Voith Torque Converter Starting System for Gas Turbines

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 VoithGmbH. Voith sets standards in the markets energy, oil&gas, paper, raw materials and transporta tion&automotive. Founded in 1867, Voith employs almost 40000 people, generates Euro 5.2billion in sales, operates in about 50 countries around the world and is today one of the biggest family-owned companies in Europe.

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

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 3500 gas turbine starters worldwide is out stand ing 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 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

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 ex pen ses are at a minimum.

TC

Starter System

Generator

Gas Turbine

Torque converter benefits, function and design

The benefits n Voith torque converters are designed and built to meet customer requirements. No other torque converter manufacturer offers this service. n Torsional vibration dampening and shock free power transmission; consequently, no stress applied to connected equipment thus delivering long service life. n No-load starting condition on the starting motor by decoupling the motor from the load through the working oil shut-off valve feature. n Low maintenance expenses. n 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. n Smooth and stepless output speed and 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 3

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.

TT TP h TT h TP

TT : Turbine torque TP : Pump torque h : Efficiency 1 : Turbine wheel 2 : Pump wheel 3 : Mass flow (oil)

Typical gas turbine start-up curve

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

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
nT
3

=nT

ax

n T=

n opt

nT= 0

2 Torque

6 0% Speed

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.

Typical starter system P&I diagram

1 M 5 R 6

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

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 accele rated to and above its self-sustained speed, an important requirement of the state-of-the-art, high tempe rature gas turbines.

n Break-away of the gas turbine through the torque converter or the integral turning gear n Acceleration to purge speed n Acceleration to firing speed n Assisting the gas turbine to and above self sustained speed n Uncoupling the starting system from the gas turbine

n Turning the gas turbine by means of the integral turning gear for slow-roll functions n Indexing the gas turbine for inspections n Fast spin-cooling of the gas turbine for rapid maintenance availability n Extended gas turbine water-wash cycles

Torque converter power chart

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

40 20 10 Converter input power PP in MW

4 2 1 0.4 400 600 1000 2000 4000 6000 8000 Converter input speed nP in rpm

Power versus input speed chart of exiting torque converters

Torque converter Model EL..Y the classic design

Torque / speed characteristics

4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 TT / TP 0 0 0.2 nT / nP 0.6 1.0 Lx = Lx = Lx = Lx = Lx = 100 % 75 % 50 % 25 % 0% nP = constant 1.0 0.5 MP 0 Lx : TP : TT : 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 VoithTurbo. 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.

Selection of EL..Y
Starter Model EL 7,5 YFG 2.2 EL 10 YFG 6.5 EL 10,5 YG 10 Max. Input power (kW) Input speed (rpm) 2 200 1 270 6 500 3 700 10 000 5 800

3 600 3 000 3 600 3 000 3 600 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

Type EL 7,5 YFG 2.2

Type EL 10,5 YG 10

1100

160

852

100

110

119

180

80

650

475

880 323 360 690 1651 900 174 600 1164 720 357 2150 540 1260

Dimensions in mm

650

1880

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 equipp ed, 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 pack ag 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 con verter 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
10 9 8 7 6 5 4 3 2 1 TT/TP 0 0 nT/nP 0.2 0.4 0.6 0.8 1.0 Lx = 100% Lx = 75% Lx = 50% Lx = 25% Lx = 0% 0.5 0 Lx : Guide vanes open TP : Input torque TT : Output torque nP : Input speed nT : Output speed TP nP = constant

Selection of EL..Z
Starter Model Max. Input power (kW) Input speed (rpm) EL 10 ZFG 1800 3000

Type EL 10 ZFG
1092

82

127

1485

111.8

720

864

Dimensions in mm

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

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 TT/TP 0 0.2 nT/nP 0.4

TT

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

0.6 TP

0.8

1.0

1.2

1.4

1.00 0.75 0.50 0.25 0

TP

Lx: Guide vanes open TP: Input torque TT: Output torque

nP: Input speed nT: Output 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 actu ator, the various operating points of the gas turbine are easily obtained. The ro bust, modular housing is designed for various torque con verter sizes as well as other torque converter types.

The hydraulic fluid for the torque con verter 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 VoithTurbo. Turning can be done using an inte gral or separate turning gear or a pony motor.

Selection of EL..
Starter Model Max. Input power (kW) Input speed (rpm) Turning speed (rpm) Breakaway torque (Nm) EL 9 G 6.0 6000 3600 3400 3000

11

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 6000 3600 3.0 50000 EL 10 GTM 7.5-86
100 119

Type EL 10 GTM 7.5-86

7500 3600 2.2 86000

337 1006 1700

119

1895

180

650

1260

357

880 1700

540 1195

1260

Dimensions in mm

650

1945

12

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 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 sem bly and alignment work. The turn ing gear is designed for long-life with emphasis on high break-away

torque and long periods of lowspeed turning over the design life of 35years. With this modular design, a large number of system combin ations are available (different turning gear and torque converter sizes) per mitting a high degree of customiz ation. A large number of this model torque converter are in oper ation world wide with integrated turn ing gears from 3600ft-lb (5000Nm) to 80000ft-lb (110000 Nm).

The turning gears are available with either AC or DC drive motors. In add ition, an electro-pneumatic turn ing device is available for con nection to the turning gear drive motor ac ces sory shaft for ultra-slow indexing of the gas turbine. The same turning gears are also avail able as stand alone units.

Simplified longitudinal section of torque converter with integral turning gear Type EL 9 YGTM 4.0-86 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

13

Selection of EL..YGTM
Starter Model Max. Input power (kW) Input speed (rpm) Turning speed (rpm) Breakaway torque (Nm) EL 9 YGTM 4.0-86 4000 3600 2.4 86000 EL 10,5 YGTM 10-110 10000

Type EL 9 YGTM 4.0-86

1150 100 180 1222

3600 6.0 110000

261.4

680

597.6 1891

830

Dimensions in mm

13

7 10

12 11

12 11

14

540

14

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 45degrees.

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.

15

3 6

11

13

11

9 8 7

10 12 13

Selection of EL..ZGTM
Starter Model Max. Input power (kW) Input speed (rpm) Turning speed (rpm) Breakaway Torque (Nm) EL 7,5 ZGTM 1000 3600 45 intermittent 35000 EL 10 ZGTM-46 1800

Type EL 7,5 ZGTM

45 intermittent 46000

119

80

3000

108

600 1340

251.5

475

1009

720

Dimensions in mm

16

Torque converter Type E.. with fixed guide vanes the compact one
For gas turbines with a power of up to 45MW, 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 avail ability, 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 com pact 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 to the diesel motor characteristic and offers a no-load engine start.

5 4 3 2 1 0 T TP TT

Selection of E..
Starter Model Max. Input power (kW) Input speed (rpm) Turning speed (rpm) Breakaway torque (Nm) E 5 WAT 280/300 3000/3600 45 intermittent 11000 E 6 WAT 450 3000 45 intermittent 11000 E 6 YAT 450 3600 45 intermittent 11000 E 7 WAT 460/460 2300/2100 45 intermittent 11000 E7W 700 3000 E7Y 700 3600 E8W 700 2100

0 0.2 0.4 0.6 0.8 1.0 1.2 nT/nP nP = constant

TP : Input torque TT : Output torque

17

P&I diagram of Type E 7 WAT

4 2

5 6

5 nP R 1 4 na 3 nT 6

Simplified longitudinal section of torque converter Type E 7 WAT 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

1 2 3 4

Torque converter Oil pump Relief valve Helical gear stage 5 Hydrostatic turning device 6 Overrunning clutch

Type E 6 WAT
1092 74

Type E 7 W without turning device

50.8

127

447.7 352.48

352.48

447.7

78.3 870 620

111.8

82

720

Dimensions in mm

18

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 world wide operation. The Voith engineers are eager to design and offer a system for your requirements.

Gas Turbine Starters

GT Starter Model Cranking (HP) Power (kW) Speed (rpm) Turning speed (rpm) Breakaway Torque
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 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

1076 800 3600

1005 750 3000

1200 896 3600 45 intermittent

2500 1865 3600 2.4

2146 1600 3600 2.3

2500 1895 3600 2.3

5000 3700 3000 3.0

3755 2800 3000

4025 3000 3600

4025 3000 3600 3.0 50000 Nm 36800 ft-lbs

35000 Nm 86000 Nm 36000 Nm 46000 Nm 110000 Nm 25800 ft-lbs 63400 ft-lbs 26500 ft-lbs 33900 ft-lbs 81100 ft-lbs

19

13

2
10

12

3 1 9

8 4 6 5 11 7

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, pack aged 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 select ed to com pli ment each other, achiev ing an eco nomical and space consc ious design. Due to the torque con verter charac ter istic, 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 re sults 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

10060 7500 3600 2.2 86000 Nm 63400 ft-lbs

12874
2986 1876 3505 6180 366 1651

9600 3600 6.0 110000 Nm 81100 ft-lbs

Dimensions in mm

20

Voith Turbo GmbH & Co. KG Variable-Speed Drives Voithstr. 1 74564 Crailsheim, Germany Tel. +49 7951 32-261 Fax +49 7951 32-650 vs.drives@voith.com www.voithturbo.com/variable-speed Voith Turbo Inc. 25 Winship Road York, PA 17402, USA Tel. +1 717 767-3200 Fax +1 717 767-3210 VTI-Information@voith.com www.usa.voithturbo.com

cr228en, S&F-aik/SVG, 1.2011, 2000. Dimensions and illustrations without obligation. Subject to modifications.