Variable-speed drives for the oil, gas and ... - Voith Turbo
Variable-speed drives for the oil, gas and ... - Voith Turbo
Variable-speed drives for the oil, gas and ... - Voith Turbo
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<strong>Variable</strong>-<strong>speed</strong> <strong>drives</strong> <strong>for</strong> <strong>the</strong> <strong>oil</strong>,<br />
<strong>gas</strong> <strong>and</strong> petrochemical industry
2<br />
We give 100 % –<br />
even under toughest conditions<br />
<strong>Voith</strong> <strong>Turbo</strong> hydrodynamic <strong>drives</strong> are in service in <strong>the</strong> <strong>oil</strong>, <strong>gas</strong> <strong>and</strong> petrochemical<br />
industry under <strong>the</strong> toughest conditions around <strong>the</strong> world.<br />
These <strong>drives</strong> are installed at facilities from production to transportation<br />
to processing. On offshore plat<strong>for</strong>ms, natural <strong>gas</strong> pipelines, crude<br />
<strong>oil</strong> <strong>and</strong> liquid pipelines, refineries, petrochemical plants <strong>and</strong> o<strong>the</strong>r<br />
industrial facilities, in <strong>the</strong> desert, or in arctic environments – <strong>Voith</strong><br />
<strong>drives</strong> are running 24 hours a day, 365 days a year. These environments<br />
require equipment that can operate economically <strong>and</strong> with maximum<br />
reliability inspite of <strong>the</strong> difficult operating conditions.<br />
Efficient <strong>and</strong> reliable <strong>drives</strong> <strong>for</strong> controlling pumps<br />
<strong>and</strong> compressors are a necessity <strong>for</strong> reduced<br />
operating costs, increased profitability <strong>and</strong>, above<br />
all, a smooth production process. <strong>Variable</strong>-<strong>speed</strong><br />
<strong>drives</strong> by <strong>Voith</strong> <strong>Turbo</strong> deliver <strong>the</strong> highest possible<br />
reliability, availability <strong>and</strong> efficiency. This per<strong>for</strong>mance<br />
is <strong>the</strong> result of <strong>the</strong> companies’ continuous<br />
research <strong>and</strong> development.<br />
Powers of 100 to 50 000 kW <strong>and</strong> <strong>speed</strong>s of 100 to<br />
20 000 rpm can be transmitted with <strong>Voith</strong> hydrodynamic<br />
variable-<strong>speed</strong> <strong>drives</strong>.<br />
Advantages provided<br />
by <strong>the</strong> hydrodynamic <strong>drives</strong><br />
■ Reliability of 99.9 %*<br />
■ Availability of 99.8 %*<br />
■ Highest efficiency<br />
■ Optimum price/per<strong>for</strong>mance ratio<br />
■ Application in explosive <strong>and</strong> dusty environments<br />
at extreme temperatures<br />
■ Very long trouble-free operating periods (MTBF)<br />
■ Compact <strong>and</strong> robust design<br />
■ Easy maintenance<br />
■ Excellent control accuracy <strong>and</strong> high control<br />
dynamics<br />
■ Vibration damping<br />
■ Integrated lube <strong>oil</strong> system supplying lube <strong>oil</strong> to<br />
<strong>the</strong> driver <strong>and</strong> driven machine<br />
■ Availability of spare parts guaranteed <strong>for</strong> many<br />
years<br />
*calculated on <strong>the</strong> basis of machines in operation
Even in toughest conditions<br />
Economic <strong>speed</strong> control upstream<br />
No matter how tough your requirements are: hot, cold, dust, environments<br />
with explosion hazards – <strong>Voith</strong> offers an economical <strong>and</strong> at <strong>the</strong><br />
same time reliable solution <strong>for</strong> every application.<br />
Compressor drive unit on <strong>oil</strong> plat<strong>for</strong>m<br />
Nam, North Sea, Vorecon type RWE,<br />
Power 4 573 kW,<br />
Speed 13 211 rpm<br />
Gas lift compressors <strong>and</strong> injection pumps<br />
Geared variable-<strong>speed</strong> couplings <strong>and</strong> <strong>the</strong><br />
Vorecon are used <strong>for</strong> <strong>speed</strong> controlling pumps<br />
<strong>and</strong> compressors in <strong>oil</strong> or <strong>gas</strong> production<br />
facilities. If <strong>the</strong> natural pressure of <strong>the</strong> field is no<br />
longer sufficient, water or <strong>gas</strong> is pumped into <strong>the</strong><br />
producing <strong>for</strong>mations at high pressures. As a<br />
result, remaining <strong>oil</strong> or <strong>gas</strong> is pushed to <strong>the</strong><br />
surface. <strong>Voith</strong> <strong>drives</strong> provide a stepless control of<br />
<strong>the</strong> required injection flow <strong>and</strong> pressure.<br />
Gas lift compressor, Oman, Geared<br />
variable <strong>speed</strong> coupling type R 19 KGS,<br />
Power 7 880 kW,<br />
Speed 9 571 rpm<br />
Gas pipeline compressor, Thail<strong>and</strong><br />
Vorecon type RWE,<br />
Power 9 955 kW,<br />
Speed 9 053 rpm<br />
Pipeline pumps<br />
In pipelines, pump stations overcome pressure<br />
losses, differences in altitude <strong>and</strong> transportation<br />
of multiple products. <strong>Variable</strong>-<strong>speed</strong> turbo couplings<br />
provide stepless control resulting in energy<br />
savings, higher service lives of motor <strong>and</strong> pump,<br />
torsional vibration damping <strong>and</strong> a more economical<br />
operation.<br />
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Crude <strong>oil</strong> loading pump, Saudi Arabia<br />
Geared variable <strong>speed</strong> coupling type R 19 KGL,<br />
Power 10 500 kW,<br />
Speed 1 622 rpm<br />
Loading pumps<br />
<strong>Voith</strong> variable-<strong>speed</strong> couplings allow pumps to be<br />
switched off while <strong>the</strong> motor is still running, as<br />
well as stepless flow rate control irrespective of<br />
<strong>the</strong> back pressure or suction pressure.<br />
Gas Pipeline compressor, USA<br />
Vorecon type RWE,<br />
Power 5 560 kW,<br />
Speed 14 000 rpm<br />
Pipeline compressors<br />
If distances are long, <strong>gas</strong> pipelines need flow<br />
control as well as increased pressure. The<br />
variable <strong>speed</strong> planetary gear Vorecon ® with its<br />
high efficiency <strong>and</strong> <strong>the</strong> absolute reliability of <strong>the</strong><br />
hydrodynamics is <strong>the</strong> ideal drive unit <strong>for</strong> pipeline<br />
compressors. Low investment costs, highest<br />
flexibility <strong>and</strong> significant energy savings as a<br />
result of <strong>speed</strong> control are fur<strong>the</strong>r advantages of<br />
this modern drive system. When replacing old<br />
<strong>gas</strong> turbine drivers with electric motor <strong>drives</strong>, <strong>the</strong><br />
Vorecon offers <strong>the</strong> possibility of reduced emissions<br />
<strong>and</strong> compliance with <strong>the</strong> latest environmental<br />
requirements.<br />
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<strong>Variable</strong>-<strong>speed</strong> <strong>drives</strong><br />
Applications<br />
<strong>Voith</strong> <strong>Turbo</strong> variable-<strong>speed</strong> <strong>drives</strong> combined<br />
with electric motors are used in a<br />
great variety of installations:<br />
Upstream – Pumps <strong>and</strong> compressors <strong>for</strong><br />
<strong>the</strong> following applications:<br />
■ Gas lift<br />
■ Gas pipelines<br />
■ FPSO ships<br />
■ Offshore plat<strong>for</strong>ms<br />
■ LNG<br />
■ Injection<br />
■ Crude <strong>oil</strong> loading<br />
■ Oil pipelines<br />
■ Water disposal<br />
Downstream – Pumps <strong>and</strong> compressors <strong>for</strong><br />
<strong>the</strong> following applications:<br />
■ Chemical processes<br />
■ Refrigeration processes<br />
■ Hydrogen recycling processes<br />
■ Wet <strong>gas</strong> units<br />
■ Delayed Cokers<br />
■ Refineries<br />
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6<br />
Highest reliability<br />
<strong>for</strong> downstream applications<br />
For turbo compressors, <strong>speed</strong> control is an effective means of process<br />
adjustment. Electric motors combined with a Vorecon variable-<strong>speed</strong><br />
planetary gear or a geared variable-<strong>speed</strong> coupling have proven to be a<br />
reliable means <strong>for</strong> <strong>speed</strong> adjustment.<br />
Complete refrigeration compressor train,<br />
assembled on base frame with integrated<br />
<strong>oil</strong> supply, Vorecon type RWE,<br />
Power 6 966 kW,<br />
Speed 8 879 rpm<br />
Advantages<br />
Compared to alternative drive systems, such as<br />
frequency inverters, <strong>the</strong> system offers distinct<br />
advantages: excellent availability <strong>and</strong> reliability of<br />
<strong>the</strong> units <strong>and</strong> high efficiency proven by field testing.<br />
In addition, hydrodynamic systems often<br />
have lower investment <strong>and</strong> maintenance costs as<br />
well as a longer life than electronic <strong>speed</strong> control<br />
systems.<br />
Compressor test facility, China<br />
Vorecon type RWC,<br />
Power 30 000 kW<br />
Speed 6 000 rpm<br />
Refrigeration compressors<br />
Refrigeration compressors are used to compress<br />
refrigerants, e.g. propane. The cold generated by<br />
exp<strong>and</strong>ing <strong>the</strong> refrigerant can be used to separate<br />
precious hydrocarbons as condensate from<br />
natural <strong>gas</strong>. With <strong>the</strong> help of <strong>speed</strong> control <strong>the</strong><br />
process can be adapted steplessly. The Vorecon<br />
enables <strong>speed</strong> control at high efficiency <strong>and</strong><br />
partially relieved start-up of <strong>the</strong> drive motor.<br />
Plant inlet compressor, Canada<br />
Vorecon type RWE,<br />
Power 7 457 kW,<br />
Speed 11 400 rpm
Hydrogen Recycle Compressors<br />
With modern processes, refineries are producing<br />
desulphurized diesel fuel to meet new environmental<br />
requirements. To control <strong>the</strong> required<br />
hydrogen recycle process, <strong>speed</strong> control of <strong>the</strong><br />
compressor is required. The compressors often<br />
run at very high <strong>speed</strong>s – The <strong>Voith</strong> Vorecon is<br />
<strong>the</strong> ideal drive unit <strong>for</strong> this application.<br />
Hydrogen Recycle Compressor, Sweden<br />
Vorecon type RWE,<br />
Power 4 200 kW,<br />
Speed 10 450 rpm<br />
Process Compressor<br />
In <strong>the</strong> chemical industry process compressors are<br />
used to initiate reactive processes. Such processes<br />
need to run without any disturbances or interruptions<br />
<strong>for</strong> several years. <strong>Voith</strong> geared variable<strong>speed</strong><br />
couplings have been proven as highly<br />
reliable <strong>drives</strong> <strong>for</strong> <strong>the</strong>se compressors.<br />
Propylene Process Compressor, Germany<br />
Geared variable-<strong>speed</strong> coupling type R 111 KGS,<br />
Power 12 000 kW,<br />
Speed 4 140 rpm<br />
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More than just components –<br />
Engineering <strong>and</strong> Service<br />
Apart from a wide range of products, <strong>Voith</strong> <strong>Turbo</strong> offers innovative<br />
engineering <strong>and</strong> comprehensive field services. With a diverse range of<br />
engineering services, such as per<strong>for</strong>mance optimisation, flow <strong>and</strong><br />
vibration calculations, <strong>and</strong> FEM calculations we can help you when<br />
selecting, <strong>and</strong> designing your drive system. <strong>Voith</strong> <strong>Turbo</strong>’s field service<br />
is available anywhere in <strong>the</strong> world, 24 hours a day. Your advantage:<br />
custom-made solutions <strong>for</strong> optimum fulfilment of all your process<br />
requirements.<br />
Flow calculation<br />
Competence <strong>for</strong> complete solutions<br />
Because of <strong>the</strong> experience <strong>and</strong> services listed<br />
above, we are able to offer our customers complete<br />
drive systems – motor, variable-<strong>speed</strong> drive<br />
<strong>and</strong> <strong>oil</strong> supply system – assembled on a single lift<br />
In our company test field, research is carried out<br />
to continually improve our products <strong>and</strong> test new<br />
technologies <strong>and</strong> materials. Prior to delivery, all<br />
<strong>Voith</strong> products are subjected to intensive test runs<br />
skid. This provides you with complete solution<br />
<strong>and</strong> offers you considerable savings in terms of<br />
transport <strong>and</strong> installation.<br />
Sample of a FEM calculation <strong>for</strong> a<br />
base frame
The right solution in all cases –<br />
The <strong>Voith</strong> product range<br />
Depending on <strong>the</strong> application, <strong>the</strong> requirements, <strong>the</strong> per<strong>for</strong>mance or <strong>the</strong><br />
output <strong>speed</strong>, <strong>Voith</strong> can offer to you a number of different solutions:<br />
<strong>Variable</strong>-<strong>speed</strong> planetary gears, geared variable-<strong>speed</strong> couplings or<br />
variable-<strong>speed</strong> turbo couplings. Toge<strong>the</strong>r with you we will find <strong>the</strong> right<br />
solution <strong>for</strong> your specific needs.<br />
<strong>Variable</strong>-<strong>speed</strong> planetary gear Vorecon ®<br />
The Vorecon is a combination of a hydrodynamic component<br />
<strong>and</strong> a planetary gear in superimposed design. The innovative<br />
drive system is based on <strong>the</strong> principle of power splitting which<br />
enables high efficiencies across a wide <strong>speed</strong> range.<br />
Geared variable-<strong>speed</strong> coupling<br />
Geared variable-<strong>speed</strong> couplings combine a hydrodynamic<br />
variable-<strong>speed</strong> coupling <strong>and</strong> a gear unit in a joint housing. The<br />
gear can be an increaser or reducer, depending on <strong>the</strong> application.<br />
For very high output <strong>speed</strong>s, <strong>the</strong> geared variable-<strong>speed</strong><br />
coupling is fitted with an additional gear stage.<br />
<strong>Variable</strong>-<strong>speed</strong> couplings<br />
<strong>Variable</strong>-<strong>speed</strong> turbo couplings offer <strong>the</strong> easiest hydrodynamic<br />
solution <strong>for</strong> <strong>speed</strong> control when <strong>the</strong> maximum output <strong>speed</strong><br />
equals <strong>the</strong> motor <strong>speed</strong>. The <strong>speed</strong> of <strong>the</strong> driven machine can<br />
be controlled steplessly <strong>and</strong> dynamically.<br />
1<br />
1 Schematic section Vorecon type RWE<br />
with base frame <strong>and</strong> <strong>oil</strong> supply system<br />
2 Schematic section geared variable<strong>speed</strong><br />
coupling<br />
3 Schematic section variable-<strong>speed</strong><br />
turbo coupling<br />
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3
<strong>Voith</strong> <strong>Turbo</strong> GmbH & Co. KG<br />
<strong>Variable</strong>-<strong>speed</strong> <strong>drives</strong><br />
<strong>Voith</strong>straße 1<br />
74564 Crailsheim, Germany<br />
Tel. +49 7951 32-0<br />
Fax +49 7951 32-650<br />
vs.<strong>drives</strong>@voith.com<br />
www.variable-<strong>speed</strong>.com<br />
www.voithturbo.com<br />
Cr 271 en, aik / WA, 03.2010, 2.000. Dimensions <strong>and</strong> illustrations without obligation. Subject to modifications.