Abstract
The reliability of a pump, compressor, fan, generator train, etc. is dependent on the reliability of the coupling, gears, and/or clutches in the train. The design, manufacture, and installation of these components directly affect the train’s safety and reliability. Properly selected and designed couplings must be mounted properly on the shaft. While keyless coupling hub designs are preferred and eliminate stress risers in shaft, they must be properly installed to avoid very costly broken shafts and major failures. I have witnessed an improperly installed coupling hub render the shaft end a molten cone which caused a major refinery fire. Gears, like couplings, are designed to transmit the torque from the driver (motor, turbine, or engine) but also change the speed and/or direction of rotation. Gear reliability has always been thought to be lower than driven machines or drivers but it is as high as those machines if gear mesh is properly designed, manufactured, aligned, and lubricated. Reliable gear operation is a testament to the gear designer, manufacturer, and field service engineer considering the high gear mesh frequencies, multiple bearings, gear spray, and bearing lubrication requirements. A typical speed increasing gear pinion with 12 teeth operating at 10,000RPM experiences 2000 gear meshes per second! A final comment regarding gear reliability, avoid gears of two-piece construction. This is an older and cheaper design but has caused numerous failures in gears.
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