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Geared Variable-Speed Couplings - Voith Turbo

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<strong>Geared</strong> <strong>Variable</strong>-<strong>Speed</strong> <strong>Couplings</strong>


<strong>Variable</strong>-<strong>Speed</strong> Drives<br />

We are the experts in hydrodynamic variable-speed drives at <strong>Voith</strong> <strong>Turbo</strong>.<br />

<strong>Voith</strong> <strong>Turbo</strong>, the specialist for hydrodynamic drive, coupling and braking systems for road,<br />

rail and industrial applications, as well as for ship propulsion systems, is a Group Division<br />

of <strong>Voith</strong> GmbH.<br />

<strong>Voith</strong> is one of the largest family-owned companies in Europe with a workforce of around<br />

39 000, with sales of EUR 5.1 billion in the 2008 / 2009 fiscal year and 280 locations worldwide.<br />

The company is active in the energy, oil and gas, paper and raw materials industries,<br />

as well as transportation and automotive markets around the world.


<strong>Geared</strong> variable-speed couplings<br />

Precise control of maximum powers 2<br />

How will you benefit? 3<br />

<strong>Geared</strong> variable-speed couplings<br />

with modular design 4<br />

<strong>Geared</strong> variable-speed couplings<br />

for high-speed driven machines 5<br />

How to select the right coupling 6-7<br />

How to operate the coupling 8<br />

Product range<br />

for high-speed driven machines 9<br />

<strong>Geared</strong> variable-speed couplings<br />

for low-speed driven machine 10-11


2<br />

Precise control<br />

of maximum powers<br />

<strong>Voith</strong> <strong>Turbo</strong> is the largest manufacturer of geared variable-speed<br />

couplings worldwide. Over 4 000 drives have been supplied so far<br />

and are operating successfully. Powers up to 60 000 kW and speeds<br />

up to 20 000 rpm are possible. Drives with geared variable-speed<br />

couplings are renowned all over the world for their outstanding<br />

features and customer benefits in a wide range of applications,<br />

i.e. in power plants, in the petrochemical industry, the chemical<br />

industry, the iron and steel industry as well as many others.<br />

Economical operation with excellent<br />

reliability is a priority in modern<br />

power plants. Whether they are<br />

installed in boiler feed pump or fan<br />

drives, in thermal power stations,<br />

in combined cycle power plants or<br />

nuclear power plants, <strong>Voith</strong> geared<br />

variable-speed couplings meet<br />

these requirements, both in the<br />

feed water and in the cooling water<br />

circuit of the power plant.<br />

Controlling the speed of the driven<br />

machine provides accurate and<br />

energy-saving adaptation of power<br />

to the operating point of the plant.<br />

In pump and compressor drives in<br />

chemical and petrochemical industry,<br />

the geared variable-speed<br />

couplings ensure that driven<br />

machines operate more economically.<br />

<strong>Voith</strong> <strong>Turbo</strong> has the perfect<br />

geared variable-speed coupling for<br />

virtually all requirements – be it the<br />

smooth acceleration of motor and<br />

driven machine or the precise and<br />

dynamic adaptation of the speed of<br />

driven machine.<br />

Offshore or onshore, in extremely<br />

hot or cold temperatures, on platforms,<br />

pipeline stations or in the<br />

desert – <strong>Voith</strong> geared variablespeed<br />

couplings have been<br />

designed and built to withstand<br />

rough and extreme conditions,<br />

year after year, with a minimum<br />

of main tenance and maximum<br />

reliability and availability. Designs<br />

to API specifications are available<br />

also.


Applications<br />

Power plants Petrochemical industry Chemical industry<br />

n Boiler feed pumps<br />

n Boiler fans<br />

n Circulating pumps<br />

n Coal mills<br />

Combined with a robust squirrelcage<br />

motor, geared variable-speed<br />

couplings have proven themselves<br />

as the preferred choice when competing<br />

against alternative drive<br />

systems.<br />

n Pipeline pumps<br />

n Crude-oil pumps<br />

n Injection pumps<br />

n Pipeline compressors<br />

n Process compressors<br />

n Compressors<br />

n Fans<br />

n Centrifugal pumps<br />

How will you benefit?<br />

n Power savings and extension of driven machine life<br />

compared to throttle control; lower operating costs<br />

n Precise load adaptation of driven machines due to<br />

the high control accuracy and fast reaction times<br />

n Reliability > 99.9 %<br />

(Evaluation based on units in operation)<br />

n Vibration damping<br />

n Relieved motor start-up and smooth acceleration<br />

of heavy masses<br />

n Robust and compact design<br />

n Easy maintenance, low maintenance costs<br />

n Long service life<br />

3


<strong>Geared</strong> variable-speed couplings<br />

with modular design<br />

The modular geared variable-speed<br />

coupling is a further development<br />

of the proven geared variablespeed<br />

coupling design. The gear<br />

stage and the hydrodynamic variable-speed<br />

coupling are provided<br />

in a range of separate modules but<br />

with a common interface so that<br />

they can be combined to provide<br />

the optimum solution for a particular<br />

driven machine power and speed.<br />

The advantages of this design<br />

are obvious:<br />

n Increased technical flexibility<br />

n Optimum adaptation by combining<br />

gearbox and coupling<br />

n Integrated rapid-start device<br />

n Compact design, short delivery<br />

times<br />

n Easy maintenance<br />

Scoop tube with electro-hydraulic actuator and<br />

mechanically operated oil circulation control valve:<br />

improved dynamics, increased precision, low<br />

auxiliary power, compact design, no electromechanical<br />

con nect ing members.<br />

4


5<br />

<strong>Geared</strong> variable-speed couplings<br />

for high-speed driven machines<br />

Design and function<br />

<strong>Voith</strong> geared variable-speed couplings<br />

combine mechanical gears<br />

and a hydrodynamic variablespeed<br />

turbo coupling in one common<br />

housing. The oil reservoir is<br />

bolted to the bottom of the housing.<br />

Depending on the application or<br />

the design, the gear stage is either<br />

arranged on the input or on the<br />

output side of the coupling.<br />

The cou pling fill can be varied as<br />

needed during operation by means<br />

of the scoop tube. As a result, the<br />

speed and power transmitted to the<br />

driven machine can be controlled<br />

steplessly.<br />

<strong>Voith</strong> geared variable-speed<br />

coupling type R..K..M<br />

Type R..K..M<br />

PI PS PS<br />

Oil supply<br />

Both working and lube oil are<br />

supplied from the integrated oil<br />

tank, but have separate circuits.<br />

The oil system can also be used<br />

to supply both the motor and the<br />

driven machine with lube oil.<br />

Design<br />

The design of a geared variablespeed<br />

coupling is essentially<br />

determined by the power and the<br />

speed of the driven machine.<br />

1<br />

2<br />

9<br />

7<br />

8<br />

3<br />

12<br />

4<br />

PDS<br />

11<br />

10<br />

5<br />

4…20 mA<br />

1 Gear stage<br />

2 Hydrodynamic variable-<br />

speed coupling<br />

3 Scoop tube<br />

4 Electro-hydraulic positioning<br />

control (VEHS)<br />

5 Working oil cooler<br />

6 Lube oil cooler<br />

7 Main lube oil pump<br />

8 Oil circulation control<br />

valve<br />

9 Working oil pump<br />

10 Auxiliary lube oil pump<br />

11 Duplex filter<br />

12 Oil reservoir<br />

6


Power [kW x 1000]<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

5<br />

4<br />

3<br />

2<br />

1<br />

0,3<br />

R 120<br />

R 119<br />

R 118<br />

R 117<br />

How to select<br />

the right coupling<br />

The power diagrams show the<br />

powers transmitted in relation to<br />

the input and output speed for the<br />

various coupling types and sizes.<br />

Input speed = 1500 rpm (50 Hz countries)<br />

R 111 K 630<br />

R 110 K 630<br />

R 19 K…M<br />

R 18 K…M<br />

R 17 K…M<br />

R 16 K…M<br />

R 120/119 GS<br />

R 119/118 GS<br />

R 118/117 GS<br />

R 15 K…M<br />

550<br />

600<br />

500<br />

450<br />

400<br />

R 14 K…M<br />

R 12 K…M<br />

R 110/111 KGS<br />

R 18/19 KGS-14<br />

R 10 K…M<br />

R 16/17 KGS<br />

R 8 K…M<br />

1 2 3 4 5 6 7 8 9 10 15 20<br />

<strong>Speed</strong> [rpm x 1000]<br />

Power [kW x 1000]<br />

Input speed = 1800 rpm (60 Hz countries)<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

5<br />

4<br />

3<br />

2<br />

1<br />

0,3<br />

R 120<br />

R 119<br />

R 118<br />

R 117<br />

R 111 K 630<br />

R 110 K 630<br />

R 19 K…M<br />

R 18 K…M<br />

R 17 K…M<br />

R 16 K…M<br />

R 120/119 GS<br />

R 119/118 GS<br />

R 118/117 GS<br />

R 15 K…M<br />

600<br />

550<br />

500<br />

450<br />

R 110/111 KGS<br />

R 18/19 KGS-14<br />

400 R 16/17 KGS<br />

R 14 K…M<br />

R 12 K…M<br />

R 10 K…M<br />

R 8 K...M<br />

1 2 3 4 5 6 7 8 9 10 15 20<br />

<strong>Speed</strong> [rpm x 1000]<br />

6


Power [kW x 1000]<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

5<br />

4<br />

3<br />

2<br />

1<br />

R 115<br />

R 114<br />

R 113<br />

R 111 K 630<br />

R 110 K 630<br />

R 19 K…M<br />

R 18 K…M<br />

R 17 K…M<br />

R 16 K…M<br />

Design to API standard are also<br />

available. The size of the machine<br />

then depends on the specified API<br />

service factor.<br />

Input speed = 3000 rpm (50 Hz countries)<br />

R 115 GS<br />

R 115 GS<br />

R 114 GS 550<br />

R 114 GS<br />

R 113 GS<br />

R 15 K…M<br />

500/450<br />

0,3<br />

1 2 3 4 5 6 7 8 9 10 15 20<br />

<strong>Speed</strong> [rpm x 1000]<br />

400<br />

R 14 K…M<br />

R 12 K…M<br />

R 110/111 KGS<br />

R 18/19 KGS-14<br />

R 10 K…M<br />

R 16/17 KGS<br />

R 8 K…M<br />

R 19 GS...M<br />

R 18 GS...M<br />

R 17 GS...M<br />

R 16 GS...M<br />

R 15 GS...M<br />

Power [kW x 1000]<br />

Input speed = 3600 rpm (60 Hz countries)<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

5<br />

4<br />

3<br />

2<br />

1<br />

R 115<br />

R 114<br />

R 113<br />

R 111 K 630<br />

R 110 K 630<br />

R 19 K…M<br />

R 18 K…M<br />

R 17 K…M<br />

R 16 K…M<br />

R 115 GS<br />

R 115 GS<br />

R 114 GS 550<br />

R 114 GS<br />

R 113 GS<br />

R 15 K…M<br />

500/450<br />

0,3<br />

1 2 3 4 5 6 7 8 9 10 15 20<br />

<strong>Speed</strong> [rpm x 1000]<br />

400<br />

R 14 K…M<br />

R 12 K…M<br />

R 110/111 KGS<br />

R 18/19 KGS-14<br />

R 10 K…M<br />

R 16/17 KGS<br />

R 8 K…M<br />

R 19 GS...M<br />

R 18 GS...M<br />

R 17 GS...M<br />

R 16 GS...M<br />

R 15 GS...M<br />

7


8<br />

How to operate<br />

the coupling<br />

The performance diagram shows<br />

the transmittable coupling torques<br />

TK at different scoop tube positions<br />

as a func tion of the output speed.<br />

The desired output speed becomes<br />

a stable intersection between coupling<br />

torque TK and load torque<br />

(load curve).<br />

Operating Ranges:<br />

I, IV Starting Range<br />

II Control Range<br />

III Overload Range<br />

The shape of the coupling characteristic<br />

curves is given for information<br />

only, since there may be minor<br />

deviations if coupling sizes, circulation<br />

oil flows, oil viscosity, etc. vary.<br />

Performance diagram<br />

T K [%]<br />

125<br />

100<br />

75<br />

50<br />

25<br />

0<br />

Parameters:<br />

T K<br />

s min<br />

30%<br />

20%<br />

10%<br />

0%<br />

Scoop tube position in %<br />

of the full scoop-tube stroke.<br />

Transmitted coupling torque<br />

Minimum slip required<br />

for torque transmission<br />

s = ( 1 – n 2 ) • 100 [%]<br />

n 1<br />

n 1<br />

n 2<br />

input speed<br />

output speed<br />

I<br />

III<br />

40%<br />

50% 60% 70% 80%<br />

II<br />

50 100<br />

Output speed [% of input speed]<br />

Typical load characteristics:<br />

1<br />

2<br />

4<br />

3<br />

IV<br />

1 constant torque<br />

(e.g. positive displacement<br />

pumps and compressors).<br />

2 decreasing torque<br />

(e.g. boiler feed pumps<br />

operating at varying pressures).<br />

3 parabolic torque<br />

(e.g. resistance parabola,<br />

pumps with back pressure,<br />

blowers).<br />

4 decreasing torque<br />

(e.g. boiler feed pumps<br />

operating at fixed pressure).<br />

100%<br />

s min


Type R..KGS<br />

Product range<br />

for high-speed driven machines<br />

Coupling types for specific applications depend on the respective<br />

arrangement of gearbox and coupling and the power and the speed<br />

of the motor and the driven machine.<br />

Type R..K..M (see page 5)<br />

A combination of step-up gear and<br />

variable speed coupling with high<br />

power density, step-up gearing.<br />

Special advantages due to modular<br />

design.<br />

Type R..KGS<br />

A step-up gear is integrated both<br />

at the input and the output side for<br />

particularly high output speeds,<br />

e.g. for high-speed compressors.<br />

Type R..GS<br />

Type R..GS<br />

The coupling is direct-driven by the<br />

motor and adapted to the required<br />

speed of driven machine by the<br />

step-up gear located at the output<br />

side of the coupling; ideal for high<br />

powers and extremely high speeds.<br />

9


10<br />

<strong>Geared</strong> variable-speed couplings<br />

for low-speed driven machines<br />

<strong>Voith</strong> geared variable-speed<br />

coupling type R..A:<br />

1 Gear stage<br />

2 Hydrodynamic variable-<br />

speed coupling<br />

3 Scoop tube (adjustable)<br />

4 Hydrodynamic brake<br />

(optional)<br />

5 Oil supply<br />

6 Working oil cooler<br />

7 Duplex filter<br />

8 Oil pump<br />

Type R..A<br />

The control requirements of low-speed driven machines such<br />

as coal mills, I.D. fans or crude oil pumps, vary greatly.<br />

Depending on the application and for optimum adaptation to<br />

the existing space conditions, the gear stage is designed as<br />

a helical gear or bevel gear.<br />

The variable-speed coupling is<br />

fitted with a helical reduction gear<br />

on the output side. Typical driven<br />

machines are coal mills, crushers,<br />

low-speed pumps and fans.<br />

Design and function<br />

For low-speed driven machines, the<br />

turbo coupling is fitted with a reduction<br />

gear on the output. Coupling<br />

and gear stage are situated in a<br />

common housing, the lower part<br />

of which serves as an oil reservoir.<br />

By adding a <strong>Voith</strong> hydrodynamic<br />

brake (optional), with an appropriate<br />

breaking torque characteristic,<br />

heavy masses of the driven<br />

ma chine can be rapidly decelerated.<br />

Type R..A<br />

7<br />

8<br />

6<br />

Oil supply<br />

Both working and lube oil are supplied<br />

from the integrated oil tank.<br />

The oil system can also be used<br />

to supply both the motor and the<br />

driven machine with oil.<br />

5<br />

2<br />

3<br />

1<br />

4


Type R..B<br />

Type R..KGL<br />

A step gear at the input side and<br />

a reduction gear at the output side<br />

make this type into a fast reacting<br />

and compact coupling used e.g. for<br />

fast respones times, loading pumps<br />

and high powers.<br />

Type R..B<br />

This type of turbo coupling is fitted<br />

with a step-up gear on the output<br />

side. <strong>Geared</strong> variable-speed couplings<br />

for low-speed driven machines<br />

with high inertia, e.g. coal mills.<br />

Type R..KGL<br />

<strong>Geared</strong> variable-speed<br />

coupling type R..B<br />

11


<strong>Voith</strong> <strong>Turbo</strong> GmbH & Co. KG<br />

<strong>Variable</strong>-<strong>Speed</strong> Drives<br />

<strong>Voith</strong>str. 1<br />

74564 Crailsheim, Germany<br />

Tel. +49 7951 32-261<br />

Fax +49 7951 32-650<br />

vs.drives@voith.com<br />

www.voithturbo.com/variable-speed<br />

cr269en, aik-S&F / SVG, 11.2010, 3 000. Dimensions and illustrations without obligation. Subject to modifications.

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