Equipment Type
Fan
Equipment Name
Induced Draft Fan
Faults
Rotor Unbalance
Early Detection of Induced Draft Fan Rotor Unbalance Fault
How AI Ensures Continuous Operation at a Metallurgical Plant
Metallurgical
Introduction
An induced draft fan is essential in metallurgical plants for managing gas flow and pressure, typically exhausting smoke or air. Efficient operation is key to continuous production and reduced energy costs. This case study shows how an AI condition monitoring solution detected a rotor unbalance fault in a critical induced draft fan, enabling timely maintenance and preventing disruption to the plant's continuous operations.
Equipment Overview
Induced draft fans are driven by a motor connected to an impeller. They create negative pressure to draw in gas or air, then accelerate it to increase speed and dynamic pressure before discharging it. Their design is critical for regulating gas flow and emission pressure, which is vital for the plant's overall efficiency and operational needs.
The Challenge
Rotor unbalance can be caused by:
Local damage or shedding of rotor components
Uneven wear or scaling of the rotor
Displacement of rotating parts due to rotor deformation
Low dynamic balance precision
Rotor manufacturing or assembly errors, or loose fit
Wisper Solution
The Wisper CMS is deployed along with Wisper wireless sensors. It detected an abnormal feature on the motor drive end of the induced draft fan on February 19, 2024. This anomaly was diagnosed as a rotor unbalance fault. Rotor unbalance can result from several factors and, if left unchecked, can lead to equipment failure. Whisper AI agent triggered a diagnostic report, advising close monitoring.
Following the initial detection, the abnormal indicator continued to decrease. A second diagnostic report was triggered on February 26, 2024. Based on the Wisper's reports and the actual site conditions, the customer performed maintenance on February 27, 2024.
Timeline of Events
The outcome
Following the maintenance, all equipment indicators were restored to a healthy condition. The on-site inspection results were consistent with the AI diagnosis, validating the accuracy of the system. This proactive maintenance action ensured the continuous operation of the metallurgical plant.
understanding the root cause
Rotor unbalance can be caused by:
Local damage or shedding of rotor components
Uneven wear or scaling of the rotor
Displacement of rotating parts due to rotor deformation
Low dynamic balance precision
Rotor manufacturing or assembly errors, or loose fit
