Presentation on

Rexnord Addax
Composite Cooling Tower Drive Shafts
By

Duane Byerly
CTI Vice Chair for Vibrations Task Group, 2009-present.
Rexnord Addax, 1989- Present

Workshop on Cooling Tower and Circulating Water System NTPC PMI

Rexnord: Company Overview

PRECISION. POWER. PERFORMANCE

Business Focus
Power Transmission
AfterMarket, 44%

Power Transmission
OEM, 56%

Water Management

Res., 19%

Water Management

Bus., 30%

Infrast., 51%

Power Transmission Platform

Power Transmission
Flattop
Products: TableTop Chain MatTop Conveyor Components

Bearing
Products: Mounted Roller Bearings Mounted Ball Bearings Cylindrical and Filament Bearings

Gear
Products: Drive OneTM Planetary Gears Shaft Mounted Gears Service

Coupling
Products: Disc Couplings Elastomeric Couplings Gear & Grid Couplings

Aerospace

Special Chain & Other Components

Products: Engineered Chain Conveying Equipment Roller Chain

Products: Products: Rolling Element Brakes and Airframe Control Clutches Bearings Miniature Motion Slotted Entry Control Devices and Split Ball Valves and Bearings Security Locks Seals

aerospace bearings

LINK BELT Rexnord is a $ 2 Billion Company

4

Worldwide Presence
Rexnord is an international company with:
47 45 total locations serving over 75 countries worldwide
29 27 manufacturing locations, 6 repair facilities Over 4400 4500associates worldwide ready to serve our partners and end users

47 Rexnord Worldwide Locations Providing Global Consistency with Localized Support.

NY001ZJ1_1.wor

Rexnord Facilities Headquarters Aerospace Coupling Flattop Gear Industrial Bearings Industrial Chain Special Components

Rexnord Sales Offices

Australia India

Korea Miami Singapore South Africa China

Brazil

Canada

TRADITIONAL STEEL SHAFT

TRADITIONAL STEEL SHAFT

Heavy

150kg +

Commercial Grade Tube

Multiple Parts

Uneven thickness - Unbalance

16 sets of pin & bush totally
10

HEAVY 150kg

OVERHEAD CRANE

ADDITIONAL MANPOWER

DANGEROUS WORKING ENVIRONMENT

ALIGNMENT TIME LONGER

11

Corrosion Prone

Effects of Corrosion 1. Loss of Material cause Imbalance Vibration 2. Entire assembly has to be replaced. Assembly Balance is done Part (hub) replacement ot possible 3. Service Life is 5-7 years. Results in RECURRING CAPITAL COSTS
12

Degraded Rubber bushing

Multiple Parts

16 sets of Pin & Bush

Rubber bush Misalignment capacity gone Vibration degraded by Chlorine Frequent Replacement
13

Bearing problems in gearbox with steel shaft

HIGH OVERHUNG MOMENT

MASS

Heavy Driveshaft = Shorter Gear Life

14

Disadvantage of Steel Drive shafts

Steel Weight Problems Heavy Slower Removal / Installation Slower Alignment ( 100- 150kg) = Longer Down time during maintenance Thermal expansion problem High Overhung Moment = Lower Bearing Life in Motor and Gear Reducer Vibration Higher
( > 10mm/sec)

Greater mass Greater Mass = Greater Unbalanced Greater Unbalanced = Greater Vibration Lower service life Repeated Maintenance required High Cost of Ownership

Corrosion

Affected

Service Life Flexible element

5-7 yrs Pin & Bush

Recurring Capital Cost Multiple Parts to be frequently replaced Repeated Maintenance reqd
15

Addax Composite Drive Shaft

Spacer ( Composite) Hub (SS 316) Flexible Element ( Composite)

CORROSION RESISTANT MATERIALS

16

Ultra light weight

LOW MASS = LOW VIBRATION LONGER BEARING & EQUIPMENT LIFE EASY TO HANDLE INSTALL / REMOVE

17

Corrosion Resistant

STEEL CORROSION PRONE

Spacer & Flex Elements Composite Hub & Hardware SS316 2.Part replacement possible Spacer Balanced 3. Service Life is Life Time of Cooling Tower

Corrosion Resistant Corrosion Resistant Interchangeability Reduced Inventory NO Recurring Capital Costs
18

Flexible Joint Differences

8 sets of Pin & Bush per End

Unitized ( 1 piece) Disc per End

Low service life rubber

Misalignment capacity min And lost due to hardening

Min 5 years Composite

Misalignment capacity 3 times standard
19

Comparison of Steel vs Rexnord

Steel Weight Vibration Corrosion Service Life Flexible joint Rexnord Composite How you WIN ? Faster Installation & Alignment Easy Maintenance Longer Bearing and End Equip life. Lesser Down Time Min Ownership cost during for life of Cooling Tower No Recurring Capital Cost Simple Replacement Replacement in 5 yrs Reduced Maintenance cost & time Trouble free operation
20

Heavy Ultra Light (100-150kg) (15-25kg) Higher

( > 10mm/sec)

Minimal
( < 2mm/sec)

High 5- 7 Yrs Pin & Bush ( 8 sets ) Higher

No Corrosion CT Life time

Unitized ( 1 Piece) Disc Type

Downtime Time & Cost

Min

The Rexnord Solution

So why does Rexnord Addax Composite Drive Shafts have all these Wonderful Qualities ? Lets go a little deeper into composite technology..

21

Composite Materials Overview Definition:

Advanced composites are generally understood to be high-performance materials consisting of a polymer matrix reinforced with high-strength continuous fibers of predefined orientation. Types of Fiber Used Fiberglass Carbon/Graphite*

1500x Magnification

22

Composite Materials Overview Density Comparison

0.30 0.20 0.10 0.00

lbs./cubic inch

E-Glass

Carbon

T6061

304 SS

Low weight for ease of handling, reduced bearing loads, reduced vibration Higher critical speeds reduced tendency for whirling
23

Composite Materials Overview Specific Stiffness

Modulus Density

x 106 inches

300 200 100

0
E-GlassCarbon T6061 304 SS
Enables long spans with smaller diameter compared to steel No cantenary deflection (no sag) no need for center support
24

Composite Materials Overview Specific Strength

400
300
Tensile Strength Density

x 104 inches

200
100

0 E-Glass Carbon T6061

Stronger than steel - for given weight
25

304 SS

Problem - Thermal expansion of steel on non rotating shaft

Issue: -Top surface of shaft experiences thermal expansion vs. lower surface due to solar exposure -The nominally cylindrical shape now become curved -At start-up, this curved shape creates serious imbalance and creates vibrations and excess wear on the bearings

Carbon fiber shafts do not experience this issue as they do not experience any thermal expansion 26

Composite Materials Overview

Dimensional Stability - Axial Coefficient of Thermal Expansion (CTE)

12 10 8 6 4 2 0 -2

CTE - in./in./F x 10-6

Carbon fiber is dimensionally stable regardless of temperature: -Reduced wear on bearing -Dependably straight shaft reduces imbalance and vibration

E-Glass Carbon

T6061

304 SS
27

Rexnord Product Testing

Rexnord meets all the requirements
Torque test
- Can demonstrate peak rating with no failure

Fatigue test simulated motor starts

Flex elements tested to 43,000 cycles Spacer tested to 20 year life of the tower

UV Test Conducted in India

Resulted in NO loss of properties
28

Addax Experience
The Addax coupling has been the standard for new construction globally for 25 years Exclusively used with all US cooling tower manufactures with the exception of SPX Marley (Marley purchases Addax when specd). More than 85,000 Rexnord / Addax couplings in service globally believed to be the world leader 29

NTPC Credentials
Existing Install at NTPC RGPPL Order received for NTPC Muzzafarpur Order from NTPC Sipat

30

1000+ Installation

31