ME Laboratory 2

(Module no. 2)

“Test of Centrifugal Fan

and
Rotary Blower”

Engr. Augusto A. Avanceña

Instructor

Alba, Edgar Luigi T.

BSME-5B
LEARNING OBJECTIVES:

At the end of this module, you should be able to;

1. Know what is a centrifugal fan and rotary blower.

2. Understand the different applications of centrifugal fan and rotary blower.

3. Discuss the major parts of the centrifugal fan and rotary blower.

4. Discuss how centrifugal fan and rotary blowers are being tested.

5. Discuss the trouble-shooting usually encountered in centrifugal fan and

rotary blower.

ACTIVITY:

1. Research Work: Write your discussion about the following topics and

upload it in your respective folders.

a. Centrifugal fan and rotary blower, and its applications

b. Major parts of centrifugal fan and rotary blower.

c. Testing of centrifugal fan and rotary blower.

d. Operations of centrifugal fan and rotary blower.

e. Trouble-shooting in centrifugal fan and rotary blower

f. Safety protocols
Introduction of Fans and Blowers

Fans and Blowers use air for ventilation and industrial process requirements. It generates
pressure to move air through ducts, dampers and other components of the fan system.
Difference of Fans and blowers
Fan is mechanical device is used to create a continuous flow of air through the system.
In any cooling system which uses gas such as air as its main fluid, fan is a compulsory unit for
the system. then higher pressure is required, blowers are used instead of fans.

A. Centrifugal fan and rotary blower, and its applications

Centrifugal fans, are among the most efficient and versatile pieces of air moving equipment.
The scroll housing in a centrifugal fan accelerates the air and changes the direction of the
airflow twice, a full 90 degree, before leaving the housing. Centrifugal fans are quiet and
reliable and are made to operate in a variety of environments and applications.

Centrifugal Fan Blade Types

Centrifugal fans come in four basic fan types, each with its own specific purpose.

• Radial These are high-pressure fans with medium airflow. Radial-bladed fans are best for
industrial applications where there is dust, or in environments where there is gas or
moisture in the air.
• Forward Curve These are medium pressure, high airflow fans that can be used in both
clean air, ventilating and exhaust applications.
• Backward Curve These are high-pressure, high flow, high efficiency fans. Power reduces
as flow increases over the most efficient area of the system.
• Airfoil These are the highest efficiency fans, best in clean air applications.
Application:

Cement Plants- Centrifugal Fans in a Cement plant play a very important role in different phases
of the cement production right from the raw grinding to Cement production. Fans are used in
raw mills for raw material preparation, filter systems for removing waste gases and also for
recirculation of air. High pressure fans find applications in the blending and storage area, and
efficient conveying of raw materials, additives and chemicals that are used in the Cement
making processes.
Steel Plants- In steel production, fans are used in grinding of raw materials, de-dusting,
sintering etc., These fans handle not only very abrasive dusty materials, but also high
temperatures and are lifeline of the Steel production.
Power station fans- These fans are again lifeline for the smooth and efficient operation of the
boiler and ensure continuous production of power. Some of these fans like ID Fans handle
extremely abrasive cases and also operate at high temperatures as well.
Chemical industry- Centrifugal fans in chemical industries must meet the norms that ensure
optimum safety. Heavy duty fans are used in chemical industries to exhaust corrosive, high
temperature or hazardous gasses from the plant.
Paper and pulp applications- Wood and paper industry mostly uses fans to dry the material
before it is sent further into the process. Fans are used to dry the paper which continuously
runs on the rolls at certain speed which usually depends on the type of paper to be produced.
Food industry- In food industry, fans are required for drying out the moisture content from the
raw food materials. Industrial fans for this industry are usually made up of less corrosive
material.

Rotary Blower
A positive displacement blower, is a type of machine that is used to move gas or air for a
variety of applications. More specifically, these devices utilize positive displacement technology
by trapping a certain volume of air then discharging or forcing it out against the system
pressure. This air is usually forced into some type of pipe or hose to propel materials or gas to a
destination.
Once a blower is in operation both rotors will rotate at the same speed but in opposite
directions in order to draw air into the blower. One rotor is called the “driving rotor” because it
is run by an external power supply, while the opposite rotor is called a “driven rotor” because it
is driven by gears connected to the driving rotor.
Common Applications

• Chemical - Vacuum Processing & Conveying

• Dairy - Automated Milking
• Environmental Services - Sewer Cleaning & Portable
• Cement & Lime - Fluidization & Conveying
• Resin & Plastic - Processing & Conveying
• Process Gas - Gas Boosting
• Soil Remediation - Vacuum Extraction & Sparging
• Industrial - Material Vacuuming

B. Major parts of Centrifugal Fan and Rotary Blower

Centrifugal Fan

• Impeller - Impeller is a rotating device consisting of number of fan blades mounted

on a hub with drive shaft that forces the air/gas in the desired direction with
increased pressure. In centrifugal fan, the air stream enters the impeller in an axial
direction, acquires acceleration due to centrifugal force as it flows through the fan
blades and gets discharged radially from the fan housing.
• Fan Blades - Fan Blades: Based on the blade configuration such as forward curved,
backward curved, radial, airfoil etc., centrifugal fans are divided into various types
and differ in their functionality. The efficiency and fan performance basically depend
on the shape of the blades that are mounted on a hub of the fan wheel. Some fans
can handle larger volumes of air with high static pressures where as some are meant
for low flow rates. Hence, it is important to select the centrifugal fan design that
 matches with the required pressure and flow-rate of any industrial process, so that
the efficiency will be high for the given operating conditions.

• Fan Housing - Housing in a fan system improves efficiency as it reduces noise and
acts as a protection for moving parts like impeller, hub etc. In centrifugal fan, the air
from the inlet enters the impeller axially through fan housing, where it picks up the
acceleration and is radially sent out in 90° direction.

• Drive shaft: It is a rotating device that holds the impeller & blades and determines
the speed of the fan wheel through various drive mechanisms like direct, belt or
variable. Shaft design depends on the installed impeller weight and the velocity of
the inlet gases.

• Inlet and outlet ducts - Ducts that are attached at the fan inlet and outlet will affect
the airflow pattern and influence the performance of the fans. Ducts at the inlet
control the flow of air/gas by admitting only required amount of air whereas ducts at
the outlet impose a resistance to the air stream. Improper inlet and outlet airflow
conditions, and ducts with sharp cornered turns result in inefficient fan operation,
high system noise and poor performance with undesired outputs.

• Dampers & Louvers - Dampers and louvers are the plates or sheets inside the ducts
which are used to control or alternatively block the airflow at the inlet or outlet of a
fan. The main difference between them is damper blades are movable or adjustable
manually or automatically to control the volume or regulate the airflow whereas
louver blades are fixed and there is no control over the air moving through them.

Rotary Blower

If you were to dissect a positive displacement blower you will notice that the main parts of the
machine are two rotors that are joined together by gears surrounded by a blower casing. Many
blowers also come with a sound absorber, air screen and other parts to improve efficiency, but
when explaining how the apparatus functions we only need to focus on the rotors (often called
the impeller), blower casing, inlet side and outlet side of the machine.
Once a blower is in operation both rotors will rotate at the same speed but in opposite
directions in order to draw air into the blower. One rotor is called the “driving rotor” because it
is run by an external power supply, while the opposite rotor is called a “driven rotor” because it
is driven by gears connected to the driving rotor.
As the rotors revolve, air is pulled into the inlet side of the blower and is confined to tight areas
between the rotors and the blower casing. This pocket of air is moved around the rotors and
blower casing to the outlet side. Once the rotors open to the outlet side, the discharge line
equalizes the pressure of the air and is forced out of the blower. The air is unable to come back
due to the small amount of internal clearance between the internals of the machine. This
process enables the blower to overcome line pressure hence the name positive displacement.
Put differently, the volume of air does not change within the device, but is rather displaced
from one end of the machine to the other.

C. Testing of Centrifugal Fan and Rotary Blower

Fan testing includes measurements of airflow, pressure, power, and efficiency. Fan
performance curves can be developed from these measured data. All the fans fabricated as
per individual and unified design methodologies, are tested experimentally to get their
optimum performance. These tests are conducted according to standard test code IS:
48941987, Indian Standard Specification for Centrifugal Fans (First Revision), Reaffirmed in
1994. Precise and calibrated measuring and sensing instruments are used to measure flow,
pressure, velocity, power and rotational speed. Proper fixtures, supports and stands are
used for sturdy and steady setup. Basic experimental set up is similar for all phases and in
accordance with IS standard.
Testing of Rotary Blower
Initial operation should be carried out under "no load" conditions by opening all valves and
venting the discharge to atmosphere, if possible. Then start motor briefly, listen for unusual
noises, and check the blower coasts freely to a stop. If no problem appears, repeat this
check and let the motor run a little longer. If any questions exist, investigate before
proceeding further. Now operate the unit for about 10 minutes. During this run feel cylinder
and headplates for development of hot spots that indicate rubbing contacts. Also listen for
knocking sounds (contact between impellers), and watch for any change or increase in
vibration. At the end of this run, check the inlet screen near the blower for collected debris.
After above tests are completed and any necessary corrections made, a final check run of a
least one hour should be performed under normal operating conditions. Start unloaded as
above, and apply the system pressure load gradually by closing the discharge atmospheric
vent. Use a mercury manometer connected to the discharge piping to see that the pressure
rating of the blower in not exceeded. Also use good thermometers to determine the
temperature rise through the blower. Both figures should satisfy the conditions listed.

D. Operations of Centrifugal Fan and Rotary Blower Centrifugal Fan Principle of Operation
The centrifugal fan uses the centrifugal power supplied from the rotation of impellers to
increase the kinetic energy of air/gases. When the impellers rotate, the gas particles near
the impellers are thrown off from the impellers, then move into the fan casing. As a result,
the kinetic energy of gas is measured as pressure because of the system resistance offered
by the casing and duct. The gas is then guided to the exit via outlet ducts. After the gas is
thrownoff, the gas pressure in the middle region of the impellers decreases. The gas from
the impeller eye rushes in to normalize this. This cycle repeats and therefore the gas can be
continuously transferred.
Rotary Blower Principle of Operation
• The two rotors rotate in opposite directions.
• As each rotor passes the blower inlet, it traps a definite volume of gas (the ‘displaced
volume’) and carries it around the case to the blower outlet. With constant speed
operation, the displaced volume remains approximately the same at different inlet
temperatures, inlet pressures and discharge pressures.
• As each rotor passes the blower outlet the gas is compressed to the system pressure
there and expelled.
• Small but definite clearances allow operation without lubrication being required inside
the air casing.
• Timing gears control the relative position of the rotors to each other.
E. Trouble-shooting in centrifugal fan and rotary blower Troubleshooting in Centrifugal Fan

• Your centrifugal fan isn’t producing the proper airflow.

When your centrifugal fan is turned on, you should notice it moving large amounts of air
around at any given moment. If it’s not, that’s an issue. There are several reasons why
this might happen. In some instances, you might have broken belts within your
centrifugal fan. In others, you might have a pipe leak or a broken drive coupling.
Whatever the case, it’s a good idea to shut your centrifugal fan down and have it
inspected as soon as possible to get it up and running again.

• The blower in your centrifugal fan isn’t rotating.

Another common troubleshooting issue with your centrifugal fan will occur when the
blower inside of it stops rotating. This can happen if rust builds up in your blower
impeller chamber. It can also take place if there is damage that has been done to your
motor winding. You could even have an electrical wiring issue on your hands. You’ll
usually need to turn your centrifugal fan off and take the blower apart to investigate the
source of the problem.

• You notice oil leaking from your centrifugal fan.

It’s not out of the ordinary to see a centrifugal fan leaking a little bit of oil. Nevertheless,
if you notice a lot of oil leaking onto the floor under your centrifugal fan, this should be
a major cause for concern. Your centrifugal fan can lose lubrication due to a worn seal, a
blown gasket, a loose drain plug, or any number of other things. You should attempt to
see if you can locate the cause of the leak or call on a professional for help.

Troubleshooting for Rotary Blowers

• Blower Failure to Rotate

This could be from rust in the blower impeller chamber, the motor winding could be
damaged, or there could be improper wiring connections within the motor itself. If
there’s rust in the blower, then it’s time for a good cleaning. Turn off the power, remove
it from the system, and clean the impeller chamber.

Reminder: whenever a blower is disassembled, whether for a deep clean or an

inspection, manufacturers always recommend that the bearings, seals, and gaskets be
replaced. This is to ensure optimum reassembly and efficiency. Overhaul kits for each
size and line of blower are available (there are exceptions, of course, for blowers that
are obsolete or very old).
 If the motor winding is damaged, a qualified electrician should inspect the motor for
damage and an assessment can go from there. This goes for having improper wiring
connections within the motor itself. When in doubt, call the manufacturer of your
blower system to see if they have a cut sheet on the motor or if they can get some
insight from the motor manufacturer.
• No airflow

A few probable causes include: broken belts or broken drive coupling, blower isn’t
turning, or a pipe leak. The most obvious solution for broken belts or a broken drive
coupling is to simply replace it. But make sure that with belts the tensioning is correct.

Belts that are too tightly strung or too loosely strung can snap or flap around and cause
the pulleys to not rotate, hence the lack of air flow.
If the blower isn’t turning, double check your check valve to see if it’s missing or if it’s
failed. Your check valve is designed to allow air to flow in one singular direction, not
both. If it’s missing or not working properly, that can be a contributing factor.

A pipe leak could mean a loose connection somewhere or that a gasket needs to be
replaced. Double check all your connections and if your gaskets haven’t been changed in
a long while, a replacement may be in your future.

• Blower Exceeds Maximum Vibration

Any number of things could cause this issue from a loose mounting, to bolts failure,
loose sheaves in the v-belt drive, foundation base is too loose, insufficient v-belt
tension. The list goes on.

When your system is vibrating, turn off the power and inspect all of the bolts, double
check the foundation base, and check the tension on the v-belt drive. If the sheaves on
the v-belt drive are loose then make sure they are installed according to your O&M
manual and make sure your blower is running at the correct speed. If you no longer
have that manual, call the manufacturer of your system and they should be able to
provide it. Double check the tensioning of the v-belts on the v-belt drive. As noted,
before, if they’re too loose or too tight then they can flap around aimlessly or snap; not
only does this cause vibration but it can prevent airflow all together.

• Excessive Blower Temperature

Each blower has a temperature minimum and maximum. If it operates outside those
restrictions, then your efficiency goes down and you run the risk of ruining the blower.
As with the other common problems, this one is caused by any number of things: too
 much oil in the gear case, too low operating speed, dirty air filter, worn impeller, inlet
air flow restricted.

If your blower has too much oil in the gear case, make sure the unit has come to a
complete stop and then drain the oil level to the specified amount. Side note, if your
blower is low on oil or has been running with that batch of oil for longer than the
recommended hours, a full oil flush to replace the old oil will aid in lengthening the
lifetime of your blower.

• Lubrication Loss
Some leaking is common. But excessive loss of lubrication (oil on the floor/under the
blower) or a consistent drip is not good. Similar to a blower overheating, there could be
too much oil in the blower. There could also be a worn seal, loose oil cover, drain plug or
line loose, a gasket could be worn, or the head plate or gear case/drive cover vents
could be plugged.

To check for worn seals, loose covers, worn gaskets, etc. this may require a complete
tear down of the blower and replacement of those seals, bearings, and gaskets. The
manual for the blower itself often gives a clear walk through on how to tear down,
clean, and rebuild a blower. When in doubt, have your blower inspected by a certified
technician. This will ensure that your blower is thoroughly inspected. Should your
blower be in good enough condition to be rebuilt, the technician has the tools and parts
necessary for proper cleaning and rebuilding of the unit.

F. Safety Protocol
1. Do not attempt to install, connect power to, operate or service your new fan without
proper instruction and until you have been thoroughly trained in its use by your
employer.
2. Do not attempt to work on, clean or service the fan, or open or remove any protective
cover, guard, grate or maintenance panel until the POWER has been turned off and
LOCKED OUT, and the fan rotor has come to a complete stop.
3. Do not manually override or electrically bypass any protective device.
4. Do not connect power to or operate the fan unless all moving parts are covered and all
covers, guards, grates and maintenance panels are in place and securely fastened.
5. Do not abuse, overload, mistreat or misuse the fan or attempt to operate the fan if it is in
need of service, lubrication, maintenance or repair.
6. Never place any part of your body near rotating members or moving parts of the fan.
7. If the fan is not equipped with factory supplied drive and guard, then all rotating
members and moving parts must be completely enclosed before connecting power and
before operation.
8. Free outlet of the product must be guaranteed at all times. Otherwise, blockage and
severe damage may result, or a dangerous situation may occur.
9. If the fan is equipped with a maintenance panel or access door incorporating a Protective
Interlocking Limit Switch (PLS), the PLS must be interlocked with all electrical controls. This is
to prevent all motors or powered devices on the unit from being energized if any protective
cover, guard, grate or maintenance panel is open or removed. Never attempt to manually
override or electrically bypass a safety device. The interlock function of the PLS must be
tested and logged daily by supervisory personnel.
10. The fan housing may have an inspection port which is fastened with captive hardware.
In addition, the port has a device that keeps it open as long as it is not fastened down.
The port may only be opened when the fan wheel is motionless and the repair switch is
turned off.
11. Many fans are installed and wired to start automatically or be controlled from remote
locations. Keep clear of all moving parts on industrial equipment at all times.
12. The fan must be equipped with a properly functioning Protective Interlocking Electrical
Control Switch (PCS), a Pad lockable Manual Power Lockout Switch, and with the other
basic safety equipment listed above. On-Off, interlock and padlock functions of the PCS
must be tested and logged daily by supervisory personnel.
13. It is the owner’s and the employer’s responsibility to adequately train the
employeeoperator in the proper and safe use of the equipment. Written safety programs
and formal instruction are essential. All new employees must be made aware of company
policies and operating rules, especially the established safety and health procedures.
Refresher training of experienced employees in the potential hazards of the job is
important. Up-to-date training records must be maintained at the job site.
14. Special attention must be devoted to outside contractors engaged to enter and perform
work on equipment or in the workplace. Special care must be exercised to insure all such
personnel are fully informed of the potential hazards and follow plant rules – with special
emphasis on explosion proof electrical tools and cutting or welding in unsafe
environments. 15. Keep the workplace cleaned up and free of dirt and dust at all times.
Do not attempt to work on slippery or unsafe ladders or work platforms when
maintenance or repair work is being performed on the fan.
16. The operator must ensure that adequate lighting conditions are provided at the location
of equipment operation.
17. Do not climb on ladders or work on platforms unless maximum load rating is posted. Do
not exceed maximum load ratings when installing or servicing the fan.
18. Never allow any kind of metal or other foreign objects to enter a fan while in operation.
Examined raw materials (cleaned air) should be used through the machine to ensure proper
and consistent operation.
19. To prevent human access while the equipment is operating, all fan inlet and discharge
openings must be completely enclosed and remain enclosed until POWER IS TURNED OFF
AND LOCKED OUT. Keep away from the moving parts of the fan during operation.
20. Kice fans must be operated at the airflow rates determined for the customer specific
application(s). This is to ensure that the fan will operate normally and under its maximum
surface temperature rating.
21. Unless otherwise specified or designed per customer requirement, Kice fans are
designed not to exceed a light dust load through the internal airstream.
22. Operate safely at all times. Use personal protective equipment when and where
appropriate, such as hard hats, helmets, gloves, earplugs, dust masks, and eye protection
devices. Keep personal protective equipment in good repair and convenient to the operator.
23. Drive components must be inspected and adjusted after transportation and periodically
as required by operating conditions. Check sheaves and coupling alignment and spacing,
Vbelt tension, set screws, keys, fasteners, bearings, shafts and motor, as appropriate to job
conditions.
24. High voltage and rotating parts can cause serious or fatal injury. Only qualified, trained,
and experienced personnel should perform installation, operation and maintenance of
electrical machinery. During installation and operation, make sure that the motor and the
frame of the fan is effectively grounded in accordance with OSHA safety and health
standards, the National Electric Code, local codes and EN ISO 60204-1 as required for the
classified area. 25. Never stand under any kind of hoist or lifting mechanism, whether or
not it is loaded or in operation. Never stand under or near a fan or component when it is
being lifted.
26. Qualified personnel, before each use, must carefully inspect all lifting devices. Never use
a lifting device to transport equipment. Never use a lifting device that is damaged,
deteriorated, or in any way in need of repair.
27. All protective covers, guards, grates, maintenance panels, switches and warning decals
must be kept in place and in good repair. Any equipment with a damaged, malfunctioning,
defective, or missing protective device must be taken out of service until the protective
device can be repaired or replaced.
28. Any device powered by air or hydraulic pressure must be equipped with a properly
functioning pad lockable Manual Pressure Lockout and Internal Pressure Relief Valve (PRV).
29. Any equipment that is used in the processing of explosive materials in hazardous
environments requires an evaluation on the part of the user and operator of proper and
adequate monitoring equipment, dust control, explosion relief venting, and electrical
 equipment enclosures. Do not use your equipment in hazardous environments unless it has
been properly equipped for the hazard.
30. It is ultimately the operator’s responsibility to implement the above listed precautions
and ensure proper equipment use, maintenance and lubrication. Keep these instructions
and list of warnings with your machine at all times.
31. It cannot be assumed that every acceptable safety procedure is contained herein or that
abnormal or unusual circumstances may not warrant or require future or additional
procedures.

Safety Precautions for Blowers

• Blower casing and associated piping or accessories may become hot enough to cause
major skin burns on contact.
• Internal and external rotating parts of the blower and driving equipment can produce
serious physical injuries. Do not reach into any opening in the blower while it is
operating, or while subject to accidental starting. Cover external moving parts with
adequate guards.
• Disconnect power' before doing any work, and avoid By-passing or rendering
inoperative any safety or protective devices.
• If blower is operated with piping disconnected, place a strong coarse screen over the
inlet and avoid standing in the discharge air stream.
• Stay clear of the blast from pressure relief valves and the suction area of vacuum relief
valves.
• Avoid extended exposure in close proximity to machinery with high intensity noise
levels.
• Use proper care and good procedures in handling, lifting, installing, operating and
maintaining the equipment.
• Casing pressure must not exceed 25 PSI (172 kPa) gauge. Do not pressurize vented
cavities from an external source, nor restrict the vents.
• Do not use air blowers on explosive or hazardous gases.
• Other potential hazards to safety may also be associated with operation of this
equipment. All personnel working in or passing through the area should be warned by
signs and trained to exercise adequate general safety precautions.
References:
Introduction
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Centrifugal fan and its applications

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displacement-blower-Blog.html Major parts of centrifugal fan and rotary blower
Centrifugal Fan
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http://14.139.13.47:8080/jspui/bitstream/10603/37646/14/14_chapter%204.pdf
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Operations of centrifugal fan and rotary blower:

Centrifugal Fan

(2019). Centrifugal Fan.

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%20processes.,Principles%20of%20operation,move%20into%20the%20fan
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Centrifugal Fan

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https://www.dynamicfan.com/troubleshooting-issues-for-centrifugal-fans/ Rotary
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Safety protocols
Centrifugal Fan

(2018). Centrifugal Fan Operators Manual. https://www.kice.com/wp-

content/uploads/2018/03/Centrifugal-Fan-Operators-Manual.pdf Rotary
Blower
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content/uploads/2016/11/roots_whispair_max_operating__and_maintenance_instructions_bu
lletin_irb-131-778_1.pdf