Industrial fans like induced draft(ID), forced draft (FD), primary air(PA) and secondary air(SA) fans play a key role in providing critical support to the various process activities and maintaining the efficiency of the factory operations.

Draught fans are a type of industrial fans and are typically heavy duty centrifugal fans. Draught fans are an essential and irreplaceable component of the industry. They are divided in two types – Forced Draught or Forced Draft (FD Fan) and Induced Draught or Induced Draft (ID Fan). The major difference between the two is that the FD fan pushes the outside air into the heating system whereas the ID fan pulls out flue gases from the system and releases them into the atmosphere. Both forced draft and induced draft fan operate in such a way that it balances the air system in the factory.

A typical arrangement of FD fan uses inlet and outlet dampers to maintain and control the air pressure needed inside the system. These fans have a wheel at the center that is hung on the shaft along with filter, silencer, rain hood, and inlet boxes. The most frequently used centrifugal fans as FD fans are airfoil and backward curved blade centrifugal fans. The FD fan builds positive pressure as it helps push the air in the systems. They are widely used in industries of oven, furnaces, boilers and also in dust collection equipment. FD fans are easier to maintain and have cleaner operating conditions as compared to ID fans.

An induced draft fan is usually located at the outlet between the dust collector and the chimney. All gaseous combustion products or flue gases are exhausted from the machines such as boilers or furnaces and released into the outer atmosphere. The ID fans withdraw the air from the systems, therefore they produce the negative pressures in the systems. They are more susceptible to corrosion and erosion problems as ID fans handle hot flue gases. The most frequently used centrifugal fans as ID fans are radial and backward inclined blade centrifugal fans.

The Primary Air (PA) fan and Secondary Air (SA) fan are also the types of industrial fans. Both primary and secondary air have a crucial role in fuel combustion and must be provided in different ratios according to the fuel quantity. Primary air is the basic amount of air required for complete combustion of fuel and it depends on the required quantity and composition of fuel. The fuel is fed either manually or through the screw feeder into the furnace and primary air is provided from the bottom through the Air box. A primary air fan helps in segregating the fuel particles so that each fuel particle could come in direct contact with the air which allows efficient combustion of fuel.

Secondary air is supplied to compensate for the primary air that went unreacted. Generally, it is said to be extra air that must be supplied for complete combustion of fuel. A secondary air fan supplies secondary air through the nozzles installed on the walls of the furnace. Steam boilers with external furnaces are mostly provided with both PA and SA fans. A forced draft fan which is designed for a particular boiler must be able to supply a sufficient quantity of air which is the sum of both primary and secondary air.

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The human errors seriously impact the profitability of the company, along with affecting the key aspects of safety and return on investment (ROI). The ROI is in relation to the processes followed and training provided to employees.

The various strategies of risk management have markedly decreased the instances of injuries and accidental deaths in the manufacturing plants. Yet, the resultant financial costs of the errors continue to be an enormous burden on the manufacturers.

• The misunderstanding and misinterpretation of the various processes and procedures of the business, by the employees, is negatively affecting the revenues of manufacturing companies. This misunderstanding and misinterpretation is the primary reason for the occurrence of human errors.

• In this connection, the major issue is that many organizations are sticking to “to err is human” to the letter. Thus, many manufacturing companies treat the financial implications of these human errors as inevitable in the course of business that can’t be avoided altogether.

• Among the many negatives of human errors, we also have downtime. Repeated instances of downtime exercise a negative effect on the company’s profits.

• Sometimes the human errors can lead to the most adverse crises such as the factory being forced to wind up its operations. Though these cases are not that common, they do happen on and off. And, the financial repercussions of these errors are too extreme.

Minimizing financial costs of human errors

There is only one way to minimize the financial costs resulting from human errors in factories: to reduce the instances of human errors, as much as possible. If any employee has a callous attitude towards their work or does not possess the experience needed for the job, errors tend to happen at a manufacturing plant. But, if there is a frequent recurrence of errors, it indicates that the flaw is with the procedures/processes of the factory operations.

• If a manufacturing organization is committed to addressing this matter, a broader approach has to be adopted. Business needs to candidly admit that not all errors can be attributed to employee carelessness; a shortcoming in the organizational processes could also be the reason.

• Manufacturing businesses need to focus on the improvement of procedures and encourage the employees to participate in the same. This greatly lessens the number of incidents of human error and contributes to the revenues.

• Manufacturers must discard the misconception that only complex procedures shall be effective. Nothing can be farther from the truth. And, the truth is that the simpler you keep the processes, the lower the risk of human errors. If manufacturing plants stick to this fundamental point, they will be able to avoid unwanted costs.

• Companies should opt for automation, at least covering those important aspects where there is a high possibility of human errors from oversight.

• Organizations are entailed to train its employees to promptly identify their errors as well as particular situations where errors are likely to take place. In these training programs, the staff has to be educated with all relevant knowledge. Subsequently, the employees can take timely remedial measures, before the issue on hand escalates to the extent of financially burdening the business.

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