TLT-Turbo schlägt im revolutionären Tunnel Digitalization Centre die Brücke von der realen zur digitalen Welt.

Im September 2021 hat TLT-Turbo einen Jet-Ventilator im TDC in Betrieb genommen, der von nun an für Forschungsprojekte in einer realen Tunnelumgebung sowie für die gemeinsame Entwicklung und Prüfung digitaler Produkte genutzt wird.

TLT-Turbo ist seit Ende 2020 Industriepartner des Swiss Center of Applied Underground Technologies (SCAUT) und beteiligt sich seitdem am gemeinsamen Forschungsprojekt des “Tunnel Digitalization Center”. Im Oktober 2019 wurde das Tunnel Digitalization Center (TDC) im Versuchsstollen Hagerbach in Flums, Schweiz, offiziell eröffnet.

Dieses einzigartige Tunnelzentrum ermöglicht zum ersten Mal in der Geschichte Demonstrationen und Simulationen in einer realistischen Umgebung.  Das Projekt wurde vom Swiss Center of Applied Underground Technologies (SCAUT) initiiert. Durch den kontinuierlichen Einsatz neuer Technologien und innovativer Konzepte im TDC besteht das Zentrum nun aus einem BIM-Zentrum, einem Kontroll- und Schulungszentrum, einem Simulationszentrum und einem Cloud-Center.

Das Swiss Centre of Applied Underground Technologies (SCAUT) ist das weltweit führende Kompetenzzentrum für die Nutzung des untertägigen Raums. Das SCAUT bündelt die gesammelten Kenntnisse, Kompetenzen und Technologien aus dem Untertagebau sowie aus anderen Industriezweigen, um sie als weltweit erstes Kompetenzzentrum seiner Art weiterzuentwickeln und für verschiedene Anwendungen im unterirdischen Raum nutzbar zu machen.

Neben TLT-Turbo besteht das SCAUT-Konsortium aus weiteren führenden Unternehmen der Branche, nämlich Amberg Engineering Ltd, Siemens Ltd, Elkuch Group Ltd und HBI Haerter Ltd. In erster Linie wurde die TLT-Turbo GmbH ausgewählt, da sie ein weltweit führender Experte in der Herstellung von Ventilatoren für eine Reihe von Branchen ist. Amberg Engineering Ltd. werden für den Infrastrukturbau eingesetzt, Amberg Technologies Ltd. für Vermessung und Scanning, Siemens AG für Automation, Elkuch Group Ltd. für Türsysteme und HBI Haerter Ltd. für Tunnelbelüftungssimulationen.

In Zukunft werden die meisten Menschen in städtischen Gebieten leben. Die Nutzung der dritten Dimension, nicht nur nach oben, sondern auch unter Tage, wird ein wesentlicher Bestandteil der Stadtentwicklung sein. Ziel ist es, den oberirdischen Raum als Freiraum und Lebensraum für Menschen und soziale Interaktion zu nutzen und den unterirdischen Raum als Teil des nutzbaren Raums einzubeziehen. Das Tunnel Digitalization Center (TDC) bietet die einzigartige Möglichkeit, die Interaktion und Transformation von real zu digital direkt im Tunnel zu erleben.

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TLT-Turbo Donates to Klinikum Bad Hersfeld

TLT-Turbo setzt sich für das Wohlergehen des Pflegepersonals in Bad Hersfeld ein

TLT-Turbo GmbH gab heute bekannt, dass der Standort Bad Hersfeld 1.500 € für das Pflegepersonal der Covid-19-Intensivstation des Klinikums Hersfeld gespendet hat. Mit dieser Spende sollen die Krankenschwestern und -pfleger unterstützt werden, die sich unermüdlich für die Bewältigung der Covid-19-Pandemie in der Region eingesetzt haben, und es sollen die nötigen Mittel bereitgestellt werden, um ihnen eine Auszeit zu ermöglichen.

Die Gelder wurden von TLT-Turbo Bad Hersfeld gespendet und am 15. Dezember 2021 von Standortleiter Christian Kosack im Klinikum Hersfeld übergeben.

“Im Rahmen unseres Jahresbudgets stellen wir einen bestimmten Betrag zur Verfügung, um der umliegenden Gemeinschaft etwas zurückzugeben. Die heutige Spende haben wir speziell für diejenigen bereitgestellt, die an vorderster Front im Kampf gegen die Pandemie stehen. Es war uns wichtig, dass diese Mittel direkt an das Pflegepersonal und nicht an das Krankenhaus gehen. Wir sind der Meinung, dass das Pflegepersonal der Intensivstation nicht nur die überreichten Mittel verdient, sondern ebenfalls die Anerkennung der Unternehmen in der Gemeinde für all das, was sie getan haben”, sagte Kosack.

Die Spende wurde an Frank Heenes, Stationsleiter der Intensivstation 1 des Klinikums Bad Hersfeld, übergeben und soll für ein besonderes Sommerfest für die Mitarbeiter der Intensivstation verwendet werden. “Unsere Absicht war es, dass die Mitarbeiter direkt von der Spende profitieren und mit dem Geld in besonderer Weise geehrt werden. Damit wollen wir ihnen für ihre wertvolle und anstrengende Arbeit danken und ihnen direkt etwas zurückgeben”, erklärt Kosack.

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Modular Design

Modular Design Redefines Mine Ventilation Efficiency and Availability

TLT-Turbo have released a modular mining ventilation fan concept that simplifies the planning of ventilation systems for customers while still providing the benefits that are synonymous with TLT-Turbo products including increased efficiency and lower power consumption. The Modular Mining Fan concept offers a range of modular solutions that cater to almost every ventilation requirement and aims to set a new standard for mine ventilation innovation.

The range offers a modular design that results in a well-engineered and efficient ventilation system at lower operational and maintenance costs. Customers have the flexibility to order required units and build on the system as their requirements grow – resulting in lower initial expenditure with more economical options for system expansion.

German engineering and extensive R&D have resulted in the highest product quality. This, paired with TLT-Turbo’s field-proven technology, provides a high-end pre-existing solution which means that mines will not incur the design and engineering costs that are usually associated with bespoke ventilation installations.

The modular concept makes it extremely convenient for customers in the mining industry to plan, design and optimize their ventilation systems to optimally benefit their operations. The modular approach eliminates guess work and ensures that the entire system can be planned to deliver predictable and accurate performance.

The modular design offers seven base fan sizes combined with six different hub sizes to ensure the right fit for all requirements. Numerous customizable and adaptable parts offer flexibility for specific customer needs. Add-ons have been developed for all seven base sizes allowing for modular pre-existing upgrades to meet individual requirements.

The modular components are designed to slot together, and no additional engineering is needed to ensure that different modules fit together to suit a specific operating environment. The advanced design ensures total fan efficiency of up to 90% lower operating costs while maintaining full performance. This entire offering is available at lower initial costs with short lead times for supply.

All the modular components can be manufactured simultaneously and are commissioned and installed once completed. Expansion of an existing TLT-Turbo Modular Mining Fan system is a simple process as new components are slotted into the existing system with minimal effort. Typically, ventilation systems need to grow or be upgraded as production demands increase. Where a major overhaul would usually be required, TLT-Turbo’s modular installation can be expanded by installing additional components to the existing system to scale up ventilation capacity or replace existing modules with higher specifications to optimise or upgrade the system.

With the modules being manufactured at state-of-the-art TLT-Turbo manufacturing facilities, customers can be assured of the highest quality end product. Continual monitoring, testing and quality checks are conducted at every stage of the manufacturing process. Well considered opportunities for varied combinations ensure shorter manufacturing and delivery lead times at lower costs to get your project running faster and smoother.

Contact TLT-Turbo to find out how the Modular Mining Fan range can benefit your operation, or visit https://www.tlt-turbo.com/en/product-and-services/mining-fans/modular-mining-fans/ to find out more.

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TLT-Turbo MVR-Reihe macht Fortschritte in der Lebensmittel- und Getränkeindustrie

Im November 2018 schloss TLT-Turbo die Installation eines MVR-Turboventilators der „Medium Flow“ Baureihe im Frischli-Werk in Rehburg-Loccum, Deutschland, ab. Der Ventilator läuft bei Frischli seit fast drei Jahren und bietet eine zuverlässige, geräuscharme Leistung, ohne dass das Ventilatorlager gewartet werden muss – was ihn zu einem idealen Anwendungsfall für die Demonstration der Fähigkeiten von TLT-Turbo in der Lebensmittel- und Getränkeindustrie macht.

TLT-Turbo sammelt seit 2018 Daten von der Frischli-Anlage über die Leistung des Ventilators und wird dies auch weiterhin fortsetzen, um auf Basis dieser Daten eine Fallstudie zu erstellen, die die Kosteneinsparungen für Frischli aufzeigt und die Art und Weise auflistet, wie die Produktion vom Einsatz des TLT-Turbo MVR-Ventilators profitiert hat. Dies wird die Bemühungen der MVR-Abteilung zur Verkaufsförderung unterstützen, da es einen klaren Beweis dafür liefern wird, wie TLT-Turbo die mechanische Brüdenverdichtung in der Lebensmittel- und Getränkeindustrie neu definiert.

„Unsere MVR-Baureihe für mittlere Massenströme eignet sich ideal für Anlagen wie die am Hauptsitz von Frischli“, sagt Mario Schmidt, Leiter des Geschäftssegments Vapor Fans. „Die höheren Wirkungsgrade dieser Ventilatoren machen uns wettbewerbsfähiger im Markt für kleine bis mittlere Massenströme, in dem viele potenzielle Kunden aus der Milchwirtschaft, der Lebensmittel- und Getränkeindustrie oder der pharmazeutischen Produktion angesiedelt sind.“

Frischli, ein inhabergeführtes Unternehmen, stellt seit über 120 Jahren Milchprodukte her, die höchsten Ansprüchen an Qualität, Nachhaltigkeit und Geschmack gerecht werden. Am Firmensitz in Rehburg-Loccum bei Hannover werden unter anderem H-Milch, Milchpulver und Sahne hergestellt. Darüber hinaus werden Milchgetränke wie Kakao, Milchpulver, Pudding und Joghurt sowie eine breite Palette von Molkereiprodukten für Gastronomie und Catering hergestellt.

Die Beziehung zwischen Frischli und TLT-Turbo dürfte sich zu einer langjährigen Zusammenarbeit entwickeln, da beide Unternehmen den Fokus auf die Förderung von Innovationen teilen. Frischli ist eine der modernsten und effizientesten Milchwerke in Deutschland. Dies ist laut Schmidt einer der Gründe dafür, dass sie sich so schnell für die neue MVR-Technologie der TLT-Turbo-Reihe entschieden haben.

„Ein klarer Beweis dafür, dass wir beide an Innovationen und technologische Fortschritte in der Lebensmittelproduktion glauben, ist die Tatsache, dass Frischli sich bereit erklärt hat, Referenzkunde für TLT-Turbo zu werden. Das bedeutet, dass wir mit potenziellen Kunden das Werk besuchen können, um ihnen den MVR-Ventilator in Aktion zu zeigen“, verrät Schmidt.

Er stellt außerdem fest, dass sie von den Eigenschaften des Ventilators begeistert waren –

insbesondere im Hinblick auf die Wartung. Frischli hat in seinem Werk eine Reihe von MVR-Ventilatoren eines anderen Anbieters installiert. Als es an der Zeit war, die jährliche Wartung aller im Werk laufenden Ventilatoren durchzuführen, wurde die fortschrittliche Technologie der TLT-Turbo MVR-Reihe deutlich.

„Im Rahmen der jährlichen Wartung der anderen MVR-Ventilatoren fragten mich unsere Techniker, ob sie den TLT-Turbo MVR-Ventilator in den Wartungsplan aufnehmen sollten. Sie waren sehr überrascht zu erfahren, dass dieser MVR-Ventilator keine Wartung benötigt. Lediglich die Wellendichtungsringe sollten bei Undichtigkeiten ausgetauscht und eine Fettpatrone für den Motor aufgeschraubt werden. Das spart eine Menge Zeit und Geld“, sagt Henrike Kaluza, Projektleiterin bei Frischli.

Sie geht weiter auf die Zeit- und Kostenersparnis ein, die mit dem TLT-Turbo MVR-Ventilator erzielt werden kann. „Die regelmäßige Wartung der beiden anderen MVR-Ventilatoren, die wir betreiben, kostet zwischen 8.500 und 9.000 Euro pro Jahr, also rund 4.500 Euro pro Ventilator“. Da die Lagerung des TLT-Turbo Ventilators mindestens zehn Jahre lang nicht gewartet werden muss, belaufen sich die Einsparungen in diesem Zeitraum auf insgesamt 45.000 Euro pro Ventilator. Auch die Stillstandzeit wird somit deutlich reduziert. Bei den wenigen erforderlichen Wartungsarbeiten an dem TLT-Turbo Ventilator liegt diese bei maximal 1-2 Stunden Stillstand und das nicht einmal zwingend in jedem Jahr.

Die Tatsache, dass die TLT-Turbo MVR-Ventilatoren keinen Ölwechsel benötigen, ist für Betreiber in der Molkerei-, Lebensmittel- und Getränkeindustrie sowie in der pharmazeutischen Industrie sehr wertvoll. „In einer sauberen Umgebung ist es sehr wertvoll, bei der Wartung wichtiger Anlagen keine Chemikalien wie Öl in die Umgebung einbringen zu müssen. Außerdem sind unsere Ventilatoren dadurch auch umweltfreundlicher. Andere Ventilatoren auf dem Markt verbrauchen etwa 40 bis 60 Liter Öl pro Jahr oder 400 bis 600 Liter über 10 Jahre, während unsere Ventilatoren nur 60 bis 120 Gramm Fett über einen Zeitraum von zehn Jahren verbrauchen“, erklärt Schmidt.

Kaluza äußerte sich auch positiv über die Leistung des TLT-Turbo Ventilators. „Der Wirkungsgrad des Ventilators ist besser als bei dem Modell, das er ersetzt hat. Die realisierten Einsparungen bei den derzeitigen Stromkosten liegen bei 8.700 Euro pro Jahr und ohne die Zuschläge aus unserem Blockheizkraftwerk würden die Einsparungen sogar bei 12.000 Euro pro Jahr liegen“.

„In Anbetracht dieser Verbesserungen und der anderen Vorteile der Maschine, wie dem niedrigen Geräuschpegel oder der Ölfreiheit, sind wir mit dem TLT-Turbo Ventilator sehr zufrieden und freuen uns, dass wir uns für ihn entschieden haben“, so Kaluza abschließend.

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Korrosion an Kraftwerksventilatoren

Die Energietechnik befindet sich weltweit im Wandel. Der rasche Ausbau der erneuerbaren Energien, volatiler Stromerzeugungsanlagen, erfordern eine deutlich höhere Flexibilität der konventionellen Anlagen. Dies hat zu einer Reihe neuer Herausforderungen für die dort eingesetzten Ventilatoren geführt, dazu zählen z. B.:

  • Eine erhöhte Anzahl von Start- und Stoppvorgängen
  • Weniger Volllaststunden,
  • Vermehrt Teillastbetrieb,
  • Geringere Abgastemperaturen durch Restwärmenutzung sowie
  • Kleinerer Abstand zum Säuretaupunkt

Diese Faktoren führen zu einer erhöhten Belastung der Systeme, was ein erhöhtes Korrosionsrisiko während des Betriebs mit sich bringt. Dies begünstigt Taupunktkorrosion, die zum Totalausfall von Ventilatoren und Systemkomponenten führen kann.

TLT-Turbo bietet Ihnen eine maßgeschneiderte Lösung für Ihre Anlage durch die Implementierung effektiver Korrosionsschutzmaßnahmen zur Aufrechterhaltung der Betriebszeit Ihrer Ventilatoren.

Effizienter Schutz gegen Korrosion

Der TLT-Turbo Korrosionsschutz für Ventilatoren umfasst zwei wichtige Maßnahmen: Verhindern von Korrosion, wo es möglich ist und Schutz von Bauteilen, bei denen Korrosion nicht verhindert werden kann.

Verhindern von korrosiven Bedingungen:
  • Vermeidung oder Reduzierung von Leckage von Sperrluft
  • Erwärmen von Ventilatorkomponenten
  • Optimierung der Isolierung
Einsatz von korrosionsbeständigen Materialien:
  • Wetterfester Stahl
  • Polymere und polymere Beschichtungen
  • Edelstahl
  • Beschichtungen oder Grundwerkstoffe auf Ni-Basis

Um die geeigneten Maßnahmen zur Vermeidung und Bekämpfung von Korrosion an Ventilatoren in Ihrer Anlage auszuwählen, führt TLT-Turbo eine individuelle Korrosionsrisikobewertung durch. Diese Bewertung basiert auf Ihren Betriebs- und Umweltbedingungen.

TLT-Turbo unterstützt Sie darüber hinaus mit einer Analyse Ihrer spezifischen Betriebsbedingungen, z. B. durch eine Taupunktmessung auf der Grundlage einer gemeinsamen Anlagenbegehung.

Setzen Sie sich mit TLT-Turbo in Verbindung, um Ihren Korrosionsschutzbedarf zu besprechen und das richtige Servicepaket für Ihre laufenden Anforderungen zu finden.

Optimaler Schutz gegen Korrosion bei Bestandsanlagen

TLT-Turbo führt Korrosionsrisikobewertungen durch und implementiert geeignete Präventivmaßnahmen bei der Konstruktion und Herstellung neuer Ventilatoren. Diese Maßnahmen können auch bei der Nachrüstung bestehender Anlagen oder im Rahmen der vorbeugenden Wartung während eines geplanten Stillstands durchgeführt werden.

Weitere Informationen zur Durchführung einer maßgeschneiderten Risikobewertung in Ihrer Anlage erhalten Sie von Ihrem Service-Mitarbeiter oder der Serviceabteilung von TLT-Turbo.

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TLT-Turbo and MoJet® Join Forces to Redefine Tunnel Ventilation

A strategic partnership between TLT-Turbo GmbH, global ventilation equipment manufacturer and Mosen Ltd, a leading tunnel ventilation innovator, will offer advanced technology delivered by the innovative MoJet® tunnel ventilation system.

The MoJet® has been developed through a close cooperation between engineers and the R&D teams at TLT-Turbo and Mosen Ltd, as well as renowned universities. Through extensive research and testing, the two firms jointly developed this innovative product for tunnel ventilation.

“TLT-Turbo was initially approached by Dr. Fathi Tarada, Mosen Ltd Managing Director and Chief Technologist for MoJet® Ventilation, about testing for his new product. What followed was a complete reimagining of tunnel ventilation systems,” says TLT-Turbo Business Head for Tunnel and Metro, Jürgen Steltmann.

According to Lars Lehmann, TLT-Turbo Tunnel & Metro Product Manager, what differentiates the MoJet® is its ability to increase aerodynamic thrust and deliver incredible ventilation performance while consuming less power.

“Conventional Jet Fans are the standard means of providing longitudinal ventilation in tunnels. However, they suffer from the following significant disadvantage compared to the MoJet®,” Lehmann explains. “Thrust is lost due to friction between the jet and the tunnel surfaces. Typically, 30% to 50% of thrust is thereby lost.”

The reversible MoJet® tunnel ventilation system can increase in-tunnel aerodynamic thrust by up to 50%, with reduced power consumption. To achieve such a significant improvement in performance, the MoJet® uses shaped nozzles which turn the jet flow away from the tunnel soffit and walls. This reduces surface friction, minimizing the Coanda Effect, where a reduction in static pressure due to the high jet velocity tends to deflect the jet towards any solid surface. The MoJet® represents a significant improvement over older technologies to reduce the Coanda effect, such as slanted silencers and jet flow deflectors.

“Major infrastructure projects must demonstrate sustainability and value for money while delivering the required performance. That is why we have developed the MoJet®, an innovative tunnel ventilation system which has been installed worldwide,” says Dr. Tarada. “The innovative design results in markedly improved energy efficiency and fewer or smaller jet fans being required to provide the same degree of ventilation, as verified by independent measurements in full-scale tunnels.”

Dr. Tarada adds that MoJets® do not encroach upon the traffic envelope and can be installed very close to tunnel walls and soffits, reducing space requirements and construction costs.

Comparison of the jet and jet diffusion of Jet Fans with standard silencers (red) and MoJet® –silencers (blue) in a tunnel.
Direct comparison of the two velocity profiles for the measurement with standard silencer (red) and with MoJet® – silencer (blue)

Tried and Tested

Earlier this year, TLT-Turbo undertook an extensive series of laboratory tests and site tests within the Rendel Street branch of the Mersey Queensway Tunnel in Northwest England on a 1.25m internal diameter MoJet® with an equivalent conventional jet fan. Mosen Ltd supported the testing with detailed aerodynamic design using 3D Computational Fluid Dynamics (CFD). The measurements indicated a dramatic increase in the in-tunnel thrust, for no increase in motor power consumption.

“The MoJet® technology represents the next generation of tunnel ventilation design, offering a reduction in the required number of jet fans and overall tunnel power demand, as well as a marked improvement in sustainability and energy efficiency,” Dr. Tarada concludes.

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TLT-Turbo Optimizes Air Flow at European Power Plant Based on CFD

In TLT-Turbo’s 145-year long history of developing centrifugal and axial fans, every fan has always been carefully evaluated through extensive testing before being deemed fit for application. These tests were greatly enhanced when computational testing became available. More recently, Computational Fluid Dynamics (CFD) simulation has greatly enhanced not only TLT-Turbo’s ability to conduct thorough product testing but has also created opportunities for developing new and improved fan types.

According to Sabine Groh, Product Manager for industry fans at TLT-Turbo in Bad Hersfeld, Germany, every TLT-Turbo fan type once was carefully evaluated and aerodynamically measured in aerodynamic test stands before being released for application in the customer’s operating environment. “The arrival of stronger computer performance has allowed us to utilize CFD simulation which has had a massive effect on our ability to develop new products and to improve existing fan types.”

Groh explains that CFD has numerous advantages, all of which have become integral to TLT-Turbo’s product development. One of the greatest advantages is that CFD has enhanced the understanding of flow phenomena more efficiently than empirical testing. By using CFD it is possible to zoom in and out of any area within the simulated geometry to determine most advantageous or disadvantageous parts or geometries. With examination options such as vectorplot, a detailed analysis of the direction within the flow is possible. Similarly, using streamlineplot or velocityplot provides a detailed view of irregularities or aerodynamic phenomena.

“This analysis helps us understand the parts or geometries that cause flow separations and turbulence which allows us to address these in our product design. We can use the CFD simulations for the development or improvement of different fan types, blade geometries or spiral casing for centrifugal fans,” says Groh.

Additionally, TLT-Turbo uses CFD to understand problems in the flow of a given customer application that might result in a loss of pressure, efficiency or untypical wear of parts exposed to the flow. This equips TLT-Turbo with the knowledge needed to carry out retrofitting and product enhancements to ensure improved future performance (see flow optimization use case below).

Flow Optimization Case Study

At a European power plant, a centrifugal fan was controlled by an inlet vane control. During operation, the blades of the vane were rattling after a while and needed repair. After replacement, the same blades were showing the same failure after some operation time. Figure 1 below shows the blade of the inlet vane control dismounted of the socket.

Figure 1: blade shaft of inlet vane control with too much clearance in the socket

It was assumed that the flow was not homogeneous before it reached the inlet vane control blade, and the use of air guiding plates was considered to correct the flow. Through the use of CFD, this pattern could be more deeply investigated resulting in a superior solution.   

Groh unpacks the process and explains how a better solution was found using CFD: “Each CFD requires four process steps. The first step is the creation of the 3D model of the geometry to be analyzed. The second step is discretization. This involves creating a three dimensional computational mesh in the model for the volume in which the medium flows. The third step is defining the boundary conditions for the simulation and as the fourth step, the simulation of the flow can be performed.”

In this specific instance, the ductwork ahead of the malfunctioning inlet vane control, the blades of the closure unit itself and the suction box behind the closure unit were all rendered in 3D models. Figure 2 below shows the geometry that was analyzed in detail in the computer model. The ductwork upstream and downstream was included to ensure the stability of the calculation in the simulation.

Figure 2: Scope of detailed simulation in the plant

After meshing of the 3D model, a simulation was performed to determine the direction of the stream in the ducting ahead the inlet vane control in more detail. Figure 3 below shows the result of the simulation.

Figure 3: direction of the stream in the ductwork ahead of the inlet vane control

The simulation showed that a separation of the stream led to turbulence in the flow ahead of the closure unit. With the validated conclusions of the simulation, TLT-Turbo was able to investigate different proposed solutions to remedy the problem. Figure 4 below shows the streamline plots of these different solutions.

Figure 4: Comparison of different countermeasures against the turbulence

The conclusion was that a combination of two countermeasures in the ducting would be the most advantageous solution. So ahead of the closure unit, TLT-Turbo installed a suction nozzle that helped guide the incoming flow into the duct (see blue colored suction nozzle in Figure 5 below).

Behind the closure unit, TLT-Turbo also welded a split plate (blue colored plate in Figure 5) into the suction box to help guide the stream further into the inlet vane control ahead of the centrifugal fan.

Figure 5: implemented solution to solve the problem with the inlet vane control

In Conclusion

The use of CFD has become an essential tool to TLT-Turbo for the development of new and more efficient fan types and blades. Instead of building numerous test models for each proposed blade or impeller type with subsequent aerodynamic model testing, different geometries can be compared in the CFD simulation directly. However, the value of CFD doesn´t end there. Increasingly, TLT-Turbo is also using CFD for aerodynamic optimization of flow in customer operating environments.  That includes solving aerodynamic problems such as the example above, and for reducing wear, pressure loss or in general creating a more homogenous flow of the gas or air in the plant to maximize efficiency. Finally, the success of performance improvements as a result of replacing a fan in an existing casing, can be verified.

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TLT-Turbo Secures Ventilation Works for Swiss Baregg Tunnel Project

TLT-Turbo (GmbH), a leading supplier of ventilation equipment and systems has received a contract to provide longitudinal ventilation and escape route ventilation for the Baregg Tunnel project through a call for tender by the Swiss Federal Roads Office, ASTRA, based in Zofingen, Switzerland.

The scope of TLT-Turbo’s delivery on the project includes 16 stainless steel, dual-speed jet fans. The jet fans will meet the project’s temperature requirement of 250 °C/2 h. The contract also includes the supply of an extensive array of services including project management, documentation of performance and technical specifications, inspections, QA, testing, training of operating personnel and future maintenance. The order is currently being processed with completion of the installation expected by January 2024.

The Baregg tunnel and the Neuenhof covering are part of Switzerland’s N01 route, located between the exits and entrances of Baden-West and Wettingen. This section is known as one of the busiest sections of the Swiss national road network.

TLT-Turbo Head of Tunnel and Metro division, Jürgen Steltmann, said: “We scoped out this project by starting with a dimensional survey and inspection of the existing tunnel structure. This will be followed by planning, fabrication, factory tests and finally delivery and installation. We are confident that our approach will result in a ventilation solution that meets the requirements of the Baregg Tunnel project and ensures and safe environment for commuters.”

TLT-Turbo has over 100 years of experience in ventilation technology and has been developing, manufacturing, and constructing fans and ventilation systems for more than 40 years. This extensive experience has been consistently incorporated into the development of their tunnel ventilation systems.

According to Steltmann, to ensure a safe environment inside tunnels, TLT-Turbo’s foremost consideration is smoke. “In an emergency, smoke is one of the major hazards for people in an underground tunnel. Our ventilation systems provide clear visibility for escape routes. In case of fire, our Metro and Tunnel fans provide smoke free emergency exit routes.”

“Our other key considerations are quality, noise abatement and energy efficiency. Our fans are tested according to EN 12101-3 give tunnel operators peace of mind that they are receiving ventilation equipment that meets their specifications and is of the highest quality. From there, TLT-Turbo combines specially selected materials, highly heat-resistant motors and design precision to blend quality assurance with the highest economic efficiency,” Steltmann explains.

The aerodynamic features of TLT-Turbo’s Jet Fan range guarantee low power consumption and installation costs. They also help to keep the acoustic noise low. These fans may be used in tunnel sections as jet fans with free inlet and outlet and as axial fans in ducted installations. The success story of these fans started in the early 1970’s in the Alps and several important Alptransit-routes have been equipped with TLT-Turbo tunnel fans since then – including ventilation for the longest railway tunnel worldwide in the Gotthard Base Tunnel.

“Our track record combined with the fact we have well-trained, experienced staff who collaborate with leading international consultants to ensure that we meet expected international standards are what have made TLT-Turbo not just a supplier, but a preferred tunnel and metro ventilation partner renowned for redefining ventilation quality and performance,” Steltmann concludes.

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Join us for a live webinar on Basics of Fan Aerodynamics and Optimization Potentials

Date: May 19, 2021 | Time: 1:00 p.m. – 2:00 p.m. (CET)

During a short journey through the topics of fan aerodynamics, our TLT-Turbo fan experts pick you up at the aerodynamic basics and show you which improvements are possible through aerodynamic optimizations.

Starting with the basic understanding of volume flow and pressure rise, the journey continues via the origin and definition of the operating points to the various aerodynamic control types of fans in technical systems. You will understand the differences between fan types and the definition of efficiency. The journey ends with the identification of different optimization potentials of axial fans and how TLT-Turbo can support you in optimizing them.

Unable to make the Live Webinar? Visit www.tlt-turbo.com to view the simulcast after the live date.

We look forward to hosting you!

Regards,

TLT-Turbo

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Research Reveals Best Wear Solutions for Ventilation Equipment

Long lasting equipment is a must have for many industries due to the cost savings that can be derived from a longer lifespan on equipment and components. At their recently upgraded testing facility, TLT-Turbo GmbH are using a new research methodology based on dust particulate samples from steel manufacturing and processing facilities to determine the best solutions for minimizing wear on ventilation equipment based on the unique abrasive factors of this specific operating environment.

TLT Turbo GmbH is one of the world’s leading suppliers of heavy-duty centrifugal fans designed to operate efficiently in the most challenging applications. In the steel industry, these fans are exposed to high dust loads which causes them to prematurely fail due to faster wear. To determine the best solutions for slowing wear and tear, TLT-Turbo researchers procured original samples of the dust present at customer facilities and used these to investigate the reasons for wear and to determine remedies for reducing it.

Factors Affecting Wear on Fans

According to Sabine Groh, Product Manager for industry fans at TLT-Turbo in Bad Hersfeld, Germany, the main contributing factor to wear is the velocity of the abrasive particle. The erosion rate measurement below illustrates the exponential increase in the erosion rate based on velocity.

(Above) Figure 1: Erosion rate in relation to velocity of particles

Groh states that additional factors include hardness, shape, number of particles and the angle between the particle jet and the surface of the fan component. The image below provides an indication of the typical shape of the abrasive particles used for research at TLT-Turbo’s newly upgraded particle jet test stand in Zweibrücken.

(Above) Figure 2: Magnified image of typical dust used in particle jet experiments

Finally, Groh argues that the particle size in comparison to the size and distribution of grain of the coating also plays a role. Figure 3 below shows a micrograph of a hardfacing layer suitable for abrasive dust with small particle sizes using a prototypical particle of 20µm. Figure 4 below shows a micrograph of a common Chrome Carbide hardfacing with a prototypical particle of 20µm as well. “In Figure 3 we can observe that the particle is less able to wash out the matrix because of the more homogenous distribution of the smaller grains. Figure 4 however shows that the large grain size and large distribution allows for easier erosion of the matrix,” Groh explains.

(Above) Figure 3: 250x magnified photomicrograph of
special Hardfacing optimized for small abrasive
(Above) Figure 4: 250x magnified photomicrograph of typical Chrom Carbide Hardfacing

This proves that if the abrasive particles are small enough to impinge between the relatively hard grains of a hardfacing, then the matrix will be washed away and the grains will easily fall out afterwards. If the grains of the hardfacing are small enough with less space between them, matrix erosion will be prevented and the hardfacing will have a higher durability.

Emerging Research Trends

Over the last 10 years, TLT-Turbo performed thousands of particle jet tests to determine the erosion rate of different coatings and materials. To achieve a comparison between these coatings, a standardized test sand with a specific grain size distribution was utilized as abrasive material (as illustrated in Figure 2 above).

“TLT-Turbo has developed an extensive database on the erosion rates of different coatings and materials that have been exposed to the test sand at different angles and velocities. This database allows us to select promising solutions for customer’s abrasive problems,” says Groh. 

TLT-Turbo has recently upgraded its test equipment and now has the capability to test using original dust supplied by the customer. Groh explains that this allows for the specific customer application, with all major influencing factors to be reproduced. In addition to the velocity and angle of the abrasive dust, a realistic indication of particle size, shape and hardness can now contribute to more accurate test results. “This means that we can provide a more definitive prediction of how a change in wear protection will affect the service lifespan of the equipment to each customer.”

Wear Test Case

The TLT-Turbo test lab asked a European customer to provide samples of dust from their facility for testing to determine how they could benefit from a coating solution suited to their specific application and environmental challenges.

(Above) Figure 5: A sample of the dust provided for testing

From this specific dust particle sample, the grain size distribution was determined by performing a sieve analysis. Particle jet experiments were then performed on two preselected coatings. These experiments are in accordance with the norm DIN 50332 and were executed for three angles: 20°, 45° and 90°.

Figure 6 below illustrates the test results. The TLT W-104 coating was determined to be the best alternative for all impact angles, however the superiority of W-104 is best illustrated when used for the 90° impact angle.

(Above) Figure 6: Erosion rate of customer dust for preselected coatings

In extremely abrasive applications, the choice of wear protection determines the service life of the fan. The upgraded test lab and particle jet test stand has afforded TLT-Turbo engineers a deeper understanding of the mechanisms behind wear and the effects of specialized solutions. This has led to new approaches in product advancement and development that are grounded in providing solutions that meet market requirements.

“The ability to use the original dust from the customer’s facility and duplicate the conditions such as velocity and the impingement angle on the coating, allows us to determine how all these factors including the shape, size and hardness of the abrasive particles affect erosion rates. TLT-Turbo has taken another great step forward in being able to reliably calculate the effect that changing in coatings to prevent wear will have on extending the service life of ventilation equipment. Establishing the best solution for wear related challenges now becomes a collaboration between TLT-Turbo and the customer.” Groh concludes.

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