Case Study: What causes a broken V-Belt Failure in Blower System?

(Images just for illustration purpose of blower pulley and V-belt)

Background

In industrial applications, blowers play a crucial role in maintaining airflow and pressure. However, if the drive components like V-belts and pulleys are not optimised, it can lead to operational issues. This case study examines how a blower system's performance was significantly improved by modifying the pulley configuration, preventing frequent V-belt failures.

Blower Information:

Brand: Taiko

Model: SSR200HB C/W 120HP/90KW, 4 POLE, B3 MOTOR

Air volume: 54.2 M³/MIN

Discharge pressure: 0.66 KGF/ CM²

Blower speed: 1420 RPM

Blower pulley: SPC-0236/04-3525

Motor pulley: SPC-0236/04-3525

Problem Overview

A customer recently installed 4 blower units at a site. Shortly after initiating operations, they reported a recurring problem: The V-belts were overheating and breaking frequently. This issue led to unexpected downtimes, increased maintenance costs, and operational inefficiencies. The quick heating and subsequent failure of V-belts raised concerns about the system’s reliability.

Initial Investigation and Findings

To address the problem, our technical team conducted a thorough on-site investigation. Key observations included:

1. V-Belt Heating and Breakage: The V-belts were heating up rapidly during blower operation, resulting in frequent failures. The issue was consistent across all four blower units.
2. Pulley Configuration Check: Each blower was equipped with a 4-groove pulley system. Analysis showed that this configuration was not adequately handling the blower’s operational load, causing uneven load distribution across the belts.
3. Belt Tension and Alignment: The team verified the belt tension and alignment, which were found to be within acceptable limits. This ruled out installation errors as the primary cause of failure.

Root Cause Analysis

The investigation pinpointed the root cause: the existing 4-groove pulley system was inadequate for the blower’s load requirements. The limited grooves resulted in excessive strain on each V-belt, causing them to overheat and fail. This uneven load distribution was detrimental to the system's performance and longevity.

Proposed Solution: Pulley Modification and V-Belt Replacement

After detailed discussions with our technicians, the recommended solution was to upgrade the existing pulley system:

• Pulley Upgrade to 5-Groove: Replace the 4-groove pulley with a 5-groove pulley. This modification would improve load distribution by allowing the load to be shared across five belts instead of four, reducing the stress on each belt.
• Install New V-Belts: Along with the new pulley, install V-belts specifically designed for the 5-groove system to ensure optimal compatibility and performance.

Implementation Process

The proposed solution was implemented as follows:

1. Pulley Replacement: All four blowers had their 4-groove pulleys replaced with 5-groove pulleys, designed to better manage the load distribution.
2. New V-Belt Installation: New V-belts matching the 5-groove pulley specifications were installed, ensuring proper fit and function.
3. Post-Installation Testing: After installation, the system was tested under full operating conditions to verify the effectiveness of the modification.

Results and Benefits

The modification yielded significant improvements:

• Reduced Heat Generation: The 5-groove pulley system improved load distribution, substantially reducing the heat generated by the belts during operation.
• Extended Belt Lifespan: By minimizing the strain on each belt, the new configuration significantly extended the operational life of the V-belts, reducing the frequency of replacements and associated costs.
• Enhanced Blower Performance: The blowers operated smoothly without further V-belt failures, ensuring reliable and efficient performance.

Conclusion

This case study demonstrates the impact of proper component selection on the performance and reliability of industrial blower systems. The upgrade from a 4-groove to a 5-groove pulley system effectively resolved the recurring issue of V-belt failure, enhancing the overall efficiency and reducing maintenance costs.

Key Takeaways and Recommendations

1. Optimise Pulley Configurations: Ensure the pulley system matches the blower’s load requirements to prevent uneven load distribution and component failures.
2. Regular Maintenance: Conduct routine inspections of V-belts, pulleys, and tension to catch potential issues early and prevent unexpected downtimes.
3. Load Analysis: Periodically evaluate the load on the belts to ensure they are operating within their designed capacity.

This case reinforces the importance of precise system design and proactive maintenance in ensuring the smooth operation of blower units, ultimately boosting productivity and reducing costs in industrial environments.