Voith Turbo

Voith Torque Converter starting system for gas turbines

Voith Our company

Voith is a reliable partner to essential industries. We set standards worldwide for paper making technology, power transmission, energy technology and for industrial services. With annual sales of approx.

3.1 billion,

24,000 employees and 180 locations worldwide Voith is one of the large family-owned companies in Europe.

We want to be our customers preferred supplier and business partner

The engine of our strong growth: innovative power and reliability

Quality, reliability and soundness are key concepts of our identity. These are expressed in three words: Voith Engineered reliability.

Voith engineers have again and again written new chapters in the history of technology. Today, Voith holds over 7,000 active patents worldwide. Approximately 400 new ones are added every year. The dynamic development and the growth over the last few years confirm that we have taken the right steps. We will continue to expand our worldwide dedication to our markets.

Reliability & Availability: Choosing the right system is important

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 turbine manufacturers and their licensees, to start gas turbines ranging in power from 20 to 270 MW.

The combination of an induction motor 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 outstanding evidence of our experience and know-how in this area.

We believe no other starting system or method equals the reliability and availability of the Voith torque converter starting system. Our exceptionally high MTBF (mean time between failure) leads to a statistical reliability of 99.97%. We also know of no other starting system

that matches the 35-year design life of the 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 expenses are at a minimum.

TC

Starter System

Generator

Gas Turbine

2 3

Torque Converter benefits, function and design

The 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 delivering 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 & torque adjustment of the torque converter.

Basic Design Hydrodynamic Torque Converter

Guide Vanes (adjustable)

Pump Wheel

Turbine Wheel

The heart of Voiths hydrodynamic torque converter is its hydraulic circuit; consisting of a pump, turbine, and a guide wheel with adjustable guide vanes (see picture above right). This is combined in a common 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 mechanical 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).

Because of the change in mass flow (due to the adjustable guide vanes) the turbine wheels speed is variable 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 decreases.

Typical Gas Turbine Start-Up Curve

MT MP 1 2 3
MT

MT MP

= = = = = =

Turbine torque Pump torque Efficiency Turbine wheel Pump wheel Mass flow (oil)

Typical gas turbine start-up curve Typical high speed setting Typical low speed setting

MP

1
nT = 0 nT = nTmax

Using a multi-position guide vane actuator, multiple hold points and acceleration speeds can easily be part of the control logic.

1 Breakaway 2 Unfired resistance 3 Purge point (air exchange) 4 Firing speed 5 Acceleration resistance to selfsustained speed 6 Self-sustained speed

4 3
1
= nT
ax n Tm

n T = n op

nT = 0

2 Torque

6 0% Speed 100%

Depending on the design of the turbine 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 turbine (output) and the pump (input) and transfer it to

the foundation. By placing the guide vanes upstream 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 disconnected from the gas turbine.

4 5

Typical Starter System P&I Diagram

1 2 3 4 5 6 7 8 9 10 11 Torque converter Torque converter housing Fill and drain valve Control valve (Filling and draining) Guide vane adjustment Orifice plate Working oil supply Lube oil and cooling oil supply Working oil return Lube oil and cooling oil return Lube oil tank of gas turbine

1
M

8
M

10

7
M

10

11

Start Up

Other Functions

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 accelerated to and above its self-sustained speed, an important requirement of the state-of-the-art, high temperature gas turbines.

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

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 turbine for rapid maintenance availability Extended gas turbine waterwash cycles

Torque Converter power chart

Power Chart
600 400 200 100 Torque converter in pump storage power plants Torque converter for gas turbine starting

40 20 10 Converter input power P p [MW]

4 2 1

0.4 400 600 1000 2000 4000 6000 8000

Converter input speed nP [min-1]

Power versus input speed chart of exiting torque converters.

Torque Converter Model EL..Y the classic design

Torque/Speed Characteristics
n P = constant 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0 0 0.2 nT/nP 0.6 1.0 Lx = 100% Lx = 75% Lx = 50% Lx = 25% Lx = 0% 1.0 0.5 MP 0 Lx = MP = MT = nP = nT = Guide vanes open Input torque Output torque Input speed Output speed

The model EL..Y with its single stage turbine offers a torque multiplication factor of 4. Its balance of features and torque characteristics in combination with an integral turning 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 precision. 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. Examples of other options for turning the gas turbine are: Installing a pony motor at the ODE of the starting motor or installing a separate turning gear.

MT/MP

Selection of EL..Y
Starter Model Max. Input power (kW) Input speed (min-1) EL 6,8 YFG 1.5 1,500 3,600 870 3,000

2 12

11

13

14

Simplified longitudinal section of Torque Converter Type EL 10 YFG 6.5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Input shaft Pump wheel Turbine wheel Output shaft Adjustable guide vanes Adjusting mechanism Filling and draining valve Working oil supply Working oil return Lube oil return Axial bearing Radial bearing Hydraulic cylinder Guide vane actuator

10 10 7 8 9

Type EL 10 YFG 6.5

EL 7,5 YFG 2.2 2,200 3,600 1,270 3,000 EL 10 YFG 6.5
1100

Type EL 6,8 YFG 1.5 / Type EL 7,5 YFG 2.2

3,600

3,000
100 160 110 80 475 174 900 600 1164

323

360

690 1651

650

852

6,500

3,700

720

8 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 various operation points of the gas turbine, the guide vane adjustment is equipped, in this case, with an electric actuator. 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. 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.

Torque/Speed Characteristics
n P = constant 10 9 8 7 6 5 4 3 2
MT/MP

1.0 Lx = 100% Lx = 75% Lx = 50% Lx = 25% Lx = 0% 0,5 MP 0.6 0.8 0 Lx = Guide vanes open MP = Input torque MT = Output torque nP = Input speed nT = Output speed

1 0 0 nT/nP 0.2 0.4

Selection of EL..Z
Starter Model Max. Input power (kW) Input speed (min-1) EL 10 ZFG

Type EL 10 ZFG
1092

1,800
1485 127 82

3,000

720 11 1,8

864

Simplified longitudinal section of Torque Converter Type EL 10 ZFG 1 2 3 4 5 6 7 8 9 10 Input shaft Pump wheel Turbine wheel Output shaft Adjustable guide vanes Adjusting mechanism Filling and draining valve Working oil supply Working oil return Lube and cooling oil return

10 7 8 9

555

10 11

Torque Converter Model EL.. where power meets speed

Torque/Speed Characteristics

2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 0

MT

Lx = 100% Lx = 75% Lx = 50% Lx = 25% Lx = 0%

MT/MP

0.2 0 nT/nP

0.4

0.6 MP

0.8

1.0

1.2

1.4

1.00 0.75 0.50 0.25 0 Lx = Guide vanes open MP = Input torque MT = Output torque nP = Input speed nT = Output speed

With its single stage turbine and its torque multiplication factor of approximately 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 robust, 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 integral or separate turning gear or a pony motor.

MP

Selection of EL..
Starter Model Max. Input power (kW) Input speed (min-1) Turning speed (min-1) Breakaway Torque (Nm) EL 9 G 6.0 6,000 3,600 3,400 3,000

6 5 3

10

Simplified longitudinal section of Torque Converter Type EL 9 G 6.0 1 2 3 4 5 6 7 8 9 10 11 12 Input shaft Pump wheel Turbine wheel Output shaft Adjustable guide vanes Adjusting mechanism Hydraulic cylinder for guide vane adjusting Guide vane actuator Housing Fill and drain valve Operating oil supply Operating oil return

11

12

Type EL 9 G 6.0
EL 9 GTM 6.0-50 6,000 3,600 3.0 50,000 EL 10 GTM 7.5-86 7,500 3,600
100 119 1895

Type EL 10 GTM 7.5-86

650

86,000

337

1006 1700

1260

357

540 880 2150

1260 1195

650

2.2

119

180

1945

12 13

Torque Converter Model EL..YGTM with integral continuous turning gear

Like many of Voiths torque converters, this powerful unit is equipped with an integrated turning gear connected to the output shaft with an over-running clutch. Among the advantages of this design are space savings and reduced cost through the elimination of an additional coupling and subsequently, reduced assembly 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 combinations are available (different turning gear and torque converter sizes) permitting a high degree of customization. A large number of this model torque converter are in operation worldwide with integrated turning gears from 3,600 ft-lb (5000 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 turning device is available for connection to the turning gear drive motor accessory 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 7,5 YGTM 2.2-86 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Input shaft Output shaft Pump wheel Turbine wheel Adjustable guide vanes Housing Filling and draining valve Control valve for filling and draining Working oil supply Working oil return Overrunning clutch Worm gear Electric motor Bevel gear

Selection of EL..YGTM
Starter Model Max. Input power (kW) Input speed (min-1) Turning speed (min-1) Breakaway Torque (Nm) EL 7,5 YGTM 2.2-86 2,200 3,600 2.4 86,000 EL 10,5 YGTM 10-110 10,000 3,600 6.0 110,000

Type EL 7,5 YGTM 2.2-86

1187 1064 180 80

174

600

600 1726

720

13

7 10

12 11

12 11

14

475

14 15

Torque Converter EL..ZGTM with integral hydraulic turning device

Simplified longitudinal section of Torque Converter with integral turning device Type EL 7,5 ZGTM 1 2 3 4 5 6 7 8 9 10 11 12 13 Input shaft Output shaft Pump wheel Turbine wheel Adjustable guide vanes Housing Filling and draining valve Control valve for filling and draining Working oil supply Working oil return Overrunning clutch Return stroke piston/cylinder Working stroke piston/cylinder

This Voith torque converter with integrated 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 various limit and position switches.

3 6

11

13

11

9 8 7

10 12 13

Selection of EL..ZGTM
Starter Model Max. Input power (kW) Input speed (min-1) Turning speed (min-1) Breakaway Torque (Nm) EL 7,5 ZGTM 1,000 3,600 45 intermittent 35,000 EL 10 ZGTM-46

Type EL 7,5 ZGTM

3,000 45 intermittent 46,000

108 600 1340 251,5 720 119 80

475

1009

1,800

16 17

Torque Converter Type E.. with Fixed Guide Vanes the compact one

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 reduction 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 converter can be easily matched to any gas turbine speed requirements. For starters, where a diesel engine is used instead of an electric starting motor, the torque converter is ideally suited to the diesel motor characteristic and offers a no-load engine start.

Selection of E..
5 4 3 2 MP 1 M 0 0 0.2 0.4 0.6 0.8 1.0 1.2
n T/n P n P = constant

Starter Model Max. Input power (kW)

MT

E 5 WAT 280/300 3,000/3,600 45 intermittent

E 6 WAT 450 3,000 45 intermittent

E 6 YAT 450 3,600 45 intermittent

E 7 WAT 460/460 2,300/2,100 45 intermittent

E7W 700 3,000

E7Y 700 3,600

E8W 700 2,100

Input speed (min-1) Turning speed (min-1)

Breakaway Torque (Nm)

11,000

11,000

11,000

11,000

MP = Input torque MT = Output torque

P&I Diagram of Type E 7 WAT

1 4 2 3 5 6 7 Simplified longitudinal section of Torque converter Type E 7 WAT
nP R nT 6

1
4 na

1 2 3 4 5

Torque converter Oil pump Relief valve Helical gear stage Hydrostatic turning device 6 Overrunning clutch 8 9

1 Input shaft with connecting coupling 2 Pump wheel 3 Turbine wheel 4 Fixed guide vanes 5 Gear stage 6 Output shaft 7 Hydrostatic turning device 8 Working oil supply 9 Working oil return

Type E 6 WAT
614.1 78.3

Type E 7 W without turning device

633

74 342.9

50.8

511.18

447,7 352.48

466.8

305

628.2

870

78.3 620

18 19

Packaged Starter a complete-system solution

Schematic diagram for oil circuit of El 9 G 6.0 Package 1 2 3 4 5 6 7 8 9 10 11 12 13 Torque converter Torque converter housing Starting motor Control valve for guide vane position Guide vane actuator Transducer Filter for control oil Filling and draining valve Thermocouples Cooling oil Indicator for guide vane position Working oil pump Pressure gauge lube oil pressure

Voith engineers configure gas turbine starting packages specifically for your gas turbines. The table shows examples of starters in worldwide operation. The Voith engineers are eager to design and offer a system for your requirements.

Gas Turbine Starters

GT Starter EL 6,8 YFG Modell EL 6,8 YFG EL 7,5 ZGTM EL 7,5 YGTM EL 7,5 YGTM EL 7,5 YGTM EL 10 YGTM 2.2-86 2.2-36 2.2-46 6.5-110 EL 9 G 6.0 EL 9 G 6.0 EL 9 GTM 6.0-50

Cranking Power Speed Turning Speed Breakway Torque

1,076 hp 800 kW 3,600 rpm

1,005 hp 750 kW 3,000 rpm

1,200 hp 896 kW 3,600 rpm 45 Intermittent

2,500 hp 1,865 kW 3,600 rpm 2.4 rpm

2,146 hp 1,600 kW 3,600 rpm 2.3 rpm

2,500hp 1,865 kW 3,600 rpm 2.3 rpm

5,000 hp 3,700 kW 3,000 rpm 3.0 rpm

3,755 hp 2,800 kW 3,000 rpm

4,025 hp 3,000 kW 3,600 rpm

4,025 hp 3,000 kW 3,600 rpm 3.0 rpm

35,000 Nm 86,000 Nm 36,000 Nm 46,000 Nm 110,000 Nm 25,800 ft-lbs 63,400 ft-lbs 26,500 ft-lbs 33,900 ft-lbs 81,100 ft-lbs

50,000 Nm 36,800 ft-lbs

13

2 10 12 3 1 9

8 4 6 5 11 7

Torque converter, motor, and all required accessory equipment are factory 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 available, onboard PLC system controls the various phases of the starting sequence. With this allinclusive solution, site assembly, alignment, and commissioning time is greatly reduced. The components of the packaged starting system are selected to compliment each other, achieving an economical and space conscious design. Due to the torque converter characteristic, the driver can be designed as a true starting motor. This means the driver (motor) can be used above its continuous rating during the short start-up of the gas turbine. This results in a smaller, space saving, and economical motor.

Type EL 9 G 6.0
EL 10 GTM 7.5-86 EL 10,5 YGTM 10-110
2530 1700

10,060 hp 7,500 kW 3,600 rpm 2.2 rpm

12,874 hp 9,600 kW 3,600 rpm 6.0 rpm

2986 1876 3505 6180 366 1651

86,000 Nm 63,400 ft-lbs

110,000 Nm 81,100 ft-lbs

20 21

Voith Turbo GmbH & Co. KG Variable Speed Drive P.O. Box 1555 74555 Crailsheim/Germany Tel. +49-7951-32-0 Fax +49-7951-32-650 vs.drives@voith.com www.voith-variable-speed.com www.voithturbo.com Voith Transmissions, Inc. 25 Winship Road, York PA 17402, USA Tel. +717-767-3200 Fax +717-767-3210 information@voithusa.com www.usa.voithturbo.com

Cr 228 e 08.2004 2000 MSW/WA Printed in Germany. Technical data and illustrations subject to change.