Subject Category 8

Couplings

Chapter 8.1

Coupling Types and Styles

INTRODUCTION
Couplings serve to connect the rotating shaft of a driver to the shaft of the driven
machine. Although the shaft centerlines are usually well aligned (see earlier
text chapter on alignment), maintaining perfect alignment is difficult or near-
impossible. A flexible component is thus needed between the coupling hub
fitted to the driving shaft and the coupling hub fitted to the driven machine's
shaft. Flexible couplings can accommodate a small amount of parallel and an-
gular misalignment; a flexing element reduces both vibration amplitude and
bearing loads.

FLEXING ELEMENTS MADE FROM ELASTOMER MATERIALS

The basic components of elastomeric couplings with a deformation-tolerant
element (usually a block or star shape) in compressive load come in dozens
of different styles. Their use in special purpose (meaning nonspared, extended
run length) petrochemical machinery is usually confined to large slow-speed
machines. Here, the primary purpose of an elastomer block or contoured insert
is to avoid torsional resonance conditions.
Resonant frequencies are rarely an issue in small pumps. However, couplings
incorporating flexible elastomer elements in compression are frequently applied
in somewhat smaller close-coupled process pumps. In these, yearly maintenance
and parts replacement are the norm.
In elastomeric couplings with tire-like flexing elements, the “tire” undergoes
twisting; tensile loading prevails. There is similarity between this flexing
element and certain vehicular tires. Rim geometries are suitable for securing
the sides of the “tire” to an adjacent coupling hub. Other brands of elastomeric
flexing elements are designed with a cross section resembling “omega,” the last
letter in the Greek alphabet. Regardless of cross section, some models or styles
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of flexing elements have each rim fused into a metal ring. In turn, the metal
ring has to be fastened to the adjacent coupling hub and the fasteners must be
selected with great care. Torque wrenches must be used to securely and properly
tighten the various bolts.
Because elastomeric couplings with tire-like flexing elements are designed
with the flexible element twisting or pulling, they are rarely used in large fluid
machines. They are, however, applied in so-called general purpose (as contrasted
with “special purpose”) small- to medium-sized pumps.
A number of factors come into play whenever elastomeric couplings are
chosen:
● Toroidal (“tire-type”) flexing elements can exert an axial pulling force on
driving and driven bearings. Also, they are difficult or near-impossible to
balance.
● Polyurethane flexing elements (or inserted elements in compression) per-
form poorly in concentrated acid, benzol, toluene, steam, and certain other
environments.
● Polyisoprene flexing elements (or elements in compression) do poorly in
gasoline, hydraulic fluids, sunlight (due to aging), silicate, and certain other
environments.
● Components made of natural rubber may be susceptible to ozone attack.

OBTAIN USER FEEDBACK

User experience feedback is of great importance in selecting toroidal couplings.
Well-trained reliability professionals always establish that a particular offer
meets their company's long run length or low failure risk expectations. These
professionals compare warranty duration and coverage, specific features, and
power capabilities, including installation details, tooling, and allowable com-
bined parallel and angular misalignment.
Occasionally, pump and coupling users have encountered sales or market-
ing personnel who will deflect user questions in the hope of making a sale. The
primary focus of such marketing strategies may be low initial cost and attractive
wear part replacement cost. A certain size elastomeric coupling may indeed
cost “X” dollars less than a competing longer-lasting coupling. But what if the
initially less expensive coupling has to have its flexible elements replaced far
more frequently? What if running a coupling to failure can cause parts to be-
come airborne? What if a precautionary shutdown prevents failure, but costs a
(hypothetical) “7X” dollars? Be sure you know as many answers as possible
before buying couplings. You may even look at past litigation involving poten-
tial vendors and verify that a particular causal event has since been addressed in
suitable redesigns. Alternatively, changes in maintenance or related work pro-
cedures should have been implemented.
 Coupling Types and Styles  Chapter | 8.1  85

Gear couplings require grease replenishment and are certainly more

­ aintenance-intensive than nonlubricated disk pack couplings. If gear ­couplings
m
are selected, they should be on the plant's preventive maintenance schedule.
Only approved coupling greases should be used for periodic replenishment.
Realize that standard and multipurpose greases are unsuitable because their oil
and soap constituents are getting “centrifuged apart” at typical pump coupling
peripheral speeds.
That usually leaves a reliability-focused user with nonlubricated disk pack
(Fig. 8.1.1) or other variants of alloy steel membrane couplings (e.g., diaphragm
couplings) as the preferred choice for lowest life cycle cost, or LCC. The LCC
design must be such that the spacer piece or center member is “captured,” mean-
ing retained between opposing coupling hubs. In the unlikely event of a disk
pack failure, a “captured center member” will not leave the space between the
two coupling hubs.
API-610-compliant disk couplings are designed to be fatigue-resistant for
a theoretically infinite service life, as long as the bending stresses applied to
the coupling disk packs do not exceed their rated limits. The disk packs are
mounted in a cartridge that is removable without any need to disturb the driving
and driven hubs, allowing for easy access to pump seals. The various coupling
elements have overlapping features (“captured center members”) to mitigate
the risk of the spacer tube being thrown from the machine in case of coupling
failure due to overload. This particular coupling design transmits rotary power
by pure face friction, eliminating shear loading and stress concentration in the
assembly bolts, making the system more reliable.
It should be noted that many brands of inexpensive couplings do not have
captured center members. Avoid using them.

FIG. 8.1.1  A widely used version of a reliable high-quality disk pack coupling for fluid machinery,
including large process pumps. (Courtesy R+W Couplings, Klingenberg, Germany.)
86   Petrochemical Machinery Insights

FIG. 8.1.2  A highly reliable special purpose (API-671 compliant) high-quality disk pack cou-
pling for fluid machinery, including large process pumps. Image shows left side configured for
gearbox fit-up; the right side is configured to fit the driver’s output shaft. (Courtesy FlexElement
Texas, Houston, TX.)

The thoroughly engineered disk pack coupling of Fig. 8.1.2 is used in nu-

merous upgraded fluid machinery installations. It complies with API-671 and
other high-performance standards. Its primary range of application is in 1000–
100,000 horsepower turbomachines. Among its important positive attributes are
high-quality materials, advantageous machining methods, and optimized disk
coatings. Lead times, that is, the time elapse between order placement and de-
livery, are almost always very attractive.

INSTALLATION AND HUB REMOVAL

Before installing a coupling, examine it for adequacy of puller holes or other
means of future hub removal. The coupling in Fig. 8.1.3 was mistreated at disas-
sembly because no thought had been given to future removal.

FIG. 8.1.3  Coupling hub damaged with severe hammer blows at disassembly.

 Coupling Types and Styles  Chapter | 8.1  87

For parallel pump shafts with keyways, use 0.0–0.0005″ (0.0–0.012 mm)

total shaft interference. Depending on user experience, several available thermal
dilation methods (heat treatment oven, superheated steam, and electric induc-
tion heater) are available to mount hubs on shafts.
Disallow loose-fitting keys for coupling hubs because they tend to cause
fretting damage at shaft surfaces. During rebuilding or repair, allocate time
needed for hand-fitting keys; they should fit snugly in keyway. On all replace-
ment shafts, reliability optimization requires avoidance of sharp corners in key-
ways. Arrange to have only “radiused” corners (meaning that the corners have
fillet radii). Sharp-edged keyways are locations where excessive stress concen-
trations exist.
Reliability-focused petrochemical plants often modify the key contours to
match the radius contour. Others are specifying coupling hub bores with special
keyless fit arrangements. Highly advantageous friction-based hub clamping op-
tions are available from some of the best coupling manufacturers.