Reliable Speed Control Geared Variable Speed Couplings
voith.comReliable speed controlGeared variable speed couplings
Voith sets the standards in the energy, oil & gas, paper, rawmaterials, and transportation & automotive markets.Founded in 1867, Voith employs more than 19 000 people,generates Euro 4.2 billion in sales, operates in over 60 countriesaround the world and is today one of the largest family-ownedcompanies in Europe.2
Writing a success storyThe geared variable speed couplingIt has been around for seven decades – the Voith geared variable speedcoupling. More than 500 customers in 83 countries trust this type of speedcontrol. Over 10 000 geared variable speed couplings contribute to savinginnumerable kilowatt hours of energy. All of this happens quietly.The principle The geared variable speed coupling combines ahydrodynamic variable speed coupling and a mechanicalgearbox in one compact unit. Input powers from 1 to30 MW and output speeds of up to 20 000 rpm arepossible. The geared variable speed coupling controls the speedof the driven machine precisely, quickly and repeatablywithin the required control range.Unique characteristicsThe reliability of the geared variable speed coupling is 99.97 %. Hydrodynamic power transmission is wear-free. The compact driveline with the geared variable speedcoupling is suited to both harsh ambient conditions andpotentially explosive atmospheres. The geared variable speed coupling provides threefunctions in one machine: Speed control, transmissionfor speed conversion, and integrated oil supply thatdelivers oil to the entire driveline. The lifetime exceeds 30 years. The supply of spare partsis guaranteed over the entire lifetime. Driveline with a geared variable speed couplingPower transmission up to 30 MWVariable flow / pressureDriven machineVariable speedGeared variablespeed couplingSpeed controlHigh-voltage motorConstant speed3
Controlling drives reliablyApplicationsVariable speed drives using a Voith geared variable speedcoupling are compact, efficient and offer unbeatable reliability.The reliability of the couplings is 99.97 %. The range ofapplication includes powers up to 30 MW and output speeds upto 20 000 rpm. The standard motor and the geared variable speedcoupling form a strong pairing in thermal power plants and in oiland gas industry applications.Power plantsThe geared variable speed coupling is indispensable tothermal power plants. It is used as a continuous boiler feedpump drive (for example, in a 3 x 50 % configuration) with thebest balance of energy. It is also used in start-up and stand‑bysolutions in conjunction with steam turbines. In these cases, itensures a controlled, smooth and fast startup even in difficultsituations.4Oil and gasWith their unbeatable reliability, the Voith geared variablespeed coupling easily convinces both onshore and offshorecustomers. One particular key use is in drives for pumps andcompressors in up-stream, midstream and downstreamapplications where there is typically no backup. Designsaccording to DIN, API and AGMA are available.
The geared variable speed coupling and possible applicationsin the oil & gas industry, thermal power plants and nuclear power plants.Thermal power plantsBoiler feed pumps Coal millsCombined cycle power plantsBoiler feed pumps Nuclear power plant Feed pumpsNatural gas liquefaction (LNG) Flash-gas compressors Refrigerating compressors Boil-off gas compressorsGas transportPipeline compressors Refineries and petrochemicals Process gas compressors Hydrogen recycling compressorsOffshore platformsGas lift compressors Export gas compressors Loading pumps Gas treatmentWet gas compressors Refrigerating compressors Acid gas compressors FPSO Injection compressors Export gas compressors Water-injection pumps Loading pumpsOil and gas production Gas lift compressors Depletion compressors Injection compressors5
Achieve success on scheduleAdvantages and benefitsIncrease the productivity of your operation utilizing theflexibility of the hydrodynamic geared variable speedcoupling for speed control of your processes. You will alsobenefit from a compact, robust machine requiring very lowmaintenance effort.Productivity – Increase productivity of your plant Speed control reduces the energy required.This increases the efficiency of your driveline.Power in %How? The hydrodynamic variable speed coupling varies thespeed of the driven machine precisely, quickly and repeatablywithin the required control range. The motor only supplies thepower that the process needs. With speed control, you savea considerable amount of energy over throttle control.10050Saving energy withspeed control0050Flow rate in %Robustness – Keep your infrastructure costs low Integrate the coupling into the drive system withoutthe costs of additional infrastructure measures.Prepare your schedule independent of extremeenvironmental conditions.How? The robust design ensures that the geared variablespeed coupling is less sensitive to environmental effects.Heat, cold, moisture, dust and dirt present no particular challenges to the unit. It can also be used in potentially explosiveatmospheres.6100
Motor start – Start the motor under no-load conditionsDriven machine Start your motor under virtually no-load conditions andsmoothly accelerate even those driven machines witha large mass moment of inertia.MotorHow? The hydrodynamic coupling is empty during motorstarting, separating the motor from the driven machine. In thisway, a motor start under no-load conditions is possiblewithout any additional measures or equipment. Starting themotor under no-load conditions is particularly important forweak power grid conditions, with driven machines having alarge mass moment of inertia or in the case of processes withan initially large load torque. Standby drives for boiler feedpumps can be started quickly and safely using the gearedvariable speed coupling.MotorGearboxVoith gearedvariable speedcouplingDriven machine Avoid unscheduled downtimes. Assure reliableplanning of maintenance and reduce costs andoperational downtimes.How? We combine wear-free hydrodynamic power trans mission with mechanical components that are designed for alifetime of at least 30 years. The recommended overhaulinterval is 8 years and can be planned well in advance.Maintenance costsMaintenance and repair – Minimize your maintenance effort1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24Operating time in yearsDesign – Reduce the installation space you need Compared to other types of speed control, you saveup to 70 % on the installation space.How? The geared variable speed coupling consists of simplemechanical components. A hydrodynamic coupling, a gearstage and the oil system are integrated into a single housing.Other solutionsVoith gearedvariable speedcoupling7
Reliably combininghydrodynamics and mechanicsFunctionThe core components of the geared variable speed coupling are a hydrodynamicvariable speed coupling combined with a mechanical gear stage. The gear stage isdesigned for the initial increase or decrease of the input driver speed. The variablespeed coupling then varies the speed of the driven machine within the required range.Design and function The hydrodynamic variable speed coupling and themechanical gear with double helical design are inte g rated into an enclosed housing with a horizontal split. The gearbox is located before or after the variable speedcoupling depending on the customer’s application. Using the hydrodynamic power transmission principle,a fluid flow transmits the power from the pump wheelto the turbine wheel. The pump wheel rotates at a constant input speed andthe turbine wheel at variable output speed.8 The scoop tube varies the coupling filling. The fillingamount determines the power transmitted andconsequently the speed of the driven machine.An actuator varies the position of the scoop tube. In thisway, the speed can be controlled in a stepless mannerover a wide operating range.Working and lube oil are supplied to the gearedvariable speed coupling from the integrated oil tank.The working and lube oil circuits are separate.The integrated lube oil supply system can supply lubeoil to the motor and the driven machine. A separate lubeoil supply system is not required.
Principal design of the geared variable speed coupling (type R.K)Input shaftPump wheelTurbine wheelOutput shaftScoop tubeOil fillingGear stageHydrodynamic couplingCoupling filling at scoop tubeminimum position (0 %)Coupling filling at scoop tubemaximum position (100 %)Operating map70 %Output torque in %10080 % 90 % 100 %60 %7550 %5040 %30 %2520 %Load00curve1010 %0%20304050Output speed in %60708090100Operating rangeScoop tube position9
Precisely adjust the speedActuatorThe Voith VEHS electrohydraulic actuator positions the scoop tubefast and in a stepless manner at high precision. The short reactiontime and the high position accuracy adapt the operating behavior ofthe driven machine to the process conditions exactly.Function The hydrodynamic variable speed coupling is filled via theworking oil control valve. The oil filling in the variable speed coupling is varied usingthe scoop tube depending upon the speed required of thedriven machine. The Voith VEHS electrohydraulic actuator ensures that thescoop tube is set fast and in a stepless manner. A simple 4 – 20 mA standard signal is required to controlthe scoop tube position.AdvantagesThe scoop tube is positioned with maximum precisionthrough the simple and reliable combination of electronicsand hydraulics. Additional intermediate electromechanicalcomponents are unnecessary. The short control time of the VEHS makes it possibleto adjust the speed of the driven machine quickly andprecisely for the process. The working oil control valve optimizes the flow in the oilcircuit and improves the overall efficiency of the system. Scoop tube positioning using the Voith VEHS electrohydraulic actuatorVEHSWorking oil control valveScoop tube10
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Find the best solutionProduct familyThe geared variable speed coupling product family always has ananswer for your requirements. Together, we will choose the gearedvariable speed coupling that best suits your drive and your system.Type overviewApplicationsTypeWhat it offersCompressorsPumpsR.K.MThe standard R.KGSThe strong one R.GS.MThe fast one R.AThe slow one R.BTurns the corner 12Coal mills
Type R.K.M – The StandardFunction – high power density at medium speeds The input shaft is connected to the gear stage.The input speed is converted up to the higher speed. The gear stage accelerates the pump wheel of thehydrodynamic variable speed coupling. When the motor starts, the hydrodynamic variable speedcoupling is empty. The drive motor and the driven machineare decoupled. The motor starts up under virtually no-loadconditions. The hydrodynamic coupling is filled after the motor hasstarted and smoothly accelerates the driven machine tothe minimum speed. The speed of the driven machine is controlled by thestepless positioning of the scoop tube. The scoop tube changes the oil filling in the variable speedcoupling and thus changes the power transmission.Using the hydrodynamic principle, a fluid flow transmitsthe power from the pump wheel to the turbine wheel.The turbine wheel is connected to the driven machine viathe output shaft.The integrated oil system fills the hydrodynamic variablespeed coupling with the working oil. At the same time,the geared variable speed coupling, the drive motor andthe driven machine are supplied with lube oil.R.K.M sectional diagramP Pump wheelT Turbine wheel6577S Shell471 Oil reservoir2 Auxiliary lube oil pump3 Main lube oil pump4 Lube oil cooler235 Double oil filter6 Lube oil for motor anddriven machine18P T7 Lube oil for gears andbearingS8 Working oil pump9 Working oil control valve10 Scoop tube11 VEHS electrohydraulicactuator1012 Working oil cooler9111213
Type R.KGS – The strong oneFunction – high power transmission at high output speeds The R.KGS geared variable speed coupling adds anadditional gear stage on the output side of the designof the R.K.M type. The second gear stage provides an even higher outputspeed than in the type R.K.M.R.KGS sectional diagram14
Type R.GS.M – The fast oneFunction – high output speeds The R.GS.M geared variable speed coupling is usedin conjunction with 2-pole standard motors. It convertsthe fast input speed into an even higher output speed. The design of the R.GS.M type is based on the provenprinciple of operation of the R.K.M geared variable speedcoupling. The hydrodynamic variable speed coupling isarranged before the gear stage, however.R.GS.M sectional diagram15
Type R.A – The slow oneFunction – low output speeds The gear stage converts the motor speed into a loweroutput speed. The hydrodynamic variable speed coupling and the gearstage are arranged in the R.A type in the same orderas for the R.GS type. Mounting a hydrodynamic brake is possible as an option.R.A sectional diagram16
Type R.B – Turns the cornerFunction – low output speeds The R.B geared variable speed coupling serves toconvert the motor speed to a lower output speed justlike the R.A type. A bevel-gear is located at the output of the hydrodynamicvariable speed coupling. The driven machine is arranged at a 90 angle fromthe drive motor. Mounting a hydrodynamic brake is possible as an option.R.B sectional diagram17
Drive solutionsthat are convincingreferencesGeared variable speed couplings meet all challenges:High speeds, special drive motors, heavy loads andharsh ambient conditions.18
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Operating around the clockOne of the leading companies in the German energy sectorhas put its trust in the hydrodynamic drive solutions from Voithfor many decades now. In this case, our couplings control thespeed of the boiler feed pumps in the second largestlignite‑fired power plant in Europe. The base load power plantis designed for round-the-clock operation spanning decades.The requirements of the geared variable speed coupling withregard to lifetime and reliability are correspondingly high. Forthis reason, our customer considered only Voith as a potentialsupplier.Incidentally, the two most modern units of this power planthave a gross power of 1 100 MW each and the considerableefficiency of 43 %. The efficiency of older lignite-fired powerplants is between 30 % and 35 %. Accordingly, the CO2emission while producing the same amount of power can bereduced by six million metric tons per year. The flexibility of thenew units is also remarkable: Each unit can change its poweroutput by 500 MW in 15 minutes.20Technical information Type:Application:Country:Driven machine:Input power:Maximum output speed:R 18 K 550 MLignite-fired power plantGermanyBoiler feed pump11.9 MW5 660 rpm
Robust machines for demanding processesOil and gas will remain an indispensable part of the globalenergy mix for decades to come. Consequently, oil producersare intensifying their search for techniques that provideimproved yields from oil fields. Using primary and secondaryextraction methods, a yield of 30 % to 40 % can usually beachieved; with tertiary methods, an increase to 40 % to 60 %is possible. The technical term for these tertiary methods is"Enhanced Oil Recovery" or "EOR." In this project, ourcustomer uses a very demanding EOR method known aspolymer flooding. High-pressure pumps inject water, to whichorganic polymers have been added, below ground. Theadditives increase the viscosity of the water, which releasesheavy crude oil more easily from the reservoir rock.Technical information Type:Application:Country:Driven machine:Input power:Maximum output speed:R 17 KOil extractionOmanWater injection pump4 MW4 700 rpmOur robust geared variable speed couplings reliably controlthe speed of the injection pumps during this process –whether outdoors in hot desert climate, in hazardous areas,and even during powerful sandstorms.2121
Successful over decadesChina, with its approximately 1.4 billion inhabitants, is theworld's largest energy producer. In 2013, electricity production was an unimaginable 5.4 TWh and the installed powerplant capacity was a considerable 1 260 GW. Experts predicta doubling of installed capacity by the year 2040. Currently,the lion's share of the power is generated from fossil fuels.Thermal power plants that use coal as a fuel produce aboutthree-fourths of the electricity. Power plant operators areincreasingly using variable speed drives to save energy andfurther increase the overall efficiency of power plants.We have been keeping pace with this development for morethan 30 years by supplying geared variable speed couplingsto power plants throughout the country. More than 1 000geared variable speed couplings are running in the drives ofboiler feed pumps. The customers are very satisfied with Voithcouplings. Their quality, performance and, last but not least,unbeatable reliability provide convincing arguments again andagain.22Technical information Type:Application:Country:Driven machine:Input power:Maximum output speed:R 17 K 500 MCoal-fired power plantChinaBoiler feed pump8 MW5 500 rpm
Reliable technology pays for itselfOur customer operates the largest power plant in the country.This plant uses lignite to produce electricity and district heating.A newly erected power plant unit has replaced four units thatare reaching the end of their service lives. The new unit isconsiderably more efficient. Using the same amount of coal, itproduces 30 % more electricity. After being commissioned, thepower plant generates one-third of the power being usedthroughout the country.Technical information Type:Application:Country:Driven machine:Input power:Maximum output speed:R 866 B 4 GLignite-fired power plantSloveniaCoal mill1.2 MW500 rpmEight Voith geared variable speed couplings are used in thenew Power Plant. They control the speed of the coal mills thatare located around the boiler in very constrained spaces.The couplings have an integrated bevel-gear drive boasting aspace-saving design. In addition, the coupling very effectivelydampens vibrations and torque shocks in the driveline withhydrodynamic power transmission. The lifetime of all drivecomponents is thus extended considerably. Our couplingswere not unknown to the power plant operator. Voith suppliedvariable speed fluid couplings for the old units that ran fora possibly record-breaking 58 years without noteworthyfailures – what more convincing reasons could you need?2323
Expensive shutdowns to be avoidedThis oil refinery has a long and eventful history. It was the firstrefinery in the country and started operation in 1950. Initially,it processed 2 500 barrels per day while today it handles arespectable 323 000 barrels. With 26 process units, 31different products are made. These range from the usual fuelsto paraffin for manufacturing chewing gum.Technical information Refineries are exceedingly complex large-scale systems. Usually, the maintenance intervals are five to six years. In themeantime, the systems run without interruption, every day,around the clock. Shutdowns during operating times areextremely expensive. The costs resulting from an unplannedshutdown are almost always in the single-digit to double-digitmillion dollar range. This fact caused our customer to consider early a Voith geared variable speed coupling for thespeed control of a hydrogen recycle compressor. Severalhundred references in similar applications quickly convincedhim to use the Voith solution.24 Type:Application:Country:Driven machine:Input power:Maximum output speed:R 16 GS 360 MRefineryBrazilProcess-gas compressor1 MW16 000 rpm
A profitable partnershipActually, the history of this power plant extends back to 1953. Atthat time, a very large lignite deposit was discovered in the northof the country. Coal mining started in 1955. Following the oilprice crisis of 1973, it was decided to build a power plant in theimmediate vicinity of the coal mine. The country wanted to uselignite to supply electricity so that it would be less dependent onimported oil. Finally, two units with a power of 75 MW each wenton line in 1978.Technical information Type:Application:Country:Driven machine:Input power:Maximum output speed:R 18 K 600 MLignite-fired power plantThailandBoiler feed pump15 MW5 630 rpmFrom the outset, the operator of the power plant used Voithgeared variable speed couplings in the drives of the boiler feedpumps. Reliable operation, low maintenance costs and, lastbut not least, a promised lifetime of 30 years were thedeciding factors for our customer. Over the years, 11additional units were added – each time with our gearedvariable speed couplings for controlling the boiler feed pumps.Today, 10 units are still operating with an installed total powerof 2 400 MW. In the coming years, the plan is to replace 4units with a single state-of-the-art unit of 600 MW. Followingcooperative negotiations, one thing quickly became obvious:Voith geared variable speed coupling will again play a role.2525
Achieving common goalsEngineeringWe don't just supply products, we also provide ideas. Voithproducts have been controlling the speed in drive systems formore than 60 years now. You benefit from this experience inplanning, use and the development of cost-optimized operationand maintenance.System competenceYou can find thousands of Voith geared variable speed couplings in thermal power plants, the oil and gas industry andthe chemicals sector.PartnershipIf you have any questions concerning the drivers of your drivenmachines, please don’t hesitate to contact Voith and we willbe delighted to discuss all of your questions.Make the right investment decision using our knowledge ofsystems and the applications in which they are employed.In this way, you increase the availability of your system whilereducing the operating costs, too.Our areas of expertise: Consultation in the planning of drive systems Torsional vibration calculation and analysis Strength calculations using FEM Run-up calculations Calculation of speed step responses Retrofit of electronic variable speed drives (VFD)26
Take advantage of themanufacturer’s knowledgeServiceYou benefit from our system and sector competence. Service from themanufacturer increases the efficiency, safety and availability of yoursystem. The engineers and technicians of Voith's service network areavailable worldwide. We maintain sales and service facilities in allregions of the world.Our services Installation, commissioning Training Maintenance and repair Original spare parts Modernization, retrofits and upgrades Service contractsThe advantages for your system Improved operational reliability Increased service life Assured productivity Optimized maintenance costs Life-cycle costs you can plan onOffices worldwide27
VT0269, en, 2019-09, BDI. Dimensions and illustrations without obligation. Subject to modifications.Voith GroupSt. Poeltener Str. 4389522 Heidenheim, GermanyContact:Phone 49 7951 32-261vs.drives@voith.comwww.voith.com
The geared variable speed coupling controls the speed of the driven machine precisely, quickly and repeatably within the required control range. Unique characteristics The reliability of the geared variable speed coupling is 99.97 %. Hydrodynamic power transmission is wear-free. The compact driveline with the geared variable speed
speeds 23 to 757 r/min. Compact in-line assemblies. SW PC-SW page 20 ac worm geared motors from 90W to 0.75kW. Based on our SW worm gearboxes, this new PC-SW range adds a helical stage to achieve lower output speeds down to 3 r/min. SW aluminium worm geared page 14 ac worm geared motors from 90W to 4kW. Cost effective and with a 15000 hour .
SIMOGEAR geared motors The SIMOGEAR portfolio is extensive and you always find a perfect geared motor that precisely meets your requirements. Our standard portfolio includes various gearbox types as basis for our geared motors. The geared motors are suitable for either horizontal or vertical mounting. Highlights: Highest perormance f
Oriental Motor Co., Ltd. offers a wide variety of speed control motors. Our speed control motor packages include the motor, the driver (controller), and a potentiometer which allows for easy speed control adjustment. There are three speed control motor product groups. The "AC speed control motor unit" that uses the most
qualifies for the variable speed. We will check the suitability in the following sections. Note: The terms variable speed drive (VSD) and variable frequency drive (VFD) have been used interchangeably through out the text in this paper. Torque, Speed and Horsepower A drive controls two main elements of induction motor: "Speed" and "Torque".
advanced variable/multi-speed drive system concepts must be developed. This report summarizes an effort to identify viable concepts for both a two-speed and variable speed drive transmission configuration. Efforts will culminate with laboratory testing of a reduced-scale variable/multi-speed drive system to validate system level tools and concepts.
Based on this industrial trend, in this paper, a human-machine interactive control method for geared systems is proposed using the load-side . Human-Machine Interactive Control for Geared Mechatronic Systems by Using Load-side Encoder (Shota Yamada et al.) Fig.3. Block diagram of the two-inertia system motor bench. 10 0 10 1 10 2-150-100-50 0 .
The Baker Hughes Electrospeed Advantage variable speed drive (VSD) is classified as a variable voltage inverter (VVI). It uses a six-pulse silicon controlled rectifier (SCR) front end to convert incoming AC power into variable voltage DC power. This DC power is inverted to variable voltage variable fr
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