RENK multi-functional test facility
Testing your drive is our strength
RENK multi-functional test facility
– Condition Monitoring for increased availability
RENK multi-functional test facility for drive systems
and components: One of the most modern and
efficient of its kind in Europe
In the spring of 2016, RENK AG put one of Europe’s biggest and
most modern test facilities for gear units and power transmission
systems into operation at its headquarters in Augsburg. Right from
the start, the shop measuring 40 x 60 m and 20 m in height, with
a broad range of multi-functional units and systems, was intended
not only for testing the special gear and power transmission sys-
tems made by RENK, but also those of other manufacturers.
Accordingly, the generously sized layout and comprehensive
equipment leave nothing to be desired. The four test beds installed
on an area of 1,250 m² have enough capacity to handle enormous
workloads and the most challenging customer demands.
Left: RENK Augsburg Plant – New hall with multi-functional test facility
Right: Test bed „B“ 37 x 15 meter
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RENK multi-functional test facility
– Condition Monitoring for increased availability
Maximum functionality – precise settings: Performance specifications of RENK’s
The test facility as a multi-functional field multi-functional test facility: Any combination
of motor and generator
The facility is built for testing a number of different parameters
under different loads. It is designed in a way that both individual
RENK multi-functional test facilities deliver top performance in
gear units and complete drive systems as well as drive components
terms of other parameters as well. They have the option of a power
can be tested.
intake of 12 MW at 10 rpm (e.g. a wind turbine gearbox in back-
to-back-operation) which results in an operating torque of
The extensive equipment allows various types of tests: from
11 million Nm in special strong baseplates.
functional tests to performance tests, measurement of process
parameters as well as highly dynamic response to the effects
With the aid of intermediate gears, test specimens can be subjected
of structure-and airborne noise. Tests for efficiency or stress
to torques of up to 500,000 Nm and maximum speeds of up to
tests are also possible.
20,000 rpm under load of up to 12 MW.
For this purpose there are five AC motors with an output of 6 MW
Perfect logistics – a generous lineup of features: each and five DC motors with outputs of 1 MW and 600 KW. Each
The dimensions of the testing facility motor can also be used as a generator, thus feeding the braking
energy back into the system. Hence, load tests of 12 MW simply
The testing area measures 1,250 m² and is subdivided into two consume the actual losses caused by the tested objects (see gene-
large and two small test facilities housed in separate rooms of the ral arrangement on page 8).
building. The two big ones measure 37 x 15 m and 37 x 13 m, the
small ones have testing areas of 15 x 6 m and 20 x 6 m. This area
is covered with slabs 30 cm thick and is anchored to a reinforced
concrete foundations up to 3 m thick for loads of up to 1,000 t.
The cranes in place can lift weights of up to 200 t.
Power supply for motors Transformer 690 V-11 KV
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Less input, maximum results: All-inclusive customer service:
Value for money! Close to the action yet safe
The test facility is adapted to the specific needs of manufac- RENK‘s multifunctional test facility is one of the few worldwide to
turers of complete drive and propulsion systems well as their allow customers to personally experience the testing in close proxi-
components such as motors, brakes, compressors, gears and, mity of drive systems and their components while safely protected
for every sector – marine, automotive or industrial. The multi- from potential hazards. To make this possible we provide observa-
functional test facility is especially suited for testing prototypes tion rooms in a gallery around the test fields. There they can follow
and pre-production assemblies. In this way manufacturers save the testing of their products in every detail, either on a monitor and
the time and costs that would be caused by setting up the test through camera installations or live from the viewing platforms.
equipment themselves.
Cost and time savings are particularly high whenever complete
marine propulsion systems need to be tested. By outsourcing
such work, contractors have the possibility of thoroughly tes-
ting the propulsion system in its entirety before the commissio-
ning stage and not having to wait for it to be installed onboard.
This translates into significant savings in time and costs
otherwise involved in onboard testing.
Another advantage: the systems are installed in the test field
complete with all the wiring and electric barring. This means
that the signals and interfaces can also be tested. Such an all-
inclusive test set-up provides a high level of validation certainty
even before commissioning.
Motor generator set 8-MW
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RENK multi-functional test facility
– Condition Monitoring for increased availability
The four pillars
The following four elements neatly sum up the testing procedures and options available on the four test beds
of the multi-functional test facility.
Oil Water
Oil as a lubricant plays a decisive role in the operation of gears The test facilities cooling system requires vast volumes of water.
and bearings. Our test systems take this into full account. In order At present, the available cooling capacity is 8 MW which, if and
to have the right amount of oil available throughout operation, when needed, can be raised to 12 MW. Added to this are three re-
each of our four test beds has an integrated hydraulic system for frigeration machines with a capacity of 600 KW each, by means of
recirculating lubrication. The oil capacity of each is 14,000 liters, which the oil temperature of the hydraulic systems can be lowered
and they can each deliver up to 4,500 liters/min during which the all year round for special tests. The complete cooling system con-
incoming oil passes through a filter with a nominal width of 10 µm. tains around 300,000 liters of water, distributed by 30 pumps along
For the purpose of heat discharge, four oil heat exchangers various circuits for cooling the test specimens, oil units, and other
(3 x 1,000 kW, 1 x 600 kW) are available per oil unit. components. The aggregate pumping capacity is 1,450 m³/h.
There are two oil filling units for test specimens which have their Pumps of cooling tower
own oil reservoir with a capacity of 24,000 liters each. In total
RENK stores about 100,000 liters of oil at its test facility.
Hydraulic system Switch gears of electrical system
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Electrics Mechanics
Another essential element of test facility is the electrical system
From torque to high-speed transmission: covering an area of
we make available to our customers. The RENK facility has
1,250 m², our test beds A, B, C, and D feature state-of-the-art
ten motors in total which also work as (bi-directional) generators.
mechanical equipment throughout to allow the testing of even
Configured adjustably, they can also operate in test combinations.
complex and bulky drive and propulsion systems, with very little
assembly and set-up time required and equally uncomplicated
The five 6-MW AC motors run at maximum speeds of up to
dismantling of the system elements. Crane capacities of 200 t make
2,400 rpm and develop a torque of 38,000 Nm each, while the
sure that assembly/dismantling work can be carried out quickly
five 1-MW DC motors run at 2,100 rpm and develop a torque of
from start to finish.
just under 12,000 Nm. In each case, two motors can be connect
ed in series. This way two 6-MW AC motors can be combined
into a 12-MW power package with two additional motors acting
as brake generators. This means that high-load test cycles are
possible without extensive set-up preparations.
All our motors are adapted to the high requirements placed on
the test specimens in terms of air- and structure-borne sound
emissions. Therefore the five AC motors each feature additional
stiffening elements and special insulation. They also have a
connecting flange at either end as well as low-noise water coolers
underneath.
With the aid of adapting transformers, various levels of voltage
ranging from 690 V (4 MVA) to 11 kV (8 MVA) can be provided for
the test beds. These are used, for example, during the testing of
complete propulsion systems. With the aid of a motor-generator
set, these voltage levels can also be used with frequencies
varying between 5 and 80 Hz, for example, when testing motors.
Thanks to the perfect sinus created, both motors for frequency-
converter- and DOL-operation can be tested at various voltages,
speeds and power levels.
Generators can also be tested. They are synchronized to the
powersystem through a synchronizing unit and can be tested for
up to 10 MW.
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RENK multi-functional test facility
– Condition Monitoring for increased availability
General possible arrangement
of a 12-MW testrun
12-MW input motor
12-MW motor break
Concept of the power flow
of a 12-MW test set-up
Power input to compensate
power loss
Load test of a high-speed gearbox at 12 MW. Two AC-Motors are used for the input, two AC Motors are
used as Motor-Break (Generator). Only the power loss (~500 KW) is needed from the mains to perform
this 12 MW test run.
1 x 10-MW synchronous generator for testing
2 x 6-MW input motor
Concept of a 10-MW load
generator synchronized with
the power supply system.
Power input to compensate
power loss
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General technical data
Dimensions
Area 1 x 37 m x 13 m
1 x 37 m x 15 m
1 x 15 m x 6 m
1 x 20 m x 6 m
Cranes up to 200 t
Oil supply
Volume 4 x 14,000 liters oil circulation units
2 x 24,000 liters oil filling units
Filtration 10 µm
Cooling capacity 3,600 KW each
Cooling plant
Power 8,000 KW (cooling tower)
3 x 600 KW (refrigerator) Intermediate gear; ratio = 4.037/6.776; 12 MW; 500,000 Nm
Motors
Power 5 x 6,000 KW
(2 x 12,000 KW power package)
4 x 1,000 KW
1 x 600 KW
Torque 5 x 38,000 Nm
4 x 12,000 Nm
1 x 3,000 Nm
Speed 5 x 2,400 rpm
2 x 2,100 rpm
2 x 1,800 rpm
1 x 2,000 rpm
Energy
Energy levels 690 V, 4,000 KW, (5 - 80 Hz)
3.3 kV, 8,000 KW, (5 - 80 Hz)
4 kV, 8,000 KW, (5 - 80 Hz)
AC-Motor; 6 MW; 2,400 rpm; 38,000 Nm
6 kV, 8,000 KW, (5 - 80 Hz)
10 kV, 8,000 KW, (5 - 80 Hz)
11 kV, 8,000 KW, (5 - 80 Hz)
Synchronisation unit 690 V, 4,000 KW, (5 - 80 Hz)
(on frequency variable 3.3 kV, 8,000 KW, (5 - 80 Hz)
mains) 4 kV, 8,000 KW, (5 - 80 Hz)
6 kV, 8,000 KW, (5 - 80 Hz)
10 kV, 8,000 KW, (5 - 80 Hz)
11 kV, 8,000 KW, (5 - 80 Hz)
Intermediate gears
Max. Power 12,000 KW
Max. Speed 20,000 rpm at 12,000 KW
Gear ratio 1– 8.5 per gear
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RENK multi-functional test facility
– Condition Monitoring for increased availability
Measurement
RENK offers a multitude of measuring possibilities for process Accoustic measurements
parameters and accoustic measurements as well as special
equipments for special customer-requests. With our well-equipped measurement department RENK measures,
records and analyzes many high-dynamic parameters such as
airborne-sound, structure borne-sound. These measurements
Process parameters can be performed according to all international standards like
ISO or MIL.
RENK is able to measure process parameters with its brand
new RENK Dynamic Data System (RDDS), developed Airborne sound is measured either as sound pressure or as sound
by our subsidiary RENK Test System (RTS). With our RDDS-system intensity. To perform high-precision, first class measurements,
it is possible to measure parameters like pressure, temperature, high quality equipment from a well-known manufacturer is used.
speed, conditions with an sampling rate up to 1000 Hz. Each
system has a capacity up to 150 channels. Structure-borne sound is measured with up to 50 channels,
each with a measuring range of 50 kHz.
For special purposes modal analyzes, ODS (Operating deflection
shape), shaker-analyzes or even laser vibrometers are used.
Dynamic deformation measured by laser vibrometer
Distribution measured by infrared camera
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Customer-Service „on-site“
Based on RENK’s vast experience with complex gear box systems A final inspection report from RENK of onboard measurements
as integral part of a propulsion plant, RENK is able to undertake is a useful decision support for the operator of the vessel to ensure
worldwide on site measurements in order to give the operator a a most efficient and economic maintenance schedule.
detailed and comprehensive overview of the current gear system
condition. RENK specialists use the latest state of the art test and
measurement equipment on board the vessel.
High dynamic vibration measurements
Vibration pickup
Level One - Airborne sounds measuring instruments
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RENK GmbH
Augsburg Plant
Goegginger Str. 73
86159 Augsburg
Germany
Phone: +49 821 57 00-0
Fax: +49 821 57 00-460
Email: [email protected]
www.renk-group.com
Edition: 04/2016
