Solving Hydraulic Coupling Challenges
When a fertilizer company located in Minas Gerais, Brazil needed an equipment upgrade they turned to MagnaDrive for a potential solution. This plant contained large mixer reactors to produce phosphate-based fertilizers. Unfortunately, the maintenance team was experiencing repeated drive failures related to the hydraulic couplings.
These couplings would frequently fail due to thermal fuse breakage/heating. Two to three of these couplings needed to be replaced in a one-year period. When replacements were necessary, the downtime was 6-8 hours for installation and alignment. Oil supply and regulation was another time-consuming process.
The Solution: Installing MagnaDrive MGD Couplings
TOP Componentes, a distributor in Brazil for MagnaDrive couplings, proposed the installation of an MGD coupling to replace the hydraulic coupling. This resulted in:
- Zero equipment failures
- No unscheduled stops
- Lowered the risk of accidents in the manufacturing facility
Installation Details
TOP selected the best product to work with:
- 550 hp motor running at 1,200 rpm.
- Reducer inlet speed was 1,180 rpm
- Total reduction, 1/24.7
- Material density, 1.91g/cm3
- Torque at reducer outlet of 8,000 kgf.m.
The Removal of the original coupling and the installation of the new MagnaDrive coupling without moving either the reactor or the motor only took about three hours to complete.
Cost Savings and Performance Benefits
Switching to the MagnaDrive MGD coupling significantly reduced maintenance, labor, and replacement costs:
- Hydraulic coupling solution cost: +$50,000 (including maintenance and replacements)
- MGD coupling installation and maintenance cost: +$30,000
After a year in use, the benefits of the upgrade included:
- Decreased maintenance needs
- Reduced vibration
- Increased equipment availability
- Greater tolerance to misalignments
The customer has also decided to replace hydraulic couplings in other equipment in the manufacturing facility with MagnaDrive magnetic couplings.
MagnaGuard Delay Start Coupling Benefits
The MagnaGuard Delay Start Coupling Family (MGD) offers numerous benefits for customers, particularly in applications requiring a cushioned or delayed start, such as bulk handling conveyors.
Key Features of MGD Couplings
- Ability to delay full torque transfer
- Cushioned start and stop
- Design is Specific for a Cushioned & Delay Start
- For applications with Pulsating and/or Shock Loading
- Partially disengagement to protect equipment
- Vertical and horizontal Installation
- 10 – 1,000 hp up to 3,600 rpm