Gear Technology

VTBS 1
Agenda

1. High-Tech behind the mountains - Brief Company information

2. Small item, but harmful impacts – gear failure modes
3. Choose the right standard – overview of gear standards
4. The world of turbo gears – Applications & Characteristics

2
Voith Turbo BHS

VTBS 3
Voith Turbo BHS
Company Figures
479th birthday - 1532 foundation year as an iron processing company (forge)

Year 1932 - Beginning of Gear Manufacturing (Stoeckicht Epicyclic Gears)

> 422 Employees - thereof 50 apprentices

85 Mio € - current turnover

31 Mio € investments - since 2006 for increase of performance

400 units / year

20.000 references

20 % market share - for turbo gears

No.1 - World market leader in Integral Gears (technology & market share)
Sonthofen
4
 Product Overview

High speed transmission products

Parallel Shaft Gear Units Epicyclic Gear Units

Free Standing Integral

5
 Product Overview

Rotor Turning Gears Diaphragm Couplings After Sales

6
Small item, but harmful impacts –
gear failure
modes
VTBS 7
Where is the gearbox?
A Chain is only as strong as its weakest
Link...

A gear is not the most important part in a drive train...

... but selecting the wrong gear will harm the entire train!

30 MW & 42 tons
8
A Chain is only as strong as its weakest
Link...

A gear is not the most important part in a drive train...

... but selecting the wrong gear will harm the entire train!

9
Gear Failures

Pitting Bending

10
Gear Failures

Flank Micro - Pitting Scuffing

Breakage

11
 What can we do to avoid
such harmful Damages?
External influences:
• wrong design of single train components Calculation methods  Choose the right
standard
• poor material quality of casing, bearing, toothing
• later additional increase of load on machines Choice of bearing  Reduce risk by right
choice
• missing maintenance or maintenance failures
• insufficient or wrong lubrication or cooling Take care about lubrication  Effectiveness
of right oil
• additional handicap by fouling
• cost saving at the „wrong side“ Monitoring

Internal influences: Right choice of materials

• ordinary abrasion of bearing, toothing and Look at manufacturing processes
sealings
• machine fatigue (expiring of life time)
Professional maintenance
• corrosion Extended quality testing
• break of shaft or teeth
• problems with lubrication, cooling and fouling
12
 Design Standards
VTBS 13
Application Standards for Gear Units

Specifications Description
DIN 3990 (1987) Calculation of load capacity of spur gears
ISO 6336 (1996) Calculation of load capacity of spur gears and helical gears
Calculation of load capacity of spur and helical gears. Application to high speed gears and
ISO 9084 (2000)
gears of similar requirements
ISO 13691 (2001) Petroleum and natural gas industries – High speed special-purpose gear units
Practice for Enclosed Speed Reducers or Increasers Using Spur, Helical, Herringbone and
AGMA 421.06
Spiral Bevel Gears
Fundamental Rating Factors and Calculation Methods for involute Spur and Helical
AGMA 2101 D04
Gear Teeth
AGMA 6011 I03 Specification for High Speed Helical Gear units
Lower speed helical, spur and bevel gears with speed limitations up to 4500 rpm and.
AGMA 6013
PLV < 7000 fpm (35 mps)
API 613 (5th) Special-Purpose gear units for Petroleum, Chemical and Gas Industry Services
API 677 General Purpose Gear Units for Petroleum, Chemical and Gas Industry Services.
Packaged, Integrally Geared Centrifugal Air Compressors for Petroleum, Chemical, and
API 672 (4th)
Gas Industry Services
Axial and Centrifugal Compressors and Expander-compressors for Petroleum, Chemical
API 617(7th)
and Gas Industry Services, Seventh Edition
14
Scope of Standards

Gear Elements o DIN / ISO is specialized in

DIN
Rating gear elements
ISO
Materials
o AGMA is focusing on the
Casing
AGMA major components of a
Dynamics
gearbox
Bearing & Housings

Sealing API o API is a general design

Lubrication specification covering the
Testing total gearbox and interfaces
Instrumentation & Control to the periphery
Couplings & Guards
Inspection
 However, not all design
criteria are covered that may
have harmful effect on gears
…

15
Toothing Calculation & Design

Integrally gears

Epicyclic gears
Bearing Rating
Micro -Pitting

Shock torque

Design Rules

Parallel shaft
gears
Bending

Scuffing
Bending

Pitting
Specifications

DIN 3990 (1987) x x x x √ √ √

Pitting
ISO 6336 (1996) x x (x) (x) x √ √ √
ISO 9084 (2000) x x

ISO 13691 (2001) x x (x) x x √

Scuffing
AGMA 421.06 x x x √ √ √
AGMA 2101 D04 x x (x) x √ √ √
AGMA 6011 I03 x x (x) x x √ √ √
API 613 (5th) x x (x) ! x x √ √
Micro-Pitting
API 617 (7th) x x x x √ √
API 672 (4th) x x (X) x x x √
BHS Standard x x x x x x x √ √ 16
√
Capability of Pitting and Bending

Comparison of

allowable to

transmitted

power for

continuous

operation

(>1000 load

cycles)

17
Why does API 613 lead
to a Bigger Gearbox?
The API standards basis is still lasting to the state of the art of 1977 regarding the
tooth calculations. But in the meantime following things changed that effect the
design:
- Calculation & Design
(e.g. more precise simulation of loads possible, more impacts considered)
- Material (e.g. improved cleanliness; quality, resistance)
- Manufacturing processes (e.g. increased precision and reproducibility)
- Testing (e.g. hardness test of tooth flanks, check for grinding burns)

All factors are improving the know how of gear technology and enabling
a safer and more reliable design and manufactured end product.
18
Let´s stop and resume....

• API 613 is the most conservative standard  most safety?!

• API 613 is giving a comprehensive overview and guidlines
• API 613 is not considering all gear failures detailed, but shows
sufficient safety to cover the missing ones?!
• State of the art material, manufacturing and engineering  more
confidence in addtion to API 613 conservatism

API 613 + Technology Developments  More Reliability

19
Let´s think further....
everything get´s bigger but....
Please consider following…

 pitchline velocity vs. fracture mechanics e. g. for GT/C drives

 tooth width vs. temperature distribution increases scuffing risk
 mass moment of inertia
 noise emission influenced by pitchline velocity
 power losses and oil consumption
 space requirements
 handling (weight, height etc.)
 costs (direct investments & indirect costs)
 same quality standards and testing as for smaller unit
 use of same materials as for smaller units
Think Big is not always the Best and Safest Solution!
20
Benefits & Savings
AGMA 6011 vs. API 613
AGMA API
Savings
HD 50-2 HD 56-2
Centerline distance mm 520 570 8,7%
Weight (gearset) kg 3400 (1580) 5100 (2400) 33,3%
Moment of inertia kgm2 140 260 46%
Total Deflection µm 29 33 12,1%
Tooth width mm 270 326 17,2%
L/D 1,85 2,20 15,9%
Pitch line velocity m/s 84 92 8,7%
Noise @ 1m dB(A) 83 85 3,4%
Oil consumption l/min 165 180 8,3%
Losses kW 119 128 7,0%
Costs € 115000 135000 14,8%
21
 Gearbox Design
VTBS 22
The familiy of turbo gears

Main Applications:
• Turbocompressors
• Motorcompressors All covered by one specification
but have own characteristics
• Turbopumps and creating different
challenges for gearbox design
• Motorpumps
• Turbogenerators

23
Variety of Applications within Turbo Gears

low medium high Critical

Power [MW]

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

• Bearing design @ HSS
EM/P EM/C

ST/G GT/G
• Fraction mechanics
GT_ST/P GT_ST/C • Material selection & testing

Low Medium High Critical

Speed [rpm]

2` 4` 6` 8` 10` 12` 14` 16` 18` 20` 22` 24` 26`

• Rotordynamic challenging
EM/P EM/C

ST/G GT/G • Bearing design @ HSS

GT_ST/P GT_ST/C • Coupling choice

Low Medium High Critical

PLV [m/s]

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 • Fraction Mechanics
EM/P EM/C
• Losses
ST/G GT/G
• Distortion
GT_ST/P GT_ST/C
• Heat Development

24
Variety of Applications within Turbo Gears

Low Medium High Critical

Bearing speed

10 20 30 40 50 60 70 80 90 100
• Temperature development
[m/s]

EM/P EM/C

ST/G GT/G • Rotordynamic

GT_ST/P GT_ST/C
Bearing Load

0-1 1-2 2-3 3-4 4-5 Critical

[N/mm2]

EM/P EM/C • Rotordynamic challenging

API 613 limit @ 3,4 ST/G GT/G
• Bearing design @ HSS
GT_ST/P GT_ST/C
• Coupling choice
0,5 1,0 1,5 2,0 2,5 3,0
L/D Ratio

EM/P EM/C Critical

ST/G GT/G

GT_ST/P GT_ST/C • Distortion

1 2 3 4 5 6 7 8 9 10 11 • Tooth contact
EM/P EM/C
• Tooth temperature
Ratio

GT/G ST/G

GT_ST/C GT_ST/P • Lubrication

25
Gear Characteristics for Application GT / C
Gearbox characteristics
 Very high velocities at toothing and bearings  PV up to 200m/s!
 Extended thermal distortion
 High load density
 High stress of materials  operating at physical limits
 Low ratios
 High deflection of toothing
 High L/D ratio
 High oil consumption
 Challenging rotordynamics
 High oil temperatures at bearings and gearing

Design provisions
 Consideration of fracture mechanics important
 Bull gear and shaft made of one piece
 Special material used for bull gear
 Axial thrust bearing as tilting pad design
 Special modification of housing to ensure higher stiffness & oil supply

26
Possible Solution for
Future GT / C Applications
Power distribution gearbox:

Load distribution  smaller parts:

Reduced velocities (toothing & bearing)
Reduced centrifugal force and stresses

 Less critical bearings and toothing results in a higher reliability

27
Field of application & Characteristics
Field of application:
 High Power + High Speeds, e.g. GT/C applications
 For ratios from 1.1 to 10, optimum between 3 and 4.5
 Acceptable efficiency ( appr. 98 % )
 Reliable and safe gear solution outside of the technical
feasibility range of parallel and epicyclic gearboxes

Characteristics of a MWG
 Load distribution leads to smaller parts
 Reduced centrifugal force and stresses
 Lower masses
 Lower stress on bearings
 Coaxial shaft arrangement leads to reduced space requirements
 No limitation of speeds (e.g. 80,000 rpm on HSS achievable)
 inspection friendly as no annulus prevailing
 Less oil requirement
28
Feasibility Study...
Reaching the next power class of turbocompressors

 Turbocompressors are limited by gearbox

 Using parallel shaft gearboxes the limit is at app. 38 MW
 Power Distribution Gearbox facilitates a higher power range (60MW)

Example for a train arrangement (out of a feasibility study for a european oil company):

29
Feasibility Study – Parallel Shaft vs. Power Distribution

30
Feasibility Study – Parallel Shaft vs. Power Distribution

31
Gear Characteristics for Application EM / C

Gearbox characteristics
 High ratios
 Big diameter of bull gear compared to pinion diameter
 Medium PV
 Challenging rotordynamics on HSS
 High bearing velocity on HSS
 High deflection of pinion toothing
 Medium L/D ratio

Design provisions
 Shrunk on design for bull gear on shaft
 Special modification of radial bearings - “ Cool design bearings“
 Axial bearing on LSS as combined radial-axial tapered land bearing

32
Possible Solution for
Future EM / C Applications
Epicyclic gearbox design:

Load distribution  smaller parts:

Reduced velocities (toothing & bearing)
Reduced centrifugal force and stresses

 Less critical bearings and toothing results in a higher reliability

33
Epicyclic gears for motor driven compressor trains

4 Design features of epicyclic gears …

- Coaxial shaft arrangement
- Compact design
- Less stressed gear set components
- Reduced sources of losses

... leads to 3 Good Reasons for epicyclic gears:

1. Reliability
2. Efficiency
3. Economic

34
Reason 1
High Technical Reliability due to load distribution effects
95 m/s RTP 80 K RTP 64 K
Type FD 90-1
149 m/s API version (BHS Standard)

98 (90) m/s Sf acc. API 613 1,62 -- --

35 (33) m/s Sf acc. AGMA 2,75 2,75 1,66

23,6 m/s
Pitch Line Velocity [m/s] 149 98 90
12,25 m/s
Speed HS bearing [m/s] 95 35 33

Speed LS bearing [m/s] 23,6 12,25 12,25

Efficiency [%] 97,5 98,7 99

Epicyclic gears achieve higher reliability by:

 smaller and stiffer parts
 Lower circumference speeds and forces
 Minimal stresses of components

35
Reason 2
Higher total gearbox efficiency (due to Stoeckicht-Principle)

Example:

Application: Electric Motor ‐ Cenrifugal Compressor

Power: 10,200 kW

Speeds: Input  1.785 rpm Output 11,239rpm

Gear type: Parallel shaft Epicyclic

Model: HD 71‐2 RTPK 56

Losses: 195,8 kW 104,9 kW

Efficieny: 98.1 % 98.9 %

 Epicyclic gears show higher efficiencies with increasing ratios.

36
Reason 3
Reduced costs (Capex & Opex) due to less space and
lower weight

 Reduction of space requirements by

 decreased DBSE due to integrated couplings
 coaxial shaft arrangement  no horizontal offset!
 Weight savings by less use of material

37
Reason 3
Example for cost savings (Capex & Opex)
FPSO application,
Electrical Motor driven Compressor
Rated power of 10.200 kW, Speeds: 1.785 / 11.239 rpm

Par. Shaft Epicyclic

Relative
gearbox gearbox Value
reduction
HD71-2 RTP56K

Capex reduction

Cost of gearbox 100% 100% 0% $0

Footprint of skid reduction 40.98 m2 32.20 m2 21% $17.360*
Weight of baseframe reduction 24.000 kg 19.926 kg 17% $61.110*
Weight of gearbox reduction 8600 kg 6400 kg 26% $33.000*

Capex savings initial $111.470

Capex Savings over design life $165.639*

Opex reduction

Efficiency 98.1% 98.9%

Power loss 195.8 kW/h 104,9 kW/h $50.288*
Opex Savings over design life $1.221.866*

TOTAL Capex + Opex $1.387.505

*Assumptions: 8,000 operating hours per year; 7 ct/kWh; 2% interest rate; $15 per kg saving; $2,000 per m² saving
38
Training offers.....Inhouse or at BHS
Inhouse training
2010 at BHS Gear Technology: Basic Training
• History of gear technology
• Gear nomenclatures & functional principles
• Gear failure modes & prevention
• Gear rating – Choose the right standard
• The manufcaturing process of a gear box

Gear Technology: Advanced Training

• Manufacturing Methods & Considerations
• Inspection & Quality Control
• Material selection & Heat Treatment: Design Considerations
• Lubrication types & Methods
Schiedam, NL
• Optimization of drive train

Tailor-Made Training according customers´ requiremnts

Monaco, • based on applications, e.g. gear solution for cmpressor trains
France
• based on products, e.g. Integrally geared compressor

39
40