TLT-Turbo GmbH today announced that their Bad Hersfeld site have donated 1.500€ for the nursing staff at the Klinikum Hersfeld Hospital’s Covid-19 intensive care unit. The intention behind the donation is to show support to these nurses who have worked tirelessly to see the local community through the Covid-19 pandemic and to provide the funds needed to ensure that they take some time out for themselves.
The funds were donated by TLT-Turbo Bad Hersfeld and were handed over by Site Manager, Christian Kosack, on 15th December 2021 at Klinikum Hersfeld.
“As part of our annual budget, we allocate a certain amount to giving back to this community that surrounds our operation. Today’s donation amounts to half of our annual budget which we specifically allocated to those who have been on the frontline of fighting the pandemic. It was important to us that these funds directly to the nursing staff instead of the hospital. We believe that the ICU nursing staff deserve not only the funds handed over, but also to be recognised by businesses in the community for all that they have done,” said Kosack.
The funds were handed over to Frank Heenes, Ward Manager of the Intensive Care Unit 1 of the Klinikum Bad Hersfeld and will be used to host a special summer event for the intensive care unit staff. “Our intention was that the staff benefit directly from the donation and that the funds be used to somehow honour them. This is our way of thanking them for their valuable and exhausting work and to be able to give something directly back to them,” Kosack explains.
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%, lowering the 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.
Energy technology is undergoing global transformation. Rapidly expanding renewable energy and other, more volatile power generation plants require significantly higher flexibility of conventional plants. This has resulted in a number of new challenges for ventilation equipment, including:
An increased number of start and stop operations
Fewer full-load hours
Increased partial load operation
Lower exhaust gas temperatures due to residual heat utilization
Smaller gap to acid dew point
These factors cause an increased load on the systems which carries increased risk of corrosion during operation. This favors dew point corrosion, which can lead to total failure of fans and system components.
TLT-Turbo offers you a tailor-made solution for your plant by implementing effective corrosion protection measures to maintain uptime of your fans.
Efficient Protection against Corrosion
TLT-Turbo Corrosion Protection for fans includes two key actions: Preventing corrosion where possible and protecting components where corrosion cannot be prevented.
Avoiding corrosive conditions:
Preventing or reducing leakage of sealing air
Heating of fan components
Optimization of insulation
Use of corrosion resistant materials:
Weather resistant steel
Polymers and polymeric coatings
Stainless steel
Ni-based coatings or base materials
In order to select the measures suitable to preventing and addressing corrosion on fans operating at your facility, TLT-Turbo conducts an individual corrosion risk assessment. This assessment is based on your operational and environmental conditions.
TLT-Turbo provides further support by conducting an analysis of your specific operating conditions, e.g. on a dew point measurement based on a plant inspection.
Contact TLT-Turbo to discuss your corrosion protection needs and to find the right service package to suit your on-going requirements.
Optimal Protection against Corrosion for Existing Plants
TLT-Turbo conducts corrosion risk assessments and implements suitable preventative measures when designing and manufacturing new fans. These measures can also be carried out when retrofitting existing plants or as part of preventative maintenance during a scheduled shutdown.
Contact your service representative or the TLT-Turbo Service Department for more information on conducting a tailored risk assessment at your facility.
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.
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.
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
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.
We are excited to announce that an order has been secured for the supply of TLT-Turbo MVR fans from a globally renowned manufacturer for installation at an instant coffee production facility in Colombia.
Securing of this order comes after extensive engagement with this client over the past 4 years. The commitment and perseverance of the sales representatives involved, and the MVR team is highly commendable. Having a relationship with this client already in place means that this order may be the first step in a long-term strategic partnership.
The MVR fan that will be supplied is from the new Low Flow MVR Series. Having been in development for the past 18 months, this new addition to the MVR range is characterized by having a significantly smaller and more compact size while still delivering higher efficiencies. The development of this range is an exceptional achievement of our R&D department and product management team. Their delivery of this new range has allowed us to enter the small mass flows market which makes us more competitive.
The scope of work for the delivery, includes the supply of a 120kW drive power, approx. 4,500 kg/h mass flow, >83% efficiency high-speed MVR fan. The final installation site is an instant coffee production facility located in Medellin, Colombia.
The securing of this contract has already caught the attention of other global coffee producers and bodes well for the continued growth of our MVR department.
For more information on the TLT-Turbo MVR Range, click here.
In 2020, TLT-Turbo GmbH in Zweibrücken has again donated EUR 2,500 for good causes. Part of the donation was handed over at Christmas, as we decided to abstain from gifts for business partners and instead donate this amount to various institutions.
A donation of EUR 350 is used to support the Diakonie Pfalz for their health retreat “Jugenddorf” (youth village). Every year, Diakonie Pfalz enables children and young people to take time out during the summer vacations. Unfortunately, in 2020 the camp could not take place due to the Corona pandemic.
The “Kinderschutzbund” (child protection agency) in Zweibrücken was supported with the purchase of a logo placement on their vehicle worth EUR 300. Their vehicle is used, for example, to distribute food to socially disadvantaged families.
A large part of the donation, EUR 600, went to “Sternenkinder” in Homburg. “Sternenkinder” is a self-help group for families who have lost one or more children before, during or after birth. The donation is used to buy fabrics and sew clothes and wrapping blankets for the deceased children.
The Diakonie Zweibrücken was supported with a donation of EUR 600 for the project “poverty due to Corona”. The Diakonie has set up a Corona relief fund to support people during the Corona crisis. However, this relief fund is very dependent on donations, which is why we wanted to make a special contribution here.
The remaining part of the donation, namely EUR 650 went to the Heinrich Kimmle Foundation Zweibrücken. It is an independent church foundation and supports people with impairments in the areas of work, living and pre-school as well as school education. There, the contribution is used as a transitional allowance to employment for people with disabilities, but also as financial support for obtaining a driver’s license.
An important task carried out by TLT-Turbo is the conducting of aerodynamic model acceptance measurements and final acceptance tests in the presence of our customers. These tests demonstrate the aerodynamic performance of TLT-Turbo fans on a model test stand to meet the required fan characteristics.
Model tests are significantly cheaper and less complex than conducting tests on a full-size performance test stand (FSPT) such as the one that TLT-Turbo has set-up in Chengdu, China. TLT-Turbo has various model test stands at their facilities in Germany and is able to test different diameters of axial fans, centrifugal fans and full-size jet fans.
Due to the restrictions of the COVID-19 pandemic, it is not possible to host clients for witnessing tests at our R&D center in Zweibruecken. In an effort to continue providing excellent customer service and for current orders to move ahead, TLT-Turbo has found a solution – making acceptance tests available for customers to attend virtually!
Inspired by the global movement to move physical business processes such as meetings and inspections online, TLT-Turbo started looking for a software solution that would allow them to conduct virtual aerodynamic model acceptance tests.
The solution was found through software, which allows classic video conferences to be combined with a connection to virtual reality on smartphones, tablets, smart glasses, or a video screen. This makes it possible for participants in a teleconference meeting to see and experience everything as if they were nearby.
“Our team has run through the process and rehearsed internally to make sure that we are ready to fully cover every aspect of the testing and we are ready to offer this service to our clients to allow work and delivery of fans to continue,” says Dr. Sebastian Fleder, TLT-Turbo Product Manager for Aftermarket and Services. “This is a major advancement in the digitalization of our offering. In future, even as we move into a post-COVID world, this model will remain an alternative option to conventional model acceptance testing, trouble shooting, inspections and many other services for all customers as it saves them both time and money.”
If you would like more information about TLT-Turbo’s ‘Remote Service Support’ or you need fan expert’s assistance, please use the contact form on our website or contact your local TLT-Turbo representative.
Like the rest of the world, India is facing the challenges of the COVID-19 pandemic and the effects of their own national lockdown. Those living below the poverty line as well as day workers and laborers have been particularly hard hit by the nationwide lockdown that started on 23 March 2020.
India’s Prime Minister addressed the nation and requested support for those in need. To facilitate donations, a special PM Office bank account was set up for individuals and organizations who wished to play their part in helping the nation’s needy.
While working from home, the team at TLT-Turbo India started discussing the unthinkable challenges facing their less fortunate fellow citizens and decided that they wanted to step up. In a moving and overwhelmingly generous gesture, the entire team decided to donate one day’s salary to the cause. This response on an individual level inspired TLT-Turbo India management to match their donations as a company. Together they reached a total amount of just over 100 000 Rupees (1300 Euro) which was deposited into the PM Office account.
“We felt a responsibility towards this cause. We are grateful to be able to continue working from home when so many others cannot work at all. The TLT-Turbo India team working from home are in contact every day and through our discussions it came to light that this cause was something we were all thinking about. I know that this amount may not be as high as some donations by larger companies, but our intent and philosophy is always do what we can to care for others and I am so proud of my team for making this happen,” says Pankaj Sohoni, TLT-Turbo India Managing Director.
Global Managing Director, Rainer Redinger applauded TLT-Turbo India for their generosity and sense of responsibility toward their fellow citizens. “Civic duty and pride are near to our hearts at TLT-Turbo. This donation demonstrates this part of our corporate culture perfectly. Throughout the COVID-19 pandemic and the various lockdowns that have been put in place across the world, the TLT-Turbo Global Team continues to show not only astounding resilience and motivation but also empathy for those who have been hardest hit. I would like to personally thank TLT-Turbo India for leading by example and for showing the world how unified action and solidarity can make a difference.”
На этом сайте используются файлы cookie, что позволяет нам обеспечить наилучшее качество обслуживания пользователей. Информация о файлах cookie хранится в вашем браузере и выполняет такие функции, как распознавание вас при возвращении на наш сайт и помощь нашей команде в понимании того, какие разделы сайта вы считаете наиболее интересными и полезными.
Строго необходимые файлы cookie
Строго необходимые файлы cookie должны быть всегда включены, чтобы мы могли сохранить ваши предпочтения для настроек файлов cookie.
Если вы отключите этот файл cookie, мы не сможем сохранить ваши предпочтения. Это означает, что при каждом посещении данного сайта вам придется заново включать или отключать файлы cookie.
