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    Lord Fan Balancer Presentation

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    Ezhil Vendhan Palanisamy
    Lord Corporation provides real-time fan balancing systems that balance rotating equipment like fans and turbines without stopping them. The systems use sensors to monitor vibration levels and controllers that signal balancers to make adjustments to compensate for imbalance. This allows customers to have improved equipment availability and reliability by reducing unplanned downtime from imbalance-related issues. Case studies showed the systems eliminated emergency shutdowns, extended maintenance intervals, and provided savings of over $250,000 per year by maintaining balance levels and preventing failures.

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    Lord Fan Balancer Presentation

    Uploaded by

    Ezhil Vendhan Palanisamy
    177 views32 pages
    Lord Corporation provides real-time fan balancing systems that balance rotating equipment like fans and turbines without stopping them. The systems use sensors to monitor vibration levels and controllers that signal balancers to make adjustments to compensate for imbalance. This allows customers to have improved equipment availability and reliability by reducing unplanned downtime from imbalance-related issues. Case studies showed the systems eliminated emergency shutdowns, extended maintenance intervals, and provided savings of over $250,000 per year by maintaining balance levels and preventing failures.

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    Lord Corporation provides real-time fan balancing systems that balance rotating equipment like fans and turbines without stopping them. The systems use sensors to monitor vibration levels and controllers that signal balancers to make adjustments to compensate for imbalance. This allows customers to have improved equipment availability and reliability by reducing unplanned downtime from imbalance-related issues. Case studies showed the systems eliminated emergency shutdowns, extended maintenance intervals, and provided savings of over $250,000 per year by maintaining balance levels and preventing failures.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    177 views32 pages

    Lord Fan Balancer Presentation

    Uploaded by

    Ezhil Vendhan Palanisamy
    Lord Corporation provides real-time fan balancing systems that balance rotating equipment like fans and turbines without stopping them. The systems use sensors to monitor vibration levels and controllers that signal balancers to make adjustments to compensate for imbalance. This allows customers to have improved equipment availability and reliability by reducing unplanned downtime from imbalance-related issues. Case studies showed the systems eliminated emergency shutdowns, extended maintenance intervals, and provided savings of over $250,000 per year by maintaining balance levels and preventing failures.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 32

    LORD Corporation RealTime Fan Balancing Systems

    Presentation Agenda
    Lord Corporation Overview Value Proposition Balancing System Descriptions & Operation Application Histories Industries & CBA Summary and Questions

    Lord Corporation
    Private Company; founded in 1924, HQ in Raleigh, NC, USA 2,400 employees worldwide with over $500 Million Revenue Vibration and Motion control Specialists
    Traditional solutions mostly elastomeric based Newer technologies utilize active systems Industrial and Aerospace market focus Developers of RealTime Balancing Technologies System Solution Provider
    Vibration Measurement and Analysis Rotor Dynamics Models Application Specific Balancer Designs

    Value Proposition to Customers


    By compensating for variable balance conditions due to process variations we offer
    Improved Equipment Availability and Reliability Reduce Unplanned Downtime and Lost Production Due to Balance Related Vibration Problems Keep Troublesome Equipment Running Until a Weekend or Planned Outage No 2:00 AM Phone Calls Reduced Wear on Bearings, Seals, Motors, etc. Extension in Planned Maintenance Intervals

    What Makes This System Unique


    1. 2.

    Makes the balance correction without stopping the fan Compensates for different forms of unbalance
    COUPLE Unbalance
    Principal mass axis offset from centerline of rotation
    Centrifugal Force Centrifugal Force

    STATIC Unbalance
    Mass offset from center of rotation
    Centrifugal Force

    DYNAMIC

    Unbalance

    Any combination of static and couple unbalance

    U = (m) x (r)
    m r
    Center of Rotation

    Centrifugal Force

    m
    c.g. Shaft Axis

    Shaft Axis
    c.g.

    r
    Principal Axis

    Centrifugal Force

    Centrifugal Force

    Unbalance Isnt The Only Cause of Vibration in Rotating Equipment


    10

    Unbalance

    -1 0 0 0 .1

    0 .2

    Overall
    10

    10

    Misalignment

    -1 0 0 0 .1 0 .2

    = +

    -1 0 0 0 .1 0 .2

    15 FFT Magnitude

    Balancing can only affect vibration at operating frequency

    10

    Bearing Defects, etc.

    10

    -1 0 0 0 .1 0 .2

    Fast Fourier Transform (FFT)

    0 0

    2000 F

    4000 (

    6000 )

    Frequency Spectrum

    What is a RealTime Balancing Systems?


    Basic System Configuration
    Vibration Sensors, Controller, Amplifier, Coil and Balance Ring(s) Balances with mechanical weights

    What is a RealTime Balancing Systems?


    Balancing System 3D Animation

    What is a RealTime Balancing Systems?


    Basic System Integration and Operation
    Balancer(s) install permanently on shaft of rotating equipment Stationary coil assembly mounts to brackets on bearing pedestal Based on Sense-then-Adjust Sensors monitor vibration levels Signals received and processed by the Controller Controller signals Balancer(s) to make an adjustment Trim Balance Corrections are made while the fan is in service Compensates for 1X (Shaft Synchronous) vibration

    General System Characteristics


    Non-Contact Power and Data Transfer Active Only During Balance Cycles
    Fail-Safe Operation Continuous Monitor Mode

    Customer Sets Vibration Limits


    Balance Cycle Start/Stop

    Automatic or Manual Operating Modes Data Output For Trend Analysis

    10

    General System Diagram


    Bearing Hsg Vibration Sensor(s) Rotating shaft with residual unbalance

    Real-Time Controller Assembly

    Balancer & Coil Assemblies


    11

    Technology Overview EM Balancer


    Electromagnetic Balancers for:
    ID/FD Fans Axial Fans Turbines, Compressors, Pumps, Generators, Propellers
    Net Resultant Balance Correction Vector Unbalanced Heavy Spots

    Machine Axis of Rotation

    Counterweight Rotors 1 & 2

    Individual Counterweight Unbalances

    12

    Technology Overview EM Balancer


    System Components
    Balancer Ring Actuator Coil Controller PWM Amplifier Vibration Sensor Tach Sensor Software

    13

    Technology Overview EM Balancer


    Inside The Balancer
    Tach and Position Sensor

    Magnetic Detent Positions

    Holes Could Be Filled for Extra Mass Additional Mass Removed

    Counterweight Section of 1st Internal Rotor 2nd Rotor on Opposite Face

    14

    Technology Overview EM Balancer


    Designed for Fans 400-3600 RPM 54-94mm Axial Width 405-700mm Diameter Balances < 60 Seconds Up to 3.31 Kg-m Capacity capacity varies with size Introduced Mid-1990s
    V ibra tion Displa ce m e nt (m icrons)
    4 3 2 1 0 -1 -2 -3

    Stationary Coil Assembly

    Balancer Ring
    Spin dle Balanced to A cceptable Lev el A fter Two Co ntrol iterations

    Co ntro l In itiated
    -4 0.00 0.25 0.50

    Firs t Con trol Iteration Complete


    0.75 Tim e (S e conds) 1.00 1.25 1.50

    15

    Technology Overview EM Balancer


    Stationary coil assembly Position sensors 0.060 air gap Magnets

    Balance rotors Balance rotor bearings

    Balancer rotating assembly

    Section View of Balancer and Coil


    16

    Windows Interface Software

    17

    Windows Interface Software


    Determine the magnitude and phase angle of the unbalance
    Data could be used for manual balance corrections

    Display the % correction capacity used/remaining Configure control parameters Log history files to look at performance over time

    18

    Technology Overview EM Balancer


    Remote Balancer Link
    Access to Control System from a Remote Location or networked location within a plant
    WAN
    RBL

    Computer

    Controller and Balancer

    19

    Technology Overview EM Balancer


    Remote Balancer Link Benefits of Remote Diagnostics
    Eliminates service technician travel time and diagnosis delay Globally Accessible Interrogate Machines Balance Integrity Establish Remaining Available Balance Correction Capacity Identify if Balance Correction Should Be Performed Determine a Cause of Action Based Upon Real-time and Historical Data Share Prognosis with Others Live Globally Initiate a Balance Correction
    20

    Technology Overview EM Balancer


    Available in three standard sizes to cover a broad range of applications Link to EM Balancer Technical Specification

    21

    Typical Fan Installations

    22

    Typical Fan Installations

    Single Control For Each Fan


    Option for Dual-Plane Controller for DWDI Fans

    23

    Industries Served
    Cement Production Power Generation Steel Production Petro-Chemical Food Processing Pulp & Paper Waste Treatment Mining/Quarrying General Industrial Processes

    24

    Balancing Case Study - Steel


    Before Vibration levels reached levels of 5.5mm/sec Manually balanced rotor as often as twice per month Cost $1,000 per cleaning + 1 day lost production Bearings replaced every 1-3 months at an estimated cost of $80,000 in parts, labor, & downtime After Maintained balance levels below 0.5 mm/sec Eliminated emergency maintenance shutdowns to clean and balance fans Estimated savings of over $250,000 per year in lost production time & maintenance


    25

    Balancers installed on (2) Pre-Carbon ID Fans. Draws mixture of air, coal, & gases in Coke Plant 305cm Rotor, 1165 RPM, 1500 Hp Motor. One balancer per fan; 78cm OD/12cm Width 216,000 g-cm correction capacity

    Balancing Case Study - Cement


    Balancers installed on Kiln ID Fan. Draws clinker material through the large rotary kiln 265cm rotor, 1330 RPM, 1250 hp motor, 650F process air temp One balancer per fan; 84cm OD/11.5cm width 100,800 g-cm correction capacity Before Fan shutdown every 8 weeks loss of 1000 tons of production 8-12 hours of sandblasting required to clean fan Manual balance shots required after cleanings Emergency shutdowns occurred in between scheduled 8 week maintenance outages Frequent shutdowns and high vibration damaged bearings & motors and caused costly failures in the refractory lining on kiln

    The result is that the fan stays in balance and only has to be
    cleaned during scheduled plant shutdowns. It takes lost production out of the picture. Harry Ohrtman GCC Dacotah

    After Maintained balance levels below 1.5 mm/s Scheduled fan cleaning every 6 months Eliminated emergency maintenance shutdowns to clean and balance fans Extended bearing and motor life

    26

    Balancing Case Study Pulp/Paper


    Before Vibration levels reached levels of 10 mm/s in less than 1 week Cleaned rotor every week Cost $500 per cleaning + 6 hrs lost production @ $3500K/hr ($21K) Bearings replaced every 1-2 months at an estimated cost of $45,000 in parts, labor, & downtime After Maintained balance levels below 2.5 mm/s Now shutdown to clean the fans every 3-4 Weeks Estimated savings of over $1.0MM in 18 months for lost production time & maintenance


    27

    Balancers installed on (2) Wet Scrubber ID Fans in MDF Plant. Draws mixture of air, sawdust, chemicals, & gases in MDF Manufacturing Process 162cm Rotor, 1780 RPM, 800 Hp Motor. One balancer per fan; 50cm OD/6.5mm Width 36,000 g-cm correction capacity

    End User Cost-Benefit Analysis


    Balancer vs. Forced Outage/Derate Outage Impact = Probability x Consequences Probability
    Prior history of trouble

    Consequences
    Production Capacity % Derate multiply for dollar impact of lost Duration of Outage production revenue $/Unit of Lost Production Direct repair costs for labor & materials

    Payback Time

    28

    Competition
    No Direct Competitors
    So Competition Becomes

    No Change
    Accept forced outage risk Manual balance as required

    Slow to Adopt New Technology Other Capital Projects


    Emissions, Product Compliance, Critical Equipment, Facilities Expansion/Upgrade

    29

    Limitations of Balancing System

    Does Not Eliminate The Need For Manual Balance Shots


    New Installation Following Equipment Rework

    Does Not Correct For Sub-Synchronous Shaft Vibrations Due to Misalignment and Bearing Wear Does Not Preclude The Need For Regular Maintenance on Rotating Equipment
    Cleanings, Inspections, etc.

    Does Not Have Unlimited Capacity to Correct for Severe Balance Problems

    30

    Summary and Conclusions


    Lord Balancing Systems Offer End Users Key Benefits:
    Increased Production Up-Time Optimization of Equipment Life Maximization of Asset Availability

    Payback of System and Installation


    Typically 1 Year or Less Often After First Use

    31

    About LORD Corporation


    Headquarters in Cary, NC Sales in excess of $500-MM Privately held company that designs, manufactures and markets devices and systems to manage mechanical motion and control noise and vibration; formulates, produces and sells general purpose and specialty adhesives and coatings; and develops products and systems utilizing magnetically responsive technologies. Manufacturing in eight countries and offices in more than 15 major business centers LORD Corporation employs more than 2,400 worldwide. Visit www.lord.com for more information.

    32

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