Blowers

While many “flexible” coupling designs claim high tolerance for misalignment, any installation performs better when aligned precisely. Poor alignment due to improper installation or a shifting base results in excessive vibration, causing blower damage and possible failure. Emerson’s proven monitoring technology generates an immediate warning if there is a misalignment issue when the blower’s motor is turned on, and it detects motor misalignment, rotor harmonics, or rolling element bearing defects based on different vibration frequencies. This allows technicians to address potential issues early and optimize maintenance scheduling. 

Unwanted high-amplitude vibration can occur when a blower motor is running at one of its resonant frequencies. Using pre-determined resonant bands for motor speed, Emerson’s asset monitoring sensors alert operators of resonance before it causes excessive vibration, allowing them to adjust motor speed or air flow rates to mitigate high vibration and avoid blower failure. Testing with a modal/impact hammer can also detect resonant frequencies, structural cracks, and dynamic stiffness. 

Faulty louver position can result in restricted air flow, causing a reduction in capacity, and safety risks when insufficient air is delivered to meet demand. A mismatch between implied and actual louver position often indicates a louver defect or problem with the positioner. Detecting louver defects early using Emerson’s monitoring solutions helps technicians carry out maintenance checks more efficiently, while maintaining continuous throughput. 

Restrictions in air inlet ducts due to plugged suction strainers have a similar effect as faulty louvers. When combustion air to a fired heater is insufficient to support efficient and safe firing, the system should trip. The safety system must do its job, but this can lead to a shutdown, and possibly a reportable environmental incident, such as flaring. Emerson’s blower health monitoring solution allows operators to measure suction strainer differential pressure online to detect when plugging threatens necessary throughput. Technicians can take corrective action early enough to maintain capacity and prevent unplanned downtime.