vorecon – variable-speed planetary...

Vorecon – Variable-speed planetary gear

2 3

Vorecon Powerful reasons. Every one a winner.

The Vorecon As you’ve never seen it before

Reliable

Efficient

Durable

Economical

For the power generation and oil and gas in-

dustries, economy and reliability are key con-

siderations. The Voith Vorecon fulfills these

requirements to perfection. Compared to other

drive systems, the Vorecon provides operators

all over the world with exceptional total cost

of ownership.

Availability is key to a plant's Life Cycle Costs. The Vorecon offers a

reliability of 99.97 percent — in other words: MTBF times of almost

40 years. As a result, the Vorecon is setting standards for variable-

speed drive technology within the oil and gas and power generation

industries.

Speed control saves valuable and expensive energy by accurately

adapting individual process conditions. The Vorecon offers very high

efficiency of more than 95% over a broad speed range. Considering

the entire drive train system with its individual component efficiencies,

the Vorecon impresses again with a top performance.

Shouldn't the components of the drive system have the same service

life as the entire facility? The Vorecon is designed for a service life

of more than 30 years. No matter how tough the environmental condi-

tions are – heat, cold, dust or explosion hazards, the robust Vorecon

can handle them.

The economy and hence the life cycle cost of your plant are influenced

by a number of factors: investment, installation and maintenance

costs, as well as service life, space requirements and particularly

energy consumption. Considering all these factors, the Vorecon is

the leading technology for variable-speed drive systems.

THE NEXT GENERATION — HOW TO MAKE A VERY GOOD

THING EVEN BETTER

RWE…AB

Vorecon RWE..AB The coal mill specialist

In addition to the torque converter and planetary

gear, the Vorecon RWE..AB has a bevel gear

connected to the output. This makes it especially

suitable for the economic and flexible control of

slow-running driven machines and for saving

space when there are several drive trains in the

power station. A typical application in the power

industry is for the coal mill drives. In addition it is

equipped with a hydrodynamic brake (retarder),

to bring the large mass of the driven machine

to a rapid stop when it is switched off.

■ Speed control range: 60 –100%

■ Application area:

– Coal mills

Vorecon type RWE…AB. Coal mill, Germany

Power: 1, 330 kW, Speed: 4 75 rpm

New developments to the Vorecon variable speed planetary gear

system have resulted in enhanced capabilities. These include improved

economics and drive train starting behavior. The new horizontally

split housing further improves the service friendliness of the Vorecons.

Improved and easier access, simpler alignment, lower crane height and

service weights are all powerful benefits enabling faster turn around for

inspection and maintenance providing cost and time benefits.

Vorecon – The next generationAdditional benefits.

Service-friendly

2 3

Vorecon Powerful reasons. Every one a winner.

The Vorecon As you’ve never seen it before

Reliable

Efficient

Durable

Economical

For the power generation and oil and gas in-

dustries, economy and reliability are key con-

siderations. The Voith Vorecon fulfills these

requirements to perfection. Compared to other

drive systems, the Vorecon provides operators

all over the world with exceptional total cost

of ownership.

Availability is key to a plant's Life Cycle Costs. The Vorecon offers a

reliability of 99.97 percent — in other words: MTBF times of almost

40 years. As a result, the Vorecon is setting standards for variable-

speed drive technology within the oil and gas and power generation

industries.

Speed control saves valuable and expensive energy by accurately

adapting individual process conditions. The Vorecon offers very high

efficiency of more than 95% over a broad speed range. Considering

the entire drive train system with its individual component efficiencies,

the Vorecon impresses again with a top performance.

Shouldn't the components of the drive system have the same service

life as the entire facility? The Vorecon is designed for a service life

of more than 30 years. No matter how tough the environmental condi-

tions are – heat, cold, dust or explosion hazards, the robust Vorecon

can handle them.

The economy and hence the life cycle cost of your plant are influenced

by a number of factors: investment, installation and maintenance

costs, as well as service life, space requirements and particularly

energy consumption. Considering all these factors, the Vorecon is

the leading technology for variable-speed drive systems.

Ps

Pi Po

A B

Reliability and economy perfectly combined

Hydrodynamics and mechanics in perfect combination

Vorecon drives have demonstrated their versatility in a diverse range

of applications. The Vorecon variable-speed planetary gear can handle

powers from 1,000 to 50,000 kW and speeds from 100 to 20,000 rpm.

All over the world, the Vorecon impresses operators with highest

availability and is the preferred solution for a variety of applications.

The Vorecon combines hydrodynamic components and planetary gear

in one housing. Its modular design permits an individual combination

of hydrodynamic and mechanical components, depending on the

requirements and the application. The advantages of hydrodynamic

and mechanical functions are combined to perfection in the Vorecon.

Based on the principle of hydrodynamics the Vorecon operates with

minimum wear, unsurpassed reliability and a high level of efficiency.

Oil & Gas and petrochemical

industries■ Pipeline compressors

■ Process compressors

■ Refrigerant compressors

■ Hydrogen recycling compressors

■ LNG flash gas compressors

■ LNG coolant compressors

■ Pumps

Function

The Vorecon's function is based on the principle

of power splitting: Most of the power is transmit-

ted mechanically straight through the main shaft

and the planetary gear. The portion required to

adjust the speed is split via the hydrodynamic

components from the main shaft and fed back

to the planetary gear. This results in an overall

efficiency of more than 95%. The Vorecon inte-

grated oil system supplies lube oil and working

oil. This system can also provide lube oil to motor

and driven machine.

Power industry■ Boiler feed pumps

■ Boiler fans

■ Coal mills

Principle of power splitting – Splitting power

from the torque converter to the gear

A: Torque converter, B: Planetary gear

Pi: Input power

Ps:Superimposing power

Po: Output power

Maximum output speed Reduced output speed

The output speed is controlled by varying the superimposing speed. The maximum super-

imposing speed ns yields the highest output speed no. A reduction or reversal in the super-

imposing speed ns yields a reduced output speed no. The variation of the superimposing

speed is achieved by adjusting the guide vanes of the torque converter.

no no

ns ns

ni ni

6 7

00 100

20

40

60

80

100

120

0%

20 40 60 80

100%

RWE

Vorecon RWECompact and economical

The RWE is the most compact version of the

Vorecon. It consists of a hydrodynamic torque

converter, stationary gear and rotating planetary

gear. Its compact coaxial design requires very

little space. It is used in hundreds of applications

all over the world, especially for compressor

applications in the oil and gas industry.


■ Areas of application:

– Compressors

– Pumps

In the oil and gas industry, turbo compressors

are are used in various applications. As a

booster compressor, for transporting gas or

as a process compressor in refineries for

example. The Vorecon type RWE has the

ideal operating range for these functions.

The Vorecon performs several tasks and

functions at the same time: increasing and

control of speed from driver as well as lube

oil supply to the entire drive train. Three in

one. Now that's what we call efficiency.

Vorecon, type RWE.

Fuel gas booster compressor, Argentina

Power: 4, 750 kW,

Speed: 13, 000 rpm

Vorecon, type RWE.

Pipeline compressor, Thailand

Power: 9 ,955 kW,

Speed: 9, 053 rpm

Vorecon, type RWE.

Gaslift compressor, Oman

Power: 13, 000 kW,

Speed: 9, 269 rpm

Vorecon, type RWE.

Gaspipeline compressor, USA

Power: 5, 560 kW,

Speed: 14, 000 rpm

Particularly in the oil and gas industry the Vorecon

RWE has built up its excellent reputation.

A: Torque converter

B: Stationary gear

C: Rotating planetary gear

D: Oil supply

Out

put t

orqu

e [%

]

Output speed [%]

Motor start-up Guide vane adjustment torque converter

A

D

B C

8 9

00 100

20

40

60

80

100

120100%

0%

20 40 60 80

RWCVorecon RWCSimple start-up at high power and weak grids

As power requirements continue to increase,

reduced load start-up becomes more and more

important. Therefore, the RWC features integrated

hydrodynamic couplings in addition to the torque

converter. This allows load-reduced start-up

where grids are weak or mass moments of inertia

are high. During the motor start-up the couplings

reduce the starting torque to relieve the motor.

The driven machine is accelerated to start-up

speed. Then, the torque converter is filled and

the couplings are drained. The driven machine

is accelerated to minimum control speed. The

torque converter now takes over power trans-

mission and speed control. To summarize: The

Vorecon type RWC offers an economical and

reliable solution for reduced load start-up and

speed control.


■ Relieved start-up of motor and driven machine


– Compressors

– Pumps

Characteristic curve of the RWC Vorecon

The operating range of the Vorecon is determined

by various factors, such as the maximum and

minimum speed, the available motor power, oil

supply and the maximum required torque. Each

point can be achieved within the operation area.

This characteristic effectively covers the

requirements of driven machines such as

compressors and pumps.

Vorecon, type RWC.

Compressor test field, China

Power: 30, 000 kW,

Speed: 6, 000 rpm

Vorecon, type RWC.

Pipeline compressor, USA

Power: 11, 931 kW,

Speed: 9, 450 rpm

Vorecon, type RWC.

Pipeline compressor, USA

Power: 12,677 kW

Speed: 9,600 rpm

A: Start-up coupling

B: Torque converter

C: Stationary gear

D: Rotating planetary gear

E: Oil supply

A

E

B C D

Out

put t

orqu

e [%

]

Output speed [%]

Coupling start-up Torque converter filling Torque converter guide vane adjustment

Coupling start-up characteristic Torque converter guide vane adjustmentTorque converter filling

10 11

0 10020 40 60 800

20

40

60

80

100

RW

Vorecon RWSpeed control for wider operating range

Excellent serviceWorldwide and 24/7

Engineered reliability — Something you can depend on

The Vorecon type RW is used whenever a very

broad control range is required such as to drive

boiler feed pumps or fans. In addition to the

torque converter, the type RW has an integrated

hydrodynamic variable-speed coupling with an

integrated lock-up device and a hydrodynamic

brake. At start-up and in the lower speed range,

the power flow is transmitted via the variable-

speed coupling. The speed is controlled via the

oil filling level in the coupling. The motor can be

accelerated with almost no load. In the upper

speed range, the lock-up device is engaged, the

torque converter is filled and now performs the

speed control function. This design provides

a broad speed control range from 10 to 100%.

This solution offers unrivalled total cost of

ownership and reliability advantages for the

power industry.

■ Speed control range 10 –100%


– Boiler feed pumps

– Boiler fans

There's nothing more expensive than unsched-

uled downtime of your plant. It will be our plea-

sure to help you prevent this. 24/7 helpline,

commissioning, monitoring, decades of spare

part supply, repair, maintenance, modernization,

optimization, training — Voith Turbo provides you

with a one-stop service for the lifetime of your

machine. Whenever you need us, our worldwide

service network is close to you. That's a promise.

Every Voith solution includes a piece of "Voith

Engineering". We analyze customer requirements

and match the solution exactly — supported by

flow, vibration and FEM calculations. The result:

the optimum solution for you in the proverbial

Voith quality. In Voith´s state of art test facility, all

Vorecons are thoroughly tested prior to delivery.

Only after successful testing they leave the factory

floor.

Vorecon type RW

Boiler feed pump, Germany

Power: 8, 500 kW,

Speed: 5, 000 rpm

All machines are tested in our state-of-the-art,

dynamic test facility.

With services such as health checks and

plant monitoring, Voith Turbo increases

your plant's availability

A B C D E F

A: Variable-speed coupling

B: Lock-up device

C: Torque converter

D: Hydrodynamic brake

E: Stationary gear

F: Rotating planetary gear

Out

put t

orqu

e [%

]

Output speed [%]

Coupling scoop tube adjustment Torque converter guide vane adjustment

RWE…AB

Vorecon RWE..AB The coal mill specialist

In addition to the torque converter and planetary

gear, the Vorecon RWE..AB has a bevel gear

connected to the output. This makes it especially

suitable for the economic and flexible control of

slow-running driven machines and for saving

space when there are several drive trains in the

power station. A typical application in the power

industry is for the coal mill drives. In addition it is

equipped with a hydrodynamic brake (retarder),

to bring the large mass of the driven machine

to a rapid stop when it is switched off.


■ Application area:

– Coal mills

Vorecon type RWE…AB. Coal mill, Germany

Power: 1, 330 kW, Speed: 4 75 rpm

New developments to the Vorecon variable speed planetary gear

system have resulted in enhanced capabilities. These include improved

economics and drive train starting behavior. The new horizontally

split housing further improves the service friendliness of the Vorecons.

Improved and easier access, simpler alignment, lower crane height and

service weights are all powerful benefits enabling faster turn around for

inspection and maintenance providing cost and time benefits.

Vorecon – The next generationAdditional benefits.

Service-friendly

Assurance that everything's running:Engineering and Service from Voith Turbo

A comprehensive engineering and service package completes the

Vorecon product portfolio. You get everything from one source — from

selection, design and construction to flow, drive train calculations,

manufacturing and comprehensive service package. The benefits:

highest level of plant availability and the optimal drive system for your

application. Additionally, Voith Turbo offers complete packaging of

motor, Vorecon, base frame and oil supply in a single lift skid. You can

rest safe in knowing that you have a complete tailored solution from

one reliable source.

10 11

0 10020 40 60 800

20

40

60

80

100

RW

Vorecon RWSpeed control for wider operating range

Excellent serviceWorldwide and 24/7

Engineered reliability — Something you can depend on

The Vorecon type RW is used whenever a very

broad control range is required such as to drive

boiler feed pumps or fans. In addition to the

torque converter, the type RW has an integrated

hydrodynamic variable-speed coupling with an

integrated lock-up device and a hydrodynamic

brake. At start-up and in the lower speed range,

the power flow is transmitted via the variable-

speed coupling. The speed is controlled via the

oil filling level in the coupling. The motor can be

accelerated with almost no load. In the upper

speed range, the lock-up device is engaged, the

torque converter is filled and now performs the

speed control function. This design provides

a broad speed control range from 10 to 100%.

This solution offers unrivalled total cost of

ownership and reliability advantages for the

power industry.

■ Speed control range 10 –100%


– Boiler feed pumps

– Boiler fans

There's nothing more expensive than unsched-

uled downtime of your plant. It will be our plea-

sure to help you prevent this. 24/7 helpline,

commissioning, monitoring, decades of spare

part supply, repair, maintenance, modernization,

optimization, training — Voith Turbo provides you

with a one-stop service for the lifetime of your

machine. Whenever you need us, our worldwide

service network is close to you. That's a promise.

Every Voith solution includes a piece of "Voith

Engineering". We analyze customer requirements

and match the solution exactly — supported by

flow, vibration and FEM calculations. The result:

the optimum solution for you in the proverbial

Voith quality. In Voith´s state of art test facility, all

Vorecons are thoroughly tested prior to delivery.

Only after successful testing they leave the factory

floor.

Vorecon type RW

Boiler feed pump, Germany

Power: 8, 500 kW,

Speed: 5, 000 rpm

All machines are tested in our state-of-the-art,

dynamic test facility.

With services such as health checks and

plant monitoring, Voith Turbo increases

your plant's availability

A B C D E F

A: Variable-speed coupling

B: Lock-up device

C: Torque converter

D: Hydrodynamic brake

E: Stationary gear

F: Rotating planetary gear

Out

put t

orqu

e [%

]

Output speed [%]

Coupling scoop tube adjustment Torque converter guide vane adjustment

Voith Turbo GmbH & Co. KG

Variable-speed Drives

Voithstr. 1

74564 Crailsheim, Germany

Tel. +49 7951 32-0

Fax +49 7951 32-650

[email protected]

www.variable-speed.com

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