221_e_cr240_en_hydrodynamic-variable-speed-drives.pdf

Hydrodynamic Variable-Speed Drives

Possibly the most reliable way to drive your

machinery to highest performance:

Variable-speed drives from Voith Turbo

Paper Energy Mobility Service

Fair. Reliable. Innovative.

This is our promise to our customers. And it is the demand we place on ourselves in the Paper, Energy, Mobility and Service markets.

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Maxima 40 CC:

The world’s most powerful single-engine

diesel-hydraulic locomotive. Introduced 2006.

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Fair Cooperation

Voith banks on a consistent partnership

and on long-term, trusting cooperation.

Long-standing customer relations, some

more than 100 years old attest to this fact.

We abide by our promises and will never

let our customers down.

Reliable Actions

Voith means continuous, dynamic growth

with solid returns and annual sales of

4 billion Euros. Our customers can be

confi dent that we will continue to support

their objectives – even in years to come –

with integrative and competent cooperation.

Innovative Thinking

For 140 years Voith has stood for

inventiveness and innovation: with around

400 new patents per year, with substantial

investments in R & D and from the

professional accomplishments of our

34,000 employees around the world.

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Maximum Performance Safely Under Control –

Variable-Speed Drives from Voith Turbo

Power stations Chemical and petrochemical industry

Industrial applicationsOil and gas industry, on- and offshore

Voith Turbo is the leading manufacturer worldwide of hydrodynamic variable-speed couplings,

geared variable-speed couplings, torque converters and Vorecon variable-speed planetary

gears. Power generation, oil, gas and chemical industry, raw material industry – our systems

are used in all cases where reliability and economy count. Variable-speed drives save energy

and costs, increase fl exibility and improve the service life and the availability of your plant.

They are extremely reliable and excel by their compact design and advantages such as vibra-

tion damping and load-free start-ups. Their output spectrum ranges from 100 kW up to 50 000 kW

and speeds of up to 20 000 rpm.

Depending on the application area,

requirement, output or output speed,

you can choose from a variety of

solutions: Vorecon variable-speed

planetary gears, geared variable-

speed couplings, variable-speed

turbo couplings or torque converters.

You have the application,

we have the solution.

Power stations■ Boiler feed pumps■ Boiler fans■ Compressors■ Circulation pumps■ Gas turbine starting systems■ Coal mills

Oil and gas industry

on- and offshore■ Crude oil feed pumps■ Injection pumps■ Pipeline pumps

■ Pipeline- and process compressors■ Compressors in LNG applications

Chemical and

petrochemical industry■ Compressors■ Pumps■ Centrifuges■ Fans

Industrial applications■ Compressors■ Fans ■ Process pumps ■ Cooling and fresh water pumps

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Where Maximum Effi ciency Counts –

Voith Vorecon

The innovative drive system Vorecon is based

on the power-split principle. It combines hydro-

dynamic drive elements such as torque converters

with a mechanically operating superimposing

planetary gear and therefore allows effi ciencies

of over 95 % across a wide speed range. Its

application areas range from compressors and

pipeline compressors to boiler feed pumps

and to boiler and dust extraction fans.

Voith Turbo offers the Vorecon also as a complete drive system consisting of: electric motor, Vorecon, base frame, and integrated oil supply.

The Vorecon was designed for outputs >1 000 kW.

It convinces by high reliability and availability

as well as a good price/performance ratio. Owing

to the varying design of the components, fl exible

adaptation to different speeds and applications is

possible. Depending on the type, the control range

is up to 10:1. The gear stage can be designed as

step-up or reduct ion gear. The application area of

the Vorecon ranges to up to 20 000 rpm and up

to 50 000 kW.

Complete Drive System with Vorecon

The function of the Vorecon variable-speed pla-

netary gear is based on the power-split principle

across a superimposing gear in planetary design.

The highest amount of output is mechanically

transmitted directly via the main shaft to the

planetary gear. Only the part which is required for

speed adaptation is split via the torque converter

and superimposed on the planetary gear. Result:

outstanding overall effi ciency.

Pipeline compressor USAVorecon Typ RWEOutput: 5 560 kW Speed: 14 000 rpm

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Controlled Power Transmission –

High-Performance Geared Variable-speed Couplings

Via an integrated fl uid coupling, the output speed

can be controlled steplessly. Due to their robust

design, geared variable-speed couplings can

be used even in dusty environments or areas with

explosion hazards. They allow load-free motor

run-ups and ensure high control accuracy and

availability, as well as noticeable energy savings

compared to throttle control systems.

Modular Combination of Gear Stage

and Coupling

From the basic modular concept of step-up gear

and coupling, a variety of different confi gurations

is available: depending on the requirements,

the gear-stage may be installed either before or

after the coupling to provide a design with a ratio

suitable for faster or slower speeds. With parti -

cularly high speeds, an additional step-up gear can

be integrated with the high-speed output shaft.

Geared variable-speed couplings combine a hydrodynamic

variable-speed coupling and a gear in one common housing.

Depending on the requirements and the design, the gear-stage

is designed as step-up or reduction gear. Geared variable-

speed couplings control input powers of up to 60 000 kW and

speeds of up to 20 000 rpm reliably and precisely. Their

main application areas are boiler feed pumps and beater mills

in power stations, as well as fans, pumps and compressors in

the oil and gas industry.

Geared variable-speed coupling type RKM in the drive of a boiler feed pump

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Variable-speed turbo couplings are fl uid couplings. Representing the easiest hydrodynamic

solution at identical output and motor speeds, they connect the prime mover – in most

cases an electric motor – with the driven machine and provide stepless speed control.

Typical applications are: power station technology, oil and gas industry, chemical and

petrochemical industry, raw materials and metallurgical industry as well as marine

applications. Variable-speed turbo couplings have proven themselves especially at

pumps, fans and belt conveyors. For pump control e. g. in water supply or irrigation plants,

variable-speed turbo couplings with water as operating medium are also available.

Getting the Speed Right –

Dynamic Variable-speed Couplings

Variable-speed turbo couplings transmit power

wear-free, allow load-free motor run-ups, as well

as mechanical decoupling and vibration damping

between input and output. Due to their robust

design, variable-speed turbo couplings from Voith

Turbo withstand even the toughest environmental

conditions.

Stepless Speed Control Through

Hydro dynamics

In a closed operating chamber, the operating

medium, in most cases oil, transmits the power

from the pump wheel (on the drive shaft) to the

turbine wheel (on the driven shaft). The radial

position of the scoop tube determines the degree

of filling in the coupling. This can be varied

steplessly from full to drained. The higher the fi lling

level, the higher the output speed.

District heating pump drive with water-operated SVTW variable-speed turbo coupling

Illustration of operating principle of variable-speed turbo coupling

Variable-speed turbo coupling in a boiler feed pump drive

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Where Precision and Reliability Count –

Torque Converters – Proven in Thousands of Applications

Hydrodynamic torque converters steplessly and inde-

pendently vary torques and speeds between input and

output shaft. They are particularly suited for starting

gas turbines. They carry out the complicated starting

process with extreme precision and high reliability

and can be switched off afterwards without problems.

Worldwide, Voith Turbo has supplied over 3 500 gas

turbine starters for turbines of output classes ranging

from 20 to 270 MW. Other fi elds of application are the

control of piston and screw pumps, as well as piston and

screw compressors.

Torque converters are hydrodynamic transmis-

sions. They transmit the torque of the drive motor

friction-free and steplessly in a closed circuit. If

the fi lling level or the fl ow direction of the operat-

ing fl uid is changed, the uptake and distribution

of torque also changes – the converter acts as a

control and regulating device.

New: Vosycon – the Converter for Starting

Large Compressors up to 250 MW

One of the biggest challenges when using large

compressors is their start. This is the main task

of the Vosycon, a torque converter with an inte-

grated lock-up device. The compressor is started

with the converter. In nominal operation, the

Vosycon is locked up mechanically, which results

in very high effi ciencies.

Torque converter, motor, oil supply, and base frame can also be supplied as a complete drive unit and hence offer all the advantages of a delivery from one single source.

Gas turbine starting system, USA, with Voith torque converter type EL10Y

Torque converter type EL

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Voith Coupling Service –

Gets You Further – Worldwide

Nothing is more expensive than plants and

systems at standstill. Apart from innovative

engineering, Voith Turbo therefore also

offers you a comprehensive range of services:

ranging from expertly carried out inspection

of your plant to maintenance. Tailor-made

solu tions for the requirements of your pro -

cesses; solutions which signifi cantly increase

the function, availability and economy of

your plant.

■ Optimization

Analysis, diagnosis and improvement measures,

such as speed adaptation by exchanging gear

stages under observation of the laws of hydrody-

namics, increase the economy of the existing plant.

■ Monitoring/Maintenance

Unscheduled downtimes often result in high

standstill costs. In order to minimize this risk,

regular maintenance is essential. Voith Turbo

has the know-how, the qualifi ed staff and state-

of-the-art measuring tools to detect possible

damage early, and also to carry out appropriate

maintenance.

■ Inspection/Commissioning

Comprehensive engineering includes expert

assembly and inspection. It forms the basis for

the trouble-free functioning of your plant. Our

specialists for assembly, maintenance and revi-

sion are at your disposal – worldwide.

If repairs become necessary, our worldwide service

network provides fast and expert help. For retro-

fi ts or maintenance work we are at your disposal

with our know-how and qualifi ed personnel –

at any time and any place.

How Can Your Plant Operate More

Economically?

Voith analyzes your plant and provides a thorough

diagnosis, based on the latest calculation me-

thods and measuring techniques – the basis for

targeted suggestions for improvement.

High availability with long MTBF-periods (Mean-Time-Between-Failures) is indis-pensable in international plant engineering today. With services such as remote moni-toring or on-site health checks, Voith Turbo increases the availability of your plant.

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Engineered Reliability

From One Single Source

Each and every Voith solution contains a piece of

Voith engineering: we analyze the requirements

of our customers and adapt the solution precisely

to this requirement. Due to our experience we

are in a position to offer our customers complete

drive systems – motor, drive and oil supply –

assembled on one single-lift skid. Using the latest

technologies, our research and development

team designs and optimizes new products and

solutions on the basis of virtual models.

At Voith Turbo, all engineering services

originate from one single source: from

selecting, designing and confi guring a

drive system which is tailored to your

requirement to fl ow, vibration and FEM

calculations up to measures geared at

optimized effi ciency. Our decades of

experience in the fi eld of hydrodynamic

drives, coupled with the latest tech no-

logies and plant engineering know-how,

enable us to provide products and ser -

vices which fulfi ll your highest expect a-

tions: Engineered reliability – literally!

In basic tests in our in-house test fi eld we continuously improve our pro-ducts and carry out meticulous trials of new technologies and materials. Here, all Voith products undergo intensive test runs prior to delivery to the customer.

Simulation of fl ow speed in highly-complex hydrodynamic circuits for optimization of function and effi ciency

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Voith Turbo GmbH & Co. KG

Variable-Speed Drives

Voithstr. 1

74564 Crailsheim, Germany

Tel.: +49 7951 32-261

Fax: +49 7951 32-650

[email protected]

www.voithturbo.com/variable-speed

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