India enters supercritical

power plant technology

Variable speed drive technology: Guarantor for economic

and efficient boiler feed pump drive operation

Alexander Schust, Area Manager, Voith Turbo GmbH & Co. KG, Germany
Wolfgang Sautter, General Manager Sales, Voith Turbo GmbH & Co. KG, Germany

Presented at Power Gen India & Central Asia, New Delhi 2008
 1. Status quo on power station unit sizes and
boiler feed pump drive configurations within India

Power station unit size [MW] Drive configuration on boiler feed pumps within Indian power market
135 2 x 100% electric motor driven boiler feed pumps with geared variable speed couplings
210 3 x 50% electric motor driven boiler feed pumps with geared variable speed couplings
250 3 x 50% electric motor driven boiler feed pumps with geared variable speed couplings
300 3 x 50% electric motor driven boiler feed pumps with geared variable speed couplings
500 2 x 50% steam turbine driven boiler feed pumps
1 x 50% electric motor driven boiler feed pump with geared variable speed coupling as start-up and stand-by unit

600 2 x 50% steam turbine driven boiler feed pumps

1 x 50% electric motor driven boiler feed pump with geared variable speed coupling as start-up and stand-by unit

660 2 x 50% steam turbine driven boiler feed pumps

1 x 50% electric motor driven boiler feed pump with geared variable speed coupling as start-up and stand-by unit

800* 2 x 50% electric motor driven boiler feed pumps with geared variable speed couplings

Figure 1: Configurations on boiler feed pump drives depending on unit sizes within India
* Future concept; not yet executed within India

With the first steps into supercritical
power plant technology India is
entering a new era in unit sizes for
power stations from 600 to 1,000
MW. When having a first look into
existing Indian power stations it is
possible to basically divide up the
Indian power market by unit sizes
and further down on the boiler feed
pump drive configurations as shown
within figure 1 above.
State of the art within India is the
use of steam turbines on boiler feed
pump drives for unit sizes of 500
and 600 MW. The traditional con-
cept to be followed within this power
stations is 2 x 50% steam turbine
driven boiler feed pumps with
1 x 50% electric motor driven boiler
feed pump operated by a geared
variable speed coupling as a start-
up and stand-by unit. For plants
smaller than 500 MW, steam turbine
drives are not seen anymore due to
high capital cost and high efforts on
maintenance to be taken. Thus,
only electric motor drives are to be
used either with 2 x 100% or
3 x 50% boiler feed pump drive con-
figurations depending on specific
unit sizes. All over the world, the
trend goes towards unit sizes bigger
than 500 MW.
Correspondingly, also within India a
drift to higher plant output is current-
ly under planning and execution.
Barh and Sipat supercritical projects
of 3 x 660 MW each under NTPC
are in an advanced stage of exe-
cution. Ultra mega power projects
(UMPPs) of 4,000 MW total output
are progressing fast towards reali-
sation. The first one is Mundra with
a plant output of 5 x 800 MW for
Tata Power Company Limited which
is currently in the execution phase.
Sasan and Krishnapatnam are the
next projects in line already secured
by Reliance Energy Limited. With
this background it is worth to take a
brief general look into currently on-
going power station projects through-
out the world which will form part of
the following paper section.

2
2. New ongoing power projects worldwide

Power station name Unit size [MW] Boiler feed pump drives configuration
Datteln 4 1,000 1 x 100% steam turbine driven boiler feed pump
Staudinger 1,100 2 x 50% electric motor driven boiler feed pump with geared variable speed coupling
Scholven 1,100 or 2 x 40% as start-up and stand-by unit
Massflakte NL 1,100
Neurath 1,100
Hamm 800
Ensdorf 800
Enshafen NL 800

Walsum 790 2 x 50% electric motor driven boiler feed pump with geared variable speed couplings

Karlsruhe RDK 8 920 2 x 50% electric motor driven boiler feed pump with variable speed planetary gear sets

Moorburg 800 2 x 50% electric motor driven boiler feed pump with variable frequency drive

Figure 2: Selection on new power station projects and boiler feed pump drive configurations in Europe

Within Europe current power station
projects with a power range exceed-
ing 600 MW can be divided up into
power stations following the tradi-
tional concept of running a 1 x 100%
steam turbine driven boiler feed
pump in combination with 2 x 40%
or 50% electric motor driven boiler
feed pumps with geared variable
speed couplings as start-up and
stand-by units and several power
station projects following new con-
cepts of running the main boiler
feed pumps purely on an electric
basis without the use of a steam
turbine on the main boiler feed
pump drives. The concept to be
followed will be 2 x 50% or 3 x 50%
electric motor drives. In these
electric motor driven configurations
either geared variable speed cou-
plings, variable speed planetary
gears or sometimes variable fre-
quency drives are being used. The
table above gives a selection of
several European power station
projects showing the basic concepts
to be followed on these power
stations.

3
 Power station name Unit size [MW] Boiler feed pump configuration
Rodemacher 600 1 x 100% steam turbine driven boiler feed pump
Spruce 750 1 x 50% electric motor driven boiler feed pump with geared variable speed coupling as start-up
and stand-by unit

Iatan 850 2 x 50% steam turbine driven boiler feed pumps

Trimble County 735 1 x 50% electric motor driven boiler feed pump with geared variable speed coupling as start-up
and stand-by unit

Nebraska City 2 600 2 x 50% electric motor driven boiler feed pump with geared variable speed couplings
Plum Point 665

Longview 600 3 x 50% electric motor driven boiler feed pump with geared variable speed couplings
Dominion City 585

Weston 500 3 x 50% electric motor driven boiler feed pump with variable speed planetary gear sets

Figure 3: Selection on new power station projects and boiler feed pump drive configurations in the USA

Within the US market, the traditional
concept mainly followed in the past
was a 1 x 100% steam turbine driv-
en boiler feed pump and for start-up
and stand-by purposes a 1 x 25-
50% electric motor driven boiler
feed pump arranged with a geared
variable speed coupling. Also today
with new power station projects of
more than 500 MW unit size, this
concept is still to be seen but also
within the US market a trend
towards the use of electric motor
drives only as main boiler feed
pump drives is noticeable as per
table shown above.
Looking into the Chinese power mar-
ket the traditional concept followed
for several 600 MW units is 2 x 50%
steam turbine driven boiler feed
pump drives with 1 x 30% electric
motor driven boiler feed pumps op-
erated with a geared variable speed
coupling as a start-up and stand-by
unit. However, new power station
projects within China are also lean-
ing more and more to electric motor
drives only without steam turbines
as per the following table.

Power station name Unit size [MW] Boiler feed pump configuration
Zhaoguang 600 2 x 50% steam turbine driven boiler feed pump
Ningxia 600 1 x 30% electric motor driven boiler feed pump with geared variable speed coupling as start-up
Yuncheng 600 and stand-by unit
Minquan 600

Hancheng 600 2 x 50% electric motor driven boiler feed pumps with geared variable speed coupling
Fenhzhen 600 1 x 50% electric motor driven boiler feed pump with geared variable speed coupling as start-up
Hequ 600 and stand-by unit
DaLaTe 600

Pucheng 600 2 x 50% electric motor driven boiler feed pump with variable speed planetary gear sets
1 x 30% electric motor driven boiler feed pump with geared variable speed coupling as start-up
and stand-by unit

Figure 4: Selection on new power station projects and boiler feed pump drive configurations in China

4
3. Resulting effects on Indian power station projects
Figure 5: Specification text for boiler feed pump package
for 5 x 800 MW UMPP Mundra, India
The trend towards the utilisation
of pure electric motor drives only
already influences ongoing Indian
power station projects. In 2007,
Tata Consulting Engineers specified
electric motor drives only without
any start-up and stand-by units for
5 x 800 MW UMPP Mundra. The
paragraphs of the specification
shown above give the wording used
to specify this concept in order to
put India also in line with the world-
wide ongoing trend.
Besides the first big step in entering
into new supercritical power plant
technology within India additionally
another big step forward is taken at
the same time when specifying and
executing drive packages as per
package No. 1 above without the
use of a steam turbine on the main
boiler feed pumps and without the
use of any start-up and stand-by
units. These huge steps taken into
further development of Indian power
Figure 6: Specification text for boiler feed pump drives
for 5 x 800 MW UMPP Mundra, India
plant technology will influence fur-
ther upcoming projects within India
and will set new standards within
power station unit sizes, drive tech-
nologies in terms of plant efficiency,
cost impacts and reliability issues.
By going to a 2 x 50% boiler feed
pump arrangement without stand-by
unit, the reliability of the boiler feed
pump trains is of utmost impor-
tance. Thus, reliability of each com-
ponent of the drive train has to be
evaluated with a special focus on
the variable speed drive system
itself. Therefore most power plants
around the world using this 2 x 50%
configuration have decided to use
hydrodynamic variable speed drives
due to its superior reliability. The
key factor is to be really seen as
highest required reliability on the
drive systems used on the boiler
feed pump drives in order to not
affect the plant output. As a result
of this insight Tata Consulting
Engineers specified hydrodynamic
drives on the boiler feed pumps.
This is shown within the following
specification text where Tata Con-
sulting Engineers specified geared
variable speed couplings only. Also
it can be noted that Tata Consulting
Engineers specified the first time
ever within India the highly efficient
variable speed planetary gear drive
as an option to the conventional
geared variable speed couplings
also shown in the specification text
above.
With this common trend towards
electric motor drives all over the
world it is now worth to take a clos-
er look into the different boiler feed
pump configurations with electric
motors only. This will form part of
the next paper section.
5
 4. Boiler feed pump drive configurations
for electric motor drives
Option (A)
3 x 50% GVSC
Figure 7: Electric motor drive configurations on boiler feed pumps
GVSC Geared Variable Speed Turbo Coupling
VSPG Variable Speed Planetary Gear Set
For electric motor drives on boiler
feed pumps it can be distinguished
between drive configurations as per
chart given above within figure 7.
6
Option (B)
2 x 50% GVSC
Option (A) is reflecting the tradi-
tional concept with a configuration
where 2 x electric motors run 2 x
main boiler feed pumps supplying
feed water into the boiler. Both
boiler feed pumps are operated on
variable speed with a geared vari-
able speed coupling installed in the
drives. Additionally, an electric
motor drive facilitates the start-up
procedure by filling the system with
water and serves as a stand-by unit
in case one of the boiler feed
pumps trips. This stand-by unit is
also operated as a variable speed
pump via a geared variable speed
coupling. Having the additional
stand-by unit provided, this drive
configuration displays together with
option (C) the most safe way to op-
erate the plant and in addition to
that, in any case a more economic
way as by utilising a steam turbine
in the drive.
Option (B) is probably the most
modern and as a matter of fact,
most economic drive configuration.
Especially for tariff based bidding
processes, this is the most attrac-
tive solution. This system is intro-
duced within India on 5 x 800 MW
UMPP Mundra where 2 x 50% main
boiler feed pumps are proposed to
be driven via geared variable speed
couplings by electric motors only.
For this specific drive configuration
no stand-by unit is specified leading
to the necessity that the installed
drives are required to prove for
highest reliability throughout the
complete lifetime of the plant.
Having no steam turbine and addi-
tionally saving the money in cutting
down the investment for a separate
stand-by unit, this drive configu-
ration reflects by far the most
economic drive system in power
utilisation.
 Option (C)
2 x 50% VSPG +
1 x 30% GVSC
Option (C) fitted with variable
speed planetary gear sets on the
main boiler feed pumps offers the
highest drive efficiencies of
course on the basis of higher initial
costs also resulting in a better
plant efficiency than drive configura-
tions as per options (A) and (B).
High drive efficiencies are especial-
ly inherent to the variable speed
planetary gear set and are put into
place most effectively when operat-
ing at variable plant loads. This
advantage of high drive efficiency
with the variable speed planetary
gear set is especially paid off
against other drive systems used.
Having additionally a stand-by unit
installed on the drive configuration
for option (C) this option reflects a
compromise between options (A)
and (B) for electric motor driven
boiler feed pump drives. As the
stand-by unit is designed smaller
than as for option (A), the invest- As all these drive configurations are
ment for this unit within option (C) is based on hydrodynamic variable
more attractive than within option speed drives it is now time to look
(A). In case of a failure of one of the into this specific technology more
main pump trains almost full plant closer.
load can be achieved with the
stand-by unit. The additional invest-
ment on the variable speed plane-
tary gear sets within option (C) over
option (A) with geared variable
speed couplings installed on the
main boiler feed pump drives will
certainly pay back due to high ef-
ficiency of the drive systems inher-
ent to it. Thus, option (C) displays
an agreement in both, satisfying
a safety-oriented plant philosophy
in having a separate stand-by unit,
as well as economically offering the
most competitive solution with
regard to drive systems with steam
turbines or traditional 3 x 50%
electric motor driven units installed
on the drive systems.
7
 5. Facts about hydrodynamic turbo couplings
and variable speed drive systems
1 2
Figure 8: Foettinger Principle as a basis
for hydrodynamic turbo couplings
1 Impeller (primary wheel)
2 Circulating operating fluid
3 Turbine wheel (secondary wheel)
Hydrodynamic turbo couplings are
based on the Foettinger Principle
where the input power developed
by a prime mover is converted from
mechanical energy acting on the
impeller (primary wheel) into kinetic
energy within the operating fluid
and converted back into mechanical
energy at the turbine wheel (sec-
ondary wheel) connected to the
driven machine.
8
3 1 2 3 4 7
8
5
Figure 9: Sectional view of a hydrodynamic
variable speed turbo coupling
1 Impeller (primary wheel)
2 Turbine wheel (secondary wheel)
3 Shell
4 Scoop tube housing
5 Oil tank
6 Oil circulation pump
7 Scoop tube
8 Oil cooler
To get variable speed on the driven
machine, the oil filling of the hydro-
dynamic turbo coupling has to be
regulated. An additional component,
a so-called scoop tube, installed
into the hydrodynamic turbo cou-
pling allows the adjustment of the
working oil filling inside the coupling
while in operation. This reflects a
hydrodynamic variable speed turbo
coupling.
 1 9 Variable speed offers
reduced energy consumption = energy and cost savings

6 process adaptation = reduced emissions and less pollution

11
load pattern orientation = increased flexibility by orientation on actual plant output

7 10 speed adaptation = increased service life of installed equipment

and in addition hydrodynamic variable speed drives offer
12
simple robust mechanical design = reduced maintenance requirements
highest availability and reliability = process stability
5 compact design = less space needed, less investment costs
load free motor start-up = start-up possible under bad power grid conditions
vibration dampening features = shocks from motor or driven machine are not transmitted
2 8 3 4 integrated lube oil system = no additional separate lube oil system needed

Figure 10: Sectional view of a hydrodynamic Figure 11: Benefits of variable speed and
variable speed coupling with integrated gear stage hydrodynamic variable speed drives

1 Gear stage
2 Hydrodynamic variable speed turbo coupling
3 Scoop tube
4 Electro-hydraulic positioning control (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 Reversible duplex filter
12 Oil reservoir

For typical boiler feed pump drives
running at high output speeds of ap-
proximately 5,000 rpm to 6,000 rpm
hydrodynamic variable speed turbo
couplings can be combined with
one or more gear stages in a com-
mon housing.
As all these drives act on the same
basic operational principle they all
imply the same advantages belong-
ing to hydrodynamic power trans-
mission technology. In addition all
benefits common to variable speed
drive systems are also realised
when installing these drives. An
overview on these benefits is given
within figure 11 above.

9
 D A
Figure 12: Sectional view of a hydrodynamic variable speed planetary gear set and principle of power splitting
Variable speed planetary gear set
A Hydrodynamic torque converter
B Stationary planetary gear
C Revolving planetary gear
D Oil supply system
Due to physical laws, efficiency of
the drives as described before de-
creases as the output speed of the
drive systems goes down. To come
around this, the variable speed
planetary gear set used within drive
configuration (C) of section 4.) of
this paper introduces the principle
of power splitting into variable
speed drives technology. Within its
10
B C
Pu 25%
Pe 75% Pa
Variable speed planetary gear set
Principle of power splitting
Pe Input power
Pu Superimposing output
Pa Output power
components the variable speed
planetary gear set consists of one
or more hydrodynamic circuits in
combination with mechanical gears
as per each individual application
required. Figure 12 illustrates the
setup of the individual components
of the hydrodynamic variable speed
planetary gear set and the principle
of power splitting applying to it.
 100

A
80
Efficiency [%]

B
60

40

0
0 20 40 60 80 100
Load [%]

Figure 13: Efficiency curves of hydrodynamic variable speed drives

A Variable speed planetary gear set

B Geared variable speed coupling

Within this power splitting principle, hydrodynamic torque converter and

the majority of power is transmitted
mechanically, directly via the main
shaft and the rotating planetary
gear. Only that portion of input pow-
er necessary for speed adjustment
of the driven machine is split from
the main shaft via the adjustable
superimposed on the rotating plan-
etary gear set. Due to the high
portion of mechanically transmitted
power, the entire unit has an effi-
ciency of over 95% over a wide
operating range as shown in figure
13 of this paper.

11
 C

Ne Ne

Nu Nu

Na Na

Figure 14: Output speed variation with a variable speed planetary gear set

Variable speed planetary gear set Ne Input speed

C Revolving planetary gear Nu Superimposed speed
Na Output speed

Within the hydrodynamic variable

Ring gear Planet carrier
speed planetary gear set the output
speed is controlled by adjusting the
superimposed speed. The maxi-
mum superimposed speed results in
the highest output speed. A reduc-
tion or reversal of the superimposed
speed results in a reduced output
speed. This is shown within figure
14 above.

Planet Sun gear

3-D-view of revolving planetary gear Vorecon type RW

boiler feed pump, Germany
Power 8,500 kW
Speed 5,000 rpm

12
 A
Figure 15: Set-up of a hydrodynamic torque converter as part of the variable speed planetary gear set
Variable speed planetary gear set
A Hydrodynamic torque converter
The superimposed speed itself is
varied by adapting the oil flow
inside the hydrodynamic torque
converter by operating and adjust-
ing internal guide vanes. Figure 15
above shows the location of the
hydrodynamic torque converter (A)
inside the variable speed planetary
gear set as well as its setup.
1 2 3
Hydrodynamic torque converter
1 Adjustable guide vanes
2 Pump wheel
3 Turbine wheel
As now the technique applying to
hydrodynamic variable speed drives
is systematically illustrated, the
upcoming paper section focuses
especially on the commercial
assessment of these drives.
13
 6. Commercial evaluation on different
variable speed drive systems

VSPG
45 m2

Motor VSPG Cooling

system

VFD
150 m2

Motor Gear Harmonic Isolation Oil Cooling Frequency Overhead

filter transformer system system drive tank

Figure 16: Comparison in field conditions of different variable speed drive systems

VSPG Variable speed planetary gear

VFD Variable frequency drive

To find the most economical drive
system, a thorough analysis of life-
cycle cost has to be done. This
analysis should include equipment
cost, installation and infrastructure
cost, commissioning and mainte-
nance cost as well as energy cost.
The variable speed planetary gear
drive system is very simple and re-
quires few components, compared
to a variable frequency drive system
as shown within figure 16 above.
This results in less required space,
less cost for setting up buildings
and more simple installation and
commissioning.
Equipment cost are significantly
lower, especially for high power ap-
plications. Due to the high reliability
of the variable speed planetary
gear drive system, maintenance
and repair cost are extremely low.

14
 Motor VSPG
losses losses

Working
13.8 kV Motor VSPG
machine

Power for
cooler (fans)

Transformer VFD Filter Motor Gear

losses losses losses losses losses

Working
Motor Gear
machine
13.8 kV VFD

Optional input Power for Power for Power for Power for
filter losses cooling system air conditioning cooler (fans) oil system (pumps)

Figure 17: Systemic efficiency line-up of different variable speed drive systems

VSPG Variable speed planetary gear

VFD Variable frequency drive

Furthermore, energy cost for the
variable speed planetary gear set is
similar to a variable frequency drive
when a sound evaluation in compar-
ing the entire drive system is done.
For this purpose it has to be en-
sured that all relevant component
efficiencies are included in the
considerations.
Figure 17 illustrates that with a vari-
able frequency drive system a lot
more drive components are set in
place reducing drive efficiency than
as for the variable speed planetary
gear set. All these different addi-
tional drive components imply ad-
ditional power losses with the result
of more energy consumed for the
variable frequency drive system.

15
Load pattern Operating points Summer
(4 x 800 MW) 75% 100% MCR 100% BMCR 103% BMCR 103% Design Point
Point A Point B Point C Point D Point E Point F
Operating time (hours per year) 500 500 7,000 10 10 5
Power consumption of pump (kW) 4,463 6,652 11,164 11,842 12,963 13,382
Operating speed (rpm) 3,663 4,131 4,804 4,890 5,008 5,069
Drive VFD Motor efficiency 97.0% 97.3% 97.7% 97.7% 97.7% 97.7%
system VFD efficiency 96.5% 97.0% 97.5% 97.5% 97.5% 97.5%
efficiency
& electri- Transformer efficiency 99.0% 99.0% 99.0% 99.0% 99.0% 99.0%
cal power Isolation transformer efficiency 99.0% 99.0% 99.0% 99.0% 99.0% 99.0%
consump- Gear box efficiency 98.0% 98.2% 98.5% 98.5% 98.5% 98.5%
tion
Overall efficiency 89.9% 90.8% 92.0% 92.0% 92.0% 92.0%
Electrical power consumption (kWh/a) 2,481,998 3,661,473 84,979,089 128,771 140,961 72,759
Lube oil pump (30 kW estimated) 15,000 15,000 210,000 300 300 150
VSPG Motor efficiency 97.2% 97.5% 97.9% 97.9% 97.9% 97.9%
Vorecon efficiency 86.2% 87.8% 94.8% 95.1% 95.1% 94.9%
Transformer efficiency 99.0% 99.0% 99.0% 99.0% 99.0% 99.0%
Overall efficiency 82.9% 84.7% 91.9% 92.2% 92.2% 92.0%
Electrical power consumption (kWh/a) 2,690,222 3,924,532 85,053,393 128,477 140,639 72,746
Energy Power savings with VFD system (kWh/a) 193,225 248,060 -135,695 -594 -622 -163
savings Power cost (Euro/kWh) 0.03 0.03 0.03 0.03 0.03 0.03
with
VFD system Savings per year in Euro 5,797 7,442 -4,071 -18 -19 -5
Total savings (S) with VFD per year 9.126 Euro
Investment VFD Estimated VFD system cost VFD 1,600,000 Euro
Gear 150,000 Euro
Oil supply system 90,000 Euro
Extra price motor 50,000 Euro
Wiring 80,000 Euro
Total 1,970,000 Euro
VSPG Price VSPG VSPG 950,000 Euro
Payback Difference in cost (C) Euro 1,020,000
calculation Interest rate (i) % 8%
Cost increase (f) %/a 3%
Payback formular N = log (r/(r-i)/log (1+i)
Payback rate Payback rate r = (S-C*f)/C -0.021052647
Payback time -21 years, 7 months

Figure 18: Example of a payback calculation for different variable speed drive systems

VSPG Variable speed planetary gear

VFD Variable frequency drive

16
Best to illustrate economic advan-
tages of hydrodynamic variable
speed drive systems over variable
frequency drive systems is to per-
form an objective payback calcula-
tion evaluating the different drive
efficiencies as well as the difference
in investment cost for the evaluated
drive systems. Figure 18 shows
this exemplarily for a power station
convoy of 4 x 800 MW.
The load pattern of the power plant
is the basis for the evaluation and is
used to calculate the electrical pow-
er consumption in kWh/a for the
different drive systems looked into.
On doing so, it is absolutely essen-
tial to evaluate the different drive
systems on the basis of all compo-
nents installed as pointed out
above. It has to be a systemic view,
each drive system has to be evalu-
ated in total, not just in its single
components only. For the evalua-
tion done within figure 18, energy
cost for the variable frequency drive
system are less than for the varia-
ble speed planetary gear set due to
having slightly better overall effi-
ciency values for the given load
pattern. This leads to total energy
savings of Euros 9,126.00 per year
when operating the variable fre-
quency drive system. To complete
the economic evaluation, the invest-
ment side has to be considered
resulting in a payback calculation to
be performed. Based on a certain
interest rate and cost increase per
year, a net present value calculation
incorporates the total energy sav-
ings calculated in combination with
the difference in investment cost
between the different variable
speed drive systems. With the vari-
able speed planetary gear drive, the
initial cost are much lower than with
the variable frequency drive system
with its advantages in cost savings
on the energy side. Thus, even with
money being saved on the energy
side, the variable frequency drive
system will not pay back due to
having a negative payback calcu-
lated. The higher investment cost of
the variable frequency drive system
cannot be recovered, not even in a
20 or more years plant life.
The outcome of this payback calcu-
lation shows the advantages of the
hydrodynamic variable speed drive
in being the most competitive drive
system. In combination with drive
configuration (B) or (C) of section 4
of this paper, tariff-based project
bids can be viewed as best served
when installing hydrodynamic vari-
able speed drive systems due to
being able to offer real economic
advantages to utility companies and
power station owners.
17
 7. Conclusion
Reliability figures of hydrodynamic variable speed drives
(based on data available on variable speed planetary gear drives)
No. of units evaluated
Power range [kW]
Output speed [rpm]
Total operating hours
No. of reported failures
Non availability time [hrs]
Figure 19: Reliability figures of hydrodynamic variable speed drives (variable speed planetary gear drives)
On the background of the ongoing
trend towards higher plant output
combined with tariff-based project
bidding systems the ambition to-
wards a most economic operation
of a power plant plays a vital role for
successfully running a state of the
art power station. Within this, hydro-
dynamic variable speed drives are
able to offer all its inherent success
factors to utility companies and
power station owners. Objective
payback calculations give proof of
that.
18
69
600 - 11,931
495 - 16,482
2,095,921
6 (based on machines in operation)
546
Operating a hydrodynamic variable
speed drive system realises all
advantages which belong to vari-
able speed drives in general in
combination with all success factors
essential to hydrodynamics as the
operational principle of the drive
systems. In this respect, more
flexibility offered by the use of the
hydrodynamic variable speed drive
system means highly efficient and
environmental-friendly processes
can be realised while saving money
at the same time. Thus, efficiency of
the drive systems used has to be
seen as yet another success factor
a drive system should be evaluated
on. Objective efficiency compari-
sons performed on a systemic view
are able to give evidence of this.
Reliability calculation:
(2,095,921 - 546) / 2,095,921 = 99.97 %
(based on machines in operation)
MTBF calculation:
2,095,921 / 6 = ~ 39 years
Durability of the drive system in-
stalled has to be seen as a further
success factor of essential interest
to the utility companies aspiring a
most satisfactorily operating plant.
A drive system shall be designed
for a minimum of the life time of the
whole plant, thus, a minimum of at
least 25 years of operation should
be considered as basis for a drive
evaluation. This means a minimum
of at least 25 years of operation
where spare parts availability has to
be ensured. The technology used
has to be long-lasting, not rapidly
changing. Proven mechanical com-
ponents still being available within
30 years from today form the basis
of a trustworthy alliance to a hydro-
dynamic variable speed drive
system on which this can easily be
proven for.

Highest reliability of the drive sys-
tem acts as the basis for longest
operating hours to be realised for
economic plant operation. Down-
time of the plant is most cost-inten-
sive and has to be avoided in order
to ensure smooth production.
Availability is the most critical factor
when calculating the life-cycle cost
of an installation. Using a hydro-
dynamic variable speed drive
system proves for a reliability of
99.97% or in other words, an MTBF
of more than 39 years based on
machines in operation as shown
within figure 19 can be adhered to.
Reliability
Economics
Efficiency
VFD
versus =
VSPG
Durability
Figure 20: Success factors for evaluation of variable speed drive systems
VSPG Variable speed planetary gear
VFD Variable frequency drive
In pursuing the optimum solution for On this background it becomes
each individual power station clear that all four success factors
project, it becomes clear that an ob- have to interlock into each other
jective assessment of different drive in order to develop an overall drive
systems has to be done on the ba- system evaluation showing the
sis of 4 essential success factors as optimum solution to the decision-
shown in figure 20 above. makers. Considering a hydro-
dynamic variable speed drive sys-
Drive reliability counts as tem within such an evaluation will,
nothing can compensate for lost in all respects, surely pay back.
production.
Drive economics count as only
the most economic system
will sustain thorough payback
evaluations done.
Drive durability counts as only a
constant running system proves
for the economic figures being
expected.
Drive efficiency counts as only
adapted processes to be run help
saving money.
19
Voith Turbo Private Limited
P.O. Industrial Estate
Nacharam
Hyderabad 500 076
Tel: +91 40-27 17 35 61, 27 17 14 40
Fax: +91 40-27 17 11 41, 27 17 31 34
info.hyd@voith.com
www.voithturbo.com

Voith Turbo GmbH & Co. KG

Variable Speed Drives
Voithstr. 1
74564 Crailsheim, Germany
Tel: +49 7951 32-261
Fax: +49 7951 32-650
vs.drives@voith.com
www.voithturbo.com/variable-speed

Cr 605 en, 04.2009, aik / SVG, 600. Printed in Germany. Subject to modification due to technical development.