Chapter 12

Common blower improvement opportunities

Blowers are low-pressure gas movers and many thousands are operating in virtually
all industries. However, in the absence of rigorous industry standards or specifica-
tions, purchasers often make initial cost and rapid delivery their primary selection
criteria. As a result of attractive pricing and de-emphasized long-term reliability, less-
than-optimally-designed products tend to enter the supply chain. As just one exam-
ple, they tend to purchase grease-lubricated equipment for inaccessible locations,
such as the blower shown in Fig. 12.1. Many plant operators are later surprised that
their equipment is maintenance-intensive, or unreliable, or both.
Fortunately, the weak links in simple blowers can be determined and remedied
by thoughtful upgrading. Such upgrading includes well-executed failure analyses
and cost justifications. As an obvious example, when a grease-lubricated pillow
block bearing (similar to Fig. 12.1) failed several times within three years, someone
decided to simply replace the failed bearing with one that had a much greater load
capacity. Not much later, the owner-operator was confronted with the fact that this
higher capacity bearing failed even more rapidly. Only then was it determined that
the original bearing had probably failed because of a lubrication flaw and that the
next three or four replacement bearings failed because they were too lightly loaded.
Lightly loaded bearings tend to skid instead of roll, confirming the fallacy of “big-
ger is better” claims.
As explained earlier in Chapter 3: When the rolling elements in a bearing skid
because they are too lightly loaded, the oil film is wiped off, and metal-to-metal
contact takes place. Heat is being generated and degradation progresses at a fast
pace. The facility went back to the originally supplied bearings and installed the
small self-contained oil mist module shown earlier in Fig. 9.11. The bearings per-
formed quite well and the belated addition of oil mist further moved the bearing life
in the right direction. Using a synthetic lubricant of purpose-optimized viscosity
added its own advantages and the earlier problems were left behind [1].
Along similar lines of reasoning, reliability-focused process companies today
foresee blower situations where the addition of a dual mechanical seal cartridge
(Fig. 12.2)drastically reduces gas losses. Used to provide both bearing lubricant and
seal oil, a well-engineered circulating seal oil support system (shown earlier in
Fig. 9.10) incorporates additional advantages over oil mist-lubricated bearings. A
circulating seal oil support system can supply oils that do triple duty as a seal bar-
rier fluid, coolant, and bearing lubricant [2]. This is but one of many examples
where reliability improvements are well within the grasp of users and technology
providers. User and provider join forces by investigating failure sources and origins.
From there, they follow up by examining innovative upgrading opportunities and
by calculating the cost justification for such upgrades. Combining the upgraded

https://doi.org/10.1515/9783110674156-012
116 Chapter 12 Common blower improvement opportunities

Fig. 12.1: Blower pillow block bearing upgraded to oil mist lubrication (Source: Lubrication Systems
LLC, Houston, TX).

Fig. 12.2: A dual cartridge seal can be considered a blower retrofit and upgrade component
(Source: AESSEAL Inc., Rotherham, UK, and Rockford, TN).
 12.1 Comparing aeration blower technologies 117

aims of technology user and technology provider almost always achieves tangible
progress. Collaboration encourages both to become value-adders.

12.1 Comparing aeration blower technologies

This text uses aeration blower technology as an example case for widely neglected
opportunities to upgrade what we might collectively call “packaged systems.” The
author’s aim is to convey the practical, experience-based approach for the owner’s
representative (the Reliability Professional) to take the lead in asset selection pro-
cesses. In this instance, the entire aeration system is considered an asset.

12.1.1 Power consumer

As the main consumers of electricity in a wastewater treatment plant, aeration blow-

ers can significantly affect the overall cost of plant operation. The most energy-
efficient selection must be based on operating parameters, which are generally far
from static. Moreover, energy efficiency is rarely the governing factor in optimized
blower selection and comparisons made at only a single hypothetical operating point
are inaccurate. We conferred with Aerzen USA (https://www.aerzen.com/en-us/appli
cations/water-and-waste-water-treatment.html) (Coatesville, PA), one of the most ex-
perienced providers of high-reliability aeration blower technology, about modern se-
lection criteria for air movers in this service category.
There is a clear need for up-to-date information that will help engineers under-
stand the importance of more closely looking at the many factors that separate differ-
ent designs. Selection and thoughtful integration of subsystems are of paramount
importance, as is the overall operating philosophy of the owner-purchaser’s facility.
As of 2020, the Internet reference explained in more depth the extent to which sub-
systems and operating philosophies influence total cost of ownership.

12.1.2 Parameters that need to be compared

Experience shows that four parameters – site condition, type of aeration system,
instantaneous mass flow of air, and related system variables both upstream and
downstream – are important in blower selection. Available blower configurations
are generally classified as either positive displacement (rotary lobe, Fig. 12.3), also
dry screw (Fig. 12.4), or the dynamic (centrifugal) machines shown in Fig. 12.5 and
12.6. Dynamic blowers incorporate either a rotor with step-up gearing (Fig. 12.5) or a
driver that can generate the requisite high (fixed or variable) speeds. Special pur-
pose high-speed single-stage centrifugal blowers (Figs. 12.5 and 12.6) incorporate
118 Chapter 12 Common blower improvement opportunities

Fig. 12.3: Rotary lobe blower stage (Source: Aerzen USA).

Fig. 12.4: Dry screw compressor rotors with timing gears (Source: Aerzen USA).

inlet guide vanes and outlet diffuser vanes to achieve wide turndown at constant
operating speed.
High-speed single-stage centrifugal blowers can be operated with a VFD (Variable
Frequency Drive) to provide additional flexibility while maintaining highest efficiency.
They are also offered as self-contained packages, Figs.12.6 and 12.7.
A standardized high-speed single-stage turbo is depicted in Fig. 12.7. These
packaged assemblies incorporate a three-dimensional radial-exit impeller, direct-
 12.1 Comparing aeration blower technologies 119

IInlet
Inl et gui
guide
de
Casing vanes
van es
((optional)
(op tional
tional))

Impeller
Seals
Bearings
Bea
e ringss

Diffuser
Dif
D i fuser vanes
((optional)
(o
(op tional)
Gears

Fig. 12.5: Section of a centrifugal blower with inlet guide vanes and diffuser vanes
(Source: Dresser Industries, Olean, NY).

Fig. 12.6: Single-stage centrifugal blower package (Source: Siemens Turbo).

 120

Inlet nozzle Spiral housing Thrust bearing

Impeller
Imp
mpeell
lller Motor/stator Cooling
C ling
Co
Coo g impeller
impelle
im er Ring
g diffusor
diffusor
(with windings)
win
in
ndin
dings)

Fig. 12.7: High-Speed single stage blower package assembly (left) and exploded view of its turbo blower core with permanent
magnet motor and airfoil bearings (right) [Source: Aerzen USA].
Chapter 12 Common blower improvement opportunities
 References 121

driven by a high-speed Permanent Magnet Synchronous Motor (PMSM). Combined

with an integrated Variable Frequency Drive (VFD) and control panel, the package
enables a wide operating range for continuous operation. Non-contact magnetic or
air foil bearings are utilized in high speed turbo blowers to reduce friction, improve
efficiency, and reduce maintenance.

12.1.3 Emphasis on modern technology

Aeration blower technology has advanced remarkably since the 1990s. The highly
effective integration of control innovation and thoughtful component upgrading
found in late-model aeration packages avoids downtime and increases the owner
plant’s profitability. Be sure to consider modern technology in 2020 and beyond.

What we have learned

– The selection approach must not take for granted that old technology is good enough
– Today’s reliability professionals must not leave the field of aeration systems to the lowest
cost provider
– Owner-purchasers should not allow EPCs (engineering and procurement contractors) to do
piecemeal procurement and splicing together a system.
– The owner-purchaser’s reliability professionals should be at the forefront of making relevant
comparisons and then designating a provider who will accept turnkey responsibility for the
entire wastewater aeration system

References

[1] Bloch, Heinz P. and Ken Bannister. “Practical Lubrication for Industrial Facilities,” Third
Edition, (2016), Fairmont Press, Lilburn, GA 30047, ISBN 0-88173-761-5.
[2] Bloch, Heinz P. “Petrochemical Machinery Insights,” (2016), Elsevier Publishing, Oxford, UK,
and Cambridge, MA, ISBN 978-0-12-809272-9.