Couplings (How to choose the right coupling)

Introduction:
A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting power. Couplings do not normally allow disconnection of shafts during operation, however there are torque limiting couplings which can slip or disconnect when some torque limit is exceeded. The primary purpose of couplings is to join two pieces of rotating equipment while permitting some degree of misalignment or end movement or both. By careful selection, installation and maintenance of couplings, substantial savings can be made in reduced maintenance costs and downtime.

Flexible couplings
Coupling functions: 1. Connect shafts. 2. Transmit torque. 3. Accommodate misalignment. 4. Protect driven and driving equipment. Couplings have: 2 hubs connected to the rotating shafts. And or also (this specifies the type of coupling): -A rubber tire. -Gear teeth -Flexible disk packs. -Flexible steel grid. Types of couplings: a) Gear: Use gear teeth to transmit torque. b) Disc: Rely on flexible metal discs to transmit torque from the driving shaft to the driven shaft. c) Elastomers: Theres 2 types of them; i) Both use a rubber ii) Compressor ones use inserts. iii) Shear ones can use bolts, bars or they can be bended to driven and driving hubs. d) Steelflex or grid couplings: These have a flexible steel grid which snaps into the hub teeth to transmit torque.

There is usually more than 1 type of coupling that is suitable for most applications. One consideration we need to make is the amount of torque that couplings must transmit.

Misalignments
The 3 types commonly known are: Parallel

Axial

Angular

Misaligned shafts not properly coupled are subject to severe stresses which damage bearings and seals. It is imperative that flexible couplings be used to avoid costly damage to the equipment. Initial alignment of machinery is one of the most critical factors affecting coupling performance and reliability. Each particular style of coupling has its own misalignment capabilities. The coupling has ample reserve to compensate for operational misalignments which develop as a result of bearing wear, foundation settling, thermal growth, pipe strain, etc. However, the closer the initial alignment, the more reserve margin a coupling has to compensate for misalignments during the life of the machine. A coupling that operates with large amounts of misalignment will have a limited life, while a coupling operating within capacity will have infinite life. The customer and coupling manufacturer must mutually select the correct size and type coupling for the application. Good service life will then become a reality if proper installation and alignment procedures are followed.

Torque:
It is the twisting force being produced by the motor; this is the tendency of a force to rotate an object about an axis, fulcrum, or pivot. Just as a force is a push or a pull, a torque can be thought of as a twist. The magnitude of torque depends on three quantities: the force applied, the length of the lever arm connecting the axis to the point of force application, and the angle between the force vector and the lever arm. In symbols:

Where is the torque vector and is the magnitude of the torque, r is the displacement vector (a vector from the point from which torque is measured to the point where force is applied), and r is the length (or magnitude) of the lever arm vector, F is the force vector, and F is the magnitude of the force, is the angle between the force vector and the lever arm vector. Or ( )( )

Example: At 10 H.P. motor running at 1750 R.P.M. We have ( )( )

Or At 100 H.P. motor running at 1750 R.P.M We have ( )( )

Service factor:
The service factor adjusts the coupling size selection based on the severity of loading, typically experienced to ensure reasonable coupling life. Coupling life depends on: Fatigue capacity. Speed. Misalignment. Environment. Lubrication. And also depends on the type of power source such as; i) Electric motors provide smooth flow of power. ii) Diesel engines provide a pulsating power (the fewer the number of cylinders, the harsher the service).

Also bore requirements must be considered, because there may not be a coupling available for different size of shafts. Another aspect to consider when choosing the right coupling should be the mounting configuration. The system may require a special coupling that mounts vertically or has no standard gaps between the shafts. The distance between the shafts is called The Shaft Gap (B.E. Between Ends). The allowable size where the coupling will be mounted is called The Envelope, if there is minimal space to mount the coupling, we might use Steelflex or Gear couplings instead of Elastomers. Environmental conditions: Temperature. Exposure to sunlight. Corrosive atmosphere. Contaminants which could break down the lubricant.

Gear Couplings
They Use 2 Hubs, 2 sleeve hubs, 1 fastener set and 2 oil seals. The hubs these couplings use are ringed with a roll of gear teeth which make up part of the loaded bearing link. The gear sleeve fits over the hubs, inside the gear sleeve there are teeth as well, which match with the hub teeth to transmit torque, the 2 hubs and the sleeves are attached together with special coupling bolts.

Advantages Gear couplings have a very high torque capacity for their size, they do not twist or line up under load, this helps synchronize the equipment and provides constant stiffness which is useful in tuning system vibrations. Strength and rigidity are 2 advantages gear couplings have over other coupling types in certain applications. Their price is the lowest of all flexible couplings. Because of their size and high torque capabilities, gear couplings are a good choice when having a limited space, or where high speed is needed.

Disadvantages It is the sensibility to the quality and quantity lubricant, 90% of all gear coupling failures are related to loss or breakdown of the lubricant.

Re-greasing is required every 6 months

Higher maintenance costs than other coupling types. It is time consuming and very expensive to replace these couplings.

This coupling is too rigid, so it does nothing to lower the shock or vibrations.

Disc Coupling
This kind of couplings has Flexible metallic membranes or discs which attach to the 2 hubs. Torque is transmitted through the disc pack by the tensile forces; these couplings can transmit high torque too. They use 2 hubs, 2 disk packs, 1 spacer and 2 fastener sets. The torque is transmitted through the disc packs by the fasteners; these are considered as the primary coupling when high speed is required or no backlash is allowed.

Advantages Long life and low maintenance.

Precision and balance for high speed operation.

Disadvantages Rigidity: they are so stiff that they do not allow shock loads or vibrations and very low axial float capacity. Their initial cost is the most expensive of all type of flexible couplings, since they require very high precision in the machine tolerances.

No lubrication required. Can be installed in different locations without worrying of the environment. Have a long fatigue life.

Elastomer couplings
There are two types of Elastomer couplings: Compression Coupling o These couplings use rubber elements. o The elements can have different shapes depending upon the manufacturer. o The rubbers may be synthetic compounds such as Urethane or Neoprene. Advantages Low initial costs. Work very well on fractional H.P. applications. Can be blind assembled. Disadvantages Low fatigue life and they wear out very quickly. Because they are so compressed they can be quite stiff. Susceptible to environment conditions, such as sunlight, temperatures (high, and low), chemicals, air, rain, etc.

Do not require lubrication and no routine maintenance. Shear Type Elastomer Couplings o These couplings use rubber as well; this rubber element is known as Tire. o The Tire is attached to the hub with the clamping ring and the coupling fasteners. Advantages These are the most torsionally flexible of all the couplings. Have a very high misalignment capacity. No lubrication is required. Disadvantages Limited life.

Wear out quickly. Environmental restrictions such as sunlight, temperatures above and below the recommended which make its life shorter. Induce thrust loads. They are too large for the torque capacity in some cases. Models with high torque capacity are very expensive compared to other coupling types.

Steelflex couplings
These couplings have a unique grid member, which transmits torque, accommodates misalignment, and dampens vibrations and shock loads, these couplings take most of the advantages of all the other flexible couplings. The hubs have teeths which assembles with the grid and use coupling covers which maintain the lubricant safe from dust, and other compounds that may affect the performance of it. Advantages These have a very high torque such as gear and disc couplings and flexibility such as Elastomers. Can be long time in service; some of them have been working up to 50 years. Spare parts are cheap. Require little or no maintenance at all. No sensitivity to weather or environments. High fatigue life ratings. Disadvantages These must be lubricated during installation. They cant be blind Assembled.

Disc coupling selection procedure

The following procedure can be used to select Disc couplings for most applications. 1. Determine HP/100RPM: 2. Determine Service Factor: Select the proper Service Factor from Table. Note: if not listed, see Load Classification Table. Note: The Service Factor Table considers the driven equipment only and assumes a normal electric motor or turbine driver. For prime movers of the reciprocating type (engines, etc.) add the following to the Service Factor: For 8 or more cylinders, add 0.5 For 6 cylinders, add 1.0 For 4 cylinders, add 1.5 For less than 4 cylinders, consult Rexnord Industries, Inc.

3. Select the Coupling: Turn to the page describing the selected coupling type and select the smallest coupling capable of transmitting the calculated HP/100 RPM at the proper Service Factor. 4. Check Limiting Conditions: a. Check maximum speed (dynamic balancing may be required) b. Check maximum bore. c. Check other dimensions such as shaft separation, overall length, O.D., etc. d. Check to be sure that the maximum torque to be transmitted, such as start-up or stall torques. Do not exceed the couplings Peak Overload Torque Rating. Note: Variable frequency and synchronous motors and certain induction motors produce transient torques several times the continuous rating of the unit. Consult motor manufacturer. Selection example: A 250 HP electric motor is driving a dredge pump at 1,800 RPM. The shaft size of the motor is 2 3/8 the shaft of the pump is 2 1/8. The distance between the shaft ends (DBSE) is 5 inches. The environment is 150 F. HP/100 RPM = 250 HP 100 1800 RPM = 13.89 HP/100 RPM

THEN Application Torque = 250HP 63,000 1,800 = 8,750 lb.-in

Service factor (See typical service factor on the table) = 2.0 Use chart on table for HP/RPM THEN Application torque requirements Service factor 8,750 2 = 17,500

Tables

Torque requirements suggest a size 225. Bore size requirement indicates a size 225 is required. DBSE requirement is met by 225 with standard 5 inch C dimension. Coupling Selection = Series 52, Size 225 with standard 5" dimension.

General Alignment Instructions

Correct installation and alignment will assure long life and smooth, trouble free service. Refer to specific instruction sheet, which accompanies shipment, for style of coupling being installed. Two methods are commonly accepted: 1. Reverse Indicator Method (preferred) 2. Face/Rim Method (angular/offset) The Reverse Indicator Method 1. Rigidly mount a dial indicator on one hub or shaft, reading the shaft or other hub outside diameter as shown. Compensate for indicator set-up sag. Rotate both shafts together. Adjust the equipment by shimming and/or moving so that the indicator reading is within maximum allowable variations for the coupling style. 2. Reverse the set-up as shown and repeat #1 above. 3. When the results of #1 and #2 above are both within maximum allowable variations for the coupling style the shafts are in good alignment.

Angular Alignment. Rigidly mount a dial indicator on one hub or shaft, reading the face of the other hub flange, as shown in Figure 2. Rotate both shafts together making sure the shaft axial spacing remains constant. Adjust the equipment by shimming and/or moving so that the indicator reading is within maximum allowable variations for the coupling style. Parallel Offset. Rigidly mount a dial indicator on one hub or shaft, reading the other hub flange outside diameter, as shown in Figure 3. Indicator set-up sag must be compensated for. Rotate both shafts together. Adjust the equipment by shimming and/or moving so that the indicator reading is within maximum allowable variations for the coupling style.

Locknut Tightening Torques

Properly tightened locknuts are essential in achieving maximum coupling torque. This table suggests the approximate locknut tightening torque values of disc couplings. Torque should be measured at the locknut while it is being turned. The tightening torques apply to locknuts as received from the factory. If plated hardware is used, tightening torque must be modified to suit. Stainless steel hardware requires special consideration. The tightening torques must be reduced to 60% of the values shown. Bolt and locknut threads must also be liberally coated with a molybdenum disulphide grease if using stainless steel hardware. Bolting instructions for Series 63 Couplings are included with coupling installation procedures.

Monitoring and Inspection

1- Purpose
Monitoring and inspection of the Thomas disc pack in the field.

2- General Information.
The flexible disc-type coupling is designed for long life when operated within the torque and alignment limits. A well chosen flexible disc coupling operates indefinitely with low cross loading of the connected shafts, has low power absorption, and induces no vibrations or resonances into the system. The installation of a flexible disc coupling operates indefinitely with low cross loading of the connected shafts, has low power absorption, and induces no vibrations or resonances into the system. The installation of a flexible process. Burrs, dirt and grit on either the shaft or in the bores can cause the hubs to gall during mounting. Poorly-fitted keys can also gall and not seat correctly. Concentrated heat on the hubs will cause distortion. The coupling must be properly assembled and the locknuts tightened in accordance with the installation instructions. Loose bolts will cause elongation of the disc bolt holes and eventual failure.

The most common forms of faillure in disc fatigue due to excessive flexure. This is usually caused by poor initial alignment of the connected machines. It also can be brought about by operational conditions.

3- Detection
The thomas disc coupling is easily inspected. Visual analysis may point to possible drive system problems. Proper evaluation of the disc packs and connecting parts may save considerable maintenance costs and downtime. When a disc coupling starts to fail, it is usually from the outer disc of the laminated pack and progresses towards the center of the pack. Figure 1.

Because of this progression, the deterioration of the coupling disc pack may be detected before ultimate failure. A. Detection of trouble with the equipment in operation. 1. Monitored equipment. Most equipment of this type is continuously monitored with vibration sensors. As a coupling disc pack deteriorates, it loses some pieces of the disc pack wich causes unbalance. This unbalance can be detected by the vibration monitoring equipment. This piece-by-piece deteroration allows controlled shutdown before ultimate disc pack failure. 2. Unmonitored equipment. Couplings using a guard with either an open bottom (U type) or open mesh can give early visual warnings. Pieces of the disc pack found under the open U guard or seen lying inside the expanded metal guard or seen lying inside the expanded metal guard are a good reason to shut the unit down. Now inspect the coupling, replace the disc packs, and realign the equipment. B. Detection of trouble with equipment out of service and guard removed: Here are some of the most evident visual inspection criteria and recommended corrective procedures.

1. Reddish brown color bleeding out between disc laminations at the O.D. of the pack. This is an indication of fretting and/or chemical attack of the disc material. Figure 2. 2. Fine line crack starting in the outer disc, tangent to the washer O.D. This is an indication of misalignment and can be seen by looking at the outside edge of the disc pack. Figures 2, 8 and 9.

3. Disc pack is wavy and dimension between flange faces N is smaller than indicated in the installation instructions or applicable assembly drawing. Figure 3. This indicates that the coupling has been installed in a compressed condition or equipment has shifted axially during operation. Check for shaft thermal growth conditions. Realign axial position of equipment so the coupling operates with a neutral, flat disc pack.

4. Disc pack is wavy and dimension between flange faces N is larger than specified on installation instructions or applicable assembly drawing. Figure 4. This indicates that the coupling has been installed in an elongated position or equipment has shifted

axially during operation. Reallign axial position of equipment so coupling operates with a neutral, flat disc pack.

5. Disc packs (both ends) are wavy. One end is compressed, and the other end is elongated. Figure 5. The conditions can be reversed by moving the center member towards the elongated end. This is called oil canned disc packs. The disc pack has no neutral center where is remains flat and parallel with the end flanges.

This condition can be the result of: 1) Tightening the disc pack locknuts while the disc packs are in the compressed or elongated coupling position. See figure 3 and 4. 2) Tightening of disc pack locknuts while coupling is misaligned or other end of spool is hanging unsupported.

3) Bound up bolts in the bolt holes. 4) Daaged discs wich could be caused by abnormal running conditions, misuse, or loose bolts. To correct oil canned disc pack: 1) Loosen all the disc pack locknuts. Correct the axial spacing of the coupling as necessary with the coupling aligned and spacer fully supported. If oil canned conditions disappears, retorque locknut while coupling is in its neutral position. 2) If (1) above is not successful, determine that all bolts, with locknuts loose, can be turned by hand. If any bolts are tight, the bolt holes should be cleaned out by lightly reaming the flange so that the bolt turns by hand in the hole. Reassemble and torque the locknuts while coupling is in its neutral position. 3) If the discs in the pack are permanently deformed, replace the disc pack with a new one and reassemble the coupling. This permanent deformation could be caused by a severe torque overload, abnormal axial loads, or even loose bolts. The cause of the deformation must be corrected before restart. The coupling, as finally assembled, should have a neutral center where the center member is free to float axially with out snapping from one end to the other when moved by hand. 4- Analysis of failed disc coupling In the event of a coupling failure, a thorough investigation shiould be made to determine the cause. The most common causes of failure are improper coupling selection, improper assembly, excessive misaligment, and corrosive attack. 1. Disc broken through the bolt hole indicates loose coupling bolts. Figure 5. Replace disc pack and tighten locknuts to specified torque value.

2. Disc embedded into bolt body are usually the result of a loose bolt or a severe torque overload. Figure 7. Replace bolt and disc pack. Tighten locknut to proper torque. Do not torque the bolt as insufficient bolt stretch may occur.

3. Disc broken adjacent to washer face usually indicates excessive shaft misalignment durin operation. Figures 1 & 8. This type of disc failure usually starts with outer disc and progresses through the disc pack. Realign equipment and replace both disc packs. Make hot check of alignment to assure it is within coupling misalignment capacity.

4. Disc broken adjacent to washer face with fretting corrosion present in the area of crack usually indicates excessive shaft misalignment during operation. Also, iron oxide will most likely be evident on outside of disc pack. Figure 2 &9. This is sometimes associated with coupling that has been in service for several years and/or operating in a corrosive athmosphere. Breaks will first appear in outer

discs and progress through the disc pack. Replace both disc packs and realign the equipment. Different disc pack material may also be considered.

5. The disc pack has a bulge near the center or is bowed toward one flange in alternate chordal sections. Figure 10. This condition is a result of a large torque overload, induced into the system, beyond the peak overload capacity of the coupling. The remaining disc pack chordal sections will be straight and tight. This indicates improper coupling selection or a momentary system torque overload. If bulged or bowed conditions appears in one chordal section only, there may be a loose bolt on one side of the distortion. Loosen all coupling locknuts and unseat the bolts. The bulge should release and flatten out. Retorque locknuts. If distortion does not disappear, replace disc pack and retorque locknuts.