Coupling Failure Investigation

Many pump couplings are designed to be a fuse that fails before major damage occurs
to expensive pump systems. Premature wear or failure is typically the first symptom of a
problem.

The most frequently encountered causes of coupling problems are:

 Misalignment

 Improper fit or assembly   

 Overload

 Abnormal environmental conditions

 Torsional Vibrations

Misalignment

Volumes have been written about misalignment, so we will highlight some of the
most frequent causes. Misalignments between the motor and pump are unavoidable
and are often created during the unit's assembly. Poor initial alignment (for example,
using a straightedge), distortion from pipe strain or an improper/weak base support are
typical causes of misalignment. Even if both components are properly aligned,
subsequent misalignment may occur from extreme temperature variations during
operation.

To compensate for these errors, engineers and maintenance technicians use a flexible
coupling that permits some axial, radial and angular misalignments. This shaft coupling
range meets special requirements that the manufacturer and end user must consider
when selecting the proper coupling. 

A prime example of these special requirements is hot medium pumps where extreme
temperature variation causes thermal growth and resulting shaft displacements
unsuitable for single-cardanic or single flexible insert designs. In these applications,
excessive shaft misalignment reduces the service life of the coupling, bearings and/or
seal systems. A double-cardanic, or two flexible inserts with a spacer design, can
compensate for excessive misalignment (see Figures 1 and 2).

Misalignment indicators:

 Changes in the running noises and/or vibration

 Premature wear of the coupling insert or cracking of disk packs

 Shaft seal leakage

 Premature bearing failure

Recommended solution:

 Shut down the unit

 Check for misalignment issues, i.e., loose baseplate bolts, a broken mounting
foot, heat expansion of the components or change in the assembly gap of the
coupling

 Check the coupling insert for wear, and replace if necessary

 Consider using a double-cardanic spacer coupling

Improper Fit or Assembly

There is no doubt that a properly selected shaft coupling extends the service life cycle
of a pump system. However, service life cycle costs should also be considered.

Taper lock bushings may seem the preferred choice from a stocking and
maintenance standpoint. However, be aware that the design is not failsafe. Taper lock
bushings require strict assembly procedures, or failure is possible. A clamping hub or
split hub design may be more reliable and easier to assemble.