This document discusses variable speed drive solutions for offshore applications, including Voith's Vorecon solution. It provides details on Vorecon, including its applications in compressors, advantages like simplicity and reliability compared to traditional variable frequency drives, installation examples, and reliability statistics. The document also summarizes Epicyclic gear units and hydrodynamic variable speed drives for subsea applications.

1. 1
Solutions for Offshore Applications

2. 2
Products
• Variable Speed Drives
• Stoeckicht Epicyclic Gears
• Hydrodynamic Variable
Speed Drives for Subsea

3. 3
The Variable Speed Planetary Gear VORECON

4. 4
VORECON Offshore Applications

5. 5
Vorecon
M-VSD for Compressors
Vorecon gives 3 in 1:  Speed variation (e.g. 60% to 105%)
 Speed increase (e.g. 1800 rpm to 15000 rpm)
 Lubrication of overall drive train
fixed speed
ne = 1500 rpm or
ne = 1800 rpm
variable speed need
(governed by process)
e.g. na = 15000 rpm
Vorecon does speed increase to MCS
& creates variable speed, e.g. 60 to 105%
lubrication of overall drive train

6. 6General Presentation | Products | Function
Vorecon Function
Basic design of the Vorecon
Combination of
hydrodynamic components
and planetary gear in a
common housing.
For powers of more than
1000 kW.

7. 7
Vorecon
Function (I)
Driver
Driven
machine
Gearbox
n1 = constant n2 = constanti0 = fixed
FIXED SPEED
n = speed
i = gear ratio

8. 8
Vorecon
Function (II)
Driver
Driven
machine
Gearbox
VFD
n1 = variable n2 = variablei0 = fixed
VARIABLE SPEED WITH VFD
(E-VSD)
n = speed
i = gear ratio

9. 9
Vorecon
Function (III)
Driver
Driven
machine
Gearbox
n1 = constant n2 = variablei0 = variable
Hydrodynamic
Drive
Vorecon
Epicyclic
Gear
Torque
Converter
VARIABLE SPEED WITH VORECON
(M-VSD)
n = speed
i = gear ratio

10. 14
Vorecon
Types for Oil & Gas Applications
RWC
Speed control range 60 - 100 %
Fully unloaded motor start-up.
Best for weak grids.
Applications:
Compressors & Pumps
RWE
Speed control range 60 - 100 %
Partially unloaded motor start-up.
Best for strong to medium strong
grids.
Applications:
Compressors & Pumps

11. 15
Simplicity ...
- Integral step-up gear
- Integral lube oil system
Standard fixed speed HV
motor
Standard
couplings
Voith
Vorecon

12. 16
Airconditio
n
Grid
filter
11 kV
Transformer
Motor (6
kV)
Gearbo
x
Compressor /
PumpSpecial
cabling
Transformer
Lube oil system
VFD
Motor (6
kV)
Gearbo
x
Compressor /
Pump
Transforme
r
VF
D
Harmonic-Filter
Special
cabling
Lube oil system
Harmonic-Filter
... versus Complexity

13. 17
Airconditio
n
Grid
filter
11 kV
Transformer
Motor (6
kV)
Gearbo
x
Compressor /
PumpSpecial
cabling
Transformer
Lube oil system
VFD
Motor (6
kV)
Gearbo
x
Compressor /
Pump
Transforme
r
VF
D
Harmonic-Filter
Special
cabling
Lube oil system
Harmonic-Filter
Create Simplicity  Use the Voith Vorecon

14. 18
Vorecon
is a simple solution
• Compact
• Integrated lube oil system
• High efficiency
• Robust
• long-life
• High reliability
Motor (6
kV)
Motor (6
kV)
11 kV Sub
Station
Compressor /
Pump
Compressor /
Pump
Motor (11
kV)
Motor (11
kV)
Integrated lube oil
system
Integrated lube oil
system

15. 19
Variable Frequency
Compressor
Drive Train
Gas Coolers
Nitrogen
Harmonic Filters
Transformer
Ventilation VFD
Lube Oil System
General Persentation | Products | Advantages
Space requirement for Offshore VFD (12 – 14 MW)

16. 20
Variable Frequency
Harmonic Filters
Transformer
Ventilation VFD
General Persentation | Products | Advantages
Space requirement for Offshore VFD (12 – 14 MW)

17. 21General Persentation | Products | Advantages

Space requirement for Offshore VFD (12 – 14 MW)

18. 22
Space requirement for Vorecon (11 – 14 MW)
Type RWE 12 F 7
Power 11.000 kW
Speed ne = 1.782 rpm
Application:
LP, MP, HP Compressors
Dresser Rand
Presalt FPSOs, Petrobras,
Brazil

19. 23
Installation Example
Type RWE 11.5 F 7
Power 8.700 kW
Speed na = 11.138 rpm
ne = 1.782 rpm
Application:
Injection Compressor
300 to 550 bar
3,500,000 Sm3
/day
Dresser Rand
Cidade de Paraty FPSO
SBM long term lease to

20. 24
Reliability
Reliability
(8 065 000 – 1 743) / 8 065 000 = 99.98 %*
MTBF (Mean Time Between Failure)
8 065 000 / 19 = 424 474 hours ~ 48 years*
MTTR (Mean Time To Repair)
1 743 / 19 = 91.74 hours ~ 4 days
Survey on Vorecon Reliability 2013
201 units
600 kW up to 31 200 kW
495 rpm up to 16 735 rpm
Total operating hours 8 065 000 hours
Reported failures 19
Non-availability time 1 743 hours
* Calculation based on machines in operation
What is the cost of a drive failure / unplanned downtime?

21. 25
Life Expectancy
Do you include a spare VFD drive in your LCC?
Or at least a complete upgrade to a new generation?

22. 26
Voith guarantees spare parts availability
for 30 years and more ...
 ask any VFD maker to supply
semiconductors of today also
within 10 years from now
Vorecon is designed for ...
 a life time of more than 30 years
 tough environmental conditions,
e.g. heat, cold, dust, explosion hazards
Life Expectancy

23. 27
Boiler feed pumps
Mannheim, Germany
Variable Speed
Planetary Gear Vorecon
Type: RW 14-12 F 7
Power: 8500 kW
Speed: 5000 rpm
Since 1989
No overhaul after 116,000 operating hours (Sep. 6th 2011)
Superior Reliability of Vorecon

24. 28
Sostanj Power plant
Slovenia
Power: 750 kW
Speed: 2950 rpm
working since 1955
This picture has been taken in summer 2010
Long Life
Superior Reliability of Voith Drives

25. 29
The World & Vorecon
A success story of a proven technology!
600x

26. 30
The World & Vorecon
VORECON installations by country of installation,
September 2014

27. 31
Epicyclic Gear Units

28. 32
Product History
1932: BHS in Sonthofen was the birthplace of
the Stoeckicht planetary gearbox.
At that date BHS acquired the first License
Agreement followed by:
Allen Gears, UK in 1947
Alcatel (Flender), F in 1957
More than 5.500 Epicyclic Gear Units delivered.
More than 80 Epicyclic Gear Units currently
delivered per year.

29. 33
Characteristics of Epicyclic Gears
• Gear set consists of
– sun gear
– 3 up to 6 planet gears
– pair of annuli
• Driving shaft and driven shaft are coaxial
(no offset)
• Power transmission effected by several
tooth contacts

30. 34
Epicyclic Gear Unit: Basic Data
• Stoeckicht load equalization
• Efficiency up to 99%
• Compact design
• Low weight
• Both connecting couplings can be
integrated

31. 35
Summary features of Stoeckicht
• No bearing high speed side
 optimised load distribution (sun / planet)
 no power loss
 no requirement for bearing oil
optimised efficiency
reduced oil flow
• Integrated high speed coupling
 reduced interfaces / design clarification
reduced coupling costs
less clarification efforts

32. 36
Summary features of Stoeckicht
• Load distribution (3 – 6 planets)
 compact design
optimised weight
• Flexible annuli / movable and flexible coupling sleeves
 optimised load distribution planet gears to annuli
long service life
• Coaxial design of Epicyclic Gears
 smaller foundation
cost effective

33. 37
Epicyclic Gear Units
Less Space Required – compact & coaxial design
• Average reduction of
space approx. 20%
(compared to parallel
shaft gears)
– Coaxial shaft
arrangement  no
horizontal offset!
– Smaller DBSE due
to integrated
couplings
• Smaller skid:
 lower weight
lower cost

34. 38
Better Efficiency
• Epicyclic gears:
higher efficiency
with increasing ratio
• Efficiency
up to 1.5% or higher !!!
advantage beginning
with gear ratio i > 4

35. 39
+
+
+
+
+ Pitch line velocity:
Toothing
Sleeve bearings
79.5 m/s
Technical Comparison: Parallel Shaft Gear
Unit HD56-1 vs Epicyclic Gear Unit RTP50K
RTP50KHD56-1
Power: 5,900 kW Installation: Steam Turbine/Generator
Speeds: 10,680 / 1,500 rpm i = 7,12
53.7 m/s
7.85 m/s
14.1 m/s
18.4 m/s
61.5 m/s

36. 40
Epicyclic Gear Unit – Parallel Shaft Gear Unit
HD56-1- RTP50K (Technical Comparison)
Type HD 56-1 RTP 50K
Power Loss 88 kW 65 kW
Efficiency 98.6 - 0.1 % 99.0 - 0.1 %
Oil Comsumption 130 l/min 140 l/min
Noise 85 +/- 2 dB 85 +/- 2 dB
Weight 4,700 kg 3,300 kg
Power: Turbine Speed:
5,900 kW 10,680 rpm
Installation: Generator Speed:
Steam Turbine - Generator 1,500 rpm

37. 41
*Assumptions: 8,000 operating hours per year; 7 ct/kWh; 2% cost increase; $15 per kg saving; $2,000 per m² saving
FPSO application, Electrical Motor driven Compressor
Rated power of 10,200 kW, Speeds: 1,785 / 11,239 rpm
Economy of Epicyclic Gears (case study)
Par. Shaft
Gearbox
HD71-2
Epicyclic
Gearbox
RTP56K
Relative
Reduction Assumption Value
Footprint of skid 40.98 m2
32.20 m2
21% $2.000 per m² $17,360*
Weight of baseframe 24,000 kg 19,926 kg 17% $15 per kg $61,110*
Weight of gearbox reduction 8,600 kg 6,400 kg 26% $15 per kg $33,000*
Efficiency 98.1% 98.9% 8.000 h / year
Power loss 196 kW 105 kW $0,07/ kWh $50,288 *
Opex Savings over design life $1,221,866*
Capex savings $111.470
Operational Costs
TOTAL Capex + Opex savings $1,333,336
Gearbox 100% 100% 0% $0
Capital Costs
(2% cost increase per year)

38. 42POG Workshop 2014 | Sylvia Lux | 2014-05-19 - 2014-05-23
Example of application
Vertical Epicyclic Gear box type RTG 36V
Power: 4,500 kW
Speeds: 7,151 / 1,800 rpm
Application: Between e-Motor
and multi-phase
pump
Operator: Oil platform
Dunbar, UK

39. 43
Epicyclic Gear Units should be the first
choice when,
• gear ratio ≥ 6  high efficiency gearbox
• highest reliability in operation required  no high speed bearings, less pitch
line velocities
• critical rotor dynamical behaviour of high speed side  high speed turbines
or compressors
• compact and light weight solution is required  cost and space savings
• input and output shafts shall have same direction of rotation
• gearbox should work in both directions of rotation
• coaxial design is needed
• design to ISO and/or AGMA 2001 resp. 2101 is required  API philosophy is
also possible by higher safety factors
• parallel shaft gears can’t be used anymore (high speeds, high power
applications)

40. 44
Hydrodynamic Variable Speed Drive
for Subsea Drivetrains

41. 45
Torque Converter for Subsea Pump Drives
- Constant speed, liquid filled motor
- Highly integrated variable speed
Torque Converter with integrated
speed increasing capability
- Single or multi phase
pump / compressor

42. 46
Torque Converter for Subsea Pump Drives
- Compact VSD solution with reduced
complexity and improved reliability
- Substitute for spacious topside equipment
(VFD) or complex electrical subsea
frequency converter
- Enabler for subsea boosting and water
injection by reduced CAPEX (greenfield)
- Empowering enhanced oil and gas
recovery by boosting or water injection for
existing platforms due to less topside
footprint (brownfield)
source: Fuglesangs Subsea

43. 47
VFD vs Torque Coverter for Subsea Applications
Complexity vs Simplicity!
VFD Competitor Solution VOITH Torque
Converter

44. 48
Contact:
Andrea Venora
Sales Manager
Tel. +971 50 481 2608
andrea.venora@voith.com

45. 49