Voit h Torque Torque Converter starting system for gas turbines
Reliability & Availability: Choo Ch oosin sing g the Right Right Syste m is Im porta po rta nt
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 35year 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.
Gas turbines are often started several times a day. Choosing the right starting system will affect the startup reliability of the gas turbine. Voith supplies torque converters to all leading gas tur-
M
TC
bine manufacturers and its licensees, to start gas turbines ranging in power from 20 to 270 MW. Starter System
2
Generator
Voith torque converters are designed and built to meet customer r equirements. No other torque converter manufacturer offers this service.
Benefits
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 dur- ing gas turbine operation without the need for a mechanical clutch through our exclusive “working oil shut-off valve” feature. Smooth and step-less output speed & torque adjustment of the torque converter.
Selection Chart 600 400 200
100
40 20
10 ] W M [ 4 p P r e w o 2 p t u p n i r 1 e t r e v n o C 0,4
Gas Turbine
400
Selection Chart; based on the application and specification the appropriate torque converter
600
1000
2000
4000
6000 8000
Converter input speed nP [min-1] Torque converter for gas turbine starting Synchronization converter
size can be defined.
3
Torque Converter Func t ion a nd Design
The heart of Voiths’ hydrodynamic Guide Vanes
torque converter is its hydraulic circuit;
Pump Wheel
Turbine Wheel
consisting of a pump, turbine, and a guide wheel with adjustable guide vanes (see picture to the 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 Fig. above: Basic design hydrody-
completely open (large mass flow), the power transmission is at its maxi-
namic torque converter
M T M P
mum. Commonly, a constant speed
Depending on the design of the
η
driver such as an induction motor or a
blade shape, the turbine (output)
diesel engine drives the pump wheel
torque at the break-away (n T = 0)
M T
point is two to ten times that of the
(input shaft of the torque converter).
pump (input) torque. The guide M P
Because of the change in mass flow
vanes absorb the torque differential between the turbine (output) and the
(due to the adjustable guide vanes) the
pump (input) and transfer it to the
turbine wheels’ speed is variable and n T = 0
can be adjusted to match the various
n T = n Tmax
vanes upstream of the pump wheel,
operating points of the gas turbine.
the torque requirement of the pump (input) remains constant at a given
At low speed, the turbine develops its
guide vane setting, independent of
highest torque. With increasing tur-
the load on the turbine (output). That
bine speed, output torque decreases
1
(see graph to the right).
n T
M T = Turbine torque M P = Pump torque = Efficiency 1 = Turbine wheel 2 = Pump wheel 3 = Mass flow (oil)
foundation. By placing the guide
. a x n T m
=
3
means an overload of the driver n T = n o
(motor or engine) is not possible
p t.
n T = 0
through the hydraulic circuit. When the hydraulic fluid is removed from the torque converter circuit, the
2
pump (input) is „uncoupled“ from the turbine (output) and consequently, the starter motor or engine is disconnected from the gas turbine.
4
Typical Gas Turbine Start-Up Curve
Typical gast turbine start-up curve Typical high speed setting Typical low speed setting
Through
its
characteristic
of
1 Breakaway
high
2 Unfired resistance
torque at low output speed, the torque
3 Purge point (air exchange).
converter is the ideal gas turbine starter. With the abundant acceleration torque available, the gas turbine can
Using a multi-position guide vane
4 Firing speed
actuator, multiple hold points and
5 Acceleration resistance to self-sustained speed
acceleration speeds can easily be
1
part of the control logic.
be quickly accelerated to and above its
6 Self-sustained speed
self-sustained speed, an important requirement of the state-of-the-art, high
4
temperature gas turbines. 3
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
5
2 e u q r o T
6
0% Speed
100%
above self sustained speed
Uncoupling the starting system from the gas turbine
Typical Starter System P&I Diagram 2 1 Torque converter
Other Functions
2 Torque converter housing
1
Turning the gas turbine by means of the integral turning gear for slow-roll
M
5
3 Fill and drain valve
R
6
4 Control valve
functions
(Filling and draining)
Indexing the gas turbine for
3
5 Guide vane adjustment 6 Orifice plate
inspections
Fast spin-cooling of the gas turbine
7 Working oil supply
T 4
8 Lube oil and
for rapid maintenance availability
Extended gas turbine water-wash
cooling oil supply 8
10
7
9
10
9 Working oil return 10 Lube oil and
cycles M
cooling oil return
M
11 Lube oil tank of gas turbine 11
5
Torque Converter Model EL..Y the cla ssic design
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. Torque/Speed Characteristics
When combining the actuator with a
4.0
4-20 mA feedback system, the torque converter becomes a true variable
Lx Lx Lx Lx Lx
3.5
speed drive with peak precision. The hydraulic fluid for the torque con-
3.0
verter can be supplied by the gas tur-
=100% = 75% = 50% = 25% = 0%
2.5
bine lube-oil system or through a complete packaged starter version includ-
2.0
ing an oil reservoir system as available from Voith.
1.5
Examples of other options for turning the gas turbine are: Installing a “pony”
1.0
motor at the ODE of the starting motor 0.5
or installing a separate turning gear.
P
M / T M 0
0 0.2 nT /nP
Selection of EL..Y Starter Model
EL 6,8 YFG 1.5
EL 7,5 YFG 2.2
nP = constant
EL 10 YFG 6.5 1.0
Max. Input power (kW)
1,500
870
2,200
1,270
6,500
3,700
Input speed (min-1)
3,600
3,000
3,600
3,000
3,600
3,000
0.5 P
M 0
0.8 Lx = Guide vanes open M P = Input torque M T = Output torque n P = Input speed n T = Output speed η = Efficiency
6
0.4
0
0.6
1.0
1
6
5
3
2 12
11
4
6
13
14
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
10
14 Guide vane actuator 10
7
8
9
0 0 1 1
0 6 1 ø
0 0 1 ø
0 5 6
Type EL 10 YFG 6.5 323
360
690 1651
900
2 5 8
0 1 1 ø
0 8 ø
5 7 4
174
600 1164
Type EL 6,8 YFG 1.5 720
EL 7,5 YFG 2.2
7
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 turTorque/Speed Characteristics
bine lube-oil system or through a complete packaged starter version includ-
10
ing an oil reservoir system as avail-
9
able from Voith.
8
By activating a simple solenoid valve
Lx Lx Lx Lx Lx
7
the torque converter operating fluid is emptied from the torque converter cir-
6
cuit and thus, uncouples the starting
5
system from the gas turbine.
4
=100% = 75% = 50% = 25% = 0%
3
Turning can be done using an integral
Selection of EL..Z
2
or separate turning gear or a pony motor.
Starter Model
EL 10 ZFG P
M /
Max. Input power (kW)
1,800
Input speed (min-1)
3,000
T
M
1 0 0 nT /nP
0.2
n P = constant 1.0
0,5 P
M 0
0.8 0.6 Lx = Guide vanes open M P = Input torque M T = Output torque n P = Input speed n T = Output speed η = Efficiency
8
0.4 0.2 0
0.4
0.6
0.8
1
6
5
3
2
4
Simplified longitudinal section
6
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
10 7
8
9
1092
7 2 1 ø
2 8 ø
5 8 4 1
5 5 5
Type EL 10 ZFG 111,8
720
864
9
Torque Converter Model EL.. w here pow er mee ts spee d
With its single stage turbine and its torque multiplication factor of ~ 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 alternate torque converter configurations. 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.
Torque/Speed Characteristics
Turning can be done using an integral 2.00
or separate turning gear or a pony
Lx Lx Lx Lx Lx
1.75
motor.
MT
1.50 1.25 1.00 Selection of EL.. Starter Model
0.75 EL 9 G 6.0
EL 9 GTM 6.0-50 EL10 GTM 7.5-86
Max. Input power (kW)
6,000
3,400
6,000
7,500
Input speed (min-1)
3,600
3,000
3,600
3,600
P
0.50
M 0.25 / T M 0
0.2 0 nT /nP
0.4
0.6
MP
Turning speed (min-1)
-
-
Breakaway Torque (Nm)
-
-
1.00 3.0
2.2
0.75 0.50
50,000
86,000
P
M
0.25 0 0.8
Lx = Guide vanes open M P = Input torque M T = Output torque n P = Input speed n T = Output speed η = Efficiency
10
=100% = 75% = 50% = 25% = 0%
0.6 0.4 0.2 η
0
0.8
1.0
1.2
1.4
1
6 5 3
2
4
10
7
8
7
6
9
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
11
12
0 0 1 ø
5 9 8 1
9 1 1 ø
0 5 6
337
1006 1700
Type EL 9 G 6.0
1260
5 4 9 1 0 8 1 ø
9 1 1 ø
0 5 6
Type EL 10 GTM 7.5-86 357
880 540 2150
1260 1195
11
Torque Converter Model EL..YGTM w ith inte gra l continuous turning gea r
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 longlife 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
Selection of EL..YGTM
are in operation worldwide with integrated turning gears from 3,600 ft-lb
Starter Model
(5000 Nm) to 80,000 ft-lb (110,000
Max. Input power (kW)
2,200
10,000
Input speed (min-1)
3,600
3,600
Turning speed (min-1)
2.4
6.0
Breakaway Torque (Nm)
86,000
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.
12
EL 7,5 YGTM 2.2-86
EL 10,5 YGTM 10-110
1
8
9
5
4
7 10
3
6
2
2
12 11
13
12 11
14
Simplified longitudinal section of Torque Converter with integral
1187
turning gear Type EL 7,5 YGTM 2.2-86
4 6 0 1 0 8 1 ø
0 8 ø
1 Input shaft
5 7 4
Type EL 7,5 YGTM 2.2-86
2 Output shaft 3 Pump wheel
174
600
600 1726
720
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 Worm gear 13 Electric motor 14 Bevel gear
13
Torque Converter EL..ZGTM w ith inte gral hydraulic t urning de vice
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.
Selection of EL..ZGTM Starter Model
EL 10 ZGTM-46
Max. Input power (kW)
1,000
1,800
Input speed (min-1)
3,600
3,000
45° intermittent
45° intermittent
Turning speed (min-1) Breakaway Torque (Nm)
14
EL 7,5 ZGTM
35,000
46,000
1
5
4
9 8
3 6
11
2
13
11
10 7
12
13
Simplified longitudinal section of Torque Converter with integral 9 0 0 1
turning device Type EL 7,5 ZGTM 1 Input shaft
Type EL 7,5 ZGTM
9 1 1 ø
0 8 ø
5 7 4
2 Output shaft 3 Pump wheel 4 Turbine wheel
108
600
251,5 1340
720
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
15
Torque Converter Type E.. with Fixed Guide Vanes the c ompac t 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 black 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.. Starter Model
E 5 WAT
E 6 WAT
E 6 YAT
E 7 WAT
E7W
E7Y
E8W
Max. Input power (kW)
280/300
450
450
460/460
700
700
700
Input speed (min-1)
3,000/3,600
3,000
3,600
2,300/2,100
3,000
3,600
2,100
Turning speed
45° intermittent
45° intermittent
45° intermittent
45° intermittent
-
-
-
Breakaway Torque (Nm)
5
1.0 0.8
4 η
0.6
3 11,000
11,000
11,000
11,000
-
-
-
MT
2
0.4
MP 0.2
1 M 0
0 0
0.2
0.4
n T /n P n P = constant
M P = Input torque M T = Output torque η = Efficiency
16
0.6
0.8
1.0
1.2
η
1
4 2 3
5 6
5 n P
n T R
7
Simplified longitudinal section of Torque Converter
6
Type E 7 WAT 1 Input shaft with
1
connecting coupling 2 Pump wheel
4
3 Turbine wheel 4 Fixed guide vanes
n a
5 Gear stage 6 Output shaft
3
2
7 Hydrostatic turning device
M
8 Working oil supply 9 Working oil return
Schematic diagram for oil circuit of Type E 7 WAT 1 Torque converter 2 Oil pump 3 Relief valve 8
4 Helical gear stage
9
5 Hydrostatic turning device 6 Overrunning clutch 614,1
3 , 8 7 ø 3 3 6
74
9 , 2 4 3
5 0 3
8 7 , 4 , 7 2 4 5 4 3 ø ø
Type E 6 WAT
628,2
50,8
8 1 , 1 1 5 ø
8 , 6 6 4 ø
3 , 0 8 2 7 6 ø ø
Type E 7 W 870
Type E 7 W without turning device
17
Packaged Starter, a com plet e-syste m solution
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 all-inclusive 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.
Voith engineers configure gas turbine starting packages specifically for your gas turbines. The table shows examples of starters in worldwide operation. Please call or send us an e-mail. Our engineers are eager to design and offer a system for your requirements. Gas Turbine Starters GT Starter
EL 6,8 YFG
EL 6,8 YFG
EL 7,5 ZGTM EL 7,5 YGTM EL 7,5 YGTM EL 7,5 YGTM EL 10 YGTM EL 9 G 6.0
Modell
2.2-86
2.2-36
2.2-46
6.5-110
EL 9 G 6.0
EL 9 GTM
EL 10 GTM
EL 10,5 YGTM
6.0-50
7.5-86
10-110
Cranking
1,076 hp
1,005 hp
1,200 hp
2,500 hp
2,146 hp
2,500hp
5,000 hp
3,755 hp
4,025 hp
4,025 hp
10,060 hp
12,874 hp
Power
800 kW
750 kW
896 kW
1,865 kW
1,600 kW
1,865 kW
3,700 kW
2,800 kW
3,000 kW
3,000 kW
7,500 kW
9,600 kW
Speed
3,600 rpm
3,000 rpm
3,600 rpm
3,600 rpm
3,600 rpm
3,600 rpm
3,000 rpm
3,000 rpm 3,600 rpm
3,600 rpm 3,600 rpm
3,600 rpm
Turning Speed
-
-
45° Intermittent
2.4 rpm
2.3 rpm
2.3 rpm
3.0 rpm
-
-
3.0 rpm
Breakway 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 86,000 Nm 110,000 Nm 36,800 ft-lbs 63,400 ft-lbs 81,100 ft-lbs
18
2.2 rpm
6.0 rpm
13
Schematic diagram for oil circuit of El 9 G 6.0 Package
2
1 Torque converter
10 12
2 Torque converter housing 3 Starting motor
3
4 Control valve for guide vane position
1
9
5 Guide vane actuator 6 Transducer 7 Filter for control oil 8 Filling and draining valve 9 Thermocouples
8
10 Cooling oil 4
11 Indicator for guide vane position 12 Working oil pump
11
6
7
13 Pressure gauge lube oil pressure
5
2530
1700
6 8 9 2 1 5 6 1
Type EL 9 G 6.0 3505
366 6180
6 7 8 1
19
Worldwide Presence, Ext e nsive and Compre hensive Se rvice
Maintenance, Optimizing, Retrofit, Assembly At Voith, Customer Service has the same priority as the quality of its new equipment. Competent, highly qualified engineers and service technicians are there to support you worldwide. With service centers around the globe, Voith strives to provide you with fast, efficient service and years of trouble free operation. Let Voiths’ experience work to your benefit; whether in optimization, retrofitting, maintenance or commissioning. Voiths’ extensive and comprehensive
Voith Turbo ensures close contact to all customers through worldwide
customer service provides you with
representation. Marketing companies
the assurance that your investment
and agencies on all continents can
Voith Turbo GmbH & Co. KG
remains productive.
offer fast and local service.
Variable Speed Drive
Quality – a corporate objective of
P.O.Box 1555
the Voith Group. The quality assur-
D-74555 Crailsheim
ance system of Voith Turbo has
Phone +49 (79 51) 32-0
been given DIN 9001 certification
Fax
as early as 1992.
[email protected]
+ 49 (79 5 1) 32-650
www.voith-variable-speed.com www.voithturbo.com Voith Transmissions, Inc. 25 Winship Road, York PA 17402, USA Phone (717) 767-3200 Fax
(717) 767-3210
[email protected] www.voithturbo.com
GROUP OF COMPANIES
. . y t n n a e m r m e p o G l e n v i e d d e l t a n i c i r n P h c e A t o W t / W e u S d M n o 0 t 0 i 0 a c 1 i f i 2 d 0 . o 7 m 0 o t e t 8 c e 2 j 2 b r u C S
