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
standing 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 expen
ses are at a minimum.

T TC

Starter System Generator Gas Turbine

2
 Torque converter
benefits, function and design

Basic design hydrodynamic torque converter

The benefits

n Voith torque converters are designed and built to meet customer

requirements. No other torque converter manufacturer offers this
Guide vanes Pump
service.
(adjustable) wheel

n Torsional vibration dampening and shock free power transmission; Turbine

wheel
consequently, no stress applied to connected equipment thus de-
livering 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.

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).
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.

3
 Typical gas turbine start-up curve
TT : Turbine torque
TP : Pump torque
h : Efficiency
TT 1 : Turbine wheel 1 Breakaway
TP
Typical gas turbine start-up curve 2 Unfired
2 : Pump wheel
h Typical high speed setting resistance
3 : Mass flow (oil)
Typical low speed setting 3 Purge point
TT (air exchange)
4 Firing speed
h 5 Acceleration
Using a multi-position guide resistance to
TP vane actuator, multiple hold selfsustained
points and acceleration speeds speed
1 can easily be part of the 6 Self-sustained
control logic. speed
nT = 0 nT = nTmax

3
1
ax
=nT
m

nT n opt
n T= 5
2
3 nT= 0
Torque

6
2
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.

4
Typical starter system P&I diagram

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

8 10 7 9 10

M
M

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 tur-
bine for rapid maintenance avail-
ability
n Extended gas turbine water-wash
cycles

5
 Torque converter
power chart

Power chart

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

40

20

10
Converter input power PP in MW

0.4
400 600 1000 2000 4000 6000 8000

Converter input speed nP in rpm

Power versus input speed chart of exiting torque converters

6
Torque converter Model EL..Y
the classic design

Torque / speed characteristics

nP = constant
4.0
Lx = 100 % 1.0
Lx = 75 %
3.5
Lx = 50 % 0.5
Lx = 25 %
3.0 Lx = 0%

MP
0

2.5 Lx : Guide vanes open

TP : Input torque
2.0 TT : Output torque
nP : Input speed
nT : Output speed
1.5

1.0

0.5
TT / TP

0
0 0.2 0.6 1.0
nT / nP

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 Selection of EL..Y
variable speed drive with peak pre- Starter Model EL 7,5 YFG 2.2 EL 10 YFG 6.5 EL 10,5 YG 10
cision. The hydraulic fluid for the
Max. Input
torque converter can be supplied by 2 200 1 270 6 500 3 700 10 000 5 800
power (kW)
the gas turbine lube-oil system or
Input
through a complete packaged starter 3 600 3 000 3 600 3 000 3 600 3 000
speed (rpm)
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.

7
 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
14 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

852
160

180
110
100

119
80

1880
650
650

475

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

Dimensions in mm

8
 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 uncouples the starting system from
plied by the gas turbine lube-oil-sys the gas turbine. Turning can be
tem or through a complete packag done using an integral or separate
ed starter version including an oil turning gear or a pony motor.
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,

Torque/speed characteristics

nP = constant
10
1.0
9
Lx = 100%
8 Lx = 75% 0.5
Lx = 50%
7 Lx = 25%
0
TP

Lx = 0%
6
Lx : Guide vanes open
5 TP : Input torque
TT : Output torque
4 nP : Input speed
nT : Output speed
3

1
TT/TP

0
0 0.2 0.4 0.6 0.8
nT/nP

9
 Selection of EL..Z Type EL 10 ZFG
1092
Starter Model EL 10 ZFG

Max. Input power (kW) 1800

Input speed (rpm) 3000

82

1485
127

555
111.8 720 864

Dimensions in mm

1 6 5 3 2 4 6 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

10

7 8 9

10
 Torque converter Model EL..
where power meets speed

Torque/speed characteristics

2.00 Lx = 100%
1.75 Lx = 75%
1.50 TT Lx = 50%
1.25 Lx = 25%
Lx = 0%
1.00
0.75
0.50
0.25

TT/TP
0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
nT/nP
TP
1.00
0.75
0.50
0.25
0
TP

Lx: Guide vanes open nP: Input speed

TP: Input torque nT: Output speed
TT: Output torque

With its single stage turbine and its The hydraulic fluid for the torque Selection of EL..
torque multiplication factor of ap converter can be supplied by the gas
proximately 2, the EL.. model offers turbine lube-oil system or through a Starter Model EL 9 G 6.0

over-synchronous output speed. complete packaged starter version

Max. Input power (kW) 6000 3400
With the powerful hydraulic guide including an oil reservoir system as
Input speed (rpm) 3600 3000
vane system, controlled by solenoid available from VoithTurbo.
valves or an electric actuator, the Turning speed (rpm)

various operating points of the gas Turning can be done using an inte Breakaway torque (Nm)
turbine are easily obtained. The ro gral or separate turning gear or a
bust, modular housing is designed pony motor.
for various torque converter sizes
as well as other torque converter
types.

11
 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

Type EL 9 G 6.0 Type EL 10 GTM 7.5-86

EL 9 GTM EL 10 GTM
6.0-50 7.5-86

6000 7500
119
100

119

180
1895

1945

3600 3600

3.0 2.2
650
650

50000 86000
337 1006 1260 357 880 540 1260

1700 1700 1195

Dimensions in mm

12
 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
13
torque and long periods of low-
speed 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)
permitting a high degree of customiz
ation. A large number of this model
torque converter are in operation
worldwide with integrated turning
gears from 3600ft-lb (5000Nm) to
80000ft-lb (110000 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 return
11 Overrunning clutch
12 Worm gear
13 Electric motor
14 Bevel gear
 Selection of EL..YGTM Type EL 9 YGTM 4.0-86
Starter Model EL 9 YGTM 4.0-86 EL 10,5 YGTM 10-110

Max. Input power (kW) 4000 10000 1150

1222
180
Input speed (rpm) 3600 3600

100
Turning speed (rpm) 2.4 6.0

540
Breakaway
86000 110000
torque (Nm)
261.4 680 597.6 830

1891

Dimensions in mm

1 5 4 6 2 2 13

8 9 7 10 3 12 11 12 11 14

14
 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 45degrees.
15
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
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.
1 5 4 3 6 11 2 13 11

9 10
8 7 12 13

Selection of EL..ZGTM Type EL 7,5 ZGTM

Starter Model EL 7,5 ZGTM EL 10 ZGTM-46

Max. Input power (kW) 1000 1800

1009

Input speed (rpm) 3600 3000

119
80

Turning speed (rpm) 45 intermittent 45 intermittent

Breakaway Torque (Nm) 35000 46000

475

108 600 251.5 720

1340

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
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 to
the diesel motor characteristic and
offers a no-load engine start.

Selection of E..
5
Starter Model E 5 WAT E 6 WAT E 6 YAT E 7 WAT E7W E7Y E8W
4
Max. Input power (kW) 280/300 450 450 460/460 700 700 700
3
TT Input speed (rpm) 3000/3600 3000 3600 2300/2100 3000 3600 2100
2
TP 45 45 45 45
1 Turning speed (rpm)
intermittent intermittent intermittent intermittent
0
T

0 0.2 0.4 0.6 0.8 1.0 1.2 Breakaway

11000 11000 11000 11000
nT/nP torque (Nm)
nP = constant

TP : Input torque
TT : Output torque

17
 P&I diagram of Type E 7 WAT
1 4 2 3 5 6 7 Simplified longitu-
dinal section of
torque converter
5
Type E 7 WAT
nP nT 6
1 Input shaft with
connecting
R coupling
1 2 Pump wheel
4 3 Turbine wheel
4 Fixed guide vanes
na 5 Gear stage
6 Output shaft
7 Hydrostatic turning
3
2 device
T 1 Torque converter 8 Working oil supply
2 Oil pump 9 Working oil return
3 Relief valve
4 Helical gear
stage
5 Hydrostatic
turning device
6 Overrunning
clutch
8 9

Type E 6 WAT Type E 7 W without turning device

1092

74 50.8
127

78.3
82

352.48

352.48
447.7

447.7

620

870
111.8 720

Dimensions in mm

18
 Packaged Starter
a complete-system solution

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

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 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 EL 9 G 6.0 EL 9 GTM
Model 2.2-86 2.2-36 2.2-46 6.5-110 6.0-50

Cranking (HP) 1076 1005 1200 2500 2146 2500 5000 3755 4025 4025

Power (kW) 800 750 896 1865 1600 1895 3700 2800 3000 3000

Speed (rpm) 3600 3000 3600 3600 3600 3600 3000 3000 3600 3600

Turning 45
2.4 2.3 2.3 3.0 3.0
speed (rpm) intermittent

Breakaway 35000 Nm 86000 Nm 36000 Nm 46000 Nm 110000 Nm 50000 Nm

Torque 25800 ft-lbs 63400 ft-lbs 26500 ft-lbs 33900 ft-lbs 81100 ft-lbs 36800 ft-lbs

19
 Torque converter, motor, and all re
13 quired accessory equipment are fac
tory mounted on a common base.
For more demanding requirements
2 such as retro-fitting to older gas
turbines, the design can include an
10
integral oil tank for a self contained,
12 3
packaged starter. An optionally avail
1
9 able, onboard PLC system controls
the various phases of the starting se
quence. With this all-inclusive solu
tion, site assembly, alignment, and
8 commissioning time is greatly reduc
4
ed. The components of the packaged
6 11 starting system are selected to com
7 pliment each other, achieving an eco
5 nomical and space conscious design.
Due to the torque converter charac
teristic, 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
2530 1700
EL 10 GTM EL 10,5 YGTM
7.5-86 10-110

10060 12874

7500 9600
1876
2986

3600 3600
1651

2.2 6.0

86000 Nm 110000 Nm 3505 366

63400 ft-lbs 81100 ft-lbs 6180

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.