RECOVAR-E. Variable-speed drives for compressors and pumps - RENK AG
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RECOVAR -E.
®
Variable-speed drives
for compressors and pumps.
Superimposition drives. Redefining availability and
efficiency of variable-speed drivetrains.
Empowering Forces.
01
Recovar®-E Recovar®-E
Drivetrain Maximum RECOVAR -E superimposition drive:
®
efficiency 95% availability The cutting edge of efficiency and
Best in class for
variable-speed solutions.
Mean time between critical
failure is over 30 years.
availability for variable-speed drives.
The RECOVAR®-E provides an unparalleled overall system efficiency
of 95% throughout the entire drive system – including the main motor.
100
95 Savings compared to conventional
solutions through RECOVAR®-E:
90 Increasing the efficiency of a 10 MW
application by 5% represents
85 energy cost savings of at least
€ 200,000 per year.
80
75
70
70 75 80 85 90 95 100 105
Compressor speed in %
RECOVAR®-E Hydrodynamic VSD
Geared converter VSD
Over the past twenty years, the industry By redefining SI for mechanical drives, RECOVAR®-E in your train:
has developed solutions to operate the RECOVAR®-E delivers the following: -- Coaxial shaft arrangement
-- Very low moment of inertia for
compressors and pumps at variable -- Unparalleled efficiency direct on-line (DOL) starting
speeds in order to preserve energy. -- An unrivaled inspection and -- RENK helps to select/provides
maintenance concept for epicyclic the main motor
-- Complies with most API 613
Prior to this, using the throttle was the drives (similar to that for parallel requirements
only way to vary the output of these shaft gears) -- API 614 oil supply system
machines. In many cases, however, this -- An unmatched low part count via possible
resulted in a loss of more than half the direct drive SI
input power. -- Oil film bearings (SI drives are
supported by hydrostatic bearings)
Empowering Forces. With the RECOVAR®-E, RENK now offers -- No scheduled mean time between
the latest development for variable-speed overhauls (MTBO)
RENK. We are the world’s leading specialists for pioneering drivetrain solutions – solutions. RECOVAR®-E is a reengineered -- Reduced total harmonic grid
electric SI drive that helps the industry build distortion (THD)
in industrial applications, energy production and beyond. Our innovative products
ideal variable-speed shaft trains. As a -- A redundant converter for the
and solutions set standards when it comes to quality, precision, and reliability. hybrid mechanical and electrical solution, superimposition variable-speed
At the same time, they represent cutting-edge technology across global markets. it offers the best of both worlds. drive (VSD)
Through RECOVAR®-E engineering, we are at the vanguard of redefining
superimposition (SI) for mechanical drives up to 20 MW and 15,000 rpm.
As such, the RECOVAR®-E delivers unparalleled efficiency, unmatched simplicity
and a low part count. Beyond this, it boasts an unrivaled inspection and
maintenance concept for epicyclic drives. The variability the RECOVAR®-E
achieves through superimposed drives is thus:
an economical must-have.
02 03
Recovar®-E Recovar®-E
Short Low Low total RECOVAR -E lowers the inertia
®
outage time inertia harmonic and the impact on the grid.
Mean time to repair Allows for easy direct grid distortion
(MTTR) is 12 hours. on-line starting of motor.
Ideal for local grids.
RECOVAR®-E improved DOL start of main motor Harmonics and THD Benefits of the RECOVAR®-E for
Power splitting gear Disc brake and the DOL start of the main motor:
without annulus SI motor terminal SI motor motor cooling in % u rel % -- Facilitated start of main
100 Speed / Torque = 100% 10 motor / drivetrain
9 -- Reduced thermal stress
Input shaft for motor
80 Speed 8
≤ 70% 7 -- In many cases, no additional
60 6 measures required (such as low
5 inrush current motor/additional
40 Torque 4 motor-starting devices)
≤ 49% 3 -- Reduced costs for main motor
20 2 -- Improved motor efficiency
1 (compared to low inrush
0 0 current motor)
10 20 30 40 50 60 70 80 90 100 THD 11 13 19 23 47 49
n (1)
RECOVAR®-E torque at motor shaft RECOVAR®-E
RECOVAR®-E compressor speed IEC 61000-2-4 limit for class 1
API 613 gear torque at motor shaft IEC 61000-2-4 limit for class 2
API 613 gear compressor speed
RECOVAR®-E Low A systems comparison for
inertia at the motor shaft:
improves the direct harmonic
Output shaft
on-line start of the distortions. RECOVAR®-E
main motor.
Since the main motors of compres- Particularly in decentralized grids,
Oil intlet
sors or pumps usually operate directly such as those on offshore oil
on the grid, the requirements for platforms, harmonic distortion must
Hydrostatic pump DOL start-up have to be considered. be prevented. RECOVAR®-E SI drives Inertia 25%
nearly eliminate the effects of THD.
Thanks to the absence of an annulus, the
Engineered for in situ
Hydrodynamic VSD
RECOVAR®-E features very low inertia. In The SI drive requires only limited power
maintenance. fact, it has by far the lowest inertia of the
known solutions for compressor drives.
to control and induce variable speeds.
Running on 690 V, the drive leverages
This facilitates the start of the motor. The the advantages of low-voltage (LV) power
Most RECOVAR®-E components can Following the planets, the central pinions Made for the petrochemical
industry. SI motor can bring the inertia of the high- supplies. This allows a small frequency
be inspected / disassembled with the can be easily removed. Since there “A mean time to repair of just speed side down to nearly zero. During converter (FC) to be used (in this case,
unit still installed in the shaft train. is no ring gear, the planet shafts are 12 hours, 20 years of service life the first part of the start cycle, the an active-front-end type). Compared to
accessible (as is the case in a parallel and 5 years of uninterrupted Inertia 50%
operation according to API 613” compressor / pump can stand still. At the a main drive FC, the RECOVAR®-E FC
Thanks to its featured horizontal split line, shaft gear with bearing caps). The end, the compressor / pump is only handles just a fraction of the power. As
the RECOVAR®-E overcomes the typical planets can be effortlessly disassembled accelerated to minimum speed. This a result, harmonic distortion is minimized. API 613 parallel shaft gear
maintenance disadvantages associated in conjunction with their bearings. results in a significantly reduced inertia at At the same time, LV service is broadly
with epicyclic gears (e.g. those associated Output and input sun gears can also the point of acceleration. As part of any available, and the limited costs of the FC
with existing SI gear concepts with an be maintained without any disruption of quotation, RENK can provide the required mean, it can be provided in a redundant
annulus). Using the SI motor and the the casing alignment. This work requires counter torque for the main drive. To take setup for critical applications.
brake, the controller turns one planet after only very limited crane capacity in the advantage of this service, please provide
another to the disassembly position. shaft axis line. the corresponding inertia of your com-
pressor / pump.
Inertia 100%
04 05
Recovar®-E Recovar®-E
Unparalleled Water, oil or RECOVAR -E: engineering excellence.
®
simplicity air cooling Maximum simplicity. Maximum resilience.
Engineered for SI motor cooling is adapted
maximum modularity. to site requirements.
RECOVAR®-E for variable speed applications:
Innovative. Intelligent. Low maintenance.
Power splitting gear Output shaft
Disc brake SI motor cooling Bearing caps Planets Variable rpm output
SI motor
cooling
Disc brake SI motor Fix rpm
input shaft
SI motor
cooling
Increasing gear
Planet carrier
Oil intlet
Input shaft Superimposition transmission reinvented.
SI motor terminal
RECOVAR®-E is a cost efficient In conventional SI layouts, the SI drives
solution whenever a high speed drive transmit their torque through complex
system above 3 MW requires speed gearing mechanism on the drivetrain. In
control. This is the case for roughly the RECOVAR®-E design, by contrast, the
50% of compression and pumping SI motor is directly coupled with the planet
systems. A system, which has been carrier.
The SI motor is an LV multipole Oil film bearings for all shafts in operation since 2017, demonstrates
induction motor which is water- or in the RECOVAR®-E are essential that power of 100 MW can be trans The axis of the RECOVAR®-E input shaft
oil-cooled. In the event of a power for continuous intervention-free mitted. runs through this hollow shaft on the
outage, a disc brake safely brings operation as required in API 613. SI motor directly into the speed increaser
the SI drive to standstill. The The SI motor is a state-of-the-art Often medium-voltage motors fed by of the RECOVAR®-E. The speed increaser
Furthermore, the SI drive bearings are induction motor.
RECOVAR®-E can be designed to FCs and parallel shaft gears are selected. itself is a 2-stage multi-path parallel shaft
supported by hydrostatic lubrication. It offers top efficiency even at the
operate continuously while the the lowest speed. The SI can also provide Others use epicyclic gears with a hydro- gear.
This enables the dependable operation
planet carrier is locked. zero speed. dynamic SI drive. The RECOVAR®-E
at low SI-speeds. The RECOVAR®-E
is the drive solution for all of these With a mere eleven bearings in total, this
design features planet bearing tem- The high torque of this multipole motor
The SI motor is a core component of the allows direct coupling of the SI motor applications. design features unparalleled simplicity –
perature monitoring by radio-frequency
RECOVAR®-E. Thanks to jacket cooling, and the planet carrier. The SI motor particularly when compared to any other
identification (RFID). Data are transmitted can be removed without disturbing
it is very compact. Where water is not The principle of SI is used in the SI drive, which has roughly twice the
wirelessly from the revolving planet. train alignment.
available as a cooling media, gear lube RECOVAR®-E's specific differential gear mechanical complexity. Beyond this, the
oil can be used. This multipole motor design to control the output speed in RECOVAR®-E has no working oil, no extra
features high efficiency in the transmission a defined range below and above the coolers, no extra oil tanks.
of SI power – even at very low speeds. natural ratio of the speed increaser.
The air in the motor is circulated by an
input-shaft-driven fan.
06 07
Recovar®-E Recovar®-E
50% smaller 70% less 80% less Innovative monitoring
footprint weight heat load for the RECOVAR -E.
®
Same output while taking than a full-power FC and in the electrical room.
up much less space in transformer.
the electrical room.
Torque and speed
measurement
Full-power FC
Vibration measurement
Bearing temperature measurement
(also on planet carrier)
RECOVAR®-E FC
Monitoring the oil supply
The optional RENK VIB-Monitor
allows for remote inspection.
Full-power
transformer The RENK VIB-Monitor analyzes The data is either stored locally or directly All components in view.
all relevant parameters of drives, in a certified RENK data center through a With RENK VIB-Monitor,
manufacturers and operators have
couplings and gear units. The system VPN data line. As a result, highly qualified online access to the condition of
logs key data and transmits it to any service personnel can check the system gearboxes, couplings, bearings and
digital device at any location via status at any time. oil units.
high-quality cryptographic encryption Maintenance can be scheduled
standards. Instrumentation based on API 670 based on comprehensive historic
RECOVAR -E
®
is built into the RECOVAR®-E can data collected by the VIB-Monitor
transformer instead of inspections and hence
Any performance detail is available on any monitor the following: can be optimized and reduce
digital device for any authorized party in -- Shaft vibration for output shaft downtime.
the world in real time. If desired, infor and SI drive
mation concerning equipment conditions -- Casing vibration
as well as maintenance recommendations -- Temperature for all bearings,
can also be delivered as individual including those of the planet carrier
reports. This recording of cross-system -- Brake status
conditions is the foundation for the efficient -- SI motor winding temperatures
Space required by a full maintenance of the entire system. -- Lube oil data and condition
power FC for the main motor
Where space is limited and weight On-site Off-site
is an issue the RECOVAR®-E is the
solution. It ensures that your shaft
train is in line without any horizontal
offset. At the same time, the low
power of its FC – which is less than Vibration expert Vibration expert of:
20% of the power of a full-power
FC – results in your electrical room OEM
only beeing subject to small heat RENK
loads and FC dimensions.
Consultant
Machine control room
08 09
Recovar®-E Recovar®-E
RECOVAR -E provides 95% or more total
®
system effciency over a wide range of output
speeds – thanks to electric superimposition.
RECOVAR®-E – Electrical and mechanical power flow
ONE SYSTEM, ONE PARTNER.
M SI M SI M SI
As your system partner for RECOVAR®-E variable-speed gears
Generator Mode Free Mode Motor Mode -- RENK’s scope comprises all mechanical and electrical components from
shaft end to shaft end.
Unique design for Application range -- RENK provides torsional shaft train analysis for your entire drivetrain.
ultimate performance. -- RENK can, upon provision of the grid data, provide you the THD
calculation of your grid or sub-grid using SINCAL software.
SI in the RECOVAR®-E uses a LV The RECOVAR®-E is available for a The RECOVAR®-E is an amplifier
-- RENK will provide you with a counter-torque curve of the main motor
induction motor fed through an variety of input speeds. The 100% for the variable speed of its to be purchased. RENK can also quote the main motor.
FC-fed SI induction motor.
active-front-end FC to rotate the output speed can range from 4,000 The electrical SI provides the -- RENK can provide a sub-control system for the RECOVAR®-E.
planet carrier. to 20,000 rpm. RECOVAR®-E with its good system
efficiency. In solutions up to 30 MW,
-- RENK can provide automated and online inspection of the RECOVAR®-E
When the speed is increased from a basic The speed control range is typically 70% to
the SI motor directly drives the through the RENK VIB-Monitor.
planet carrier. Solutions for up
gear ratio, the SI motor works as an extra 105%. Lower control ranges result in even to 100 MW are available with
driver. Functioning as a generator, it allows greater efficiencies and lower costs. Higher geared SI.
the speed to be decreased below the control ranges are also possible. The Please contact our sales team
basic gear ratio. efficiencies given here do include the main for further details.
motor. With the RECOVAR®-E, the drive
The SI motor is rated according to the power is the total of the main motor power
required torque and speed range of your and the SI motor power. As a result, part of
application. The low power and high the drive power comes from the SI motor.
efficiency of the SI motor and FC boost RENK is more than happy to quote the main
the efficiency of the RECOVAR®-E to a motor which normally is not part of the
level beyond that of all other available scope of the RECOVAR®-E.
solutions for variable-speed drives.
Savings
in % 20% 40% 50% 60% 75% RECOVAR®-E
100 -- Is based on an electric SI drive
(with a fraction of the main
80 motor power)
-- This results in high efficiency,
60 a small FC and a lube oil system
similar to a parallel shaft gear.
40
20
0
System cost Floor space System loss Oil flow Inertia
When compared to conventional solutions
10 11
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RENK Aktiengesellschaft
Augsburg Plant
4000000011 – EN – Edition: 05/2020
Goegginger Str. 73
86159 Augsburg, Germany
Phone: +49 821 5700-0
Fax: +49 821 5700-460
E-mail: info.augsburg@renk.biz
www.renk-ag.com
Details provided about the properties and usability of the products are purely for information purposes and do not
constitute a guarantee of these characteristics. The extent of goods delivered is determined by the subject matter
of the specific contract. No liability accepted for errors or omissions. Subject to technical alterations. © RENK 2020You can also read
