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

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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

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Bearing Defects, etc.

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-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

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General System Diagram

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

Real-Time Controller Assembly

Balancer & Coil Assemblies

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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

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Technology Overview EM Balancer

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

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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

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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

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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

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Windows Interface Software

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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

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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

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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
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Technology Overview EM Balancer

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

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Typical Fan Installations

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Typical Fan Installations

Single Control For Each Fan

Option for Dual-Plane Controller for DWDI Fans

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

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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

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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

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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

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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

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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

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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

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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

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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.

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