Manoeuvring a 3m-diameter 23t gear for Blue Circle Southern in Australia is just one example of the resourcefulness regularly shown by David Brown's on-site services team.
Overcoming extremely limited clearances while manoeuvring a 3m-diameter 23t gear for Blue Circle Southern in Australia is just one example of the resourcefulness regularly shown by David Brown's on-site services team. In this case a special cradle was constructed under David Brown's guidance and the gear was transferred into place on rails. The cement mill gearbox operated by Australia's major cement producer had suffered a bearing failure and the resulting debris caused significant damage to the slow speed dual drive double helical pinions and gear teeth.
Engineers from David Brown attended the site to make repairs and allow continued production, at a reduced rate of 75% of full capacity, while the replacement gear and pinions could be manufactured by David Brown Australia.
In the interim there was close liaison with the client to plan the gear set replacement method and keep downtime to a minimum.
Production resumed at 100% following installation of the new gear set in 2004.
An inspection carried out in 2005, following 12 months of full production, showed exceptional tooth contact patterns and an absence of tooth wear, giving the overall refurbishment project a double 'thumbs up'.
The contract underlines the scope of David Brown's on-site services in a market which is increasingly driven by service as well as product excellence.
The team that worked on the project is just part of David Brown's fully qualified field service engineer resource which is available in most key geographies to provide a number of key services from performance testing, fault diagnostics through to installation/commissioning, alignment checks and emergency repairs.
Recognising the importance of preventative maintenance, the company also boasts a range of applications knowledge, gained through close long-term customer partnerships in many heavy process industries, to offer performance improvements to transmissions and other rotating equipment.
Using appropriate condition monitoring and analysis techniques, David Brown is able to pin point critical process issues and recommend courses of action to substantially reduce the associated risks.
David Brown's deep knowledge of transmissions and other rotating equipment, combined with its close geographic proximity, means it is well positioned to respond rapidly to its customers' needs, seeking to identify and predict issues, and offering solutions to improve their process performance.
Service engineers are also available to install and inspect transmissions and other rotating equipment throughout the world and David Brown provides installation services and alignment checks that cover everything from a simple equipment installation to a complete drive system installation.
To ensure a proper startup of the equipment, David Brown service engineers can also provide its customers with inspection services and advice on project managing installations.
Finally, experienced service engineers, using modern equipment and leading technology, provide repair services at the site to restore or enhance performance of transmissions or other rotating equipment.
The services range from emergency repairs, as in Australia, to repairs of equipment during planned shutdowns.
Repair services cover all transmissions used in a variety of heavy process industries, from metals processing through to mining and cement manufacture.
Gearboxes drop in to upgrade mill capacity
David Brown Engineering has supplied five large gearboxes and pinions to JSW Steel in India in the first stage of a major upgrading of the company's hot strip mill facilities.
David Brown Engineering has supplied five large gearboxes and pinions to JSW Steel in India in the first stage of a major upgrading of the company's hot strip mill facilities completed during April and May 2006. This initial project will increase capacity by 40% and other planned improvements are designed to progressively double throughput at the facilities. The plant near Bellary in the province of Karnataka has six finishing mills with 5000hp motors and these motors have been upgraded to 7000hp.
The replacement gearboxes and pinions from David Brown Engineering have the same footprint and critical dimensions as the existing ones, enabling a 'drop-in' solution.
This caused the minimum disruption to production when they were installed together with new motors as well as obviating the main obstacle to upgrading given that reorganisation of the mill equipment layout invariably involves monumental cost and long term disruption.
Close co-operation between JSW Steel and David Brown and all the partners in the project has been the hallmark of the operation and experts from the engineering company made a number of visits to the plant to discuss the project, offer technical advise, take measurements and work in conjunction with other major suppliers who were involved in motors and couplings and in overall consultancy.
In fact representatives of David Brown Engineering visited the plant to take measurements and plan for the project five times in conjunction with the other three partners in the project: main contractor VAI (UK), motor manufacturer Siemens, Germany and couplings producer Maina, Italy.
A good example of the spirit of co-operation that characterises the project was the fitting of couplings before dispatch of the gearboxes from Huddersfield.
In the original plan the Italian-built Maina couplings would have been fitted on site in India, but it was judged that critical installation time could be reduced on site by first shipping the couplings to the UK.
Furthermore David Brown Engineering supplied services of commissioning engineering, flying out to India to supervise the installation of the gearboxes, and in the run-up to the operation team meetings are being held at VAI offices in Sheffield.
The installation took place in one planned 5 week shutdown with the actual installation performed by JSW Steel.
VAI and Siemens were also present to oversee the installation of the motors.
The existing plant was purchased in its entirety from the United States a decade ago and the gearboxes were reaching the end of their natural life.
The plant, in the remote province of Karnataka in southern India, is part of the JSW Group, in turn part of India's fourth largest business conglomerate, the Jindal Organisation with interests in mining, carbon steel, stainless steel, power and oxygen and currently valued at US $4 billion.
The group was founded in 1964 by OP Jindal who from humble beginnings, rose to become one of India's leading industrialists and founded a steel making dynasty of world importance.
This particular step in investment and expansion is seen as a major opportunity for the group against the current backdrop of a world steel shortage.
David Brown Engineering has supplied five large gearboxes and pinions to JSW Steel in India in the first stage of a major upgrading of the company's hot strip mill facilities completed during April and May 2006. This initial project will increase capacity by 40% and other planned improvements are designed to progressively double throughput at the facilities. The plant near Bellary in the province of Karnataka has six finishing mills with 5000hp motors and these motors have been upgraded to 7000hp.
The replacement gearboxes and pinions from David Brown Engineering have the same footprint and critical dimensions as the existing ones, enabling a 'drop-in' solution.
This caused the minimum disruption to production when they were installed together with new motors as well as obviating the main obstacle to upgrading given that reorganisation of the mill equipment layout invariably involves monumental cost and long term disruption.
Close co-operation between JSW Steel and David Brown and all the partners in the project has been the hallmark of the operation and experts from the engineering company made a number of visits to the plant to discuss the project, offer technical advise, take measurements and work in conjunction with other major suppliers who were involved in motors and couplings and in overall consultancy.
In fact representatives of David Brown Engineering visited the plant to take measurements and plan for the project five times in conjunction with the other three partners in the project: main contractor VAI (UK), motor manufacturer Siemens, Germany and couplings producer Maina, Italy.
A good example of the spirit of co-operation that characterises the project was the fitting of couplings before dispatch of the gearboxes from Huddersfield.
In the original plan the Italian-built Maina couplings would have been fitted on site in India, but it was judged that critical installation time could be reduced on site by first shipping the couplings to the UK.
Furthermore David Brown Engineering supplied services of commissioning engineering, flying out to India to supervise the installation of the gearboxes, and in the run-up to the operation team meetings are being held at VAI offices in Sheffield.
The installation took place in one planned 5 week shutdown with the actual installation performed by JSW Steel.
VAI and Siemens were also present to oversee the installation of the motors.
The existing plant was purchased in its entirety from the United States a decade ago and the gearboxes were reaching the end of their natural life.
The plant, in the remote province of Karnataka in southern India, is part of the JSW Group, in turn part of India's fourth largest business conglomerate, the Jindal Organisation with interests in mining, carbon steel, stainless steel, power and oxygen and currently valued at US $4 billion.
The group was founded in 1964 by OP Jindal who from humble beginnings, rose to become one of India's leading industrialists and founded a steel making dynasty of world importance.
This particular step in investment and expansion is seen as a major opportunity for the group against the current backdrop of a world steel shortage.
Distributor takes clutches and couplings to Spain
Renold Clutches and Couplings has gone into partnership with Spanish distributor USA Brammer, a sister company to BSL Brammer in the UK.
Renold Clutches and Couplings of Cardiff has gone into partnership with Spanish distributor USA Brammer, a sister company to BSL Brammer in the UK. The Spanish distributor will stock Renold's range of interchangeable trapped roller and sprag clutch freewheels to provide an off-the-shelf service to engineers throughout Spain. Martin Slade, Renold Clutches and Couplings' Sales Director said: 'We are delighted with this new agreement with another distributorship within the Brammer group'.
'Spain is an important country for us and we know that USA Brammer will provide the best possible service for our customers there'.
Renold recently announced that its entire range of trapped roller and sprag clutch freewheels is interchangeable with those of other leading American and European manufacturers such as Formsprag, Stieber, Ringspann and Cross and Morse.
Renold Clutches and Couplings of Cardiff has gone into partnership with Spanish distributor USA Brammer, a sister company to BSL Brammer in the UK. The Spanish distributor will stock Renold's range of interchangeable trapped roller and sprag clutch freewheels to provide an off-the-shelf service to engineers throughout Spain. Martin Slade, Renold Clutches and Couplings' Sales Director said: 'We are delighted with this new agreement with another distributorship within the Brammer group'.
'Spain is an important country for us and we know that USA Brammer will provide the best possible service for our customers there'.
Renold recently announced that its entire range of trapped roller and sprag clutch freewheels is interchangeable with those of other leading American and European manufacturers such as Formsprag, Stieber, Ringspann and Cross and Morse.
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