Courtesy of Kop-Flex/Emerson Power Transmission Corp. JRM16.

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Pump Couplings
By carefully selecting, installing and maintaining
couplings, you can save substantial dollars in
reduced maintenance costs and downtime.

A
variety of flexible couplings
are used on pumps. Yet, only
a small number of specifica-
tions and requirements exist
for these coupling types. The
American Petroleum Industry (API)
addresses a few of these require-
ments in one of its specifications,
API 610, Centrifugal Pumps for
General Refinery Service (Seventh
Edition). This specification states that
couplings must have an alignment
diameter concentric to the bore with-
in 0.003 TIR” to help with alignment,
and that couplings must meet bal-
ance requirements of AGMA 515,
Class 8. There are not many other
industry standards for pump applica-
tions that specify additional require-
m e n t s f o r c o u p l i n g s . More
importantly, these specifications and
requirements do not explain how
couplings work or help in the selec-
tion process.
FUNCTIONS OF FLEXIBLE COUPLINGS
Flexible couplings join two
pieces of rotating equipment while
permitting some degree of misalign-
ment or end movement or both. The
three basic functions of a flexible cou-
pling are to (Figure 1):
1. Transmit power
2. Accommodate misalignment
3. Compensate for end movement
In general, the power lost by a Mechanical element coupling: grid type, horizontal split cover
flexible coupling is small, although
I :

54 MARCH1994 PUMPS AND SYSTEMS MAGAZINE

Mechanical element coupling: gear type,
crowned teeth
donut, block, jaw, urethane tire,
corded tire, shear donut, disc and
diaphragm.
GEAR COUPLINGS
Gear type couplings consist of
two hubs with external teeth that
engage internal teeth on a two- or
one-piece sleeve. The teeth may be
straight or curved (crowned). For an
application requiring over l/4 degree,
curved teeth may be better. These
couplings obtain their flexibility
because of the looseness (backlash)
between the mating teeth. Gear cou-
plings are used for medium and large
pump applications, and are probably
the most power dense type available.
They require periodic lubrication,
every l-2 years, depending on duty
and type of lubrication. If properly
maintained (good lubrication and rea-
sonable alignment), these couplings
have a service life of 3-5 years, and in
many cases 5-10 years.
Some gear couplings have sleeves
that are made of plastic (nylon, or
high molecular plastic) and do not
require lubrication. These have much
lower torque capacities than the all-
steel couplings and are used mainly
on small pumps.
PUMPS AND SYSTEMS MAGAZINE
Mechanical element coupling; gear type, straight teeth
GRID COUPLINGS
Grid type couplings are similar to
gear couplings. Composed of all
metal, they have some degree of
resilience. These couplings can damp-
en vibration and reduce peak or
shock loads by 10-30%. They have
two hubs with serrations (grooves)
rather than teeth. The grooves are
connected by a steel grid. The covers,
which keep the lubrication in, are
either vertically or horizontally split.
These couplings do not transmit as
much power (per the same outside
diameter) as gear couplings but are
usually less costly. Grid couplings are
used for medium and small pump
applications.
These couplings were originally
designed for torsional dampings (soft-
ness). They are often misapplied in
pumps because of their low cost, and
will fail immediately with loss of
packed lubricants.
COMPRESSION DONUT COUPLINGS
Compression donut couplings
have a precompressed elastomeric
donut. Screws force the donut to a
smaller diameter. All legs of the
donut are in compression before the
load is applied. Low torsional and lat-
era1 stiffness is achieved with this
design. Medium and some small
pumps incorporate these couplmgs.
BLOCK COUPLINGS
Block couplings use rubber in
compression. The rubber blocks are
installed in cavities formed by inter-
nal sleeve blades, external hub blades
and two end plates. This type is
unique among couplings due to its
“fail-safe” feature. If the elastomeric
fails, the coupling may run for some-
time on the metal blades. These cou-
plings can provide up to l/2 degree of
misalignment and parallel off set capa-
bilities of 1/64-1/4 inch. Large
pumps use these type couplings to
reduce vibratory torques or because
it is torsionally soft and is used to
tune a system. Sometimes medium
and small pumps will use these cou-
plings because if properly aligned,
they require no maintenance (except
for replacement of blocks every 3-5
years).
JAW COUPLINGS
Jaw couplings have their elas-
tomers in compression. The flex ele-
ment can be one piece or split to
facilitate replacement. They also have
MARCH1994 59
a “fail-safe” feature. Flex elements are flexibility, When the
made of many types of elastomeric coupling fails, usually
materials, such as, rubber and ure- only the elastomeric
thane. The properties (that is, hard- element is replaced.
ness, resilience, etc.) can be varied to CORDED TIRE
suit required loads. These couplings COUPllNGS
are used primarily to accommodate
misalignment and transmit power. Corded tire cou-
Small and medium pumps employ plings also have their
these couplings. Be careful, since elastomeric elements
sometimes these couplings are used in shear. They use a
to absorb energy and dampen loads, reinforced element
particularly when equipment is (similar to belted auto
engine driven. Also be careful tires). Because of the
because they are torsionally soft and reinforcement in the
in the past were used to tune a sys- element, the torque
tem out of a torsional critical mode. capacity is greater per
outside diameter than
URETHANE TIRE COUPLINGS the urethane tire cou-
pling. Most small and
Common on small pumps, ure- some medium pump Metallic element coupling; disc type,
thane tire couplings have their elas- applications use these continuous disc
tomeric elements in shear. The tires
are split to enable easy assembly
without removing hubs. Urethane SHEAR DONUT COUPLiNGS can and has been optimized for its
tire couplings offer a high degree of (UNCLAMPED) characteristics. These couplings are
composed of all metal, and do not
Another type require lubrication. The discs are usu-
common on small ally continuous but can be individual
pumps, shear donut links. Most disc couplings use multi-
couplings have their ple thin discs rather than one thick
elastomeric elements disc/link because the stresses from
in shear. They pro- misalignment are proportional to Nts
vide low torsional versus T^3. These couplings are used
stiffness and low reac- in medium pump applications. If
tionary forces. Over- properly installed and misalignment
sizing can lead to is kept under 1/4 degree, this type
premature failure by will provide a long life with little
wearing the engaging maintenance. If the misalignment
teeth rather than a increases beyond 1/2 degree during
material failure from operation, the flexible element will
flexing. probably fail in fatigue.
OISC COUPllNGS DlAPHRAGM COUPLlNGS
Disc couplings Diaphragm couplings transmit
transmit torque by a torque between the inside and out-
simple tensile force side diameters of the flex element.
between alternating The diaphragm can be constant or of
driving and driven variable thickness, and singular or
bolts on a common multiple. The diaphragm shapes are
bolt circle. Misalign- usually modified to increase flexibili-
ment is accomplished ty (such as, tapered, convoluted, and
from the flexibility cut out profiles). These couplings can
that comes from the usually handle up to l/2 degree of
length of material misalignment. Large, critical pump
between the bolts. applications rely on these couplings.
Disc couplings have
been around for
HHOWDlAPHRAGM COUPLlNGSTOSELECHTCOUPl
How To Select Couplings
Elastomeric element coupling; compression years but with the use When selecting a coupling how
type, compression donut of Finite Element do you know which one is best? The
Analysis, this type chart in Table 1 shows there is no

62 MARCH1994 PUMPS AND SYSTEMS MAGAZINE

Metallic element coupling: diaphragm type, multiple
6. Stiffness requirements
7. Bearing load restrictions
8. Potential excitation or critical fre-
quencies
If you change the coupling,
make sure that all maintenance per-
sonnel understand the requirements.
For example, changing from a gear
coupling to a disc coupling will
require different instructions for set-
ting a motor on its magnetic center.
Alignment procedures also differ.
Review all coupling changes to
ensure success.
INSTALLATION CONSIDERATIONS
Most coupling failures occur rela-
tively soon after installation or after a
coupling has been reassembled on
the equipment. Usually failures occur
because the installer didn’t read and
follow the manufacturers instruc-
tions. To achieve success, the
installer needs to read and follow
those instructions!
Things not to do, or a sure way
to increase failures:
1. The coupling doesn’t fit on the
shaft. Get out the torch and heat
the “H” out of the hub, or open
up the bore until the coupling
slides on.
PUMPS AND SYSTEMS MAGAZINE
2. The keys are too tight. Grind
them until they fall in.
3. You lost a bolt. Take one from
the maintenance department’s
bolt can-any one will do.
4. These bolts are snug enough.
5. The pump or motor is unbal-
anced. Let’s rebalance and take it
all out of the coupling.
6. Part of the coupling looks bad.
Replace the bad part with anoth-
er part that you took out last
year.
7. Put the same grease in the cou-
pling, like you do in your bear-
ings.
8. Don’t check alignment. The
pump has been running fine for
2 years.
9. You request a coupling to fit on
your 3” shaft and with one l/2”
keyway. You supply no other
information.
10. You buy another coupling type
because it costs 30% less than
the current one.
continuad