voith.

com

Powerful, efficient, reliable

Key components for
combined cycle power plants
Voith has been a trusted partner for the
combined cycle power plant market for
50 years. Our products are extremely reliable
and make your operation more efficient.

Our product portfolio:

Speed control for boiler feed pump Page 4 – 7

Starting and turning devices for gas Page 8 – 9

and steam turbine

Connecting and safety couplings Page 10 – 11

Actuators and control systems Page 14 – 15

for turbomachinery

Integral gear units for fuel gas booster Page 16

compressors

Turbo gear units for gas and steam turbine Page 17

Service partner at your side Page 18 – 19

Speed control for boiler feed pump
Variable speed couplings

In a combined cycle power plant, many design safety margins tem’s head loss by throttling. In addition to the head loss, the
are considered for the feed water pump. This means that even pump efficiency decreases significantly when operating at
in a base load plant, the pump already operates far within lower flow rates.
the throttle mode and thus a lot of energy is wasted.
A more economical way to control the pump flow is to change
- Safety margins in flow (10 to 25 %) its speed, resulting in different pump characteristic curves.
- Safety margins in pump speed (5 %)
- Safety margins in pressure (5 to 20 % ) The use of a variable speed coupling allows reducing the speed
- Safety margins in steam production (5 %) of the boiler feed pump for partial load conditions.This results in
significant energy savings compared to fixed speed operation
The operating point of a pump results from the intersection of with throttle valve. In addition, the pump can be operated close
pump characteristic curve with the system’s resistance curve. to its optimum efficiency over the whole speed range.
Other operating points may be obtained by increasing the sys-

Benefits Product description

++ Outstanding reliability Variable speed turbo couplings are fluid couplings,

++ Increases the reliability of the whole drive train connecting the motor with the boiler feed pump.
++ Energy saving against throttle control They enable stepless speed control of the pump.
++ Simplicity  low grade of complexity Hydrodynamic couplings provide wear free power
++ Robustness  suitability for outdoor operation also transmission and vibration dampening between input
under extreme climatic conditions and output. In addition they can also serve as the lube
++ Spare parts availability throughout the whole lifecycle oil system in the drive train; i.e., they can supply lube oil
(30 years and more) to the motor and to the boiler feed pump. With the
++ Low maintenance expenditures (maintainability / scoop tube (moved by an actuator), the content of oil
serviceability) are very high inside the runner parts is being changed and therefore
++ Integral lube oil system the output speed of the machine.

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When using speed regulation, additional cost savings can be
Comparison of motor power consumption between the
achieved by selection of a less expensive recirculation control
use of throttle control and variable speed turbo coupling
flow valve and a 100% control valve (small differential pressure).
With service life of a power plant averaging about 30 years, no
one can predict fuel and gas prices as well as load patterns 120
over this period of time. Flexibility is a key issue for today’s
advanced power station technology. The operation of boiler 100
Throttle control
feed pumps should be flexible, too. This can only be achieved
Motor power [%]
80
by variable speed operation of pumps. Power savings
60
Variable speed
turbo coupling
40

20

0
0 10 20 30 40 50 60 70 80 90 100 110

Flow [%]

S-Type variable speed turbo coupling

200 kW to
6000 kW
power and
3000 / 3600
rpm speed
5
Cost comparison of throttle control versus variable speed turbo coupling

3 x 50 % Boiler feed pumps Throttle control Turbo couplings

Operating points 425 MW Test block 425 MW Test block

Operating hours [h/yr] 7 990 10 7 990 10

Flow [kg/s] 62.70 78.38 62.70 78.38

Head [bar] 131.99 115.21 93.50 115.21

Feed water density [kg/m ] 3

925.87 925.87 925.87 925.87

Pump efficiency [%] 78.96 80.00 80.00 80.00

Pump speed [rpm] 2 980 2 980 2 487 2 872

Absorbed power [kW] 1 132 1 219 791 1, 19

Slip losses [kW] – – 157 46

Mechanical losses [kW] – – 12 12

Total power [kW] 2 x 1 132 2 x 1 219 2 x 960 2 x 1 277

Energy per year [kWh] 18 089 360 24 380 15 340 800 25 540

Total energy per year [kWh] 18 113 740 15 366 340

Energy cost 1 kWh: 0.05 € [€] 905 687 768 317

Savings: 137 370 € per year

Example: Cost return studies have shown that amortization time by speed variation is usually between 6 and 20 months.

RKM-Type geared variable speed turbo coupling

RKM-Type
geared variable speed turbo
coupling for a BFP with

5000 to
6000 rpm
6
“For almost 40 years Voith has supplied variable speed
fluid couplings as boiler feed pump drives for combined
cycle power plants, successfully supporting the CCPP
boom since the beginning of this millennium. A fleet of
more than 1,300 units is currently (2018) in operation.
The main success factor is the unmatched reliability
based on a robust design.”
Ralph Höfert, Product Manager Variable Speed Couplings at Voith, Germany

7
Starting and turning devices for gas
and steam turbine
Hydrodynamic torque converters

Reliable starting of gas turbines is essential for safe operation The momentum support, which is essential for torque and
of combined cycle power plants. Providing a high torque for speed conversion, is achieved by changing the flow by means
breakaway and acceleration into the self-sustaining speed of guide vanes. This principle is the basis for high availabilities
range of the gas turbine are the key functionalities of the Voith and a long life-time. In numbers: Mean time between failures
torque converter family for starting gas turbines. of >100 years are achieved based on our experience with
thousands of torque converters in operation all over the world.
Based on the indirect principle of hydrodynamic power Challenging environmental conditions like dessert, offshore or
transmission invented more than 100 years ago by Hermann extreme cold conditions are also typical areas of operation.
Föttinger, torque converters are used to optimally adapt the Optional available integrated turn devices are used for
characteristics of a driver to the needs of the driven machine. maintaining the gas turbine as well as safe cooling of the
turbine rotor.
Mechanical energy, from a typically constant speed driver, is
transformed into kinetic energy in a fluid flow by a pump wheel Various models and add-ons are available to match the torque
and reconverted back into mechanical energy via a turbine converter to your specific starting needs.
wheel.

Hydrodynamic torque converter Benefits

++ Fixed or variable guide vanes for smooth and

controlled startup
++ Drainable housing to eliminate disconnecting coupling
++ Integrated turn device for safe cooling and
maintenance
++ Single torque converters for space saving integration
into gas turbine frame
++ Complete starter packages ready commissioned

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Rotor turning gears

Rotor turning gear units primarily provide safe cooling for hot latches lock in, and the rotor turning gear unit and the shaft
rotors in a steam or gas turbine or compressor by slow turning. connect upon speed synchron­ization. The shaft train is brought
This helps the rotor remain dimensionally stable. Rotor turning to a low speed in a controlled manner. The rotor turning gear
gear units also provide for breakaway, startup, or precisive unit is switched off in order to stop the rotor.
positioning of shaft trains.
Swivel pinion operating principle
Overrunning clutch operating principles The rotor turning gear unit can be mounted on the bearing
The rotor turning gear unit can be mounted on the free pinion housing of a gas turbine, for example. After checking the start
shaft end of a gear unit, for example. After checking the start- up conditions – such as compressed air feed, electrical volt-
up conditions (electrical voltage, lu­bricating oil pressure, hy- age, lubricating oil pressure, hydraulic fluid boost and stopped
draulic fluid boost, turbine rotor stopped), the rotor turning turbine rotor – the swivel pinion engages with the gearing on
gear unit establishes the connection with the rotor on startup. the turbine shaft. In this way, the rotor turning gear unit brings
The rotor turning gear unit then brings the shaft train to a pre- the shaft train up to the rated speed for the rotor turning gear
defined speed. unit. This enables the gas turbine to continue accelerating on
its own. The rotor turning gear unit disengages and spins
As the line continues to accelerate, the rotor turning gear unit down until it shuts off. If the shaft train is shut down for main-
decouples by having the slip gearing release the connection tenance work, the rotor turning gear unit returns to its rated
from the rotor turning gear unit and the swivel pinion in the speed once a specific turbine coastdown speed is reached.
axial direction and allowing the centrifugal forces to push the When the speeds are synchronized, the rotor turning gear unit
locking latches radially outwards. The rotor turning gear unit swivel pinion re-engages and brings the shaft train to a low
now spins down until it shuts off. If the shaft train shuts down speed in a controlled manner. The rotor turning gear unit is
for maintenance work, for example, the rotor turning gear unit switched off in order to stop the rotor.
is simultaneously brought back up to its rated speed. The

Rotor turning gear units Benefits

++ High reliability and low failure rates

++ High degree of flexibility in line configuration
++ Repair-related costs will be lower
++ An additional increase in system availability
++ Fully automatic operation

9
Connecting and safety couplings
Diaphragm couplings

The diaphragm coupling converts torque reliably, safely and Designs are available for all possible connection applications.
without wear or the need for maintenance. Equipped with The rotor dynamics, noise and airflow characteristics of the
single or double diaphragms, these connection couplings couplings can be optimized as needed.
cover a performance range between 100 and 70 000 kW.
High-performance diaphragm couplings are extremely robust,
Diaphragm couplings from Voith are the ideal connection and their ability to compensate for an angular displacement of
of a turbo gearbox with the driving or driven machine. The up to 0.5 degrees increases drive train operational reliability.
EconTors single diaphragm coupling runs at speeds up to
8 000 rpm in medium-speed applications, whereas the Twin-
Tors double-diaphragm coupling is used in high-performance
compressors or test rigs at speeds up to 80 000 rpm.

TwinTors diaphragm coupling Benefits

++ Adapted to the operator’s technical requirements

++ Favorable total cost volume (CAPEX + OPEX)
++ Designed to provide the best rotor dynamic
characteristics
++ High level of safety
++ Minimizes maintenance expenses
++ Low turbulence
++ Special noise-protection measures
++ Cooling and monitoring equipment

10
SafeSet torque limiting couplings
for driveline protection

The SafeSet principle is simple: friction and adaptability. No

Benefits
material fatigue or wear ensures constant torque protection
during operation. ++ Maximum driveline protection
++ Accurate and constant release
The SafeSet coupling includes a twin-walled hollow sleeve. ++ Adjustable release torque
Friction is generated upon expansion by pressurized hydraulic ++ Quick resetting for maximum uptime
oil. The integrated shear tube holds pressure to ensure a ++ Custom made to suit individual requirements
constant but easy adaptable torque transmission. In an over-
load situation, the SafeSet slips and the shear tube shears off.
Oil pressure drops and the frictional surfaces separate. Then
the SafeSet rotates on the bearings without transmitting any
torque.

Torque capacity available between 1 kNm and 20 000 kNm.

SafeSet torque limiting coupling SafeSet with instant release

Torque

Time

11
Voith – Proven technology in
combined cycle power plants

12
13
Actuators and control systems
for turbomachinery

Control actuators
Benefits
We design the actuator solutions in line with your requirements
for safety and availability. For example, we offer redundant ++ Our actuators reduce the complexity of your
products for high-availability process units or certified products overall control system.
for potentially explosive atmospheres. In addition, most of our ++ The results are increased reliability and availability
actuators are SIL certified and thus comply with the interna- of your plant.
tional standard for operational safety. ++ This helps you to run a trouble-free and profitable
operation.
++ The outstanding control speed and precision of
the actuators provide stable processes that ensure
high quality for your products.

Three different product groups for actuating control valves

Product I/H converters Way valves Servo motors

Current-to-pressure Servo valve with

Linear actuator
converters position controller

Function
Pilot valve

Hydraulic cylinder Hydraulic cylinder

Control valve Control valve Control valve

Valve actuation Complex Less complex Simple

Voith product Provided by the customer

14
Safety actuators
Benefits
The design of the products is compact and modular. This al-
lows nearly all standard safety concepts for turbine control ++ In the event of a trip, your turbine safely shuts down
systems to be implemented in a cost-effective way. As an op- via our actuators in the shortest possible time.
tion, the products are available in explosion-proof design. ++ You avoid immediate and consequential damage
resulting from turbine overspeed.

Controllers
Benefits
Voith control systems are suitable for all steam turbines used
to drive generators, compressors, pumps and other mechani- ++ Your turbine or compressor operates safely, reliably
cally driven machines. and efficiently with our controllers.
++ You ensure the productivity of your plant and the
The control systems are available in two designs: quality of the produced products.
1. Standard controllers that are “pre-engineered” ++ Your turbine or compressor operates very efficiently
with standard software. with proven and multiple tested software algorithms.
2. Customized controllers offering different functionality Our engineers are continually refining these algorithms
and redundancy options with adapted software and and adapting them to the current state of the art.
optional redundancy.

Three product groups for actuating trip valves

Product Trip block Trip actuator Overspeed protection

Electrohydraulic Overspeed detection

On/off actuator
safety control unit and tripping

Hydraulic cylinder
Function Hydraulic cylinder
(direct mounting)

Trip valve Trip valve Trip valve

Voith product Provided by the customer

15
Integral gear units for fuel gas booster
compressors
Integral gears

With more than 45 years of experience, Voith has supplied the Our standardized and customized gearbox solutions for fuel
core unit for over 2 000 integrally geared compressors. These gas boosting applications provide the customer the ideal solu-
types of compressors have now established themselves in the tion for their integrally geared compressor and help the opera-
process industry. Originally this field was clearly reserved for tor to keep their power generation facility reliable and efficient.
freestanding axial, radial and also reciprocating piston com-
pressors. Among the main reasons for this development is the
lower space requirement and the higher total efficiency of the
compressor package.

Integral gear Benefits

Integral gear technology provides a very efficient and

reliable solution combined with space savings:

++ Customized to the operator´s needs

++ Optimized for the compressor application
++ Long periods without unscheduled downtimes
++ Higher efficiency than comparable single-shaft designs
++ Each stage can be optimized to run at its ideal speed
++ Smaller footprint and low weight

16
Turbo gear units for gas and steam turbine
Parallel shaft gears and planetary gears

Voith gear units are used between gas or steam turbines and
Benefits
generators of combined cycle plants to convert torque with
high efficiency. ++ Efficiency: saving energy with high efficiency gear
solutions
Planetary gear units cover powers up to 45 MW, speeds of up ++ Availability: increased lifetime and operational safety
to 80 000 rpm and torques of over 550 000 Nm. With single- ++ Reliablility: very long periods without unscheduled
stage designs, ratios up to 12:1 are achieved; with two-stage, downtime
even ratios up to 80:1. ++ Predefined standards customized to the operator’s
needs
Parallel shaft gear units transmit power levels up to 85 MW ++ Low noise levels due to the use of double helical gears
with gear ratios available from 1:1 to 10:1. ++ Lightweight and space-saving drive trains

All gear units can be customized to fit the application and

meet the operator’s needs. This means the driving and driven
rotational direction, the toothing design, and the shape and
material of the housing are all optimized to your equipment.
Parallel shaft gear and planetary gear
The international standard for ISO, AGMA or API are fulfilled.
The “Stoeckicht principle” ensures an ideal load balance be-
tween the sun pinion, planet gears and ring gears on planetary
gears. Planetary gears achieve highest efficiencies at higher
gear ratios i>6, enable coaxial drive trains and are very com-
pact.

Parallel shaft gears can be equipped with internal quill-shafts

for direct connection of the generator, shaft-driven lube oil
pumps, turning gears or with the AeroMaXX technology for
high efficiency gears.

Connection couplings to the high-speed machine are already

integrated into the planetary gear unit or can be ordered as a
package with the parallel shaft gears.

These features enable a highly reliable solution with a service

life over 250 000 operational hours. Unit efficiency can reach
levels of up to 99.3 %, especially with AeroMaXX technology.
This means that a very high level of overall productivity is
achieved, particularly in applications where high powers are
transmitted.

17
 Our Service –
Part of Your
Business.

A competent service partner at your side

Backed by 500 service technicians, 43 workshops, and more In addition to conventional services, Voith has options of spe-
than 150 years of industry experience, Voith Service is a cial interest to the power plant industry: service agreements,
reliable partner for operators of gas and steam turbine power rapid production and delivery of spare parts, individual ware-
plants. This team helps customers conquer daily challenges. housing concepts for machine fleets, prompt and economical
Its guiding principle is to make operating power plant compo- equipment condition assessments, expert technical support
nents from Voith’s own production or third parties even more for operational problems, as well as upgrades and retrofits
safe, reliable, durable and efficient. for performance-increasing measures and modifications to
operating methods.
In this process, Voith sees itself as a partner to power plant
operators and, in accordance with its service philosophy, Consult our experts on further optimizing the operation of your
focuses its actions and efforts on the needs of each individual plant!
customer.
Explore service cases for drive trains with turbines, pumps
and compressors at our website: www.voith.com/turbo-
industry-service

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Technical service & Spare parts & Maintenance, repair & Retrofit & modernization
agreements replacement machines overhaul

• 24/7 emergency number • Spare parts packages • Installation and • Modernization

• Engineering support • Replacement machines commissioning • Upgrades
• Fault and root cause • Parts manufacture • Outdoor installations • Exchange
analysis • Express delivery • Repair shop-based • Retrofit
• Troubleshooting • Warehousing servicing • Turnkey solutions
• Remote service • Tools and accessories • On-site repairs
• Status monitoring • Emergency repairs
• Condition assessment • Test runs
• Measurements and
analyses
• Customer training
classes
• Service agreements
• Warranty extensions

Offices and workshops worldwide

19
 VT0303, en, vvk, 2019-02. All data and information without obligation. Subject to change.
Voith Group
St. Poeltener Str. 43
89522 Heidenheim, Germany

Contact:
Variable speed drives
Phone +49 7951 32-261
[email protected]
www.voith.com/vsd

SafeSet
Phone +46 650 540-150
[email protected]
www.voith.com/safeset

Actuators and governors

Phone +49 7951 32-470
[email protected]
www.voith.com/turbine-control

Turbo gears
Phone +49 8321 802-0
[email protected]
www.voith.com/BHS-turbogears

Voith Service
[email protected]
www.voith.com/turbo-industry-service