Middle East

Sales Workshop 2009

Voith Variable Speed Drives

Technology & Benefits

Why Variable Speed?

Benefits of Variable Speed
Voith Turbo
Our core competency

Power trasmission
Torque conversion
Speed conversion
Oil supply system

Voith Turbo
Driving machine Voith Turbo Driven machine

• Torque Connect • In industry

• Speed Disconnect • On the roads
• Tractive power Transmit • On the rails
Control • On ships

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 2

Hydrodynamic Power Transmission ... an ingenious idea:
„The Föttinger Principle“ (conceived by Dr. Hermann Föttinger, 1905)

Hydrodynamic
Fluid Coupling

Motor Working
Machine

Pump Turbine

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 3

Hydrodynamic Power Transmission:
„The Föttinger Principle“
oil flow

Pump wheel Turbine wheel

Föttinger principle

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 4

Variable Speed Coupling Type SV...

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 5

Variable Speed Coupling Type SV...
Technology
1. Pump wheel
2. Turbine wheel
3. Shell
4. Scoop tube housing
5. Oil sump
6. Oil circulation pump
7. Scoop tube
8. Working oil cooler

Simplified longitudinal section (SVTL)

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 6

Variable Speed Coupling Type SV...
Benefits
ƒ Compact & space saving design
ƒ Robust design
ƒ Energy saving
ƒ Proven technology
ƒ Excellent reputation in all industries
(Oil & Gas, Power, Water, etc.)
ƒ Extremely reliable
ƒ Adjustable design from very basic to high
level design configurations
ƒ Integrated lube oil system possible

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 7

Variable Speed Coupling Type SV...
Different types for different applications

SVTL
e.g. BFP drives in CCPS

SVNL horizontal
e.g. Fan drives in PS

SVNL vertical SVTL in a boiler feed pump drive

e.g. Water pump drives

SVNL G
e.g. Oil pipeline pumps

SVL M
e.g. Water injection pumps
SVNL vert. in a water pump drive
Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 8
Geared Variable Speed Couplings Type RK...

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 9

Geared Variable Speed Couplings Type RK...
Principle

Motor Gear
box

Variable
Driven
Speed
Machine
Coupling

Geared
Motor Variable
Speed Driven
Coupling Machine

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 10

Geared Variable Speed Couplings Type RK...
Design facts & Applications
Stepless speed control of various driven machines
up to highest powers & speeds:

Units: up to 5 000 installed machines

Power: up to 19 MW
Speed: up to 15 000 rpm

Main applications:
Compressors, Boiler feed pumps,
Pipeline pumps, Injection pumps, etc.

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 11

Geared Variable Speed Couplings Type RK...
Technology
1. Gear stage
2. Hydrodynamic variable
speed coupling
3. Scoop tube (adjustable)
4. Scoop tube controller
(VEHS)
5. Working oil cooler
6. Lube oil cooler
7. Main lube oil pump
8. Oil circulation control valve
9. Working oil pump
10. Auxiliary lube oil pump
11. Duplex filter
12. Oil tank

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 12

Geared Variable Speed Couplings Type RK...
Technology / Gears

ƒ High speed machines

ƒ Double helical gearing

ƒ Single-piece forged gear

ƒ Integrated pinion

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 13

Geared Variable Speed Couplings Type RK...
Technology / Fluid Coupling
ƒ Coupling module integral
to the unit

ƒ High grade material

ƒ Highest rotational speeds

ƒ Electrohydraulic
actuator made by Voith
(new RKM generation)

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 14

Geared Variable Speed Couplings Type RK...
Technology / Integral Oil System
Lube oil filter
ƒ Working oil circuit
Lube oil
cooler
ƒ Lube oil circuit

ƒ Lube oil supply to

Main oil pump Auxiliary pump pump and motor

Working oil
cooler

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 15

Geared Variable Speed Couplings Type RK...
Design features with integral benefits

It is 3 in 1 ...

1. Speed increasing gear

2. Speed variator

3. Lubrication system

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 16

Geared Variable Speed Couplings Type RK...
Benefits
ƒ Compact & space saving design
ƒ Robust design
ƒ Energy saving
ƒ Proven technology
ƒ Excellent reputation in all industries
(Power, Oil & Gas, etc.)
ƒ Extremely reliable
ƒ Modular design for easy maintenance
ƒ Modular design for short delivery times
ƒ Adjustable design from very basic to
high level design configurations
ƒ Integrated rapid startup device
ƒ Integrated lube oil system possible

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 17

Geared Variable Speed Couplings Type RK...
Selection Chart
Wide range of couplings

Power 500 - 50 000 kW

Speed 200 - 20 000 rpm

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 18

Geared Variable Speed Couplings Type RK...
Different types

R...KM R...KGS R...GS

R...KGL R...A R...B

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 19

Geared Variable Speed Couplings Type RK...M
ƒ Modular design

ƒ Combines different gearbox sizes

and coupling sizes

ƒ Latest design standards

ƒ Advanced materials and

technologies

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 20

Geared Variable Speed Couplings Type RK...M
Technology
1. Gear stage
2. Hydrodynamic variable
speed coupling
3. Scoop tube (adjustable)
4. Scoop tube controller
(VEHS)
5. Working oil cooler
6. Lube oil cooler
7. Main lube oil pump
8. Oil circulation control valve
9. Working oil pump
10. Auxiliary lube oil pump
11. Duplex filter
12. Oil tank

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 21

Geared Variable Speed Couplings Type R..GS
Directly driven type

For high powers at very

high speeds i.e. for
compressor drives

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 22

Geared Variable Speed Couplings Type R..GS
Technology

2 3 1 1. Gear
2. Variable-speed turbo
coupling
3. Oil pump
4. Scoop tube (adjustable)

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 23

Geared Variable Speed Couplings Type R...KGS
A step up gear is located
both at the input and output
side

High power at high speed

For particularly high output

speeds, e.g. compressors

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 24

Geared Variable Speed Couplings Type R...KGS
Technology
1. Gear
3 2. Variable speed turbo
coupling
3. Oil pump
2
1 4. Scoop tube (adjustable)
1

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 25

Geared Variable Speed Couplings Type R...A
With helical step down gear
Load free start-up

Suitable for applications in

coal mills, crushers, low speed
pumps and fans.

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 26

Geared Variable Speed Couplings Type R...A
Technology
1. Gear stage
2. Hydrodynamic variable
speed coupling
3. Scoop tube (adjustable)
4. Hydrodynamic Brake
(optional)
5. Oil supply
6. Working oil cooler
7. Duplex filter
8. Oil pump

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 27

Geared Variable Speed Couplings Type R...B
Coal Mill Drives
Type: R 866 B 4 G
Power: 1600 kW
Speed: 500 rpm
with retarder for
faster slowdown

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 28

Geared Variable Speed Couplings Type R...B
Technology

2 3 4 5 1. Input shaft
2. Pump impeller
3. Turbine wheel
4. Scoop tube
5. Combined spur and
bevel gear
6. Hydrodynamic
brake
1
6

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 29

Variable Speed Coupling Types S & RK
Combined benefits for our customers
Become more economical, save energy!

Get flexible, adjust your process to its needs!

Make your motor happy, unload it!

Don‘t ‚shock‘ your equipment, damp it!

Low maintenance - Happy operators - Low budget

Save your space, don‘t waste it!

Availability + Reliability - We set the benchmark!

Adapt speed - Extend your equipment life!

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 30

Variable Speed Control versus Throttle Control

Pump Characteristic Pump Operation at Design Point

%
H1 Head x Flow
100
Power =
H Efficiency
80

Efficiency η [%]
Resistance Curve

60
Head H

η1 For reducing the pump Flow Q there

Efficiency Curve
90
are 2 different ‚philosophies‘ possible:
40 80
50
40 A.) Throttle Control
20
B.) Speed Control
00 20 40 60 80 100 120 %
Flow Q
Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 31
Variable Speed Control versus Throttle Control

Pump Characteristic A.) Throttle Control

%
Hi H1 Æ Reduction of Flow Q by creating
100
a new system resistance curve
H
Æ Pump characteristic + pump
80
efficiency curve remain the same

Efficiency η [%]
Resistance Curve
Æ Effect:
60
Head H

Pump absorbs more power due

η1 90
Efficiency Curve to a increase in Head H while at
40 80 the same time the pump efficiency
ηi 50 at the new operating point drops
20 40
Head Ï x Flow Ð
Power Ï =
00 Efficiency Ð
20 40 60 80 100 120 %
Flow Q
Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 32
Variable Speed Control versus Throttle Control

Pump Characteristic B.) Speed Control

%
H1 Æ Reduction of Flow Q by creating
100
a new pump characteristic with
H
a new corresp. efficiency curve
80
Æ System resistance curve

Efficiency η [%]
Resistance Curve
remains the same
60
Head H

Æ Effect:
ηi η1 90
Efficiency Curve Pump absorbs less power due
40 80 to a decrease in Head H while at
50 the same time the pump efficiency
20 40 at the new operating point is high
Hi
Head Ð x Flow Ð
00 20 40 60 80 100 120 % Power Ð =
Efficiency Ï
Flow Q
Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 33
Variable Speed Control versus Throttle Control

Pump Characteristic A.) Throttle Control

%
Hi H1
100
H
80
Power
ΔH =

Efficiency η [%]
Resistance Curve

60
Savings
Head H

ηi η1 90
Efficiency Curve
40 80
ηi 50
20 40
Hi B.) Speed Control
00 20 40 60 80 100 120 %
Flow Q
Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 34
Variable Speed Couplings
Economical and energy saving / Adapted processes

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 35

Variable Speed Couplings
Unloaded motor start-up / Smooth mass acceleration

I I
200

200
600 % IN 600 % IN
Motor
50 100 150

50 100 150
Motor
Current 400 %

Speed [%]
Speed [%]

Speed 400 %
Motor &
Driven Machine Driven
Speed 200 % Motor Machine 200 %
Current Speed
0

0 5 10 0 0 5 10
Time [sec] Time [sec]

without variable speed coupling with variable speed coupling

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 36

Variable Speed Couplings
Inherent shock and vibration dampening features

oil flow

Pump wheel Turbine wheel

OIL

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 37

Variable Speed Couplings
Low maintenance - Happy Operators - Low budget

Recommended overhaul time

for standard maintenance
Simple + robust
mechanical design 8 Years

Predictable & low

$
Local maintenance staff possible, maintenance budgets

$
no specialists needed

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 38

Variable Speed Couplings
Save your space, don’t waste it!

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 39

Variable Speed Couplings
Availability + Reliability - We set the benchmark for you!

99,97 %

99,83%

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 40

 Variable Speed Couplings
Adapt speed - Extend your equipment life!

After 40 years of operation in the Kosovo Power Station

before overhaul after overhaul

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 41

Variable Speed Couplings
References Oil & Gas Industry
Pipeline Booster Pumps

Iraq-Turkey Oil Pipeline

with approx. 1000 km and
5 boosting stations

Type : 620 SVL

No. of units : 10
Power : 3075 kW
Speed : 3000 rpm
Year : 1982

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 42

Variable Speed Couplings
References Oil & Gas Industry
Oil Pipeline Pumps
Oil Pipeline in Saudi Arabia
Over 45 years in service and still
performing like the very first day!

Type : 620 SVL

No. of units : 30
Power : 2500 HP
Speed : 3000 rpm
Year : 1962

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 43

Variable Speed Couplings
References Oil & Gas Industry
Water Injection Pumps

Oil Field in Oman

Type : 682 SVL

No. of units : 2
Power : 3400 kW
Speed : 2920 rpm
Year : 2003

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 44

Variable Speed Couplings
References Oil & Gas Industry
Oil Pipeline Pumps

Oil Pipeline in Russia

Type : 487 SVTL 22

No. of units : 12 + 8
Power : 1170 kW
Speed : 2980 rpm
Year : 1983 / 1988

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 45

Variable Speed Couplings
References Oil & Gas Industry (extract only)
Year Qty Type Driven Power Speed Customer, End User / Country
Machine (kW) (rpm) Plant

1996 1 1150 SVNL 21 vert. Oil pipeline 890 3600 Sulzer Pumps UAE
pump ADNOC, DAS Island

1998 2 620 SVNL 33 G Oil pipeline 3687 3506 Weir Pumps UK

pump Texaxo, Captain Platform
North Sea
1998 3 562 SVNL 33 G Oil pipeline 1887 3522 IDP, SHELL USA
pump Glider Brutus Platform,
Gulf of Mexico
2002 5 562 SVTL 33 Oil pipeline 3100 3488 Sulzer Pumps, BP USA
pumps Thunder Horse Platform,
Gulf of Mexiko
2008 3 562 SVL M Water injection 1991 2880 Sulzer Pumps, PDO Oman
pumps Sayyala Oil Field

2008 3 562 SVL M Water injection 2099 2872 Sulzer Pumps, PDO Oman
pumps Zauliyah Oil Field

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 46

Geared Variable Speed Couplings
References in Oil & Gas Industry
Gaslift Compressor
PDO Lekhwair field
Oman
Nuovo Pignone, Italy

Geared Variable Speed

Coupling

Type: R 19 KGS 14 API

Power: 7880 kW
Speed: 9571 rpm

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 47

Geared Variable Speed Couplings
References in Oil & Gas Industry
End Flash Compressor
TIGA LNG
Malaysia
Hitachi, Japan

Geared Variable Speed

Coupling

Type: R 19 KGS 14.1 API

Power: 6664 kW
Speed: 8900 rpm

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 48

Geared Variable Speed Couplings
References in Oil & Gas Industry
Crude oil loading pumps
Aramco, Saudi Arabia

Geared Variable Speed

Coupling

Type: R 19 KGL
Power: 10500 kW
Speed: 1622 rpm

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 49

Geared Variable Speed Couplings
References in Oil & Gas Industry
Oil Pipeline Pump
Oil Booster Pumps
PDO Hubara field
Oman

Geared Variable Speed Coupling

Types: R 17 K.2 / R 17 K 400 M

Power: 3687 kW / 3800 kW
Speed: 4685 rpm / 4747 rpm
Year: 1997 / 2004

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 50

Geared Variable Speed Couplings
References in Oil & Gas Industry
Water Injection Pump
Weir Brae Platform
North Sea

Geared Variable Speed

Coupling

Type: R 15 K 400 M API

Power: 1255 kW
Speed: 4560 rpm
Year: 2000

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 51

Why Variable Speed? Product Know How & Benefits | 25.06.2009 | 52