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News

The Customer Magazine of Voith Turbo

Everyday Technology P.06 | At 500 Kilometers per Hour from Beijing to Shanghai P. 34 The world's most powerful mining coupling P. 38 | Drive for installation vessels P. 46

1 / 2011

EDITORIAL

Peter Edelmann, Board Member of Voith GmbH, Chairman of the Board of Voith Turbo

Dear Customers, Dear Readers,


Technological heroes cross our paths on countless occasions every day even if we do not always see them. These heroes are the result of technological developments that guarantee progress and ensure our future. Technological development has always been part of our evolution combined with a clear mission: it must be beneficial to mankind. With innovative technologies, Voith ensures the reliability of technical systems all around the globe. This includes the development of new technologies and also the consistent further improvement of existing methods and systems for road, rail and industrial applications, as well as for ship propulsion systems. In this issue we are introducing a new feature presenting technologies that are used in a wide variety of applications world wide. We are starting with the SteamTrac. A system that utilizes waste heat and makes it available as drive power. It allows a reduction in fuel consumption and CO2 emissions in rail vehicles, ships, power stations and trucks. Future-oriented mobility policies are a central theme at the 59th UITP World Congress, which is held in Dubai in April. Dubai has plans for ambitious transport projects with the defined goal Smooth and Safe Transport for All. Voith Turbo recognized the market potential of the emirate in the early nineties and is now successfully represented there with all its business divisions. Voith is particularly involved in the expansion of public transport systems from metros and new railway lines to the modernization of bus networks. In our Marine section you can read about a true supply giant, a floating 600-bed hotel. With a capacity like this it is possible to accomodate entire platform crews. This platform supply vessel is driven by Voith Schneider Propellers. On our Industry pages we introduce a new fluid coupling. More powerful than ever before, this mining coupling makes coal extraction even more efficient it is about to enter service at one of the leading mining companies in Chinas.

As always, I hope that you will enjoy this issue of News!

Yours sincerely, Peter Edelmann

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CONTENTS

The Century of Resource Efficiency Prof. Dr. Rolf Kreibich on the challenges presented by future transport technologies.

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First of 130 Gravitas for DB German Railways Powerful shunting loco with soot particle filter enters service at Europes largest shunting yard.

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In Focus Everyday Technology

Technology
SteamTrac Applications in All Combustion Engines Waste heat is the key toward higher outputs and lower consumption

Rail
Drivers Look Forward to Their New Locomotive First of 130 Gravita 10 BB at DB German Railways Order for Regio-Shuttle Stadler continues to rely on DIWA transmission Everyday Heroes At the same time in twelve different places all around the globe News from the Voith Group The 21st Century Must Be an Era of Resource Efficiency Interview with Prof. Dr. Rolf Kreibich Voith Is Solidly Established in Dubai Participating in the expansion of the traffic system Acting Fast and Competently in the Region Huub Hendrickx about Voith Trubo in Middle East

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Megacity Between Mecca and Medina Monorail for connecting the districts of King Abdullah Economic City in Saudi Arabia At 500 Kilometers per Hour from Beijing to Shanghai Test train for the fifth generation of Chinese high-speed trains

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CONTENTS

Retarder Development for Chinese Trucks First haulage operator in China relies on hydrodynamic Voith Retarder for safety and comfort.

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Hirth Couplings for Connecting and Positioning A frequently unnoticed machine element for transmitting high torques.

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Road
Retarders for Chinese Trucks First haulage operator with hydrodynamic retarder

Voith Helps
Aid for Orphans and Flood Victims Social Commitment of Voith Turbo in India

Industry
New Fluid Couplings for Armored-Face Conveyors Mining output increased by more than half Strong Teeth for Connecting and Positioning Hirth Couplings a very special machine element

Regulars
38 40
Editorial Personalia Exhibitions and Events Imprint Multimedia Contents Via QR-Code Two articles in this issue provide multimedia contents via QR-Codes. This is how it works: 1. Download a free QR-Reader-App onto your smartphone. 2. Scan the QR-Code in the magazine with your smartphone camera. 3. The smartphone opens the link to the multimedia contents.
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Marine
Floating 600-Bed Hotel Fides latest addition to Edda platform supply vessel Platform Suppliers for the Gulf of Mexico Edison Chouest relies on Voith Water Tractor (VWT) with Voith Roll Stabilization New Installation Vessel With Voith Drive More wind energy from Nordic waters

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At the Same Time in 12 Different Places all Around the Globe

Everyday Heroes
Running water, energy supply or reliable public transport everyday services that are taken for granted by millions of people. With innovative technologies, Voith ensures the reliability of technical systems that have become a convenience in the daily life of many people. This is what simultaneously happens when its 13:00 hours in Germany.

The crew of the citys fire department patrols the harbour of Los Angeles on the L. A. Fireboat. Driven by a Voith Schneider Propeller and fitted with extremely efficient fire pumps, the boat ensures safety.

Safety in the Harbor


04:00 hours Shortly before sunrise, the sky above Los Angeles Harbor is slowly turning red. The night was quiet for the crew of the fire department, which patrols the harbor basin regularly Los Angeles on the L. A. Fireboat. Safety has top USA priority in the two harbors Los Angeles and Long Beach, the largest goods terminals at the American west coast. 16 400 people work here. With a freight handling capacity of 170 million tons (2010), the harbors hold place ten among the worlds busiest ports. The L. A. Fireboat is optimally equipped for an emergency in the harbor. There is no comparable fireboat with equally efficient fire extinguishing pumps or a similar degree of maneuverability in a confined space when disaster strikes. Fitted with ten water canons, the L. A. Fireboat is capable of directing 10 300 cubic meters of foam-water mixture onto the source of the fire and maneuver flexibly in the harbor basin. This maneuverability is provided by the Voith Schneider Propeller. It also allows using the main motors of the boat as drives for the water pumps. With this unique marine drive, thrust can be generated in all directions and at any magnitude smoothly, fast and with high precision.

1/2011 | Voith Turbo | News

Better Quality of Life for Commuters


07:00 hours The early morning rush hour chaos in the Columbian capital Bogot is about to begin. 5.5 million people commute from the suburbs to their workplaces in the city. Most of them travel Bogot on one of the 25 000 buses or 50 000 Columbia taxis. Every day, South Americas fastest growing metropolis experiences the same scenario. An exception is the traffic concept TransMilenio. Since 2000 the BRT (Bus Rapid Transit) system brings some order to the chaos that is otherwise typical for Latin American metropolises. As a result, the quality of life of the commuters is significantly improved. Since the introduction of the system, 1.4 million people use one of the 1 100 articulated buses of the TransMilenio lines every day. The BRT system excels by very short intervals between buses and high transport capacities, flexibility and low infrastructure costs for the bus network. A special feature is the dedicated and, above all, completely separate bus lane, allowing the buses to drive through the traffic without any obstacles. As a result, the daily commute for the passengers is reduced by more than 30 percent. No wonder that Bogot has become the worldwide role model for BRT systems. Over 80 percent of the vehicles are fitted with Voith DIWA transmissions. In conditions such as these, the DIWA automatic transmission, which was developed specifically for city buses, offers genuine fuel savings for operators and higher comfort for drivers and passengers. The Voith Retarder that is integrated in the DIWA.5 provides a plus in safety. This wear-free continuous brake keeps the temperature of the service brake low, making it fully functionable in an emergency. The retarder is suitable as a continuous braking system, be it on long and demanding serpentine routes, holiday and long-distance journeys or in urban stop and go traffic.

In Bogot alone, 5.5 million people commute day after day to their workplaces on the articulated buses of the TransMilenio line.

1/2011 | Voith Turbo | News

Photo: Shreya Gadepalli, ITDP

IN FOCUS EVERYDAY TECHNOLOGY

The mine Quebrada Blanca is situated on a stony high plateau in the Chilean Andes.

Latin Americas largest metropolis has a well-developed metro system.

Nothing Works Without Copper


08:00 hours The loud crash quickly fades away in the desert. What remains are meter-high clouds of dust and falling rocks. An everyday occurrence for the workers in the Quebrada Iquique Blanca copper mine. The rocks in the Chile area contain large amounts of copper, which is being extracted in a fairly complex process. Our everyday life would be unthinkable without the soft and pliable heavy metal. It would be difficult to find a cell phone or other high-tech electronics without copper components. The material is used for cables, tubes, electronic devices or cooling systems. Copper tubes are heat, cold and pressure-resistant. It would be impossible to build electric motors without copper. The work in copper mines, such as the one in Chile, is there-fore all the more important. Every hour, 1 300 tons of rock are passing through the mining and production process. Conveyor belts measuring up to 1.6 kilometers in length and fitted with Voith fluid couplings ensure the trouble-free transport of the copper ore. The Voith couplings absorb jolts and guide the conveyor smoothly from start-up to normal operation.

Metro Trains Every 100 Seconds


09:00 hours Vast, teeming crowds underground, the picture is always the same: day after day, three million people use the metro in the Brazilian So Paulo metropolis So Paulo. The infrastructure and the network are well develBrazil oped, making it possible for most of the trains to run at 100-second intervals. After Paris and Moscow, the So Paulo metro is therefore one of the worlds leading underground systems. The network of South Americas largest metro spans nearly 70 kilometers, and the passengers rely on safe transfers to one of the over 60 underground stations. In order to make traveling more comfortable for the passengers, Metro So Paulo has been modernized in 2010 with semi-permanent and automatic couplers from Voith Turbo Scharfenberg. The couplers improve the safety and offer impact protection. Voith Turbo has developed a completely new Scharfenberg coupler with energy absorption elements. The new couplers, designed for an impact of 800 kilonewton (approx. 82 tons), are gashydraulic dampers and increase the passive safety of the passengers.

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IN FOCUS EVERYDAY TECHNOLOGY

Living on an Oil Platform


12:00 hours Supply vessels such as the Edda Fram sail regularly from Aberdeen Port, in order to deliver provisions and new working materials to platform Aberdeen crews. The trip to one of the altogether 16 Brent platforms across the Shell UK oilfields in the North Sea takes about 20 hours. The men on the Brent Alpha north of the Shetland Isles do not have an easy job. Every day they ensure that the valuable raw materials oil and gas are safely extracted and transported to the large refineries via pipelines. It is estimated that, until 2020, the daily oil production in the North Sea will amount to two million barrels. Life on one of the oil platforms, which measure approximately 8 000 square meters, is marked by long shifts and rough environmental conditions. Platform supply vessels set off whenever something has to be delivered to the oil platforms, however rough the weather. In a heavy storm, the waves can easily be ten meters high. In order to cope with such conditions, the ships are fitted

Platform supply vessels take provisions and working materials to the oil platforms outside Aberdeen.

with a special propulsion system the Voith Schneider Propeller. It is used in vessels that require a high degree of maneuverability and ensures dynamic positioning against wind, strong currents and rough seas.

Water Supply in the Sahara


13:00 hours This is the time when numerous taps are turned on all around the globe. And as always, the pipes deliver fresh water to millions of households. In Algeria, one of the most arid Salah countries in the Mediterranean, this Algeria does not happen so automatically. 80 percent of the state territory in the Sahara is extremely dry, with only 16 days of rain per year. In order to ensure regular water supplies to the population, desalinated and processed water has to be pumped to those regions, where drinking water is otherwise not available. One of the most important supply lines is the 740-kilometer water pipeline from In Salah to Tamanrasset. Every hour, millions of liters of water flow through the two lines with a diameter of 800 millimeters. The six pumping stations need 18 pump units plus motors. Voith Turbo delivered the gear technology for all pump units. The Voith helical gears for
In some regions in Algeria, where drinking water is not available, specially processed desalinated water has to be pumped to the population.

transmitting high outputs have been designed and configured specifically for the requirements of this project in Algeria.

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IN FOCUS EVERYDAY TECHNOLOGY

With 350 km/h Through Spain


13:00 hours The signal shows green. The high-speed train Velaro E of the Spanish state railway company RENFE slowly rolls out of Madrids main station. When fully booked, it Madrid can accommodate 405 passengers Spain in three classes. And the train is often fully booked: since entering service in 2008, a total of 2.3 million passengers utilized the high-speed route between Madrid and Barcelona. This popularity is mainly due to the high comfort and the time savings offered by the train with a top speed of 350 km/h, the Velaro shortens the journey time by more than two and a half hours. Passengers therefore only need two hours and 38 minutes for the 621-kilometer trip. An essential contribution to this high-speed performance is made by a specially developed final drive from Voith Turbo. Every train features 16 drives that are installed directly beneath the passenger compartments. The final drives were designed to ensure extremely low unit weights (only 311 kilogram) and low nose emissions. The Velaro is a platform and can therefore be modified to the special requirements of customers in various countries. Voith final drives and Scharfenberg couplers can thus also be found in Chinese high-speed trains (Velaro CN), as well as in the German ICE. They make rail traffic reliable and allow fast connections between large cities.

The fascination of high-speed: in a few minutes, the Velaro will depart from Madrid station for Barcelona.

IN FOCUS EVERYDAY TECHNOLOGY

Commuting by ferry more and more people use this option of getting from one side of the Bosporus to the other.

Every year, 79 million tons of semi-finished and finished products are transported by rail.

Clothes Delivered by Rail Cargo


13:00 hours When the new season starts, fashion designers have to make sure that their new collections get to the shops as quickly as possible. Some of these deliveries are Magdeburg carried out by rail, for example from Germany Magdeburg. Several times per year, tons of leather goods, textiles and clothes are loaded into freight cars that are pulled by a powerful locomotive. With 79 million tons, semi-finished and finished products occupy the largest part of the freight transported by rail (in total 312 million tons). The Gravita locomotive, which was approved in June 2010, also performs this kind of service. The Gravita locomotive family from Voith has been developed mainly for regional distribution traffic and local shunting duties. With a weight of 80 tons, an output of 1 360 HP and a maximum speed of 100 kilometers per hour, the Gravita is suitable for both mainline and shunting service.

By Ferry from Europe to Asia


14:00 hours 15 minutes ago, the ferry MIF SUHULET left the European terminal Serkeci. After successfully crossing the Bosporus, it will soon land in Harem on the Asian side. Istanbul A short but very important crossing Turkey for people who want to get from one to the other side of the Turkish metropolis Istanbul. Commuter traffic on the sea strait is continuously increasing. This is why the municipal ferry operator in Istanbul decided four years ago to put four double-ended ferries in service. With the new ferries, 10 000 vehicles can be transported. The Bosporus is notorious for dangerous currents, rapidly changing winds and huge amounts of traffic caused by tankers and container ships. This is why the ferry operator decided in favor of ferries that are not only highly reliable, but also allow safe berthing and casting off. In the four double-ended ferries, this is ensured by a total of eight Voith Schneider Propellers.

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IN FOCUS EVERYDAY TECHNOLOGY

Transporting Natural Gas Into Peoples Homes


15:00 hours The water for the afternoon tea is boiling in the kettle. The kettle stands on the bluish flame of a gas range. It is taken for granted that natural gas is available 24 hours a day for Moscow lighting a flame. It is both a habit and Russia an expectation. But the path of the raw material from the source to the consumer somewhere in Russia can be long. It is often located in an area where not a single soul is to be found for example in north-west Siberia, beyond the Arctic circle, buried underneath a vast snow desert or deep down on the seabed. The main pipes of the extensive Russian pipeline network cover over 185 000 kilometers. In order to make sure that the gas arrives at the end of the pipeline, compressor stations have to be installed at regular intervals. Without them, the gas, when transported over long distances, would lose pressure due to friction caused by the pipeline walls. At the stations, the gas is compressed, and then sent on to the next pipeline section. Compressor stations such as these operate with a Voith Vorecon. The variable-speed planetary gear combines hydrodynamic control components with a superimposed gear.

Eco-Friendly Monorail
17:30 hours Rush hour in Mumbai, Indias financial center. At this time of day, commuters are often stuck in traffic, and the exhaust and noise pollution in the city with its nearly 14 million inhabitants Mumbai is correspondingly severe. As the popuIndia lation is set to grow further over the next few years, the city has launched a new kind of urban transport: the monorail. With the monorail, which entered service only recently, 300 000 passengers can be moved every day. All destinations in the metropolis Mumbai can be reached within one hour. With the electric monorail system, India also clearly opts in favor of eco-friendly solutions: every day, monorails save 25 percent energy and emit 2 000 tons less CO2. For the first 15 trains on the route that covers 20 kilometers so far, Voith Turbo Scharfenberg has delivered 30 front end modules. The trains of this first route section connect the south of Mumbai with the eastern suburbs (Jacob Circle Wadala Cembur). 18 Stops will be built along this line segment. The trains run at six to nine-minute intervals. A four-car train can move up to 600 passengers per trip.

The main pipes of the Russian pipeline network are 185 000 kilometers long enough to circle the earth 4.5 times.

The electric monorail in Mumbai entered service in 2011.

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The electricity for chinese metropolises such as Shanghai is increasingly generated from renewable sources. Wind power stations like the one shown in the picture are fitted with the Voith WinDrive.

More Electricity From Wind Energy


20:00 hours In China, the electricity consumption in private households begins to rise dramatically. The power to cover this demand is increasingly generated by renewable sources for Shanghai example wind or hydro power. The China highest percentage of electricity is still won by coal-fired power stations, but the share of renewable energies is growing. More and more wind parks are emerging, especially in the windy northern and western regions of the country. Jiuquan in the Gansu Province, north of Beijing and a threehour flight away. By the middle of 2011, it will be home to pilot wind power stations fitted with the Voith WinDrive as core component in the driveline. The WinDrive stands out for excellent grid feeding quality. Higher availability combined with reduced maintenance requirements result in lower power generation costs. Due to earlier capacity problems, the Chinese government now invests in the development of its power grids excellent preconditions for further growth of Chinas booming wind and hydro power industry. Alongside other projects, Voith Hydro also participates in the Three Gorges Dam.

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The Sunlander connects the moderate south of the Australian east coast with the tropical north.

Train Ride through Several Climate Zones


22:00 hours Shortly before sundown, a train sets off in Australia offering fantastic views of a wide variety of sceneries. The Sunlander runs from Brisbane to Cairns, alongside pineapple plantations Cairns Australia and sugar cane fields along the east coast, through gold mining towns, unspoilt nature reserves and primeval rain forests. This route makes particularly high demands on the train technology. The Sunlander, complete with sleeping coaches and restaurant cars, must technically comply with the moderate climate in the south, as well as the tropical temperatures in the north. The Walkers multiple units master the 1 681-kilometer route with Voith technology. Turbo transmissions, cooling systems, axle drives and cardan shafts have been developed specifically for this train. Since the new trains were launched, the travel time could be reduced from 31 to 27 hours.

Cairns Townsville Mackay Proserpine Rockhampton Hervey Bay Brisbane

AUSTRALIA

Gladstone

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IN FOCUS EVERYDAY TECHNOLOGY | NEWS FROM THE VOITH GROUP

Voith Hydro

Voith Paper

Voith Industrial Services

Europes Green Battery


The energy requirements of a society can fluctuate quite strongly. There can be periods of peak demand, especially during live TV broadcasts of huge, popular sports events. Pumped storage power plants are the ideal back-up to ensure that the grid does not collapse during such peak times. These plants recognize high-demand periods and feed large volumes of energy into the grid within seconds. This is made possible by reservoirs that are able to store electricity like huge batteries. During load peaks, the water from the upper reservoir is directed into a lower reservoir and drives turbines and generators. If there is an energy surplus in the grid, the water is pumped back into the upper reservoir. Turbines for such power stations, which can be found all around the globe, often originate from Voith Hydro. The most modern plants in the world are Goldisthal (Thuringia, Germany) and Kopswerk II (Austria). At the moment, Voith Hydro is producing a machine set for Rodundwerk II (Austria), which is to re-enter service at the end of 2011 with an output of 295 megawatt.

Blowing Your Nose Gently Thanks to Voith Tissue Machines


Tear-resistant, highly absorbent and ultra-soft this is what modern hygienic papers should be. In 2008, 27.8 million tons of tissue paper were used worldwide. Paper tissues, toilet paper or kitchen rolls these products can be found in virtually every household; they are part of our daily life. Voith Paper develops and builds paper making equipment including machines for tissue paper. One aspect is always in focus: using fewer raw materials and less energy for the production of such papers. The key is the ATMOS technology. It has been developed in the Tissue Process Technology Center at Voith Paper So Paulo. ATMOS allows the production of premium tissue paper at 40 percent lower investment cost, 60 percent less energy, fewer fibers and with up to 100 percent recycled fibers.

Voith Ensures Energy Supplies


In many regions around the world, energy power generation by wind power is an everyday appearance. Relevant prognoses claim that by 2020, there will be wind power plants with an output of 1 900 000 megawatt all over the world. Last year, the output was still 203 500 megawatt. FKi Engineering Ltd., UK, has signed a comprehensive service contract with Voith Industrial Services for a wind park with 46 MW in Vienna. In this way, the Londonbased operator is making sure that the plant is always available. The maintenance agreement comprises the immediate elimination of failures, as well as the remote monitoring of the power station. The performance of the wind park is audited in weekly and monthly reports. Two service teams are permanently based in the wind park. Already in the first few months, the availability of the park could be increased from 85 to 98 percent.

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IN FOCUS EVERYDAY TECHNOLOGY

Prof. Dr. Rolf Kreibich of the IZT Institute for Futures Studies and Technology Assessment in Berlin

The 21st Century Must Be an Era of Resource Efficiency


Technical development is part of our evolution. All over the world, scientists are working on implementing their knowledge into new technologies. The question is: which technologies are beneficial to humankind in the sense of sustainable technologies? Prof. Rolf Kreibich explains, why the challenge of new technologies lies in energy and resource efficiency.
Prof. Kreibich, do you expect to see completely new technologies, or rather an improvement of existing systems? I can see both. When it comes to further developments I anticipate enormous rationalization measures regarding working processes and even more so in terms of resource utilization. Just look at our daily shopping in the supermarket. The goods are displayed on shelves, put in a shopping trolley that runs through a reading sensor, which displays the total bill. Cashiers are no longer required. In medicine, things are even more interesting through the use of chip sensors. These sensors can access organs far more efficiently, diagnoses can be made much quicker and with higher precision, and medication can be determined more accurately. The result is fully individualized medicine. And there will also be new and individual technologies for households and mobility. A field in which we urgently need progress is energy storage technology. There are now new developments and not enough research on how to store energy and heat effectively and affordably. After more than 100 years, pumped storage power

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IN FOCUS EVERYDAY TECHNOLOGY

plants are still regarded as the best storage technology for electricity. And where can you see new areas for technical development? We will see new developments in gene technology or in bionics. In bionics, it is a matter of applying systems found in nature to the world of engineering. The goal is energy and material efficiency. This is a vast research field, which we have approached too timidly for too long. At least there are some new approaches, for example regarding ship contours that increasingly emulate the shape of fish. Another important area for innovation are modern, ecological and solar construction technologies. I am thinking for example of a better passive utilization of solar energy. Solar-thermal systems or insulating materials made from biomass with only one tenth of the thickness of conventional polystyrene panels. They offer the same insulating properties, but are far more eco-friendly. In your studies, you are asking for increased efforts toward more sustainable traffic and transport technologies. Give us a few examples. Regarding public transport, I think that high-speed trains are the way of the future. They are a genuine alternative to planes on short and mid-range routes. Our next efforts should concentrate on making these trains even more energy efficient and using even fewer raw materials for their construction and this also applies to the interior fittings.

Personal Details

Prof. Dr. phil., Dipl.-Phys. Rolf Kreibich is the Director and Executive Vice President of the Institute for Future and Technology Assessment in Berlin. Kreibich studies physics and mathematics, followed by social and economic sciences. The prize winner of the B. A. U. M. Environmental Award (German Environmental Management Association) is a member of the World Future Council. His scientific output covers about 400 publications; he writes about education, science and technology policies, as well as on futurology and sustainable development.

More drastic changes are required in the field of freight transport. There should be a noticeable shift to transport by rail and water. There have been predictions that until 2025 road transport in Europe will grow by another 60 65 percent. Sooner or later the system will collapse. Countries such as China or Brazil, which still have an opportunity to move more goods by water or by rail, should jump at the chance. You also count airships among ecofriendly transport carriers but they run on well-known technologies which does not automatically make them bad. For me, lighter than air technologies with balloons, drones or airships are quite promising. Today, thousands of kilometers

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IN FOCUS EVERYDAY TECHNOLOGY

Will our everyday life become even more high-tech? I am convinced it will. We cant turn the wheels back. It is, however, important to keep an eye on these development and always assess and evaluate the consequences of this technical progress: which technologies are really useful to mankind? I am thinking of sustainable developments and an improvement of living standards. We must focus more on cycles, handle resources more thoughtfully and efficiently and understand technology as a useful extension of our possibilities. It is of course clear that there will always be people who say I dont have to use every new technology. To which degree a technical withdrawal is possible in our modern society, remains to be seen. People who do not want to receive e-mails and dont use the Internet, are more or less left behind and isolated. At the same time we should always accept lifestyles, which consciously renounce one or the other technical application. It is hardly possible to talk about everyday technology without looking at future mobility. What do you expect in this area? We need to rethink as far as individual traffic is concerned. 70 percent of all commuters do not really have to use their car in order to get to work. They would normally get there equally fast by using other means of transport. In the car sector, a lot could be changed today, but the industry is not willing to go ahead. In cooperation with Greenpeace, our institute developed a 2.8-liter car as

Airships are eco-friendly means of transport, helping to reduce fuel consumption and CO2 emissions.

of gas and oil pipelines are monitored by helicopters. This is cost and energy intensive and causes enormous noise emissions. Balloons, remote-

would be able to come to the rescue. In tourism, sightseeing flights across cities and scenic areas could also become more eco-compatible

Technology is the useful extension of our possibilities.


controlled and fitted with cameras, can watch such networks eco-friendly and nearly without any noise. Or think of rescue operations during natural disasters, when people flee onto their roofs. Helicopters cannot land there or might even blow people into the floods. But airships with airships, saving on aviation fuel and reducing noise emissions. Our long-term goal should be to use airships also for freight transports. Several countries, among them the USA and Canada, are already working on this concept. Not participating in this idea means missing a great opportunity.

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early as 1996 the SMILE. It was small, light, intelligent, used little energy and was perfectly suitable for four people. This is the way forward to a combination of individual and public mobility. This also applies to car sharing. In Germany, there are currently 560 cars per 1 000 inhabitants, in the USA this figure amounts to 780 cars, with California holding a record of 1 140 cars. In China, we have a mere 21 cars per 1 000 people, in India 11 and in Pakistan 7. Our earth could simple not cope with a catch-up race by these countries on the basis of our current automotive technologies. This is why we have to rethink consistently and go for sustainable mobility and traffic technologies. Could it be generally said that technology has made the world a better place? Technology has certainly stirred up a lot and shaped todays industrial societies. Yet people primarily expect that technologies improve their quality of life. To me, the most farreaching development is probably the generation of electricity and its universal utilization. Other milestones worthy of this name are the development of omnipresent water supplies or raw material extraction. In general, it can be said: technology has had a dramatic impact on mankind. Over the last 100 years, our life expectancy has increased by 38 years. Thanks to modern traffic systems, mobility has been improved by a factor of nearly 100. People can travel wherever they want. Today, a single employee generates the same production value as 45 people 100 years ago.

Your prognosis for the 21st century? The 20th century was the age of labor efficiency, the 21st century must become the era of resource efficiency, if we want to stay ahead of the game. This also includes people who use far too much heat, electricity and raw materials in

for our quality of life. And industrial companies have to learn that it is indeed possible to make economic and simultaneously ecological and social profits, i. e. go for sustainable production and marketing. Environmental requirements have to be incorporated into our economy. We have a wealth of knowledge on how to handle our life and our busi-

We must consistently pursue sustainable mobility and transport technologies.


their private households. Our efforts should aim at utilizing technical possibilities, particularly in the field of resource protection. Then technology will be even more beneficial ness in an ecological and socially compatible manner, which would result in genuine sustainability. But sadly, we rarely put this knowledge into practice.

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Apart from many new buildings, Dubai is also getting a comprehensive public transport system, including a metro.

Voith Is Solidly Established in Dubai

Participating in the Expansion of the Traffic System


Dubai continues to be the boomtown at the Persian Gulf. Even after the economic crisis, there are numerous construction projects, the infrastructure is being expanded and the public transport network is constantly being developed further. Voith Turbo recognized the immense market potential of the emirate already in the early nineties and is meanwhile successfully established there with all Group Divisions. Huub Hendrickx, Executive Vice President of Voith Turbo in Middle East, reckons that the best opportunities lie in the market for drive components for buses and rail vehicles.
Anybody who wants to do business in Dubai has to be present in the region, this is how Huub Hendrickx summarizes the situation. And he also explains why Voith no longer looks after its customers in this emirate from Cyprus as in the years before. Voith Turbo moved to the neighboring emirate Sharjah as early as 2003, and opened a subsidiary

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with workshop, sales and accounts departments in the free trade zone. At the time, the main focus was on drive components for industrial plants, especially for the oil and gas industry and also for energy generation. In this field, Voith is highly successful in Dubai, having sold 3 000 units, among them fluid couplings and Vorecons.

Expansion of the Bus Fleet


Since 2006, the citybuses rolling on Dubais roads day after day

would be unthinkable without Voith. In 2006, the booming region needed new buses for the expansion of its public transport system. Voith received an order for the delivery of DIWA transmissions for 660 vehicles of Dubais Roads & Transport Authority (RTA). This paved the way for Voith to enter the emirates market for road vehicles. At present, 1 650 new buses of RTA have Voith DIWA transmissions, a market share of 100 percent. We also aim to ensure that Voith provides the after sales service for the majority of

the vehicles, once the transmissions have been delivered, says Huub Hendrickx. Voith offers long-term maintenance and service programs, which keep the drive components in optimum condition.

Metro Through the Desert


Public transport enjoys a high profile in the Middle Eastern region. And whats more, Dubai strives to establish itself as a sustainability role model for countries such as Saudi Arabia, Kuwait, Qatar, Bahrain

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During the rush hour, metros run at 100-second-intervals.

or Oman. Urban planning projects therefore not only allow for an increasingly mobile society, but also continuously work on the further extension of rail transport. This is reflected in new trams, but most of all in Dubais metro. Two lines of the metro, which runs right across the desert, are already in service. The metro system connects the city center and offers links to important outer stations. This relieves the roads, which are already heavily congested. The service intervals are often very close: during the rush hour, the waiting time between trains is less than 100 seconds. All RTA metro vehicles are fitted with Scharfenberg couplers, which are also serviced by Voith. The climatic conditions, ranging from extreme heat, sand storms to high salinity in the air make enormous demands on the couplers. It is expected that the metro network is completed by 2012.

Voith has already delivered some 3 000 fluid couplings and Vorecons for the oil and gas industry in the Middle East.

Special Vessels with VSP from Dubai Shipyard


In the meantime, Dubai has also become an interesting market for Voith Marine. The Dubai shipyard Lamprell Energy currently builds a Windcarrier with three Voith Schneider Propellers. Windcarriers are special vessels for installing wind power stations on the high seas. These jack-up vessels can drive four columns or jacks to the bottom of the ocean. These jacks then lift the vessel and turn it into a stable operating platform in the water. Executive Vice President Huub Hendrickx plans to expand the marine business to Kuwait and Qatar in future.

Voith Turbo has been delivering DIWA transmissions for Dubais citybuses since 2006.

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IN FOCUS EVERYDAY TECHNOLOGY

Huub Hendrickx On Voith Turbo in Middle East

Acting Fast and Competently in the Region


Huub Hendrickx has been looking after Voith Turbo Middle East as Executive Vice President for the last five years. In an interview he talks about the market potential of this region, strategic considerations and the standing of Voith in Dubai.
Mr. Hendrickx, road or rail vehicles, industrial or marine applications Voith Turbo is successful with all its Business Divisions in Dubai. What is the reason? Voith has been a reliable partner for the OEMs and transport operators from day one. And we act locally: in April, we are celebrating the opening our new subsidiary in the TechnoPark in Dubai a nine million square meter industrial park in the desert. At the moment, only about ten percent of this area are covered by buildings; many investors have backed off last year because of the economic crisis. Voith Turbo was one of the few companies to put its plans into practice and start with a new building on 12 000 square meters in 2009. This has earned us a good reputation. Tell us about the Voith premises in the TechnoPark! We have workshops for DIWA and rail transmissions and a performance test stand with an output of 400 kW. It will be used for testing overhauled components before they are returned to the customers. I think it can be said without exaggeration that Voith Turbo has the most modern and bestequipped workshop in the entire region. This has already been highly acknowledged by our large customers. What are your key strategies in the Middle East? Apart from new orders and the delivery of drive components we aim for long-term maintenance contracts. We are not here for quick profits, we want to look after our customers for years to come. Voith Turbo in Dubai will be a subsidiary, covering all business areas and able to act competently and fast in the region. For this purpose, we are hiring qualified personnel, especially for service and order handling in the industrial business. In the areas road and rail we do of course provide service exchange transmissions, and we have a test stand and skilled personnel to deal with the after sales market. You keep mentioning Dubais high market potential. How does this manifest itself? The high market potential derives from the market region. With 19 million square kilometers, the Middle East is almost twice as large as Europe. The oil and gas fields of Saudi Aramco or the gas fields in Qatar offer a fantastic potential for our industrial products. Both for new plants and also for overhauls, maintenance and retrofits. Due to the permanent rise of mobility we are involved in the expansion of the public transport system. After buses, trams and metro trains in Dubai, it is now time to develop the infrastructure in the prosperous emirate Abu Dhabi. There is an enormous need for trams, metros, water taxis and buses. Voith is already represented with DIWA transmissions in 600 buses. I can also see a huge potential in the establishment of the rail network of the Gulf Cooperation Council (GCC). We are talking about an investment of 130 billion Dollar over the next 10 to 15 years. And we want and have to be part of it.

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TECHNOLOGY

In principle, SteamTracs can be installed in all diesel-driven rail vehicles.

The SteamTrac also makes sense in thermal power stations and biogas plants. The extra power generated from waste heat can amount to up to 250 kW.

SteamTrac for Applications in All Combustion Engines

Waste Heat is the Key Toward Higher Outputs and Lower Consumption
Reducing fuel consumption effectively and simultaneously achieving higher energy levels this is not a contradiction. The SteamTrac system from Voith proves it. In rail vehicles, ships, thermal power stations and soon also in trucks the end result is always a 4 to 12 percent drop in fuel consumption and CO2 emissions.
The operating principle is simple: from the waste heat of combustion engines, super-heated steam is directed into the SteamTrac via heat exchangers. The SteamTrac then generates additional mechanical energy, which is fed directly into the driveline. Since March, a SteamTrac has been operating in a rail test vehicle. The single-car diesel railcar type NE81 made by Waggon Union Berlin in 1993 has been fitted with two 250-kW diesel-hydraulic drive systems and a Voith T211r turbo transmission. According to Voith calculations, the SteamTrac, which is connected to one of the two engines, results in fuel savings of 6 to 10 percent, depending on the vehicles current driving cycle.

Barge Needs 40 000 Liters Less Diesel


What is still in a trial phase for rail vehicles, has already proven itself

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TECHNOLOGY

A CV-specific SteamTrac is being developed for road vehicles.

In a barge, the SteamTrac allows significant fuel savings.

excellently in industrial applications. In Germany and the United Kingdom, SteamTrac units have been in continuous operation in three thermal power stations for several months. The performance of the gas engines has been increased by 7 to 10 percent without requiring extra fuel or releasing additional CO2. The SteamTrac has also increased the output of a barge. The boat sails between Rotterdam and Duisburg and supplies the local furnaces with iron ore and coal. It is fitted with three diesel engines. For demonstration purposes, the SteamTrac was installed at one of them. The effect is enormous. Projected for one year, the fuel consumption per engine is reduced by 40 000 liters of diesel. At the same time, the CO2 emissions are cut down by 106 tons.

Series Currently Offers Five Expanders


In principle, SteamTrac systems can be fitted to all combustion engines. Based on the R2/800 expander for off-road applications, which is now in series production, a modular expander family is currently being designed to allow the installation of SteamTrac systems in a wide range of applications. They vary in terms of number of cylinders and capacity. For trucks and buses, Voith Turbo is currently developing a CVspecific piston expander with a capacity of 800 cubic centimeters. In a 40-ton vehicle, it will ensure fuel reductions of 6 percent and output increases of approximately 20 kW.

Piston Expander R2/800

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RAIL

First of 130 Gravitas 10 BB Enters Service at DB German Railways

Drivers Look Forward to Their New Locomotive

Eco-friendly Voith locomotive the 130 Gravitas for DB German Railways have soot particle filters.

After nine days of training, the drivers are ready to operate the Gravita.

Wow, look at all those electronics in the drivers cabin, and everything smells new. This is what you can hear these days in Maschen, when locomotive drivers enter the cabin of a Gravita for the first time. The Voith locomotive is the first of 15 Gravitas to enter service in Europes largest switching yard located just outside Hamburg. DB Schenker Rail ordered a total of 130 locomotives from Voith Turbo. Delivery is to be completed by 2013.
The seven-kilometer yard in Hamburg-Maschen is impressive. Every day, up to 150 trains are handled here, this means up to 3 500 railcars per day. 750 switches ensure that the freight cars are combined into new trainsets on a total of 112 marshalling tracks, and then leave the station for 30 different directions. As far as we are concerned, rail freight transport is almost back on the level of 2008 after the economic crisis, says Frank Erschkat, Manager of the Cargo Center in Hamburg. Definitely the perfect time for investing in modern shunting locomotives. The 130 Gravitas planned for nationwide service send the right signal.

Soot Particles Cut by 97 Percent


The powerful shunting locomotive of the series 261 is fitted with soot particle filters and regarded as eco-

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RAIL

friendly for a good reason: 97 percent of the soot particles in the exhaust gases are filtered out. Deutsche Bahn is the first German rail company to operate large numbers of diesel locomotives with particle filters. With these filters, the exhaust limits planned for 2012 can already be met today, says Frank Erschkat. The new series 261 is intended to largely replace older vehicles of the 291 and 295 series, which are used for heavy shunting service and for transfer trips to railway sidings. The four-axle bogie locomotive Gravita with its hydrodynamic drive has, indeed, been designed for both shunting and light mainline service. Measuring 14 meters in length and weighing 80 tons, it has an output of 1 000 kW.

Nine Days of Training for Gravita Drivers


Our locomotive drivers really look forward to the new vehicles, states Manfred Stobrave, Production Manager in Maschen and in charge of 450 employees. 42 drivers have been trained so far for service on the Gravita. The training takes nine days; apart from four days of theory there is also plenty of time for practical experience, followed by a driving test and a final exam. The first 3 179 kilometers have already been completed and the enthusiasm of the locomotive drivers is unabated: Every trip is a new aha-experience, not only are there two drivers cabins, there are also the new electronics, which are a lot more complex than in the old

295 locomotives we have been using for many years. Additionally, the new locomotives comply with the latest occupational safety regulations and noise protection requirements. At the same time they are

The 261 series has been designed for shunting and light mainline service.

RAIL
In Hamburg-Maschen, Europes largest shunting yard, up to 3 500 railcars are handled every day.

Order of Regio-Shuttle

Stadler Continues to Rely on DIWA Transmissions

more reliable, require less maintenance and are therefore more economical.

Shunting and Combining New Trains


The new Voith locomotive of DB German Railways will make frequent appearances in the Port of Hamburg, in order to pick up railcars, take them there or perform shunting duties. In future, a total of 15 Gravitas will be used in Maschen for shunting and combining new trainsets. For this reason, the marshalling yard is more accurately described as a train formation yard. The locomotives working here have to be able to move 30 or 40 railcars with a weight of up to 2 000 tons. The train formation principle works like this: upon entry into the station, the trains are marked with separators on the basis of a cut list. The locomotive pushes the railcars slowly across a so-called hump. Afterwards the railcars roll independently toward the intended

sorting siding, the points are set automatically by a hump control computer. The speed of the individual rolling railcars is controlled by rail brakes. This is how new trains are combined.

The Regio-Shuttle of Ostdeutsche Eisenbahn (ODEG).

Info Product: Gravita 10 BB diesel hydraulic locomotive with central drivers cabin Application: light mainline or heavy shunting service Technical features: engine output 1 000 kW, 3 000 liters tank volume, max. tractive effort 259 kN at = 0.33 and 330 kN at = 0.42. Maximum speed 100 km/h, v-constant mode of 125 km/h. When you scan the image with the camera of your cell phone, you can see a picture gallery of the BR 261. www.voithturbo.com/gravita

Stadler Pankow continues to rely on Voith DIWA transmissions for the Regio-Shuttle commuter train. About 700 of these vehicles have already been fitted with DIWA transmissions, distribution gears and underfloor cooling systems from Voith. The vehicle manufacturer has just ordered another 242 DIWARail transmissions. The Regio-Shuttles are intended for the Czech Republic and various railway operators in Germany, among them Ruhrtalbahn, Hohenzollerische Landesbahn, Hunsrckbahn, Strohgubahn and Ostdeutsche Eisenbahn, which operates routes in Mecklenburg and the Lusatia region.

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Such a monorail will connect the individual districts with the city center.

Monorail to Connect Districts of King Abdullah Economic City in Saudi Arabia

Megacity Between Mecca and Medina


The first high-rise blocks of the six city districts are already in place. And at the new university for science and technology, young people have been studying for more than a year. Since 2005, Saudi Arabia has been building a new megacity, named after the Saudi ruler: King Abdullah Economic City. With this city, Saudi Arabia wants to display its modern and cosmopolitan outlook.
On an area of 168 000 square kilometers, construction work has been going on since 2005. A surface that corresponds more or less to the size of 24 000 football fields. It is expected that two million people will be living in the new city by 2020. The New Age city is situated on the coast of the Red Sea right between Mecca and Medina. With ten container terminals stretching across a length of one kilometer, the new sea port will be among the largest harbors in the Middle East. what the planners of King Abdullah Economic City have in mind. Therefore, one third of the city area alone will be occupied by the industrial quarters of the new megacity. Among the residential areas are the Sea Resort, the Educational Zone and the Central Business District. 260 000 apartments and 56 000 houses for half

By Monorail Through the City Center


Combining business and modern life in a contemporary city this is

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Cosmopolitan and modern this is the vision of King Abdullah Economic City in Saudi Arabia.

a million people are currently under construction. Some of them have already been completed. The planners also give high priority to tourism. When finalized, King Abdullah Economic City will have over 120 hotels. Mobility in the city is ensured by a modern monorail network. The new transport system consists of a total of six four-car trains, gliding through the city districts on elegant concrete tracks. The monorail is scheduled to enter service in 2014.

Test Run This Year


A consortium of Bombardier Transportation and Saudi Oger Limited will

build the trains. They are based on the Innovia 300 platform. The front end systems including discs, inner trims, automatic couplers and semipermanent couplers, as well as energy absorption elements with override protection, will be supplied by Voith Turbo Scharfenberg. Voith also supplies the cooling system. The cooling system is integrated into two parallel circuits, which protect all important traction components against overheating. The units to be cooled are the complete vehicle driveline, consisting of inverter, auxiliary systems inverter and traction motors. The Voith cooling system is a self-sufficient unit that automatically provides exactly the required cooling output. A prototype with all components

will undergo a test ride in Canada, where the vehicles are being produced, this year.

Info Products: Front end systems, automatic couplers and semi-permanent couplers with energy absorption, energy absorption elements with override protection, cooling systems for the complete driveline with inverter, auxiliary systems inverter and traction motors. Application: Monorail King Abdullah, six monorails with four cars each Application area: King Abdullah Economic City, Saudi Arabia

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Test Train for the Fifth Generation of Chinese High-Speed Trains

At 500 Kilometers per Hour from Beijing to Shanghai

From 2012, the CRH420 high-speed train will run between the central business district of Chinas capital Beijing (picture) and the industrial metropolis Shanghai.

RAIL

This is how the CRH420 is supposed to look, the Chinese high-speed train of the fifth generation.

Seven years have passed since the CRH1 was celebrated as the first generation of Chinese high-speed trains capable of 250 km/h. With the CRH420, the fifth generation is now entering the market. A test train has already been built: the CIT400. It is expected to reach 420 km/h when in commercial use. Voith participates in the ambitious project with final drives, automatic Scharfenberg couplers, semi-permanent couplers and adapter couplers, as well as GFK front end systems.

The eight-car CIT400 for the Chinese transport ministry is close to its crucial test runs. Come June, it is expected to whiz along the rails at 500 km/h. If these trials are successful, a milestone will have been reached in the development of trains that can achieve 420 km/h in regular service in China. These super fast trains would be able to run on the 1 300 kilometer high-speed track from Beijing to Shanghai, which will be completed by 2012. Voith received the order for the delivery of final drives, automatic

Scharfenberg couplers, semi-permanent and adapter couplers and GFK front systems from the Chinese OEM Tangshan Railway Vehicle (TRC). A reason for this contract was the previous, good cooperation between the two companies, as Voith already delivers similar components to TRC and Changchun Railway Company for the type CRH3 trains: While the couplers are identical, the CIT400, when compared with the CRH3, has different contours and therefore a different front module. And whats more, Voith Turbo Scharfenberg

is currently the sole supplier for all Chinese high-speed trains of the CRH1 and CRH3 series.

Info Products: final drive SE-380, automatic Scharfenberg couplers, semipermanent couplers, adapter couplers, GFK front ends Application: 8-car test train CIT400 Application area: Chinese high-speed network

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Voith Turbo Develops Retarder Specifically for Chinese Trucks

First Trucker in China With Hydrodynamic Retarder

In future, heavy trucks have to have additional and/or continuous brakes in China.

The truck driver, Xiang Lu, drives his truck on one of the eight-lane highways through mountainous territory. His 3 000-kilometer route leads from Shanghai to Chengdu. A demanding trip with steep downward gradients, on which the vehicle service brakes quickly reach their limits and run hot. This can result in most serious accidents. In order to counteract this hazard, Xiang Lu was one of the first Chinese end customers to have his truck retrofitted with a hydrodynamic Voith Retarder. This makes him a true pioneer on Chinas highways.

The problem of hot service brakes on Chinas mountainous roads is well known. On certain sections, it is even the polices duty to cool down truck brakes with water hoses. After longer trips, brakes can reach temperatures of up to 1 000 degrees Celsius. This leads to cracks and heavy wear. The ensuing risk of

accidents, not least because some of the vehicles are notoriously overloaded, has brought about new legislation: in future, heavy trucks in China have to be equipped with a secondary or endurance brake. Xiang Lu in his 56-ton truck has not only been on the road without

any accidents, but he is also ahead of his colleagues. While a number of large Chinese manufacturers are still running prototypes of the Voith Retarder in test vehicles, the trucker in his Shaanxi truck is the first one with a hydrodynamic retarder on board. Xiang Lu, his brother and his brother in law cover

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ROAD

Retarder Market China


In 2010, the Chinese market for heavy trucks (56 tons) has increased by 60 percent compared with the previous year. In the past year, the ten largest truck OEMs sold about 1 million heavy trucks. At the same time, some 3 500 kilometers of high-speed roads are added to the network every year to connect large cities. With 1.6 million kilometers of highways and 45 000 kilometers of high-speed roads China is now the number two behind the USA.
From left: Huang Shifu, Cheng Zhongyuan, Andreas Haseloff (Voith), Benson Peng (Voith).

some 200 000 kilometers per year. The three share the vehicle and are typical owner-drivers, which make up nearly 60 percent in the Chinese trucking industry. On their tours they transport heavy loads of all kinds: building materials, steel girders or complete construction vehicles. There is no fixed route. Xiang Lu travels all over China, depending on his transport order. Chengdu is a frequent destination. The three drivers often do not see their families for weeks and, on average, only come home every three months if they happen to be on the road near home.

Higher Safety on Long Downward Gradients


Voith has developed a retarder specifically geared toward the Chinese market. Also Xiang Lus colleagues could profit from the development. The design is similar to that of the VR 115 step-up retarder family, thousands of which have been installed in MercedesBenz trucks. Through the combination of engine brake and retarder, the braking power is significantly increased, and the retarder is always fully operational on the long downward gradients of Chinas highways. Voith Retarders allow

higher average speeds and have made it possible for Xiang Lu to move his loads more safely and more economically.

Info Product: Retarder 115 CT Application: retarder for heavy trucks Technical features: higher average speed and increased safety reserves, lower operating costs, improved availability of the vehicle, cold and fully operational service brakes in emergencies

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INDUSTRY

New Fluid Couplings for Armored-Face Conveyors

Mining Output Increased by More Than Half


The figure alone is almost unthinkable: at present, Chinese mines extract about three billion tons of coal per year. This statistic from the International Energy Agency makes China the worlds largest producer of bituminous coal, followed by the USA, India and Australia. And the output continues to increase. In order to meet the countrys enormous demand, more and more coal has to be mined within shorter and shorter times. During mining the coal is transported from the seam on armored-face conveyors. For the conveyor drives, Voith Turbo has developed the worlds most powerful mining coupling with a transmission capacity of 1 600 kW the CPC 1600 (Chain Protection Coupling).
The new coupling is a further development of the 1 200 kW CPC 1200 launched by Voith only about a year ago. Since their market introduction, 20 CPC 1200 couplings have been successfully installed in various Chinese coal mines. In principle, both couplings have to fulfill the same requirements: they have to work reliably under extreme operating conditions in underground mines. Both are robust and cope with rough surroundings, for example high amounts of dust and debris from fallen coal. They are fill-controlled and use water as an eco-friendly, non-flammable operating fluid. The CPC 1600 is currently the most powerful hydrodynamic AFC coupling for OEMs. In order to achieve this increase in output, Voith has developped a fundamentally new geometry of the runner parts.

The new coupling convinced the Chinese customers during the inspection run in Crailsheim.

INDUSTRY

CPC 1600 makes coal mining even more efficient


A coupling of this output class offers clear advantages to operators: compared to a standard coupling of a similar size, the transmission output of the CPC 1600 is 60 percent higher. In comparison with the CPC 1200, the increase in performance amounts to approximately one third. As a result of this improved capacity, the ten to twelve meter high coal faces in Chinese and Australian mines can be cut to their full height. In short, the CPC makes coal extraction even more efficient, as none of the seams remain unexploited.

Transmitting 4 MW during peak periods


It goes without saying that the CPC 1600 offers the same advan-

tages as any other Voith hydrodynamic start-up coupling. It ensures that the armored-face conveyor starts reliably, even if fully loaded. At the same time, the coupling protects the drive motor against overloads. If oversized lumps of coal cause the conveyor to jolt, the fill-controlled Voith coupling slips as a result of its hydrodynamic characteristics. This slip provides effective protection for the entire driveline and especially the conveyor chain. Should the conveyor be blocked, the CPC 1600 shows its particular strength: during several start-up attempts, it can transmit a peak output of 4 MW, until the conveyor finally breaks away. This output corresponds to the power of approximately 40 mid-range cars. Miners appreciate this extra strength, because they do not have to clear the conveyor by hand. Additionally,

the coupling increases overall operating safety, because it is extremely reliably due to its wear-free power transmitting capabilities.

Chinese mining operators rely on Voith


During its inspection in front of Chinese customers, the CPC 1600 proved its function and its efficiency: a test run in Crailsheim demonstrated that the coupling meets all aspects of the required performance profile. In the middle of January, the coupling was handed over to one of the leading mining equipment suppliers in China and has since then successfully passed all tests. Chinese OEMs and mining operators have been relying on the advantages of hydrodynamic couplings in armored-face conveyors for many years. Voith is a regular supplier to Chinese AFC manufacturers and also provides round-the-clock service to its customers in China with its own country-wide sales and service network, offering installations, commissioning and maintenance of Voith couplings.

Info Product: fill-controlled CPC 1600 fluid coupling Application: armored-face conveyor Technical features: overload protection, frequent break-away of the driving machine, longer service life for the chain, water as operating medium
Armored-face conveyors are the backbone in longwall mining. They transport coal from the longwall by means of a circulating chain fitted with scrapers.

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INDUSTRY

Customers are offered comprehensive service for Hirth couplings: design consultation, calculations, production and quality assurance.

The fascination of versatility: from shafts to discs.

Hirth Couplings a Very Special Machine Component

Strong Teeth for Connecting and Accurate Positioning


Just imagine: 41 600 Formula 1 racing cars simultaneously reach their average torque of 360 Newton meters. An incredible 15 million Newton meters would be accumulated in this way. A torque volume that an otherwise fairly anonymous machine component transmits: the Hirth coupling. At the end of last year, Voith Turbo produced its largest ever turbine section, which was delivered to an American turbine manufacturer in February 2011. In this particular case, the Hirth coupling on the turbine connects discs with a diameter of over one meter.

It often leads a shadowy existence, and yet, there is hardly a connecting element that is more versatile than the Hirth coupling. Transmitting high torques with a relatively small diameter this is one of its major strengths. This is why Hirth couplings can be found in pumps, compressors and fans, as well as in milling machines, gears and turbines. Voith produces these connecting elements and also carries out all calculations and design consulta-

tions. And it was exactly this kind of know-how that was required for the latest order to an American turbine manufacturer.

Masters of transmitting high torques


Voith and the customer jointly developed the Hirth coupling, created drawings and carried out, verified and amended calculations. The engineering consultation included the

definition of tolerances, preparatory work on the turbine discs and the constructive design. The end product was a high-strength, quickrelease connection of the turbine discs. The Voith Turbo plant in Heidenheim then produced its largest ever turbine section: the diameter measures 1100 millimeters, and the part weighs 800 kilograms. The key features of the turbine component are extremely accurate centering (self-centering) with high

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INDUSTRY

concentricity and low radial run-out. Without these characteristics, damage to the turbine is almost certain. The end surfaces of both discs are finished with conical teeth. The discs are held together by screws and bolts in a form-locking, selfcentering connection. The force is evenly distributed across all teeth, allowing the connecting element to transmit extreme torques. Hirth couplings on universal joint shafts cope with even higher forces, especially in steel mills. As installation space in these rolling plants is usually scarce, the high torque capacity of the Hirth coupling offers an enormous advantage. Hirth couplings also allow modular universal shaft designs. The removal from the driveline merely requires the amount of space taken up by the tooth height. Further classic

benefits are high wear-resistance and indexing accuracy. Voith is certain that there will be numerous further applications for Hirth couplings in the future, for example in turbine construction, for crankshafts and in all cases where single forged parts have to be replaced.

accuracy is required, among other applications, in machine tool making: for rotary indexing tables and for tool carriers. Additional installations where exact positioning is essential are medical examination couches and operating tables.

Positioning with hairs breadth accuracy


Yet Hirth couplings are not only suitable as connecting elements for shafts, discs wheels and cranks. They also function as positioning elements with astounding accuracy. Deviations amount to maximally 1 to 2 arc seconds. Such precision would, for example, allow the positioning of the wooden horses on a childrens merry-go-round with a diameter of 6 m within a distance of half a hairs breadth. This degree of

Info Product: Hirth couplings Application: turbomachinery, machine tools Technical features: transmitting high torques with small dimensions, wear-free, small rotating masses compared to flange connections, high concentricity and very low radial run-out, high operating safety, easy assembly

Gerhard Fischer and Jaroslaw Klamann examine the Hirth couplings on turbine discs with a 3-D measuring machine.

MARINE

Fides the Latest Addition to Edda Platform Supply Vessel Series

Floating 600-Bed Hotel


Ships such as these have many different names: hotel ship, floating operating platform or supply giant for offshore oil fields. At the Norwegian shipping company stensj, it is a member of the platform supply vessel family. stensj operates all of these ships under the designation Edda, followed by a second name. The new giant is called Edda Fides.

The 130-meter supply vessel Edda Fides can take its crew safely to the platform, even if the sea is rough.

Fides comes from Latin and means protection, reliance or faith. Right from the beginning, the shipping company had every faith in what was technically feasible. A 130-meter long platform supply vessel has never been built before especially with this type of drive concept. As many as five Voith Schneider Propellers (VSP) are supplied with drive energy from six generators. They allow the

colossus with its crane and gangway to sail at a speed of 12 knots. High sailing speeds are important. After all, time is money in the energy supply business. The Edda Fides has onboard sleeping accommodation for 600 people. This means: when the Edda Fides docks at an oil or gas platform, it would be theoretically possible to exchange the entire crew. This makes these

ships particularly attractive. Especially because the platforms in the offshore energy market are situated further and further away from the coast.

Dynamic Positioning of the Highest Order


The Edda Fides is unique, because it allows hundreds of people to cross over to the oil platform via a

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MARINE

gangway, even if the sea is rough. The ship is fitted with Class 3 DP equipment. DP stands for dynamic positioning. There are three classifications. DP3 is the highest stage. The Edda Fides can therefore take its crew safely to the workplace, i. e., the platform, even if the weather is very bad. Yet the men also work while the ship is in transit. An open working area on deck

covers 1 100 square meters. Other workshops with a total surface of 240 square meters offer sufficient space for vital preparatory and repair work.

Info Product: 5 VSP size 32 R5 EC/265-2, each rated at 2 500 kW, dynamic positioning (DP) Application: Offshore Supply Vessel Edda Fides of stensj Reederi AS, Norway Technical features: length 130 meters, width 27 meters, maximum speed 12 knots

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MARINE

Edison Chouest Relies on Voith Water Tractor (VWT) With Voith Roll Stabilization

Platform Assist Vessel for the Gulf of Mexico


The Forte transports spare parts and people to the platforms in the Gulf of Mexico.

There are over 4 000 production sites for oil and gas in the Gulf of Mexico and along South America's shores. The discovery of the mega oil fields Tupi and Jupiter off of Brazil three years ago have turned the coasts of the USA, Mexico and Brazil into one of the most important oil regions in the world. New platforms are being built, and correspondingly sophisticated offshore support vessels are chartered. The reliability, technology, and safety of all personnel and equipment have first priority, especially after the devastating oil disaster in the Gulf of Mexico.
The M/V Forte is a very special offshore vessel. Its owner, Edison Chouest Offshore in Louisiana (USA), is one of the largest vessel operators in the Gulf of Mexico. Petrobras has chartered the Forte for services in the Gulf where it has recently commissioned a floating production ship. Petrobras is the Brazilian oil company that discovered the above mentioned oil fields in the Santos Basin off of Brazil and also conducts operations in the Gulf of Mexico. Forte has been in operation since April 2010 and was initially deployed in support of the Gulf spill. Now, the Forte directly supports Petrobras' first FPSO in the Gulf of Mexico. A key operational feature of the ship is active Voith Roll Stabilization (VRS) in combination with a direct diesel drive. The Forte is driven by two Voith Schneider Propellers and

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MARINE App for Voith Schneider Propeller

There is now an App to explain how a Voith Schneider Propeller works. Voith Turbo Schneider Propulsion has developed the iVSP (interactive Voith Schneider Propeller) in German and English languages. The new App turns smartphone users into captains, the VSP reacts immediately and visibly to any change of the rudder or the driving pitch. A kinematic or hydrodynamic viewing option illustrates the actual function of the VSP. The App allows watching a Voith Water Tractor during its maneuvers from a birds eye perspective. The iVSP App is available from the App store (category Education). You can get to the iVSP by scanning the
The name says it all: M/V Forte is a vessel capable of efficiently supporting many roles offshore.

image with the camera of your cell phone.

designed for a bollard pull of over 100 tons.

Reversing the Propeller Within Three Seconds


The Gulf of Mexico brings further performance characteristics of the ship to the fore: dynamic positioning, in order to safely maneuver and position shuttle tankers at the FPSO. The captain of the Forte can reverse the Voith Schneider Propellers electronically within three seconds. When the waves are particularly high, the captain can also engage

the VRS, installed for the first time on this type of vessel. This total package increases the operational availability of the Forte in all assigned missions. A loading crane and a Stern Roller turn the Forte into a multi-functional ship that can also handle anchors and containers. With two 1 200-cubic meter water monitors, equally powerful pumps and a spraying system, the platform assist vessel is also suitable for fire fighting operations.

Info Product: 2 VSP size 36 R6 ECR/285-2, with diesel-electric drive, each rated at 4 060 kW, plus Voith Roll Stabilization, dynamic positioning (DP2) Application: Platform Assist Vessel of Edison Chouest ship owners, Louisiana, USA Technical features: length 51.21 meters, width 15.85 meters, maximum speed 14.5 knots Application area: supplying offshore platforms in the Gulf of Mexico

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MARINE

The two vessels Sea Worker and Sea Energy during the installation of new wind power stations.

MARINE

New Installation Vessel With Voith Drive

More Wind Energy From Nordic Waters


In autumn 2012, the Danish ship owner A2SEA will put another installation vessel for wind power stations in service. The company already operates four such ships. The new Sea Installer is the largest vessel so far. It can set up offshore plants in sea depths of up to 45 meters.
The Sea Installer, A2SEA relies on a combination of Voith Schneider Propellers and a Voith Inline Thruster (VIT). The latter is located in the extremely narrow space in the bulb of the ships bow. The three VSP, the VIT, as well as a conventional transverse thruster, ensure propulsion and dynamic positioning. has a rotor diameter of 93 meters. The hub is situated at a height of 67 meters. All 21 wind turbines are connected on sea and land through more than 77 kilometers of cable. This ensures the reliable transport of electricity to households. In future, Baltic 1 will have an annual energy output of 176.4 GWh/a. In order to put up such a plant safely, heavy steel pipes, so-called monopiles that weigh 500 tons, are installed up to 25 meters deep into the seabed with the help of the installation vessels. This will also be the task of the Sea Installer although only to a depth of 20 meters, which is standard for Baltic 1. With its jack legs that can be extended to 105 meters, the Sea Installer can anchor plants in sea depths of up to 45 meters.

Info Product: 3 VSP size 36 R6 ECR/285-2, each rated at 3 800 kW, dynamic positioning (DP2), Voith Roll Stabilization (VRS), VIT with 2 300 mm inner propeller diameter; among the many special features of the VSP are extremely short reversing times Application: installation vessel for wind energy plants Sea Installer of A2SEA ship owners, Denmark Technical features: length 132 meters, width 39 meters, maximum speed over 12 knots, suitable for installations in water depths of up to 45 meters Application area: setting up wind energy plants in the North Sea and the Baltic Sea

Over 500 Wind Power Stations Are Already Installed


Since 2002 the experienced installation company has already erected over 500 wind power plants and 300 foundations in the North Sea and the Baltic Sea. Among them is also the offshore wind park Baltic 1 in the Baltic Sea, which has been under construction since 2010. When completed, the wind park will have 21 wind turbines. Each wind turbine

1/2011 | Voith Turbo | News

47

VOITH HELPS

Social Commitment of Voith Turbo in India

Aid for Orphans and Flood Victims


India has been enjoying considerable economic growth over the past few years. Yet a large part of the population still lives in poverty. Voith Turbo in India is aware of its social responsibility and supports institutions and organizations that look after orphans and flood victims and provide education for girls.
High productivity, an export-oriented industry and a booming IT business have converted India from a developing country into a huge growth market. This year, the Indian government anticipates an 8.5 percent rise of the countrys gross national product. At the same time, more than one third of the population exists below the poverty threshold. Apart from factors such as unequal income distribution, illiteracy, often very large families and a caste system, Indias striking poverty rate is also due to the enormous population growth.

A Hot Meal for Children


In 2030, India is expected to become the worlds most highly populated country with 1.53 billion inhabitants.

Voith supports several organisations in providing free teaching materials.

For Indian girls going to school is not typical.

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VOITH HELPS

The most blatant consequences of poverty are health problems such as malnourishment, unhygienic living conditions, high infant mortality rates and short life expectancies. Voith Turbo in India makes a small contribution towards improving the living standards of young people who do not benefit from the countrys economic growth. For this purpose, the management has an annual budget for social aid. This budget is distributed to trustworthy institutions

and verified institutions in Hyderabad. These institutions ensure, for example, that orphans find a home, that girls can go to school or that school children are given a hot meal as well as free teaching materials.

Improved Chances in the Labor Market


Voith Turbo in India also ensures that flood victims receive food and equips libraries in educational institutions with technical text books.

In the current business year, Voith Turbo would like to launch another project and offer training facilities for disabled youths, in order to improve their chances in the labor market. The young people will receive theoretical instruction that is necessary for becoming qualified craftsmen, such as welders, electricians, machine builders or painters.

Young people should be encouraged and supported.

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PERSONALIA

Dr. Norbert Klapper New Head of Business Division Rail


On 1 January 2011, Dr. Norbert Klapper (48) took over as Executive Vice President of the Business Division Rail of Voith Turbo. Over the last nine months, the Division was temporarily headed by the Chairman of the Board of Voith Turbo, Peter Edelmann. Dr. Klapper studied at Darmstadt Technical University and gained a doctorate at Munich Technical University in 1993. After a post at Arthur D. Little International, Dr. Klapper was appointed as a member of the Management Board of Drr AG in Stuttgart, where he was in charge of services and Final Assembly Systems. In 2005, Dr. Klapper joined Voith to work in the Group Division Voith Industrial Services to head the Division Facility Services Europe as Executive Vice President. In October 2010 he was appointed as Executive Vice President of the Division Automotive at Voith Industrial Services.

Claus Peroutka to Lead CRM of the Product Group Drive Line


Claus Peroutka is the new head of the Customer Relationship Management of the Product Group Drive Line. Until recently, this post was provisionally held by Werner Koch. As Vice President Sales, Peroutka is responsible for sales, service and after market activities in the areas retarders, VIAB and dampers. Claus Peroutka studied mechanical engineering at Munich Technical College. He began his professional career as a process engineer at IWIS Ketten in Munich, where he stayed for eight years holding various posts, finishing as Project Manager for innovation products. From 2004, he worked for Hoerbiger Antriebstechnik GmbH in a number of sales positions. Prior to joining Voith Turbo in Crailsheim, Claus Peroutka was Global Key Account Manager in the car wholesale customer segment of Hoerbiger SynchronTechnik.

Mar van Sluijs New Managing Director of Voith Turbo in Singapore


Voith Turbo in Singapore has a new Managing Director: Mar van Sluijs (45). The industrial engineer studied at Eindhoven Technical University in the Netherlands from 1989 until 1993. Afterwards he gained overseas experience at Gemco Industries and Damen Shipyard until 2006. Van Sluijs held various positions in Nigeria, Vietnam and the Netherlands. Five years ago, he joined Voith Turbo. Prior to his appointment as Managing Director of Voith Turbo Singapore he was in charge of Voith Turbo in Vietnam.

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EXHIBITIONS AND EVENTS

Date
10.04. 13.04.2011

Event
UITP World Congress

Further information
www.uitp.org

Dubai, United Arab Emirates


14.04. 17.04.2011 Sheet Metal Working India

www.blechindia.com

Mumbai, India
05.05. 07.05.2011 Power Gen India

www.power-genindia.com

New Delhi, India


24.05. 27.05.2011 Nor-Shipping

Oslo, Norway
10.05. 13.05.2011 MASZBUD

www.messe.no/en/ntf/Projects/ Nor-Shipping www.mazbud.de

Kielce, Poland
21.05. 25.05.2011 APTA Bus Roadeo & Paratransit Conference

www.apta.com

Memphis, USA
01.06. 03.06.2011 OGA, The 13th Asian Oil, Gas & Petrochemical Exhibition

www.oilandgas-asia.com

Kuala Lumpur, Malaysia


06.06. 09.06.2011 Sheet Metal Processing Expo

www.blechexpo-messe.de

Stuttgart, Germany
07.06. 10.06.2011 UGOL ROSSII & Mining

www.ugol-mining.com/

Novokuznetsk, Russia
14.06. 16.06.2011 Railtex Exhibition

www.railtex.co.uk

Earls Court London, United Kingdom


15.06. 17.06.2011 Offshore Wind China 2011

www.offshorewindchina.com

Shanghai, China
20.09. 22.09.2011 TRANSEXPO

www.targikielce.pl

Kielce, Poland
03.10. 05.10.2011 Middle East Workboat

www.middleeastworkboats.com

Abu Dhabi, United Arab Emirates


21.10. 26.10.2011 Busworld

www.busworld.org

Kortrijk, Belgium

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News and Information for the worldwide customers, partners and friends of Voith Turbo

Publisher: Voith Turbo GmbH & Co. KG April 2011 Editorial head office: Marion Jooss Voith Turbo GmbH & Co. KG Corporate Marketing/PR P.O. Box 20 30 89510 Heidenheim, Germany Phone +49 7321 37 2802 Fax +49 7321 37 7110 info.voithturbo@voith.com www.voithturbo.com Text: ecomBETZ PR GmbH, Schwbisch Gmnd Layout: Eberle GmbH Werbeagentur GWA, Schwbisch Gmnd Printing: C. Maurer Druck und Verlag GmbH & Co. KG Geislingen an der Steige

PR 0011 April 2011 Reproduction and copying are subject to the express approval of the editorial head office.