Voith Hydraulic Start System

Voith TorqueConverter starting system for gas turbines

M TC

GeneratorStarter System

2

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 its licensees, to start gas tur-

bines ranging in power from 20 to 270 MW.

The combination of an induction motor

with a Voith torque converter is syn-

onymous 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 convert-

er starting system. Our exceptionally

high MTBF (mean time between fail-

ure) 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 guar-

anteed availability of parts and service

matching the life of our machines.

The compact and rigid design offers

trouble free operation while mainte-

nance expenses are at a minimum.

3

Voith torque converters are designed andbuilt to meet customer requirements. No other torque converter manufactureroffers this service.

Low maintenance expenses.

“No-load starting” condition on the startingmotor by decoupling the motor from the load through the “working oil shut-off valve”feature.

The Voith torque converter decouples thestarting 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.

Torsional vibration dampening and shockfree power transmission; consequently, no stress applied to connected equipmentthus delivering long service life.

Benefits

Selection Chart; based on the

application and specification the

appropriate torque converter

size can be defined.

Gas Turbine

Con

vert

er in

put p

ower

Pp

[MW

]

Converter input speed nP [min-1]

Torque converter for gas turbine startingSynchronization converter

400 600 1000 2000 4000 6000 80000,4

1

2

4

10

20

40

100

200

400

600

Selection Chart

4

Torque ConverterFunction and Design

MT

MP

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 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 transmit-

ted 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 maxi-

mum. 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 tur-

bine speed, output torque decreases

(see graph to the right).

MT = Turbine torqueMP= Pump torque� = Efficiency1 = Turbine wheel2 = Pump wheel3 = Mass flow (oil)

MT

MP

ηη

nT = 0

n T = n Tmax.

nT = nopt.

nT = 0

nT = nTmax

1

2

3

Guide Vanes Pump Wheel Turbine Wheel

Fig. above: Basic design hydrody-

namic torque converter

Depending on the design of the

blade shape, the turbine (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.

0%Speed

Torq

ue

5

M

8 10 7

11

9 10

4

3

6

1

2

5 R

T

MM

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

1 Breakaway

2 Unfired resistance

3 Purge point (air exchange).

4 Firing speed

5 Acceleration resistance to

self-sustained speed

6 Self-sustained speed

Typical gast turbine start-up curve

Typical high speed setting

Typical low speed setting

100%

Typical Gas Turbine Start-Up Curve

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.

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 turbine

for rapid maintenance availability

� Extended gas turbine water-wash

cycles

1

4

3

Using a multi-position guide vane

actuator, multiple hold points and

acceleration speeds can easily be

part of the control logic.

25

6

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 hy-

draulic guide vane system, controlled

by solenoid valves or an electric actu-

ator, 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 con-

verter can be supplied by the gas tur-

bine lube-oil system or through a com-

plete packaged starter version includ-

ing an oil reservoir system as avail-

able from Voith.

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.

6

Torque Converter Model EL..Ythe classic design

Max.Input power (kW)

Input speed (min-1)

1,500

3,600

870

3,000

Starter Model

Selection of EL..Y

EL 6,8 YFG 1.5

2,200

3,600

1,270

3,000

EL 7,5 YFG 2.2

6,500

3,600

3,700

3,000

EL 10 YFG 6.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

0.5

0 0 0.2 0.6 1.0

1.0

0.5

0

0.8

0

0.4

nP = constant

MT/M

PM

P

nT/nP

Torque/Speed Characteristics

Lx = Guide vanes openMP= Input torqueMT = Output torquenP = Input speednT = Output speedη = Efficiency

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

7

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



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

900

650

1100

3231651

360 690

ø10

0

ø16

0

720

475

852

6001164

174

ø11

0

ø80

Type EL 10 YFG 6.5

Type EL 6,8 YFG 1.5

EL 7,5 YFG 2.2

0.4

0.2

0.6

0.8

0

0.2 0.6 0.8 0 0.4

9

8

7

4

3

2

0

5

6

1

10

MT/M

P

nT/nP

MP

nP = constant

1.0

0,5

0

Torque Converter Model EL..Zthe 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 adjust-

ment is equipped, in this case, with an

electric actuator.






able from Voith.

By activating a simple solenoid valve

the torque converter operating fluid is

emptied from the torque converter cir-

cuit 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%



Input speed (min-1)

Starter Model

Selection of EL..Z

EL 10 ZFG

1,800

3,000

8

864

555

1485

ø12

7

ø 8

2

720111,8

1092

Type EL 10 ZFG


of Torque Converter

Type EL 10 ZFG

1 Input shaft

2 Pump wheel

3 Turbine wheel

4 Output shaft






10 Lube and cooling oil return

9

1 6 5 3

87 9

10

2 4 6

Torque Converter Model EL..where power meets speed

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 vari-

ous 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 con-

verter configurations.






able from Voith.

Turning can be done using an integral

or separate turning gear or a pony

motor.

0.25

0.50

0.75

1.00

0

MP

MT/M

P

nT/nP

0.25

0.50

0.75

1.00

0

1.25

1.50

2.00

1.75

0 0.2 0.4 0.6 0.8 1.0 1.2 1.4

MT

0.8

0.6

0.4

0.2

0ηM

P


Input speed (min-1)

Turningspeed (min-1)

BreakawayTorque (Nm)

6,000

3,600

-

-

3,400

3,000

-

-

Starter Model

Selection of EL..

EL 9 G 6.0

6,000

3,600

3.0

50,000

7,500

3,600

2.2

86,000

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

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


10


1 56 3 2

11

12

4 10 7 8 7 6 9

1260

1945

2150

ø18

0

357

ø11

9

1195

650

540880

1260

650

1895

3371700

ø11

9

1006

ø10

0


of Torque Converter

Type EL 9 G 6.0

1 Input shaft

2 Pump wheel

3 Turbine wheel

4 Output shaft



7 Hydraulic cylinder for

guide vane adjusting


9 Housing

10 Fill and drain valve

11 Operating oil supply

12 Operating oil return

11

Type EL 9 G 6.0

Type EL 10 GTM 7.5-86

12

Torque Converter Model EL..YGTMwith integral continuous turning gear

Like many of Voiths’ torque convert-

ers, this powerful unit is equipped with

an integrated turning gear connected

to the output shaft with an over-run-

ning clutch. Among the advantages of

this design are space savings and

reduced cost through the elimination

of an additional coupling and subse-

quently, reduced assembly and align-

ment 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 inte-

grated 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 accesso-

ry shaft for ultra-slow indexing of the

gas turbine. The same turning gears

are also available as stand alone

units.


Input speed (min-1)



Starter Model

Selection of EL..YGTM

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

13


of Torque Converter with integral

turning gear

Type EL 7,5 YGTM 2.2-86

1 Input shaft

2 Output shaft

3 Pump wheel

4 Turbine wheel


6 Housing


8 Control valve for

filling and draining



11 Overrunning clutch

12 Worm gear

13 Electric motor

14 Bevel gear

1 645 2 2

Type EL 7,5 YGTM 2.2-86

174

ø18

0

1064

720

475

6001726

600

1187

ø80

8 9 7 10 1112 12 11

13

143

14

Torque Converter EL..ZGTMwith 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 cylin-

ders produce the output torque, which

is transmitted to the output shaft via

an overrunning clutch. With each for-

ward piston stroke, the gas turbine is

turned 45 degrees.

With its double stage turbine the

torque converter offers a torque multi-

plication 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.


Input speed (min-1)



Starter Model

Selection of EL..ZGTM

EL 7,5 ZGTM

1,000

3,600

45°intermittent

35,000

EL 10 ZGTM-46

1,800

3,000

45°intermittent

46,000

15

251,5600108

ø11

9

ø80

1340 720

475

1009

Type EL 7,5 ZGTM


of Torque Converter with integral

turning device

Type EL 7,5 ZGTM

1 Input shaft

2 Output shaft

3 Pump wheel

4 Turbine wheel


6 Housing


8 Control valve for

filling and draining




12 Return stroke

piston/cylinder

13 Working stroke

piston/cylinder

1 6 11 13 114 35 2

8

9 10

7 12 13


Input speed (min-1)

Turningspeed


280/300

3,000/3,600

11,000

Starter Model

Selection of E..

E 5 WAT

450

3,000

11,000

450

3,600

11,000

460/460

2,300/2,100

11,000

E 6 WAT E 6 YAT E 7 WAT

45°intermittent

45°intermittent

45°intermittent

45°intermittent

700

3,000

-

-

E 7 W

700

3,600

-

-

E 7 Y

700

2,100

-

-

E 8 W

Torque Converter Type E.. with Fixed Guide Vanesthe compact one

MP= Input torqueMT = Output torqueη = Efficiency

16

For gas turbines with a power of up to

45 MW, torque converters with fixed

guide vanes are available and in oper-

ation in a large international fleet. The

design is purposely built for high relia-

bility 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 charac-

teristic and offers a no-load engine start.

5

4

3

2

1

00 0.2 0.4 0.6 0.8 1.0 1.2

1.0

0.8

0.6

0.4

0.2

0 ηM

nT/nP

MP

η

MT

nP = constant

M

R1

4

6

23

5

nP nT

na

Schematic diagram for oil circuit of

Type E 7 WAT

1 Torque converter

2 Oil pump

3 Relief valve

4 Helical gear stage

5 Hydrostatic turning device



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



1 24

98

3 5 6 7

74

ø44

7,7

ø35

2,48

ø46

6,8

ø51

1,18

ø78

,3

ø62

0

870

50,8

614,1

633

342,

930

5ø

78,3

628,2

17

Type E 6 WAT

Type E 7 W

Type E 7 W without turning device

Torque converter, motor, and all

required 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 available, onboard

PLC system controls the various phas-

es of the starting sequence.

With this all-inclusive solution, site

assembly, alignment, and commission-

ing time is greatly reduced. The com-

ponents of the packaged starting sys-

tem 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 start-

ing motor. This means the driver

(motor) can be used above its contin-

uous rating during the short start-up of

the gas turbine. This results in a

smaller, space saving, and economi-

cal motor.

Packaged Starter,a complete-system solution

18

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 EL 9 G 6.0 EL 9 GTM EL 10 GTM E L 10,5 YGTM

Modell 2.2-86 2.2-36 2.2-46 6.5-110 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 - - 45° 2.4 rpm 2.3 rpm 2.3 rpm 3.0 rpm - - 3.0 rpm 2.2 rpm 6.0 rpmSpeed Intermittent

Breakway - - 35,000 Nm 86,000 Nm 36,000 Nm 46,000 Nm 110,000 Nm - - 50,000 Nm 86,000 Nm 110,000 NmTorque - - 25,800 ft-lbs 63,400 ft-lbs 26,500 ft-lbs 33,900 ft-lbs 81,100 ft-lbs - - 36,800 ft-lbs 63,400 ft-lbs 81,100 ft-lbs

2986

2530 1700

1651

3505

6180

366

1876

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


6 Transducer

7 Filter for control oil


9 Thermocouples

10 Cooling oil

11 Indicator for guide vane position

12 Working oil pump

13 Pressure gauge lube oil pressure

11

2

3

13

12

4

5

67

8

9

10

1

19

Type EL 9 G 6.0

Voith Turbo GmbH & Co. KG

Variable Speed Drive

P.O.Box 1555

D-74555 Crailsheim

Phone +49 (79 51) 32-0

Fax +49 (79 51) 32-650

[email protected]

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

G R O U P O F C O M PA N I E S

Worldwide Presence, Extensive and Comprehensive Service

Voith Turbo ensures close contact

to all customers through worldwide

representation. Marketing companies

and agencies on all continents can

offer fast and local service.

Quality – a corporate objective of

the Voith Group. The quality assur-

ance system of Voith Turbo has

been given DIN 9001 certification

as early as 1992.C

r 22

8e 0

7.02

100

0 M

SW

/WA

P

rinte

d in

Ger

man

y.S

ubje

ct to

mod

ifica

tion

due

to te

chni

cal d

evel

opm

ent.

Maintenance, Optimizing, Retrofit,

Assembly

At Voith, Customer Service has the

same priority as the quality of its new

equipment. Competent, highly quali-

fied 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, retro-

fitting, maintenance or commissioning.

Voiths’ extensive and comprehensive

customer service provides you with

the assurance that your investment

remains productive.

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Voith Hydraulic Start System

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