In the case of axial fans, bring the on-line fan to a pressure below the fan’s stall point; this
often requires backing down the unit.
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Technical Description
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4
FAILURE MODES AND EFFECTS ANALYSIS
A failure modes and failure causes review is discussed in this section. The data presented here
were obtained from NERC/GADS and other sources. The failure data presented here were
supplemented with information obtained in a survey on FD/ID fans sent to select fossil plants
and with information obtained in follow-up interviews from those surveys.
The most common problem areas for centrifugal ID fans are blades, bearings, and foundations,
which account for over 50% of all problems. Other problem areas include inlet vanes, motors,
dampers, hubs, shafts, and controls. The most common direct causes of these problems are
erosion and vibration. Bearing problems can be caused by either a design problem or improper
maintenance and operation. The major cause of foundation problems is improper design, and the
impact is high fan vibration.
Over 50% of the problems with axial ID fans were with blades, shaft bearings, and blade thrust
bearings. Other problem areas include the hydraulic supply unit, blade adjusting mechanism, and
the shaft. As with centrifugal fans, axial fans have problems with erosion of blades and the main
shaft bearings. However, the biggest problem area with axial fans is related to the variable-pitch
blades: 33% of the problems were due to either the hydraulic supply unit, blade thrust bearings,
regulating arm, or blade adjusting mechanism.
Axial fans have less massive rotors and shorter bearing spans than centrifugal fans. Therefore,
the bearing loads are less, which should increase availability. However, axial fans have much
higher loads on the thrust bearings.
The major difference between axial and centrifugal fans that can affect availability is the control
mechanism. The control mechanism for centrifugal fans—whether it is inlet vanes, inlet
dampers, or fluid drives—is much less complicated than the blade adjusting mechanism for axial
fans. There were nearly twice as many problems with blade positioning systems in axial fans.
EPRI report CS-1693, Failure Cause Analysis – Fans, documents the results of the survey
performed in 1981 on the causes of fan failures in fossil plants. The data in Tables 4-1 and 4-2
were taken from this report and show the failure causes and the failure rates of the FD and ID
fans. The failure data shown in Tables 4-3 and 4-4 for 1982 through 1995 were taken from
NERC/GADS.
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Table 4-1
Summary of Centrifugal Fan Problem Areas
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Table 4-2
Summary of Axial Fan Problem Areas
Foundation 0 0
Shaft bearings 19 0
Shaft 7.1 0
Hub 0 0
Blade shaft 0 0
Blades 19 0
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Table 4-3
FD Fan Failure Data for U.S. Fossil Plants from 1982 Through 1995 (NERC/GADS Data)
FD Fans
Number of Units: 1343
Description Total No. of Forced Outages No. of Forced Forced Outage Equivalent Actual No of Parallel Mean Time Mean
Occurrences Forced – Outage per Forced Deratings, Hours Lost per Derated Derated Components Between Down
Outages Unit Year Deratings Occurrence Occurrence Hours Lost Hours Lost Failures (hrs) Time
per per per (hrs)
Unit Year Occurrence Occurrence
FD fans 4798 355 0.0213 4443 0.2667 23.707 9.30 18.60 2 40,000 18.97
FD fan lubrication 674 57 0.0034 617 0.0370 16.233 4.921 9.84 2 287,000 10.38
system
FD fan motors 1732 139 0.0083 1593 0.0956 59.037 25.043 50.09 2 112,000 50.80
FD fan motors – 177 43 0.0026 134 0.0080 8.852 9.592 19.18 2 1,095,000 16.67
variable-speed
FD fan drives 323 34 0.0020 289 0.0173 13.462 7.25 14.50 2 600,000 14.39
(other than motor)
FD fan controls 1622 357 0.0214 1265 0.0759 6.613 3.04 6.08 2 119,000 6.20
Other FD fan problems 2189 222 0.0133 1967 0.1181 9.776 6.426 12.85 2 89,000 12.54
Total 11515 1207 0.0725 10308 0.6188 18.987 20.199 17,000 20.1
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ID Fans
Number of Units: 872
Description Total No. of Forced No. of Forced Forced Outage Equivalent Actual No of Parallel Mean Time Mean
Occurrences Forced Outages – Forced Deratings, Hours Lost per Derated Derated Components Between Down
Outages Outage per Deratings Occurence Occurence Hours Lost Hours Lost Failures Time
Unit Year per per per (hrs) (hrs)
Unit Year Occurrence Occurrence
ID fans 6600 359 0.0341 6241 0.5934 19.6 7.50 14.99 2 18,000 15.24
ID fan lubrication 479 45 0.0043 434 0.0413 7.61 5.429 10.86 2 254,000 10.55
systems
ID fan fouling 492 21 0.0020 471 0.0448 21.511 5.918 11.84 2 247,000 12.25
ID fan motors and 2263 236 0.0224 2027 0.1927 39.077 18.04 36.09 2 54,000 36.40
drives
ID fan motors – 302 56 0.0053 246 0.0234 7.268 8.27 16.54 2 402,000 14.82
variable-speed
Induced draft fan 2269 676 0.0643 1593 0.1515 7.715 3.83 7.66 2 54,000 7.68
controls
Other ID fan 4325 402 0.0382 3923 0.3730 20.033 6.94 13.88 2 28,000 14.45
problems
Total 16730 1795 0.1707 14935 1.4199 17.119 16.585 7,000 16.6
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4.1 Blades
Blade erosion is a significant failure mechanism for both centrifugal and axial fans. While
erosion of ID fans is the major problem, erosion has also been reported on FD fans.
The ID fan erosion rate is determined by a number of variables, including the following:
• The fuel ash content and the ash constituents. The chemical composition of the ash and the
size of the particles affect the rate, type, and location of the erosion.
• The fuel firing rate. A low Btu fuel requires a higher firing rate with consequent higher ash
flow to the fans.
• The actual efficiency of the ash-collection equipment ahead of the fan. Deterioration of this
equipment with age along with overloading due to the use of higher-ash coal has a significant
effect on fan erosion.
• Distribution of the ash in the gas stream as it enters the fan. The duct configuration leading
up to the fan may tend to concentrate the ash on one side of the fan or at one side of the inlet
boxes.
• The action of the flow profile through the fan, which may further concentrate the ash.
• The blade shape, which may present a profile that is more susceptible to erosion effects, for
example, blade tips that create a strong turning effect on the gas flow.
• Blade velocity relative to the ash/gas velocity. Assuming the same total flow, a smaller,
higher-speed rotor will erode faster than a larger, lower-speed rotor.
• Blade material. Common blade materials have a small impact on erosion, but erosion liners
have a large impact.
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Continual surveillance of vibration, inspection (when indicated), and good maintenance or repair
have the best chance to succeed. The personnel accountable for a fan outage should be
responsible for proper surveillance, inspection, cleaning, and repair.
The best method for preventing ID fan erosion is to collect the fly ash before it reaches the fan.
Erosion rates are directly proportional to fly ash concentrations. Stratification of ash due to
gravity or duct configuration can create high, localized concentration and localized erosion and
should be considered in addition to average concentrations. Baghouses have higher collection
efficiencies and are less likely to experience excursions than electrostatic precipitators; therefore,
they reduce the erosion potential for ID fans.
The primary erosion area for airfoil centrifugal fans and axial fans is the leading edge of the
blades. The gas flow in a centrifugal fan must make a 90° turn inside the fan. Because the inertia
of the ash particles prevents them from turning as quickly as the gas, the particles and erosion
will be concentrated at the junction of the blades and the fan center plate. As the size of the ash
particles increases, this effect will increase; thus, center plate erosion will increase as will
erosion of the trailing edge of the blade.
The erosion rate varies approximately with the cube (or higher) of the velocity of impact. Thus,
fan tip speed relative to the gas speed is a significant factor. A direct comparison between the tip
speeds of axial and centrifugal fans is not valid. The leading edge of centrifugal fan blades is
toward the inside diameter and has a lower velocity than the periphery of the wheel, whereas the
leading edge of an axial fan blade extends to the periphery.
Reduced erosion rates are a significant benefit of variable-speed fans (because erosion rates will
vary approximately with the cube of fan speed). Variable-speed fans are generally capable of
meeting the full-load system requirements at 90% speed, considering the design margins used.
Therefore, at full load, the fan erosion rate of variable-speed fans should be only 73% as great as
the erosion rate of constant-speed fans. The difference is even larger at lower loads. At 50%
load, the erosion rate of a variable-speed fan should be only 12% of that of a constant-speed fan.
If high particle loading is expected, a single-thickness-blade centrifugal fan is the best choice.
Properly protected hollow airfoil blades have a relatively high resistance to erosion. However,
erosion of hollow airflow blades can cause a hole in a blade and fill the interior of the blade with
fly ash. This can cause fan imbalance and vibration problems.
A related failure mechanism is the buildup of particle on fan blades. This causes fan imbalance
and vibration and may require the fan to be shut down for repair and cleaning.
4.2 Bearings
According to two EPRI reports, Failure Cause Analysis – Fans, CS-1693 [2] and Electric Motor
Predictive and Preventive Maintenance Guide, NP-7502 [3], bearing failures are a major
contributing factor to fan outages. Main shaft bearings are a leading cause of centrifugal fan
problems and are prominent in the list of axial fan problems. Nearly all centrifugal fans use
sleeve bearings, while axial fans are typically supplied with ball/roller types.
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The main shaft bearings support not only the static load of the rotor, but also the dynamic load
due to vibration. Prolonged operation at high vibration levels puts a severe strain on the bearings,
mostly due to manufacturing and maintenance deficiencies. Most bearing failures are a result of
loss of oil, contaminated oil, loss of cooling, high level vibration, or maintenance deficiencies.
Bearing failure can lead to high vibration, which can result in the damage of various
subcomponents such as blades, rotors, shafts, fan housings, ductwork, and flexible couplings.
Successful bearing maintenance includes proper lubrication and lube oil quality, correct
alignment of rotating elements, trend analysis, and adherence to regular inspection intervals.
Section 5 of this report addresses troubleshooting procedures.
Anti-friction ball bearings or roller bearings are used for the main shaft bearing on axial fans.
When used, sleeve bearings are similar to those for centrifugal fans except that they are built to
have greater capability to sustain thrust.
4.3 Foundations
Larger fans require more substantial foundations. These foundations should be level, rigid, and
of sufficient mass for the equipment. The supports must be rigid enough to ensure permanent
alignment and to prevent excessive vibrations. The minimum frequency of any foundation part
should be 25–50% higher than the fan speed. When the fan is mounted on the foundation, the fan
shaft should be level at the coupling end, and shims should be used as support points before the
bolts are tightened. To obtain a level shaft at the coupling end, it may be necessary to raise the
outboard end of the shaft end due to the sag in the shaft. This procedure will prevent any
distortion or twisting of equipment and any possible rubbing of rotating parts [4].
The three principal causes of crack development in concrete machinery foundations are improper
foundation design, poor construction practices, and poor operating conditions. This section
addresses the latter two causes.
There are two types of foundation cracking, and the first type occurs during the curing process.
As concrete cures, it normally shrinks between 0.02% and 0.03%. The interaction of the
reinforcing steel with the concrete during shrinkage produces tension forces in the concrete and
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compression forces in the steel. As a result of this reaction, cracking (referred to as curing
cracks) develop in the concrete. Although these cracks are not considered detrimental to the
structural integrity of the foundation, if left unchecked, they can provide “avenues” for oil and
water to penetrate into the concrete foundation. Water can expand and contract during
temperature changes, causing further crack damage. Oil penetration may, over time, cause
degradation of the concrete and introduce a degree of difficulty in the repair process.
The second type of cracking affects the structural integrity of the fan foundation. This cracking is
caused by dynamic forces such as those produced by excess fan vibration. Two possible
conditions may appear with this form of cracking: first, the cracking progresses throughout the
concrete block, producing segments of various sizes; second, the segments may move. This
movement may cause further crack progression, potentially leading to structural failure of the
foundation and the potential for serious damage to the fan.
The inlet vane assembly includes sleeves, rods, shafts, center ring, operating levers and linkage,
gears, and tabs. The failure modes for inlet vanes include the following:
• Binding
• Wear of control linkage
• Vane bearing failure
• Breakage of vanes
• Wear of control gears, levers, and bearings
• Erosion
• Insufficient clearance to fan inlet cone to allow maintenance and lubrication
• Weak control arms and linkage
In addition, breakage of dampers results in the loss of fans when broken parts are drawn into the
rotor.
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4.5 Couplings
Coupling problems usually result from insufficient or loss of lubrication and improper alignment.
Coupling/shaft interaction produces tortional vibration problems. The failure modes for
couplings include the following:
• Seizing
• Sheared stub shaft
• Broken flexible element or gear teeth
More details are provided in Flexible Shaft Couplings Maintenance Guide, EPRI report
1007910 [5].
The hydraulic actuating mechanism on axial flow fans is the system that is used to vary the blade
angle and the control mechanism for the fan. The following failure modes apply to this
mechanism:
• Oil leaks
• Contaminated oil
• Failure of the servomechanism
Ninety percent of motor failures and problems are the result of four basic causes: dirt, moisture,
vibration, and friction. The primary damage includes the following:
• Overheating due to undersizing
• Damage to the insulation, resulting in its inability to hold the voltage
• Moisture intrusion combined with dirt, causing a sticky mass to form inside the motor
• Loose connections
• Wires or winding shorting
• Loose windings
• Insulation breakdown
• Bearing failure
• Breakage of hold-down pads
• Misalignment
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More details can be found in Electric Motor Predictive and Preventive Maintenance Guide,
EPRI report NP-7502 [3].
4.8 Hubs
4.9 Housing
Examples of problems that a housing subsystem may be subject to include the following:
• Cracking and breakage due to insufficient bracing and/or welding
• Bolt failures due to high vibration levels
• Inlet cones having erosion, corrosion, cracking, or breaking
• Improper clearance between the fan wheel and housing
• Improperly maintained access doors and/or plates
• Damaged slide plates
• Seal rubs as a result of misalignment or improper setting
• Rubber liner that came loose
• Liner pieces that broke off and fell into the rotor
• Corrosion or erosion
Recognition of the cause of the trouble, problem, or failure will usually be a major step toward
solving it. Corrective measures may include alteration to the system, modifications to the fan
outlet and/or inlet connections, or adjustments to the fan. Excessive speed beyond manufacturer
recommendations may cause catastrophic impeller failure. Identification of a problem associated
directly with the fan may require the assistance of the fan manufacturer. Figure 4-1 illustrates
centrifugal fan housing components.
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Figure 4-1
Centrifugal Fan Housing Components
Problems with turning gears may result from insufficient capacity to maintain proper speed to
provide lubrication.
4.11 Shaft
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Hydraulic couplings are subject to instability, which results in fan speed surging.
4.16 Controls
4.17 Ductwork
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5
TROUBLESHOOTING
Troubleshooting and industry experience help identify probable causes and provide suitable
corrective actions. Tables 5-1 through 5-7 provide potential problems, possible causes, and
corrective actions. Many of these problems apply to both centrifugal and axial flow fans.
Problems that are unique to one type of fan have been identified, but virtually all of the potential
problems apply to both FD and ID fans.
Table 5-1
Fan Troubleshooting
Fan wheel moving on shaft Inspect hub bolts and hub-to-shaft fit.
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Troubleshooting
Table 5-1
Fan Troubleshooting (continued)
High vibration (cont.) Fan wheel distortion Verify whether the fan has
experienced extreme temperature
transient; inspect the wheel for
distortion.
Seal wear (seals that have Motor problem Check motor vibration, check motor
excessive wear permit bearings, verify that the motor is
air/gas stream leakage) running within its magnetic center,
and check motor bearing
temperatures.
Air/gas distribution: ducts, Excessive wear; improper Reinstall the seal according to the
fan housing, expansion joint installation proper procedure.
leaks (increase the hp
required)
Fan wheel clearance Dirty filters, inadequate lubrication Check and realign the motor.
(excessive clearance will of bearings
cause recirculation to
develop)
Shaft Excessive clearance between the Check clearances between the fan
inlet ring of the fan wheel and the and the housing.
housing inlet cone
Horsepower too high Bent, undersized Verify and replace the shaft.
Fan size or type not the best for Check the fan type and design.
the application
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Troubleshooting
Table 5-1
Fan Troubleshooting (continued)
Horsepower too high (cont.) Incorrect motor selection Verify motor selection/size per
application.
Fan will not start Blown fuses Inspect fuses.
Impeller touching housing Inspect and verify access.
Wrong voltage Verify voltage for application.
Air volume too small Wrong fan rotation Check blade angles in relation to fan
rotation.
Inlet or outlet obstructions Remove obstructions.
Table 5-2
Bearing Troubleshooting
High bearing temperature Inadequate cooling Verify water flow and temperature
(self-contained bearing cooling).
Lube oil contaminated Verify that the lube oil is clean and of
sufficient amount.
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Troubleshooting
Table 5-2
Bearing Troubleshooting (continued)
High bearing temperature Fan shaft alignment Verify that the fan shaft is not
(cont.) distorted or misaligned.
Cooling fan problem (axial flow Verify that the cooling fan is
fan) operating properly.
Table 5-3
Lubrication System Troubleshooting
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Troubleshooting
Table 5-3
Lubrication System Troubleshooting (continued)
Oil contamination Cooling water leaks Examine and test heat exchangers.
Table 5-4
Hydraulic System Troubleshooting
Hydraulic oil leakage in the Leakage in rotating union Replace the union.
fan diffuser
section (axial flow fan) Leakage in oil line Replace the line.
Hydraulic oil leakage in Cooling air fan stopped Start the fan.
intermediate section (axial
flow fan) Cooling air duct blocked Clear the duct.
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Troubleshooting
Table 5-5
Troubleshooting Noise Level
Damper or inlet vanes failed close Inspect and repair the dampers or
vanes.
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Troubleshooting
Table 5-6
Troubleshooting Fluid Drive
High fluid drive oil Inadequate cooling 1. Verify that the ambient
temperature temperature of the cooling water is
within design limits.
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Troubleshooting
Table 5-6
Troubleshooting Fluid Drive (continued)
High fluid drive oil Poor oil circulation 1. Check filters: shift or clean as
temperature (cont.) required.
2. Verify that the hydraulic oil system
is aligned for operation.
3. Inspect all piping, valves, and filter
assemblies for leakage.
4. Verify that all designated valves
are opened correctly, and inspect oil
side of the heat exchanger for clogs
or buildup of dirt. Restrictions at the
pump suction point may indicate a
buildup of sludge in the oil reservoir.
5. Inspect pumps for proper
operation; low discharge pressure
may indicate a worn impeller. Check
for dirty suction strainers.
6. Verify that relief valves are
properly set and not opening
prematurely.
7. Vent oil side to remove any air
pockets that may have formed if the
system was opened.
Incorrect oil viscosity or Verify that the proper oil is used, and
contamination analyze oil quality.
Low fluid drive oil pressure High oil temperature See corrective actions for high oil
temperature in Table 5-3.
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Troubleshooting
Table 5-6
Troubleshooting Fluid Drive (continued)
High fluid drive vibration Loose bolts Verify that all foundation and
machinery hold-down bolts are
properly tightened; inspect for
cracked bolt heads. Ensure that
fasteners on the steel housing are
properly tightened. Inspect all
peripheral connections and
equipment for damaged or loose
fittings.
Fluid drive oil leaks Labyrinth seal Inspect seals for damage.
Table 5-7
Fan Performance Troubleshooting
Poor fan performance Inlet vanes Verify that inlet vanes are responding
to the controls. Verify that the inlet
vanes on double-inlet fans are
synchronized.
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Troubleshooting
Table 5-7
Fan Performance Troubleshooting (continued)
Turning gear high oil Oil contaminated Analyze oil, and check viscosity.
temperature
Turning gear high vibration Alignment Check alignment between fan and
turning gear.
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6
CONDITION MONITORING
Condition monitoring is the use of advanced technologies to determine equipment condition and,
potentially, predict failure. It includes technologies such as the following:
• Vibration measurement and analysis
• Oil analysis
• Nondestructive examination (NDE)
• Infrared thermography
• Motor current analysis
The goal of condition monitoring is to identify changes in the condition of the fan, motor, or
auxiliary that could indicate some potential failure. Physical characteristics are measured,
recorded, and analyzed so that trends can be identified.
Vibration monitoring consists of acquiring and analyzing specific machine operating parameters.
6.1.1 Parameters
The following parameters can be used to form a database for draft fans:
• Amplitude
• Frequency
• Phase angle
• Vibration form
• Vibration mode shape
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Condition Monitoring
6.1.1.1 Amplitude
6.1.1.2 Frequency
Vibrations occurring at frequencies that are a direct multiple (for example, lx, 2x, 4x) of the
machine’s rpm are termed synchronous or harmonic. Vibrations occurring at frequencies that are
an integer fraction (for example, l/2X, 1/3X) of the machine’s rpm are termed subsynchronous.
Nonsynchronous vibrations occur at frequencies other than direct multiples of the machine’s
speed.
Machine problems will most often occur at low vibration frequencies, typically less than 4 times
(4X) the running speed. Frequency should not be used as a measure of the problem’s severity,
unless roller and ball bearings are involved. Although, in certain cases, specific frequencies can
be linked to specific problems (for example, unbalance and misalignment), this does not mean
that there is a direct correlation between problems and vibration frequencies.
The phase angle provides a reference measure of movement of a specific point on the shaft or
rotor. This point can be a high spot located on a shaft or a concentration of uneven weight that
may have collected on the fan rotor. The measurement is taken relative to either another moving
point or to a fixed point such as a transducer. The phase measurement or angle is expressed in
degrees. Accurate phase angle measurement plays an important role in balancing fan rotors and
in analyzing the mode shape of the vibration.
Vibration form is the actual vibration displayed as a wave pattern. The wave pattern generated
will represent shaft motion. Short-lived, transient types of vibrations are best analyzed through
observing their wave form characteristics (such as shape, amplitude, and pattern) on an
oscilloscope. This provides the ability to “see” what the fan is doing at any moment.
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Condition Monitoring
Vibration mode shape is obtained by recording vibration amplitude and phase values at many
points on the structure of the entire machine, including fan bearings, driver, and foundation. The
vibration mode of a draft fan provides a means of confirming resonance conditions, locating
nodal points (that is, points of minimum amplitude), and identifying points of structural
weakness. By conducting casing measurements along a drive train, problems such as pipe
resonance, structural resonance, or loose/cracked foundations can be determined.
Primary equipment needed to conduct this test includes a vibration-pickup (probe) and vibration
analyzer. Use of an X-Y recorder provides the added feature of automatically producing a plot of
frequency-versus-vibration amplitude. An additional option available on some vibration
analyzers is an automatic frequency tuner, which eliminates the need for operators to manually
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Condition Monitoring
tune through the frequency spectrum. Using an automatic frequency tuner also provides extended
troubleshooting capability. It reduces the element of human error by eliminating the chance of
missing significant vibration frequencies, and it reduces the actual analysis time by eliminating
time spent on fine-tuning each significant frequency.
The following are additional recommendations to follow when using the amplitude-versus-
frequency technique:
• Take vibration readings along the horizontal, vertical, and axial directions at each bearing.
• Select an amplitude range setting on the vibration analyzer sufficient for the maximum
vibration signature in order to obtain data that are plotted on the same range.
• Select a single amplitude range setting sufficient for the entire analysis.
• Obtain an overall “filter out” reading (in each of the three positions) at each bearing.
This method is most effective when the vibration is not steady state or transient. Use of a real-
time spectrum analyzer allows O&M personnel to “capture” and analyze vibration signatures.
Two features available with real-time analyzers are the “hold” and “peak hold.” The “hold”
control is operator-initiated when the transient frequency reaches its maximum amplitude. This
action stores the transient signal into the analyzer’s memory for future analysis. The “hold”
feature provides a means for manually capturing the transient signal. This method will work if
the following conditions are met:
• The operator is fully aware of when the transient signal will occur.
• The transient signal occurs slowly enough for the operator to depress the “hold” button.
The “peak hold” feature provides a method to capture and store a transient signal in situations
that do not meet the above two conditions. If this feature is used, the operator must set the trigger
level, which specifies the percentage of the signal’s amplitude used to begin the process. For
example, if the operator chooses 50%, detection circuits will look for an amplitude level
exceeding this value from incoming signals. Once this 50% criterion is met, the circuit will
trigger and automatically capture an incoming transient signal.
Time waveform analysis uses an oscilloscope to provide a time display of vibration amplitude.
The oscilloscope can be set up to receive an input vibration signal either directly from the
transducer or from a real-time spectrum analyzer. Either method allows operators to analyze
vibration quickly and easily. Data obtained are not filtered, thereby providing a true measure of
maximum amplitude present. Using an oscilloscope can also provide an excellent means for
observing and evaluating transient vibration signals that may be present because of fan
pulsations or control problems.
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Condition Monitoring
Essential to any on-line monitoring system is the choice of sensors (that is, transducers) to be
used. For vibration measurement, there are three types of transducers available: proximity
(noncontact), velocity, and accelerometer probes.
A proximity probe is a transducer used for vibration and position measurement. Physical contact
with the object being measured (for example, the shaft) for vibration or position is not required.
Proximity probes are used to measure the relative movement between the shaft and bearing or
bearing housing. Principal components include the probe, pickup, connecting cable, and driver.
Inside the probe is a coil that receives high-frequency current from the driver. As this current
passes through the coil, a magnetic field is established. Conductive material, such as a steel shaft,
brought in proximity to the coil due to vibration or axial motion will “cut” the lines of the
magnetic flux, thereby setting up eddy currents on the conductive material’s surface. Stronger
eddy currents are established as the shaft gets closer to the probe and weakens the magnetic field
around it.
The strength of the magnetic field is directly related to the level of equipment vibration. In
practice, the field strength is monitored by detection circuitry located in the driver. Output from
the driver is either in the form of a dc signal or a combination of a dc and ac signal. When no
vibration is present, a dc voltage directly proportional to the distance (that is, gap) between the
shaft and probe is transmitted from the driver. As vibration levels develop, a dc signal
proportional to the average gap and an ac signal proportional to vibration amplitude are
generated.
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Operation of a velocity probe is based on the movement of a conductor (in this case, the coil)
through a magnetic field. The amount of voltage that is induced in the coil will be proportional to
the relative velocity between it and the magnetic field. Unlike a displacement probe, a velocity
probe requires no external power source to operate.
A velocity pickup consists of six principal parts: pickup case, wire coil, damper, mass, springs,
and permanent magnet.
The pickup case provides a structure to house the remaining components. The wire coil is
wrapped around the mass that in turn is suspended between the permanent magnet by the springs
and damper. The permanent magnet is attached to the pickup case and provides a magnetic field
around the suspended coil.
In certain applications, velocity probes and their cables can be susceptible to magnetic
interference. The magnetic interference may be caused by the alternating magnetic field that is
generated around large ac motors. Without proper shielding, these fields can induce a voltage in
the pickup or cable; consequently, an erroneous vibration signal is generated.
If this condition is suspected, the magnetic field’s intensity and presence can be determined. To
perform this test, personnel will need a vibration analyzer connected to a portable velocity probe.
The probe should be held steady by its cable near the permanently installed velocity probe, and
the suspended probe should not come in contact with the operating equipment. During draft fan
operation, a reading on the analyzer indicates that a strong magnetic field is causing interference.
To alleviate this problem, a magnetic shield should be installed around the fixed velocity probe.
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Condition Monitoring
The internals of an accelerometer probe are made up of four components: mounting stud, frame,
piezoelectric disks, and mass.
The mounting stud provides a means for attaching the probe assembly to the equipment being
monitored. The frame assembly houses the mass and the piezoelectric disks; these last two
components form the heart of an accelerometer probe.
Piezoelectric material can generate an electric charge when it undergoes mechanical stress,
which can be compressive or tensile. Disks of piezoelectric material are rigidly “sandwiched”
between the frame and the mass. In the event of vibration, these disks undergo a series of
compressive and tensile reactions. These in turn produce an electric signal proportional to the
magnitude of the force imparted to the mass. Because the amount of mass is known, the signal
generated represents the acceleration of the mass.
Accelerometers are small, lightweight, and rugged. A principal advantage of this type of probe is
its ability to operate over a wide frequency range. This capability makes an accelerometer well
suited for monitoring high-frequency vibration that can develop in anti-friction bearings or gears.
Accelerometers are unaffected by magnetic fields that may originate from nearby electric
machinery. They require no special shielding or other provisions.
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For draft fans equipped with installed vibration sensors, obtaining data means monitoring and
recording vibration levels displayed on the gages or output devices provided. Monitoring
programs using portable equipment either to supplement existing installed vibration sensors or to
check equipment not outfitted with an installed monitoring system will require personnel to
identify specific locations on which to place the probe. These locations should be identified both
on the equipment or component and on the forms used to record the data. This procedure will
help ensure that consistent and reliable information is obtained. Use of color-coded marks (such
as “red dots”) provides operators with an easily seen reference point from which to take vibration
readings. Stenciling the equipment with identification marks such as “FD 1 EAST” to distinguish
between the various fans at the site will also help prevent confusion—a prime consideration
because introducing incorrect data into trending and equipment history files will produce
erroneous results.
An important part of the data acquisition process is the machine diagram. A diagram of this type
forms a link between the actual physical location on the equipment or component and the record
used to log the results. To be effective, the diagram should show all the essential elements. For a
draft fan, these elements should include the driver (motor), driven unit (fan), bearings, coupling
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fluid drive (if applicable), and installed vibration sensors. Additional information such as motor
rpm, type of bearings (sleeve or antifriction), pickup points, date, name of persons performing
the check, and space to enter vibration amplitudes and frequencies should also be incorporated
into the form.
Recommended practice indicates that readings should be taken in the horizontal, vertical, and
axial directions at each bearing housing. The three-axis approach can assist the maintenance
organization in distinguishing between various mechanical problems such as imbalance and
misalignment. For example, both of these problems are manifested as an increase in vibration.
The frequency of this vibration level is typically lx rpm for both misalignment and imbalance.
With the exception of overhung rotors, an out-of-balance fan will have high vibration levels in
the radial directions (that is, horizontal and vertical); vibration levels observed in the axial
direction would be significantly less. Misalignment, however, typically produces high vibration
levels in all three directions.
Analyzing horizontal and vertical readings can also provide insight into the condition of the
equipment. For horizontally mounted draft fans with a floating outboard bearing, the vibration
levels in the horizontal direction will be higher than those in the vertical direction. This
difference is considered normal for rigidly mounted fans where the vertical stiffness is greater
than the horizontal stiffness. A deviation from this condition may indicate loose equipment hold-
down bolts, damaged grout layers and/or foundation, wiped bearings, or excessive bearing
clearance.
The basic parameters that will be monitored are bearing temperature, vibration level, flue gas
temperature, and motor amperage. This system package can be used as a guideline for
determining the amount of protection needed. Primary features of this system include the
following:
• A remote monitoring capability that allows control room operators to monitor equipment
operating parameters.
• A configuration with safety interlocks that provides audible and visual indications to
operators if an operating parameter has exceeded a defined safe limit.
• A safety interlock system that can initiate a shutdown of a draft fan if a condition develops
that is dangerous to equipment or personnel.
Additional parameters and/or features such as lube oil flow and gas stream temperatures (for
inside a duct) may also be added if the system configuration requires it. The decision of whether
to elect a continuous demand display or an operator demand display setup should be based on the
type of fan. For example, fans subjected to blade erosion or buildup are suggested candidates for
a system that can be continuously monitored. Fans operating in a clean gas stream are less likely
to develop damage from erosion; therefore, they require less stringent monitoring.
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Oil samples taken for oil analysis purposes are also appropriate for out-of-service checks. A
basic spectro-chemical analysis can provide maintenance personnel with the following
information:
• Particle count
• Viscosity
• Total acid/base measure
• Condition of oil additives
This information can be used to determine whether it is necessary to open and inspect a bearing
for wear and damage as well as provide a “snapshot” picture of the lube oil’s quality. However,
because there are not any recognized industry standards for what is acceptable in lubricating oil,
the oil analysis should be used to identify changes and trends. Oil analysis tests are often offered
free or for a nominal charge by the lubricant supplier as part of the overall service provided. If
the physical design of the fan prevents ready access to the bearings, the pre-startup checks should
be accomplished during the out-of-service maintenance period before “closing up” the fan for
operation.
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Infrared thermography is typically used to identify problems with electric motor leads. It is not
used on the fans.
Condition monitoring of the electric motors is addressed in EPRI report NP-7502, Electric Motor
Predictive and Preventive Maintenance Guide [3].
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7
MAINTENANCE
Fans require periodic inspection and maintenance to ensure their mechanical and aerodynamic
integrity for reliable operation. This section identifies the recommended maintenance tasks and
their frequencies. Because each application could be different, the experience at a given plant
should be reviewed and these frequencies adjusted.
The major maintenance areas for centrifugal fans are the blade liners, main shaft bearings, and
inlet vane or inlet damper linkages. Repair or replacement of the blade liners requires the most
specialized labor. The liners can often be repaired by welding instead of being replaced. Either
case requires balancing the fan wheel. The main shaft bearing requires the same type of
maintenance as that required for the bearings for most other large rotating equipment.
Maintenance of inlet vane or control damper linkage presents no special problems if the linkage
is properly designed.
Axial fans require considerably more maintenance than centrifugal fans. The maintenance areas
include blade bearings, main shaft bearings, the hydraulic blade positioning system, and blade
replacement. The blade bearings are subjected to high loads and require frequent maintenance.
Hydraulic blade positioners have been a source of problems for some axial fan installations.
Some utilities send the hydraulic actuators back to the manufacturer for rebuilding rather than
repairing them. Blades on axial fans are designed to be replaced.
Previous surveys and studies indicated that some plants have had availability problems with axial
flow fans—and the availability has a strong correlation with maintenance practices. Stations that
follow the manufacturer’s recommendations and rebuilt the axial fan rotors have high
availability; those that do not have had problems. It was found that the units that follow the
recommended maintenance had axial fan availability similar to that for centrifugal fans.
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Actual maintenance will depend on the design of the fans, actual operating conditions, and the
owner’s philosophy on preventive maintenance.
Maintenance inspections at specified frequencies must be performed on draft fans and on their
supportive auxiliaries in order to maintain a high standard of safe and reliable operation. This
section provides checks for specific fan components. Recommendations are provided for routine
maintenance and for overhauls. The frequency of the activities varies with the application, and
suggested frequencies are provided for some activities.
Warning signs, such as excessive equipment failure after maintenance has been completed, could
be indications of inadequately trained personnel and/or poor quality control standards. The
philosophy of “if it works, don’t fix it” should be considered in any maintenance program.
Opening and inspecting components such as bearings or actuators can lead to additional
problems and equipment downtime. A balance must be attained by performing PM but avoiding
opening and inspecting equipment if no problems (such as high temperature or pressure) are
present. This balance is achieved by carefully determining an adequate time period (that is,
frequency) between checks. Note that this does not in any way suggest that basic sound operating
engineering practices—such as ensuring adequate lubrication, clean lubrication, daily visual
inspection of the equipment, and clean equipment—should be ignored.
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Once this list of checks is finalized, the next step is to develop written formatted PM tasks. Each
PM task should provide an itemized listing of what is required to accomplish the specific
maintenance action. Actual procedures to conduct a specific maintenance action may also be
incorporated on this PM task sheet. For example, a well-thought-out PM task should include
information such as the trades involved in the check; related additional checks that could be
accomplished simultaneously, special tools required to accomplish the job, person-hours
required, technical manuals and drawings required, and data readings to be taken. A database
incorporated into a PM task can provide a ready reference for personnel to use during equipment
maintenance periods. In certain cases, a “pictorial map” could also be attached to a task sheet to
provide standard locations to take measurements.
To avoid unnecessary injury to personnel or damage to the equipment, sound basic maintenance
rules should be practiced at all times:
• Keep the area around the disassembled equipment clean.
• Take inventory of the tools brought in and out of a job.
• Use the correct tool for the job specified.
• Do not take shortcuts when safety is involved.
• Follow proper tag-out and valve-out procedures.
• Keep the shop supervisor informed of the progress and any problems encountered.
• For PM actions, verify that the required parts are available before starting the job.
Table 7-1 presents typical surveillance and PM frequencies. The actual tasks and frequencies for
a specific plant should be reviewed based on the plant-specific experience.
Table 7-1
Surveillance and Preventive Maintenance Frequencies
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Table 7-1
Surveillance and Preventive Maintenance Frequencies (continued)
Analyze vibration X
Inspect and overhaul main shaft X
bearings
Inspect and overhaul coupling X
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Table 7-1
Surveillance and Preventive Maintenance Frequencies (continued)
For extended shutdowns (shutdowns greater than one month), the following maintenance tasks
should be performed:
• Start hydraulic unit once every two weeks, and run it for 30 minutes.
• Inspect and clean flue gas fan, and check for wear of impeller blades.
The following subsections describe the maintenance tasks for the components and accessories of
centrifugal and axial fans.
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7.4.1 Bearings
Ensuring that the lubricant is at the correct level, clean, and of good quality is essential to
prolonging the operational life of a bearing. An inadequate amount of oil being supplied to a
bearing will result in its operating at higher-than-normal temperatures. High-temperature
conditions can cause the oil to break down and the bearing to be damaged by excessive friction
levels. Similarly, excessive amounts of oil or grease can cause the bearing to overheat as well.
Levels recommended by the manufacturer should be adhered to.
Static lubricating oil systems offer a particular challenge to a maintenance department. If a low-
level condition is discovered during operation, personnel should proceed with caution when
adding oil to the affected bearing while the fan is in operation. Relatively colder oil that is added
while the shaft is rotating can disrupt the oil film that has been formed. If this condition occurs,
metal-to-metal contact can be expected, with resulting damage to the bearing.
The quality of the oil being used is best determined by taking an oil sample. Visual inspections
taken before fan startup can assure operators that the oil quality is satisfactory. Periodic oil
samples taken while the fan is in operation are recommended for bearings lubricated by a
circulating oil system. Taking an oil sample on a static system during fan operation is not
recommended. Use of a drain valve installed in place of a drain plug can provide some measure
of control if personnel consider it necessary to sample oil during fan operation. If a drain valve is
used, it is good practice to install a cup or plug to seal the discharge line from dirt and to act as a
safeguard to prevent draining of the system if the valve is accidentally opened. Two primary
concerns are that the oil film may be disrupted as the oil is being replenished with colder oil and
that the sump may run dry while the fan is in operation.
Do not mix oils in the lubrication system or bearing housing. Chemical additives in different oils
can cause a breakdown in the viscosity, cooling, or bearing lubrication.
There are four general indicators for impending bearing failure: vibration, excessive noise,
steady increase in bearing operating temperature over time, and/or a lube oil sample
contaminated with babbitt or water.
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It should be noted that the recommended minimum temperature varies for each manufacturer.
For bearings cooled by a circulating oil system, the following tasks should be performed:
• For bearing fitted with inspection covers, verify lube oil flow through the bearings, check for
proper operation of oil rings, and visually observe oil circulation.
• Wipe the inspection cover thoroughly before opening to prevent any dirt or debris from
entering the bearing system. Bleed any air pockets from the system by “cracking open” a
vent valve.
• Inspecting the bearing cooling systems:
– Verify alignment and start the system.
– Inspect for leaks.
– Verify that flow has been established.
– For a closed system, bleed any air pockets from the system by cracking open a system
vent valve.
• Drawing an oil sample and conduct a visual inspection for the following:
– Water contamination
– Particulate contamination (for example, dirt or metallic)
Note: When drawing an oil sample, ensure that the sample bottle is clean and dry; if not, it
should be wiped with a lint-free rag.
• Ensure that the area around the sample petcock/sample plug is clean before opening.
• For systems having sample lines, adequately flush the line to remove any dirt or
condensation that may have collected inside the line.
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Worn components should be replaced as required. The replacement criteria are directly related to
physical damage caused by cuts, heat, corrosion, or other factors.
An inspection should be made of the babbitt surface for surface scoring or wiping (axial scoring
is unacceptable; circumferential scoring is not to exceed the manufacturer’s recommendations),
noting the following:
• Fatigue cracking
• Corrosion
• “Black scab” or “wire wool” damage
• Pitting due to electrical discharge
• Overheating
• Uneven wear
• Fretting
• Inadequate lubrication
During normal open and inspect periods, maintenance personnel can check tightness by applying
hand pressure at the ends and horizontal joint of the babbitt. If oil is observed to permeate out,
then the babbitt is loose. A dye penetrant test could also be used.
The sleeve bore inner diameter should be checked. If bearing sleeves must be replaced, the rust
preservative used on the new sleeves must be verified as being compatible with the lubricating
oil. If it is not, then any rust preservative applied to the new sleeves must be thoroughly removed
with a manufacturer-approved solvent.
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An inspection should be made of the shaft journal for ridges, grooves, and/or sharp edges, and, if
they are present, they should be removed with an approved abrasive cloth. The shaft journal
should have a finish range specified by the manufacturer.
Thrust collars should be inspected for axial and radial run out. On a thrust bearing, the face-to-
face dimension is critical. A check should be made that the passes are perpendicular to the face.
Maintenance will vary with the complexity of this system. Specific components requiring
various degrees of maintenance include the following:
• Pumps and motors
• Gauges, pressure relief valves, pressure switches, temperature switches, and motor
controllers
• Piping and valves
• Heat exchanger
• Cooling fan
• Sump
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Some routine maintenance tasks should be completed to verify that the lube oil is at the proper
level in the sump and at the required temperature. To control the temperature through the heaters
or cooling system (which is either air or water), it should be verified that the cooling fans are
running (if installed). The cooling water flow should be checked, and correct heater operation
should be verified.
Discharge filters and pump suction strainers should be cleaned and inspected. In addition, all
electrical connections (such as cables for pumps, sensors, and so on) should be checked for
cracks or looseness, and all control panel access doors should be checked to verify that they are
closed and properly secured.
External fasteners should be checked for the pumps, fan motor, heat exchanger (air/water cooled
type), and pressure switches.
In the event of a low-pressure alarm, it should be verified that the standby pump will start by
checking for signs of leaks in the following:
• Supply/return piping and flexible hoses
• Filter and strainer assemblies
• Pump suction and discharge liner
• Inlet/outlet of heat exchangers (if installed), including both water and oil sides
• Valves and sight glasses
Any unusual conditions of noise or vibration should be noted. The differential pressure across
filter elements should be checked—and shifted, inspected, and cleaned as required.
The calibration and inspection of all system instrumentation and sensors should include the
following:
• Pressure switches
• Thermostats
• Relief valves
• Liquid-level switches
Pump operation and alarms at given system test pressures should be verified.
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In the event of low-discharge pressure, the pump should be opened and the impeller surfaces and
wear ring, as well as the foot valve, should be inspected.
When poor oil quality is suspected, the sump should be drained and cleaned; all door gaskets
should be inspected and replaced as necessary. Before re-closing the sump, it is important to
ensure that all rags have been removed.
In the maintenance of all electrical components, the following tasks should be performed:
• Conduct continuity checks on electric motors and heater coils.
• Inspect all cables for cracking or other damage.
• Open, inspect, and clean all control and relay boxes.
• Verify that all electric motors have been connected properly by checking component rotation.
All exterior surfaces should be inspected and cleaned; all corrosion should be removed; and
priming and painting should be performed, as required.
An inspection and cleaning of cooling fan blades and air-cooled heat exchanger surfaces should
also be performed.
All filters and strainers should be inspected and cleaned. The location of filters is very important.
Filters installed only at the suction side of the oil pump do well in protecting the pump.
However, pump wear or damage can pass to the bearings if oil is not final-filtered before it enters
the bearing. The optimum system has both suction filters and final filters. These final filters
should be installed as close to the bearings as possible.
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7.4.3 Couplings
Couplings provide a means of connecting the prime mover (that is, electric motor or steam
turbine) to the designated load—the draft fan rotor. There are two types of couplings: flexible
and rigid. Flexible couplings are used extensively in draft fan service.
Depending on the design and service requirements, flexible couplings can provide the following
benefits:
• Provide protection for slight misalignment caused by thermal expansion and contraction
between the prime mover and its load
• Lessen vibrational torque to reduce noise and absorb any torsional oscillation that may be
generated during a transient condition (startup, shutdown, and speed changes associated with
a variable-speed motor).
There are four types of flexible couplings used with draft fans: grid, gear, elastomeric sleeve and
elements, and disk. These couplings can be divided into two broad categories:
• Sealed lubricated (grid and gear types)
• Non-lubricated (rubber sleeve, rubber elements, and disk)
Gear and grid type couplings are designed with limited end float to prevent motor rotor axial
movement that can cause damage to the motor.
Coupling maintenance is discussed in more detail in EPRI report 1007910, Flexible Shaft
Couplings Maintenance Guide [5].
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These checks are performed on fans having couplings that are readily accessible for a pre-start
inspection.
• Inspecting for cracked disks (disk-type coupling)
• Visually inspecting for unusual noise or vibration
• Visually checking for collection of rubber-like dust directly below the coupling (elastomeric
sleeve/element type only)
• Replenishing grease
• Performing alignment checks:
– Parallel alignment
– Angular alignment
Note that the gap spacer is in place and correctly installed (for limited end float coupling
designs).
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Note: The order or number of the shims in a disk pack coupling must not be changed.
• Replacing the fasteners if the locking feature is in doubt.
Note: The locking feature of these fasteners becomes compromised when they are removed and
reinstalled a certain number of times. As an example, Rexnord recommends replacing the
fasteners after they have been removed and reinstalled between 7 and 10 times.
Misalignment can result in high fan vibrations. For fan installations that have high vibration
sensitivity, the coupling can be aligned to a tighter tolerance, which reduces vibration. A tighter
tolerance on coupling alignment can be achieved by using a computerized alignment device.
It is important to verify that the thrust load of the fan is not imposed on the motor thrust bearing.
This requires knowledge of the magnetic center of the motor.
For more detailed information on alignment, refer to EPRI report TR-112449, Shaft Alignment
Guide [6].
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On centrifugal fans, the variable inlet vanes require the most maintenance.
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4. Disassemble the damper bearings and inspect and clean the roller bearings, paying particular
attention to the following items:
– Broken or cracked rings
– Dented shields and seals
– Cracked or broken separators
– Broken or cracked balls or rollers
– Flaked or spalled areas on balls, rollers, or raceways
– Brownish-blue or blue-black discoloration caused by overheating
– Indented, brinelled, or etched raceways
The fan wheel is the most critical area of the fan in terms of structural reliability. Inspections
should be conducted at regularly scheduled intervals and whenever the opportunities arise
(termed inspections of opportunity). A more detailed description of fan wheel inspection and
weld repair is provided in Appendix A. However, as an overview of recommended maintenance,
particular attention is suggested for the structural welds that connect the blades, center plate, and
side plates as a functional unit.
The integrity of these welds is critical. Damage (manifested in the form of cracking or corrosive
wear) can be partial or total. Unchecked damage may result in an increase in vibration levels
with additional wheel damage, which, subsequently, may increase in severity to catastrophic
failure with a serious potential for injury to personnel.
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A typical centrifugal fan rotor (wheel) is shown in Figure 7-1 and comprises the following
components:
• Blade
• Center plate
• Side plate
• Shaft
• Hub
The fan wheel consists of the blades, center plate, and side plates.
The primary goal of the maintenance program is to maintain a high state of material upkeep and
availability of these components.
Figure 7-1
Centrifugal Fan Wheel
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Large centrifugal fan wheels are highly stressed rotating equipment. The design stress may be as
high as 80% of yield, and the material may be a quenched and tempered high-strength material
such as ASTM A514 or A517, with a yield strength of 100,000 psi. Many large centrifugal fans
have had cracks, and there have been a few mechanical failures. It is important to periodically
conduct NDE (such as wet fluorescent magnetic particle) of welds and to properly repair any
cracks. The techniques for examining and repairing welds are covered in Appendix A.
7.4.5.2 Blades
Several problem areas associated with centrifugal fan blades include the following:
• Erosion with subsequent imbalance
• Loss or deterioration of blade liners due to erosion
• Failed bolts or poor or failed welds
• Cracking
• Buildup of fly ash inside airfoil blades
These problems can be readily detected and corrected in their early stages if proper cleaning and
inspection (both visual and nondestructive methods) are conducted regularly.
Regular cleaning of fan wheel blades subjected to erosive or corrosive environments is highly
recommended to avoid fly ash or corrosion buildup. Successful cleaning methods include steam
cleaning, high-pressure water, or abrasive blast cleaning. Blasting with frozen CO2 pellets has
been used for cleaning, with the benefit of eliminating the need to remove the blast medium from
the fan. Care should be exercised when cleaning the blades with either steam or high-pressure
water. To prevent thermal shock to the blades, personnel should defer cleaning until the fan
blades have adequately cooled. The temperature difference between the blades and the cleaning
medium should not exceed the manufacturer’s recommendations. A second consideration
concerning all three techniques deals with “filling” the hollow sections of the airfoil blades with
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either water or grit or sand, thereby causing imbalance. To avoid this situation, a visual
inspection is recommended before any cleaning is undertaken. Direct impingement of areas
noted to have large cracks or surface separation should be avoided. Cleaning should be done
using wire brushes or scrapers to minimize particles from entering the blade interior.
Buildup of fly ash inside airfoil blades is caused by erosive wear providing a path for the gas
stream to enter the blade interior. Correction of this situation (should it occur) involves two
steps:
1. Confirming that the cause of the vibration is from fly ash buildup inside the blades
2. Removing the fly ash from the blade interior
The first step involves the detection of a high vibration level followed by pinpointing which
blades are affected. High vibration can be detected through daily monitoring and trending of the
vibration levels. Once a high vibration condition is reached, diagnostic equipment allows
maintenance personnel to determine the exact cause and location.
Once the blade(s) has been identified, the next step is to remove the fly ash. This step will
require a section of the blade skin to be removed to allow personnel to access the blade interior.
If this is required, reviewing technical data—such as drawings that show how the blade is
constructed and the applicable welding procedure used to determine blade material—is
recommended before any work is begun. After the section(s) has been removed, maintenance
personnel may be required to use a metal rod to mechanically dislodge fly ash that has hardened.
This material should be “broken up” as best as possible and removed with a vacuum. Some
utilities recommend using a high-pressure water jet to fully remove fly ash in difficult-to-reach
places. Rotating the blade 180° will allow for the water to adequately drain out. Using high-
pressure air to remove remaining pockets of water should also be considered.
Any holes due to erosion or made to remove ash from hollow blades should be repaired. The fan
manufacturer should be consulted for recommendations for cutting holes and repairing holes.
One method of protecting centrifugal ID fan blades from erosion is to use protective liners and
solid nose pieces, as shown in Figure 7-2. The liner should cover the nose of the blade and the
full length of the blade adjacent to the center plate. Liners should not be added without
evaluating the impact of the additional weight on the stresses in the fan wheel and the additional
starting load on the motor. The fan manufacturer should be consulted to evaluate the effect of
liners on the stresses on the fan.
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Figure 7-2
Wear and Erosion Protective Accessories
Liners can create a problem with NDE of the fan welds. Also, cracks in liners can propagate into
the blade material. The capability to perform NDE should be considered when the material of the
liners is selected. Using the same material as the fan blades may not provide the same erosion
resistance as a hardened material but will avoid the NDE and crack propagation problems.
Many plants have had success with flame spray coatings (usually with 45% chrome) on ID fans
and gas recirculation fans.
Coating fan blades to improve erosion resistance has met with varying degrees of success.
Coatings can affect the physical properties of the base materials of the fan. Cracks in coatings
can propagate into the fan members. Tests using proposed coatings and fan structural material
should be performed and evaluated before the coatings are actually used.
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Coatings create a problem with NDE of the fan welds. The coating in the area of the welds may
need to be removed for NDE.
An inspection program that encompasses both visual (VT) and nondestructive evaluation (NDE)
inspections will greatly assist maintenance personnel in detecting these problems. Consideration
should be given to increasing the frequency of the inspection and performing a detailed NDE
inspection for fans that exhibit cracking problems that continue to increase in severity.
If replacement wheels are being considered, acceptability standards for the welds should be
given a high priority before being written into the specifications. A standard that requires no
linear indications and welds that are contour ground will lessen problems associated with
interpretation and subjectivity during future inspections. For older fans where insufficient weld
penetration is suspected, an ultrasonic test could be used to identify problem areas.
7.4.6 Shaft
Results from previous EPRI reports [2, 3] as well as surveys conducted in support of this project
indicate that shafts continue to have limited problems. Operationally induced problems range
from bowing to scored journal surfaces. Cracking may sometimes develop at the step change of a
section as well. If cracking is suspected, either from surface indications noted during a visual
inspection or from an increase in vibration levels, follow-up NDE inspections are recommended
to confirm or eliminate the possibility of cracks at the step.
Technology exists to determine the presence of cracks elsewhere on the shaft. The practicality
and economics involved in work of this scope together with low stress levels placed on a fan
shaft and few, if any, incidents of cracked shafts being reported make this maintenance action
difficult to justify. A cracked shaft may develop as a second-order vibration. Unfortunately, this
condition may also indicate a bowed shaft, misalignment, or looseness. However, inspection of
cracks on a fan shaft is recommended in the case of catastrophic wheel failure or serious
misalignment or imbalance.
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7.4.7 Hubs
Although feedback from the surveys for this project indicated no problems with this component,
a regular visual inspection of hubs is recommended to examine for erosion or damaged fasteners.
This inspection could easily be incorporated into the maintenance program for the entire wheel.
An ultrasonic test (UT) can effectively be used to supplement a VT inspection, checking a hub
for cracks, inclusions, cracked fasteners, and erosive wear. A UT examination of the hub should
be a low priority, however, and is recommended only once every 10 years unless a problem is
suspected or the VT identifies potential problems.
Assuming that the soil base has been properly stabilized, the repair of concrete foundations
encompasses two areas:
• Surface cleaning
• Crack repair
To gain maximum effectiveness, each of these maintenance actions should include both
prevention and detection. Prevention is a two-tiered process. Early detection through regular
inspections will provide a decisive step toward prevention of major problems and the major
repairs that follow. Investigating and determining the cause of the casualty is the second part of a
PM action. Maintenance personnel should avoid hasty repairs without first addressing the
question: “What caused this problem?” This is especially true in the case of concrete foundation
repair. If the foundation continues to crack, hidden problems such as voids in a concrete
foundation or an unstable soil base should be considered for investigation.
The correction or repair of a concrete foundation involves the choice between a permanent fix
(which may require the erection of a new foundation) and a semi-permanent fix used as a “stop
gap measure” to keep the fan on-line until a scheduled outage or until the needed logistics are
brought together to effect more permanent repairs.
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Over time, oil may degrade the structural integrity of concrete by causing a physical breakdown
in the matrix structure of the concrete. This breakdown process is not immediate and may take
years to develop into a serious problem; however, it is one problem that can certainly be
prevented and corrected.
Steam cleaning provides one possible solution for concrete surfaces that have been subjected to
oil spillage over a period of years.
Curing cracks do not have any appreciable depth or pattern; structural cracks, however, are large
and deep. If structural cracks are not addressed, they may continue to develop in severity. As the
foundation continues to degrade, operators and maintenance personnel can expect equipment
misalignment, bearing problems, and an increase in vibration amplitude. Early detection is
critical to limiting damage to both the foundation and the draft fan.
Because anchor bolts are stress risers, structural cracks will appear most often in the immediate
vicinity of these bolts. Proper installation of these anchor bolts and correction of equipment
vibration offer the best courses of action to take in avoiding this problem.
Before actual repairs can begin, several factors, primarily the following, should be considered:
• Choice of the correct grout
• Severity of the damage
• Urgency to bring the fan back on line
• Access to the damaged area
The effectiveness of a grout is based on its ability to act as an adhesive and to bond the damaged
area into a structurally sound joint. Determining which grout resin system to use is an important
factor in the repair process. Variables such as pot life (curing time), non-shrink capability, ability
to bond through oil films, viscosity, and wetability all factor into the effectiveness of the grout to
penetrate the crack and bond the two cracked segments into a cohesive unit.
The extent of damage is the final determining factor in deciding whether a foundation can be
repaired. Experienced personnel in the field of concrete foundation repair should be consulted to
assist in the decision process. Once it has been determined that the foundation can be repaired,
the need for the draft fan provides an important input into the decision to conduct temporary
repairs or defer the maintenance action until a scheduled outage.
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An anchor bolt functions as a clamp to provide a secure means for holding the base plate to the
concrete foundation. This clamping effect is accomplished through a spring-type action between
the anchor bolts and the concrete foundation/grout layer system. As the bolt nuts are tightened,
the bolt itself begins to stretch. This stretching phenomenon plays an important part in the
successful application and performance of the anchor bolt. As each anchor bolt is tightened, the
bolts become a system of springs that will collectively apply a clamping or compressive effect
around the entire base plate. The net effect achieved is a secure base on which the draft fan can
operate.
During the operational life of the draft fan, anchor bolts will be subjected to three loading
conditions:
• Initial preload: Load developed when the anchor bolt is first tightened.
• Residual preload: The load remaining after all anchor bolts have been properly tightened.
• Working load: The load to which the anchor bolt is subjected while the draft fan is in
operation.
If properly installed and tightened, the residual pre-load on the bolts should be less than any load
caused by operation.
Critical to achieving a good installation is the need to properly isolate the anchor bolt, and there
are two areas that require special attention to ensure anchor bolt isolation. First, foam insulation
in the area around the grout where the bolt penetrates can provide adequate isolation. Failure to
accomplish this allows the grout to bond to the bolt. Should this occur, the bolt would be limited
to stretch in a short section. Two consequences of this condition are the following:
• Loose bolts after fan startup with subsequent cracking of the grout around the bolt.
• Inability of the anchor bolt to flex in case the base plate moves laterally.
Second, the area between the sleeve and the anchor bolt requires isolation. AMCA 202, “Fan
Application Manual” [7], suggests filling the sleeve with a pliable material such as silicone
rubber. If the sleeve is filled with grout or other rigid material, extremely high stresses can
develop in the foundation by preventing the anchor bolts from developing the spring action. As a
direct consequence, cracking can occur in the foundation in the area around the affected anchor
bolt(s).
There are three principal checks associated with these components. Maintenance is based on
“good housekeeping” practices and consists of surface cleaning, corrosion prevention, and
inspecting hold-down bolts for proper tightness.
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An oil-soaked surface can easily mask small leaks and provides a slip hazard to personnel
required to work in the affected area. It also provides a mechanism for oil to migrate down to the
grout and the concrete foundation, encourages an attitude that accepts leaks or standing oil as
normal station procedure, and presents a potential fire hazard. Conversely, a clean surface
provides a visual baseline for personnel to quickly detect leaks, prevents oil from reaching the
grout and concrete, and allows inspections of bearing housings or hold-down bolts to be
accomplished without danger of injury to personnel due to a slip hazard or a hand injury
resulting from a wrench slipping off the bolt head.
Corrosion prevention begins with the initial installation. Surfaces that will be in contact with the
grout layer should be coated with a primer that is compatible with the grout being used. Base
metal, blisters, rusted surfaces, and oil- or grease-soaked surfaces are all unacceptable. Failure to
heed this precaution will prevent adequate bonding between the base plate/sole plate and the
layer of grout, which will lead to the grout cracking over time.
Inadequate corrosion prevention and unchecked corrosion can have serious consequences to
machinery using cementatious grout with metallic filings. If corrosion develops at the metal-
grout interface, it will continue and spread to the metallic filings. The pressure caused by the
corrosive forces can be of such magnitude as to cause misalignment of the machinery and
cracking of the concrete foundation.
7.4.9 Housing
Housing problems can be detected in their early development stages through a regular visual
inspection program. A visual inspection will be the primary element of a maintenance program
supporting this subsystem. Additional recommended maintenance actions include cleaning and
repair.
Frequently, the need for proper maintenance of the fan housing is either deferred or not fully
understood by station personnel. If these components do not receive adequate care, station
personnel can expect minor problems to escalate into major problems, requiring additional
capital and person-hours to correct.
If the fan housing cracks either at the welds or at various points, the following actions are
recommended:
• Check the quality of the original welds through a visual and NDE inspection.
• Check the quality of the weld repair procedure that was used.
7.4.9.1 Housing
Housing may undergo erosion due to ash in the flue gas. The erosion can be controlled by liner
plates welded to the housing.
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Corrosion can result from air leakage around shaft seals; corrosion of the housing from the
outside can be a problem if the insulation and lagging allow rain to penetrate and collect next to
the housing.
Inlet cones that operate in an erosive environment can erode or crack. Use of protective coatings
or hard-surfacing techniques offers protection, but these are susceptible to wear as well.
Although this particular topic is covered in more detail in the fan wheel maintenance section, it is
important to understand the effects of each part on the whole system. Improper fan wheel
clearance, for example, can have a negative impact on overall fan performance (see Figures 7-3
and 7-4). A simple adjustment of the fan-wheel-to-inlet-cone clearance can affect fan
performance by 5% or more.
Figure 7-3
Cross-Section View of a Fan Illustrating Clearance Requirements Between the Wheel Inlet
and the Inlet Bell
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Figure 7-4
Enlarged View of Figure 7-3
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Specific maintenance actions are required to ensure that the access plate can be used when
needed and to prevent the door from acting as a large crack or leak. This condition can cause the
following:
• Escape of corrosive or erosive gases into the environment.
• Negative effect on fan performance by not providing a gas-tight surface.
• Escape of corrosive gases that “attack” the surrounding lagging.
• Leakage of air on the ID and GR fan inlet, causing reduced capacity and corrosion.
To prevent these conditions from occurring, the following maintenance actions are
recommended:
• Proper securing of the hold-down bolts.
• Replacement of missing or damaged hold-down bolts.
• Inspection and replacement of door gaskets.
• Reinstallation of insulation covers over the access plates at the completion of the work.
(Failure to reinstall an insulation cover will cause cold air to condense and initiate a corrosive
attack in the immediate area.)
Although expansion joints are not a direct fan component, they are a relatively high-maintenance
component related to fans. The routine maintenance recommendations for expansion joints
consist of the following:
• Inspect joints for cracks and holes.
• Check for fly ash buildup in the folds of the expansion joints.
• Verify that the dust shields are in place and that the space behind the shields is not filled with
ash.
• Visually check expansion joints for uneven expansion or contraction.
• Conduct cold checks to verify proper alignment between the fan housing and joints.
Note: If painting is in progress, ensure that painters do not paint fabric expansion joints.
The overhaul of expansion joints consists of replacement. Expansion joints typically last 15–20
years.
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Maintenance
Problems with motors can be identified early and corrected through a maintenance program that
is structured around motor cleanliness, lubrication, and routine inspections. These three elements
will form the necessary foundation for an effective electric motor maintenance program that will
lead to dependable and economical operation.
7.4.11.1 Dirt
Dirt is a common element in any generating station. Controlling this problem is a 24-hour a day
job. Electric motor ventilating spaces will be restricted over time if dirt is allowed to build up.
This problem will directly impact the ability of the motor to cool itself, and consequences of this
problem (if it is allowed to go unchecked) include the following:
• Breakdown of motor insulation
• Increase in auxiliary power consumption
• Potential for abrasion and wear of motor internal components
An effective cleaning program requires regularly cleaning the exterior of the electric motor,
regularly cleaning the motor’s filter assemblies, and cleaning the motor internals. Components
such as access panels and covers also play an important role in keeping dirt outside. Verifying
that gasket material and dust seals are in good condition, together with properly installing the
access panels, will pay valuable “maintenance dividends” in the battle to keep dirt out. Use of a
pre-filter assembly has an added advantage of allowing personnel to clean the filters without
requiring the motor to be shut down. Cleaning should be performed during every scheduled
boiler shutdown.
Use of clean, dry, compressed air is effective in removing dry, loose dust and particles. Air
pressure at 30 psig can be effective in blowing out a motor. Considerations when using
compressed air include the following:
• Blow out any accumulation of water in the air line and hose before using it.
• Consult the manufacturer on recommended air pressure; pressure exceeding the
recommended value can drive abrasive particles into the insulation and puncture it.
• Use recommended safety equipment when blowing out the motor; safety goggles, respirators,
and hearing protection are highly recommended.
• Install a suction blower or similar device at the opposite end to remove dirt-laden air.
Additional options for removing dirt include the use of clean lint-free rags and vacuum cleaners.
Lint will adhere to the insulation, resulting in an increase in dirt collection. Lint is also
particularly damaging on high-voltage insulation because it causes corona discharge to
concentrate in one area.
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7.4.11.2 Moisture
In all of these cases, simple anti-moisture precautions such as the following can be taken to avoid
motor damage:
• Protecting motors opened for maintenance against moisture by using space heaters,
coverings, and, when feasible, reinstalling access panels.
• Identifying and removing sources of moisture in and around the motor:
– Verify that all piping is properly insulated.
– Correct all leaks.
– Install protective coverings over motors when required; ensure that these coverings do
not restrict air movement.
7.4.11.3 Friction
To avoid damage caused by friction, the motor manufacturer’s lubricating instructions should be
followed, and the proper type of lubricant in the proper quantities and intervals suggested should
be used. Verifying the proper quantity of lubricant is vital. Excess amounts of lubricant can be
just as damaging as insufficient lubricant. Too much grease can promote friction and heat and
can leak onto stationary windings and rotating elements. This, in turn, can cause overheating and
deterioration of the insulation, resulting in eventual grounds and shorts.
7.4.11.4 Vibration
Excessive vibration can damage electrical connections, loosen fasteners, promote frictional wear,
and cause portions of the metallic structure to develop cracks. Checks to avoid vibration damage
include the following:
• Verifying correct alignment between the motor and fan.
• Inspecting the foundation for cracks.
• Opening and inspecting bearings when heavy wear or damage is suspected.
• Verifying that machinery hold-down bolts are installed and properly torqued.
• Inspecting the motor bearings at regular intervals during operation; personnel should check
for signs of rapid heating and unusual noise.
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The rotor shaft assembly of induction motors will have a certain amount of end play designed
into it. End play refers to the axial distance through which the motor’s shaft is free to move when
it is uncoupled from the load. This freedom of movement occurs because of tolerances that
inevitably occur in the design and manufacturing process. These tolerances include machining
variations, bearing design requirements to prevent binding, and allowances for any thermal
growth of the rotor shaft assembly during motor operation.
Induction motors designed with sleeve bearings have a larger end play than those that use roller
bearings. Typical values given for large motors with sleeve bearings are 1/4 to 1/2 inch. Motors
outfitted with roller bearings may have an end play range from 1/32 to 1/8 inch. If a bearing
locking arrangement is used, this range will be even smaller. Because induction motors with
sleeve bearings do not have any locking arrangement, the rotor shaft assembly is free to “float.”
This does not become a problem while the motor is in operation and is not subjected to any
external forces. Under these conditions, the rotor shaft assembly will align itself to the magnetic
center of the applied field.
Endwise restraint that limits the movement of the rotor shaft is achieved through one of the thrust
bearings. The forces of these bearings are designed to withstand momentary thrust that may
develop during the starting or stopping of the motor. Damage from continuous thrust occurs
when external forces are applied that prevent the rotor shaft from seeking its magnetic center.
External forces can result from coupling misalignment or locking. When a coupling is
misaligned, asymmetrical forces between the hubs develop. This imbalance may cause the load
and motor coupling halves to move apart. This separation is limited by the thrust bearings on the
load and motor. Continuous thrust resulting in damage to the motor bearing thrust faces is likely
to occur. Limited end float couplings will prevent motor damage to the motor journal bearings by
excessive axial movement of the motor rotor.
External forces may also develop from a coupling locking. If a coupling is worn or poorly
lubricated, torque transmission through the coupling gear teeth sets up high friction, which
resists endwise movement (in and out or side-to-side movement of the coupling gear teeth or
grids). This condition could prevent the motor shaft from seeking its magnetic center and could
subject the thrust faces of the motor bearings to continuous thrust.
Figure 7-5 provides a basic block diagram of a hydraulic regulating system used with variable-
pitch axial draft fans. Note that the boiler combustion control system and rotor assembly are
added to provide an overview of the system. This auxiliary system provides a means to adjust the
blade pitch upon demand for an increase or decrease in airflow from the boiler’s combustion
control system. The following three major subsystems make up a hydraulic regulating system:
• Hydraulic supply system
• Impeller blade adjustment system
• Regulating lever assembly
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Figure 7-5
Basic Block Diagram of a Hydraulic Regulating System
The maintenance recommendations for fluid drives are similar to those for the circulating lube
oil system. In addition to controlling the fan by varying the speed, the fluid drive may also
provide cooling for the oil for the fan bearings.
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Fluid drives are specialized rotating equipment. The manufacturer or other specialists should be
used for an overhaul that includes disassembly of the fluid drive. The scope of a typical overhaul
includes the following:
1. Disassemble the fluid drive unit and check for wear or damage on the following components:
– Impeller and runner
– Pillow blocks
– Journal bearings
– Thrust bearings
– Scoop tube and scoop slide to guide
– Control rod mechanism
– Labyrinth seals
2. Replace gaskets.
3. Clean out hydraulic oil sump.
4. Conduct a dye penetrant test on the impeller and runner.
5. Inspect valves, fittings, flexible hoses, and piping (including supports) for wear or damage.
6. Inspect the relief valve for proper operation.
7. Inspect internal fasteners for damage or wear and proper torque value.
8. Overhaul the oil supply pump:
– Disassemble the pump; inspect gears and bearings for signs of wear or damage.
– Check alignment of the drive shaft and pump shaft.
– Check the condition of all fasteners.
– Open and inspect the filters and strainers, and clean or replace as required.
9. Check the condition of the foundation; inspect for signs of corrosion, excessive cracking, and
deterioration.
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10. Check alignment of fluid drive shafts with fan rotor and motor shafts.
11. Inspect and clean flexible couplings (see Section 7.4.3, “Couplings”).
12. Calibrate vibration and temperature sensors if installed.
13. Flush oil lines with clean hydraulic oil.
1. Worm gear:
– Clean and inspect the shaft bearings
– Clean and inspect the motor couplings
– Measure the axial play of the worm shaft
– Replace the oil seal
– Check contact of the gear teeth
– Clean all disassembled parts, and protect them from dirt and moisture
– Replace all seals, shims, and gaskets
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2. Overrunning clutch:
– Thoroughly drain and clean internal parts
– nspect the primary pawls and primary pawl springs for signs of wear
– Inspect ball and roller bearing surfaces and sliding surfaces for signs of wear
– Inspect oil seals for signs of wear
Specific maintenance for this system has the same requirements as a circulating lube oil system.
The hydraulic oil system should be inspected similar to the lube oil system (that is, for oil level,
temperature, and pressure). As with the lube oil, the hydraulic oil should be analyzed by a
laboratory.
The blade adjustment system on an axial fan consists of a hydraulic servo and linkage within the
fan rotor. These parts should be inspected and overhauled during every minor outage. The servo
is one of the highest maintenance items on an axial fan.
The blades on an axial fan with variable-pitch blades have bearings that allow the blades to rotate
along the blade axis and take the thrust due to the centrifugal load of the blade. These are
typically grease-lubricated ball bearings. These bearings should be lubricated using the
manufacturer’s recommended grease, and manufacturers typically recommend lubrication at
least once a year.
Note: The same amount of lubricant should be added to each blade bearing to prevent impeller
imbalance. A special injector may be required to add a measured amount of lubricant to each
blade bearing.
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Axial fan rotor overhaul is important to maintain high reliability of the fans. Previous studies
have shown that there is a significant difference in reliability if the overhauls are not performed.
The overhaul should be performed according to the manufacturer’s recommendation, which is
typically every four to five years. Some plants ship a spare rotor to the manufacturer’s shop for
overhaul; other plants overhaul spare rotors on site. If the overhaul is performed on site, the
manufacturer’s service technician should be consulted.
Axial fan blades are more prone to erosion than centrifugal fan blades. Some studies indicate that
hollow-blade airfoil centrifugal fans can tolerate three times the particle loading that an axial fan
can tolerate. However, the axial fan blades are easier to replace. Axial fan blades should be
designed to be relatively insensitive to erosion with respect to performance deterioration and
structural integrity.
Fan wheel imbalance is cited as the most common cause of vibration; however, this should not
deter station personnel from conducting additional checks. Troubleshooting a high-vibration
condition can be a complicated process that involves eliminating one possibility at a time.
Prematurely deciding that wheel imbalance is the source of a fan’s high vibration may
temporarily eliminate the vibration. However, the vibration will resurface (after a period of time
depending on its severity) with damage to the affected component (such as bearing or coupling)
having subsequently increased.
Once it has been determined that the wheel is out-of-balance, the next step is to undertake
corrective action. The first step is to clean the entire wheel in an effort to determine whether that
will eliminate the imbalance condition. If the imbalance condition persists, the wheel should be
balanced by adding weights at the appropriate spots. Adding weights can be necessary in cases
where erosive wear of the wheel surfaces has taken place.
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Cleaning the entire wheel is recommended to eliminate an out-of-balance condition. The major
advantage of this procedure over spot cleaning is that welding a balance weight on the wheel
may not be required. In fact, stringent welding procedures and welding-induced cracking and
errors can be avoided altogether. Arbitrarily adding weights without first completely cleaning the
wheel can result in a fan wheel that is “covered” with balance weights. This added weight may
induce stresses for which the wheel was not originally designed.
Based on the operating environment, ID or GR fans are considered more susceptible to wheel
imbalance than “clean air” fans. An imbalance condition on an ID fan could be caused by any of
the following conditions:
• Fly ash buildup on the blade surface and/or blade interior
• Cracked blades
• Loss of balance weight(s)
• Loose rivets on blades
• Erosion/corrosion of wheel surfaces
• Partial loss of the erosion liner
To avoid vibration problems, it is important to perform vibration trending. Vibration levels taken
once every eight hours and trended over time will assist personnel in identifying an imbalance
condition in its early stages.
Both amplitude and phase measurements are required to balance a draft fan in the field. A variety
of instrumentation exists to obtain these two parameters. Automatic balancers are available that
provide step-by-step visual instructions to guide the maintenance team through the balancing
procedure. This equipment can indicate the amount and location of the correction weight to be
added, thus eliminating the need for manual vector diagrams. If an automatic balance is not
available, use of a vibration analyzer together with either an oscilloscope or phase meter is
suggested.
Balancing a fan wheel in the field should be approached in a methodical manner. It is not simply
a matter of stopping the fan and attaching a weight. The following steps are presented for use as
a check list before actually balancing a fan wheel:
1. Verify that the fan and motor alignments are within recommended tolerances.
2. Ensure that all hold-down bolts are securely tightened.
3. Remove any accumulated buildup that is present on the fan wheel.
4. Verify that all instrumentation (for example, balances, vibration analyzers, and probes) is
calibrated and functioning correctly.
5. Conduct a visual inspection of the fan wheel for indications of cracks developing.
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In all four steps, it is recommended that the fan manufacturer’s requirements and
recommendations be thoroughly reviewed and understood.
The dimensions of a balance weight may have specific limitations and restrictions. The thickness
of the balance weight should be equal to or less than the thickness of the side plate, and the
balance weight should be rectangular. Consult the manufacturer about any specific length-to-
width ratios that may apply.
The optimum position for balance weights is centered between the blades. Manufacturers may
specify minimum distance from blades and the outside diameter of the impeller. Welding a
balance weight in an area over the top edge of the blade is not recommended because doing so
may result in serious damage to the structural welds that join a side plate and blade. Consult the
manufacturer for any restrictions on the minimum separation distance between balance weights.
It is important to follow the proper weld procedure, including heat treating, for attaching balance
weights to the wheel. Improper welding of balance weights can cause cracks in the attachment
weld that can propagate into the base metal of the fan.
When fans are balanced, the change in vibration and the balance weights added should be
recorded. The vibration sensitivity of the fan should also be calculated and recorded. Vibration
sensitivity is usually defined in ounces/mil, which is the balance weight in ounces, added at the
wheel outer diameter to change the vibration by one mil. The range of typical sensitivity is 8–12
oz/mil. A value less than 8 oz/mil indicates the fan has a high vibration sensitivity and will
probably require frequent balancing.
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8
SPECIAL MAINTENANCE TASKS
During extended shutdown of the fan, the lube oil and hydraulic oil systems should be started at
least once every two weeks to maintain an oil film on all surfaces. For axial fans, the impeller
should be rotated a few turns to ensure proper lubrication of the bearings. If the fan is shut down
for a short time (that is, less than a few weeks), it is better to keep the lube oil and hydraulic oil
systems in operation.
Failures of centrifugal fans, including catastrophic failures as well as cracking problems that
have required replacement, have been a chronic industry problem over the past 20 years. The
problem is now under control but still requires a significant effort on the part of owners to
maintain their fans. NDE of the fans’ welds is a time consuming and expensive process, and the
proper inspection including documentation is important. This subject is covered in detail in
Appendix B.
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9
FAN UPGRADE OPTIONS
ID and FD fans are often cited as the load-limiting factor on fossil-fired units. In some cases, the
fan performance may be poorer than design because of wear, housing clearances, or other
problems as described in Section 5, “Troubleshooting.” However, the root cause may be due to
poor performance of other equipment such as air heater leakage or pluggage, higher-than-design
excess air, or higher-than-design flue gas temperatures. Although the fan may not be the root
cause of the problem, upgrading the fans may be the most practical solution.
In addition to performance problems, fan capacity may need to be increased due to plant
modification such as the addition of new pollution control equipment.
If additional fan capacity is needed, there are fan upgrades that can be implemented that require
only a fraction of the cost and outage time of complete new fans.
9.2 Tipping
The capacity of centrifugal fans with airfoil blades can be increased by tipping the blades.
Tipping refers to extending the trailing edge of the fan blades, either with a straight extension or
an angle. (Figure 9-1 is a sketch of tipping a fan blade.) As a general rule, tipping will increase
the fan head by 10%, the flow by 5%, and the horsepower requirement by 15%. The performance
improvement is a “rule of thumb”; actual performance will depend on the fan and is best
determined by the fan manufacturer. The cost of tipping is approximately $10,000 per fan.
Note that the existing motors may not have the capability to support the required increase in
power or inertia.
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Figure 9-1
Airfoil Blade with the Blade Tipped
Replacing the blades with blades with a longer cord can sometimes increase the performance of
axial flow fans. The manufacturer would need to review the rotor design to determine whether
this alteration is practical.
Blade tipping of centrifugal fans or blade replacement of axial flow fans should be investigated if
a small increase in fan performance is needed.
The replacement of the wheel in an existing centrifugal fan housing with either a larger diameter
wheel or a wheel operating at a higher speed can be a cost-effective alternative to replacing the
entire fan or adding booster fans. In most cases, this will require a new motor. A similar type of
modification can be made to an axial flow fan by replacing the blades.
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In some cases, the housing of a centrifugal fan with airfoil blades can be modified to
accommodate a larger wheel or improve performance. One of the critical dimensions is the
distance between the wheel and the cutoff. This dimension should be approximately 10% of the
wheel diameter.
In some cases, the housing has been modified to increase the dimension (when it was less than
10%), resulting in a slight increase in fan performance and a decrease in fan noise.
Any housing modifications should be verified with the manufacturer and may require a model
study to quantify the impact.
9.5 Coatings
Erosion of ID fan blades is a major issue that causes unscheduled downtime as the fly ash
constantly bombards the hollow airfoil of the ID fan blades, eventually blowing holes in the
blades. The erosion may be caused by burning lower grade coal and/or burning at a reduced
temperature.
The blades may be coated with a hard surface coating, one of which available in the market is
tungsten carbide.
There is a conflict between erosion protection and weld inspection. Coatings can be effective in
erosion protection but inhibit NDE of fan welds. The coating has to be removed in order to
conduct effective magnetic particle examination of the welds.
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10
SAFETY
Operating, inspecting, and maintaining fans and accessories exposes personnel to various safety
hazards. Many of the safety hazards associated with fans are present elsewhere in the plant and
are therefore not addressed in this guide. All personnel that operate, inspect, or maintain fans
should be trained in the plant safety procedures.
Fans are rotating equipment, and appropriate tag-out procedures should be followed before any
inspection or maintenance is started.
Fan housings are confined spaces that may be filled with harmful gases. Confined space entry
procedures, including air checks, should be followed before entry.
The lubrication oil of all fans and motors provides lubrication and cooling of the bearings, and
the temperature of the oil may be high enough to present a burn hazard. ID fans and GR fans
operate at elevated temperatures and may retain heat for a long period after being shut down.
10.4 Electrical
The fan motor and fan auxiliaries are electrical and therefore present the risk of electrical shock.
Before work on any electrical equipment is performed, the equipment should be de-energized
and properly tagged out.
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Safety
Some testing and inspection, such as vibration and performance testing, require the fans to be
running during the tests. Special precautions must be observed while performing these tests.
Respiratory health is the primary concern when personnel are involved in abrasive blast cleaning
operations. Use of sand abrasives carries with it a specific health hazard termed silicosis.
Silicosis is a disease of the lungs resulting from prolonged breathing of very fine particles of
silica. The effects of this disease can be permanently disabling or fatal. While the use of grit
abrasives does not carry a risk for a specific disease, it nonetheless exposes an individual to some
risk. A correct and fully functioning air supply and hood are essential and must be used at all
times by personnel engaged in this operation; heavy duty gloves, a helmet or hood, and upper
body covering should be standard items as well.
A nozzle equipped with a “dead-man” feature should also be included in any type of blast
cleaning operations. An air nozzle operating at 100 psi that gets away from an operator could
cause serious injury to personnel as well as damage to fan internals. Additional safety-related
equipment includes a replacement hood lens (because they tend to become frosted after a period
of time) and an ample supply of filters for air supply systems that are outfitted with them.
Fans can suck in loose material and discharge it as dangerous projectiles. Large fans can also be
dangerous to personnel. Access doors should never be opened with the fan running. On the
downstream side, releasing the door may result in explosive opening. On the upstream side, the
inflow may be sufficient to suck in materials such as tools and clothing.
Even when a fan is locked out electrically, it may be subject to “windmilling.” Therefore, the
impeller should be secured to physically restrict rotational movement. When personnel need to
climb on the wheel to perform work or an inspection, the wheel should be mechanically secured.
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Safety
Fans contain various rotating components such as fan wheels, shafts, couplings, and shaft
coupling wheels—all of which are potential hazards. Therefore, guards should be provided at
exposed fan inlets and outlets as well as over the couplings and other equipment.
Fans should not be operated above their recommended speeds. Excessive speed may result in
catastrophic impeller failure.
Before a fan is started, it should be ensured that all personnel have exited the fan housing, inlet
boxes, inlets, and discharge ductwork. In addition, all material and tools should be removed from
the housing.
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11
TRAINING
Formal training programs on boiler draft fans are not readily available. The best source of
training is documents on fans.
This document provides basic information on the design and operation of fans. More detailed
information on fans and their applications can be found in other references.
The most comprehensive book on fans is Fan Engineering. The first edition was published by
the Buffalo Forge Company in 1914. The ninth edition is available in hard copy or on CD from
Howden Buffalo. Fan Engineering covers all types and sizes of fans, including HVAC fans, as
well as boiler draft fans.
Steam, Its Generation, and Use (first edition published in 1879; 40th edition available from
Babcock and Wilcox) includes a section on fans related to boilers.
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12
REFERENCES
General Reference
Operation and Maintenance Guidelines for Draft Fans, EPRI, Palo Alto, CA: 1993. TR-101698.
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A
CENTRIFUGAL FAN WHEEL INSPECTION AND REPAIR
Introduction
This section provides guidelines for conducting field inspections of centrifugal fan wheels. An
inspection program for fan wheels is a logical extension of any preventive maintenance strategy
for a draft fan. A maintenance department can realize two benefits from a well-designed and
properly implemented fan inspection program. First, it offers personnel a way to identify
cracking or erosion problems for early corrective action, before the damage escalates into major
problems with a potential for catastrophic failure. Second, it can help in establishing a database
for either a newly installed wheel or one that has been in operation. A database is a good starting
point for maintenance personnel before they begin inspecting or conducting repairs. Well-
documented records along with blade maps and photographs can help a station’s maintenance
department begin a material history file on the fan wheel. A material history file provides the
following:
• A training tool for new personnel to use as a guideline.
• A consistent and reliable way to track surface irregularities that have not been designated as
cracks but should be monitored for indications of growth.
• A central listing of information such as chemical composition, hardness, and heat treatment
of the metals used to construct the fan wheel; engineering drawing numbers and their
locations; electrodes and rods used in the original fabrication and/or repair; modifications
made to the fan during its operational life; and contractors used at various times (for
example, to clean, repair, and inspect).
• A record of cracking and erosion problems that can easily be adapted to a trend analysis
program. A trend analysis program can serve the following functions:
– A form of input into the procurement of new fan wheels and blades
– A way to identify unique problem areas associated with the fan wheel
– A way to assist in establishing an accurate cycle for fan wheel inspections
There are specific maintenance actions that should encompass a fan wheel inspection. For
example, before repairs can begin, it is important to know the exact chemical makeup of the
material used in constructing the particular fan wheel component. This particular check need
only be done once during the operational life of the fan.
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Inspection Areas
Before beginning an inspection, maintenance personnel should consult and review the fan
manufacturer’s recommendations on areas to inspect, records of how the fan was constructed,
and records of previous fan wheel inspections. Review of previous blade maps in particular will
provide invaluable information on alerting personnel to potential problem areas identified by
crack patterns reappearing.
Recommended areas to be inspected during visual and magnetic particle examinations include
the following:
• The entire length of every weld joining the fan blades to the center plate and side plate.
• Splice welds on the side and center plates.
• Welds attaching stiffeners to center plates, hubs, and/or shafts.
• Welds in fabricated hubs.
• Welds attaching balance weights to the side plates or center plate.
• Pad welds used in place of balance weights.
• Seal welds of bolted-on erosion liners. These welds are not structural; however, cracks
beginning in these seal welds may propagate into the structural weld or component. These
cracks may also form an area on which erosive gas streams may concentrate.
• Cracks in erosion liners made of some hardened material are common but are normally not
considered to be detrimental to the fan operation.
Survey Results
Survey results involving 256 fans from participating utilities provided information on inspection
practices currently being used. Table A-1 provides a summary of the survey results and key
points noted.
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Table A-1
Summary of Inspection Practices for Centrifugal Fan Wheels
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Scheduled Inspection
An average of 70% of the 256 fans receives a regularly scheduled fan wheel inspection of some
type.
Inspection Techniques
VT and wet-magnetic particle are the two most common types of inspection techniques utilized.
Inspection Cycle
A 12-month period is the most common cycle employed in fan wheel inspections.
Other Inspections
An average of 50% of the fans that undergo a wheel inspection receives both an annual VT and
magnetic particle inspection.
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It is recommended that the permanent identification marks be centered on the trailing edge of
each blade. This area is readily accessible, allowing marks to be easily identified for future
inspections. Care should be exercised to avoid creating a stress concentration when marking the
blades.
The numbering direction could coincide with the fan’s rotation. Top/front and bottom/back of a
blade should be identified as an individual observes a fan blade moving toward him. The surface
seen first should be the top/front of the blade. Letter identifiers such as “T” for top could be
included with the number to further clarify blade identification.
Various methods may be used to individually mark blades, such as using a low impact punch to
stamp a number on the blade (or other designated location) or using the hub-to-shaft keyway as a
standard reference mark. With this technique, the nose of the blade that is closest to the key is
always blade Number 1. Blade numbers could increase against fan rotation. Paint or other such
markers will eventually wear off during operation or during abrasive blast cleaning operations.
Mapping Procedures
Mapping all inspection areas is recommended. Diagrams for a blade and center plate are shown
in Figures A-1 through A-3. Note that the diagrams do not have to be complex in order to be
effective. Accuracy in indicating crack location is essential. Note that Figure A-3 has a grid
superimposed that could easily be adapted for pinpoint cracks. A pattern of cracks that continues
to repeat itself in a specific area would be cause for concern.
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Figure A-1
Blade Map Example
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Figure A-2
Blade Map Example
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Figure A-3
Blade Map Example
The fan casing is normally the barrier between the work area and the outside environment. The
casing must have adequate dust-tight lighting and ventilation to control the level of dust
generation. Ventilation hoses can be placed above or directly across from the area being worked
on in order to move the dust away from maintenance personnel. Refer to Section 10 for
additional information.
Surface Cleaning
Surface cleaning is one of the prerequisites for an accurate magnetic particle test. Cleaning
provides a surface that is free of dirt, fly ash deposits, and rust, thereby preventing any cracks
from being masked. Two methods used in surface cleaning are water blasting and dry blasting.
Dry blasting appears to be the most prevalent method used for surface cleaning. One California
utility reports successful results using water blasting. Fans are cleaned using glass beads
entrained in a 30,000-psi water stream. Reduction in potential respiratory hazards and easy
disposal of the residual are two reported benefits of this method.
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Dry blast cleaning is one method used to prepare fan internals for both magnetic and visual
inspections. This technique employs several different types of abrasive materials, of which grit
and sand are the two most common. No matter what type of abrasive material is used, the
principle behind dry blast cleaning remains the same: propel abrasive material in a well-defined
stream with sufficient force to dislodge any buildup on the fan surfaces.
Grit abrasive material consists of angular metallic particles, such as cast steel, that have been
crushed and hardened. This type of material offers several advantages over traditional sand
abrasives:
• Less time to clean a fan wheel
• Less breakdown of the abrasive
• Less dust abrasives
• Recycling of grit abrasives (in most cases, they can be “recycled” for reuse 200 times more
than conventional sand abrasives)
The disadvantage of using this type of material is that it can remove a layer of material from the
fan component.
Sand abrasive is a term used to cover a wide spectrum of nonmetallic abrasives as well as
ordinary silica sand. Both natural (for example, flint quartz, silica, slag, and garnet) and man-
made (aluminum oxide and silicon carbide) nonmetallic abrasives exist. As would be expected,
natural abrasives have the lowest initial cost, followed by man-made abrasives, which are less
costly than metallic abrasives. Because sand abrasives are susceptible to breakdown, it is
recommended that they be used only once. Reuse of an abrasive that has broken down can result
in the material becoming lodged or embedded into crevices that may already exist in the weld,
increasing the potential for masking any problem areas.
The key to good results is the type of blast nozzle used. According to the American Society for
Metals (ASM), the principal materials used in manufacturing a blast nozzle are hard iron, boron
carbide, aluminum oxide, and tungsten carbide. ASM recommends purchasing a nozzle with a
boron carbide liner encased in a steel jacket. This type of nozzle provides the longest wear per
dollar of initial cost. The operational life of a boron carbide nozzle is much longer because of its
ability to retain its internal contour. As a result, less air is consumed and a more uniform abrasive
velocity and stream contour are maintained. A nozzle should be replaced when its outlet has
worn to 1.5 times its original size.
There are two abrasive blast techniques that can be used by a cleaning crew. Brush blasting
refers to a relatively quick cleaning operation in which the nozzle tip is held between 3 and 4 feet
away from the work surface. Brush blasting can be used for rapidly cleaning areas not having a
build up of deposits and on surfaces having a protective coating. In the latter case, before any
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abrasive surface cleaning can take place, the personnel actually doing the work should clearly
understand where the coating has been applied and what type of surface finish they will see on
the coating after applying the abrasives. Extreme care should be exercised by the crews to avoid
“blasting away” the protective coating. As a second recommendation, blade maps should have
these coated areas clearly marked to avoid any confusion.
The second cleaning technique is often referred to as strip blasting. With this method, personnel
should maintain a distance of 9 to 10 inches from the nozzle tip to the work surface. Increasing
this distance will reduce the abrasive effect of the material.
A shorter distance tends to produce more dust when nonmetallic abrasives are used and tends to
cause impact damage and layer removal to the work surface when metallic abrasives are used.
This technique is used to clean down to a white metal finish in preparation for conducting NDE
tests on welds.
When cleaning fans with hollow airfoil blades, crews should avoid directing the abrasive stream
on suspected crack areas. There is a potential for “filling” the blade with abrasive material,
causing an imbalance condition. To avoid this problem, these suspect areas should be cleaned by
hand with a wire brush.
When carrying out abrasive cleaning operations, special care must be given to fan internals that
could easily be damaged from high-velocity particles impacting them. Heat fingers and shaft
seals can be protected by securely wrapping them in a rubber or urethane cover. Operators
should exercise caution when working around these components.
Surface preparation consists of two parts: maintaining a clean surface once it has been
sandblasted and eliminating any surface discontinuities (such as undercutting, overlap, and lack
of fusion) that may mask or give false indications.
Coordination between the abrasive cleaning team and the station’s NDE inspectors is a must in a
geographical area or seasonal period where there is a high level of moisture in the air. This
condition will cause corrosion to develop on freshly cleaned fan internals. The time lag between
cleaning and inspecting should be kept to a minimum.
Better coordination between the abrasive cleaning team and NDE inspectors and the use of
electric space heaters inside the fan casing will help reduce moisture and dampness levels.
Closing access doors and dampers will also aid in reducing the flow of moisture-laden air into
the fan.
Visual Inspection
Qualified personnel classified as Level II or higher (or Level I personnel under the direct
supervision of Level II or III personnel) should conduct the visual inspection of the rotating
elements, weld joints, blade surfaces, and hubs. A visual inspection should check for visible
cracks and surface discontinuities. It is recommended that any surface discontinuities be
removed before conducting a magnetic particle test because these areas can produce false
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indications. Often, experienced personnel can successfully excavate the area in question without
disturbing the surface to the point where a weld repair would be required. One utility reported
that an overlap condition obscured serious underbead cracking. Specific surface discontinuities
that should be removed include undercut and overlap (see Figure A-4) and erosion cutting.
Figure A-4
Example of Undercut and Overlap
If both manpower and funding are available, consideration should be given to blend or contour
grinding the weld joints. Blend grinding involves the use of a rotary file to remove surface
irregularities. One utility takes this process a step further by requiring fan welds to be contour
ground. This technique requires the weld to be ground down to a concave shape. Contour
grinding, while time consuming and costly, can improve the fatigue strength of the weld by
providing a surface that is free from discontinuities. Implementing contour grinding into a fan
maintenance program can be accomplished in one of four ways:
• Establish a general policy that all welds on existing fans shall be contour ground.
• Require future fan wheel specifications to include contour grinding all welds.
• Contour grind welds that have been repaired during an outage period.
• Phase-in contour grinding requirements over a period of years by reworking a fixed amount
of fan wheels per year.
Both blend and contour grinding require the use of a rotary file with a grinding surface
attachment. Improper use of this tool can result in undersizing the welds, cutting into the base
metal, and creating sharp notches in the weld, which will lead to cracking and induce heat cracks
in the weld joint. Heat cracks can be avoided by not using excessive pressure (that is, attempting
to remove too much material too quickly). Carbide blades will change to a red-hot color if
excessive pressure is applied. After blend grinding, scratches can be removed using a belt sander.
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Although this process is time consuming, it will eliminate false indications of cracks and will
result in a higher confidence in the examination.
A second option is to use a flapper wheel of emery paper. This generates less heat, making it less
likely to produce cracking. Using this tool, however, is extremely time consuming when
compared to using a grinder.
Once the grinding procedure has been completed, the area to be inspected is wiped down with a
lint-free rag. Residual dust and particles from abrasives and grinding operations should be
removed before conducting a magnetic particle test. Inspection for any missed problem areas
also takes place at this time.
A different approach involves the use of experienced NDE personnel to determine whether the
indication is a crack or a surface discontinuity based on NDE results. If it is determined to be a
potential crack, it is then documented on a map. If subsequent inspections indicate no growth, the
indication is downgraded to a surface discontinuity, and no further action is taken unless the test
group recommends that the discontinuity be removed. The following points should be noted:
• Consistent and accurate mapping techniques should be used to make this procedure effective.
• Even with experienced personnel, there is an element of subjectivity that becomes difficult to
control unless an acceptance standard is developed and adhered to.
• Certain surface discontinuities can lead to cracks.
The first step in implementing a fan inspection program is verifying the chemistries and heat
treatment process applied to the materials used in the construction of the fan wheel components.
Although this may appear to be an unnecessary recommendation, experience has shown it to be
important on older fans. Several utilities that have analyzed their fans have found the materials to
fall outside the ASTM limits. Some catastrophic failures have been attributed at least in part to
materials outside the specified limits. An accurate record of the fan wheel’s metallurgical
properties can provide the following:
• Verification that the actual material, hardness, and heat treatment concur with those specified
in the original design.
• Identification of potential problems that may develop with respect to the conditions (such as
temperature or weather) under which the fan operates.
• Verification that current weld repair procedures are correct.
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Developing this database for each installed fan at any given power station can be a difficult and
costly task. One utility has taken two paths to chemical verification:
• For existing fans without reliable documentation on file, the utility initiated its own
independent chemical analysis testing program. This was a one-time test requirement to
obtain a database for each fan, and material samples were taken during normal scheduled
outage periods.
• For new fan wheels being constructed, a quality assurance program was organized to monitor
and verify the materials specified. A certified material test report was required from the fan
wheel manufacturer for records purposes.
If the utility elects to conduct a chemical analysis test, care should be exercised as to where the
samples are taken. Consulting the fan wheel manufacturer before taking any samples is highly
recommended to avoid inadvertently damaging the wheel.
Portable equipment is now available that allows the chemical analysis of fan components without
the removal of material samples. Equipment cost is expensive; however, fan repair is minimized
because no samples need to be removed.
Table A-2
Percent of Fans Undergoing NDE
Note that the figures above are straight percentages and do not reflect draft fans that are
inspected using two or more of the above methods. Of the 256 draft fans involved in the survey,
45.7% of them received a magnetic particle examination. The wet-magnetic method is more
sensitive to fine surface defects than the dry method, making it the preferred method when
inspecting for surface cracks. The dry magnetic particle method, however, is considered more
sensitive for the detection of subsurface discontinuities.
Use of a yoke probe with ac/pulsating dc capability in conjunction with a wet fluorescent
magnetic particle (WMP) test offers the best capability to utilities for examining fan wheels for
cracks. The WMP medium is available in either a prepared or mixed bath. Prepared baths are
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available in aerosol cans. Mixed baths must be prepared by station personnel before use and are
considerably less expensive than prepared baths. Additional equipment requirements include a
Pie gage to check the magnetic field strength, a black light, and a black light meter.
Specific reasons for choosing a wet fluorescent magnetic particle system and yoke probes are
listed below:
• A WMP test is more sensitive and produces more rapid results than a dry particle test.
• While prods can develop a stronger field, yoke probes will not produce arc burns on the
working surface.
• A yoke probe having both ac and pulsed dc options gives the station more capability. A
magnetic field set up with dc power can detect cracks below the surface; this becomes
especially useful when inspecting fan hubs for cracks or cracks starting at the roots of the
welds.
Pre-Examination Requirements
There are several requirements that must be satisfied before conducting a magnetic particle
examination:
• The surface to be examined must be adequately cleaned.
• When using wet fluorescent particles, the examination must be performed in a darkened area.
• Designated personnel responsible for carrying out the test must have their eyes adjusted to
the dark. This can normally be accomplished by being inside the darkened area for at least
five minutes before conducting the test.
• The black light should be warmed for a minimum of five minutes before use.
• The intensity of the black light should be measured using a black light meter. A minimum of
800 microwatts/cm2 on the surface being checked is recommended for best results.
• The black light intensity should be measured at least once every eight hours and whenever
shifting to a different fan.
• The yoke must be calibrated annually.
• Each ac electromagnetic yoke must have a lifting power of 10 lb at the maximum pole
spacing that will be used.
• Each dc electromagnetic yoke must have lifting power of at least 40 lb at the maximum pole
spacing that will be used.
• Before using a weight for the first time, it must be verified that it has been checked with an
accurate scale.
• A grid must be laid out on the areas to be inspected. The size of the grid should be less than
the maximum spacing of the articulated arm to ensure that the entire area is inspected. Chalk
or paint markers are typically used to mark the grid spacing on the work.
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Examination Procedure
This procedure describes the necessary steps to conduct a magnetic particle examination using a
yoke with articulated legs (see Figure A-5). This type of yoke provides the inspector with the
flexibility needed to accommodate surfaces offset from one another because of curvature or
orientation. In addition to being articulated, the legs are also adjustable. The maximum spacing
between the legs is 8 inches. Exceeding this limit will result in a weakened magnetic field.
Figure A-5
Hand-Held Yoke Probe with Articulated Legs
After the area to be inspected has been cleaned and prepared, a final check for any residual dust
should be conducted before applying the wet fluorescent particle medium to the surface. Once
this has been accomplished, the strength and direction of the magnetic field should be verified. A
yoke within its calibration period is not a guarantee that sufficient field strength is being
generated.
The magnetic particle indicator will provide the inspector with a simple indication of direction
and sufficient or insufficient field strength. An indicator should be used once per fan to check for
proper field strength. Suitable field strength is indicated by a clearly defined line of magnetic
particles forming across the copper face of the indicator while the magnetizing force is applied.
The direction of the field coincides with the orientation of the formed line. Field direction plays
an important role in detecting the presence of cracks. Because of this, it is necessary to examine
each area at least twice. As a rule of thumb, the lines of flux in each check should be
perpendicular to one another. The weld line can easily be used as a reference to achieve this
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condition. For example, with the weld line shown in Figure A-6, orienting the yoke to first
straddle the line and then placing both yoke legs on the weld will produce flux lines at right
angles. In this case, surface cracks that develop parallel or perpendicular (longitudinal or cross
cracks) to the weld can be detected by experienced personnel.
Figure A-6
Orientation of an Articulated Yoke Probe to Produce Flux Lines at Right Angles
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The procedure described above uses what is known as the “continuous” method. This method
requires inspectors to apply the wet fluorescent medium while the magnetic field is being
applied.
Follow-Up Examinations
The second time a follow-up exam should be done is after completion of the field weld repairs.
Care should be taken by the individuals conducting this examination to ensure that the proper
waiting period between completion of the repair and actual inspection is adhered to. Failure to
follow the required waiting period can lead to false results. ASTM A514 steels, for example,
require a 48-hour waiting period before conducting a final wet magnetic particle examination
(and visual examination).
DC Coil Wraps
This technique was reported in use by one California utility. It consists of wrapping the fan
wheel with coils of wire that are energized with dc current. The utility reports that this method
provides a significant time savings when compared to using a yoke and results in no loss in
sensitivity when used in conjunction with a wet florescent magnetic particle inspection.
Wrapping the fan shaft will produce a field in only one direction. A comprehensive examination
using this technique would require placing a coil in several positions on the wheel.
Marking Indications
A standardized marking procedure for fan wheel inspections provides an efficient way for station
personnel and contractors involved in the work to communicate. A standardized marking
procedure is particularly important when plant maintenance engineers and NDE personnel are
assigned to different shifts.
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Simplicity and consistency are the key features of a well-thought-out marking system. Simplicity
is vital to ensure that personnel spend minimal time and effort when working with the system.
Consistency implies standardization; once a system is developed, it should be followed. Use of
unauthorized modifications will only cause unnecessary confusion and lost time.
The following recommended practices were observed to work effectively in the field (see
Figures A-7 and A-8).
• Use a yellow crayon or grease pencil to mark indications.
• Number indications consecutively, and circle each number.
• Annotate multiple indications within a 6-in2 area with a single number and the letters MULT
(for multiple indications); place this annotation underneath the corresponding number.
• Write a red letter “W” to indicate that the indication has been ground and cleared and is
ready to be welded.
• Use the red letters “OK” to show that the indication cleared with minor grinding and that
welding is not required.
• Place a yellow check (“√”) at an indication where the cracks have been ground out to indicate
that the area is ready for inspection.
• Write a red letter “R” to indicate that the completed weld repair has failed the NDE
inspection and must be ground out for re-inspection.
• Write a red letter “P” to indicate that the completed weld repair has passed the NDE
inspection.
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Figure A-7
Indications Are Consecutively Numbered and Circled
Figure A-8
Marking Multiple Indications
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Wet fluorescent magnetic particle inspection offers the maintenance department a highly
effective method of detecting potential problems on a fan wheel. The following points should be
noted:
• The training and experience level of the individuals conducting the test are absolutely
critical. AMCA 803, Site Performance Test Standard [4] lists the personnel qualifications
needed to conduct and interpret test results.
• A written and approved fan inspection guideline must be developed for use by the individuals
conducting the WMP inspection. If current, these guidelines can provide consistency by
defining the acceptance standards to be used during the inspection.
• As a minimum, utilities are recommended to adapt acceptance standards from American
Welding Society (AWS) standard D 14.6-81, “Specification for Welding of Rotating
Elements of Equipment,” for magnetic particle inspection of welds, which states the
following:
– Cracks, laps, and fissures are not acceptable.
– Indications in excess of 0.25 inches (regardless of direction) are unacceptable.
– Indications less than 0.015635 (1/64) inches in length are considered non-relevant.
Note: The acceptance criteria listed above are recommended for fans currently in service. For
new fans, several utilities have specified that they are to be constructed with a more stringent
requirement of zero linear indications.
Ultrasonic Testing
From the surveys received, ultrasonic testing (UT) is not widely used. Detection of cracks or
voids below the surface is one advantage of UT inspections. Visual or magnetic particle tests
offer no real capability in this area. Fan Handbook: Selection, Application, and Design [9]
provides current standards and practices for UT inspections. Utilities that employed this
technique used it primarily for thickness measurements of fan surfaces (including housings) that
operate in an erosive environment. A second application involved the use of UT to inspect for
voids in fan hubs manufactured from cast iron or cast steel. This second application was a one-
time test.
Inspection Frequency
The final step in implementing an inspection program is to determine the interval for conducting
visual and nondestructive examinations. Careful analysis in deciding this inspection interval is
essential. If the time period between inspections is excessive, undetected cracking or erosion
could increase in severity.
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If cracks are allowed to go undetected, the potential for serious and costly damage to the fan
wheel is clear. The key is early detection. Uncorrected damage can escalate into a catastrophic
failure of the fan with the overall operational availability of the unit being jeopardized as well.
Early detection is achieved by conducting regular inspections and by carefully noting any
upward swings or trends in vibration levels while the draft fan is in operation.
Developing an accurate assessment of the inspection frequency needed requires the maintenance
department to collect and analyze the key factors that have an effect on the operational health of
the fan wheel. The following factors need to be considered:
• What does the manufacturer of the fan wheel recommend?
• What were the results from the previous inspections?
• What is the operating environment of the fan?
• Are there sufficient funds in the maintenance budget to support an inspection program?
• How often has the fan wheel been repaired?
• Has the fan wheel ever undergone an NDE or VT inspection?
• What is the inspection cycle currently in use? Is it effective?
• Who will conduct the inspection? Does the power station have its own manpower assets
sufficient to conduct an inspection of the fan wheel?
Manufacturer’s Input
Both the manufacturer’s own suggested inspection frequency as well as the feedback it can
provide to the utility on current inspection practices are extremely valuable. An exchange of
information can be beneficial to both groups.
Reviewing blade maps and other related maintenance records from previous inspections provides
a mechanism to check for trends. Specific trends that should be cause for concern include the
following:
• Cracks that redeveloped in the same location, suggesting a high-fatigue area or a poor weld
repair.
• Cracks that are increasing in size and/or number.
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In either of the above cases, it is strongly recommended that the time between inspections be
reduced and that the fan wheel be replaced.
Operating Equipment
The operating environment of a draft fan is probably the most important factor to consider. The
following are specific operating conditions that could lead to fatigue cracks:
• Start/stop cycles greater than 100 per year.
• Blade tip speed greater than 25,000 fpm.
• Temporary excursions by the fan.
Responses to the following questions may also indicate conditions that could lead to fatigue
cracks:
• How well do the isolation dampers and sealing air systems work to protect the fan?
• Are thermocouples installed to warn operators of a temperature excursion (and are they
accurate)?
• Is there erosion wear caused by fly ash?
• How well do the precipitators operate? How well are they maintained?
• Is the surface hardening system in good condition? Are the wear plates in good condition?
• Is there vibration?
• Has the fan been operated for long periods with inlet vanes or dampers closed?
Repairs
As the number of weld repairs to a fan wheel increases, the fatigue life remaining on the wheel
decreases. Because of the lead time involved in manufacturing a new wheel (unless a spare
wheel is kept on hand), it is important to take into account the amount of repair work that should
be done, to consider reducing the number of start/stop cycles that the wheel currently undergoes,
and to reduce the inspection interval to allow for more inspections with subsequent repair work.
Initial Inspection
If the fan wheel has never undergone an NDE or VT inspection, one should be scheduled as soon
as possible. The condition of the fan wheel will determine the schedule of the next inspection.
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Input was received from private contractors specializing in NDE inspections, fan manufacturers,
and participating utilities. The fan manufacturers and NDE specialists contacted favored annual
NDE inspections. Feedback from utilities indicated a wide variety of inspection cycles currently
in use. Of particular interest is the group of utilities employing inspection cycles that ranged
from 18 to 60 months. These included inspection of fans with blade tip speeds both above and
below 25,000 fpm. Generating stations using these extended intervals reported successful results
(that is, low incidence of cracks). This indicates that, for given situations, NDE inspection cycles
may be extended beyond a one-year period. The following were common features of fans having
NDE inspection intervals greater than 12 months:
• Low number of annual start/stop cycles (typically less than 20 per year).
• Most fans were monitored for high-vibration levels (vibration monitoring ranged from
continuous to every six months).
• New fan wheels with proper design, low hydrogen weld rod, and proper heat treatment.
For fans meeting the conditions listed above, a 48-month interval is recommended for an NDE
inspection cycle. This time period was chosen based on successful results reported by several
utilities. An NDE inspection conducted every 12 months or less is recommended for the
following conditions:
• High number of annual start/stop cycles (100 or greater).
• Persistent high vibration/temperature excursions.
• Fan wheels identified by the manufacturer as having a high risk of cracking because of their
design.
A visual inspection is its own unique program and should not be viewed as an initial preparation
for a magnetic particle examination. This fact becomes especially evident when NDE inspections
extend beyond a year. Annual visual inspections are highly recommended. This interval is
chosen based on the following:
• Feedback from the utilities suggests that annual visual inspection cycles are beneficial.
• Visual inspections, while not as sensitive as magnetic particle examinations, can still provide
valuable information on the condition of the fan wheel. A well-trained individual can quickly
identify and check for erosion, gross cracking, and blade damage.
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Repairs
Second, there are a variety of materials that can be used in the construction of a wheel. Table A-3
provides a sample list of various materials used in the manufacture of blades, center plates, side
plates, and hubs. The ASTM A242 material shown in Table A-3 has been used on gas
recirculation fans. When drawings show this material, repair should be approached cautiously.
This is a low alloy steel specification that does not specify the type or amount of alloy added.
The potential trouble area pertains to the high phosphorus allowed by Type 1 in this material
specification. As a rule, the high-strength/low-alloy steels have relatively poor low-temperature
impact strength. After a few years of service at temperatures above 650ºF, the high phosphorus
alloy material is very susceptible to temper brittleness. This does not affect the tensile properties
but causes a shift in the ductile-to-brittle transition curve at higher temperatures. Thus, the room
temperature impact strength can decrease to values less than 10 ft-lb. If cracks are present,
catastrophic failure can occur.
A third consideration is defective or incorrect material (see Section 5). In some cases, utilities
have discovered material that did not meet the ASTM specifications called for in the design
specifications. In other instances, materials different from those shown on the design drawings
were found to have been used. These discrepancies can include chemical specifications, Charpy
V-notch impact values, or quenching and tempering processes. If this is suspected, a sample
from the material should be chemically analyzed. The first requirement in any weld repair is to
determine the material type and grade used in the wheel’s construction. Generic terms such as
carbon steel, forged steel, or boiler plate should not be accepted as accurate information,
because fan wheels can be made of several materials. For example, the center plate could be
constructed of a low-alloy carbon steel such as A441, while the blades could be made from
A514, which is a high yield strength material.
The fourth consideration is that individuals performing the actual weld repair must be fully
qualified as required in either ASME Section IX or AWS D1.1 Section 5 parts A, B, and C.
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Table A-3
Typical Materials in Power Plant Fans
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Weld repair demands attention to detail. This is especially true for high strength steels subject to
high fatigue stresses. When repair is necessary because of cracks, it is important that all cracks
are removed before repairing. There are seven fundamental rules for weld repair:
• Make sure that the electrode strength is consistent with design requirements.
• Make sure that the weld is not a source of any undue hardening or softening of the parent
metal.
• Know the material type and grade of the parent metal.
• Use the specified electrodes.
• Follow all instructions concerning preheat, interpass temperatures, and post-heat.
• Know the handling procedures of the electrodes specified for the job.
• Follow the prescribed weld procedure for the job.
Review of several repair procedures written by utilities and fan manufacturers indicates a
common ground shared by all.
Before any welding is attempted to repair a fan, the welder should be familiar with the welding
guidelines described in the following paragraphs.
Surface Preparation
Before welding, surfaces must be clean and dry. Rust is hygroscopic; its removal is an absolute
necessity—especially when welding the A514/A517 materials. Grease and oil are also sources of
hydrogen that must be removed.
The welding procedure should show a sketch of the minimum slope angles of the cavity walls
(when a deep cavity results from defect removal). If there is insufficient slope or a sharp corner
at the base of the cavity, incomplete fusion may occur.
Welding Technique
If possible, the repairs should be made in the flat position. For fillet welds, this will likely be
impossible; therefore, try to maneuver the fan wheel in such a way that the fillet weld can be
made in the horizontal position. For the A514/A517 materials, welds should be made using
stringer beads (that is, no weaving of the electrode) to minimize the heat input. One fan
manufacturer recommends 60 kilojoules-inch maximum heat input.
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Preheat
Preheat should be at least 200ºF minimum with a maximum interpass temperature of 400ºF for
the quenched and tempered materials. The reason for the higher preheat is to drive off moisture
that is likely to be present in the fan installation area. Under certain conditions, such as deep
and/or long repair welds that cannot be completed without interruption, it is recommended that
either the preheat temperature or a 300ºF post-heat temperature be maintained for about 8 hours.
After this time, the weld should be allowed to cool slowly. This can be accomplished by
resuming welding the next day and reapplying the preheat.
Shielded metal arc welding (SMAW) is the common welding process used for fan repairs. The
SMAW electrode that matches A514/A517 materials in strength is E-l 1018-M. To keep welding
current (and thus heat input low), the electrode size should not exceed 5/32 inches in diameter.
The fan manufacturer should be consulted regarding the use of electrodes lower in strength, such
as the E9018-M, which is generally used for tee or corner joints. Use of the E-7018-Al electrode
is possible when the higher strength electrode weld repairs result in cracking. The alloy pickup
from the base metal can produce welds of about 100 ksi in strength from the E7018-A1. The
E7018-A1 electrodes should be baked for 1 hour at 700–800ºF to reduce their moisture content.
Portable rod ovens should be used for all electrodes on the A514/A517 materials.
The vanadium containing grades of A514/A517, such as Grade F, are subject to stress relief
cracking and should not be subjected to a post-weld heat treatment (PWHT). For the other high-
strength grades, the fan manufacturer performs PWHT on the entire wheel. However, a local
PWHT may not be practical. For example, high thermal stresses may result from the temperature
gradients during PWHT. These could cause cracking problems. One method of eliminating the
hard heat-affected zone (HAZ) in all of the A514/A517 materials is to use the temper bead
method. With this method, any weld bead deposited on base metal is tempered by the deposit of
another bead on top of it that does not contact the base metal. The temper beads may even be
removed by grinding, if the contour is improved. One Midwest utility avoids PWHT but
performs contour grinding at the toes of the T-joint welds and then has the entire weld shot
peened. This is done primarily to improve the fatigue life. Another Midwest utility improves the
fatigue life by hollow grinding the T-joint fillet welds (that is, the fillet welds are ground
concave). For fans built using structural steel materials, PWHT is not performed.
Welder Qualification
A welder should be qualified in accordance with either ASME Section IX or AWS Dl. 1. The
welder must be qualified for the position(s) he will be welding and for an F-4 electrode. This
means that a welder qualified for welding carbon steels such as a A36 with an E-7018 electrode
is also qualified to weld the quenched and tempered fan materials with the E-1 1018-M, E-9018-
M, etc. However, a welder who has never welded high strength materials before could have
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problems, and it would be advisable that the individual be given some training about the
necessity of not deviating from the welding procedure or the electrode storage and handling
requirements. For example, the welder should know that even for tack welds or temporary welds,
the required preheat must be used.
Generic Problems
Certain fans have excessive stresses because of their design. Repairing fatigue cracks in such
fans will be ongoing until the wheels are replaced.
Feedback from several utilities indicates that major weld repairs can be accomplished in the
field. Establishing and maintaining a suitable environment is essential to the success of repairs
performed on quenched and tempered steels. To maintain a minimum ambient temperature of
50ºF during cold weather, use of portable electric heaters in conjunction with an airlock system
is recommended. Use of plastic bulkheads to seal both the inlet and discharge ducts is suggested
to reduce drafts. Erecting a temporary plywood vestibule around the opened manway will further
help control the ambient temperature inside the fan housing. Use of two doors will help seal the
fan housing from a rush of cold air as personnel enter and leave the fan housing.
There are two types of cracking that can occur when making weld repairs. First, cracking can
start during the repair welding process. Such cracks are discovered visually and frequently occur
in the HAZ immediately adjacent to the weld. If the welding is interrupted for a significant time,
a visual examination should be performed before welding is resumed.
Hydrogen-delayed cracking is the second type of cracking that can develop and surface after
weld repairs. The chances of hydrogen cracking can be greatly reduced by adhering to correct
electrode handling procedures, by using electrodes that have a low-hydrogen coating, and by
slowly cooling the welded area to allow hydrogen to escape into the atmosphere. However, in
view of the potential for catastrophic failure if any cracking goes undetected, a visual and
magnetic particle test should be conducted. For ASTM A514 and A517 steels, a 48-hour waiting
period is required before conducting a final VT or wet magnetic particle examination. The wet
magnetic particle test is recommended because it is more sensitive to finding very fine cracks.
Specific information and pass/fail criteria can be found in the AWS standard Dl.l-1990.
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B
KEY POINT SUMMARY
3.2.7 3-6 The fewest number of fans usually results in the lowest initial cost.
3.11.8 3-38 The best practice is to follow the fan manufacturer’s recommendation. If a change
in damper operation is desired, data on startup times and motor current should be
collected and discussed with the suppliers of the fan and motor.
6.2 6-10 Oil analysis tests are often offered free or for a nominal charge by the lubricant
supplier as part of the overall service provided.
7.1 7-2 Recommendations from the manufacturer and operational experience can provide
valuable insight in determining not only what checks should be done, but also how
often they should be done.
7.1 7-2 A balance must be attained by performing PM but avoiding opening and inspecting
equipment if no problems (such as high temperature or pressure) are present.
7.4.5.2 7-19 Blasting with frozen CO2 pellets has been used for cleaning, with the benefit of
eliminating the need to remove the blast medium from the fan.
7.4.9.3 7-27 A simple adjustment of the fan-wheel-to-inlet-cone clearance can affect fan
performance by 5% or more.
9.1 9-1 If additional fan capacity is needed, there are fan upgrades that can be
implemented that require only a fraction of the cost and outage time of complete
new fans.
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3.2.1 3-3 Temperature affects fan performance, and thus, a margin on temperature is
included to allow for variations in operation.
3.2.2 3-4 When specifying FD fans, pressure loss through the silencers (if they are provided)
must be taken into consideration.
3.6.3 3-24 The design speed of the turning gear is critical. Most centrifugal fans have sleeve
bearings that have a minimum speed. Below the minimum speed, the oil film
between the journal and the sleeve is not adequate to prevent metal-to-metal
contact, and the bearing will be damaged.
3.7 3-25 In many coal-fired plants, the ID fans are the limiting factor on plant electrical
output. Although the ID fans may be the apparent cause of a load limit, in many
cases the root cause is high air heater leakage, air heater pluggage, high gas
temperatures, precipitator infiltration, or something similar.
3.7 3-25 Note that most curves are labeled as cfm, where it is understood that cfm is acfm.
Because fan performance depends on inlet density, the fan curve should specify
the density.
3.7 3-26 Fan manufacturers usually present their curves in terms of vane angle, with 90
degrees being the full open position. Many boiler controls identify inlet vane
position in terms of percent open, with 100% being full open.
3.7 3-27 The inlet vanes are designed for flow control and not to isolate the fan, and—with
the vanes fully closed—the performance will be approximately the same as with
the vanes 15 degrees open. Thus, controllability at this low vane opening may be a
problem.
3.7.2 3-30 Note that fan static pressure is not the same as static pressure rise.
3.7.2 3-31 The pressure rise across the fan must be converted to the density on the fan curve.
6 6-1 The goal of condition monitoring is to identify changes in the condition of the fan,
motor, or auxiliary that could indicate some potential failure.
7.4.1 7-6 If oil in a self-contained sump is below the normal level, adding relatively cold oil
may disrupt the oil film. Shut down the fan before adding oil.
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7.4.1 7-6 Do not mix oils in the lubrication system or bearing housing. Chemical additives in
different oils can cause a breakdown in the viscosity, cooling, or bearing
lubrication.
7.4.3.2 7-13 Verify that components used to restrict motor shaft movement are installed.
7.4.5.2 7-20 Coatings can affect the physical properties of the base materials of the fan. Cracks
in coatings can propagate into the fan members. Tests using proposed coatings
and fan structural material should be performed and evaluated before the coatings
are actually used.
7.5.2 7-38 Improper welding of balance weights can cause cracks in the attachment weld that
can propagate into the base metal of the fan.
3.11.2 3-35 The startup procedures, in addition to the controls and interlocks, should follow the
requirements of the current version of NFPA 85.
3.11.9 3-39 The fan control system should monitor the head and flow and give the operator a
stall warning so that the operator can take action before a stall occurs.
4.1 4-6 Erosion is a significant failure mechanism for both centrifugal and axial fans. While
erosion of ID fans is the major problem, erosion has also been reported on FD
fans.
7.4.3.2 7-14 The locking feature of these fasteners becomes compromised when they are
removed and reinstalled a certain number of times.
7.4.3.3 7-14 It is important to verify that the thrust load of the fan is not imposed on the motor
thrust bearing. This requires knowledge of the magnetic center of the motor.
7.4.5 7-17 Damage (manifested in the form of cracking or corrosive wear) can be partial or
total. Unchecked damage may result in an increase in vibration levels with
additional wheel damage, which subsequently may increase in severity to
catastrophic failure with a serious potential for injury to personnel.
7.4.5.1 7-18 Large centrifugal fan wheels are highly stressed rotating equipment. The design
stress may be as high as 80% of yield, and the material may be a quenched and
tempered high-strength material such as ASTM A514 or A517, with a yield
strength of 100,000 psi. Many large centrifugal fans have had cracks, and there
have been a few mechanical failures.
10.1 10-1 All personnel that operate, inspect, or maintain fans should be trained in the plant
safety procedures.
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10.6 10-2 Fans can suck in loose material and discharge it as dangerous projectiles. Large
fans can also be dangerous to personnel.
10.7 10-2 Even when a fan is locked out electrically, it may be subject to “windmilling.”
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TRANSLATED TABLE OF CONTENTS
(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH
RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM
DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED
RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS
SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE, (IV) THAT ANY TRANSLATION FROM THE
ENGLISH-LANGUAGE ORIGINAL OF THIS DOCUMENT IS WITHOUT ERROR; OR
(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING
ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF
THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS
DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN
THIS DOCUMENT.
THE TRANSLATION OF THIS DOCUMENT FROM THE ENGLISH-LANGUAGE ORIGINAL HAS BEEN PREPARED WITH
LIMITED BUDGETARY RESOURCES BY OR ON BEHALF OF EPRI. IT IS PROVIDED FOR REFERENCE PURPOSES ONLY
AND EPRI DISCLAIMS ALL RESPONSIBILITY FOR ITS ACCURACY. THE ENGLISH-LANGUAGE ORIGINAL SHOULD BE
CONSULTED TO CROSS-CHECK TERMS AND STATEMENTS IN THE TRANSLATION.
EPRI
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RESUME
Objectifs
• Fournir des informations sur les ventilateurs axiaux et centrifuges utilisés pour les chaudières
• Aider le personnel de maintenance des centrales thermiques dans la détection des pannes des
ventilateurs
• Fournir des conseils de maintenance courante et préventive pour améliorer la fiabilité des
ventilateurs
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2 GLOSSAIRE.......................................................................................................................... 2-1
2.1 Termes et acronymes .................................................................................................... 2-1
2.2 Conversions des unités utilisées ............................................................................... 2 ou 3
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10 SECURITE .........................................................................................................................10-1
10.1 Matériel tournant ....................................................................................................... 10-1
10.2 L'espace confiné ....................................................................................................... 10-1
10.3 Risques de brûlure .................................................................................................... 10-1
10.4 Risques électriques .................................................................................................... 10-1
10.5 Contrôle de fonctionnement ...................................................................................... 10-2
10.6 Nettoyage .................................................................................................................. 10-2
10.7 Ventilateurs en mouvement ....................................................................................... 10-2
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LISTE DE FIGURES
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Figure A-7 Les indications sont à la suite numérotées et entourées .................................... A-19
Figure A-8 marquage des signes multiples ........................................................................... A-19
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LISTE DE TABLEAUX
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レポートの概要
目的
• ボイラー・ドラフト・サービス(供給空気、排気空気)に使用する軸流および遠心フ
ァンに関する情報を提供すること。
• 問題解決およびファンの保全にあたる火力発電所の所員を助けること。
• 日常および予防保全のガイドをファンの信頼性の向上のため提供すること
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目次
1 はじめに................................................................................................................................. 1-1
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5 問題解決................................................................................................................................. 5-1
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7 保全........................................................................................................................................ 7-1
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10 安全................................................................................................................................ 10-1年
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12 参照................................................................................................................................ 12-1年
A 遠心ファンウィール点検および修理.................................................................................... A-1
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図のリスト
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表のリスト
表4-3 1982年から1995年までの米国の化石プラントのFDファン不良データを集めたもの。
(NERC/GADSデータ )........................................................................................................4-4
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Objetivos
• Para ofrecer información en los ventiladores axial y centrífugos usados para servicio de
corriente de aire de caldera
• Para asistir a el personal de mantenimiento de la central eléctrica fósil en localización de
averías y mantenimiento de ventiladores
• Para ofrecer guía en mantenimiento rutinario y preventivo para asistir en mejorar la
confiabilidad de ventiladores
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CONTENIDO
1 INTRODUCCIÓN ....................................................................................................................1-1
1.1 Propósito .........................................................................................................................1-1
1.2 Organización ...................................................................................................................1-1
1.3 Puntos Claves .................................................................................................................1-2
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5 LOCALIZANDO AVERÍAS.....................................................................................................5-1
6 VIGILANCIA DE CONDICION................................................................................................6-1
6.1 Vigilancia de Vibración ....................................................................................................6-1
6.1.1 Parámetros ..............................................................................................................6-1
6.1.1.1 Amplitud...........................................................................................................6-2
6.1.1.2 Frecuencia .......................................................................................................6-2
6.1.1.3 Angulo de Fase................................................................................................6-2
6.1.1.4 Forma de Vibración..........................................................................................6-2
6.1.1.5 Forma de Modo de Vibración...........................................................................6-3
6.1.2 Análisis de Vibración ..............................................................................................6-3
6.1.2.1 Amplitudes Contra Análisis de Frecuencia ......................................................6-3
6.1.2.2 Análisis del Espectro del Tiempo Real ............................................................6-4
6.1.2.3 Análisis de Forma de Onda de Tiempo ...........................................................6-4
6.1.3 Probetas de Proximidad ..........................................................................................6-5
6.1.4 Probetas de Velocidad ............................................................................................6-6
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7 MANTENIMIENTO..................................................................................................................7-1
7.1 Desarrollando un Programa de Mantenimiento Preventivo.............................................7-2
7.2 Reglas Básicas para Mantenimiento Conductivo............................................................7-3
7.3 Recomendaciones de Mantenimiento Periódica .............................................................7-3
7.4 Mantenimiento de Componente ......................................................................................7-5
7.4.1 Cojinetes..................................................................................................................7-6
7.4.1.2 Recomendaciones de Mantenimiento Rutinario ..............................................7-7
7.4.1.2 Revisión de Cojinete ........................................................................................7-8
7.4.2 Sistema de Lubricación ........................................................................................7-10
7.4.2.1 Mantenimiento de Rutina ...............................................................................7-10
7.4.2.2 Revisión de Sistema de Aceite de Lubricación Circulando............................7-10
7.4.3 Acoplamientos .......................................................................................................7-12
7.4.3.1 Recomendaciones de Mantenimiento Rutinario ............................................7-12
7.4.3.2 Revisión de Acoplamiento .............................................................................7-13
7.4.3.3 Alineamiento de Acoplamiento ......................................................................7-14
7.4.4 Aletas de Entrada Variable y Amortiguadores de Control .....................................7-15
7.4.4.1 Mantenimiento de Rutina ...............................................................................7-15
7.4.4.2 Revisión de Aletas de Entrada.......................................................................7-15
7.4.5 Ruedas de Ventilador Centrifugo ..........................................................................7-16
7.4.5.1 Rueda de Ventilador Centrifugo NDE ............................................................7-18
7.4.5.2 Alabes ............................................................................................................7-18
7.4.5.3 Placa Central/Placa de Lado .........................................................................7-21
7.4.6 Eje .........................................................................................................................7-21
7.4.7 Buje .......................................................................................................................7-22
7.4.8 Sistema de Soporte Estructural.............................................................................7-22
7.4.8.1 Fundación de Concreto..................................................................................7-22
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10 SEGURIDAD ......................................................................................................................10-1
10.1 Rotación de Equipos ...................................................................................................10-1
10.2 Espacio Limitado .........................................................................................................10-1
10.3 Peligro de Quemaduras ..............................................................................................10-1
10.4 Eléctrica ......................................................................................................................10-1
10.5 Prueba de Operación ..................................................................................................10-2
10.6 Operaciones de Limpieza............................................................................................10-2
10.7 Movimientos de Ventilador .........................................................................................10-2
11 ENTRENAMIENTO.............................................................................................................11-1
12 REFERENCIAS ..................................................................................................................12-1
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LISTA DE FIGURAS
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LISTA DE TABLAS
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