Fans in the cement industry

Topics
1. Brief portrait of Konrad Reitz Ventilatoren GmbH & Co. KG

2. Design of fans
2.1 Volume flow and total pressure difference
2.2 The influence of density and temperature
2.3 Consideration of humidity
2.4 Consideration of installation or operational altitude
2.5 The interaction of fan and plant system
2.6 Lay-out design of fans
3. Fans in practice
3.1 Type overview
3.2 Cordier diagram
3.3 Structural design of impellers and inlet variants
4. Conveyance of solid matter with radial fans in the cement industry
4.1 Wear and sticking material on radial fans
4.2 Problem areas on impeller
4.3 Design features of fans for material transport

Zuverlssigkeitskonzept_Hydro_BLA4_1

Topics
5. Vibrations on fans
5.1 Mechanical vibrations
5.2 Aerodynamic vibrations
5.3 Vibrations caused by variable speed operation
5.4 Reduction of vibrations - measures
6. Modernisation of existing fans in the cement industry
6.1 Factors that necessitate alterations
6.2 Requirements and effects
6.3 Examination of existing fans
6.4 Options to modifications
7. Fans working in the cement industry
7.1 Prehater fan
7.2 Raw mill fan
7.3 Separator fan
7.4 Primary air fan
7.5 Clinker cooler fan
7.6 Filter fan
7.7 Air slide fan

Flow sheet

production of cement

Zuverlssigkeitskonzept_Hydro_BLA4_1

2. Design of fans
2.1 Volume flow and total pressure difference

Ideal gas rule

p = System pressure
V = Volume flow
m = Mass flow
V=m*R*T/p
R = Gas constant
T = Absolute system temperature
= Density of flow medium

Total pressure inlet

Total pressure discharge

p*V=m*R*T

p=m*R*T/V

p1 = p pt1
p2 = p + pt2

2. Design of fans
2.2 Influence of density and temperature

Density
p=m*R*T/V

with
equals

Temperature

T0 = Absolute temperature = 273,15 K

t= Temperature inlet or discharge

=m/V

results in

=p/R*T

T = T0 + t

1 = (p-pt1) / R * T

Density inlet
2 = (p+pt2) / R * T

Density discharge

pt1 = Total pressure inlet of fan

pt2 = Total pressure discharge of fan

Zuverlssigkeitskonzept_Hydro_BLA4_1

2. Design of fans
2.3 Consideration of humidity

relative humidity

= pD / pStr

pD = saturation vapour pressure of dew point

pStr = saturation vapour pressure of dry air temperature

= relative humidity

Rf = Ri / 1-(1-(Ri / RD) * pD / p0)

Gas constant of humid air

Rf = Gas constant humid gas

Ri = Gas constant dry air in standard conditions 287 J kg-1 K-1
RD = Gas constant of water vapour in standard cond. 461 J kg-1 K1
pD = saturation vapour pressure of dew point R = 287 / 1-0,377* * p / p )
f
Str
0
p0 = atmospheric pressure

Reduced formula of Rf
7

2. Design of fans
2.4 Consideration of installation or operational altitude
Atmospheric pressure

Atmospheric pressure p0n in standard conditions 273,15 K (0 C) for

air,
0 m amsl
p0n = 10132,5 daPa
Density of air in standard conditions (dry air) at 273,15 K (0 C),
Ln = 1,293 kg m-3.
Valid for the troposphere h <= 11 km installation height, that is to say
5,256
the temperature falls in accordance to pheight
~15 C to 56 C
h = p0n * [1- (0,0065 * H) / (T0 + t ) ]

Boltzmann barometric equation

ph = atmospheric pressure of installation height [ daPa ]

p0n = atmospheric pressure in standard conditions at 273,15 K and 0

m amsl for air,
H = installation height [ m ]
T0 = absolute temperature [ 273,15 K ]
t = system temperature [ C ]

Zuverlssigkeitskonzept_Hydro_BLA4_1

2. Design of fans
2.5 The interaction of fan and plant system

The interface point of the fan characteristic curve and the plant
characteristic curve is the actual operating point OP
The nominal point NP is the point of optimal range of efficiency.
The plant characteristic curve follows a quadratic equation p = c *
V2
As the fan can operate on any point of its characteristic curve
pt
pt/Pw
depending on the plant resistance, the actual working point in the
plant is called the operating point OP.
ptI
Should the plant resistance be lower than calculated,
ptII
fort example in new plants or when the safety
resistance is calculated too high, there will be
PwII
a stronger volume flow V1II at the operating point OP.

NP
BP/OP

PW

PwI

As a result the mounted motor will be

overloaded to PWII and will be damaged.

V1 I

V1 II

2. Design of fans
2.6 Lay-out design of fans

Anlagenwiderstand /
Pressure variations
of fans
plant resistance

Pressure operation

pt2 = total pressure increase discharge

V0
pst2= static pressure discharge
0
Pdy2=dynamic pressure discharge
pt2 = pst2 + pdy2

pd2
pt2

pd2

p0 ; 0

V0 = V1
0 = 1

pst1

Vacuum operation

pt1 = total pressure increase inlet

pst1= static pressure inlet (-)
Pdy1=dynamic pressure
pt1 = pst1 inlet
+ pdy2 - pdy1

pt = pt 2

pdpst22
pd1

pt1 pt = pt 1
pst1

V1; 1
pst1 ; pd1

p0 ; 0

pd1

pst2
pd2

pt

pst2

p0 ; 0

Mixed operation
pt = pst2 +pst1 + pdy2

- pdy1

pst1
pd1

pst1

pt2 pd2

pt1
pd1

10

Zuverlssigkeitskonzept_Hydro_BLA4_1

3. Fans in practice
3.1 Type overview

Structural design MXE

directly driven by the motor shaft on which the impeller is mounted

Structural design KXE (overhung design)

Power transmission from motor shaft to fan shaft by flexible
coupling, the fan shaft runs in two antifriction bearings

Structural design RGE

Power transmission from motor shaft to fan shaft by V-belt,
the fan shaft runs in two antifriction bearings

11

3. Fans in practice
3.1 Type overview, further designs
Strucural design MSE directly driven by the motor shaft on
which the impeller is mounted, hinged drive unit

Structural design, KBA, KXZ (SISW, DIDW)

Power transmission from motor shaft to fan shaft by flexible coupling,
the fan shaft runs in two antifriction bearings
mounted on concrete foundation

Structural design RBE

Power transmission from motor shaft to fan shaft by V-belt,
the fan shaft runs in two antifriction bearings,
mounted on concrete foundation

12

Zuverlssigkeitskonzept_Hydro_BLA4_1

3. Fans in practice
3.2 Cordier diagramm, characteristic field

Aerodynamic model rules

The aerodynamic characteristic functions (model rules) are to be differentiated
by the type of analysis. It differs in its correspondence to the types: type-related
and not-to-type related analysis. For the type-related analysis the following rule
applies to the complete range of characteristic curve of a fan:

(
i, , i, ,

) = f (
, Re)
The figure shows the non-dimensional characteristic field of a radial fan with
high efficiency in correspondence to the latest relation of a defined Re-numberrange.

Cordierdiagramm

13

3. Fans in practice
3.3 Structural design of impellers and inlet variants

Impeller design

The impeller design provides for an ideal layout of the

impellers in dependence on the impeller geometry. The fields
that influence the impeller design are:
- Fluid technology
- Acoustics
- Manufactering techniques
- Strength of material
- Costs
- and operational needs

14

Zuverlssigkeitskonzept_Hydro_BLA4_1

3. Fans in practice
3.3 Structural design of impellers and inlet variants
Bauart

Beschreibung

DN1

Normlaufrad mit Dse nur fr den Kennzahlbereich AKZ1.0 und

AKZ1.1.
Bei anderen Kennzahlbereichen mu das Rad modifiziert werden.

DN2
DN3

Laufrad in schmaler Ausfhrung und mit vergrertem

Auendurchmesser. Fr dynamisch beanspruchte Rder.
Einsatz fr alle Kennzahlenbereiche mglich.

DZ

Bild / Skizze

Zylindrisches Laufrad
Einsatz nur fr den Kennzahlbereich AKZ1.0.
Einsatzbereich siehe Tabelle

ZD1/ZD2 Laufrder DN1 bis DN3 in ein- bzw. zweiflutiger Ausfhrung mit
ZD3
durchgehender Welle.
Einsatzbereich fr die Ausfhrungskennzahl AKZ1.0 und AKZ1.1.

TR

Transportlaufrder offene Ausfhrung (ohne Deckscheibe).

Einsatz fr direkte Frderung.
Transportrder mssen auftragsbezogen den jeweiligen
Anwendungen entsprechend modifiziert werden wie z.B.:
a) mit oder ohne Transportkonus
b) mit oder ohne modifizierte Einstrmvarianten

Transportkonus

15

3. Fans in practice
3.3 Structural design of impellers and inlet variants, continuation

Inlet variants
The inlet configurations that depend on the operational conditions
result in the different inlet variants

16

Zuverlssigkeitskonzept_Hydro_BLA4_1

3. Fans in practice
3.3 Structural design of impellers and inlet variants, continuation

Type of blades
In general, radial fans are classified by
their
type of blade:
- backward curved blades or
backward inclined straight
blades
- straight blades radial tipped
- foreward curved blades

There is a variety of blade designs in

order to
meet the different operational
requirements in
practice.
The types of blades are subdivided in
series of
blade design.

17

4. Conveyance of solid matter

with radial fans
4.1 Wear and sticking material on radial fans

In the case of fans that handle air with certain dust content, the degree of dust charge or the
mixing ratio is of decisive importance. The degree of dust charge is the ratio of the mass
flow of solid to the mass flow of the handled air. With a mixing ratio of 0.5 we speak of
hydraulic transport, in the case of which the particle floats in the current of air; basically, this
is what should be striven for. In the case of closed impeller, the limit of the handling capacity
is reached with =0.5. For the correct dimensioning of the impeller, knowledge of the dust
that is to be handled is an important precondition, such as the dust type, composition, grain
size distribution and its abrasive, adhesive, sticking or hygroscopic features.
Tendency of the impellers to build up sticking material or to wear, depending on the blade
angle 1 and 2 or type of blades

18

Zuverlssigkeitskonzept_Hydro_BLA4_1

4. Conveyance of solid matter

with radial fans
4.1 Wear and sticking material, continuation

Wear and building-up of sticking material in the case of fans

The tendency towards building-up of sticking material or to wear of the individual blade
form can be shown by means of the different impeller designs, particularly with the
different blade angles 1 and 2.
Tendency of the impellers to build up sticking material or to wear, depending on the blade
angle 1 and 2 or type of blades
backward curved blade

backward inclined straight blade

increasing built-up of sticking

material underside of the blade

20

with optimum angle of inclination

self-cleaning to some extent

40

15 bis 35

60
angle 2
30 bis 90
angle 1

foreward curved blade

increasing wear on the rear side of
the blade

80

100

120

30 bis 90

19

4. Conveyance of solid matter

with radial fans
4.2 Problem areas on impeller
Problem zones on the impeller that tend to build up sticking material
Sticking material occurs on the underside of the blade and to some extent, in the area of the
impeller inlet nozzle. Fig. 2 shows the possibility on the underside of the blade with the zones
inner middle outer; Fig. 3 with sticking material across the entire underside of the blade.
Fig. 4 shows the sticking material in the area of the impeller inlet nozzle .

Fig. 2 Sticking material

in partial zones

Fig.3 Sticking material

on the underside of the
blade

Fig. 4 Sticking material in

the nozzle area

20

Zuverlssigkeitskonzept_Hydro_BLA4_1

10

4. Conveyance of solid matter

with radial fans
4.2 Problem areas on impeller, representations

Sticking
material on the
impeller and in
the nozzle area
Sticking material on the
hub side and on the
underside of the blade

Sticking material on
the underside of the
blade

Sticking material on
the inlet guide vane

21

4. Conveyance of solid matter

with radial fans
4.3 Design features of fans for material transport
Physical factors can be influenced by the shaping of the impeller (impeller configuration and
type of blades). Important design features that can be controlled, the shroud angle and the
blade angle, are depicted in Figures 5 and 6. The angle of repose is depicted in Fig. 7. The
angle of repose S is a measure of the flowing ability of a granular material. This can also
be viewed as the friction angle of the material used. Knowledge of these values is greatly
important for the selection of the impeller, since the angle of repose S should be less than
the blade angle .
Fig. 5 blade angle

Fig. 6 shroud angle

Fig. 7 angle of the

respective material

22

Zuverlssigkeitskonzept_Hydro_BLA4_1

11

4. Conveyance of solid matter

with radial fans
4.3 Design features of fans for material transport,
continuation
Figures 8 to 9 show impeller construction types that depict the inclination to build up sticking
of the dust in the impeller, depending on the shroud angle [ ] and the nozzle radius [ ].

Fig. 8 Broad impeller with

tendency to build up
high D1/D2
strong sticking material

bad

Fig. 9 Impeller with a

D1/D2>0,6<0,7 with small
shroud angle
tendency to build up sticking
material present

Fig. 10 Impeller with a

D1/D2<0,6 and a pronounced
shroud angle, and small nozzle
radius, low tendency to build
up sticking material

good

better

23

4. Conveynance of solid matter

with radial fans
4.3 Design features of fans for material transport

An optimal anti-sticking design is illustrated in Figures 11 and 12. Often, however, the local
installation dimensions are not conducive for such a design. In addition, the rotational
speeds sometimes have to be reduced to such an extent that the prices become
unacceptable. Therefore, it is advisable to discuss all the advantages and disadvantages in
advance .
Caution ! If the impeller tends to build up sticking material, the use of inlet guide vanes is
not recommended. The impeller then has an even higher inclination to build up sticking
material on the undersides of the blades and at the impeller inlet. Particular attention must
be paid to the respective operating points on the fan characteristic curve and the damper
valve position. Intense damping must be avoided without fail.
Fig.11 Optimum impeller
configuration matched to the behavior of the dust type

Fig. 12 Optimum blade angle

matched to the angle of respons S
of the dust type

24

Zuverlssigkeitskonzept_Hydro_BLA4_1

12

5. Vibrations on fans
5.1 Mechanical vibrations
Fans are besides pumps the turbo-machines that are mainly employed in industry. They
have a broad operative range and are often applied for ventilation purposes in a complex
process. Characteristic features of fans are a high variety of structural designs and a broad
diversity of size. They are basically defined by the volume flow that is to be generated and
the total pressure increase.
When working with fans we are repeatedly confronted with the problem of vibration. The
vibrations are, however, often difficult to classify due to the variant diversity and the different
structural designs as well as the various appliances. Nonetheless, an exact analysis of the
vibrations is the decisive factor for their elimination. We distinguish two types of vibrations,
these are
mechanical vibrations
aerodynamic vibrations.

25

5. Vibrations on fans
5.1 Mechanical vibrations, continuation
Mechanical vibrations are most frequently caused by out-of-balances at the rotating parts.
Unbalances result from uneven wear and / or sticking material at the impeller blades.
Alignment errors of shafting produce mechanical vibrations as well; they are visible in the
frequency spectrum as 2. and 3. harmonic of the speed. Other mechanical vibrations, that
often occur, originate from alignment results and resonance effects of fan parts in dependence
of their arrangement and installation. Furthermore, damages to the antifriction bearings also
excite mechanical vibrations in the form of shock pulses.
Representation of design parameter that influence vibration
no.

event

out-of-balance forces

unbalance impeller
unbalance keyway, coupling
belt flutter

impeller rigidity

natural resonance

running and positional tolerance

of the impeller

in axial (wobble)
impacts) direction

alignment errors

motor, coupling, bearing housing, belt

pulley

rigidities

bearing rigidity
rigidity of the sub-structure (base frame,
elastic mounting, etc.)

fit tolerance

deflexion of the shaft

8
9

constitutional resonances
torsional vibration, pulsatory torques

fit clearance bearing

fit clearance hub / shaft (eccentricity)
f1, f2, f3 =
deflexion of the shaft
observe the gyroscopic effect and the
critical lateral speed
housing, pedestal and impeller
excited by electrical errors of the drive
motor or in the mains and the transmitting
devices

effecting part

and

radial

(vertical

26

Zuverlssigkeitskonzept_Hydro_BLA4_1

13

5. Vibrations on fans
5.1 Mechanical vibrations, continuation
Mechanical vibrations, whatever, can be easily measured, located and analysed.
Example for mechanical vibrations
Unbalance

Alignment errors at coupling

speed 17,8 Hz
1. Harmonic

Speed 49,8 Hz
Spektren

Spektrum

1. Harmonic 177932 3H 1K [1]

KXE063-063030

28.04.2003 16:45:39

49,883 Hz

2. Harmonic
99,6 Hz

35,6 Hz
2. Harmonic

3. Harmonic
149,4 Hz, higher than
1. Harmonic

177932 3H 1K [1]

27

5. Vibrations on fans
5.1 Mechanical vibrations, continuation
Example for mechanical vibrations
Mechanically detached connections (e.g. shaft-hub)
e.g. inner ring
5. Harmonic and the
following

anti-friction bearing damage,

Damage frequency anti
friction bearing inner ring
fi=181 Hz
Modulation with speed
fn=16,25 Hz
2. Harmonic of the
inner ring frequency
2*fi=362 Hz

28

Zuverlssigkeitskonzept_Hydro_BLA4_1

14

5. Vibrations on fans
5.2 Aerodynamic vibrations
Aerodynamic vibrations manifest themselves in air vibrations with pressure or flow deviations,
they produce excessive noise and they may come up to strongly distinctive pumping, which could
even influence the volume flow to change its direction in the fan or in parts of the system. The
origins of aerodynamic vibrations can be very manifold. In many cases, the fan is not solely
responsible for the vibrations but they result from the interaction of plant system or of its
component parts to the fan.
We have to examine the complete plant system and not only the fan exclusively to find out how to
eliminate the undesired vibrations. We need therefore profound knowledge about the physical
processes that prevail in the system and the interactions and reciprocities of all system
components. The design engineering of the plant system has to include all necessary steps to
avoid in the first place potential problems in the field of aerodynamic, acoustics, physical
properties and vibration technique as well as monitoring of the system.
The following pages show typical vibration problems that have been found in praxis and
systematically explain their different symptoms and their origins and give examples.

29

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
fig. 1.1 Outline of a ventilation system, the numbers refer to vibration phenomenon acc. to table 1.2

Table 1.2
1
vortex caused by stall at system components
2
stationary waves in the duct work (air column vibrations)
3
vortex caused by stall due to lacking chutes
4
vortex caused by stall at the silencer baffles (inlet and outlet of silencer)
5 + 6 vortex caused by stall at vent stack that is not optimally designed with
resulting air column vibration, stationary waves
7
vortex caused by stall at the vanes of the nearly closed damper
8
air column vibrations caused by flow whirls /vortex in the dead area of the
suction boxes (areas where no flow is present) when the inlet flow is disturbed
9
vortex/whirl caused by stall at the guiding blades of the inlet guide vane
when the flow is too strongly reduced
10
rotating stall at fan impeller
11
main residual frequency
12
swirled stall caused by misarranged components; possible to occur
in all system areas
13
vibrations due to pumping

Zuverlssigkeitskonzept_Hydro_BLA4_1

AK
AKM
AKO
DF
DJ
DR
KP
LB
SD

suction box
vent stack
system component
diffusor (duct piece)
damper
inlet guide vane
flexible connection
chute
silencer

30

15

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation

31

5. Vibrations on fans
Stalls

5.2 Aerodynamic vibrations, continuation

Technical flows often vary from the ideal of controlled flow because they feature the so-called
stalls
For example, the flow does no longer stream closely to the components (the flow burbles),
when it flows in the area of sharply bended surfaces or edged protruding or recessing parts
(fig. 3.1 3.2). Also, stalls can occur in duct or parts of it, in which the flow streams, if the flow
direction is changed considerably (e.g. in duct bend) or where strong constant or suddenly
occurring cross section alterations or obstacles (thinks built-in) exist (fig. 3.3).
Stalls result from the fact that so-called dead areas are formed between the wall that is no
longer in the flow due to stalls and the definitely directed duct flow. These dead areas are filled
with eddy water. Energy has to be provided for keeping up the vortex, which has to be taken
away from the flow energy of the handled gas. This leads on the one hand to a loss of effective
energy in the form of pressure loss. On the other hand, vibrations of the flow speed and the
pressure in the flow field arise since the flow in the eddy water is always more or less
unsteady. These local vibrations could also excite vibrations in the complete system (as well
as in the fan).

32

Zuverlssigkeitskonzept_Hydro_BLA4_1

16

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Examples for aerodynamic vibrations

Fig. 3.1 stall behind a protruding part

Fig. 3. 2 stall at objects in the flow stream;

Krmnsche Wirbelstrasse

Fig. 3. 3 stall at an aerofoiled wing that is set too steep

33

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Examples for aerodynamic vibrations
Ablsungen

Fig. 3.4 stalls in duct work, duct bend

Fig. 3.5 stall when the duct is considerable widend,

Fig. 3.6 stall at obstacles

bad diffusor

34

Zuverlssigkeitskonzept_Hydro_BLA4_1

17

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Inlet guide vanes
Upstream installation of inlet guide vanes to the fan can lead to low-frequent and more often
than not comparatively broadband air vibrations, especially when the inlet guide vane strongly
reduces the volume flow. The frequencies observed have nothing in common with the rotary
frequency of the fan. Frequently, the installation performance curve also deviates from the
characteristic curve of the test bench. The reason for this is a considerably disturbed inlet flow
to the fan impeller..
Stall at the guiding blades of the inlet guide vane. Under specific conditions, excessive
reduction of flow by an inlet guide vane will result in a critical stall at its guiding blades, which
impede a defined vortex (fig. 3.8). The mentioned specific conditions are: unfavourable inlet
flow conditions and a small range of angle setting, when the guiding vanes are strongly to
almost closed. We can avoid the stall at the inlet guide vane by optimally designing the inlet
flow and avoiding the special critical angle setting. Preconditions for this are the ideal specific
fan size definition and a secured realisation of the calculated operating point. In addition, we
have to choose a control range in the top 2/3 of the inlet guide vane position. If 0
corresponds to a closed damper and 90 to an open one, setting of the vanes at angles of
more than 60should be avoided at all events.

35

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation

Fig. 3. 7 fan with inlet guide vane

characteristic curve

Fig. 3. 8 inlet guide vane, unfavourable flow

with vortex

36

Zuverlssigkeitskonzept_Hydro_BLA4_1

18

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Dampers
It is common practice to mount dampers on top of the suction box for double inlet as well as
single inlet application with a separate upstream suction box, fig. 3.9.
The valves of the damper can be adjusted in parallel or in opposite direction depending on the
customers specification and the required load conditions.
Stellklappen

SKA

Ansaugkasten

V/2

V/2

Ventilator

KP1
DJ1

Drallerzeugung
durch Mitdrall

Bild 3. 9 production of whirl by spin forward

arrangement of a damper at a suction box
with valves adjusted in parallel line

AK

Bild 3. 10 asymmetric inlet flow from distribution

duct

37

5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Vent stack
An unfavourable design of the branch point leads to stalls with swirls when the flow enters the
vent stack (fig. 3.11). A smooth design of the branching, possibly with chutes (fig. 3.12) will
guarantee a constant flow that is low in vibration.

WH

LB

WB
LB

AKM

AKM

LB

Fig 3.11 flow stall on vent stack entering,

WH = vortex height, WB = vortex width

Fig. 3.12 favourable design of duct at branch point

of vent stack: on the left an angle of 30to 60
With chutes (LB) to prevent stall vortex
on the right alternative design

38

Zuverlssigkeitskonzept_Hydro_BLA4_1

19

5. Vibrations on fans
5.3 Vibrations caused by variable speed operation
The operation of fans by drive motors with variable speed operation may result in additional vibration excitations
by the variable speed control. There are primarily upper harmonic waves that occur from the rotating field (e.g.
1., 5., 7., 11. and 13. harmonic for a 6-pulse converter connection), the rotor current generate the so-called rotor
remanence field. The difference of the stator current harmonic and the feed current harmonic results in an
alternating torque which is zero-point transient in timely regard. This alternating torque is also called oscillating
torque which has a synchronous moment impact on the stator lamination steel. The resulting forces are
transmitted to the motor housing and the foundation (pedestal). The height of the oscillating torques amplitudes
depends on varying types of the variable speed control (current (I-) or tension (U-) controlled). Hence, the
excitability of systems varies in dependence of the variable speed drive employed. It is most likely that the
critical torsional speed of the shafting is excited (the shafting consists of impeller, coupling and motor stator). In
addition, the variable speed control operation can excite natural frequencies of fan parts like housing or impeller
and even the natural frequency of anti-vibration mounts could be animated in case the fan is mounted on
vibration damping elements.

Primary air fan with variable speed drive

39

5. Vibrations on fans
5.4 Reduction of vibrations - measures
Mechanical vibrations
In principle, regular and expert servicing and maintenance considerably contribute to a high operational
quality and reliability of fans. Even the first stage of system planning can considerably influence the
thorough and exact design of the necessary equipment. Fans have to be laid out and designed meeting the
individual requirements and specifications in order to achieve the maximum operational reliability in
practice. This is particularly important for fans that have to transport abrasive or sticking material within the
handled gas. The fan manufacturer has hence necessarily to be informed about all relevant parameter to
choose the correct fan. The most important parameter besides volume flow and pressure are temperature,
handled gas, humidity, inlet flow conditions and the use of dampers, if foreseen.
List of measures

event

measure

out-of balances caused by sticking material or

wear

choose appropriate impeller type and material

in the planning stage
servicing of fans in operation at regular
intervals, remove sticking material, timely
repair of damaged parts
take measures for reduction of stickings
and/or wear; e.g. fan after separator

vibrations due to alignment errors

check of coupling alignment, align if

necessary, timely replace worn coupling parts

vibrations due to damage of shafting

replace damaged parts

40

Zuverlssigkeitskonzept_Hydro_BLA4_1

20

5. Vibrations on fans
5.4 Reduction of vibrations - measures , continuation
Aerodynamic vibrations
The reasons for aerodynamic vibrations in systems can be manifold. It is recommended to pay particular
attention to the design of the duct work conduit and the systems process when planning a new system or
remodelling an existing one. A basic principle is: the better the system components are designed in
consideration of the flow guidance, the smaller is the probability of exciting aerodynamic vibrations.

List of measures

event

measure

aerodynamic vibrations

cause analysis, change the duct work, if

necessary, by built-ins like chutes etc., avoid
discontinuous duct parts
consider the effects of changes of individual
system parts on other, depending parts and
the fans concerned (change in the
charateristic curves, operational point of fan
e.g. to the left of the ideal design point)
additional dampers in the duct work, if
possible, to change the system characteristic
curve and adapt the curve of the damper

41

5. Vibrations on fans
5.4 Reduction of vibrations - measures , continuation
Vibrations caused by variable speed control
Again, all relevant operational parameter have to be made known to the fan manufacturer to the avoid
vibrations that are caused by the variable speed control operation. The said parameter are speed range
and possible speed changes per time unit, type of variable speed control (current (I-) or tension (U-)
controlled) and the installation condition of the fan.

List of measures event

vibrations caused by variable speed control

measure
tune the unit consisting of fan, motor and
variable speed control to a resonance-free
operation
choose suitable machine parts like coupling,
shaft and impeller type
choose proper way of vibration-absorbing fan
installation: foundation, suitable arrangement
of anti-vibration mount

42

Zuverlssigkeitskonzept_Hydro_BLA4_1

21

6. Modernisation of existing fans

in the cement industry
6.1 Factors that necessitate alterations
The motivation to modernise fans in existing systems can have
numerous reasons.
In the first place, these can be demands of economic nature.
On the other hand, the operating companies of plant systems
more and more focus on environmental compatibility and
ecology. The most important factors for the modernisation of
system parts and fans are the reliability of a system and its
availability, which greatly influence its profitability.

At first, the requirements have to be defined that are necessary to achieve a

certain objective.
The following parameter can influence the decision on modernisation of fans.
1. change of operational parameter, e.g. by improving the production processes
2. installation of additional filter,
3. installation of big heat exchanger or rotary kilns
4. increase of capacity of the raw mill or separator,
5. extension and modernisation of the clinker cooler,
6. expansion of storage capacities for finished products
7. change in the system plants lay-out
8. exchange of used-up fans or parts of them

43

6. Modernisation of existing fans

in the cement industry
6.2 Requirements and effects
6.2 Requirements and effects
When the list of parameter is drawn
up, we have to consider how to
achieve the required aims. Based on
the parameter list, the requirements
and the actions to achieve them are
listed below.

ref no.
1.
2.
3.

4.

demand
action / requirement to be achieved by
adaptation of volume flow and exchange of impeller, observe motor capacity
pressure increase
exchange of fan
adaptation of pressure increase

exchange of impeller, observe motor capacity,

exchange of fan,

adaptation of flow volume and

pressure increase, alteration of
working temperature

exchange of impeller, observe motor capacity

exchange of fan,
other measures

adaptation of flow volume and

pressure increase, modified
residual dust content in the
handled gas

exchange of impeller, observe motor capacity,

echange of fan

5.

adaptation of flow volume and exchange of impeller

pressure increase, perhaps change exchange of fan
of working temperature

6.

additional duct work, adaptation of

pressure increase

7.

adaptation
parameter

8.

of

all

additional fans

operating exchange of impeller, observe motor capacity

exchange of fan

worn or used-up fan components exchange the defective parts, check remaining
like impeller, shaft, bearings, components for suitability and use technical
coupling etc.
innovations if possible, include all fan components
in the tests if fan parts have been exchanged

44

Zuverlssigkeitskonzept_Hydro_BLA4_1

22

6. Modernisation of existing fans

in the cement industry
6.3 Examination of existing fans
6.3 Examination of existing fans
We have to determine all practicable improvements and
modifications for the existing fan when the new
operational parameters for the fan operation are defined.
Proceed as follows:
Ascertain the current performance data like
1.1
volume flow
1.2
pressure increase,
1.3
working temperature,
1.4
max. working temperature,
1.5
speed,
1.6
max. speed
from the technical documentation or nameplate. If necessary,
carry out measurements to determine the data.
RADIAL VENTILATOR / Radial fan
Typ
Type
Fabr. - Nr. / Baujahr
Serial No. / year of construction
Kom. - Nr.
com. No.
Ventilatordaten bei einer Dichte von /
Fan dates at a density of

1 = 1,2 kg/m

Eintrittstemperatur
Inlet temperature

Volumenstrom
Volume flow

V1

m/min

Totaldruckerhhung
Total pressure increase

pt2

daPa

Totaldruckerhhung
Total pressure increase

pt1

daPa

Wellenleistung
Shaft rating

PW

kW

Drehzahl
Speed

1/min

Betriebstemperatur
Operating temperature

Measuring in the dust system

45

Nameplate of fan

6. Modernisation of existing fans

in the cement industry
6.3 Examination of existing fans, continuation
Ascertain the maximum loads that have to be observed for the mechanical design
of the fan; e.g. for the
- impeller material as to strength, temperature resistance etc.
- bearing sizes and design, e.g. limiting speed, grease or oil lubrication, etc.
- critical lateral and critical torsional speeds,
- load on coupling or belt drive,
- housing dimensions,
- design of inlet and discharge,
- FEM analysis of the impeller,
- natural frequency of the impeller,
- natural frequency of the type of mounting,
e.g. rigid or flexible mounting
Ventilation performance test
- structural details of housing,
pedestal and base frame.

fan data sheet

46

Zuverlssigkeitskonzept_Hydro_BLA4_1

23

6. Modernisation of existing fans

in the cement industry
6.4 Options of modifications
6.4 Options of modifications
1. replace the exisiting impeller by a new one that offers suitable blade
form, impeller design and inlet nozzle
2. provide anti-wear layer at impeller and housing
3. increase of speed by using variable speed operation or,
in case of V-belt drive, by modification of the transmission ratio
as long as the machine-dynamic limiting values are not exceeded,
4. replace fan components like bearings, shaft,
coupling and V-belt drive or
5. replace complete fan
In case the existing fan is modernised, compare the new technical data
with the maximum allowable data.

Wear protection repair on the

impeller

Wear protection on the inlet

box and inlet nozzle

47

7. Fans working in the

cement industry
7.1 Preheater fan

Double inlet fan with silencer, resiliently

mounted
KZB125-1120010-00

48

Zuverlssigkeitskonzept_Hydro_BLA4_1

24

7. Fans working in the

cement industry
7.2 Raw mill fan

Arrangement of fan for raw mill

Wear protected impeller

KAE125-500010-00
3

-1

V1 = 5000 m min pt2 = 1250 daPa

KAE125-500010-00

49

7. Fans working in the

cement industry
7.3 Separator fans

Separator fan with damper and suction

box
KXA080-224010-00
V1 = 2240 m3 min-1 pt2 = 800 daPa

Zuverlssigkeitskonzept_Hydro_BLA4_1

Impeller SFV 6.1.4 wear protected

50

25

7. Fans working in the

cement industry
7.4 Primary air fan

Primary air fan KXE355-080030-00

V1 = 800 m3 min-1, pt2 = 3550 daPa
Primary air fan KXE315-016030-00

51

V1 = 160 m3 min-1, pt2 = 3150 daPa

7. Fans working in the

cement industry
7.5 Clinker cooler fans

Arrangement of fan with suction

box, silencer and inlet guide vane

Fan with suction box and inlet guide

vane
KXE050-056030-00
V1 = 560 m3 min-1, pt2 = 500 daPa

52

Zuverlssigkeitskonzept_Hydro_BLA4_1

26

7. Fans working in the

cement industry
7.6 Filter fans

High efficency double inlet impeller

Filter fan KZB100-1600010-00
V1 = 16000 m3 min-1 pt2 = 1000 daPa

53

7. Fans working in the

cement industry
7.7 Air slide fan

Fan with inlet air filter

MXE080-002830-00
V1 = 28 m3 min-1, pt2 = 800 daPa

54

Zuverlssigkeitskonzept_Hydro_BLA4_1

27

End of
presentation
Thank you for your kind attention

55

Zuverlssigkeitskonzept_Hydro_BLA4_1

28