Upgraded couplings increase mill safety factor
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David Brown Engineering product story
Edited by the Engineeringtalk editorial team
Sep 28, 2006
The raw mill unit at Cemex's South Ferriby cement plant has undergone several upgrades over a period of years, and the company contacted David Brown regarding an analysis of the drive train.
The raw mill unit at Cemex's South Ferriby cement plant has undergone several upgrades over a period of years, and the company contacted David Brown regarding an analysis of the drive train to determine service/safety factor under current conditions and anticipated life expectancy of gears, bearings and related equipment.
It was seeking a solution that was both cost effective and minimised disruption to production.
David Brown reviewed the system, assessing the girth gear and associated drive, identifying that the existing cardan shaft gear couplings were not adequate for increased torque and duty but were already the largest of the standard X type.
A solution was immediately offered and subsequently accepted, the chosen route being to manufacture complete new cardan shaft unit and pre-assemble with upgraded single engagement gear couplings of the heavy duty type (623 size 16).
The upgraded couplings gave an increased safety factor of 2+.
Furthermore, as the whole cardan shaft assembly could be changed complete without the need for removing and refitting gear hubs to old shaft, the installation ensured minimum downtime for the operation.
In addition, the old shaft was assessed for suitability for re-use to same specification as the new assembly, thus providing a strategic spare as further protection.
With down time minimised, safety factors enhanced and with the additional bonus of strategic spare coverage, the operation is now safely running at higher production levels.
Previous work had involved upgrading ancillary equipment such as the dynamic separator, conveying equipment to and from the mill, DCS control to optimise production along with the traditional upgrades, such as main motor power and speed increases to make use of maximum available power supply (1500kW/11kV supply).
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