The companies of Altra Industrial Motion offer many critical drivetrain products utilized in power generation applications including couplings, clutches & brakes, gearing and geared motors, belted drives and torque-limiting devices.

1. Applications & Innovations
Power Generation
Market

2. We’re committed to the
Power Generation Market
The companies of Altra Industrial Motion offer many critical
drivetrain products utilized in power generation applications including
couplings, clutches & brakes, gearing and geared motors, belted
drives and torque-limiting devices.
Altra Brands Deliver Value Throughout the Drivetrain
Altra Industrial Motion is positioned to provide OEMs with
exceptional drivetrain value by ensuring component compatibility
and optimized performance combined with time-saving,
single-source convenience.
Extensive Technical Experience in Power Generation
Applications
Major OEMs routinely rely on the vast power gen application
knowledge of Altra’s engineering teams that collaborate to
thoroughly analyze specific customer applications and then apply
the latest technologies in design, materials and manufacturing.

3. Ameridrives Couplings Help Meet the World’s
Growing Need for Portable Power Generation
Application ProfileApplication Profile

4. • Ameridrives was contacted by a major aeroderivative gas turbine
generator OEM’s engineering team to help design and integrate a
coupling solution for their completely new, next-gen engine design.
• The new, dual-engine 120 MW package will utilize 2 Ameriflex
couplings which will connect the two turbine engines to the common
generator.
• Each 124" long coupling weighs approximately 1,500 lbs. and features
a speed capacity of 4,400 RPM.
• Ameridrives engineers designed and proposed a new, economical
overload protection device
• A unique shear section, that could easily be integrated onto the drive
end of the Ameriflex couplings, was supplied to shield the turbine
from
potential damage.
• The innovative shear device saved the customer 90% when
compared to the originally specified 3rd party device.
Ameridrives Couplings Help Meet the World’s
Growing Need for Portable Power Generation
www.altraenergyoilandgas.comP-7765-AC.pdf

5. Power Generators
Problem:
Ameridrives was contacted by a major aeroderivative gas
turbine generator OEM to help design and integrate a high
performance coupling solution for their next-generation engine
design. The 60 MW engine was larger than their previous
models. A dual-engine configuration feeds a common generator
to create a full 120 MW of power.
Solution:
Two Ameriflex diaphragm couplings were required for the new
twin-engine package. The couplings connect the two turbine
engines to the common generator positioned between them.
Each 124" long coupling weighs approximately 1,500 lbs. and
features a 4,400 RPM speed capacity.
• Unique separated multi-convoluted diaphragm configuration
• Ameridrives also designed and proposed a new, economical
shear section that could easily be integrated onto the Ameriflex
couplings supplied. The device saved the customer 90%
compared to the originally specified 3rd party device.
Application Profile
Ameriflex®
Couplings

6. Aeroderivative Gas Turbine
Problem:
The IHI Group, located in Japan, specializes in taking jet engines
that were originally designed for aerospace applications and
adapting them to generate electricity in land-based, combined
cycle gas turbine (CCGT) power plants. High-speed couplings
that connect the rotor shaft of the turbine to the gearbox and
low-speed couplings that connect the gearbox to the generator
were needed for a new CCGT installation.
Solution:
IHI worked closely with Bibby Turboflex to develop a pair of
API 671 compliant high-performance couplings to meet the
application requirements.
• High-performance 3.5 meter long high-speed coupling with
interlocking element and spacer end flanges to reduce
overhung mass
• High-performance low-speed coupling with shear pin
overload protection device
Application Profile
High-Performance Couplings

7. Application Profile
Motor-Generator Sets
Problem:
A major manufacturer of motor-generator sets required a
heavy-duty gearbox for one of it’s reduction gear gen-sets.
Motor-generator sets are primarily used for frequency
conversion, in this case, 50 Hz to 60 Hz. The reducer is
positioned between an induction motor operating at 1500 RPM
and a 1800 RPM synchronous generator.
Solution:
Nuttall Gear speed reducers were selected for this demanding
application due to their reputation for rugged construction and
reliable performance.
• Input range from 400 HP to 1500 HP
• Reduction ratio of 1:1.2 nominal
• Dynamically-balanced, precision double-helical gearing
• Self-contained, circulating lube oil system with an oil-to-air
heat exchanger
Heavy-Duty Speed Reducers

8. Application Profile
Dual Drive Steam Turbine
Generator Set
Problem:
A manufacturer of turbine generator sets required
overrunning clutch couplings for use on in-line mounting of
dual drive fan systems to provide a smooth transfer of power
from one drive/power system to another (electric motor to
steam turbine and gear reducer).
Solution:
Formsprag Model FWW 640 clutch couplings were selected
with a torque capacity of 2,066 lb.ft. (2800 Nm). FWW clutch
couplings are comprised of an FSO clutch with a disc coupling.
• PCE® sprags are designed to overcome the effects of
severe torsional and linear vibrations as well as high transient
torque overloads
Model FWW Overrunning Clutch Coupling

9. Application Profile
Gas Turbines
Problem:
A leading gas turbine system OEM needed a reliable clutch
solution for use on an electric starting system. The system
utilizes an electric motor combined with an overrunning clutch.
When starting, the electric motor rotates the main turbine shaft
until the air blowing through the turbine’s compressor and
combustion chamber is sufficient to light the engine. Once the
engine reaches a self-sustaining speed, the overrunning
clutch automatically disengages the electric starting motor.
Solution:
To meet the OEM’s requirements, Formsprag Clutch provided
its Model FTS-2500 clutch, designed specifically for turbine
starter applications to provide a smooth transfer of power from
the electric starter motor to the engine.
• Centrifugal throw-out (C/T) sprag technology for longer life
• 330 lb.ft. drive torque
• Custom splined output shaft
Starter Clutches

10. Power Plant
Problem:
A new engineered coupling solution was needed at the first
coal-fired power plant in the U.S. that utilizes ultrasupercritical
boiler technology, where water moves directly from a liquid to
superheated steam. The coupling is located between the
boiler’s water feed pump and the steam turbine. At certain
times, such as during scheduled maintenance, the coupling
needs to allow plant operators the ability to disengage the feed
pump from the turbine in order to stop the water flow, which
allows the turbine to continue to rotate on the turning gear.
Solution:
Ameridrives provided a custom-engineered Ameriflex RMD
(Reduced Moment Disconnect) diaphragm coupling, the most
technically advanced disconnect coupling.
• Unique separated multi-convoluted diaphragm configuration
• No wearing parts, no lubrication and no required maintenance
• Diaphragms designed for infinite life
Application Profile
Ameriflex®
Disconnect Couplings

11. Power Station
Furnace Conveyors
Problem:
A global conveyor supplier required torque overload protection
on screw conveyors used at a power plant in Indonesia. The
conveyors move waste material to and from the facility’s
furnaces. The material being transferred often contains large
pieces of steel and concrete that could cause jams and possibly
damage the conveyor’s screw element.
Solution:
The conveyor OEM selected Bibby Modular Torque Limiters
based on Bibby’s reputation as well as their previous working
history of providing reliable solutions.
• 8,990 Nm (6,630 lb.ft.) torque breakout
• Easy on-site breakout torque adjustment
• Accurate release torque repeatability
• Simple, fast manual re-engagement
• Easy replacement without coupling removal
Application Profile
Modular Torque Limiters

12. Application Profile
Coal-Fired Power Plant
Conveyors
Problem:
A large coal-fired power plant was experiencing problems with
lip seal degradation on their oil lubricated holdbacks. It became
difficult for maintenance crews to keep up with the required lip
seal lubrication schedule resulting in an increase of costly
downtime.
Solution:
Formsprag engineered new grease-filled LLH (Long Life
Holdback) models. Eight units were installed on various
conveyors as replacements to older Formsprag and competitive
oil lubricated holdbacks.
• LLH units feature sprag technology and are designed for
conveyor headshafts where reverse rotation must be prevented.
• Reduced maintenance and downtime
• LLH units supplied have torque capacities ranging from
4,000 to 135,000 in.lbs.
LLH Holdbacks

13. Nuclear Plant Charging
Pump Drive
Problem:
A nuclear power plant in Spain suffered a catastrophic failure
of its charging pump speed increaser. The cause of the
failure was a loss of lubrication due to a rupture in one of the
lubrication lines which had been modified by the utility
without regard to theOEM design.
Solution:
Nuttall Gear was the original supplier of the speed increaser and
maintained all of the drawings and specifications for the unit,
which was manufactured in 1978. This allowed Nuttall Gear to
supply a newly manufactured drop-in replacement unit without
the need for costly and time-consuming reverse engineering.
• The speed increaser contained over 220 individual parts, with
each part verified to meet or exceed the original specification.
• The unit was assembled at Nuttall Gear and tested in-house
• 10CFR50 Appendix B Quality Program with NQA-1 compliance
Drop-In Replacement Speed Increaser
Application Profile

14. Application Profile
Nuclear Power Plant
Pump Drive
Problem:
A nuclear power plant located in New York needed replacement
gearing for the main feedwater pump speed increaser. The
plant houses a single Westinghouse 2-loop pressurized water
reactor. The original gearing, supplied by Nuttall in 1967, had
become obsolete and was nearing the end of its service life.
Solution:
Nuttall was selected to provide the new gearing since they were
the original supplier of the speed increasers in Westinghouse
pressurized water reactors.
• Costly and time-consuming reverse engineering was not
necessary since Nuttall maintains all original design drawings
and specifications for their speed increaser units.
• Precision-ground, AGMA Q12 gear set
• 10CFR50 Appendix B Quality Program with NQA-1
compliance
• Reduced vibration and stress on other pump components
Custom Heavy-Duty Gearing

15. Nuclear Waste Handling
Crane
Problem:
A reliable coupling solution was needed for a crane used at a
European nuclear waste reprocessing plant. A special overhead
crane is used to raise and lower the heavy flasks of the waste
material at various reprocessing stations throughout the plant.
The coupling connects the output shaft of the drive gearbox to
the hoist’s cable winding drum.
Solution:
Bibby supplied a stainless steel Series II size 45 gear coupling
to meet the critical nuclear application requirements.
• Full nuclear documentation was required
• 41.8 kNm (30,830 lb.ft.) torque rating
• Double engagement design to accommodate high parallel
and angular misalignment
• 3200 rpm maximum speed
• High torque-to-weight ratio
Application Profile
Series II Gear Coupling

16. Power Plant
Induced Draft Fans
Problem:
A major global industrial fan OEM needed a replacement
coupling solution for an induced draft fan drive at a large power
plant. The fan maintains system pressure on a coal-fired boiler
at the facility. The existing fan drive used an old gear coupling
design which had reached the end of its useful life.
Solution:
The OEM contacted TB Wood’s and requested a disc coupling
solution since they wanted to increase expected service
life and eliminate the need for lubrication. TB Wood’s engineers
recommended switching to a Form-Flex floating shaft coupling
to mount between the drive motor and the fan.
• 21.5 ft. long coupling with an oversized tube diameter (24 in.)
to meet torsional requirements
• Modified for limited end float
• Special adapter connects directly to fan drive flange
Application Profile
Form-Flex®
Floating Shaft

17. Variable Pitch Axial Fans
Problem:
A leading global manufacturer was looking for ways to improve
the safety on its axial fans used at coal-fired power plants. The
large forced draft, induced draft, and primary air type fans are
critical to boiler air and flue gas flows in the steam generating
process. Workers hands could easily get trapped within the tight
space between the fan blade tips and duct during any
uncontrolled rotation while performing maintenance.
Solution:
Upon hearing about Twiflex’s new TLB (turning, locking, and
braking) system, the OEM, a longtime Twiflex customer,
recognized it could be a solution to their current maintenance
challenge. The built-in flexibility of the TLB system allowed
Twiflex engineers to design a complete custom delivered
system included turning control (at a very low speed of 0.05
rpm), a manual locking device and hydraulically applied brakes.
Application Profile
TLB Turning, Locking & Braking System

18. Application Profile
Motorized Valves
Problem:
A manufacturer of engines that convert excess steam pressure
into electricity needed a gear-set that would allow remote
adjustment of a hot rotary valve and hold the valve in position
when the motor is turned off. By channeling excess steam
through a valve, the steam can drive a turbine which in turn
drives a generator.
Solution:
Boston Gear was contacted to provide worm gear sets for use
in this high-temperature application. An 80:1 ratio was achieved
with a 5” diameter bronze gear and mated motor-driven low
carbon steel worm.
• Standard gear hub length was reduced to meet the customer’s
small footprint requirement.
• High ratio gear set combined with a servo motor prevents the
valve from back-driving out of position.
Modified Worm Gear Set