\ndustria\ Fan

Draft System

The function of draft in a combustion system is to exhaust the products of

combustion into the atmosphere. The draft can be classified into two types
namely Natural and Mechanical Draft.

Natural Draft
It is the draft produced by a chimney alone. It is caused by the difference in
weight between the column of hot gas inside the chimney and column of
outside air of the same height and cross section. Being much lighter than
outside air, chimney flue gas tends to rise, and the heavier outside air flows in
through the ash pit to take its place. It is usually controlled by hand-operated
dampers in the chimney and breeching connecting the boiler to the chimney.
Here no fans or blowers are used. The products of combustion are discharged
at such a height that it will not be a nuisance to the surrounding community.
Mechanical Draft
It is draft artificially produced by fans. Three basic types of drafts that are applied are :

Balanced Draft: Forced-draft (F-D) fan (blower) pushes air into the furnace and an
induced draft (1-D) fan draws gases into the chimney thereby providing draft to remove
the gases from the boiler. Here the pressure is maintained between 0.05 to 0.10 in. of
water gauge below atmospheric pressure in the case of boilers and slightly positive for
reheating and heat treatment furnaces.

Induced Draft: An induced-draft fan draws enough draft for flow into the furnace,
causing the products of combustion to discharge to atmosphere. Here the furnace is
kept at a slight negative pressure below the atmospheric pressure so that combustion air
flows through the system.

Forced Draft: The Forced draft system uses a fan to deliver the air to the furnace,
forcing combustion products to flow through the unit and up the stack.
ID FD Fan - Scheme of Boiler

r+--�Feedwater
Heat

Exchanger �Flue Gas

�---,,F� Induced
Draft
Furnace Fan

Forced
�-------w
- Combustion Air /(J)\ Draft
Fan

FIGURE 1 Typical Single Burner Boiler

Induced Draft
Advantages
•Better distribution of air across the bundle.
-Less possibility of hot effluent air recirculating into the intake. The hot air is
discharged upward at approximately 2.5 times the intake velocity, or about 1,500 feet
per minute.
•Better process control and stability because the plenum covers 60% of the bundle face
area, reducing the effects of sun, rain, and hall.
•Increased capacity in the fan-off or fan failure condition, since the natural draft stack
effect is much greater.
Disadvantages and limitations
•Possibly higher horsepower requirements if the effiuent air is very hot.
•Effluent air temperature should be limited to 220°F to prevent damage to fan blades,
bearings, or other mechanical equipment in the hot air stream. When the process inlet
temperature exceeds 350°F, forced draft design should be considered because high
effluent air temperatures may occur during fan-off or low air flow operation.
-Fans are less accessible for maintenance, and maintenance may have to be done in the
hot air generated by natural convection.
•Plenums must be removed to replace bundles.
Induced Draft & Forced Draft

Forced
draft
•
Induced 1. Fan 4. Nozzle 7. Drive assembly

draft 2. Fan ring 5. Header 8. Column support

3. Plenum 6. Tube bundle 9. Inlet bell
Forced Draft
Advantages
•Possibly lower horsepower requirements if the effluent air is very hot. (Horsepower
varies inversely with the absolute temperature.)
•Better accessibility of fans and upper bearings for maintenance.
• Better accessibility of bundles for replacement.
•Accommodates higher process inlet temperatures.
Disadvantages
-Less uniform distribution of air over the bundle.
•Increased possibility of hot air recirculation, resulting from low discharge velocity
from the bundles, high intake velocity to the fan ring, and no stack.
•Low natural draft capability on fan failure.
•Complete exposure of the finned tubes to sun, rain, and hail, which results in poor
process control and stability.
In most cases the advantages of induced draft design outweigh the disadvantages.
Fan is a machine used to add energy to the gaseous fluid to increase its
pressure. Fans are used where low pressures (from a few mm of water to
(50 mm Hg) and comparatively large volume are required. They run at
relatively low speed, the casing and impeller usually built of sheet iron.

FAN TYPES

1) AXIAL FLOW FANS - the flow of the gases is parallel to the fan shaft.
a. tube axial
b. vane axial
c. Propeller

2) RADIAL OR CENTRIFUGAL FLOW FANS- the flow of gases depends

upon the centrifugal action of the impeller or rotor.
a. Straight blades
b. Forward curved blades
c. Backward curved blades
d. Double curved blades
I Propeller Fan I I Tubeaxial Fan I I Vaneaxial Fan I

I
.. I

.
I Centrifugal Fan I
Air in

Air out

Rotor

Motor
 Air
Out

Figure 5.1 Centrifugal Fan

Construction

Rotatable Fans

'-@"'--@
"@ 1. Inlet Support
2. Inlet Sleeve
Non-Rotatable Fans 3. Inlet Cone/Cylinder
4. Wheel (BISW shown)
'---@ 5. Shaft
6. Housing
7. Housing/Bearing
Pedestal Assembly
8. Drive Side Support
9. Bearings
Figure 5.2 Axial Fan
 Construction
Belt Drive
ADB, EOB, TI8 (EDS Shown)
Adjustable Motor Plate

Inlet Mounting
Flange

Ex1ended lube Lines

Beh Tunnel LOfenized • Powder Coating

Air-Handhng Qualrty
Outlet Mounting Flange
Ball or Roller Bearings --

Extruded Aluminum
Airfoil Propeller
(EDB)

Keyed Hub and Shaft

 Construction
AFB-C AFBV-C
Inlet side Outlet side

_. .- Adjustable motor plate ---.

Fixed pitch 6 blade,

Belt
tunne airfoil prop

Pre-punched mount flanges

Inner enclosure lor bearings,

sheave and shaft
vane section
Centrifugal Fan: Types
The major types of centrifugal fan are: radial, fo11vard curved and backivard curved (see
Figure 5.3).
Radialfans are industrial workhorses because of their high static pressures (upto 1400
mm WC) and ability to handle heavily conaminated airsireams. Because of their simple
design, radial fans are well suited for high tenperamres and 111ediu111 blade tip speeds.
r'or1vard-c11rved fans arc used in clean environments and operate at lower
temperamres, They are well suited for low tip speed and high-airflow work · they are best
suited for moving large volumes of air against relatively !01v pressures.
Backivard-inclined fans are more efficient than forward-curved fans. Backward-
inclined fans reach their peak power consumption and then power demand drops off well
within their useable airflow range. Backward-inclined fans are known as "non- overloading"
because changes in static pressure do not overload the motor.
Paddle Blade (Radial blade) Forward Curved (Multi-Vane)
Fi ture S.J T,• cs of Ccnlrifu ral Fans
Axial Flo11• Fan: Types

The major types of axial Oo1v fans are: tube axial, vane axial and propeller (see Figure
5. 4.)

Tubeaxial fans have a 1vheel inside a cylindrical housing, 1vith close clearance be!lveen
blade and housing to i1nprove airllew efficiency. The 1vheel tum faster than propeller
fans, enabling operation under high-pressures 250 - 400 mm WC. The efficiency is up to
65o/o.
Vaneaxial fans are similar to tubeaxials, but 1vith addition of guide vanes that i1nprove
efficiency by directing and straightening the Oo1v. As a result, they have a higher static
pressure 1vith less dependence on the duct static pressure. Such fans are used generally for
pressures upto 500 mmWC. Vaneaxials are typically the most energy-efficient fans
available and should be used 1vhenever possible.
Propeller fans usually run at lcw speeds and 1noderate te1nperatures. They experience a
large change in aaflcw 1vith small changes in static pressure. They handle large volumes
of air at lo1v pressure or free delivery. Propeller fans are often used indoors as exhaust
fans. Outdoor applications include air-cooled coudensers and cooling to1vers. Efficiency is
bw- approximately 50% or less.
Tube Axial Vane Axial Propeller

PROPEU.ER FAN
B.itOriYol ot
• 0,111tc;t Co1wi.cbon
I I I,
'
TlJBEAXW. FAN
"'"'
vanes

VANEAXIAL FAN

Figure 5.4 Types of Radial Fans

Tahir !'i •.1 T,·pr,i or Fan$, Charactrrl'llk11-. and Typical Applkallon•

Cenh·irugul Fu11s A:\.lul-Oon• Funs

Typical Typical
,·ypc Characteristics ·rype Characlerisl res
Applications Applicarions

Radial lligh pressure. Vartous Propeller Low pressure. high Air-circulation.

medium flow. industrinl flow. low efficiency. ventilation.
efficiency close 10 applications. pcnk cOlckncy close cxhaus1
tube-axial fon1>. suitable for 10 pomt of free air
power increases dust laden, delivery (zero srn1ic
conlinuously 1noi;,1 pressure)
air/ga.."'-"s

Forv.•ard· Mcdiu1n pre:<.'lurc. Low pressure Tube-axial J\'1ediun1 prcs!>urc. l·IVAC. drying
curved high !low, dip in HVAC. high flow. higher ovens. cxhi1us1
blades pressure curve. packagOO cllidcncy than systems
efficiency higher units, suitable propeller type. dip in
than rudinl fans. for clean and pressure-flow curve
power rises dust laden air I before peak pressure
continuously gases pomt.

Back"•ard High pressure. high HVAC. Vanc-a.xml High pressure. H 1gh pressure
curved flow, high various nuxlium !low. dip in applications
blades eOlciency. power indul>lrial pressure-flow curve. including
reduces as flow applications. use of guide vanes HVAC
increases beyond forced drafl improves efficiency systems,
point of highcs1 fans. etc. exhausts
efficiency

Airfoil Saine as backward Suruc as

lypc curved type. highest backward
efficiency cur,•cd, but for
clean a,r
applica1ions
 COMMON USES OF FANS
1. Ventilation and air conditioning
2. Forced and induced draft service for boilers
3. Dust ccllection
4. Drying and ccoling of materials
5. Cooling towers
6. Mine and tunnel ventilation
7. Pneumatic conveying and other industrial process work

Head Calculations
2
1 discharge
suction

For a fan & = 0 ; i'>PE = 0 and Q = 0, because fans are designed to

overcome fluid friction. No ccoling system is needed due to small temperature
differential between suction and discharge.
Boiler ID fan selection
There are many factors that need to be taken into account when
looking at the fan requirements
Noise-what is the allowable noise limit?
Application-does the gas stream contain solids or particulates? Is the
gas stream explosive? Is the fan in a hazardous zone?
Corrosion-is the gas stream corrosive? If so, a selection of materials
and/or coatings should be designed to resist corrosion.
Control-what type of control does the fan require? Devices such as
variable inlet vanes, dampers and variable frequency drives should
be considered.
Gas density-this needs to take into account the altitude,
temperature, humidity, and negative barometric pressure and gas
combinations.
Duty location-what part of the fan curve is the system to operate in?
Entry/exit conditions-will the entry/exit conditions allow the fan
to operate at its design point? If excessive turbulence is
present, then the impeller may not properly impart energy on
the airstream.
Accessories-consider application and cost or accessories such as
vibration or temperature monitoring, flow control or acoustic
treatment.
Foundations-where is the fan to be located? If above ground on
a structure, then consider what level of isolation is required.
Maintenance-consider fan location; provide safe and adequate
working space and access for lifting equipment.
INSTALLATION

Position the fan in such a way to assure minimum space for the maintenance and
repair work.
"D�
OK

Foundations

The foundation should, by preference, be made in reinforced concrete and its

minimum weight must to be four times the weight of the rotating mass (around
double the total static weight).
POSITIONING
Take the anti-vibrations supports (if included with the supply) from the plastic bag

� ���������������������-
attached to the fan. Lift up the fan, remove the wood feets and install the anti
vibrations support .
Coupling Installation
Remove all foreign material from the fan and motor shafts and coat with machine oil for
easy mounting of the coupling halves
Mount the coupling halves on each shaft, setting the gap between the faces as specified
Lightly polish the shafts with crocus cloth if necessary in order to avoid using excessive
force.
Align the coupling to within the manufacturer's limits for parallel and angular
misalignment
COUPLING ALIGNVENT

� 11r

PAAlllil. GAP
UISAL.ICNU[NT
Flexible Coupling Installation and Alignment

These instructions cover, in general, the installation of flexible couplings of the pin, gear,
or grid types.

1. Before mounting coupling(s), be sure all bearing(s), inlet vane(s), etc., have been
installed.
2. Install each coupling half cover with an "O" ring on its shaft.
3. Determine which direction, long or short shank of coupling hub should be located; see
manufacturer's manual.
4. Heat coupling hub to approximately 3000F by means of hot oil bath or oven. Do not
apply flame to hub teeth.
5. Install coupling hub(s) on shaft. Hub and shaft face should be flush.
6. Key the couplings to the shafts while the hub(s) are still hot.
7. Adjust the clearance between the coupling faces.
8. When a sleeve bearing motor is used, locate it so that when the motor rotor is closest
to the fan, the motor shaft v.ill not touch the fan shaft. It the motor shaft has its magnetic
center marked, align it in this position; otherwise equally divide the maximum play to
obtain the mechanical center
9. With tapered wedge, feeler gauges, or dial indicator, observe that the faces of the fan
and driver couplings are parallel.
10. Align the shafts until a straightedge appears to be parallel to the shafts. Repeat at
three additional points at 900 from each other. Recheck angular alignment and hub
separation.
Damper Installation

When installing dampers in the field, refer to the assembly drawinq to assure that
damper linkage is in the proper position and the blades rotate from closed to open
position in the correct rotation. Desired fan performance may not be obtained if proper
damper blade rotation shown on drawing is not observed.
Double width fans using two dampers operate with a single control arm and a shaft
connecting the two dampers. Blades in both dampers must fully open and close
together. The connecting shaft often is in two pieces and although a setscrew is provided
in the coupling as an aid for assembly, this section should be field welded to the shaft
after the damper blades are synchronized. Fans operating at higher temperatures have
shaft-coupling arrangement to provide for expansion; do not weld both ends to the shaft.
Checking Belt Tension
Check the belt tension with a tensioning gage and adjust
using the motor slide base.

For initial tensioning, the proper belt deflection half way

between the sheave centers is 1/64 inch (0.4mm) for each
inch of belt span.

For example, if the belt span is 64 inches (1625 mm), the

belt deflection should be I inch (25.4 mm) using moderate
thumb pressure at the mid-point of the belt span.

Note,
Deflection : Bet"t Spo.n
64

DeFlectlon

f----Bet"t Spon---,
Bearing

'Standard grease lubricated fan bearings should be maintained with high quality lithium
based grease conforming to NLGI grade 2 consistency .
.f Avoid mixing greases with different bases, as they may be incompatible and result in
rapid deterioration of the lubricant and premature bearing failure.

Prepare Bearings, Set Rotor Assembly:

1. For Sleeve Bearings:
Remove bearing caps and clean bearings with solvent; Coat with clean oil and cover to
avoid contamination. Clean oil rings and shaft seals. Do not mix parts between the
bearings, as they are not interchangeable. Bolt the lower half of the bearing loosely in
place. Again cover to prevent contamination. Sling the rotor assembly as previously
described. To prevent damage to the liner in the fixed bearing (having the thrust collars)
when puffing large rotor assemblies in place follow this procedure: The rotor assembly is
to be positioned above the bearing journals and the liner for the fixed bearing is then
fastened to the shaft and lowered into the bearing housing with the rotor assembly.
2. For Anti-friction Bearings-Solid Pillow Blocks:
Non-split pillow blocks are slipped over the shaft ends prior to putting the rotor in place,
Check to insure that the floating bearing (unless specified on the assembly drawing) is
on the side opposite the driver. See figure . Bolt bearings loosely on pedestals.

DfllVl!lt

."."."."....
-
- -·------- � - - - -
=
----- 3 I

"'"""° (i ")

AGURE 12

3.For Anti-friction (roller) Bearings-Adapter mount, Split Pillow Block: - Cleaning

of internal parts should not be required as the corrosion preventative compound
applied by the manufacturer is compatible with recommended lubricants. Careful
inspection of all internal parts is good practice, as any corrosion present is likely to
cause problems at a later date. Do not mix parts between bearings as they may
not be Interchangeable
 I
STARTING / /
Before starting up it is important to carry out
various checks :
"check that the bearings of the fan and motor
are correctly lubricated. �
® ,.--

'Make sure the drive flexible connection is

adequately lubricated.
'Make sure that all the bolts are fully tightened,
with a torque force indicated in the table below

TORQUE FORCE "SECO;IDO UNr

.
Bolt
4.8 I �.8
'.\Iarerial Class
s.s I 10.9
Tor, ue force (Nm)
12.9
 20 216 270 431 607 728
24 365 457 731 1030 1230
27 534 667 1070 1500 1800
30 738 923 1480 2080 2490
In
parti

"
cula rl

'y be
caref
ul
with
the
bolts
of
supp
ort
Check , that there is
no foreign matter
inside the fan
Check the alignment of the coupling joint Check the alignment of the pulleys

'

Rotate the impeller by hand to be sure that it does

not touch the walls
Check the tension of the belts Check that the access door is closed

• •
• •
•
 Operation check points

Damper Control
After the machine attains full speed, operating the air control damper closed
for a lone time incurs dancer, because the accumulation of compressed
heat within the blower casing may cause heat distortion. Therefore as soon
as full speed is reached, when usino discharoe damper. the air control
damper needs to be opened with a minimum amount of air quantity so that
surging phenomenon may not occur. Then loading can be successfully
increased gradually.
When usino the suction damper, there is no fear for surornc. Control the
damper by watching the ammeter of the motor to make that the motor
doesn't overload. Confirm at this time that the motor ampere is below the
rated value.
Temperature of the Bearing
Confirm the circulation of oil after full speed has been attained and measure
the temperature increase in bearing. This should be under 40t and the
bearino temperature should be kept under 70t: under any condition.
The temperature will become constant after one hour from starting.
It is considered safe if you can keep your palm on the bearing for more than
10 seconds. For the blower which is provided with a gland. pay attention so
as not to tighten the gland unbalancedly. Then. operate the motor for a
moment to ascertain the revolving direction and inner contact.

Treatment of Gases of other Temperature than Normal

In the case where the gas has a smaller specific gravity than that of a
normal temperature air treated under normal temperature. it sometimes
develops an overload.
Pay attention not to commit such an irregularity.
Surging

When the fan is operating in the ranges

between A and B in Fig. 1, a Pressure

backward flow is generated among the

vanes of the fan and this in turn gener-
A
ates periodic pulsation in the flow.
Metallic sound is due to this phenomenon.
Since the casing itself will vibrate
Air Volume
dangerously. avoid operation in the Fig.l Surging Area
ranges between A and B.
 Vibration check
VIBRATKJN SEVERITY OiART
Vibration in mills (peak to peak)
Maxirrum or flbrnal = 2865 Alarm= 4200 Shutdown = 9550
Desigl RPM
400
=
7.1
=
10.5 23.9
=
600 4.8 7.0 15.9

800 36 5.3 11.9

1000 2.9 4.2 9.6

1200 2.4 3.5 7.8

1400 2.0 3.0 6.8

1600 1.8 2.6 6.0

1600 1.6 2.3 5.3

2000 1.4 2.1 4.8

 2200 1.3 1.9 4.3

2400 1.2 1.8 4.0

2600 1.1 1.6 3.7

2800 1.0 1.5 3.4

3000 .9 1.4 3.2

3200 .9 1.3 3.0

3400 .8 1.2 2.8

3600 .8 1.2 2.7

3800 .7 1.1 2.5

4000 .7 1.1 2.4

Approx. Velocity
.15 .22 .5
(In.) Sec
 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION

Accumulation of foreign material on wheel Clean and rebalance as necessary
Worn or corroded wheel Replace
Bent shaft Replace
Loose wheel, dove sheave or beanng Tighten and ahgn
Imbalanced wheel motor rotor or sheave Balance
Wheel beann or dnve mrsah nment Aban
Belts too loose or too r ht Tension
Detective or wom beanngs, belts, Replace
coupling
Loose fan mounbng bolts Tighten check torque values
lnadequatetor resonant foundation Increase absorptive capacity, increase mass, add
stiffeners
Excessive vibratJon.lnoise
lnadequatety supported inlet or outlet Add bracing
duct
Aerodynam1c: pulsation Channe point of operation via damper pcslton etc
Excessive svsten nressure Ooen dom r
Uneven wheel loading Improve inlet conditions via turning vanes etc.
Nearhv sound reflection surface Install sound bamer
PROBLEM POSSIBLE CAUSE SOLUTION
Actual fan speed higher than design Reduce speed
Air density h19her than design Install larger motOf, damper flow
H19h BHP Of CFM Wheel rotating wrong direction Reverse direction
Actual system resistance jcwer than Add system resistance via damper, etc

�·
desinn
Actual fan s.......d lower than cescn Increases
Wheel rotati� wm= dnecnon Reverse drrectron
Decrease system resistance, damper, duct
des-,
Actual system resistance higher than
cxcnce etc
Wheel not al19ned property to inlet Align
LowCFM Uneven wheel air loadmg Improve inlet or outlet condition via turning vanes
etc.
POOf outlet condition Add stack, stra19ht duct run before elbow etc

Inspection
Troubles Causes Countermeasures
Point

High 9. Overheat of bearing Replacement of Metal

Bearing 10. Defective alignment Coupling Additional tightening of
of coupling bolts and nuts
Temperature 1 I. Excessive tightening V-bell Correct the tension
of V-bell
12. Vibration Bearing Refer to 'Vibration•
 Inspection
Troubles Causes Countermeasures
Point

Deterioration 1. Drop In rpm, drop In Adjustment required

In power cycle
performance 2. Reverse revolution Change the motor wiring
3. Adherence of foreign Cleaning, repair or
matters to impeller. replacement
wear and corrosion
4. Clogging of suction Repair
filter
5. Defective opening I Repair
closing of suction &
discharge valves
6. Accumulation of dust Cleaning
in casing duct
7. Leakage through drain Repair
hole & other sections
8. Difference In the gas Measurement of the specific
specific gravity gravity of gas and analysis of
gas
9. Excessively large Planing of gas booster
actual resistance replacement of Impeller
 Inspection
Troubles Causes Countermeasures
Point

Suction 1. Rusting of lever Disassemble, feed grease and

damper repair
2. Rusting ol bearing Disassemble, feed grease and
repair
3. Contacting of blades Repair the distortion of
blades. inspect its contact
duct
Problem Cause Corrective Action

Duct system
Change obstructions in system. Use correction factor to adjust
has more or less
for temperature/altitude. Resize ductwork. Clean filters/coils.
restriction than
Change fan speed:
anticipated
Filters need to be cleaned or replaced. To remove the existing
Static Pressure filters, open the top hood panel(s). The filters can now be
Wrong removed by lifting them vertically and out of their racking. Be
sure to carefully note the quantity and size of the filters being
Dirty filters
removed as some LSF units utilize multiple fitters sizes. After the
• Model LSF
filters have been cleaned, or new filters are ready to be installed,
place the filters back into the racks in the reverse order of which
they were removed. When all fitters are in place, close and
secure the top roof panels.
Problem Possible Cause Remedy
Overamping Fan Motors Reduction in air static t. On a forced draft untt verify that the pu� is on, and water is
pressure flowing over the coil. If the pump is off, and the untt was not sized
for dry operation, the motor may over-amp.
2. If tbe forced dlatt unrt is docted, verify that ti.. des,gn ESP
matches ti.. actual ESP.
3. Verify the correct pump rotatoo direction. If the pump is rotating
incorrectly, tt will result in less water flow, and therefore less overall
static pressure.
4. Check tbe basin water �v� against the reoomrronded level.
Note: Air density directly affects AMP reading. Low air density
can cause the fans to spin faster, thus increasing the amp draw.

E�lricai issue 1. Check voltage across all tlvee legs of too motor.
2. Verify that the motor is wired per the wiring diagram, and
oonnections are tight.

Fan rotation Verify that the fan is rotating in the correct direction. If not, switch the
�ads so rt runs oorrectly.

Mechanical failure Verify that ti.. fan and motor tum freely by hand. If not, there may be
damage to the internal motor comporans or bearings.

Belt tension Check for proper belt tension. Extreme belt tenson can cause the
motor to overamp.