Presentation Industrial Fans_kl - TLT

Transcription

TLT-Turbo GmbH
© TLT-Turbo
© TLT-Turbo
GmbH
GmbH
2010
a Siemens Company
TLT-Turbo GmbH History
▲
in 1873
Centrifugal Fan
in 1925
Seite 2
►
© TLT-Turbo GmbH
a Siemens Company
Oberhausen
Zweibrücken
Bad Hersfeld
KK&K
Frankenthal
Seite 3
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© TLT-Turbo GmbH
a Siemens Company
Industrial Fans
System Babcock Bad Hersfeld
Industrial Fans
System Babcock
Oberhausen
Industrial Fans
System
KK&K-Frankenthal
TLT-Turbo GmbH
Seite 4
© TLT-Turbo GmbH
a Siemens Company
Locations of TLT-Turbo GmbH in Germany
Oberhausen
Seite 5
Zweibrücken
Frankenthal
Bad Hersfeld
© TLT-Turbo GmbH
a Siemens Company
Solutions for Each Type of Application
▲
▲
power plants
mining
Seite 6
▼
steel industry
technical building ▼
equipment
▲
(petro)chemical
industry
tunnel systems
metro
▼
▲
cement industry
automobile and
aircraft industry
© TLT-Turbo GmbH
a Siemens Company
▼
BU Industrial Fans
Centrifugal Fans
Axial Impulse Fans
installed world-wide: 7,500
impeller diameter: up to 5,500 mm
power consumption: 8,000 kW
installed world-wide: 200
impeller diameter: up to 4,220 mm
power consumption: up to 5,500 kW
Seite 7
© TLT-Turbo GmbH
a Siemens Company
Application Range of Compressor Types and
Fan Applications
3.500
discharge pressure [bar]
1.000
600
Reciprocating
250
100
Turbo radial
10
Fan applications
Screw / Rotary vane / Roots
Turbo
axial-(radial)
1,5
100
1.000
10.000
20.000
100.000
70.000 200.000
1.000.000
3.500.000
actual suction volume [m3/h]
Seite 8
© TLT-Turbo GmbH
a Siemens Company
Operating Ranges of Various Fan Types
specific energy Y in J / KG
100000
50000
40000
Centrifugal Fans Tailor-Made
Centrifugal Fans Standard
20000
Axial Impulse Fans
10000
5000
1000
500
200
2
5
10
20
50
100
200
500
1000
2000
.
volume flow V in m3/s
Seite 9
© TLT-Turbo GmbH
a Siemens Company
Characteristics of Various Impellers
efficiency
ratio impeller diameter
η
δ
u
ratio of volume flow and pressure increase
Seite 10
© TLT-Turbo GmbH
a Siemens Company
Standard Fans
Standard Fans
Single Suction Fans.
Impeller overhung or between
bearings.
With standard accessories.
Type RUM (REM)
Type RUK (REK/RSK)
Seite 11
Type RUR (RER/RSR)
Type RUR (RER/RSR)
Type RUK (REK/RSK)
Based on a modular
construction system.
Type RUK (RSK)
© TLT-Turbo GmbH
a Siemens Company
Standard Fans
Standard Fans
Double Suction Fans.
With standard accessories.
Type ZEK
Type ZER
Seite 12
Type ZSK
Type ZSR
Type ZEK
Type ZER
Type ZSK
Based on a modular
construction system.
Type ZSR
© TLT-Turbo GmbH
a Siemens Company
Standard Fans
Fan Types and Type Designation for Standard Fans
nominal size
inlet diameter of the fan casing
nomination
I
II
III
IV
V
-
without common base frame
with common base frame for installation with vibration dampers
for installation on concrete foundation
for installation on concrete foundation with common base frame
for installation on concrete foundation with common base frame
and impeller located between bearings
configuration
R
Z
-
single inlet
double inlet
U
E
S
-
directly connected to the piping
free suction via suction nozzle
with suction box
M
K
R
-
impeller directly connected with the motor shaft
with coupling
with belts and pulleys
14
45
-
ratio of impeller inlet diameter to impeller outlet diameter
outlet angle of the impeller blade
series
Seite 13
-
© TLT-Turbo GmbH
a Siemens Company
Tailor-Made Fans
assigned casings
gradation of impeller shapes
gradation of size
Optimally designed operating points for highest
efficiency and economy.
gradation of casing shapes
Continuously adjustable casing shape in accordance with the outside diameter.
Seite 14
© TLT-Turbo GmbH
a Siemens Company
Tailor-Made Fans
Single Inlet Centrifugal Fan
Supported on one side of impeller (overhung
design).
Single Inlet Centrifugal Fan
Supported on both sides of impeller (simply
supported).
Individual fan design & manufacturing in accordance with customer specifications.
Seite 15
© TLT-Turbo GmbH
a Siemens Company
Tailor-Made Fans
Double Inlet Centrifugal Fan
Supported on both sides of impeller.
Axial Impulse Fan
I.D. Fan arranged as horizontal axial impulse
fan with inlet vane control.
Individual fan design & manufacturing in accordance with customer specifications.
Seite 16
© TLT-Turbo GmbH
a Siemens Company
Tailor-Made Fans
Fan Types and Type Designation for Tailor-Made Fans
inlet diameter of the impeller
configuration
Seite 17
B
Z
M
_A
-
impeller located between bearing
double suction fan
double stage fan
revised version
series
impeller type
relation inlet to
outlet diameter
ratio of impeller inlet diameter and impeller outlet diameter
multiplied by 100
© TLT-Turbo GmbH
a Siemens Company
Different Blade Designs
For Impellers with Single Thickness Blades
straight blades
backward-curved
blades
backward-curved
blades
forward-curved
inclined blades
application for
adhesive dust
high pressure at high
efficiency
for dust application
which optimizes
efficiency and
minimizes build-up
for wet dust
inlet angle:
60 °
inlet angle:
35 °
inlet angle:
45 °
inlet angle:
40 °
outlet angle:
78 °
outlet angle:
40-45 °
outlet angle:
45 °
outlet angle:
90 °
Seite 18
© TLT-Turbo GmbH
a Siemens Company
Impeller with Aerofoiled Blades
aerofoiled blades for high efficiency (90 %)
volume flow up to 800 m3/s
pressure increase up to 15,000 Pa
shaft power up to 8,000 kW
Seite 19
reinforced on the inside for high strength
© TLT-Turbo GmbH
a Siemens Company
Coke Dry Quenching System
Recirculation Fans
trolley
Double Suction Fan.
tube cooler
baghouse filter
Impeller is mounted between
bearings.
crane
fan
With sleeve bearings.
▼
ante
chamber
pre-separator
cyclone
steam
exhaustion
coke
battery
heat recovery
boiler
cooling chamber
water
suction hood
coke hoppit
discharge
coke gas recirculation fan
Seite 20
© TLT-Turbo GmbH
a Siemens Company
Recirculation Fans
Coke Gas Recirculation Fan
Special Features
Designed as centrifugal fans with wear protection on impeller and housing to protect
the fan against the abrasive coke dust.
Operation behind cyclone.
Mostly double width, double inlet design, with impeller supported on both sides on an
elevated concrete foundation.
These fans are controlled by speed and additionally by inlet damper.
Seite 21
© TLT-Turbo GmbH
a Siemens Company
Recirculation Fans
Coke Gas Recirculation Fan
Typical Data
volume flow:
50-150 m3/s
temperature:
about 175 °C
mech. design temperature:
250 °C
static pressure increase:
approx. 10,000 – 14,000 Pa
Seite 22
© TLT-Turbo GmbH
a Siemens Company
Converter with Wet Cleaning Application
flare
converter
scrubber
converter waste
gas fan
gasholder
Converter Waste Gas Fan
fresh air
executed as a centrifugal fan
Seite 23
© TLT-Turbo GmbH
a Siemens Company
Waste Gas Fan
Special Features
Dust loaded with 1 g/m3 (build-up and wearing).
Operation behind converter.
Gastight application, 52-66 % CO gas.
Blade and main disc of the impeller are equipped with wear protection (compound
wear plates with hard-surfacing; chromium carbide with HRC 60).
Spiral of casing with additional wear protection made from Hardox 400.
Water injection device; 2 nozzles for the blades, 1 nozzle for the cover disc, 1 nozzle
for the main disc.
Rotor designed for 35,000 load-cycle changes.
Fan control: speed control via inverter or hydraulic coupling.
Seite 24
© TLT-Turbo GmbH
a Siemens Company
Waste Gas Fan
Typical Data
volume flow:
50-60 m3/s
temperature:
60-70 °C
120 °C
pressure increase:
20,000 – 28,000 Pa
shaft power:
up to 2,200 kW
maximum speed:
1,500 rpm
Seite 25
© TLT-Turbo GmbH
a Siemens Company
Converter with Dry Cleaning Application
pre-separator
steam
flare
water
heat recovery
boiler
converter
electrical precipitator
converter waste
gas fan
gasholder
fresh air
Converter Waste Gas Fan
executed as an axial impulse fan
Seite 26
© TLT-Turbo GmbH
a Siemens Company
Waste Gas Fan
Special Features
Designed as axial impulse fans because of possible explosions or pressure shocks in
the plant; circular housing and an axial flow direction across the impeller are safer as
with a centrifugal fan.
Higher tightness of an axial fan against the ambient area because of toxic parts in the
gas composition.
Static pressure increase is executed by a diffuser, not by impeller.
Seite 27
© TLT-Turbo GmbH
a Siemens Company
Waste Gas Fan
Typical Data
volume flow:
30-170 m3/s
temperature:
about 150 °C
250 °C
static pressure increase:
6,000 – 9,000 Pa
Seite 28
© TLT-Turbo GmbH
a Siemens Company
Axial Impulse Fan
Seite 29
© TLT-Turbo GmbH
a Siemens Company
Axial Impulse Fan
electric drive motor
inlet guide vane
impeller
diffuser
guide vanes
downstream
suction box
actuator
performance characteristic
stabilisation
Seite 30
cooling air for the
bearing
© TLT-Turbo GmbH
a Siemens Company
Axial Impulse Fan
Seite 31
© TLT-Turbo GmbH
a Siemens Company
Pelletizing Plant
CAF – Cooling Air Fan
Designed for high volume flows and ambient
temperature.
Double inlet centrifugal fan with aerofoil
blades.
An axial flow fan would also be possible.
UDF – Updraught Drying Fan
Draws process gas (250-400 °C) from the
hood above the second cooling zone into the
updraught drying zone.
Protected by hard-surfaced liners.
WRF – Windbox Recuperation Fan
Handles hot process gas (300-400 °C).
Seite 32
© TLT-Turbo GmbH
a Siemens Company
Pelletizing Plant
WEF – Windbox Exhaust Fan
Installed behind filter with lower dust content
(ca. 100 mg/m3).
Temperature: 50-300 °C.
Double inlet fans with backward-curved
blades.
HEF – Hood Exhaust Fan
Similar design features as the windbox
exhaust fans.
An axial flow fan would also be possible (only
without wear protection).
Seite 33
© TLT-Turbo GmbH
a Siemens Company
Pelletizing Plant
impeller diameter:
4,500 mm
rotor weight:
13,000 kg
shaft power:
3,150 kW
speed:
890 rpm
temperature:
470 °C
Impeller material: S890QL, S960QL with corresponding material tests.
Centre disc with liners and scalloped design.
Blades with hard-surfaced liners (welded or bolted).
Seite 34
© TLT-Turbo GmbH
a Siemens Company
Pelletizing Plant
Windbox Recuperator Fan, year of delivery: 2005.
Seite 35
© TLT-Turbo GmbH
a Siemens Company
Sinter Plant
Sinter Waste Gas Fan
ready-mix silo
air
gas, oil
sinter machine
ignition kiln
crusher
stack
electrical precipitator
exhaust pipe
fan
Draws the process gas (120-200 °C) through the sinter machine and electrical
precipitator to the stack.
The gas contains highly abrasive dust (ca. 100-200 mg/m3).
The double suction impeller is equipped with wear protection in form of hardsurfacing.
Seite 36
© TLT-Turbo GmbH
a Siemens Company
Sinter Plant
Centrifugal Fan
double inlet
impeller between bearings
regulation by inlet damper
shaft with sleeve bearings
oil supply unit
Seite 37
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Main process gas fans in the cement
industry
Raw-Mill Fans
Compound Fans
Kiln Exhaust Fans
Clinker Cooler Exhaust Fans
Coal Mill Fans
Electrical Precipitator Fans
Usually the production rate of a cement plant
adds up to 1,000-10,000 tons per day.
Seite 38
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Raw-Mill Fan
Typical Data
volume flow:
80-350 m3/s
temperature:
90-100 °C
250 °C
pressure increase:
7,000 – 10,000 Pa
shaft power:
up to 4,500 kW
maximum speed:
1,000 rpm (50 Hz)
900 rpm (60 Hz)
Seite 39
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Raw-Mill Fan
Special Features
Dust loaded with 30-50 g/m3 (wearing).
Operation behind cyclone.
impeller and main disc are equipped with wear protection (compound wear plates).
Spiral of casing with additional wear protection made from St 52 (NAXTRA).
Fan control: in the majority of cases with damper flaps on the suction boxes.
Seite 40
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Compound Fan
Typical Data
volume flow:
100-450 m3/s
temperature:
ca. 150 °C
200 °C
pressure increase:
2,500 – 3,500 Pa
maximum speed:
1,000 rpm (50 Hz)
900 rpm (60 Hz)
Seite 41
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Compound Fan
Special Features
Often equipped with aerofoiled blades.
Fan control: in the majority of cases the speed control is performed by frequency
converters.
Sometimes the speed is less than mentioned before (600-750 rpm instead of
1,000 rpm), conditioned by high amounts and low pressure at the same time.
Broad blades, low-speed motor.
Seite 42
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Kiln Exhaust Fan
Typical Data
volume flow:
70-180 m3/s
temperature:
280-430 °C
450 °C (steady-state performance)
500 °C (for a short time in event of fault)
pressure increase:
7,000 – 10,000 Pa
(exception: 13,000 Pa)
maximum speed:
1,000 rpm (50 Hz) or
1,200 rpm (60 Hz)
Seite 43
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Kiln Exhaust Fan
Special Features
Dust loaded with 30 g/m3 (strong build-up).
Use of a special blade shape to extend the period between maintenance outages.
Use of an air blower unit (compressed air onto the blades).
Fan control: speed control by frequency converter.
Sometimes equipped with coasting drive.
At high volume flows two fans are run at the same time.
Seite 44
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Clinker Cooler Exhaust Fan
Typical Data
volume flow:
100-350 m3/s
temperature:
200-430 °C
450 °C (steady-state performance)
pressure increase:
2,000 – 3,500 Pa
maximum speed:
1,000 rpm (50 Hz)
900 rpm (60 Hz)
Seite 45
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Clinker Cooler Exhaust Fan
Special Features
Operation behind filter (therefore generally no wearing).
Increased number of damages in case of filter failure or outages (therefore not
equipped with profiled blades).
Wear protection (as Raw-Mill Fan).
Fan control: speed control by frequency converter.
Sometimes the speed is less than mentioned before (750 rpm instead of
1,000 rpm), conditioned by high amounts and low pressure at the same time.
Seite 46
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Coal Mill Fan
Typical Data
volume flow:
20-60 m3/s
temperature:
ca. 100 °C
150 °C
pressure increase:
ca. 8,000 Pa
maximum speed:
1,500 rpm (50 Hz)
1,800 rpm (60 Hz)
Seite 47
© TLT-Turbo GmbH
a Siemens Company
Cement Plant
Coal Mill Fan
Special Features
Often applications in dust-laden air (risk of explosive pressure shocks).
Therefore casing and suction boxes are designed with a pressure shock resistance of
1.4 bar (casing and suction boxes may deform but not break).
Fan control: in the majority of cases with damper flaps on the suction boxes.
Seite 48
© TLT-Turbo GmbH
a Siemens Company
Power Plant
Fans For Power Plant and Air Pollution Control Applications
1
4
5
2
1
3
2
Seite 49
3
4
5
1
2
3
4
5
NOx-Air Fan
Sealing Air Fan
Primary Air Fan
Forced Draught Fan
Induced Draught Fan
© TLT-Turbo GmbH
a Siemens Company
Power Plant
Fans For Power Plant and Air Pollution Control Applications
Configurations.
Seite 50
© TLT-Turbo GmbH
a Siemens Company
Power Plant
——— Variable pitch blade Axial Flow Fan in horizontal position. ————————
Seite 51
© TLT-Turbo GmbH
a Siemens Company
Power Plant
expansion joint
suction side
suction box
drive motor
intermediate
shaft
rotor
diffuser
spring damper
foundation block
expansion joint
pressure side
fan housing
oil supply unit
cooling air fan
——— Variable pitch blade Axial Flow Fan in horizontal position. ————————
Seite 52
© TLT-Turbo GmbH
a Siemens Company
Power Plant
confuser
rubber lining (inside)
sound insulation
actuator
aerodyn. measuring taps
vibration pick-up
motor cooling system
sealing air system
fan housing
built-in motor
oil supply unit
shock absorbers
diffuser
drain pipe
system
acid proof expansion
joint
Vertical FGD Axial Flow Fan with hub mounted drive motor.
Seite 53
© TLT-Turbo GmbH
a Siemens Company
Power Plant
Booster Fan in China
floating
bearing
suction
box
impeller
suction
box
fixed bearing
motor
gear box
auxiliary
drive
bearing
support
overrunning flexible
clutch
coupling
Seite 54
hollow
shaft
housing
inlet vane
control
flexible coupling
with brake disc
bearing
support
© TLT-Turbo GmbH
a Siemens Company
Power Plant
Stainless Steel Application
Impeller for a Booster Fan for
a power plant in Italy.
Fan is installed behind a FGD
plant (wet application).
year of delivery: 2004
Seite 55
impeller mat.:
1.4565
(austenite)
shaft power:
5,054 kW
efficiency:
88.3 %
blade design:
aerofoiled
© TLT-Turbo GmbH
a Siemens Company
Power Plant
ID Fan
volume flow:
518.9 m3/s
pressure increase: 10,415 Pa
temperature:
160 °C
speed:
890 rpm
shaft power:
5,792 kW
efficiency:
90 %
impeller diameter: 3,550 mm
tip speed:
165 m/s
control:
inlet vane control
With scalloped main disc to reduce
weight and moment of inertia.
During balancing in the work shop.
Seite 56
© TLT-Turbo GmbH
a Siemens Company
Impeller of an ID Fan for a
power plant
impeller diameter:
3,550 mm
impeller weight:
16,850 kg
power requirement (shaft): 5,779 kW
Seite 57
speed:
890 rpm
temperature:
185 °C
impeller material:
P355NH, S690QL
hollow shaft material:
St 52-3
© TLT-Turbo GmbH
a Siemens Company
Power Plant
Booster Fan
volume flow:
755.1 m3/s
pressure increase: 3,377 Pa
temperature:
153 °C
speed:
495 rpm
efficiency:
88 %
impeller diameter: 4,160 mm
tip speed:
108 m/s
control:
inlet vane control
Inlet vane control located inside the
housing to minimize the bearing
distance.
Seite 58
© TLT-Turbo GmbH
a Siemens Company
Petrochemical Industry
Centrifugal Fan
With dual drive via
turbine and motor.
Seite 59
© TLT-Turbo GmbH
a Siemens Company
Fresh Air Fan
volume flow:
68.61 m3/s
total pressure increase: 11,140 Pa
motor power rating:
Seite 60
turbine:
1,060 kW
speed:
1,500 rpm
1,120 kW
© TLT-Turbo GmbH
a Siemens Company
Applications
Fan Types
FD Fans (Combustion Air Fans)
ID Fans (Flue Gas Fans, Recirculation Fans)
Process Gas Fans
CO2-Gas Fans
Axial Flow Fans
Seite 61
© TLT-Turbo GmbH
a Siemens Company
Actual Applications
Heater / Reformer Section:
Combustion Air Fans
Flue Gas Fans, Recirculation Fans
Urea / NH3 (Fertilizer):
Process Gas Fans
Gas Turbines / Heat Recovery Steam Generators (HRSG):
FD Fans for substitute firing
ID Fans behind HRSG
Furnaces:
Process applications
Seite 62
© TLT-Turbo GmbH
a Siemens Company
Possible Applications
Prilling Tower Fans:
Platform Installations for Gas Regeneration:
Package Units
Chlorine Gas Fans:
Axial Fans, stainless steel
high-alloy steel (up to 550 °C)
Sealing Air / Seal Gas Fans
Seite 63
© TLT-Turbo GmbH
a Siemens Company
Design Details
Fans in Heater / Reformer Section
Heating of process gases in heat exchangers by LNG firing, sometimes by
residue firing. However, there is no contact between fan and process gas.
LNG firing:
residue firing:
clean flue gas.
possibly corrosive agents in the flue gas.
As per API 560 / 673 –
Fans with turbine and / or motor drive, dual drive with coupling / clutches;
shaft power up to 3.5 MW.
Accessories:
Air intake tower with filter, silencer, venturi, inlet guide vanes / dampers with
pneumatic actuator, sleeve bearings with external oil lubrications system,
instrumentation and controls as per API 670.
Seite 64
© TLT-Turbo GmbH
a Siemens Company
Seite 65
© TLT-Turbo GmbH
a Siemens Company
Design Details
Fans in Urea / NH3 Process
Granulation Fluidisation Fan
Granulation Atomisation Fan
First Cooler Fluidisation Fan
Granulator Scrubber Exhaust Fan
Dedusting Fan
Final Cooler Fluidisation Fan
Fumes Extraction Fan
Seite 66
© TLT-Turbo GmbH
a Siemens Company
Seite 67
© TLT-Turbo GmbH
a Siemens Company
Design Details
Fans in Urea / NH3 Process
Fans in contact with process gases and products, therefore partly made from
stainless steels.
Fans as per API 560 / 673, mostly motor driven, turbines are possbile.
Shaft power between 50 kW and 1,500 kW.
Accessories depend on the location of the fan in the process.
Sometimes connecting ducts and components as control dampers and supports
with static calculation are included.
Instrumentation and controls as per API 670.
Seite 68
© TLT-Turbo GmbH
a Siemens Company
Design Details
FD Fans for substitute firing in HRSG
Fans as per API 560 / 673, mostly motor driven, turbines are possible.
Shaft power between 50 kW and 500 kW.
Accessories:
Air intake tower with filter / sand trap, silencer, venturi tube, instrumentation,
external oil lubrication system, etc.
Accessories depend on the client and / or location.
Sometimes connecting ducts and components as control dampers and supports
with static calculation are included. Instrumentation and controls as per API 670.
Seite 69
© TLT-Turbo GmbH
a Siemens Company
Standards, Guidelines
API
NEMA, OSHA, EEMUA, NFPA
ASTM, ASME
Company Standards (additions, supplements, substitutions to API)
SHELL DEP, Flour PMD, Sabic, BASF
International Fan Specifications
AWS
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© TLT-Turbo GmbH
a Siemens Company
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© TLT-Turbo GmbH
a Siemens Company
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© TLT-Turbo GmbH
a Siemens Company
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© TLT-Turbo GmbH
a Siemens Company
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© TLT-Turbo GmbH
a Siemens Company
Impeller with Scalloped Main Disc
Advantages
weight of the impeller is reduced
moment of inertia of the rotor is reduced
less wearing on scalloped main disc
more space to handle the changeable wear plates
Seite 75
© TLT-Turbo GmbH
a Siemens Company
Impeller with Scalloped Main Disc
——— Manufacturing of the main disc in the workshop. ————————————
Seite 76
© TLT-Turbo GmbH
a Siemens Company
Manufacturing of the Impeller
——— Fixing the blades on the main disc. ——————————————————
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© TLT-Turbo GmbH
a Siemens Company
Impeller Flange Connection
Seite 78
© TLT-Turbo GmbH
a Siemens Company
Hollow Shaft
shaft end is
shrinked to the tube
welded after
shrinking
flange is welded on
the shaft
Reducing the weight of the shaft.
Creates sufficient space to the critical speed (at least 30 %).
Seite 79
© TLT-Turbo GmbH
a Siemens Company
Hollow Shaft
Hollow Shaft
During the shrinking process in
the workshop.
The shaft extension joint is
cooled down to -170 °C with
N2 gas.
The tube is going to be
preheated up to 80 °C.
Seite 80
© TLT-Turbo GmbH
a Siemens Company
Balancing Machine
maximal impeller diameter:
4,500 mm
maximal impeller weight:
20 tons
maximal length of the shaft:
7,000 mm
Seite 81
© TLT-Turbo GmbH
a Siemens Company
Performance Tests
volume flow:
304.3 m3/s
pressure increase:
4,454 Pa
temperature:
40 °C
shaft power:
1,509 kW
efficiency:
88.1 %
control:
Performance test for a F.D. Fan in the TLT
workshop with reduced speed, driven by diesel
engine.
Seite 82
combined hydraulic
coupling, inlet vane
control
year of delivery:
1996
© TLT-Turbo GmbH
a Siemens Company
Sleeve Bearing with Oil Ring
Sleeve bearings as used in most of modern conceptions with many variations of the
unit composed system.
With natural cooling, water cooling in oil sump or cooling by circulated oil.
Seite 83
© TLT-Turbo GmbH
a Siemens Company
Sleeve Bearing with Hydrostatic Jacking
Designed with Two Lubrication Pockets
for applications with high start-up load, frequent operation at low speed and very
long rundown periods to avoid wearing on the bearing shell
The high pressure pumps for hydrostatic lifting units are constant volume systems, i.e. they
supply a defined oil throughput. The maximum load carrying capacity of the system is
usually limited to 200 bar.
The maximum pump pressure occurs during the starting process, due to the oil wedge
being narrow when the bearing is still at rest. The beginning of the shaft lifting thus involves
a remarkable pressure surge. As soon as the oil wedge gets wider as the shaft is further
lifted, the pressure decreases depending on the bearing geometry and the oil throughput,
since the effectively load carrying surface is increased.
The constant pump pressure for holding up the shaft should be adjusted to 100 bar.
Seite 84
© TLT-Turbo GmbH
a Siemens Company
Wear Protection
Blades are designed as aerofoiled
blades.
As the customer requested, the profile
blades are equipped with a light wear
protection in form of welded steel plates.
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© TLT-Turbo GmbH
a Siemens Company
Wear Protection
hard-surfacing on
100 % of the blade
wear protection on
the blade inlet
hard-surfacing on
the main disc
cover disc
Unchangeable (welded )wear protection in form of hard-surfacing on the leading face of the blades and for the main plate.
Hardness of the wear protection: at least HRC 60. Repair of the wear protection: with welding electrodes.
Seite 86
© TLT-Turbo GmbH
a Siemens Company
Wear Protection
main disc
chromium carbide on
100% of the blade
wear protection on
the main plate
wear liner, bolted
on the main disc
blade material with
high yield stress value
base material for the
wear protection
Changeable wear protection in form of hard-surfacing on 100% of the blade.
Seite 87
© TLT-Turbo GmbH
a Siemens Company
Resistance Against Wearing
70
[HRC]
Hardness
life time
60
50
40
30
20
10
0
NAXTRA
Seite 88
ABRAZO 400
Hardox 400
Chromkarbid
Steel
Chromium Carbide
Steel
© TLT-Turbo GmbH
a Siemens Company
Wear Protection
New modern wear protection made from chromium carbide.
Seite 89
© TLT-Turbo GmbH
a Siemens Company
Wear Protection
Changeable, hard-surfaced, parted
wear protection (xuperwave method).
Seite 90
© TLT-Turbo GmbH
a Siemens Company
Wear Protection
►
►
Seite 91
wear protection:
hard-surfacing on
100 % of the blades
Typical cracks in the hard-surfacing layer
because of the hardness of the material.
© TLT-Turbo GmbH
a Siemens Company
Wear Protection
protected inlet of the blade
impeller for a converter fan
impeller diameter:
2,778 mm
volume flow:
119 m3/s
pressure increase:
24,034 Pa
temperature:
72 °C
shaft power:
3,123 kW
Seite 92
▼
© TLT-Turbo GmbH
a Siemens Company
Wood Chip Drying Application
Fans for wood
chip-, OSB- and
MDF-dryers.
Seite 93
© TLT-Turbo GmbH
a Siemens Company
OSB (oriented strand board)
MDF (medium-density fibreboard)
wood chips
Seite 94
© TLT-Turbo GmbH
a Siemens Company
OSB-Dryer
fan
feeding
device
cyclone
filter
hot gas
generator
material outlet
mixing
chamber
drying drum
Seite 95
© TLT-Turbo GmbH
a Siemens Company
MDF-Dryer
cyclone filter
mixing
chamber
fan
material outlet
hot gas
generator
Seite 96
feeding
device
© TLT-Turbo GmbH
a Siemens Company
MDF-Dryer
Drying Fan 11/45 RUR III 2500
volume flow:
713,000 m3/h
pressure increase:
4,000 Pa
temperature:
195 °C
speed:
750 rpm
shaft power:
2 x 630 kW
Seite 97
© TLT-Turbo GmbH
a Siemens Company
MDF-Dryer
Drying Fan 1494 B/1972
Seite 98
volume flow:
866,160 m3/h
pressure increase:
7,412 Pa
speed:
995 rpm
shaft power:
2,300 kW
© TLT-Turbo GmbH
a Siemens Company
Wood Chip-Dryer
feeding
device
cyclone
filter
fan
hot gas
generator
material outlet
mixing
chamber
Seite 99
drying drum
© TLT-Turbo GmbH
a Siemens Company
Drying Fan 11/45 RUK III 2000
volume flow:
490,000 m3/h
speed:
980 rpm
pressure increase:
4,600 Pa
shaft power:
900 kW
temperature:
125 °C
Seite 100
© TLT-Turbo GmbH
a Siemens Company
New vane control (left), used vane control (right).
Seite 101
© TLT-Turbo GmbH
a Siemens Company
Seite 102
at low wood chip
and dust loading
at high wood chip
and dust loading
at high dust loading
backward-curved,
straight blades,
forward-curved, radial tip,
e.g. type 14/45
e.g. 14/60 St and 11/45.14
e.g. 11/60
© TLT-Turbo GmbH
a Siemens Company
Research and Development Centres
Zweibrücken and Bad Hersfeld
We assure that all TLT products are continuously
adapted to current local and international requirements.
Our concept
Application of the latest data processing programs to achieve the latest investigation and
test methods in the TLT laboratories.
Advanced measuring technique is also
available for you at your local site.
Continuous exchange of ideas with our
customer.
Intensive cooperation with well-known
universities.
Seite 103
© TLT-Turbo GmbH
a Siemens Company
Subsupplier Stator Parts
►
manufacturing of
stator company.
DOKA/Turkey
supplier of high quality
since 20 years
►
Seite 104
example:
Fan-casing for a steel plant located in
Ukraine.
© TLT-Turbo GmbH
a Siemens Company
Fan Control
In principle, there are three possibilities to control a fan:
Control by inlet vane control (IVC).
Control by damper on the suction box.
Control by speed.
Seite 105
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Control by IVC (left), control by speed (right).
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© TLT-Turbo GmbH
a Siemens Company
Fan Control
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© TLT-Turbo GmbH
a Siemens Company
Fan Control
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© TLT-Turbo GmbH
a Siemens Company
Fan Control
Seite 109
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Seite 110
© TLT-Turbo GmbH
a Siemens Company
Fan Control
The fan is always working
on the point of intersection
between fan performance
curve and resistance-line
of the plant.
Seite 111
© TLT-Turbo GmbH
a Siemens Company
Fan Control
In case of changing this
resistance-line, the point of
intersection also changes.
As the fan performance curve
is constant, this point moves on
the fan performance curve.
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© TLT-Turbo GmbH
a Siemens Company
Fan Control
Control by IVC or damper
If the resistance-line is constant and the fan performance
curve is changed by variation
of the control device the point
of intersection moves on the
resistance-line.
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© TLT-Turbo GmbH
a Siemens Company
Fan Control
Control by Speed
The point of intersection also
moves on the resistance-line
in case of variation of the performance curve by speed variation (e.g. speed controlled
motor).
Seite 114
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Control by IVC or damper
If the fan performance curve
and the resistance-line are
changed at the same time,
the fan is still working in the
point of intersection. So the
point 1 “moves” accordingly.
Seite 115
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Control by speed
This is also valid in case of
speed control.
Seite 116
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Gebläsekennlinie
14000
Anlagenwiderstand (Auslegung)
J/kg
Arbeitspunkt
aktueller Anlagenwiderstand
12000
WAHR
aktuelle Gebläsekennlinie
WAHR
Wirkungsgrad Kennlinie
Verlust im Gebläse
10000
Auslegungspunkt
8000
100%
6000
4000
50%
2000
30%
0
0
Seite 117
50
100
150
200
250
300
350
400
Anlagen
widerstand
Regler
position
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Seite 118
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Seite 119
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Power Pw at shaft at MCR operation point
IVC
1,890 kW
speed
1,518 kW
damper
2,156 kW
Seite 120
© TLT-Turbo GmbH
a Siemens Company
Fan Control
Power Pw at shaft at MCR operation point
Pw
IVC
speed
damper
= 1,890
1,518
2,156
kW
Operation costs of an estimated operation time
of 8,000 hours / year and costs of 0.10 € / kWh
(electric power).
IVC
Seite 121
speed
damper
Costs = 1.512 1.214
1.725
m. €
Diff.
+ 213
t.
= 0
- 298
€
© TLT-Turbo GmbH
a Siemens Company
Manufacturing of Industrial Fans
1. Factory Premises
area:
4,500 m2
production hall:
2,900 m2
dimension:
63 m x 45 m
crane
hook height:
up to 8.8 m
lifting capacity:
2 x 25 t; 1 x 16 t
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© TLT-Turbo GmbH
a Siemens Company
2. Transport Connection
railway
Hamburg port:
360 km
Frankfurt airport:
140 km
federal motorway (A 4 and A 7): 3 km
3. Internal Means of Transport
mobile crane:
1,000 kg
forklift:
3,500 kg
Seite 123
© TLT-Turbo GmbH
a Siemens Company
4. Materials
non-alloyed and alloyed quality steels,
EN 10025-1
non-alloyed stainless steels,
EN 10025-2
alloyed stainless steels, stable to chemicals,
heat resistant , highly heat resisting,
EN 10088-1
fine-grained steels,
EN 10025-6
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© TLT-Turbo GmbH
a Siemens Company
5. Welding Techniques
according to DIN 1910 parts 2, 3, 4, 5
6. Manufacturing and Testing Permissions
according to DIN 18800 part 7
according to DIN EN 287 and by following classification societies and
regulations
Technical Supervisory Association
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© TLT-Turbo GmbH
a Siemens Company
7. Method of Testing/Testing Facility
Nondestructive Methods
x-ray inspection (external service)
ultrasonic checking
crack detection (dye penetrant examination)
crack detection (magnetic powder)
leak tests
hydraulic pressure tests
surface roughness and layer thickness tests
hardness tests
Seite 126
© TLT-Turbo GmbH
a Siemens Company
7. Method of Testing/Testing Facility
Destructive Methods
folding tests
Other Methods
fan testing facility
devices for ventilation measurement
dust measurements
immission measurements
vibrometer
sound-level meter
Seite 127
© TLT-Turbo GmbH
a Siemens Company
8. Machinery
Non-Machining Manufacturing
round bending machine (max. plate width: 3,040 mm; max. plate thickness: 30 mm)
Kraftformer (675/450 mm outreach, max. plate thickness: 8 mm)
flange bending machine (3,600 mm Ø x 12 mm)
three-roll plate bending machine (max. plate width: 2,500 mm; max. plate thickness:
20 mm)
Seite 128
© TLT-Turbo GmbH
a Siemens Company
8. Machinery
Machining Manufacturing
turning lathes
(max. 1,050 mm turningØ at 3,000 mm turning length,
max. 800 mm turning length at 900 mm turningØ)
vertical lathe
(max. 2,350 mm turningØ, max. 1,250 mm working height)
radial drill machine
(max. 60 mm drillØ)
keyseating machine
(max. 650 mm drawing length, max. 65 mm keyseat width)
balancing machine 1
(max. 2,800 mm Ø, 4,300 mm length, 7,000 kg loading)
balancing machine 2
(max. 4,500 mm Ø, 7,500 mm length, 20,000 kg loading)
blasting plant
(7,000 mm length, 5,000 mm width, 3,000 mm height)
spray station
(5,000 x 5,000 mm)
Seite 129
© TLT-Turbo GmbH
a Siemens Company
9. Welding
two rotary tables with 2,000 mm Ø
one rotary table with 2,500 mm Ø
15 welding machines (MAG)
two plasma slicing machines
Seite 130
© TLT-Turbo GmbH
a Siemens Company
10. Power Supply, electrical drive
transformer station ( up to 400 kW)
facility for test runs (400 kW)
Seite 131
© TLT-Turbo GmbH
a Siemens Company
Stress Calculation with FE-Method
Seite 132
© TLT-Turbo GmbH
a Siemens Company
Construction Software
Pro/ENGINEER Mechanica
CAD AutoCAD Mechanical 2007
ANSYS CFX
Pro/ENGINEER
Microsoft Office Project 2003
Seite 133
© TLT-Turbo GmbH
a Siemens Company
Thank you very much
for your attention!
Seite 134
© TLT-Turbo GmbH
a Siemens Company

Presentation Industrial Fans_kl - TLT

Transcription

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