Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Topics
1. Brief portrait of Konrad Reitz Ventilatoren GmbH & Co. KG
2. Design of fans
2.1 Volume flow and total pressure difference
2.2 The influence of density and temperature
2.3 Consideration of humidity
2.4 Consideration of installation or operational altitude
2.5 The interaction of fan and plant system
2.6 Lay-out design of fans
3. Fans in practice
3.1 Type overview
3.2 Cordier diagram
3.3 Structural design of impellers and inlet variants
4. Conveyance of solid matter with radial fans in the cement industry
4.1 Wear and sticking material on radial fans
4.2 Problem areas on impeller
4.3 Design features of fans for material transport
Zuverlssigkeitskonzept_Hydro_BLA4_1
Topics
5. Vibrations on fans
5.1 Mechanical vibrations
5.2 Aerodynamic vibrations
5.3 Vibrations caused by variable speed operation
5.4 Reduction of vibrations - measures
6. Modernisation of existing fans in the cement industry
6.1 Factors that necessitate alterations
6.2 Requirements and effects
6.3 Examination of existing fans
6.4 Options to modifications
7. Fans working in the cement industry
7.1 Prehater fan
7.2 Raw mill fan
7.3 Separator fan
7.4 Primary air fan
7.5 Clinker cooler fan
7.6 Filter fan
7.7 Air slide fan
Flow sheet
production of cement
Zuverlssigkeitskonzept_Hydro_BLA4_1
2. Design of fans
2.1 Volume flow and total pressure difference
p = System pressure
V = Volume flow
m = Mass flow
V=m*R*T/p
R = Gas constant
T = Absolute system temperature
= Density of flow medium
p*V=m*R*T
p=m*R*T/V
p1 = p pt1
p2 = p + pt2
2. Design of fans
2.2 Influence of density and temperature
Density
p=m*R*T/V
with
equals
Temperature
=m/V
results in
=p/R*T
T = T0 + t
1 = (p-pt1) / R * T
Density inlet
2 = (p+pt2) / R * T
Density discharge
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2. Design of fans
2.3 Consideration of humidity
relative humidity
= pD / pStr
= relative humidity
Reduced formula of Rf
7
2. Design of fans
2.4 Consideration of installation or operational altitude
Atmospheric pressure
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2. Design of fans
2.5 The interaction of fan and plant system
The interface point of the fan characteristic curve and the plant
characteristic curve is the actual operating point OP
The nominal point NP is the point of optimal range of efficiency.
The plant characteristic curve follows a quadratic equation p = c *
V2
As the fan can operate on any point of its characteristic curve
pt
pt/Pw
depending on the plant resistance, the actual working point in the
plant is called the operating point OP.
ptI
Should the plant resistance be lower than calculated,
ptII
fort example in new plants or when the safety
resistance is calculated too high, there will be
PwII
a stronger volume flow V1II at the operating point OP.
NP
BP/OP
PW
PwI
V1 I
V1 II
2. Design of fans
2.6 Lay-out design of fans
Anlagenwiderstand /
Pressure variations
of fans
plant resistance
Pressure operation
pd2
pt2
pd2
p0 ; 0
V0 = V1
0 = 1
pst1
Vacuum operation
pt = pt 2
pdpst22
pd1
pt1 pt = pt 1
pst1
V1; 1
pst1 ; pd1
p0 ; 0
pd1
pst2
pd2
pt
pst2
p0 ; 0
Mixed operation
pt = pst2 +pst1 + pdy2
- pdy1
pst1
pd1
pst1
pt2 pd2
pt1
pd1
10
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3. Fans in practice
3.1 Type overview
11
3. Fans in practice
3.1 Type overview, further designs
Strucural design MSE directly driven by the motor shaft on
which the impeller is mounted, hinged drive unit
12
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3. Fans in practice
3.2 Cordier diagramm, characteristic field
(
i, , i, ,
) = f (
, Re)
The figure shows the non-dimensional characteristic field of a radial fan with
high efficiency in correspondence to the latest relation of a defined Re-numberrange.
Cordierdiagramm
13
3. Fans in practice
3.3 Structural design of impellers and inlet variants
Impeller design
14
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3. Fans in practice
3.3 Structural design of impellers and inlet variants
Bauart
Beschreibung
DN1
DN2
DN3
DZ
Bild / Skizze
Zylindrisches Laufrad
Einsatz nur fr den Kennzahlbereich AKZ1.0.
Einsatzbereich siehe Tabelle
ZD1/ZD2 Laufrder DN1 bis DN3 in ein- bzw. zweiflutiger Ausfhrung mit
ZD3
durchgehender Welle.
Einsatzbereich fr die Ausfhrungskennzahl AKZ1.0 und AKZ1.1.
TR
Transportkonus
15
3. Fans in practice
3.3 Structural design of impellers and inlet variants, continuation
Inlet variants
The inlet configurations that depend on the operational conditions
result in the different inlet variants
16
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3. Fans in practice
3.3 Structural design of impellers and inlet variants, continuation
Type of blades
In general, radial fans are classified by
their
type of blade:
- backward curved blades or
backward inclined straight
blades
- straight blades radial tipped
- foreward curved blades
17
In the case of fans that handle air with certain dust content, the degree of dust charge or the
mixing ratio is of decisive importance. The degree of dust charge is the ratio of the mass
flow of solid to the mass flow of the handled air. With a mixing ratio of 0.5 we speak of
hydraulic transport, in the case of which the particle floats in the current of air; basically, this
is what should be striven for. In the case of closed impeller, the limit of the handling capacity
is reached with =0.5. For the correct dimensioning of the impeller, knowledge of the dust
that is to be handled is an important precondition, such as the dust type, composition, grain
size distribution and its abrasive, adhesive, sticking or hygroscopic features.
Tendency of the impellers to build up sticking material or to wear, depending on the blade
angle 1 and 2 or type of blades
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20
40
15 bis 35
60
angle 2
30 bis 90
angle 1
80
100
120
30 bis 90
19
20
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Sticking
material on the
impeller and in
the nozzle area
Sticking material on the
hub side and on the
underside of the blade
Sticking material on
the underside of the
blade
Sticking material on
the inlet guide vane
21
22
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11
bad
good
better
23
An optimal anti-sticking design is illustrated in Figures 11 and 12. Often, however, the local
installation dimensions are not conducive for such a design. In addition, the rotational
speeds sometimes have to be reduced to such an extent that the prices become
unacceptable. Therefore, it is advisable to discuss all the advantages and disadvantages in
advance .
Caution ! If the impeller tends to build up sticking material, the use of inlet guide vanes is
not recommended. The impeller then has an even higher inclination to build up sticking
material on the undersides of the blades and at the impeller inlet. Particular attention must
be paid to the respective operating points on the fan characteristic curve and the damper
valve position. Intense damping must be avoided without fail.
Fig.11 Optimum impeller
configuration matched to the behavior of the dust type
24
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5. Vibrations on fans
5.1 Mechanical vibrations
Fans are besides pumps the turbo-machines that are mainly employed in industry. They
have a broad operative range and are often applied for ventilation purposes in a complex
process. Characteristic features of fans are a high variety of structural designs and a broad
diversity of size. They are basically defined by the volume flow that is to be generated and
the total pressure increase.
When working with fans we are repeatedly confronted with the problem of vibration. The
vibrations are, however, often difficult to classify due to the variant diversity and the different
structural designs as well as the various appliances. Nonetheless, an exact analysis of the
vibrations is the decisive factor for their elimination. We distinguish two types of vibrations,
these are
mechanical vibrations
aerodynamic vibrations.
25
5. Vibrations on fans
5.1 Mechanical vibrations, continuation
Mechanical vibrations are most frequently caused by out-of-balances at the rotating parts.
Unbalances result from uneven wear and / or sticking material at the impeller blades.
Alignment errors of shafting produce mechanical vibrations as well; they are visible in the
frequency spectrum as 2. and 3. harmonic of the speed. Other mechanical vibrations, that
often occur, originate from alignment results and resonance effects of fan parts in dependence
of their arrangement and installation. Furthermore, damages to the antifriction bearings also
excite mechanical vibrations in the form of shock pulses.
Representation of design parameter that influence vibration
no.
event
out-of-balance forces
unbalance impeller
unbalance keyway, coupling
belt flutter
impeller rigidity
natural resonance
in axial (wobble)
impacts) direction
alignment errors
rigidities
bearing rigidity
rigidity of the sub-structure (base frame,
elastic mounting, etc.)
fit tolerance
8
9
constitutional resonances
torsional vibration, pulsatory torques
effecting part
and
radial
(vertical
26
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5. Vibrations on fans
5.1 Mechanical vibrations, continuation
Mechanical vibrations, whatever, can be easily measured, located and analysed.
Example for mechanical vibrations
Unbalance
Speed 49,8 Hz
Spektren
Spektrum
28.04.2003 16:45:39
49,883 Hz
2. Harmonic
99,6 Hz
35,6 Hz
2. Harmonic
3. Harmonic
149,4 Hz, higher than
1. Harmonic
177932 3H 1K [1]
27
5. Vibrations on fans
5.1 Mechanical vibrations, continuation
Example for mechanical vibrations
Mechanically detached connections (e.g. shaft-hub)
e.g. inner ring
5. Harmonic and the
following
28
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5. Vibrations on fans
5.2 Aerodynamic vibrations
Aerodynamic vibrations manifest themselves in air vibrations with pressure or flow deviations,
they produce excessive noise and they may come up to strongly distinctive pumping, which could
even influence the volume flow to change its direction in the fan or in parts of the system. The
origins of aerodynamic vibrations can be very manifold. In many cases, the fan is not solely
responsible for the vibrations but they result from the interaction of plant system or of its
component parts to the fan.
We have to examine the complete plant system and not only the fan exclusively to find out how to
eliminate the undesired vibrations. We need therefore profound knowledge about the physical
processes that prevail in the system and the interactions and reciprocities of all system
components. The design engineering of the plant system has to include all necessary steps to
avoid in the first place potential problems in the field of aerodynamic, acoustics, physical
properties and vibration technique as well as monitoring of the system.
The following pages show typical vibration problems that have been found in praxis and
systematically explain their different symptoms and their origins and give examples.
29
5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
fig. 1.1 Outline of a ventilation system, the numbers refer to vibration phenomenon acc. to table 1.2
Table 1.2
1
vortex caused by stall at system components
2
stationary waves in the duct work (air column vibrations)
3
vortex caused by stall due to lacking chutes
4
vortex caused by stall at the silencer baffles (inlet and outlet of silencer)
5 + 6 vortex caused by stall at vent stack that is not optimally designed with
resulting air column vibration, stationary waves
7
vortex caused by stall at the vanes of the nearly closed damper
8
air column vibrations caused by flow whirls /vortex in the dead area of the
suction boxes (areas where no flow is present) when the inlet flow is disturbed
9
vortex/whirl caused by stall at the guiding blades of the inlet guide vane
when the flow is too strongly reduced
10
rotating stall at fan impeller
11
main residual frequency
12
swirled stall caused by misarranged components; possible to occur
in all system areas
13
vibrations due to pumping
Zuverlssigkeitskonzept_Hydro_BLA4_1
AK
AKM
AKO
DF
DJ
DR
KP
LB
SD
suction box
vent stack
system component
diffusor (duct piece)
damper
inlet guide vane
flexible connection
chute
silencer
30
15
5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
31
5. Vibrations on fans
Stalls
Technical flows often vary from the ideal of controlled flow because they feature the so-called
stalls
For example, the flow does no longer stream closely to the components (the flow burbles),
when it flows in the area of sharply bended surfaces or edged protruding or recessing parts
(fig. 3.1 3.2). Also, stalls can occur in duct or parts of it, in which the flow streams, if the flow
direction is changed considerably (e.g. in duct bend) or where strong constant or suddenly
occurring cross section alterations or obstacles (thinks built-in) exist (fig. 3.3).
Stalls result from the fact that so-called dead areas are formed between the wall that is no
longer in the flow due to stalls and the definitely directed duct flow. These dead areas are filled
with eddy water. Energy has to be provided for keeping up the vortex, which has to be taken
away from the flow energy of the handled gas. This leads on the one hand to a loss of effective
energy in the form of pressure loss. On the other hand, vibrations of the flow speed and the
pressure in the flow field arise since the flow in the eddy water is always more or less
unsteady. These local vibrations could also excite vibrations in the complete system (as well
as in the fan).
32
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5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Examples for aerodynamic vibrations
33
5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Examples for aerodynamic vibrations
Ablsungen
bad diffusor
34
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5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Inlet guide vanes
Upstream installation of inlet guide vanes to the fan can lead to low-frequent and more often
than not comparatively broadband air vibrations, especially when the inlet guide vane strongly
reduces the volume flow. The frequencies observed have nothing in common with the rotary
frequency of the fan. Frequently, the installation performance curve also deviates from the
characteristic curve of the test bench. The reason for this is a considerably disturbed inlet flow
to the fan impeller..
Stall at the guiding blades of the inlet guide vane. Under specific conditions, excessive
reduction of flow by an inlet guide vane will result in a critical stall at its guiding blades, which
impede a defined vortex (fig. 3.8). The mentioned specific conditions are: unfavourable inlet
flow conditions and a small range of angle setting, when the guiding vanes are strongly to
almost closed. We can avoid the stall at the inlet guide vane by optimally designing the inlet
flow and avoiding the special critical angle setting. Preconditions for this are the ideal specific
fan size definition and a secured realisation of the calculated operating point. In addition, we
have to choose a control range in the top 2/3 of the inlet guide vane position. If 0
corresponds to a closed damper and 90 to an open one, setting of the vanes at angles of
more than 60should be avoided at all events.
35
5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
36
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5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Dampers
It is common practice to mount dampers on top of the suction box for double inlet as well as
single inlet application with a separate upstream suction box, fig. 3.9.
The valves of the damper can be adjusted in parallel or in opposite direction depending on the
customers specification and the required load conditions.
Stellklappen
SKA
Ansaugkasten
V/2
V/2
Ventilator
KP1
DJ1
Drallerzeugung
durch Mitdrall
AK
37
5. Vibrations on fans
5.2 Aerodynamic vibrations, continuation
Vent stack
An unfavourable design of the branch point leads to stalls with swirls when the flow enters the
vent stack (fig. 3.11). A smooth design of the branching, possibly with chutes (fig. 3.12) will
guarantee a constant flow that is low in vibration.
WH
LB
WB
LB
AKM
AKM
LB
38
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5. Vibrations on fans
5.3 Vibrations caused by variable speed operation
The operation of fans by drive motors with variable speed operation may result in additional vibration excitations
by the variable speed control. There are primarily upper harmonic waves that occur from the rotating field (e.g.
1., 5., 7., 11. and 13. harmonic for a 6-pulse converter connection), the rotor current generate the so-called rotor
remanence field. The difference of the stator current harmonic and the feed current harmonic results in an
alternating torque which is zero-point transient in timely regard. This alternating torque is also called oscillating
torque which has a synchronous moment impact on the stator lamination steel. The resulting forces are
transmitted to the motor housing and the foundation (pedestal). The height of the oscillating torques amplitudes
depends on varying types of the variable speed control (current (I-) or tension (U-) controlled). Hence, the
excitability of systems varies in dependence of the variable speed drive employed. It is most likely that the
critical torsional speed of the shafting is excited (the shafting consists of impeller, coupling and motor stator). In
addition, the variable speed control operation can excite natural frequencies of fan parts like housing or impeller
and even the natural frequency of anti-vibration mounts could be animated in case the fan is mounted on
vibration damping elements.
39
5. Vibrations on fans
5.4 Reduction of vibrations - measures
Mechanical vibrations
In principle, regular and expert servicing and maintenance considerably contribute to a high operational
quality and reliability of fans. Even the first stage of system planning can considerably influence the
thorough and exact design of the necessary equipment. Fans have to be laid out and designed meeting the
individual requirements and specifications in order to achieve the maximum operational reliability in
practice. This is particularly important for fans that have to transport abrasive or sticking material within the
handled gas. The fan manufacturer has hence necessarily to be informed about all relevant parameter to
choose the correct fan. The most important parameter besides volume flow and pressure are temperature,
handled gas, humidity, inlet flow conditions and the use of dampers, if foreseen.
List of measures
event
measure
40
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5. Vibrations on fans
5.4 Reduction of vibrations - measures , continuation
Aerodynamic vibrations
The reasons for aerodynamic vibrations in systems can be manifold. It is recommended to pay particular
attention to the design of the duct work conduit and the systems process when planning a new system or
remodelling an existing one. A basic principle is: the better the system components are designed in
consideration of the flow guidance, the smaller is the probability of exciting aerodynamic vibrations.
List of measures
event
measure
aerodynamic vibrations
41
5. Vibrations on fans
5.4 Reduction of vibrations - measures , continuation
Vibrations caused by variable speed control
Again, all relevant operational parameter have to be made known to the fan manufacturer to the avoid
vibrations that are caused by the variable speed control operation. The said parameter are speed range
and possible speed changes per time unit, type of variable speed control (current (I-) or tension (U-)
controlled) and the installation condition of the fan.
measure
tune the unit consisting of fan, motor and
variable speed control to a resonance-free
operation
choose suitable machine parts like coupling,
shaft and impeller type
choose proper way of vibration-absorbing fan
installation: foundation, suitable arrangement
of anti-vibration mount
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21
43
ref no.
1.
2.
3.
4.
demand
action / requirement to be achieved by
adaptation of volume flow and exchange of impeller, observe motor capacity
pressure increase
exchange of fan
adaptation of pressure increase
5.
6.
7.
adaptation
parameter
8.
of
all
additional fans
worn or used-up fan components exchange the defective parts, check remaining
like impeller, shaft, bearings, components for suitability and use technical
coupling etc.
innovations if possible, include all fan components
in the tests if fan parts have been exchanged
44
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22
1 = 1,2 kg/m
Eintrittstemperatur
Inlet temperature
Volumenstrom
Volume flow
V1
m/min
Totaldruckerhhung
Total pressure increase
pt2
daPa
Totaldruckerhhung
Total pressure increase
pt1
daPa
Wellenleistung
Shaft rating
PW
kW
Drehzahl
Speed
1/min
Betriebstemperatur
Operating temperature
45
Nameplate of fan
46
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47
48
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KAE125-500010-00
3
-1
KAE125-500010-00
49
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25
51
52
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53
54
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End of
presentation
Thank you for your kind attention
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