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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
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
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.
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.
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.
Torque/Speed Characteristics
Lx =100%Lx = 75%Lx = 50%Lx = 25%Lx = 0%
Lx = Guide vanes openMP= Input torqueMT = Output torquenP = Input speednT = Output speedη = Efficiency
Max.Input power (kW)
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
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
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.
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.
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
Max.Input power (kW)
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%
Lx = Guide vanes openMP= Input torqueMT = Output torquenP = Input speednT = Output speedη = Efficiency
10
Torque/Speed Characteristics
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
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
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.
Max.Input power (kW)
Input speed (min-1)
Turningspeed (min-1)
BreakawayTorque (Nm)
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
Simplified longitudinal section
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
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
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.
Max.Input power (kW)
Input speed (min-1)
Turningspeed (min-1)
BreakawayTorque (Nm)
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
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
1 6 11 13 114 35 2
8
9 10
7 12 13
Max.Input power (kW)
Input speed (min-1)
Turningspeed
BreakawayTorque (Nm)
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
6 Overrunning clutch
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 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
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
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
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
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.