John Crane Flexibox
Barry Vowles
Director - Couplings
Introduction to Couplings
The Overlooked Component
Contents
Introduction
Types of coupling in use
Membrane couplings
Disc type
Diaphragm style
API Reliability and Safety issues
Good Alignment practices
Special designs
Conclusion
Introduction
Driver
Introduction
Driver
Driven
Introduction
Driver
Connector
Driven
Introduction
Driver
Turbines - Gas & Steam
Reciprocating engines
Hydraulic motors
Electric Motors
Introduction
Driver
Connector
Driven
Pumps
Generators
Fans
Marine
Other machinery
Introduction
Driver
Connector
Couplings
Modifiers
Driven
Introduction
Couplings
Rigid
Flexible
Gear
Universal Joint
Spring Grid
Chain
Rubber Tyre
Rubber Block
Pin & Bush
Elastomeric
Membrane
etc.
Modifiers
Gearbox
Fluid Coupling
Variable Speed
Belts
Chains
Powder
Flywheel
Introduction
Function of a shaft coupling
Transmit Power or Torque
Duties from
< 0.1 kW to > 100 MW
Transmits rotation
Speeds from 0 to 80,000 rev/min
Absorbs / reduces shock torque loads (optional)
Introduction
In the beginning ...
Driven
Coupling
Rigid connection
Driver
Introduction
But ..
Introduction
But ..
Misalignment exists
Pump
Motor
Introduction
Transmit torque and speed
Accommodates misalignment and end
float
End float
Axial
Angular
Lateral
Introduction
Why Misalignment ?
Initial residual alignment
Thermal expansions - axial
- vertical
- horizontal
Pipe strain
Clearance or float in bearings
- axial
- radial
Foundation movements
Earthquakes
etc
Introduction
Flexible elements introduced
Driven
Coupling
Driver
Contents
Introduction
Types of coupling in use
Membrane couplings
Disc type
Diaphragm style
API Reliability and Safety issues
Good Alignment practices
Special designs
Conclusion
Types of Coupling
Rigid - not flexible
Flexible
Mechanical
Gear (TR)
Universal joint (TR)
Spring grid
Elastomeric
Jaw - compression and shear types
Tyre and similar types
Pin & bush
Rubber block
Membrane (TR)
disc
diaphragm
TR = torsionally
rigid
Types of Coupling
Gear type
Lubrication essential
Will wear out
Needs maintenance
Torsionally rigid
Medium initial cost
High torque capacity
Types of Coupling
Universal Joint
Lubricated
Can wear out
Splines for end
float
Low initial cost
Not high speeds
Not high powers
Types of Coupling
Spring Grid
Lubrication essential
Will wear out
Needs maintenance
Torsional resilience
Medium initial cost
Not high speeds
Not high powers
Types of Coupling
Elastomer in shear
tyre
No lubrication
Can wear / degrade
Some torsional resilience
Medium initial cost
Not high speeds
Not high powers
Types of Coupling
Elastomer in
compression or jaw
No lubrication
Can wear / degrade
Some torsional
resilience
Low initial cost
Not high speeds
Not high powers
Types of Coupling
Elastomer in shear
- spline sleeve
No lubrication
Can wear / degrade
Some torsional
resilience
Medium initial cost
Not high speeds
Not high powers
Types of Coupling
Elastomer in shear jaw type
Maintenance without moving
hubs or equipment
Can rotate hubs independently
for motor test
No metal to metal contact
Limited torque range
Types of Coupling
Elastomeric - spacer types
Spacer does not give additional misalignment capacity
Types of Coupling
Pin and Bush coupling
Old technology
Wears fast
Low initial cost
Not high speeds
Not high powers
Types of Coupling
Rubber Block
Diesel drives
No lubrication
Can wear / degrade
Torsional
resilience
Higher initial cost
Not high speeds
Types of Coupling
Membrane
Couplings
Disc
Diaphragm
Types of Coupling
Assembled Disc Coupling
Multiple discs
Types of Coupling
Contoured Single Diaphragm type
Diaphragm membranes
Types of Coupling
Membrane Couplings
Transmit torque through tension or shear of thin
material
Accommodate misalignment by elastic bending of
element
No lubrication, minimum maintenance
Zero backlash
Should last as long as machinery
Can be used from lowest to highest powers and
speeds
Medium to high initial cost
Extra safety features possible
Torsionally rigid - very low resilience
Types of Coupling
Which Coupling type ?
Initial Cost
Torque v Speed Capability
Shock Loading / Overload Torque
Vibration effects
- balance
- loads
Torsional resilience or rigidity
Backlash
Environmental Tolerance
Durability
Ease of Installation
Types of Coupling
1000
Quill shaft
Elastomer
Inserts
Key
High Powers
& Speeds
kNm
Gear
HP/RPM
1000
Multiple
Membrane
100
Flexible in
Torsion
Grid Spring
100
10
General
Engineering
Contoured
Disc
Elastomer
Tyre
10
1
Chain
Pin & Flexible Disc
1
0.1
50
Torque v Speed
100
1000
Operating Speed rpm
10000
50000
Types of Coupling
Torque Loading
Motor types to consider
Normal operation - smooth torque
Direct on line start - > 2 x normal
Star Delta or soft start - < 1.5 x normal
Synchronous - high peak values
Variable speed - usually smooth
Re-acceleration torque - very high
Short circuit torque - > 4 x normal
Types of Coupling
Vibration - causes
Weight
Mass distribution
Axial stiffness or frictional forces
Bending stiffness or friction
Transmission of torque through angle
Unbalance effects
Types of Coupling
Vibration - causes
Unbalance
F2
u2
Rotational Axis
u1
F1
Principal Inertia Axis
Types of coupling
Balancing (Two Plane)
Types of coupling
Contributors To Unbalance
Balance tolerance limits
Balance fixture/mandrel unbalance
Balance machine error
Balance fixture/mandrel eccentricity
Indicating eccentricity
Pilot eccentricity
Pilot clearances
Hardware unbalance
Effect of keyways
Shaft runout
Types of coupling
Balance issues
Cylindrical Shaft with Key
Clearances around key
Excess key length
How
to control balance better
Types of coupling
Better balance
Conical Tapered Hydraulic Without Key
Pull up (draw)
Bore fits
Interference 0.002 in/in
Special tools required
Perfect balance repeatability
Types of Coupling
Backlash
v
Paper making
Gear
couplings
have an in built backlash
require maintenance causing expensive downtime
require lubrication - can be dirty
Membrane couplings
zero backlash - best paper production
No lubrication and no maintenance
Types of Coupling
Do you require
Long life - no lubrication, no maintenance
Low shaft loads
High standard of inherent balance
Easy access - Spacer Between Shaft Ends
Zero backlash
Precise rotational location or timing
but
Torsional damping is not required
Types of Coupling
Then
Torsionally rigid couplings are probably best
Membrane / disc couplings are preferred
Types of Coupling
Membrane Couplings
The Solution for
Reduced maintenance
Easy to fit
No lubrication
Low loads on bearings
Low induced vibration - better balance
Reliability and safety
element type dictates failure mode
Freedom from backlash
Spacer types standard
Contents
Introduction
Types of coupling in use
Membrane couplings
Disc type
Diaphragm style
API Reliability and Safety issues
Good Alignment practices
Special designs
Conclusion
Membrane Couplings
Standard API
designs
Highest reliability
Membrane Couplings
Early disc designs
Razor blade failure
Tension can cause
high bending stresses
Often loose discs
Membrane Couplings
Basic early Disc type designs
Membrane Couplings
Basic early Disc type designs
- difficult assembly
- looser fits
- early failures
Carbon steel discs - corrosion
Solved lubrication problem
but
Limited life
Safety issues
Loose components
Membrane Couplings
Unitised Disc Pack
Bush
Membrane Pack
Spacer
Washer
Membrane Couplings
Completed Assembly
Overload collar
(option)
Hub
Spacer
Membrane Couplings
Unitised Disc Pack
Pre assembled discs - less risk on assembly
Better control of fit on disc
Reduces risk of failures
Still requires careful bolt tightening
Best suited to lower speeds/lower powers
Lower balance quality - repeatability poor
- API demands better
Fail safe - continues drive
- bolts can break
Membrane Couplings
Industrial Coupling
Membranes
Hub
Drive Shaft
Spacer
Hub
Driven
Shaft
Membrane Couplings
Current basic unitised disc design
Membrane Couplings
Coupling Required
Pump
Driven
Motor
Driver
Membrane Couplings
Fit Hubs
M/Unit Spacer
Pump
Driven
M/Unit
Motor
Driver
Membrane Couplings
Coupling Fitted
Pump
Driven
Coupling
Motor
Driver
Main drive bolts
must be torque tightened
Membrane Couplings
Improved disc
design
Tension
Compression
Tension
100%
Fatigue
failure
area
Maximum torque stress
Membrane Couplings
Optimising design
Life
Maximum
Life
Profiled Washers
Optimum Radius
Washer Radius
Membrane Couplings
CYCLIC STRESS
Disc element stresses
Modified Goodman Diagram
FRETTING LIMIT
MEAN TORQUE
(MAX)
SPEED
(MAX)
(MAX) AXIAL
DEFLECTION
STEADY STRESS
RATED
OPERATING
POINT
Membrane Couplings
Contoured Diaphragm type
Membrane Couplings
Diaphragm type
Multiple Membrane
Membrane Couplings
The original Metastream coupling
Membrane Couplings
Diaphragm type
Retaining
Ring
Rivets
Guard Rings
Centre Fix
Bolted
Centre Fix
Anti-fly Bush
Membrane Couplings
Diaphragm type
Hub
Membrane
Units
Spacer
Drive Shaft
Hub
Driven Shaft
Transmission Unit
Membrane Couplings
Diaphragm type
Hub
Spacer
Spigot / Recess
Locations
Torsionally Rigid Couplings
Diaphragm type
Membrane Couplings
Diaphragm type
Hub
Membrane
Unit
Hub
Contents
Introduction
Types of coupling in use
Membrane couplings
Disc type
Diaphragm style
API Reliability and Safety issues
Good Alignment practices
Special designs
Conclusion
Power Transmission Couplings
Key Issues
Compliance with API 610 (or 671)
Easy installation
- minimal tools and skills
- spacer types
Zero maintenance
- no lubrication
Reliability
- Fit and Forget / Long life
Safety
- overload capability
- fail safe design
Low bearing loads
- increased machinery life
and performance (seals)
API 610
Pump
Driven
5.0 in
Motor
mm
Driver
3.2.2 Unless otherwise specified, couplings shall be flexible element. Coupling
hubs shall be steel. Flexible disc types shall have discs of corrosion resistant
material. The make, model, materials, service factor, and mounting arrangement of
couplings will be specified by the purchaser. A spacer coupling shall be used
unless otherwise specified. The spacer shall have a nominal length of at least 125
mm (5 in.) and shall permit removal of the coupling, bearings, seal, and rotor as
applicable, without disturbing the driver or the suction and discharge piping.
Note: For flexible element couplings, consideration should be given to designs
that will retain the spacer if a flexible element ruptures.
3.2.5 Couplings and coupling to shaft juncture shall be rated for at least the
maximum driver power, including any service factor.
API 610
3.2.6 Couplings shall be manufactured to meet the requirements of
ANSI/AGMA 9000 Class 9.
3.2.7 Couplings operating at speeds of 3800 RPM or less shall be
component balanced. Each component such as hubs, sleeves,
flexible elements, spacers and adapters shall be balanced
individually. All machining of components, except keyways of
single keyed hubs, shall be completed before balancing.
Balancing shall be in accordance with [Link]. Two-plane
balancing is preferred; however, single-plane balancing may be
used in accordance with [Link] .
3.2.8 Couplings operating at speeds in excess of 3800 RPM shall
meet the requirements of API Standard 67l for component
balancing and assembled balance check.
API 610
couplings shall be flexible element type
RELIABILITY - LONG LIFE
Flexible disc types shall have discs of corrosion resistant material
RELIABILITY - LONG LIFE
service factor specified by purchaser ( torque characteristics ?)
RELIABILITY & SAFETY
.. design will retain the spacer if a flexible element ruptures
SAFETY
Couplings shall be manufactured to meet the requirements of
ANSI/AGMA 9000 Class 9. (balancing specification)
RELIABILITY & MACHINE LIFE & INSTALLATION
Reliability
API requirements
Reliability/long life
Ease of maintenance
Safety
containment
fail safe
Reliability
Cartridge assembly
Sleeve
Drive Bolt
Spacer
Hub
Flexing Discs
Reliability
Guard Ring
Membranes
Hub
Hub
Spacer
Drive Shaft
Driven Shaft
Transmission Unit
Reliability
Hub
Hub
Drive Shaft
Driven Shaft
DBSE
Reliability
Transmission Unit
Reliability
Hub
Drive Shaft
Hub
Driven Shaft
Reliability
Additional Safety
Containment
Pre-assembled
Membrane Unit
Spigot
for high
inherent
balance
Spacer
Hub
Anti-fly feature
Guard Ring
Safety and Reliability
Metastream T Series type TSK
Drive Shaft
Driven Shaft
Safety and reliability
Fail safe
What does it mean
retains spacer - how long
continues drive
- how long to run
- how to detect
- total failure
- non spark
disconnects drive - no flow detection
- how long to run
- non spark
Safety and Reliability
Disc type - fail safe
Continue drive if failure occurs due to
mal-operation
Drive bolts can eventually break
Difficult to monitor
Will I Detect Failure?
This failure did not set off the vibration alarm
and was found by visual inspection
(And could soon have been a catastrophic failure )
Will I Detect Failure?
No apparent vibration
until after failure
Safety and Reliability
Metastream M Series
Unique style flexible element
Disconnects drive if failure occurs due
to mal-operation
Simple replacement of membrane pack
Spark resistant option for hazardous
areas
Exceeds API requirements
Safety and Reliability
Membrane Shear
Driven Shaft
Drive Shaft
Will I Detect Failure?
No Flow Alarm,
Better Try To
Start It Again
Will I Detect Failure?
Oh Dear !!
Safety and Reliability
Membrane Failure
Driven Shaft
Drive Shaft
Safety Bush Retains
the Spacer - fail safe
Contents
Introduction
Types of coupling in use
Membrane couplings
Disc type
Diaphragm style
API Reliability and Safety issues
Good Alignment practices
Special designs
Conclusion
Reliability
Membrane couplings
Long or Infinite life
No routine maintenance required
Why do they sometimes fail ?
Reliability
Excessive misalignment
Contamination
Upset conditions
Overtorque
Cyclic torque
Machinery movement
Excessive temperature
Reliability
Axial
Angular
Lateral
Poor alignment is a frequent cause of rotating
machinery outage
Shaft Alignment
Ruler or straight edge
Not accurate
Lateral check only
No data recorded
Shaft Alignment
Dial Indicators(DTIs)
Skill & experience
required
Best results with
reverse periphery
method
Time consuming for
calculation and
accuracy
Shaft Alignment
Laser based system
Significant reduction in
alignment time
Significant reduction in
downtime
Very high degree of
accuracy
Very high degree of
repeatability
Printed record with
some systems
Shaft Alignment
Use good
shims
Safety
Oh By The Way,
If You Do Have A Failure
Dont Try This !!
Safety
Rope Trick
Contents
Introduction
Types of coupling in use
Membrane couplings
Disc type
Diaphragm style
API Reliability and Safety issues
Good Alignment practices
Special designs
Conclusion
Special designs
Other features
Electrical Insulation
Limited End Float
Vertical Applications
Close Coupled
Rigid Couplings
Long spacers
Large Axial Movements
Shear Devices
High Powers and
Speeds
Torque Monitoring
Special designs
Electrical Insulation
Bearings
Insulate
Pump
Driven
Insulated
Bearings
Motor
Driver
Special designs
Vertical applications
Coupling bears the
weight of its own
spacer only
Thrust Bearing
DRIVER
Coupling
Thrust Bearing
Pump Impeller
Special designs
Rigid Coupling
Coupling bears
the weight of the
pump impeller,
shaft and spacer
Thrust Bearing
DRIVER
Coupling
Pump Impeller
Special designs
Rigid Adjustable Coupling
Vertical applications
Supports pump shaft
Allows for axial setting of
pump
Special designs
Shear Devices
Protects equipment from damage due to torque
overload
Shear device disconnects the drive
Controlled disconnection (preset torque)
Special designs
Shear devices
Hydraulic method
Shear device releases pressure
Hydraulic pressure clamps shaft
Special designs
Limited End Float
Arises from use of sleeve or plain journal
bearings with no thrust bearing
Allows motor rotor to float at its magnetic centre
position
Protects prevent high axial/thrust forces
Metal membrane couplings are usually inherently
limited end float
Special designs
Long spacer Couplings - Cooling Towers
Composite
Spacer
Light weight
Special designs
Close Coupled - short DBSE
Replacement of gear coupling on API pump
Split Spacer
Reversed
Driven
Hubs
Driver
Special designs
High Performance Couplings
Turbo Compressor drives
Powers to 100 MW
Speeds to 40,000 rpm
API 671 required
Special designs
API 671
Special Purpose Machinery
Critical unspared machines
Turbine drives
Compressor drives
High Power/High Speed critical pumps
typically > 2000kW and/or 5000 rev/min
More detailed technical specifications
Now at 3rd Edition
Special designs
ISO 10441
Special Purpose Machinery
Critical unspared machines
1st Edition released
similar to API 671
balancing specification more practical and relates
more to installed repeatability
API 671 3rd Edition gets closer to ISO
not widely utilised
Special
Specialdesigns
designs
Factors affecting design for Turbo-machinery
Rotor- dynamic behavior / natural vibration
frequencies (coupling & machine)
Lateral
Axial
Torsional
High speeds
- dynamic balance is critical
- windage effects
Shaft interface requirements/assembly
Peak torque - short circuit effects
Electrical insulation etc.
Special designs
High Performance Couplings
Standard Marine-type Construction
247
235
193,5 kg
160,2 kg
Special designs
High Performance couplings
Reduced moment design
27,3
27,3
6,1 kg
6,1 kg
Special designs
High Performance Couplings
Coplanar Coupling
Ultra Low Moment
Low Windage
Special designs
High Performance couplings
27,3
27,3
Overhung moment 166,5 kgmm
6,1 kg
6,1 kg
Overhung moment 115,6 kgmm
-30%
Special designs
Reduced Torsional stiffness
248
235
193,5 kg
160,2 kg
Special designs
High Performance Couplings
Dynamic Balance to API 671
Formula proportional to
Weight
Speed
At 10,000rpm eccentricity of mass < 0.001mm
Repeatability is critical
Dynamic balancing techniques are critical
Special designs
Special Balancing Requirement
Special designs
Design Option: Shear Pin
Special designs
High Performance couplings
Retrofit coupling for Turbine Compressor Drive
To replace existing gear type
Special designs
Diaphragm type
GE Frame 6 Generator drive - 50 MW
Special designs
Duty 10 MW at 200 rpm
Dia = 1385 mm
W = 3.1 tons
for
LDPE Hypercritical Recip.
Special designs
Torque Measuring Couplings
Monitor machine performance
Phase shift or Strain gauge
Contents
Introduction
Types of coupling in use
Membrane couplings
Disc type
Diaphragm style
API Reliability and Safety issues
Good Alignment practices
Special designs
Conclusion
Conclusion
The Ideal Coupling
Infinite misalignment / end float capacity
No reaction forces on bearings
No mass - zero out of balance
Torsionally rigid
and Zero torsional stiffness
Fails safely when necessary
plus
Zero cost
JUST A DREAM ???
Couplings
The Overlooked Component
Specify them correctly
