Feature Machine Building & Frameworks


Bespoke grid coupling for 10,000 tonne press pump


Sheffield Forgemasters Engineering (S.F.E.L.) has commissioned Altra Industrial Couplings to provide a bespoke coupling of a large water pump, thus avoiding costly re-engineering


S


.F.E.L. is the manufacturing arm of Sheffield Forgemasters International, a company that specialises in steel production and machining for global supply. Using steel supplied by a sister com- pany it produces some of the world’s largest steel castings (1 to 350 tonnes), steel forged items (up to 280 tonnes) and forged steel bars. Its manufacturing facilities include a 10,000 tonne press pump which is capable of moving over 6,500 litres of water every minute. To keep such a large pump flowing a coupling is required to transfer the 6,000hp produced by the motor at speeds of between 70/83rpm. Pump applications are notorious for high levels of shock loading and vibration, meaning a coupling was required that could deal with these stresses. Grid couplings provide the ideal solution as the metal grid which connects the hubs to the shaft allows for small amounts of movement which smoothes out torque spikes and minimises the negative effects of misalignment.


Replacement required


During a recent site inspection it was decided that the current coupling was approaching the end of its operational life and a replacement would be needed to prevent a breakdown. To avoid a costly and time consuming re- engineering project to the pump, S.F.E.L. needed to source a new cou- pling that would match the dimen- sions of the outgoing coupling. Most of the coupling manufacturers that it approached didn’t have the facilities to manufacture a coupling of the required dimensions. David Bartholomew, engineering manager at S.F.E.L., commented, “The outside diameter of the coupling is 1,620mm and its width is approxi-


Automation MARCH 2013


Right: the grid coupling of a large water pump at S.F.E.L. was coming to the end of its operational life. To avoid costly


re-engineering of the pump, S.F.E.L. wanted to commission a


bespoke coupling to match the


original’s footprint


mately 650mm. While some manufac- turers could meet the load require- ments for the project, none could offer a grid coupling which met these dimensions. The original coupling was manufactured by Bibby, now part of Altra, so we asked if its coupling divi- sion would be able to help with a replacement. It was able to use the original design to manufacture a bespoke coupling which matched our criteria exactly.”


required by the application, all on a very short lead time.


Built to last


David Proud, sales director for Altra Industrial Couplings, added, “It is extremely rare that a grid coupling is required of this size, and there aren’t many manufactures with the means and experience to complete the pro- ject. Fortunately Altra Industrial Couplings has the capabilities to


“The original coupling was manufactured by Bibby, now part of Altra, so we asked if its coupling division would be able to help with a replacement. It was able to use the original design to manufacture a bespoke coupling which matched our criteria exactly.”


David Bartholomew, engineering manager at S.F.E.L


Bibby was one of the original pio- neers of grid coupling technology and using the design for the pump’s origi- nal coupling, which was manufac- tured in the 1970s, as a starting point, Altra engineers were able to use the company’s high-tech manufacturing facilities to produce a new grid cou- pling. The new unit matches the same performance envelope as the original, but employing modern materials and the latest grid profile to provide the flexibility and also the longevity


make couplings of almost any size. To make this project even more spe- cial, Sheffield Forgemasters Engineering acted as a supply partner for the couplings hub material. Working with our customer as a man- ufacturing partner helped us to ensure that this coupling will keep turning for another 40 years.”


Altra Couplings www.altramotion.com T: 01992 514 620


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