GEARING SYSTEM FOR HYDROPOWER INSTALL IT AND FORGET ABOUT IT EISENBEISS LEADING THE WAY IN SPECIAL GEAR ENGINEERING FOR THE MARKETS OF THE WORLD

Transcription

1 GEARING SYSTEM FOR HYDROPOWER INSTALL IT AND FORGET ABOUT IT EISENBEISS LEADING THE WAY IN SPECIAL GEAR ENGINEERING FOR THE MARKETS OF THE WORLD

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3 HYDROPOWER GEARS YOUR SUCCESS. OUR DRIVE. CONTENT HYDROPOWER P. 4 Hydropower program P. 5 Conceptual explanation P. 6 Vertical spur gear units for kaplan turbines P. 8 Horizontal spur gear units for PIT turbines P. 10 Helical bevel and spur gear units for open-flume turbines P. 12 Bevel gear units for bulb-type turbines P. 14 i:gear 4.0 P. 15 GearControl-OiL Contact/Location Page 3

4 HYDROPOWER PROGRAM HYDROPOWER GEARS DEVELOPED FOR CLEAN ENERGY INSTALL IT AND FORGET ABOUT IT EISENBEISS PROVIDE YOU WITH THE RIGHT GEAR SYSTEM SO THAT WATER POWER IS NOT DISSIPATED AS HEAT. Our gear systems are exceptionally efficient, due to fine-tuned tooth meshing and bearing arrangements, and require very little maintenance, due to a condition monitoring sensor technology we have developed. All of which makes the facility very profitable. The gear units are known to be extremely quiet impact on people and nature is minimal. Regardless of whether pit, bulb-type or vertical water turbines are involved, Eisenbeiss have the better solution. Page 4

5 CONCEPTUAL EXPLANATION EXPLANATIONS OF STANDARDISED TYPE DESIGNATIONS TYPE DESIGNATION (EISENBEISS STANDARD) TGVF 450 Our gear systems are custom-designed and adapted according to your requirements. In the hydropower sector, axial bearings are installed in gears of Eisenbeiss to absorb the forces of the turbine. Examples of Eisenbeiss Type Designation: TGU830 (single-stage spur gear unit with overlapping input and output with a centre distance of 830 mm) TKGV280 (two-stage helical bevel gear unit with a centre distance of 280 mm) TGVF745 (single-stage vertical spur gear unit incl. output flange, with a centre distance of 745 mm) TKF1300 (single-stage bevel gear unit with a pitch diameter of the crown gear of 1300 mm and flange attachment) T: turbine U: overlapping V: vertical F: flange K: bevel G: single spur gear stage D: two spur gear stages Centre distance in mm The following tables show you the dimensions, torques and gear ratios for our entire product range. Page 5

6 VERTICAL SPUR GEAR UNITS FOR KAPLAN TURBINES This gear concept is especially engineered to fully meet the tough requirements of vertical water turbines. For instance, the turbine shaft is bored hollow so that the rotor blades can be adjusted from above by way of the gear system. The bell is of massive design with suitable fins and is welded directly to the housing. As a result, the weight of the generator is accommodated securely and the risk of critical vibration is minimized. A special wear-free seal system on the input shaft side prevents any lubricant from escaping from the gear system. SERIES: TGVF (single-stage) or TDVF (two-stage) POWER RATING: 100 kw to 7,500 kw OUTPUT SPEED: 500 to 1,000 rpm RATIO: 2.5 to 7 (single-stage), 5.5 to 18 (two-stage) Page 6

7 DIMENSIONS size oil-water cooler oil filter inspection hole cover heating element GearControl-OiL terminal box start-up pump Size Power [kw] L 1 L 2 L 3 L 4 L 5 D Page 7

8 HORIZONTAL SPUR GEAR UNITS FOR PIT TURBINES Developed specifically for pit turbines, these gears are of robust, compact design and are around 99% efficient. They feature double helical gearing optimized for this particular application, anti-friction bearings and perfectly-matched oil lubrication. In conjunction with a gear unit support halfway along the shaft, an intelligent, FE analyses developed fin design transfers forces from the turbine directly to the foundations. As a result, flexural stresses in the housing are avoided, and excellent tooth meshing is guaranteed even at maximum load. SERIES: TGU POWER RATING: 500 kw to 7,500 kw OUTPUT SPEED: 500 to 1,000 rpm RATIO: 2.5 to 7 Page 8

9 DIMENSIONS oil flow sensor lifting point oil/water cooler terminal box start-up pump manometer inspection hole cover main pump output shaft oil filter pressure switch thermometer drive shaft oil level and oil temperature sensor GearControl-OiL oil dipstick Turbines BG1 BG2 BG3 BG4 BG5 BG6 Maximum Power 950 kw 1450 kw 2300 kw 3200 kw 4150 kw 7500 kw Maximum Axial Thrust 150 kn 210 kn 300 kn 380 kn 420 kn 490 kn Maximum Reverse Thrust 150 kn 210 kn 300 kn 380 kn 420 kn 490 kn A 180 mm 200 mm 220 mm 260 mm 300 mm 330 mm G 120 mm 140 mm 180 mm 200 mm 220 mm 250 mm J 1200 mm 1070 mm 1600 mm 1750 mm 1885 mm 2060 mm K 660 mm 480 mm 830 mm 920 mm 1000 mm 1090 mm L 960 mm 1060 mm 1200 mm 1270 mm 1370 mm 1470 mm M 1620 mm 1540 mm 2000 mm 2190 mm 2370 mm 2560 mm R 415 mm 460 mm 570 mm 640 mm 700 mm 770 mm U 1140 mm 1260 mm 1540 mm 1660 mm 1780 mm 1940 mm Y 1210 mm 1300 mm 1500 mm 1645 mm 1795 mm 1940 mm Page 9

10 HELICAL BEVEL AND SPUR GEAR UNITS FOR OPEN-FLUME TURBINES Hydroelectric power stations are often inside listed buildings. The structure of these buildings cannot be altered. If such a power station with open-flume turbines needs to be modernized, it is essential to adapt to the circumstances on site; in particular, the way the generator is situated determines which gear unit design is required. The gear unit series developed by Eisenbeiss for such cases takes full account of this and the generator can be positioned horizontally by means of a bevel gear. Because the lubrication system is mounted on the gear unit, this compact unit can easily be installed on the existing system. SERIES: TKGV POWER RATING: 50 kw to 2,000 kw OUTPUT SPEED: 500 to 1,500 rpm RATIO: 4 to 16 Gear- Size A Power [kw]* Ødm6 x 1 B D E F G H I L 1 N O P Q ØR S T U V W m [kg] QÖ Ø 60 x Ø Ø 65 x Ø Ø 70 x Ø Ø 80 x Ø Ø 90 x Ø Ø100 x Ø Ø110 x Ø Ø120 x Ø Ø135 x Ø *Application factor 1.5 Generator Power at 750 rpm and Ratio 9 Page 10

11 DIMENSIONS manometer mechanical oil pump thermometer electric oil pump GearControl-OiL inspection hole cover switchable double filter Coupling For Gear- Size ØKH7m6 L 2 J ØdLk z ØM m [kg] C Ø Ø80 6xM10 Ø C Ø Ø80 6xM10 Ø C Ø Ø110 6xM12 Ø C Ø Ø110 6xM12 Ø C Ø Ø130 8xM12 Ø C Ø Ø130 6xM16 Ø C Ø Ø170 8xM16 Ø C Ø Ø190 6xM20 Ø C Ø Ø220 8xM20 Ø Page 11

12 BEVEL GEAR UNITS FOR BULB-TYPE TURBINES The heart of an Eisenbeiss bevel gear unit for bulb-type turbines is a bevel gear hard milled in a special process which ensures the very highest surface quality of the gear teeth. In conjunction with a housing designed for strength, this guarantees low levels of noise and vibration. The layout of the gear unit precisely matches the particular application. The housing is cylindrical and has a circular flange that enables quick and easy mounting to the turbine housing. To ensure ease of maintenance, all the lubrication system components are mounted on the rear side of the gear unit where they are easily accessible. SERIES: TKF POWER RATING: 100 kw to 2,500 kw OUTPUT SPEED: 500 to 1,000 rpm RATIO: 2.5 to 5.6 Size Power [kw]* L 1 L 2 L 3 L 4 L 5 L 6 L 8 L 10 L 11 L 12 L 13 D 1 D 2 D 3 h8 D 4 D 5 h6 D 6 D 7 h9 D 12 D 13 D 14 m [kg] 560/ / / / / / / / / / / / / / / / *Application factor 1.5 Generator Power at 750 rpm and Ratio 5.6 Page 12

13 DIMENSIONS output shaft thermometer manometer oil/water cooler drive shaft terminal box main pump start-up pump oil filter heating element GearControl-OiL i Size D 11 h ,5-2,79 2,8-3,14 3,15-3,54 3,55-3,99 4,0-4,49 4,5-4,99 5,0-5,65 L L h6 D L L h6 D L L h6 D L L h6 D L L h6 D L L h6 D L L Page 13

14 i:gear 4.0 THE GLOBAL INNOVATION IN GEAR MAKING! EISENBEISS IS THE FIRST GEAR MANUFACTURER IN THE WORLD TO COMBINE INDUSTRIAL GEARS WITH A COMPREHENSIVE GEAR SUPPORT SYSTEM. Eisenbeiss offers drive solutions and supervision from a single source a global first! You receive an optimized drive system including supervision and integrated engineering knowhow from our gear design engineers. This means that i:gear 4.0 can analyse its operating conditions independently and signal any potential improvements. Increased service life and maximum plant availability with minimal operating costs are the result. i:gear 4.0 ensures the cost-effectiveness of your plants with a fast ROI! Gear system status indication Torque Speed Oil level Bearing condition/ toothing condition Filter status Oil pressure Oil condition Filling level Oil temperature With i:gear 4.0 an alarm is given automatically in critical situations and you can avoid routine checks. This enables you to spend more time on your key tasks involving economical and innovative production processes. Page 14

15 GearControl-OiL A SMALL SENSOR TO PREVENT MAJOR DAMAGE! PIONEERING INSTRUMENTATION TECHNOLOGY FOR YOUR GEAR SYSTEMS. AVOID DAMAGE TO GEARS, MAXIMIZE RELIABILITY IN OPERATION, EXTEND SERVICE INTERVALS, SCHEDULE SHUTDOWNS. GearControl-OiL is a multi-parameter measuring instrument and data storage device in one. The sensor continuously measures six variables specific to lubricant condition, and detects deficiencies in the lubricant reliably and at an early stage; the facility operator is thus in a position to take action well before serious damage is done to the gear unit. GearControl-OiL at a glance Continuous data recording to determine real operating times Configurable warning and alarm threshold measurement of medium and ambient temperature for the use of calculation modes Measuring process in picosiemens range, galvanic gold-plated sensors Controls signalling equipment and is integrated in existing control systems Gives information on impurities, water content, transmission, air bubble development and differentiation of oil additives Gives information on oil type, oil change and oil mixture, plus warning if large quantities of oil are lost WE LOOK FORWARD TO RECEIVING YOUR INQUIRIES! EISENBEISS GmbH Lauriacumstraße 2, 4470 Enns, Austria Tel.: power@eisenbeiss.com 24h Hotline: Bern Hanover Frankfurt Munich Milan Berlin Prague Bratislava Vienna Ljubljana Eisenbeiss Inc. Repair and Service 8845 Elder Creek Road - Unit B Sacramento, CA / USA Phone: office@eisenbeiss.us 24h Hotline: Seattle San Francisco Los Angeles Phoenix Denver Dallas Printed in Austria 09/2017 Page 15

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