Blowers: learn about the most common faults and how to detect them

Blowers are used in a wide range of industries, including aeration, fermentation, pneumatic conveying and other processes. For each activity, there is an ideal model, taking into account the operation itself and the cost-benefit ratio.

Before discussing the types of blowers, it is important to differentiate them from compressors. The operating principle of both is the same, the difference lies in the pressure and air flow produced. In other words, the aim of the blower is to generate a relatively large flow of air at a relatively low pressure. The compressor, on the other hand, produces a small flow of air at a fairly high pressure.

Read also: Industrial compressors: learn about the main faults  (dynamox.net) 

Types of blowers

Flow blowers: They convert kinetic energy into pressure energy. Some examples are the screw type and the centrifugal type.

• Screw or helical screw: It has two types of rotors – a male with three convex lobes, and a female with five concave flutes, which rotate in opposite directions. The movement pulls in air, which is then expelled. 
• Centrifugal: Works on the principle of centrifugation. In other words, it accelerates the fluid that enters parallel to the centerline of the shaft and is launched perpendicular to it, performing a centrifugal movement when its rotor rotates. 

Volumetric blowers: Displace the fluid in defined volumes with each rotation. The most common model is the trilobular or “Roots”. 

• Roots: The process works by displacement. Thus, it works by pumping fluids using a pair or trio of synchronized lobes.

Most common blower faults

Despite the variety of models, there are some faults that are quite common: 

Component	Fault	Effect	Possible cause	Solution*
Motor	Diffuse burnout	Disarming	Lack of phase and natural wear	Electrical replacement and investigation
	Faulty limit switch actuation	Lack of information on working conditions
	Premature bearing wear	Motor locking	Inadequate lubrication	Bearing replacement and lubrication
	Rotor unbalance	Abnormal vibration and overheating	Damaged bearings	Bearing replacement
	Faulty windings	Motor burnout
	Problems with the electric drive	Sudden stop	Overheating	Electrical investigation
	Inefficient ventilation system	Overheating
	Bearing heating	Bearing wear	Component wear	Replacement
Engrenagens	Assembly wear	Excessive vibration	Natural wear	Replacing the assembly
	Gear misalignment
Sistema de refrigeração	Inefficient cooling	Damage to internal components	Natural wear	Component replacement and lubrication
	Oil pump failure	Excessive friction
Controles de pressão e temperatura	Communication failure	Inadequate temperature and pressure	Natural wear	Replacement
	Faulty instruments
Válvula	Valve burnout	Excessive pressure in the line	Internal wear	Replacement
	Damaged bearing
	Damaged indication contacts
	Demaged seat

Industrial blower maintenance

In industry, efficiency is a market differentiator. In other words, the better the use of resources and raw materials, the higher the performance tends to be. And in order to achieve this goal, it is essential that maintenance is seen as a strategic element.

This requires a schedule of inspections, action plans and, above all, tools to measure the operating condition of the asset. In this way, as well as efficiency, it is possible to increase the reliability and availability of blowers. Here are some suggestions:

1. Periodic cleaning: the accumulation of dust, debris and other contaminants can contaminate lubricants, cause overheating and overloading, impacting operation and even reducing their useful life.

2. Pay attention to lubrication: lubrication is essential to prevent premature and excessive wear of rotating components. It is therefore essential that it is done periodically, in the right quantity and with the recommended lubricant.

Read also: Relation between lubrication and vibration analysis (dynamox.net) 

3. Inspect the drive belt: it is important to inspect it periodically. This component, when worn or out of its optimum condition, contributes to misalignment of the pulleys and a host of other problems that occur as a result. 

4. Monitor vibration levels: vibration is an excellent indicator of the general health of assets. This is because it is possible to identify failure modes by noticing changes in vibration levels, helping to increase equipment availability, reduce costs, prevent premature wear, avoid unnecessary interventions and, of course, reduce the risk of accidents.

Blower fault diagnosis

Dynamox has developed an algorithm based on Artificial Intelligence that specialises in blowers. It knows how the machine operates and is able to identify failure modes with precision.

With automated detection, it is possible to increase the number of analyses. This optimises the time of the analyst, who can manage more diagnoses, since they already know what the problem is.

This feature is part of the Dynamox Solution, which aims to offer the best system for monitoring and analysing conditions using vibration and temperature data.

In the case of blowers, monitoring takes place via 2 sensors installed on the motor, at least 3 sensors on the reducer and one per bearing on the extractor hood, as shown in the illustration.

Want to increase your plant’s availability? Talk to our experts and bring the Dynamox Solution to your industry!