Generator Couplings

TC Conference Malaga October 2007

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Agenda
Generator Set Couplings Cat Coupling Centa Couplings Ringfeder Renolds Geislinger Summary

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Generator Set Coupling System

Coupling is integral part of dynamic system which includes Generator rotor Engine crankshaft, rods, pistons Damper Coupling selection is part of dynamic system design Single Bearing Generator Flex plates Quantity and thickness depends on package configuration Two Bearing Generator Couplings require maintenance Coupling and damper problems frequently happen together

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Cat Coupling
Used on older designs Maintenance Periodic inspection Frequency depends on application Generator sets rated at 2 MW or more Inspect every 2,000 hrs Generator sets rated below 2 MW Inspect every 4,000 hrs Inspection interval can be adjusted with experience Boots should be replaced if wear more than 2 mm If boot wear exceeds 5 mm Measure the gap between bearings and bearing sleeve Both bearings! Replace bearing & sleeve if gap is greater than 0.10 mm
EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Cat Coupling
5N-3527 boots Suspect boots Manufactured between Aug-06 and Mar-07 Date is stamped on side, usually not readable after installation The rubber of these boots may have a manufacturing defect Low spring rate and/or high compression set Affected boots wear out very fast Possibly as early as 20 hrs Fraction of population affected Boots produced from Mar-07 on are good Boot life Decreases as generator set rating increases 1,000 hrs to 20,000 hrs (more in rare cases)
EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Centa Couplings
Two types used CentaMax Single engine generator sets Between generator and engine on tandems Multiple models Multiple damper configurations CentaFlex Used in tandem generator sets between the engines

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

CentaMax Coupling
Maintenance Periodic inspections Inspect for liquids, grease, oils If present, remove coupling for cleaning and repair source of liquid Inspect for diagonal cracks These indicate a worn out rubber element Replace the rubber element if present Rubber element is a wear item Life expectation Estimates range from 10,000 hrs to 20,000 hrs Longer life if system has low torsionals Life is shortened significantly if damper has failed

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

CentaMax & Ringfeder Wear out Indicators

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

CentaFlex Coupling
Typical use is Marine We use it in some G3532 & G3524 tandems Maintenance Periodic inspections Inspect for liquids, grease, oils If present, remove coupling for cleaning and repair source of liquid Rubber element is a wear item Life expectation Very limited experience Expect 10,000 hrs to 20,000 hrs
EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Ringfeder
Similar to CentaMax Coupling Primarily used in custom packages Maintenance Periodic inspections Inspect for liquids, grease, oils If present, remove coupling for cleaning and repair source of liquid Inspect for diagonal cracks These indicate a worn out rubber element Replace the rubber element if present Expected life Unknown due to very little experience Estimates range from 10,000 to 20,000 hrs One lasted 15,000 hrs
EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Renolds
New coupling for Caterpillar Will be used in a limited number of higher rated generator sets Design Similar to Cat coupling but uses rubber pucks instead of the familiar boots

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Coupling Failure Consequences

If an engine damper has failed it may have done damage to the coupling Conversely, a coupling failure may damage the damper Failure of either increases the torsional vibrations in the system Excessive wear on the Cat coupling Can transmit engine axial vibration to the generator Axial generator vibration is usually absorbed in the interface between the generator bearings and their sleeves

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Summary
The rubber element is a wear item Life is highly dependent on engine combustion, torsionals in the driveline, and the generator set rating Coupling maintenance must be part of your maintenance schedule

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007