Reliability Membrane Couplings + Long or Infinite life + No routine maintenance required So why do they sometimes fail ?Metastream Reputation Metastream couplings have been supplied to the highest standards for 50 Years No recorded failures due to bad design of M or T series Few due to manufacturing errors + Some wrong selections, due to misunderstanding of the specification Reliability Data Recorded life for Industrial Coupling 4 failure in 1/2 million hours operation Recorded life for High Performance coupling + 1 failure in 2 million hours operation Causes of failure Installed misalignment 75% Torsional Failure 10% + Movement in service misalignment 5% + Torsional resonance 5% Other inc. corrosion, axial, bolts etc 5%Failure Records John Crane recorded failures 2009 - 2013 2009 2010 2011 Torsional Vibration 3 4 5 3 - Torsional Overload 1 2 - 2 2 Axial /Lateral Vibration 1 - - = Mis-alignment 5 Ser 35 Design Ste Assembly 1343-0 17 Why did it fail? 2012 3 2013 2014Failure Modes Assembly problems — bolts, errors, tightening torques etc Misalignment = Angular = Axial Torsional Overload Torsional Vibration = Resonance — e.g. Fan drives * Application related — e.g. reciprocating Axial Vibration Lateral Vibration — critical Speed, Whirling etc | Assembly — Hub fit?How did it fail? LOOSE BOLTSAssembly - Drive Bolt Failure Assembly - Drive Bolt Failure M20 12.9gr at 120-140m/sOver Compression Membrane liftDamaged Electrical Insulation Klunk, PantAlignment Poor alignment is a frequent cause of rotating machinery outage End float Axial M Series Spoke GB 1.T Series Link ‘Clamping Washer contact aren ‘Arc of maxima Failure Modes Failures develop here + Highest stress at edge of was! Primary cause + Fatigue / cyclic stresses Mjgali Washer Area Secondary cause + CorrosionAngular and LeterabMisalignment=_—_ Lateral misalignment resolves into angular misalignment at the membrane packs. Thus, the symptoms of lateral misalignment are identical to those of angular misalignment Axial Misalignment Rare failure due to pure axial misalignm some degreeCyclic axial Misalignment — 6 hours! Torsional Overload M - Series wrinkling of the spokes T - Series bowing of the leading link or rupture at mid span of the 6 link. Tends to rupture around the holes of an 8 linkLateral Vibration Torsional OverloadExample of devastation Torsional Vibration M - Series fail on the inner radius of the spoke T - Series fail on both trailing and leading linksTorsional VibrationTorque Measurement (Striped Tape) Torque Measurement (Striped Tape) '3000Nm, 1000rpm ANAT.Torque Frequency Check (Strain Gauge)Measured Torque @ 100Hz (Strain Gauge) ‘Coupling Data Logged Torque @ 1, 6,10 & 15H2 SK) (400 & 800m Peak to Pea Corrosion and ChemicalSummary of Typical Questions Driver equipment — fully review Driven equipment fully review ‘Variable Frequency Drive (VFD) Shaft detalls Speed fluctuations Dow? Does the failure difer at each end”? How long to reach operational speed? Start/ stops? Vibration trends ‘Torque measurement “Torque constant? ‘Temperatures and recordings ‘Thermal growth How many fairs Detall of the fallure Is the motor a Sleeve bearing design i. magnetic centre? ‘Check for manufacture deviations and dimensions ‘Start up conditions Installed lengths Is any alignment recordings ava sipped: ‘Any freting on cive bolt / washer face ‘Membrane conciton Inspection ofthe bits for material properties, falure mode and cracks ‘machine ineras and torsional stiffness of both shafts lo?Example of Good Video Qutside Membrane Inside Membrane Failure Analysis Log http://jbucsap66/CouplingFailure/Default.aspx