Using Vibration Analysis To Identify & Correct An Induced Draft Fan's Foundation Problem of A Pollution Control Device - A Case Study

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 8 (2018) pp.
5831-5840
© Research India Publications. http://www.ripublication.com
Using Vibration Analysis to Identify & Correct an Induced Draft Fan’s

Foundation Problem of a Pollution Control Device
- A Case Study
Rana Dutta1, Jai Prakash Dwivedi2,V P Singh2,Abhijit Ghosh1

Electrosteel Castings Limited, 30 Barrackpore Trunk Road, Kolkata 700 115, India.
1
2
Department of Mechanical Engineering, Indian Institute of Technology (Banaras Hindu University)
Varanasi 221005, Uttar Pradesh, India.
Abstract time between failures)substantially and at the same time

prevent impeller blade wear.
Condition monitoring engineers regularly report of high
vibration of induced draft(ID) fans that run in tandem with the Keywords: ID Fan, Blade Wear Out, Fan Vibration,
pollution control devices. These fan’s mean time between Resonance. MTBF, Pollution Control Device
failures (MTBF) is much higher than the common ID fans and
the reason is that due to the high abrasive nature of the dust
that the ID fan blades are frequently subjected due to the INTRODUCTION
filter bag failures of the pollution control devices.
At the stock house of a Blast Furnace a pollution control
In this case study, high vibrations were observed from a unit(PCU) has been installed to arrest the dust generated by
recently commissioned ID fan connected to a Blast Furnace the conveyor belts transporting the raw materials and the
stock house pollution control device and analysis showed that induced draught fan (Figure:1) draws in the dust fines
cause of vibration was principally due to resonance. The generated from the conveyor belts which after passing through
fan’s prime mover was of constant rpm hence speed could not the bag filters passes through the ID fan as a comparatively
be altered to avoid resonance. Second option was to increase cleaner air and escapes through the chimney into the
the concrete base mass but due to site restrictions that was not atmosphere. (Fig:1)
feasible either.
Balancing the unit reduced the vibration to certain extent as
masses were being added to the fan blades but within a very
short period high vibrations re-occurred due to wearing out
of the fan blades as they were subjected to abrasive dust
particles and the mean time between failures ( MTBF) was as
low as 30 days. In this case study the whole sequence of the
fault detection and its analysis with corrective measure taken
has been shown and the conclusion drawn is that whenever
a high vibration of a pollution device ID fan is observed with
resonance as a key factor and if the prime mover is of constant
speed then instead of increasing the base mass which is quite Figure 1. Picture of the ID Fan for the Blast Furnace Stock
expensive and at times not permissible due to space restriction House
and if the capacity of the prime mover permits it is
The specification of the blower and the motor is given in
economical to increase the weight of the fan preferably by
Table 1.
hard facing the impeller blades with deposition of abrasion
resistant materials which can offset resonance due to extra
added mass on the impeller blades and increase MTBF (mean
Table 1. Motor & Blower Specification:

Motor Type Motor Motor Motor Full Motor Fan Bearings Cooling Water Number of
Rating Voltage rpm Load Bearings (Water Cooled) Pressure Impeller Blades
Current
Induction 1120 kW 6.6kV 992 117 A Anti-friction Anti-friction 0.0429 MPa 12

Motor Bearings Bearings
5831
International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 8 (2018) pp. 5831-5840
The blower is coupled to the motor with a flexible coupling as The first step was to analyze the reason for high vibrations in
shown in the Figure:2 . The measuring points for vibration the motor and as William R Finley et al. [2] had observed that
monitoring has been numbered. to solve a vibration problem in an induction motor one must
differentiate between cause and effect and in order to get this
happen one has to first find the root cause of each abnormal
vibration. Glenn H Bate [3] had observed that the vibration
problems of the induction motor can be the combination of
two groups which can be called ‘magnetic’ and
‘mechanical’. Vibrations due to magnetic phenomenon can
also be due to two reasons (a) air gap variation (b) current
variation. In (a) air gap variations typical magnetic vibration
has been listed as (i) static eccentricity (ii) weakness of stator
support (iii) dynamic eccentricity and (iv) loose rotor bars. In
Figure 2. Schematic layout of the blower & motor unit (b) current variation typical magnetic vibration has been listed
showing the Vibration Measuring Points as (i) stator winding faults (ii) broken and cracked rotor bars
(iii) shorted rotor laminations. Glenn H Bate[3] also
described a simple test called ‘power trip test’ wherein in the
After commissioning the blower unit the vibrations, both of test the magnetic components of vibration will disappear
the fan and motor, were found to be quite high and the plant’s immediately once the power is removed. This test was carried
condition monitoring team were asked to monitor and out and it was observed after power switch off the vibrations
diagnose the reason for the high vibrations .The initial remained but gradually minimized with the drop in the motor
vibration readings of the motor & blower drive end & non- speed. It was confirmed that the components of the vibration
drive end bearings at the measuring points are shown in were mechanical in nature so it became evident that the
Table:2 specific components of mechanical vibrations have to be
sorted through vibration signature analysis and
countermeasures to take on specific causes to reduce the
Table 2. Vibration of Motor & Blower after commissioning. overall vibration amplitude to the acceptable limit. Mikhail
(30th August 2014) (Abnormal vibrations marked *). Tsypkin [4] had observed that major vibration sources of
mechanical origin in induction motors are: shaft bow, rotor
Measuring Measuring Axis imbalance, misalignment, discrepancies in bearing operations
Points Horizontal (H) Vertical(V) Axial(A) as well as in the couplings ,sheaves, and other mechanical
(Unit: RMS (Unit: RMS (Unit: RMS rotating elements of the assembly. Mechanical looseness,
value mm/sec) value mm/sec) value foundation problems and/or structural resonances also may
mm/sec) significantly changes vibration signal amplitudes and
configurations.
Point No:1 11.3* 3.1 2.4
(Motor NDE) Though the ‘power trip test’ indicated the problem of high
Point No:2 9.8* 0.8 2.7 vibration in the motor was mechanical in nature still current
(Motor DE) signature analysis was also carried out to negate any problems
with the rotor bars.(Fig:3)
Point no:3 5.8* 1.8 3.5
(Blower NDE)
Point No:4 4.9* 3.0 4.0 CURRENT SIGNATURE ANALYSIS-1
(Blower DE)
From Figure 3 it is observed that there is no phase unbalance
in the 3 phases and from the spectrum analysis we find there
It was observed that the motor drive end & non-drive end is no rotor initiated problem. With the current signature
vibrations in the horizontal axes were higher than the analysis it was confirmed that though the motor vibration is
accepted vibration level as per ISO -10816-3.[1] as compared high but there is no broken rotor bar related issue of the
to the blower unit horizontal vibrations. The other axes motor.
vibration of the fan and the motor were within the accepted
standard[1]. As the horizontal vibration readings were
comparatively much higher than the vertical & axial readings
in this case study we have considered only the horizontal
readings in all our analysis.
5832
Figure 3. Current Signature Analysis Report and the Load in the RYB Phases.
PHASE ANALYSIS Phase Analysis at various locations of Machine base:

In the next step a phase analysis was carried out of the 1. Motor NDE horizontal to vertical :120
motor’s both end bearings ( Figure: 4) and results are shown 2. Motor NDE horizontal to Motor DE horizontal :1 0
in Table:3
3. Motor DE horizontal to Fan DE horizontal :14 0
4. Motor DE axial to Fan DE axial:170
5. Fan DE horizontal to vertical :1100
6. Motor base vertical to base frame vertical:10
7. Motor base vertical to foundation vertical :40
From the above result we find the phase shift (delta) value is
00 or 1800 (approximately) vibration analysis concludes weak
base rigidity/mechanical looseness at structure and unbalance
and to confirm the same the next first step was to do the bump
test to check for resonance..
BUMP TEST
Jack D Peters [ 5 ] in his work has described Bump Test as :
 Measured response of an impact to an object
 The force of the impact is not controlled or
Figure 4. Phase analysis axis & location are being shown
measured.
 The response of the object is not controlled but
Table 3. Phase Analysis Measuring Results measured.
Velocity RMS (mm/s) Acceleration RMS  A single channel response measurement.

Location Horizontal Vertical Axial Horizontal Vertical Axial In the same work Jack D Peters described the necessity of the
Bump Test:
Motor 10.9 3.5 2.1 1.2 0.6 0.4
NDE  To excite and measure the natural frequency of an
object .
Motor 10.1 1.7 2.1 1.1 0.4 0.6
DE  To identify a resonance.
Fan DE 6.7 1.4 3.2 2.2 2.3 2.4  To understand a change in mass.
Fan NDE 5.1 2.8 3.6 1.3 1.5 2.1  To understand a change in stiffness.
 To understand a change in damping.
The maximum overall vibration amplitude recorded was 10.9 Before doing the Bump test the vibration of the equipment
mm/sec in horizontal direction at motor NDE & 10.1 mm/sec and the base was mapped.(Fig:5)
in motor horizontal direction at DE bearing.
5833
Figure 5. Vibration level mapping of the equipment and the base(view from both side).Dimension mm/sec
It is evident from the above vibration mapping that the higher So the next step is to find an alternative method to off-set the
vibration was at the motor side and the same was being resonance.
transmitted to the base.
After the mapping of the equipment and the base the bump
RESONANCE CHARACTERISTICS:
test was conducted and the result is given in Figure:6
Eugene Vogel[6] has expressed a method for solving vibration
problems due structural resonance .Structural resonance refers
to excessive vibrations of non-rotating components usually
machine parts or supporting structures. Even slight vibratory
forces from residual unbalances and misalignment effects of
the machine can excite the resonant base structure resulting in
severe vibration. The Bode Plot (fig:7) shows the operating
speed versus the amplitude.
Figure 6. The result of the bump test.
Figure 7. Bode Plot Amplitude versus Speed

From the above result of bump test it is evident that the blade
pass frequency(the impeller has 12 numbers of blades) and the
natural frequency of the concrete base is coinciding which is From the above plot it is observed that as the operating speed
causing resonance. is increased beyond the resonant frequency the vibration
Normally to avoid the resonance the usual practice is to either amplitude will decrease somewhat but in this case study it was
reduce the fan speed or to increase the stiffness of the base not possible to vary the motor speed so a next alternative had
further. In this case study it was not possible to reduce the to be implemented.
motor speed as it was a fixed speed induction motor and due
to site restriction to increase the base size was not possible.
5834
The formula for calculating the natural frequency is: From equation (1) and also considering and above basic
vibration principles it is evident that increased stiffness will
raise the natural frequency and increased mass will lower it.
F(hz) = ½π k/m (equation-1) That’s logical since stiffness creates a force that is always
directed against motion , while mass has inertia, which is
Where k is the stiffness of the structure & m is the mass
force always directed with motion. Resonance is what
Core formula is : happens when these two opposing forces are equal and they
cancel each other out increasing vibration. The option was to
k/m ≈ stiffness/mass either increase the concrete base mass or increase the mass of
Barry T Cease[7] of Cease Industrial Consulting also in a the impeller but as because of area constraint it was not
similar case study of resonance in foundation had carried out a feasible to increase the concrete base mass so the sole
modification work on the following basic principles of alternative was to increase the mass of the rotating impeller.
vibration. A third factor which can reduce resonance is damping but as
 From Newton’s 2nd Law of Motion :F=m*a where ‘F’is the whole fan structure was a heavy mass weighing about 6
Force ,’m’ is mass & ‘a’ is acceleration. And when we metric tonne it was directly mounted on the concrete base and
rearrange the equation we get the following :a=F/m no shock absorber were used.
 Thus, when we increase the mass(m) , in general , we

will lower the acceleration levels(a) INCREASING THE MASS OF THE IMPELLER:
 Also from Hooke’s Law: F=k*x where ‘k’ is stiffness & The rotating speed of the impeller is constant so the exciting
‘x’ is displacement. force will be the residual unbalance of the impeller at the
 Thus, when we increase the stiffness(k), in general ,we rotating speed. In reference to the readings noted in Table :3
will lower the displacement levels(x). it was noted that both in the fan & motor bearings the
vibration in the horizontal direction is much higher than the
 By upgrading the foundation we may very well have vibrations in the other two axes i.e. vertical & axial. The
moved a potential fan natural frequency higher(> 900 vibration signature analysis of the motor non-drive
rpm) thus reducing or eliminating its amplification of our end(MNDE) & drive end(MDE) bearing’s horizontal axis and
vibration levels. also the fan’s drive end(FDE) & non-drive(FNDE) end was
done for further analysis(Fig:8)
 The upgrading of the foundation was not feasible in our
case study because of space restriction so if we increase
the mass of the rotating impeller the acceleration level
will be lower
Figure 8. Vibration Signature Analysis of the Motor & the Fan Bearings in Horizontal axis
5835
In the vibration signature analysis it was observed that the BALANCING OF THE IMPELLER-1ST TIME (25TH
highest amplitude was at 1* running speed(X). MAY 2014)
Troy D Feese & Phillip E Grazier [5] had observed that The first balancing of the impeller was done and the
generally when machinery experiences high vibration at 1 x correction mass that was added is given below:
running speed the first cause can be of unbalance of the
Total 780 grams weight added at 315 0 on the impeller.
impeller and the same to be checked first. As the signature
analysis indicates there is some unbalance in the impeller it After the balancing there was an drastic improvement in the
was decided to check the same first and to correct the fan and the motor vibration.(Table:4)
unbalance as there will be some addition of weights which
may off-set the resonance forces.
Table 4. Vibration Reading Before & After Balancing -1st time
Vibration Reduction Record Before & After Balancing (all units are RMS mm/sec)
Measuring Points Before Balancing After Balancing % Reduction
Motor Non-Drive End Horizontal Axis 16.17 4.73 70.7
Motor Drive End Horizontal Axis 16.06 4.25 73.5
Fan Drive End Horizontal Axis 11.09 3.06 72.4
Fan Non-Drive End Horizontal Axis 8.09 2.49 69.2
Since horizontal axis vibration were the highest in both the increase in vibration in the 1X in the horizontal axis for both
fan and the motor we have shown its readings only but the motor and the fan.
similarly there reduction in vibration in all the axis.
It is evident that after addition of mass there was a noticeable
Balancing of the Impeller-2nd Time(20th July 2015)
shift in the resonance which resulted in the reduction of
vibration in all the axes. The second balancing of the impeller was done and the total
correction mass added was1500 gms. And after addition of
However after some weeks later again the vibration in all the
extra weights for balancing the vibration dropped
axes increased considerably and signature analysis indicated
drastically.(Table:5)
Table: 5. Vibration Reading Before & After Balancing -2nd Time
Vibration Reduction Record Before & After Balancing (All Units are RMS mm/sec)
Measuring Points Before Balancing After Balancing %Reduction
Motor Non-Drive End Horizontal Axis 23 4.9 78.89
Motor Drive End Horizontal Axis 21 4.3 79.52
Fan Drive End Horizontal Axis 14 3.2 77.14
It was observed that after adding mass to the impeller during impeller blades it was found that though the weights added in
balancing resonance has drastically reduced for which overall the previous balancing was intact but there was a considerable
vibration had drastically dropped but after few weeks wearing out of the impeller blades (Fig:9)
vibration increased again . On close observation of the
Figure 9. The tip and the edges of the impeller blades were wearing out very fast
5836
The reason of fast wearing out was due to abrasion of sand the pollution control device unit the fan was again put into
materials which were leaking from the partially damaged filter operation after addition of weights as required for balancing.
bags of the pollution control device. In the pollution control
On expected lines again after few weeks the overall vibration
device there are 12 chambers and each chamber has 192
increased and fan was stopped again for inspection.
bags and to locate and replace the damaged from the total
2304 total bags is a time consuming task which needs a long
shut down which the operation cannot afford because of
production schedule. Balancing of the Impeller-3rd time(24th Aug 2015)
On inspection it was found that the wear of the impeller
This abrasion was reducing the overall mass of the impeller
and resonance was occurring for which the overall vibration blades were increasing now at a faster rate. (Fig:10)
was increasing again. As it was not possible then to overhaul
Figure 10. The impeller blades were wearing out at a faster rate
For the third time again the impeller was balanced by adding
weight 1310 gms. and after adding the mass overall vibration
reduced.(Table:6)
Table 6. Vibration Reading Before & After Balancing -3rd Time
Vibration Reduction Record Before & After Balancing
(All Units are RMS mm/sec)
Balancing of the Impeller and if the same is not contained the damage of the cast
base will be irreversible. (Fig:11)
It was evident from the above analysis and vibration records
that high vibration of the fan was due to resonance and as the
same could not be avoided by varying the motor speed or
increasing the base stiffness it was achieved by increasing the
impeller mass as extra weights were added to balance the
impeller but the corrective measure was not very effective as
the total effect of the additional weight was getting
counterbalanced as the fan blades were wearing out at an
extremely faster rate due to abrasion as because it was
subjected to constant flow of sand and other particles due to
the damage of some filter bags of the pollution control device
Figure 11. Initiation of Crack Propagation at the Base
unit. The average mean time between failures (MTBF) was as
low as 45 days on the average.
After the third balancing , the impeller had to be Final Diagnosis:
balanced further two times for the same reason but
Till now after each balancing the fan would be operating
during the 5th balancing it was observed that due to
frequent high vibration the fan base was getting damaged within the vibration limits [1] for certain number of days
5837
only. The graph(Fig:12) shows that the MTBF of the motor &
the fan drive & non-drive end bearings..
Impeller balanced Impeller balanced
Impeller balanced Impeller balanced
Figure 12. Horizontal vibration of the motor & the fan DE & NDE bearings after each balancing.
From the above graphs it is evident that the mean time given in the general drawing supplied by the overseas original
between failures was as low as 45 days on the average and equipment manufacturer . The fan blade material
this was due to the fast wear rate of the impeller blades due to specification was Q235B whose IS equivalent is IS: 2062
abrasion of the dust effusing from the partially damaged which is a common structural steel material but is not
pollution control unit filter bags. suitable for abrasion resistance.(Table:7)
The reason for fast rate of wear of the impeller blades was
found after checking the impeller blade material grade as
Table 7. IS :2062(IS equivalent of Q235B)

Carbon % Silicon% Manganese% Phosphorous % Sulphur % Hardness
0.20 0.35 1.40 0.045 0.045 22 HRC(approx.)
From the Manganese % it is evident it is not a abrasive

resistant material and not suitable for an impeller blade which
is subjected to high velocity abrasive particles. This was the
reason for high wear out of the impeller blades.
With even best maintenance practices filter bags getting
damage is a routine aspect and most of the time operation
need to be continued with partial damaged filter bags till a
major shut down is available to replace the bags. In this case
study the filter unit has 2304 bags distributed in 12 chambers.
(Fig:12)
Figure 12. Picture of the 12 Chamber Filter Bag Unit
Frequent balancing of the fan was a hindrance to production

and there were two counter measures to solve the issue.:
1: Change the damage filter bags to arrest abrasion on the
impeller blades .
5838
2: Coat the impeller blade surface with abrasion resistant Abrasion Resistant Coating of the Impeller Blades:
material to reduce erosion due to abrasion.
Based on the base metal of the blades an abrasion resistant
The 2nd. option was certainly better as to locate the damaged electrode [8]was selected with the following description:
bags from a bundle of 2304 bags is by itself a mammoth task
‘Newly formulated heavy coated high recovery electrode
and even after replacing the damaged bags there is no
designed specially for extreme abrasion resistance at higher
guarantee that other bags in due course of time will not get
temperature to about 600 0 centigrade. Deposits consists of
damaged in phases and start the process of corrosion. Routine
high percentage of primary chromium carbide and secondary
damages of filter bags occur due to aging of the filter bags
vanadium carbides and Borides for optimum results .
and natural deterioration due to common wear and tear.. So it
Hardness 61-66 HRC [8]
was decided to coat the impeller blades with abrasion resistant
material. After coating the impeller blades the total weight of the
electrodes added was 35 kg. After checking the final balance
the fan was commissioned on 16th June 2015. And reading
taken before and after the final balancing is given in Table :7
Table 7. Vibration Reading Before & After Welding the Impeller Blades with Abrasion Resistant Metal & Balancing.
Vibration Reduction Record Before & After Balancing
(All Units are RMS mm/sec)
After the coating of the impeller blades fan has run un-
interrupted for more than two years and monitoring done
during schedule maintenance showed that all the vibrations
were well within the acceptable range[1].(Fig:13)
Figure 16. Motor & Fan’s DE & NDE Bearing Horizontal Vibrations after Abrasion Coating Till 2018
5839
DISCUSSION [3] Glenn H Bate, Vibration Diagnostics for Industrial

In this case study the initial problem was that an abnormal Electric Motor Drives. Bruel & Kjaer
vibration was observed after commissioning of an ID fan’s [4] Mikhail Tsypkin, (2011) Induction Motor Condition
motor and fan unit and by vibration analysis the reason of Monitoring: Vibration Analysis Technique-A
high vibration was found out to be because of resonance. As Practical Implementation (IEMDC) IEEE
the motor was of fixed rpm neither its speed could be varied International
nor due to space restriction the stiffness of the concrete base
could be increased by adding extra mass. to avoid the [5] Jack D Peter – “What’s Up in The Bump Testing”
resonance . As the motor was not running on full load current www.ctconline.com
even with 81% damper opening the impeller mass was
increased and balanced to avoid resonance. When the problem [6] Eugene Vogel (2013) Understanding of Resonance
was analyzed and solved with vibration analysis ,a new Essential for Solving Vibration Problems-Control
dimension was added and that was due to the depletion of the Engineering
impeller blades as they were subjected to constant abrasion [7] Troy D Feese ,Philip E Grazier (2004) Case Histories
particles that leaked from some of the damaged filter bags of from Difficult Balance Jiobs.33rd. Turbo Machinery
the pollution control unit. This metal erosion problem was Symposium (September 2004).
then solved by overlaying of the impeller blades with an
additional abrasion resistant material which not only arrested [8] Diffusion Engineers Catalogue
the fast wear out of the impeller blades but also added
substantial mass to the impeller blades as desired to avoid
resonance.
The experiment was successful as before welding the
abrasive resistant material mean time between failure (MTBF)
was a low as 30-45 days but after the welding the fan operated
with out a single failure for the next two years.
CONCLUSION
From the above discussion we can conclude that in a ID fan
with a fixed speed prime mover if there is an vibration
increase due to resonance and due to economical or space
restriction increasing the concrete base stiffness is not feasible
and if there is unbalance of the fan impeller then the best
option is to balance the impeller .The added mass on the
impeller will lower the fan acceleration level and off-set the
resonance.
In case the blower unit is connected to a pollution control
device handling abrasive material like sand dust or any other
raw material dust then its feasible to weld a suitable abrasive
resistant material on the impeller blades provided the prime
mover is operating below its rated capacity(full load current)
and there is some provision to load the prime mover further .
Apart from increasing the impeller mass it will also prevent
the wearing out of the impeller blades which not only
weakens the blades but also reduce the weight of the impeller
and re-create resonance and increase vibration. In the above
case study it has been demonstrated that with the corrective
action MTBF could be increased from barely 45days to two
years and more.
REFERENCES:
[1] ISO-10816-3:2009
[2] William R Finley, Mark H Hodowanec, Warren G
Holter (1999). An Analytical Approach to Solving
Motor Vibration Problems IEEE Paper No.PCIC-99-
20
5840

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International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 8 (2018) pp.

Using Vibration Analysis to Identify & Correct an Induced Draft Fan’s

Rana Dutta1, Jai Prakash Dwivedi2,V P Singh2,Abhijit Ghosh1

Abstract time between failures)substantially and at the same time

Table 1. Motor & Blower Specification:

Induction 1120 kW 6.6kV 992 117 A Anti-friction Anti-friction 0.0429 MPa 12

PHASE ANALYSIS Phase Analysis at various locations of Machine base:

Velocity RMS (mm/s) Acceleration RMS  A single channel response measurement.

Figure 6. The result of the bump test.

Figure 7. Bode Plot Amplitude versus Speed

 Thus, when we increase the mass(m) , in general , we

Table: 5. Vibration Reading Before & After Balancing -2nd Time

Impeller balanced Impeller balanced

Impeller balanced Impeller balanced

Table 7. IS :2062(IS equivalent of Q235B)

From the Manganese % it is evident it is not a abrasive

Figure 12. Picture of the 12 Chamber Filter Bag Unit

Frequent balancing of the fan was a hindrance to production

DISCUSSION [3] Glenn H Bate, Vibration Diagnostics for Industrial

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