BHS Gear AcademyA Look inside the Box

What you should know

High-speed gear units in turbomachinery trains represent the Champions League for gearboxes. As they run in industries like oil & gas, petrochemicals, chemicals and power generation the huge daily production value demands utmost reliable, safe and energy efficient machinery. Very often the gear units are neither in the focus of the original equipment manufacturer, the engineering company, nor the plant operator. But as high-speed gearboxes are installed in turbine or electrical motor driven centrifugal compressor, pump or generator drives they are crucial for the overall performance of such

driving trains. So knowledge about the design, manufacturing, testing and servicing of turbo gears are decisive to sense the pros and cons, chances and risks of individually solutions and providers.In special trainings this knowlegde can be transferred from gear experts to experts in the necessary depth and as practi-cal orientated as possible. Tailor-made to the individual requirements the series of seminars from Voith Turbo BHS Getriebe about high-speed gears offer the participant a real value in day-to-day routine.

PS

| 11.

001.

03 |

en |

file

| 130

3 | a

io |

bax

Voith Turbo BHS Getriebe GmbH Hans-Boeckler-Str. 787527 Sonthofen, GermanyPhone +49 8321 802-0Fax +49 8321 802-689info.bhs@voith.com

bhs-getriebe.de

The course provides an indepth understanding of gear systems used in turbomachinery trains. It transfersknowledge how to configurate a reliable and efficient gear system for an utmost trouble-free operation.It begins by delivering a fundamental understanding of gearboxes and its components during the trainingblocks of the basic training level. Then it proceeds giving guidelines for the selection of proper gear systemsand how to optimize drive train configurations during the advanced training level.

The training courses are composed of modules that are built on each other. It starts at a fundamentallevel and ends up at a highly sophisticated level of gear knowledge. The course is suitable forpost graduates or senior engineers, that can enter at a advanced level. Due to the pure technicalnature it is tailored for engineers who are involved in the conception or evaluation of rotating equipment.It adds value to engineers dealing with turbomachinery at all levels of the value chain, starting from rotatingequipment engineers involved in feasibility studies, engineers conducting detailed engineering, evaluatingdesign concepts, manufacturing and designing of drive trains and operators dealing everyday with theequipment on site. The modular conception of the BHS Gear Academy training course shows a high flexibility and can betailored to the customer needs or conducted as a whole.The entire training course is structured in a basic and advanced training section, each of them consistingof 5 topical blocks that contain several modules of 30 - 60 minutes of duration. By booking the course fora company, flexibility is given to adapt the training to special demands. So trainings from 30 minutes up to3.5 days are possible.

The training is conducted in a diversified manner. This includes a combination of theoretical parts and manyreal life case studies, enhancing discussions and interactive exercises to create a long lasting learningsuccess.

The training can be held in the customers´ premises or at BHS´s headquarter at Sonthofen, Germany. Thetraining at BHS site provides the advantage of experiencing real life products in our workshops. BHS isproviding support to organize of travelling and accomodation. All Blocks 1-5 ‚Basic‘ (1.5 days): 3,000 Euros, 30 minutes of block 1-5: 150 EuroAll Blocks 6-10 ‚Advanced‘ (2 days): 4,500 Euros, 30 minutes of block 6-10: 200 EuroFees for single companies (up to 15 persons) individually negotiable.

The course can be booked as single participant for a ‚standardized‘ course or for company groups from5 - 15 persons in a ‚adapted‘ course. None course will have more than 15 persons to have it as intensiveas possible. Way of booking is either directly or via Voith representative.

Booking: training.bhs@voith.com; phone +49 8321 802-502; http://training-bhs.voith.comIn depth information: Tome Stanic, Head of Buisness Development, phone +49 8321 802-535

Purpose

Attendee Profile

Concept & Duration

Methodology

Place

Cost

Participation / Registration

Voices from the markets:„The training presentation was pitched at the correct level for the group of Maintenance Engineers who attended, in terms of technical content. The focus appeared to be on the latest innovative developments and applications in gear design and gearbox construction rather than the basics of gear design, geometry and machining which was appreciated. It never came across as a ‚sales pitch‘, only as a technical presentation by an engineer with significant in depth knowledge of industrial gears and their applications.” Total, UK

„A superb training seminar delivered by gear specialists who understand exactly what gearbox operators need to know. Other OEM‘s could learn a lot from Voith‘s customer focussed service deliver.” Talisman, UK

“Really useful in depth discussion about gear technology. Much more like going to ‚gear school‘ than attending a sales pitch.” BP, UK

012 - Introduction to High-Speed GearboxesDefinition of high-speed gearboxes and restriction. Classification of diffe-rent turbo gear types. Overview of applications and characteristics.

022 - Gear components II - Gear TechnologyComparison of gear mode types - double helical, single helical and spur gearing regarding efficiency, reliablity, noise emission etc. Current tech-nical limitations and future developments.

032 - Epicyclic GearboxesFunctionality of this efficienct and compact turbo gear representative. Comparison of different load share principles. Recognizing advantages and limitations.

042 - Material Selection & Heat TreatmentImpacts of gear material selection, comparison of different heat treated material, like through hardened, nitrited, carburized, their comparison and challenges. Historical development and state-of-the-art heat treat-ment process.

052 - RotordynamicsUnderstanding the impact of single components to the rotordynamical behavior. Conducting and understanding of a rotor response analysis.

062 - Gear Element Failure ModesUnderstanding gear failure modes like pitting, scuffing etc. and how they develop. Preventive actions.

072 - Service & Maintenance Concepts to increase LifetimeExplore the different service attitudes, their resulting risks and side effects. Comparison of different service concepts regarding down time probability, availability rates and budget planning.

082 - Lubrication Modes - Avoiding PitfallsDifferent modes of gear & bearing lubrication. Various demands of oil during gearbox operation. How to deal with contradictive requirements for lubricating the gear mesh and bearing, i.e. in operation, shutdown.

092 - API 613 - “Design Bible“ for High-Speed Gearboxes in Oil & Gas Design philosophy, purpose and historical development. Understand and interprete single paragraphs and API 613 datasheet. Consideration from different perspectives (enduser, contractor, OEM, gear manufacturer).

102 - Gear Selection of Turbo-CompressorsRisk assesment of gear systems used for turbo-compressor at high power density. Gear challenges and derving design recommendations by either improving design details or changing the entire gear system.

011 - Gear FundamentalsUnderstand the „“law of gearing““ including the principle of gear tooth action. Tooth geometry, basic terminology, gear arrangements and gear mode types.

021 - Gear Components I - Bearing TechnologyFunctionality of hydrodynamic bearings - radial & axial types + applica-tion fields. Comparison of benefits / risks and bearing concepts for e.g. load gears, compressor gears. Current technical limitations and future developments.

031 - Parallel Shaft GearboxesFunctionality and variety of this „“Allrounder““. Discover the advantages and allocate risks. Fields of application, limitations, future developments, design criteria and philosophies.

041 - Mechanical Manufacturing ProcessProcess steps in manufacturing high-speed gearboxes including deman-ding requirements on grinding, turning etc. Challenges and recommen-dations to achieve a high quality product.

051 - Gear Design and RatingsGeneral Design process of a gearbox providing an overview of design steps, handling of data, use of calculations & simulations plus delivering high sophisticated engineering work. Use of state-of-the-art calculation programs.

061 - General Introduction to Gearbox Failure ModesAllocation of critical parts for the different gearbox types and understan-ding external and internal impacts.

071 - Starting the Right Way - Avoiding Pitfalls already during the CommissioningDifferent case studies dealing with start up and commissioning scenarios, e.g. impacts of small alignment mistakes on train performance. Intepre-ting a gearbox manual to avoid possible pitfalls.

081 - Impact of Oil Selection on Gearbox PerformaceDiscover the impact of oil selection on gearbox performance, e.g. failure probability, life time, scuffing and efficiency. Selection of proper oil for extended lifetime.

091 - Applicable Standards for High-Speed GearboxesOverview on gear standards and fields of applications, e.g. API, AGMA, ISO. Understand the scope of each standard and their different philoso-phies and historical development. Comparison of rating systems.

101 - Gear Selection of Motor-CompressorsRisk assessment of gear systems used for high-speed motor-compres-sor application. Gear challenges and deriving design recommendations by either improving design details or changing the entire gear system.

„Law of gearing“, basic nomenclature & definition of high-speed gearbo-xes and their applications

Bearing technology, types and field of applications. Gear technology, characteristics of different gearing types

Design & field of application for parallel shaft gearboxes, epicyclic gear-boxes, integral gearboxes and power distribution gearboxes

Manufacturing process steps, material selection depending on applica-tion, heat treatment procedures and comparison, testing procedures & test run types

Gear design process & rating philosophies, rotordynamics, finite element analysis, torsional analysis

Failure probabilities of gearbox components. Modes of gear failure, bearing failure, casing and sealing failure, their root causes and avoidance

Gearbox start up & commissioning considerations. Service & mainte-nance concepts, their impact on life time. Preventive maintenance

Impact of oil selection on gear systems and the various lubrication modes

Gear Standards (AGMA, ISO), understanding API 613, delivering a proper gearbox specification

Selection of gearbox types for compressor drives and turbo generators. Optimizing reliability and efficiency of gear design

Gearbox Fundamentals - The ABC´s of Gear Systems

105 minutes total

Look inside a Gearbox - Examination of Components

165 minutes total

Exploring different High-Speed Gearbox Types

180 minutes total

Manufacturing Process & Quality Assurance

195 minutes total

Gear Design Process - Analytical Tools

135 minutes total

Gearbox Failures - Types and Preventation

180 minutes total

Extending Lifetime of a Gearbox - Maintenance & Service Considerations

165 minutes total

Lubrication & Principles for Gear Systems

90 minutes total

Gear Rating - Understanding & Use of applicable Standards

180 minutes total

Optimizing drive Train by proper Gearbox Selection

180 minutes total

1

2

3

4

5

6

7

8

9

10

023 - Gear Components III - Casing TechnologyRequirements involved in the design process of a gear casing. How to achieve sufficient rigity and stiffness, heat dispensation, noise reduction. Comparison of different casing materials & designs in regards to cost, reliabilty etc.

033 - Integral GearboxesExplore the different gear arrangements depending on driver selection and compressor arrangement. Challenges and design solutions for the core unit of a geared compressor. Allocating limits and future trends.

043 - Testing Procedures and Quality AssuranceDifferent testing types of single parts and their purpose, e.g. non-destructive testings like e.g ultrasonic or magnetic partical test. Purpose and comparison of different test run types, e.g. No Load- Full Speed, Back-to-Back Test runs.

053 - Finite Element AnalysisInfluence of external conditions on the stiffness of the gear casing. Conducting a FEA and using the results in the design process. Case studies on load gears and big integral gears.

063 - Bearing Failure ModesUnderstanding bearing failure modes like bonding, corrosion and how they develop. Preventive actions.

073 - Preventive MaintenanceHow to increase gearbox lifetime and decrease risks of downtimes in a very early stage. Discussion of ABC- inspection intervals regarding their content and impact depending on gearbox type.

093 - How to write a Specification for a reliable and efficient GearboxImpacts on gear design and resulting risks. Risk assessment sys-tems. Selection, comparison of applicable gearbox designs in terms of reliability, efficiency, CAPEX, LCC. Design recommendations for gearbox parts, monitoring etc.

103 - Gear Selection for GensetsExplore different gear systems designs for turbo generators. Discover different design philosophies for steam turbine or gas turbine driven gen-sets. Load gear design to increase train efficiency and operational life.

024 - Gear Components IV - Sealing TechnologyDifferent sealing types and concepts used for high-speed gearboxes. Design variations and recommendations according to the different application fields.

034 - Power Distribution GearboxesUnderstanding the functional principle of this gearbox type, used for high power density applications, e.g. GT/C or Gensets. Exploring the design features and field of applications.

044 - Monitoring and Interpretation of Resulting DataExplore the monitoring concepts according to the gear box type. Tempe-rature and vibration measurements, types of measuring and interpretati-on of measured results, e.g. waterfall diagrams.

054 - Torsional AnalysisOptimizing the torsional stiffness of an entire train by connecting the interface between driver and driven machine. Case study on an integral geared compressor train.

064 - Casing & Sealing FailuresUnderstanding casing and sealing failures like leakages and how they develop. Preventive actions.

Block Learning goals Module 1 Module 2 Module 3 Module 4

Bas

ic |

1.5

days

tota

lA

dvan

ced

| 2.0

day

s to

tal