218 e Cr228 en Voith-Torque-converter
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Transcript of 218 e Cr228 en Voith-Torque-converter
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Voith Torque Converter
Starting System for Gas Turbines
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Variable-Speed Drives
We are the experts in hydrodynamic variable-speed drives at Voith Turbo.
Voith Turbo, the specialist for hydrodynamic drive, coupling and braking systems for road,
rail and industrial applications, as well as for ship propulsion systems, is a Group Division
of Voith GmbH.
Voith sets standards in the markets energy, oil & gas, paper, raw materials and transporta-
tion & automotive. Founded in 1867, Voith employs almost 40 000 people, generates Euro
5.2 billion in sales, operates in about 50 countries around the world and is today one of thebiggest family-owned companies in Europe.
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2
Gas turbines are often started several times a day. Choosing the
right starting system will affect the start-up reliability of the gas
turbine. Voith supplies torque converters to all leading gas tur-
bine manufacturers and their licensees, to start gas turbines
ranging in power from 20 to 270 MW.
Reliability & Availability:
Choosing the right system is important
We believe no other starting systemor method equals the reliability and
availability of the Voith torque con-
verter starting system. Our excep-
tionally high MTBF (mean time be-
tween failure) leads to a statistical
reliability of 99.97 %. We also know
of no other starting system that
The combination of an inductionmotor with a Voith torque converter
is synonymous with trouble free
start-ups, high reliability, and long
service life. More than 3 500 gas
turbine starters worldwide is out-
standing evidence of our experience
and know-how in this area.
matches the 35-year design life ofthe Voith torque converter; and this
comes with a guaranteed availability
of parts and service matching the
life of our machines. The compact
and rigid design offers trouble free
operation while maintenance expen-
ses are at a minimum.
Generator Gas TurbineStarter System
T TC
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3
The heart of Voiths hydrodynamic
torque converter is its hydraulic cir-
cuit; consisting of a pump, turbine,
and a guide wheel with adjustable
guide vanes (see picture above
right). This is combined in a com-
mon housing filled with hydraulic oil.
The mechanical energy of the motor
is converted into hydraulic energy
through the pump wheel. In the
turbine wheel the same hydraulic
energy is converted back into mech-
anical energy and transmitted to the
gas turbine / generator shaft. The
adjustable vanes of the guide wheel
regulate the mass flow in the circuit.
At closed guide vanes (small mass
flow) the power transmission is at
its minimum. With the guide vanes
completely open (large mass flow),
the power transmission is at its
maximum. Commonly, a constant
speed driver such as an induction
motor or a diesel engine drives the
pump wheel (input shaft of the
torque converter).
Torque converter
benefits, function and design
Basic design hydrodynamic torque converterThe benefits
Voith torque converters are designed and built to meet customer
requirements. No other torque converter manufacturer offers this
service.
Torsional vibration dampening and shock free power transmission;
consequently, no stress applied to connected equipment thus de-
livering long service life.
No-load starting condition on the starting motor by decoupling
the motor from the load through the working oil shut-off valve
feature.
Low maintenance expenses.
The Voith torque converter decouples the starting motor from the
gas turbine train during gas turbine operation without the need for
a mechanical clutch through our exclusive working oil shut-off
valve feature.
Smooth and stepless output speed and torque adjustment of the
torque converter.
Because of the change in mass flow
(due to the adjustable guide vanes)
the turbine wheels speed is vari-
able and can be adjusted to match
the various operating points of the
gas turbine.
At low speed, the turbine develops
its highest torque. With increasing
turbine speed, output torque de-
creases.
Guide vanes
(adjustable)
Pump
wheel
Turbine
wheel
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4
nT=nTm
ax
nT=nopt
nT=0
Typical gas turbine start-up curve
Typical high speed setting
Typical low speed setting
1
4
3
Using a multi-position guide
vane actuator, multiple holdpoints and acceleration speeds
can easily be part of the
control logic.
0%
Speed
Torque
25
6
1 Breakaway
2 Unfired
resistance
3 Purge point
(air exchange)
4 Firing speed
5 Acceleration
resistance to
selfsustained
speed
6 Self-sustained
speed
Typical gas turbine start-up curve
Depending on the design of the tur-
bine wheel the output torque at the
break-away (nT= 0) point is two to
ten times that of the pump (input)
torque. The guide vanes absorb the
torque differential between the tur-
bine (output) and the pump (input)
and transfer it to the foundation.
By placing the guide vanes up-
stream of the pump wheel, the
torque requirement of the pump
(input) remains constant at a given
guide vane setting, independent of
the load on the turbine (output). That
means an overload of the driver
(motor or engine) is not possible
through the hydraulic circuit. When
the hydraulic fluid is removed from
the torque converter circuit, the
pump (input) is uncoupled from the
turbine (output) and consequently,
the starter motor or engine is dis-
connected from the gas turbine.
TT
TP
TT
TP
nT= 0 n
T= nTmax
1
2
3
TT
: Turbine torque
TP
: Pump torque
h: Efficiency
1: Turbine wheel
2: Pump wheel
3: Mass flow (oil)
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5
Through its characteristic of high
torque at low output speed, the
torque converter is the ideal gas
turbine starter. With the abundant
acceleration torque available, the
gas turbine can be quickly accele-
rated to and above its self-sustained
speed, an important requirement of
the state-of-the-art, high tempe-
rature gas turbines.
Start Up
Break-away of the gas turbine
through the torque converter or
the integral turning gear
Acceleration to purge speed
Acceleration to firing speed
Assisting the gas turbine to and
above self sustained speed
Uncoupling the starting system
from the gas turbine
Other Functions
Turning the gas turbine by means
of the integral turning gear for
slow-roll functions
Indexing the gas turbine for
inspections
Fast spin-cooling of the gas tur-
bine for rapid maintenance avail-
ability
Extended gas turbine water-wash
cycles
Typical starter system P&I diagram
1 Torque converter
2 Torque converter housing
3 Fill and drain valve
4 Control valve
(Filling and draining)
5 Guide vane adjustment
6 Orifice plate
7 Working oil supply
8 Lube oil and cooling oil supply
9 Working oil return
10 Lube oil and cooling oil return
11 Lube oil tank of gas turbine
8 10
M
M
M
T
R
109
4
3
5
6
1
2
11
7
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Torque converter
power chart
Power chart
Power versus input speed chart of exiting torque converters
Torque converter
for gas turbine
starting
Torque converter
in pump storage
power plants
ConverterinputpowerPPinMW
Converter input speed nPin rpm
400 600 1 000 2 000 4 000 6 000 8 000
0.4
1
2
4
10
20
40
100
200
400
600
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7
The model EL..Y with its single
stage turbine offers a torque multi-
plication factor of 4. Its balance of
features and torque characteristics
in combination with an integral tur-
ning gear makes it the ideal starter
for a broad range of gas turbines.
With the powerful hydraulic guide
vane system, controlled by solenoid
valves or an electric actuator, the
various operating points of the gas
turbine are easily obtained. When
combining the actuator with a
4-20 mA feedback system, the
torque converter becomes a true
variable speed drive with peak pre-
cision. The hydraulic fluid for the
torque converter can be supplied by
the gas turbine lube-oil system or
through a complete packaged starter
version including an oil reservoir sys-
tem as available from VoithTurbo.
Examples of other options for turn-
ing the gas turbine are: Installing a
pony motor at the ODE of the
starting motor or installing a sep-
arate turning gear.
Torque converter Model EL..Y
the classic design
Selection of EL..Y
Starter Model EL 7,5 YFG 2.2 EL 10 YFG 6.5 EL 10,5 YG 1
Max. Inputpower (kW) 2 200 1 270 6 500 3 700 10 000 5 800
Input
speed (rpm)3 600 3 000 3 600 3 000 3 600 3 000
Lx= 100 %
Lx= 75 %
Lx= 50 %
Lx= 25 %
Lx= 0 %
Torque/speed characteristics
Lx: Guide vanes open
TP
: Input torque
TT
: Output torque
nP
: Input speed
nT
: Output speed
4.01.0
nP= constant
0.5
03.0
2.0
1.0
3.5
2.5
1.5
0.5
0 0.2n
T/ n
P
TT/TP
MP
0.6 1.00
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mensions in mm
Simplified longitudinal section
of torque converter
Type EL 10 YFG 6.5
1 Input shaft
2 Pump wheel
3 Turbine wheel
4 Output shaft
5 Adjustable guide vanes
6 Adjusting mechanism
7 Filling and draining valve 8 Working oil supply
9 Working oil return
10 Lube oil return
11 Axial bearing
12 Radial bearing
13 Hydraulic cylinder
14 Guide vane actuator
1 6 5 3
87 9
10
10
2 12 11 4 6 13 14
Type EL 10,5 YG 10
357 540 1260
2150
880
119
180
650
1880
Type EL 7,5 YFG 2.2
600 720174
1164
80
110
475
852
Type EL 10 YFG 6.5
900
1651
323 360 690
100
160
650
1100
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9
Torque converter Model EL..Z
the mighty one
We call it the mighty one because,
with its double stage turbine, it
offers a torque multiplication factor
of 10! It is used in applications with
high break-away torque. For vari-
ous operation points of the gas tur-
bine, the guide vane adjustment is
equipped, in this case, with an elec-
tric actuator. The hydraulic fluid for
the torque converter can be sup-
plied by the gas turbine lube-oil-sys-
tem or through a complete packag-
ed starter version including an oil
reservoir system as available from
Voith Turbo. By activating a simple
solenoid valve the torque converter
operating fluid is emptied from the
torque converter circuit and thus,
uncouples the starting system from
the gas turbine. Turning can be
done using an integral or separate
turning gear or a pony motor.
Lx= 100 %
Lx= 75 %
Lx= 50 %
Lx= 25 %
Lx= 0 %
Torque / speed characteristics
Lx: Guide vanes open
TP
: Input torque
TT
: Output torque
nP
: Input speed
nT
: Output speed
1.0
nP= constant
0.5
0
nT/ n
P
TT/TP
TP
1
4
7
2
5
8
3
6
10
9
0 0.2 0.4 0.6 0.8
0
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Selection of EL..Z
Starter Model EL 10 ZFG
Max. Input power (kW) 1 800
Input speed (rpm) 3 000
10
Dimensions in mm
Simplified longitudinal section
of torque converter
Type EL 10 ZFG
1 Input shaft
2 Pump wheel
3 Turbine wheel
4 Output shaft
5 Adjustable guide vanes
6 Adjusting mechanism
7 Filling and draining valve
8 Working oil supply
9 Working oil return
10 Lube and cooling oil
return
1 6 5 3
87 9
10
2 4 6
Type EL 10 ZFG
720 864
1092
111.8
82
127
555
1485
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Selection of EL..
Starter Model EL 9 G 6.0
Max. Input power (kW) 6 000 3 400
Input speed (rpm) 3 600 3 000
Turning speed (rpm)
Breakaway torque (Nm)
1
Torque converter Model EL..
where power meets speed
With its single stage turbine and its
torque multiplication factor of ap-
proximately 2, the EL.. model offers
over-synchronous output speed.
With the powerful hydraulic guide
vane system, controlled by solenoid
valves or an electric actuator, the
various operating points of the gas
turbine are easily obtained. The ro-
bust, modular housing is designed
for various torque converter sizes
as well as other torque converter
types.
The hydraulic fluid for the torque
converter can be supplied by the gas
turbine lube-oil system or through a
complete packaged starter version
including an oil reservoir system as
available from Voith Turbo.
Turning can be done using an inte-
gral or separate turning gear or a
pony motor.
Lx: Guide vanes open
TP: Input torque
TT: Output torque
nP: Input speed
nT: Output speed
Lx= 100 %
Lx= 75 %
Lx= 50 %
Lx= 25 %
Lx= 0 %
Torque / speed characteristics
TT
TP
TT/TP
TP
1.00
0.50
0.75
0.25
0.25
1.00
0.50
1.25
1.75
0.75
1.50
2.00
0
0
nT/ n
P
0 0.2 0.4 1.00.6 1.20.8 1.4
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EL 9 GTM
6.0-50
EL 10 GTM
7.5-86
6 000 7 500
3 600 3 600
3.0 2.2
50 000 86 000
12
1 6 5 3
12
11
2 4 7 8 7 6 910
1006 1260337
1700
100
119
650
1895
880 540
1195
1260357
1700
119
180
650
1945
Dimensions in mm
Type EL 9 G 6.0 Type EL 10 GTM 7.5-86
Simplified longitudinal
section of torque converter
Type EL 9 G 6.0
1 Input shaft
2 Pump wheel
3 Turbine wheel
4 Output shaft
5 Adjustable guide vanes
6 Adjusting mechanism
7 Hydraulic cylinder for
guide vane adjusting
8 Guide vane actuator
9 Housing
10 Fill and drain valve
11 Operating oil supply
12 Operating oil return
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3
Torque converter Model EL..YGTM
with integral continuous turning gear
Like many of Voiths torque conver-
ters, this powerful unit is equipped
with an integrated turning gear con-
nected to the output shaft with an
over-running clutch. Among the ad-
vantages of this design are space
savings and reduced cost through
the elimination of an additional coup-
ling and subsequently, reduced as-
sembly and alignment work. The
turning gear is designed for long-life
with emphasis on high break-away
torque and long periods of low-
speed turning over the design life of
35 years. With this modular design,
a large number of system combin-
ations are available (different turning
gear and torque converter sizes)
permitting a high degree of customiz-
ation. A large number of this model
torque converter are in operation
worldwide with integrated turning
gears from 3 600 ft-lb (5 000 Nm) to
80 000 ft-lb (110 000 Nm).
The turning gears are available with
either AC or DC drive motors. In
addition, an electro-pneumatic turn-
ing device is available for connection
to the turning gear drive motor ac-
cessory shaft for ultra-slow indexing
of the gas turbine. The same turning
gears are also available as stand
alone units.
Simplified longitudinal section
of torque converter with integral
turning gear
Type EL 9 YGTM 4.0-86
1 Input shaft
2 Output shaft
3 Pump wheel
4 Turbine wheel
5 Adjustable guide vanes
6 Housing
7 Filling and draining valve
8 Control valve for filling and
draining
9 Working oil supply
10 Working oil return11 Overrunning clutch
12 Worm gear
13 Electric motor
14 Bevel gear
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1 65 4 2 2 13
8 7 10 39 12 11 12 11 14
Selection of EL..YGTM
Starter Model EL 9 YGTM 4.0-86 EL 10,5 YGTM 10-110
Max. Input power (kW) 4 000 10 000
Input speed (rpm) 3 600 3 600
Turning speed (rpm) 2.4 6.0
Breakaway
torque (Nm)86 000 110 000
14
Dimensions in mm
680261.4 597.6 830
1150
1891
100 1
222
180
540
Type EL 9 YGTM 4.0-86
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5
Torque converter EL..ZGTM
with integral hydraulic turning device
This Voith torque converter with inte-
grated hydraulic turning device is a
well-proven design with hundreds of
installations worldwide. Hydraulic
cylinders produce the output torque,
which is transmitted to the output
shaft via an overrunning clutch. With
each forward piston stroke, the gas
turbine is turned 45 degrees.
With its double stage turbine the
torque converter offers a torque
multiplication factor of 10. For the
various operating points of the gas
turbine, the guide vane adjustment
system is equipped, in this case,
with an electric actuator with var-
ious limit and position switches.
Simplified longitudinal section
of torque converter with integral
turning device
Type EL 7,5 ZGTM
1 Input shaft
2 Output shaft
3 Pump wheel
4 Turbine wheel
5 Adjustable guide vanes
6 Housing 7 Filling and draining valve
8 Control valve for filling and
draining
9 Working oil supply
10 Working oil return
11 Overrunning clutch
12 Return stroke
piston / cylinder
13 Working stroke
piston / cylinder
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1 6 11 13 114 35 2
8
9 10
7 12 13
Selection of EL..ZGTM
Starter Model EL 7,5 ZGTM EL 10 ZGTM-46
Max. Input power (kW) 1 000 1 800
Input speed (rpm) 3 600 3 000
Turning speed (rpm) 45 intermittent 45 intermittent
Breakaway Torque (Nm) 35 000 46 000
16
Dimensions in mm
Type EL 7,5 ZGTM
600 720108 251.5
1340
475
1009
119
80
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Selection of E..
Starter Model E 5 WAT E 6 WAT E 6 YAT E 7 WAT E 7 W E 7 Y E 8 W
Max. Input power (kW) 280 / 300 450 450 460 / 460 700 700 700
Input speed (rpm) 3 000 / 3 600 3 000 3 600 2 300 / 2 100 3 000 3 600 2 100
Turning speed (rpm)45
intermittent
45
intermittent
45
intermittent
45
intermittent
Breakaway
torque (Nm)11 000 11 000 11 000 11 000
7
Torque converter Type E.. with fixed guide vanes
the compact one
TP
: Input torque
TT
: Output torque
For gas turbines with a power of up
to 45 MW, torque converters with
fixed guide vanes are available and
in operation in a large international
fleet. The design is purposely built
for high reliability and has a proven
availability, superior to other types of
starters. The output speed of this unit
is controllable using a pressure re-
duction valve. Optionally, a hydraulic
turning device can be integrated into
this torque converter. Economical
savings are achieved through the
compact and simple design. With its
integral gear step, this torque conver-
ter can be easily matched to any gas
turbine speed requirements. For star-
ters, where a diesel engine is used
instead of electric starting motor, the
torque converter is ideally suited tothe diesel motor characteristic and
offers a no-load engine start.
TP
TT
T0
1
2
3
4
5
nT/ n
P
nP= constant
0 0.2 0.4 0.6 0.8 1.0 1.2
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Dimensions in mm
Simplified longitu-
dinal section of
torque converter
Type E 7 WAT
1 Input shaft with
connecting
coupling
2 Pump wheel
3 Turbine wheel
4 Fixed guide vanes5 Gear stage
6 Output shaft
7 Hydrostatic turning
device
8 Working oil supply
9 Working oil return
P&I diagram of Type E 7 WAT1 24
98
3 5 6 7
1 Torque converter
2 Oil pump
3 Relief valve
4 Helical gear
stage
5 Hydrostatic
turning device
6 Overrunning
clutch
T
4
3
5
6
1R
nP
na
nT
2
Type E 7 W without turning device
50.8
870
352.48
78.3
620
447.7
Type E 6 WAT
720111.8
82
127
447.7
352.48
1092
74
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Gas Turbine Starters
GT Starter
Model
EL 6,8 YFG EL 6,8 YFG EL 7,5 ZGTM EL 7,5 YGTM
2.2-86
EL 7,5 YGTM
2.2-36
EL 7,5 YGTM
2.2-46
EL 10 YGTM
6.5-110
EL 9 G 6.0 EL 9 G 6.0 EL 9 GTM
6.0-50
Cranking (HP) 1 076 1 005 1 200 2 500 2 146 2 500 5 000 3 755 4 025 4 025
Power (kW) 800 750 896 1 865 1 600 1 895 3 700 2 800 3 000 3 000
Speed (rpm) 3 600 3 000 3 600 3 600 3 600 3 600 3 000 3 000 3 600 3 600
Turning
speed (rpm)
45
intermittent2.4 2.3 2.3 3.0 3.0
Breakaway
Torque
35 000 Nm
25 800 ft-lbs
86 000 Nm
63 400 ft-lbs
36 000 Nm
26 500 ft-lbs
46 000 Nm
33 900 ft-lbs
110 000 Nm
81 100 ft-lbs
50 000 Nm
36 800 ft-l
9
Packaged Starter
a complete-system solution
Voith engineers configure gas turbine starting packages specifically
for your gas turbines. The table shows examples of starters in world-
wide operation. The Voith engineers are eager to design and offer a
system for your requirements.
Schematic diagram for oil circuit
of El 9 G 6.0 Package
1 Torque converter
2 Torque converter housing
3 Starting motor
4 Control valve for guide vane
position
5 Guide vane actuator
6 Transducer
7 Filter for control oil 8 Filling and draining valve
9 Thermocouples
10 Cooling oil
11 Indicator for guide vane
position
12 Working oil pump
13 Pressure gauge lube oil
pressure
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EL 10 GTM
7.5-86
EL 10,5 YGTM
10-110
10 060 12 874
7 500 9 600
3 600 3 600
2.2 6.0
86 000 Nm
3 400 ft-lbs
110 000 Nm
81 100 ft-lbs
20
Dimensions in mm
Torque converter, motor, and all re-
quired accessory equipment are fac-
tory mounted on a common base.
For more demanding requirements
such as retro-fitting to older gas
turbines, the design can include an
integral oil tank for a self contained,
packaged starter. An optionally avail-
able, onboard PLC system controls
the various phases of the starting se-
quence. With this all-inclusive solu-
tion, site assembly, alignment, and
commissioning time is greatly reduc-
ed. The components of the packaged
starting system are selected to com-
pliment each other, achieving an eco-
nomical and space conscious design.
Due to the torque converter charac-
teristic, the driver can be designed
as a true starting motor. This meansthe driver (motor) can be used above
its continuous rating during the short
start-up of the gas turbine. This re-
sults in a smaller, space saving, and
economical motor.
Type EL 9 G 6.0
11
2
3
13
4
5
67
8
10
19
2986
1876
1651
2530
3505
6180
366
1700
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28en,
S&F-aik/SVG,
1.2
011,
2000.
Dimensionsandillu
strationswithoutobligation.
Subjecttomodifications.
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]/variable-speed
Voith Turbo Inc.
25 Winship Road
York, PA 17402, USA
Tel. +1 717 767-3200
Fax +1 717 767-3210
www.usa.voithturbo.com