Voith Torque Converter starting system for gas turbines

Reliability & Availability: Choosing the Right System is Important

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 turbine manufacturers and its licensees, to start gas turbines ranging in power from 20 to 270 MW.
Starter System Generator

TC

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 step-less output speed & torque adjustment of the torque converter.

Selection Chart 600 400 200

100

40

20

10 Converter input power Pp [MW]

4 2 1

Gas Turbine

0,4 400 600 1000 2000 4000 6000 8000 Converter input speed nP [min-1] Torque converter for gas turbine starting Synchronization converter

Selection Chart; based on the application and specification the appropriate torque converter size can be defined.

Torque Converter Function and Design

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 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 (see graph to the right).
MT = Turbine torque MP = Pump torque = Efficiency 1 = Turbine wheel 2 = Pump wheel 3 = Mass flow (oil) 3 1
nT = n Tm
. ax

Guide Vanes

Pump Wheel

Turbine Wheel

MT MP MT

Fig. above: Basic design hydrodynamic 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.

MP

nT = 0

nT = nTmax

nT =

n opt. nT = 0

Typical Gas Turbine Start-Up Curve

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

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.
3 4 1 Using a multi-position guide vane actuator, multiple hold points and acceleration speeds can easily be part of the control logic.

1 2 3 4 5

Breakaway Unfired resistance Purge point (air exchange). Firing speed Acceleration resistance to self-sustained speed 6 Self-sustained speed

Start Up Break-away of the gas turbine through the torque converter or the 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
2 Typical Starter System P&I Diagram 1 2 3 4 5 6 7 8 9
M

2 Torque

integral turning gear

6 0% Speed 100%

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
M M

1 5
R

6 3

T 4

10

10

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

11

Torque Converter Model EL..Y the classic 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. 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. Examples of other options for turning the gas turbine are: Installing a pony motor at the ODE of the starting motor
MT/MP 1.0 2.0 2.5 3.0 Torque/Speed Characteristics 4.0 Lx Lx Lx Lx Lx =100% = 75% = 50% = 25% = 0%

3.5

1.5

or installing a separate turning gear.

0.5 0 0 0.2 nT/nP 0.6 1.0

Selection of EL..Y Starter Model Max. Input power (kW) Input speed (min-1) EL 6,8 YFG 1.5 EL 7,5 YFG 2.2 EL 10 YFG 6.5 1.0 1,500 3,600 870 3,000 2,200 3,600 1,270 3,000 6,500 3,600 3,700 3,000 MP Lx = Guide vanes open MP = Input torque MT = Output torque nP = Input speed nT = Output speed = Efficiency 0.5 0 0.8

n P = constant

0.4

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

100

160

650

1100

Type EL 10 YFG 6.5

323 360 690 1651 900

110

80

475

852

174

600 1164

720

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

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. 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
Max. Input power (kW) Input speed (min-1)
MT/MP

Torque/Speed Characteristics 10 9 8 7 6 5 4 3 Selection of EL..Z Starter Model EL 10 ZFG 2 1 0 0 nT/nP 0.2 0.4 0.6 0.8 Lx Lx Lx Lx Lx =100% = 75% = 50% = 25% = 0%

motor.

1,800 3,000

n P = constant 1.0

0,5 MP Lx = Guide vanes open MP = Input torque MT = Output torque nP = Input speed nT = Output speed = Efficiency 0 0 0.8 0.6 0.4 0.2

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

1092

127

82

1485

555

Type EL 10 ZFG
720 111,8 864

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 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. Turning can be done using an integral or separate turning gear or a pony motor.
2.00 1.75 1.50 1.25 1.00 Selection of EL.. MT/MP Starter Model Max. Input power (kW) Input speed (min-1) Turning speed (min-1) Breakaway Torque (Nm) EL 9 G 6.0 EL 9 GTM 6.0-50 EL 10 GTM 7.5-86 0.75 0.50 0.25 0 0.2 0 nT/nP 0.4 0.6 0.8 1.0 1.2 1.4 MT Lx Lx Lx Lx Lx =100% = 75% = 50% = 25% = 0% Torque/Speed Characteristics

6,000 3,600

3,400 3,000

6,000 3,600

7,500 3,600

MP 1.00 3.0 2.2 0.75 0.50 MP 50,000 86,000 0.25 0 0.8 Lx = Guide vanes open MP = Input torque MT = Output torque nP = Input speed nT = Output speed = Efficiency 0.6 0.4 0.2 0

10

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

100

119

650

1895

Type EL 9 G 6.0
337 1006 1700 1260

180

119

650

1945

Type EL 10 GTM 7.5-86

357 540 880 2150 1260 1195

11

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 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 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.
Starter Model Max. Input power (kW) Input speed (min )
-1

Selection of EL..YGTM EL 7,5 YGTM 2.2-86 EL 10,5 YGTM 10-110

2,200 3,600

10,000 3,600

Turning speed (min-1) Breakaway Torque (Nm)

2.4

6.0

86,000

110,000

12

13

7 10

12 11

12 11

14

180

80

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

1064

Simplified longitudinal section of Torque Converter with integral turning gear

1187

475

Type EL 7,5 YGTM 2.2-86

174 600 600 1726 720

13

Torque Converter EL..ZGTM with integral hydraulic turning device

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 Max. Input power (kW) Input speed (min )
-1

EL 7,5 ZGTM

EL 10 ZGTM-46

1,000 3,600 45 intermittent 35,000

1,800 3,000 45 intermittent 46,000

Turning speed (min-1) Breakaway Torque (Nm)

14

3 6

11

13

11

9 8 7

10 12 13

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
119 80 475

1009

Simplified longitudinal section of Torque Converter with integral turning device

Type EL 7,5 ZGTM

108

600 1340

251,5 720

15

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 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 Max. Input power (kW) Input speed (min )
-1

E 5 WAT

E 6 WAT

E 6 YAT

E 7 WAT

E7W

E7Y

E8W

280/300 3,000/3,600 45 intermittent 11,000

450 3,000 45 intermittent

450 3,600 45 intermittent

460/460 2,300/2,100 45 intermittent

700 3,000 -

700 3,600 -

700 2,100 5 4 3 0.6 MT MP 1 M 0 0 0.2 0.4 0.6 0.8 1.0 1.2

n T/n P n P = constant

1.0 0.8

Turning speed Breakaway Torque (Nm)

11,000

11,000

11,000

0.4 0.2 0

MP = Input torque MT = Output torque = Efficiency

16

1
5 nP R nT 6

4 2

5 6

Simplified longitudinal section of Torque Converter Type E 7 WAT 1 Input shaft with connecting coupling

1
4 na

3 2

2 3 4 5 6 7 8 9

Pump wheel Turbine wheel Fixed guide vanes Gear stage Output shaft Hydrostatic turning device Working oil supply Working oil return

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 6 Overrunning clutch
614,1

78,3

633

74 342,9

447,7 352,48

Type E 6 WAT

628,2 50,8

511,18

466,8

305

78,3 620

Type E 7 W
870

Type E 7 W without turning device

17

Packaged Starter, a complete-system 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 Modell 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 EL 10 GTM 7.5-86 EL 10,5 YGTM 10-110

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 35,000 Nm 25,800 ft-lbs

2,500 hp 1,865 kW 3,600 rpm 2.4 rpm 86,000 Nm 63,400 ft-lbs

2,146 hp 1,600 kW 3,600 rpm 2.3 rpm 36,000 Nm 26,500 ft-lbs

2,500hp 1,865 kW 3,600 rpm 2.3 rpm 46,000 Nm 33,900 ft-lbs

5,000 hp 3,700 kW 3,000 rpm 3.0 rpm 110,000 Nm 81,100 ft-lbs

3,755 hp 2,800 kW

4,025 hp 3,000 kW

4,025 hp 3,000 kW

10,060 hp 7,500 kW

12,874 hp 9,600 kW 3,600 rpm 6.0 rpm 110,000 Nm 81,100 ft-lbs

3,000 rpm 3,600 rpm

3,600 rpm 3,600 rpm 3.0 rpm 2.2 rpm

50,000 Nm 86,000 Nm 36,800 ft-lbs 63,400 ft-lbs

18

13

2 10 12 3 1 9

8 4 6 5 11 7

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

2530

1700

2986

1651

Type EL 9 G 6.0
3505 6180 366

1876

19

Worldwide Presence, Extensive and Comprehensive Service

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 customer service provides you with the assurance that your investment remains productive.
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 assurance system of Voith Turbo has been given DIN 9001 certification as early as 1992.

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 vs.drives@voith.com 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 information@voithusa.com www.voithturbo.com
Cr 228e 07.02 1000 MSW/WA Printed in Germany. Subject to modification due to technical development.

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