Fan Control - TLT Turbo GmbH

TLT-Turbo GmbH 

© TLT-Turbo © TLT-Turbo GmbH GmbH 2010 

a Siemens Company

TLT-Turbo GmbH History 

▲ in 1873 

Centrifugal Fan 

Seite 2 

in 1925 ► 

© TLT-Turbo GmbH 

a Siemens Company


Oberhausen 

Zweibrücken 

Bad Hersfeld 

KK&K 

Frankenthal 

Seite 3 

First centrifugal fan 

for power plants 

First axial action fan 

for power plants 

Foundation of Dingler Werke 

First centrifugal fan 

First large axial fans 

First Wind Tunnel 

First Tunnel Ventilation 

Foundation of Benno Schilde 

Maschinenwerke 

Foundation of Turbo Lufttechnik 

First centrifugal fan is built 

by Benno Schilde 

Foundation of Serial Factory 

Takeover of TURMAG 

AG KK&K 

Merger with 

All european fan manufacturing companies 

was founded 

Büttner-Schilde-Haas AG 

belonging to Babcock Borsig merge with TLT 

Takeover of TROMAG 

First 

Takeover of KK&K fan devision 

centrifugal fan 

Takeover of TURBON 

Takeover of TLT Babcock 

KK&K Frankenthal Takeover, 

First axial fans 

TLT-Turbo GmbH founded 

of „Schicht“ type series AN 

Foundation of TurboGroup 

Axial fans with variable 

pitch blades 

Siemens PGI 

takes over KK&K 

and TLT-Turbo GmbH 

The New York Blower 

takes over TLT-Babcock Inc. 

1827 1873 1932 1936 1963 1970 1981 1992 1995 1996 

1874 

1925 

1951 

1878 1966 1970 1972 1973 

1899 

1900 

1936 

1960 

2001 

2003 

2003 

2005 

2006 


a Siemens Company


Seite 4 

Industrial Fans 

System 

KK&K-Frankenthal 


System Babcock Bad Hersfeld 

TLT-Turbo GmbH 


System Babcock 

Oberhausen 


a Siemens Company

Locations of TLT-Turbo GmbH in Germany 

Seite 5 

Oberhausen Zweibrücken Frankenthal Bad Hersfeld 


a Siemens Company

Solutions for Each Type of Application 

▲ power plants 

Seite 6 

mining ▼ 

▲ steel industry 

technical building ▼ 

equipment 

▲ (petro)chemical 

industry 

tunnel systems ▼ 

metro 

▲ cement industry 

automobile and ▼ 

aircraft industry 


a Siemens Company

BU Industrial Fans 

Centrifugal Fans 

installed world-wide: 7,500 

impeller diameter: up to 5,500 mm 

power consumption: 8,000 kW 

Seite 7 

Axial Impulse Fans 

installed world-wide: 200 

impeller diameter: up to 4,220 mm 

power consumption: up to 5,500 kW 


a Siemens Company

Application Range of Compressor Types and 

Fan Applications 

discharge pressure [bar] 

Seite 8 

3.500 

1.000 

600 

250 

100 

10 

1,5 

100 

Reciprocating 

Turbo radial 

Screw / Rotary vane / Roots 

1.000 10.000 

100.000 

20.000 70.000 200.000 1.000.000 

actual suction volume [m 3 /h] 

Turbo 

axial-(radial) 

Fan applications 

3.500.000 


a Siemens Company

Operating Ranges of Various Fan Types 

Seite 9 

specific energy Y in J / KG 

100000 

50000 

40000 

20000 

10000 

5000 

1000 

500 

200 

Centrifugal Fans Tailor-Made 

Tailor Made 

Centrifugal Fans Standard 

2 

5 

10 

20 

50 

100 

volume flow V in m3 . 

/s 

Axial Impulse Fans 

200 

500 

1000 

2000 


a Siemens Company

Characteristics of Various Impellers 

Seite 10 

ratio impeller diameter 

u 

efficiency 

ratio of volume flow and pressure increase 

ηηηη 

δδδδ 


a Siemens Company

Standard Fans 

Seite 11 

Type RUM (REM) Type RUR (RER/RSR) Type RUK (REK/RSK) 

Type RUK (REK/RSK) Type RUR (RER/RSR) Type RUK (RSK) 


Single Suction Fans. 

Impeller overhung or between 

bearings. 

With standard accessories. 

Based on a modular 

construction system. 


a Siemens Company


Seite 12 

Type ZEK Type ZSK Type ZEK 

Type ZSK 

Type ZER Type ZSR Type ZER Type ZSR 


Double Suction Fans. 

With standard accessories. 

Based on a modular 

construction system. 


a Siemens Company


Fan Types and Type Designation for Standard Fans 

Seite 13 

nominal size - inlet diameter of the fan casing 

nomination I - without common base frame 

II - with common base frame for installation with vibration dampers 

III - for installation on concrete foundation 

IV - for installation on concrete foundation with common base frame 

V - for installation on concrete foundation with common base frame 

and impeller located between bearings 

configuration R - single inlet 

Z - double inlet 

U - directly connected to the piping 

E - free suction via suction nozzle 

S - with suction box 

M - impeller directly connected with the motor shaft 

K - with coupling 

R - with belts and pulleys 

series 14 - ratio of impeller inlet diameter to impeller outlet diameter 

45 - outlet angle of the impeller blade 


a Siemens Company

Tailor-Made Fans 

Seite 14 

assigned casings gradation of impeller shapes gradation of size 

gradation of casing shapes 

Continuously adjustable casing shape in accordance with the outside diameter. 

Optimally designed operating points for highest 

efficiency and economy. 


a Siemens Company


Seite 15 

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. 


a Siemens Company


Seite 16 

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. 


a Siemens Company


Fan Types and Type Designation for Tailor-Made Fans 

Seite 17 

inlet diameter of the impeller 

configuration B - impeller located between bearing 

Z - double suction fan 

M - double stage fan 

_ A - revised version 

series impeller type 

relation inlet to ratio of impeller inlet diameter and impeller outlet diameter 

outlet diameter multiplied by 100 


a Siemens Company

Different Blade Designs 

For Impellers with Single Thickness Blades 

straight blades 

application for 

adhesive dust 

inlet angle: 60 ° 

outlet angle: 78 ° 

Seite 18 

backward-curved 

blades 

high pressure at high 

efficiency 


outlet angle: 40-45 ° 

backward-curved 

blades 

for dust application 

which optimizes 

efficiency and 

minimizes build-up 



forward-curved 

inclined blades 

for wet dust 




a Siemens Company

Impeller with Aerofoiled Blades 

aerofoiled blades for high efficiency (90 %) 

volume flow up to 800 m 3 /s 

pressure increase up to 15,000 Pa 

shaft power up to 8,000 kW 

Seite 19 

reinforced on the inside for high strength 


a Siemens Company

Coke Dry Quenching System 

Recirculation Fans 

Double Suction Fan. 

Impeller is mounted between 

bearings. 

With sleeve bearings. ▼ 

Seite 20 

coke 

battery 

crane 

coke hoppit 

exhaustion 

trolley 

cooling chamber 

suction hood 

ante 

chamber 

discharge 

pre-separator 

heat recovery 

boiler 

tube cooler 

baghouse filter 

water 

steam 

coke gas recirculation fan 


a Siemens Company 

fan 

cyclone



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 


a Siemens Company



Coke Gas Recirculation Fan 

Typical Data 

Seite 22 

volume flow: 50-150 m 3 /s 

temperature: about 175 °C 

mech. design temperature: 250 °C 

static pressure increase: approx. 10,000 – 14,000 Pa 


a Siemens Company

Converter with Wet Cleaning Application 

fresh air 

Seite 23 

converter 

scrubber 

converter waste 

gas fan 

flare 

gasholder 

Converter Waste Gas Fan 

executed as a centrifugal fan 


a Siemens Company


Waste Gas Fan 


Dust loaded with 1 g/m 3 (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 


a Siemens Company



Typical Data 

Seite 25 


temperature: 60-70 °C 


pressure increase: 20,000 – 28,000 Pa 

shaft power: up to 2,200 kW 

maximum speed: 1,500 rpm 


a Siemens Company

Converter with Dry Cleaning Application 

Seite 26 

fresh air 

pre-separator 

converter 

heat recovery 

boiler 

Converter Waste Gas Fan 

steam 

water 

electrical precipitator converter waste 

gas fan 

flare 

executed as an axial impulse fan 


a Siemens Company 

gasholder




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 


a Siemens Company



Typical Data 

Seite 28 


temperature: about 150 °C 


static pressure increase: 6,000 – 9,000 Pa 


a Siemens Company


Seite 29 


a Siemens Company


Seite 30 

electric drive motor 

suction box 

performance characteristic 

stabilisation 

actuator 

inlet guide vane 

impeller 

cooling air for the 

bearing 

guide vanes 

downstream 

diffuser 


a Siemens Company


Seite 31 


a Siemens Company

Pelletizing Plant 

Seite 32 

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). 



a Siemens Company


Seite 33 

WEF – Windbox Exhaust Fan 

Installed behind filter with lower dust content 

(ca. 100 mg/m 3 ). 

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). 


a Siemens Company


Seite 34 

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). 


a Siemens Company


Windbox Recuperator Fan, year of delivery: 2005. 

Seite 35 


a Siemens Company

Sinter Plant 

Sinter Waste Gas Fan 

Seite 36 

stack 

fan 

ready-mix silo 

electrical precipitator 

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/m 3 ). 

The double suction impeller is equipped with wear protection in form of hardsurfacing. 

air 

gas, oil 

ignition kiln 

sinter machine 

crusher 

exhaust pipe 


a Siemens Company

Sinter Plant 

Seite 37 


double inlet 

impeller between bearings 

regulation by inlet damper 

shaft with sleeve bearings 

oil supply unit 


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 


a Siemens Company

Cement Plant 

Raw-Mill Fan 

Typical Data 

Seite 39 





shaft power: up to 4,500 kW 

maximum speed: 1,000 rpm (50 Hz) 

900 rpm (60 Hz) 


a Siemens Company

Cement Plant 

Raw-Mill Fan 


Dust loaded with 30-50 g/m 3 (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 


a Siemens Company

Cement Plant 

Compound Fan 

Typical Data 

Seite 41 


temperature: ca. 150 °C 




900 rpm (60 Hz) 


a Siemens Company

Cement Plant 

Compound Fan 


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 


a Siemens Company

Cement Plant 

Kiln Exhaust Fan 

Typical Data 

Seite 43 



mech. design temperature: 450 °C (steady-state performance) 

500 °C (for a short time in event of fault) 


(exception: 13,000 Pa) 

maximum speed: 1,000 rpm (50 Hz) or 

1,200 rpm (60 Hz) 


a Siemens Company

Cement Plant 

Kiln Exhaust Fan 


Dust loaded with 30 g/m 3 (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 


a Siemens Company

Cement Plant 

Clinker Cooler Exhaust Fan 

Typical Data 

Seite 45 



mech. design temperature: 450 °C (steady-state performance) 



900 rpm (60 Hz) 


a Siemens Company

Cement Plant 

Clinker Cooler Exhaust Fan 


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 


a Siemens Company

Cement Plant 

Coal Mill Fan 

Typical Data 

Seite 47 


temperature: ca. 100 °C 


pressure increase: ca. 8,000 Pa 


1,800 rpm (60 Hz) 


a Siemens Company

Cement Plant 

Coal Mill Fan 


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 


a Siemens Company

Power Plant 

Fans For Power Plant and Air Pollution Control Applications 

Seite 49 

1 

2 

3 

2 3 4 5 

1 

1 

2 

3 

4 

5 

4 

5 

NO x -Air Fan 

Sealing Air Fan 

Primary Air Fan 

Forced Draught Fan 

Induced Draught Fan 


a Siemens Company

Power Plant 

Fans For Power Plant and Air Pollution Control Applications 

Configurations. 

Seite 50 


a Siemens Company

Power Plant 

——— Variable pitch blade Axial Flow Fan in horizontal position. ———————— 

Seite 51 


a Siemens Company

Power Plant 

Seite 52 

diffuser 

expansion joint 

pressure side 

rotor 

intermediate 

shaft 

fan housing 


expansion joint 

suction side 

suction box 

cooling air fan 

drive motor 

spring damper 

foundation block 

——— Variable pitch blade Axial Flow Fan in horizontal position. ———————— 


a Siemens Company

Power Plant 

Seite 53 

actuator 

motor cooling system 


shock absorbers 

drain pipe 

system 

confuser 

rubber lining (inside) 

sound insulation 

aerodyn. measuring taps 

vibration pick-up 

sealing air system 

fan housing 

built-in motor 

diffuser 

acid proof expansion 

joint 

Vertical FGD Axial Flow Fan with hub mounted drive motor. 


a Siemens Company

Power Plant 

Booster Fan in China 

gear box 

auxiliary 

drive 

bearing 

support 

floating 

bearing 

overrunning 

clutch 

Seite 54 

suction 

box 

flexible 

coupling 

hollow 

shaft 

housing 

impeller 

inlet vane 

control 

suction 

box 

fixed bearing 

flexible coupling 

with brake disc 

bearing 

support 

motor 


a Siemens Company

Power Plant 

Stainless Steel Application 

Seite 55 

Impeller for a Booster Fan for 

a power plant in Italy. 

Fan is installed behind a FGD 

plant (wet application). 

year of delivery: 2004 

impeller mat.: 1.4565 

(austenite) 


efficiency: 88.3 % 

blade design: aerofoiled 


a Siemens Company

Power Plant 

ID Fan 

During balancing in the work shop. 

Seite 56 

volume flow: 518.9 m 3 /s 

pressure increase: 10,415 Pa 




efficiency: 90 % 


tip speed: 165 m/s 

control: inlet vane control 


With scalloped main disc to reduce 

weight and moment of inertia. 


a Siemens Company

Seite 57 

Impeller of an ID Fan for a 

power plant 


impeller weight: 16,850 kg 

power requirement (shaft): 5,779 kW 



impeller material: P355NH, S690QL 

hollow shaft material: St 52-3 


a Siemens Company

Power Plant 

Booster Fan 





efficiency: 88 % 


tip speed: 108 m/s 

control: inlet vane control 


Inlet vane control located inside the 

housing to minimize the bearing 

distance. 

Seite 58 


a Siemens Company

Petrochemical Industry 

Seite 59 


With dual drive via 

turbine and motor. 


a Siemens Company


Fresh Air Fan 

volume flow: 68.61 m 3 /s turbine: 1,060 kW 

total pressure increase: 11,140 Pa speed: 1,500 rpm 

motor power rating: 1,120 kW 

Seite 60 


a Siemens Company


Applications 

Fan Types 

FD Fans (Combustion Air Fans) 

ID Fans (Flue Gas Fans, Recirculation Fans) 

Process Gas Fans 

CO 2 -Gas Fans 

Axial Flow Fans 

Seite 61 


a Siemens Company


Actual Applications 

Heater / Reformer Section: 

Combustion Air Fans 

Flue Gas Fans, Recirculation Fans 

Urea / NH 3 (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 


a Siemens Company


Possible Applications 

Prilling Tower Fans: 

Axial Fans, stainless steel 

Platform Installations for Gas Regeneration: 

Package Units 

Chlorine Gas Fans: 

high-alloy steel (up to 550 °C) 

Sealing Air / Seal Gas Fans 

Seite 63 


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: clean flue gas. 

residue firing: 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 


a Siemens Company


Seite 65 


a Siemens Company



Fans in Urea / NH 3 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 


a Siemens Company


Seite 67 


a Siemens Company



Fans in Urea / NH 3 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 


a Siemens Company



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 


a Siemens Company


Standards, Guidelines 

API 

NEMA, OSHA, EEMUA, NFPA 

ASTM, ASME 

Company Standards (additions, supplements, substitutions to API) 

Seite 70 

SHELL DEP, Flour PMD, Sabic, BASF 

International Fan Specifications 

AWS 


a Siemens Company


Seite 71 


a Siemens Company


Seite 72 


a Siemens Company


Seite 73 


a Siemens Company


Seite 74 


a Siemens Company

Impeller with Scalloped Main Disc 

Seite 75 

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 


a Siemens Company

Impeller with Scalloped Main Disc 

——— Manufacturing of the main disc in the workshop. ———————————— 

Seite 76 


a Siemens Company

Manufacturing of the Impeller 

——— Fixing the blades on the main disc. —————————————————— 

Seite 77 


a Siemens Company

Impeller Flange Connection 

Seite 78 


a Siemens Company

Hollow Shaft 

Reducing the weight of the shaft. 

Seite 79 

shaft end is 

shrinked to the tube welded after 

shrinking 

flange is welded on 

the shaft 

Creates sufficient space to the critical speed (at least 30 %). 


a Siemens Company

Hollow Shaft 

Seite 80 

Hollow Shaft 

During the shrinking process in 

the workshop. 

The shaft extension joint is 

cooled down to -170 °C with 

N 2 gas. 

The tube is going to be 

preheated up to 80 °C. 


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 


a Siemens Company

Performance Tests 

Performance test for a F.D. Fan in the TLT 

workshop with reduced speed, driven by diesel 

engine. 

Seite 82 





efficiency: 88.1 % 

control: combined hydraulic 

coupling, inlet vane 

control 



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 


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 


a Siemens Company

Seite 85 

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. 


a Siemens Company


wear protection on 

the blade inlet 

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 

hard-surfacing on 

100 % of the blade 

cover disc 


the main disc 


a Siemens Company


Seite 87 

wear liner, bolted 

on the main disc 

chromium carbide on 

100% of the blade 

Changeable wear protection in form of hard-surfacing on 100% of the blade. 

blade material with 

high yield stress value 

main disc 

wear protection on 

the main plate 

base material for the 

wear protection 


a Siemens Company

Resistance Against Wearing 

Seite 88 

life time 

Hardness [HRC] 

70 

60 

50 

40 

30 

20 

10 

0 

NAXTRA ABRAZO 400 

Hardox 400 

Chromkarbid Chromium Carbide Steel 

Steel 


a Siemens Company


New modern wear protection made from chromium carbide. 

Seite 89 


a Siemens Company


Seite 90 

Changeable, hard-surfaced, parted 

wear protection (xuperwave method). 


a Siemens Company


Seite 91 

► 

► 

wear protection: 


100 % of the blades 

Typical cracks in the hard-surfacing layer 

because of the hardness of the material. 


a Siemens Company


protected inlet of the blade 

impeller for a converter fan 


volume flow: 119 m 3 /s 




Seite 92 

▼ 


a Siemens Company

Wood Chip Drying Application 

Seite 93 

Fans for wood 

chip-, OSB- and 

MDF-dryers. 


a Siemens Company


Seite 94 

OSB (oriented strand board) 

MDF (medium-density fibreboard) 

wood chips 


a Siemens Company


OSB-Dryer 

hot gas 

generator 

Seite 95 

mixing 

chamber 

fan 

feeding 

device 

drying drum 

cyclone 

filter 

material outlet 


a Siemens Company


MDF-Dryer 

Seite 96 

mixing 

chamber 

fan 

hot gas 

generator feeding 

device 

cyclone filter 



a Siemens Company


MDF-Dryer 

Drying Fan 11/45 RUR III 2500 

volume flow: 713,000 m 3 /h 




shaft power: 2 x 630 kW 

Seite 97 


a Siemens Company


MDF-Dryer 

Seite 98 

Drying Fan 1494 B/1972 

volume flow: 866,160 m 3 /h 





a Siemens Company


Wood Chip-Dryer 

Seite 99 

hot gas 

generator 

feeding 

device 

mixing 

chamber 

drying drum 

cyclone 

filter 

fan 



a Siemens Company


Drying Fan 11/45 RUK III 2000 

volume flow: 490,000 m 3 /h speed: 980 rpm 

pressure increase: 4,600 Pa shaft power: 900 kW 


Seite 100 


a Siemens Company


New vane control (left), used vane control (right). 

Seite 101 


a Siemens Company


Seite 102 

at low wood chip 

and dust loading 

backward-curved, 

e.g. type 14/45 

at high wood chip 

and dust loading 

straight blades, 

e.g. 14/60 St and 11/45.14 

at high dust loading 

forward-curved, radial tip, 

e.g. 11/60 


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 


a Siemens Company

Subsupplier Stator Parts 

Seite 104 

► 

example: 

► 

manufacturing of 

stator company. 

DOKA/Turkey 

supplier of high quality 

since 20 years 

Fan-casing for a steel plant located in 

Ukraine. 


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 


a Siemens Company


Control by IVC (left), control by speed (right). 

Seite 106 


a Siemens Company


Seite 107 


a Siemens Company


Seite 108 


a Siemens Company


Seite 109 


a Siemens Company



Seite 110 


a Siemens Company


Seite 111 

The fan is always working 

on the point of intersection 

between fan performance 

curve and resistance-line 

of the plant. 


a Siemens Company


Seite 112 

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. 


a Siemens Company


Control by IVC or damper 

Seite 113 

If the resistance-line is con- 

stant and the fan performance 

curve is changed by variation 

of the control device the point 

of intersection moves on the 

resistance-line. 


a Siemens Company


Control by Speed 

Seite 114 

The point of intersection also 

moves on the resistance-line 

in case of variation of the per- 

formance curve by speed va- 

riation (e.g. speed controlled 

motor). 


a Siemens Company


Control by IVC or damper 

Seite 115 

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. 


a Siemens Company


Control by speed 

Seite 116 

This is also valid in case of 

speed control. 


a Siemens Company


Seite 117 

14000 

J/kg 

12000 

10000 

8000 

6000 

4000 

2000 

0 

WAHR 

WAHR 

0 50 100 150 200 250 300 350 400 

Gebläsekennlinie 

Anlagenwiderstand (Auslegung) 

Arbeitspunkt 

aktueller Anlagenwiderstand 

aktuelle Gebläsekennlinie 

Wirkungsgrad Kennlinie 

Verlust im Gebläse 

Auslegungspunkt 

100% 

50% 

30% 

Anlagen Regler 

widerstand position 


a Siemens Company



Seite 118 


a Siemens Company



Seite 119 


a Siemens Company


Seite 120 

Power P w at shaft at MCR operation point 

IVC 

1,890 kW 

speed 

1,518 kW 

damper 

2,156 kW 


a Siemens Company


Seite 121 

Power P w at shaft at MCR operation point 

IVC speed damper 

P w = 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 speed damper 

Costs = 1.512 1.214 1.725 m. € 

Diff. = 0 - 298 + 213 t. € 


a Siemens Company

Manufacturing of Industrial Fans 

1. Factory Premises 

area: 4,500 m 2 

production hall: 2,900 m 2 

dimension: 63 m x 45 m 

crane 

hook height: up to 8.8 m 

lifting capacity: 2 x 25 t; 1 x 16 t 

Seite 122 


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 


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 

Seite 124 


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 

Seite 125 


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 


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 


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 


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 


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 


a Siemens Company


10. Power Supply, electrical drive 

transformer station ( up to 400 kW) 

facility for test runs (400 kW) 

Seite 131 


a Siemens Company

Stress Calculation with FE-Method 

Seite 132 


a Siemens Company

Construction Software 

Pro/ENGINEER Mechanica 

CAD AutoCAD Mechanical 2007 

ANSYS CFX 

Pro/ENGINEER 

Microsoft Office Project 2003 

Seite 133 


a Siemens Company

Seite 134 

Thank you very much 

for your attention! 


a Siemens Company

Fan Control - TLT Turbo GmbH

Create successful ePaper yourself

Delete template?

Save as template?