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Abnormalities in Water Ring Vacuum Pumps and Combustion Blowers in Chemical Plants?

Diagnostic Cases｜Abnormalities in Water Ring Vacuum Pumps and Combustion Blowers in Chemical Plants?

In chemical plants, water ring vacuum pumps and combustion blowers are critical rotor equipment for ensuring process stability and energy efficiency. These devices operate at high speeds for extended periods, and without timely monitoring, may cause shutdowns, product scrap, and energy waste.

Water Ring Vacuum Pumps and Combustion Blowers Requiring Long-Term Stable Operation

In chemical industrial sites, water ring vacuum pumps and combustion blowers are among the most common and essential equipment. Their shared feature is the need for long-term stable operation to ensure smooth production processes. Water ring vacuum pumps mainly rely on the high-speed rotation of the impeller to form a water ring inside the pump chamber, using volume changes to achieve gas extraction and vacuum creation. They are widely used in distillation, drying, and gas transfer processes. If the vacuum level is insufficient, it can reduce reaction efficiency, lower product purity, or destabilize the process.

The combustion blower is a critical component that supplies air for combustion
In comparison, the combustion blower is responsible for delivering sufficient and stable airflow into the combustion chamber, ensuring complete combustion and stable thermal energy output. If the blower operates abnormally, causing insufficient or uneven airflow, combustion efficiency will decrease, leading to energy waste and even excessive emissions. From this perspective, although the combustion blower may appear to be only auxiliary equipment, it is actually a key element in ensuring energy utilization and environmental performance.

An Issue That Cannot Be Ignored
Because of the importance of these two types of equipment, monitoring their condition has become an issue that cannot be ignored in the chemical industry. Both water ring vacuum pumps and combustion blowers are typical rotor equipment that face challenges such as high rotation speeds, fluid resistance, and mechanical stress during operation. Any minor abnormality—such as shaft misalignment, bearing wear, or impeller imbalance—will first manifest as vibrations. If these abnormalities are not detected and addressed in time, they tend to worsen over time. Chemical plant products often involve continuous processes, and even a single shutdown can turn tens of tons of raw materials into waste. An unexpected stoppage not only increases maintenance costs but may also result in batch scrap, production delays, and energy waste, with losses often amounting to millions.

Unexpected Shutdowns: Once rotor vibration goes out of control, production can be interrupted at any time.
Expensive Maintenance: Agitation tanks usually require disassembly of pipelines and seals for repair, making maintenance costs far higher than regular machinery.
Quality Risks: Even slight vibrations can cause uneven mixing, leading to extended reaction times or product deviations.
Safety ＆ Environment: Chemical materials are often hazardous; abnormal vibrations causing damage may lead to leaks or explosions.

Common Problems of Water Ring Vacuum Pumps and Combustion Blowers

The common problems of water ring vacuum pumps and combustion blowers each have distinct characteristics. Typical failures of vacuum pumps include bearing wear, impeller corrosion, and cavitation, all of which are reflected in high-frequency or irregular vibrations. Combustion blowers, on the other hand, are prone to imbalance caused by dust or residue buildup, or periodic vibrations due to poor shaft alignment and loose foundations. In more severe cases, excessive vibrations not only shorten mechanical lifespan but may also cause seal failures, resulting in gas leakage that threatens both safety and the environment.

Solutions and Monitoring Description

IMS-PR Motor Rotor Inspection Analyzer
When the IMS-PR Motor Rotor Inspection Analyzer is combined with sensors and applied to rotor equipment, it can instantly collect vibration and operation data, and analyze it to assess the equipment’s health condition. This approach allows maintenance personnel to use data as a basis to detect potential issues in advance, such as bearing wear, impeller imbalance, or misalignment. In addition, an inspection map can be independently created to help inspectors perform regular inspections and track the condition of each piece of equipment during every inspection.