BHS Gear Academy full program, PDF

„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
PS| 11.001.03 | en | file | 1303 | aio | bax
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
“Really useful in depth discussion about gear technology. Much more like going to ‚gear school‘ than attending a sales pitch.”
BP, UK
BHS Gear Academy
A Look inside the Box
What you should know
Purpose
The course provides an indepth understanding of gear systems used in turbomachinery trains. It transfers
knowledge 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 training
blocks of the basic training level. Then it proceeds giving guidelines for the selection of proper gear systems
and how to optimize drive train configurations during the advanced training level.
Attendee Profile
The training courses are composed of modules that are built on each other. It starts at a fundamental
level and ends up at a highly sophisticated level of gear knowledge. The course is suitable for
post graduates or senior engineers, that can enter at a advanced level. Due to the pure technical
nature 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 rotating
equipment engineers involved in feasibility studies, engineers conducting detailed engineering, evaluating
design concepts, manufacturing and designing of drive trains and operators dealing everyday with the
equipment on site.
Concept & Duration
The modular conception of the BHS Gear Academy training course shows a high flexibility and can be
tailored 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 consisting
of 5 topical blocks that contain several modules of 30 - 60 minutes of duration. By booking the course for
a company, flexibility is given to adapt the training to special demands. So trainings from 30 minutes up to
3.5 days are possible.
Methodology
The training is conducted in a diversified manner. This includes a combination of theoretical parts and many
real life case studies, enhancing discussions and interactive exercises to create a long lasting learning
success.
Place
The training can be held in the customers´ premises or at BHS´s headquarter at Sonthofen, Germany. The
training at BHS site provides the advantage of experiencing real life products in our workshops. BHS is
providing support to organize of travelling and accomodation.
Cost
All Blocks 1-5 ‚Basic‘ (1.5 days): 3,000 Euros, 30 minutes of block 1-5: 150 Euro
All Blocks 6-10 ‚Advanced‘ (2 days): 4,500 Euros, 30 minutes of block 6-10: 200 Euro
Fees for single companies (up to 15 persons) individually negotiable.
Participation / Registration
The course can be booked as single participant for a ‚standardized‘ course or for company groups from
5 - 15 persons in a ‚adapted‘ course. None course will have more than 15 persons to have it as intensive
as possible. Way of booking is either directly or via Voith representative.
Booking: [email protected]; phone +49 8321 802-502; http://training-bhs.voith.com
In depth information: Tome Stanic, Head of Buisness Development, phone +49 8321 802-535
Voith Turbo BHS Getriebe GmbH
Hans-Boeckler-Str. 7
87527 Sonthofen, Germany
Phone +49 8321 802-0
Fax+49 8321 802-689
[email protected]
bhs-getriebe.de
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 highspeed 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 practical 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.
1
„Law of gearing“, basic nomenclature & definition of high-speed gearboxes and their applications
011 - Gear Fundamentals
Understand the „“law of gearing““ including the principle of gear tooth
action. Tooth geometry, basic terminology, gear arrangements and gear
mode types.
012 - Introduction to High-Speed Gearboxes
Definition of high-speed gearboxes and restriction. Classification of different turbo gear types. Overview of applications and characteristics.
Bearing technology, types and field of applications. Gear technology,
characteristics of different gearing types
021 - Gear Components I - Bearing Technology
Functionality of hydrodynamic bearings - radial & axial types + application fields. Comparison of benefits / risks and bearing concepts for e.g.
load gears, compressor gears. Current technical limitations and future
developments.
022 - Gear components II - Gear Technology
Comparison of gear mode types - double helical, single helical and spur
gearing regarding efficiency, reliablity, noise emission etc. Current technical limitations and future developments.
023 - Gear Components III - Casing Technology
Requirements 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.
024 - Gear Components IV - Sealing Technology
Different sealing types and concepts used for high-speed gearboxes.
Design variations and recommendations according to the different
application fields.
Design & field of application for parallel shaft gearboxes, epicyclic gearboxes, integral gearboxes and power distribution gearboxes
031 - Parallel Shaft Gearboxes
Functionality and variety of this „“Allrounder““. Discover the advantages
and allocate risks. Fields of application, limitations, future developments,
design criteria and philosophies.
032 - Epicyclic Gearboxes
Functionality of this efficienct and compact turbo gear representative.
Comparison of different load share principles. Recognizing advantages
and limitations.
033 - Integral Gearboxes
Explore 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.
034 - Power Distribution Gearboxes
Understanding 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.
Manufacturing process steps, material selection depending on application, heat treatment procedures and comparison, testing procedures &
test run types
041 - Mechanical Manufacturing Process
Process steps in manufacturing high-speed gearboxes including demanding requirements on grinding, turning etc. Challenges and recommendations to achieve a high quality product.
042 - Material Selection & Heat Treatment
Impacts 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 treatment process.
043 - Testing Procedures and Quality Assurance
Different testing types of single parts and their purpose, e.g. nondestructive 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.
044 - Monitoring and Interpretation of Resulting Data
Explore the monitoring concepts according to the gear box type. Temperature and vibration measurements, types of measuring and interpretation of measured results, e.g. waterfall diagrams.
Gear design process & rating philosophies, rotordynamics, finite element
analysis, torsional analysis
051 - Gear Design and Ratings
General 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.
052 - Rotordynamics
Understanding the impact of single components to the rotordynamical
behavior. Conducting and understanding of a rotor response analysis.
053 - Finite Element Analysis
Influence 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.
054 - Torsional Analysis
Optimizing the torsional stiffness of an entire train by connecting the
interface between driver and driven machine. Case study on an integral
geared compressor train.
Block
Learning goals
Module 1
Module 2
Module 3
Module 4
Gearbox Failures - Types and Preventation
180 minutes total
Failure probabilities of gearbox components. Modes of gear failure,
bearing failure, casing and sealing failure, their root causes and
avoidance
061 - General Introduction to Gearbox Failure Modes
Allocation of critical parts for the different gearbox types and understanding external and internal impacts.
062 - Gear Element Failure Modes
Understanding gear failure modes like pitting, scuffing etc. and how they
develop. Preventive actions.
063 - Bearing Failure Modes
Understanding bearing failure modes like bonding, corrosion and how
they develop. Preventive actions.
064 - Casing & Sealing Failures
Understanding casing and sealing failures like leakages and how they
develop. Preventive actions.
Extending Lifetime of a Gearbox Maintenance & Service Considerations
Gearbox start up & commissioning considerations. Service & maintenance concepts, their impact on life time. Preventive maintenance
071 - Starting the Right Way - Avoiding Pitfalls already during the Commissioning
Different case studies dealing with start up and commissioning scenarios,
e.g. impacts of small alignment mistakes on train performance. Intepreting a gearbox manual to avoid possible pitfalls.
072 - Service & Maintenance Concepts to increase Lifetime
Explore the different service attitudes, their resulting risks and side
effects. Comparison of different service concepts regarding down time
probability, availability rates and budget planning.
073 - Preventive Maintenance
How 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.
Impact of oil selection on gear systems and the various lubrication
modes
081 - Impact of Oil Selection on Gearbox Performace
Discover the impact of oil selection on gearbox performance, e.g. failure
probability, life time, scuffing and efficiency. Selection of proper oil for
extended lifetime.
082 - Lubrication Modes - Avoiding Pitfalls
Different 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.
Gear Standards (AGMA, ISO), understanding API 613, delivering a proper
gearbox specification
091 - Applicable Standards for High-Speed Gearboxes
Overview on gear standards and fields of applications, e.g. API, AGMA,
ISO. Understand the scope of each standard and their different philosophies and historical development. Comparison of rating systems.
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).
093 - How to write a Specification for a reliable and efficient Gearbox
Impacts on gear design and resulting risks. Risk assessment systems. Selection, comparison of applicable gearbox designs in terms of
reliability, efficiency, CAPEX, LCC. Design recommendations for gearbox
parts, monitoring etc.
Selection of gearbox types for compressor drives and turbo generators.
Optimizing reliability and efficiency of gear design
101 - Gear Selection of Motor-Compressors
Risk assessment of gear systems used for high-speed motor-compressor application. Gear challenges and deriving design recommendations
by either improving design details or changing the entire gear system.
102 - Gear Selection of Turbo-Compressors
Risk 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.
103 - Gear Selection for Gensets
Explore different gear systems designs for turbo generators. Discover
different design philosophies for steam turbine or gas turbine driven gensets. Load gear design to increase train efficiency and operational life.
Gearbox Fundamentals - The ABC´s of Gear Systems
105 minutes total
2
Look inside a Gearbox - Examination of Components
Basic | 1.5 days total
165 minutes total
3
Exploring different High-Speed Gearbox Types
180 minutes total
4
Manufacturing Process & Quality Assurance
195 minutes total
5
Gear Design Process - Analytical Tools
135 minutes total
6
Advanced | 2.0 days total
7
165 minutes total
8
Lubrication & Principles for Gear Systems
90 minutes total
9
Gear Rating - Understanding & Use of applicable
Standards
180 minutes total
10
Optimizing drive Train by proper Gearbox Selection
180 minutes total