DOKU1G531W0013E_0_0_VULKAN_COUPLING.pdf

DOKU1G531W0013E

Highly-flexible VULKAN - RATO – S Couplings

Customer:

Comm.-No.:

Dimension Group:

Series:

Drawing No.:

Partslist No.:

Coltec

G531W

1G53100013

1G53100013

VULKAN Kupplungs- und Getriebebau B. Hackforth GmbH & Co. KG

Postfach 200462, 44634 Herne / Germany Heerstrasse 66, 44653 Herne / Germany

Tel. +49-2325/922-0 Fax +49-2325/71110

E-Mail: info.vkg@vulkan-vkg.de http://www.vulkan24.com http://www.vulkan24.com/

Contents of Documentation:

Technical Data RATO-S-G531W

General Drawing 1G53100013

Partlist 1G531W0013

Flexible Part, Drawing EG5310A002

Partlist EG531WAD02

Membrane dimension group 2G56R0005M

Partslist 2G56R0005M

Delivery Condition AG53100013

InstallationandOperating Instructions E&B RATO_S_G3810-G5310_BR2100-2200

Aliment Instructions for highli flexible VULKAN-RATO-S/R Couplings S/R-A- 1/3 to 5/3

Criteria for the inspection of VULKAN-RATO-S/R Couplings S/R-CRIT-1/1a to 9/1a

Surface Protection COATING 113 for VULKAN RATO- S/R Couplings S/R-COAT-1/2 to 7/2

Technical Data for RATO-S Coupling Size G531W Drawing-No.: 1G53100013

Rubber qual. W T KN kNm 250 T K max.1 kNm 310 T K max.2 kNm 1125 ∆ T max kNm 372 T KW kNm 62,5 P KV50 - total kW 1,46 n K max min -1 600 ∆ K a mm 14 ∆ K r mm 21,5 F ax1,0 kN 2,9 C rdyn kN/mm 4,72 nominal 1500 C T dyn-total kNm/rad warm 1050 nominal 1,13 rel . Damping Ψ warm 0,79

The guide lines in the RATO - catalogue S-ETD-5 have to be considered

Echtfirma VULKAN: PRODUKTIONSSTÜCKLISTE OHNE SUFFIX Datum : 25.05.04 10:48 Seite : 1 gedruckt von: marschal Manuf.Prod.1G531W0013 RATO-S Author : kempka Drawing 1G53100013 Info: Date : 15.10.2003 Pos │Quant. │Article │Description │Measurement │Material │Remark

1 │ 1│EG531WAD02 │FLEX.ELEMENT │G531WAD │ST/GUMMI │

5 │ 1│4G56B0014M │HUB │FM 889 x 335 x 520 │42CRMO4V │EN 10083-1

7 │ 1│3G56B5010M │INN.CLAMP.RING │FM 889X 606 X 48 │C45N │

10 │ 1│2G56R5005M │MEMBRANE-DG. │ │ │

16 │ 32│3G56S20000 │DISC │FM 70X 34 X 8 │42CRMO4V │VERG.17200

19 │ 32│7000133150 │HEXAGON BOLT │M 33 X150 │10.9 │ 931

20 │ 32│7000033160 │HEXAGON BOLT │M 33 X160 │ 8.8 │ 931M

22 │ 24│7000136150 │HEXAGON BOLT │M 36 X150 │10.9 │931M

28 │ 32│7019133000 │HEX NUT │M 33 │10 │DINEN24032

29 │ 32│7019033000 │HEX NUT │M 33 │8 │DINEN24032

32 │ 24│7040135085 │SPRING DOWEL │35 X 85 │C67 │E9404-18A

35 │ 24│7033636000 │DISC │36 │42CRMO4V │EN 10083-1

39 │ 32│7033633000 │DISC │33 │42CRMO4V │EN 10083-1

39 2 │ 32│7033633000 │DISC │33 │42CRMO4V │EN 10083-1

41 │ 32│3G56S50000 │DISTANCE DISC. │FM 70X 36 X 0.25│CUSN6 F55 │

Echtfirma VULKAN: PRODUKTIONSSTÜCKLISTE OHNE SUFFIX Datum : 25.05.04 10:47 gedruckt von: marschal Manuf.Prod.EG531WAD02 ELAST.ELEMENT Author : brandtp Drawing EG5310A002 Info: Date : 03.11.2003 Pos │Quant. │Article │Description │Measurement │Material │Remark

1 │ 4│2G530WAD02 │RATO-S SEGMENT │ │ST/GUMMI │

2 │ 8│3G53D70000 │LINK │FM 1679 X 1563 X 6 │42CRMO4V │EN10083-1

3 │ 16│7001130070 │HEXAGON BOLT │M 30 X 70 │10.9 │ 933M

4 │ 16│7019130000 │HEX NUT │M 30 │10 │DINEN24032

4 │ 0│7057600000 │COATING 113-2 │1 L │CHLOROPRENKAUTSCHUK │Hauptanstrich 4 │ 0│7057500000 │PRE COATING 113-1 │1 L │CHLOROPRENKAUTSCHUK │Vorstreichlösung

Echtfirma VULKAN: PRODUKTIONSSTÜCKLISTE OHNE SUFFIX Datum : 25.05.04 10:48 gedruckt von: marschal Manuf.Prod.2G56R5005M MEMBRANE-BG. Author : GRIHN Drawing 2G56R5005M Info: Date : 09.11.1998 Pos │Quant. │Article │Description │Measurement │Material │Remark

1 │ 3│3G56R5000M │MEMBRANE │FM1685X 740 X 1.95│50CRV4 │

2 │ 12│3G56R80000 │SPACER SHEET │FM1186X 294 X 0.25│CUSN6 F55 │

3 │ 16│3G56R70000 │SPACER SHEET │FM 623X 179 X 0.25│CUSN6 F55 │

4 │ 1│3G56S6021M │CLAMPING RING │FM1710X1490 X 58 │42CRMO4V │EN 10083-1

5 │ 8│7033630000 │DISC │30 │42CRMO4V │EN 10083-1

6 │ 8│7001030040 │HEXAGON BOLT │M 30 X 40 │8.8 │ 933M

Title Installation and Operating Instruction Theme RATO-S Standard Execution Authoring Checked and released Document: E&B_RATO-S_G3810-

G5310 BR2100-2200 englisch.doc Respon-sibility 25.05.04 25.05.04 Version: 001 TB 10 Simonetta Marschall Jürgen Kestermann Page: 1/9

Installation and Operating Instruction

E&B-G3810_G4510_G5310_series 2100_2200

VULKAN-RATO-S Couplings

VULKAN Kupplungs- und Getriebebau B. Hackforth GmbH & Co. KG

PO Box 200462, 44634 Herne / Germany Heerstraße 66, 44653 Herne / Germany

Phone: +49-2325/922-0 Fax: +49-2325/71110

E-Mail: info.vkg@vulkan24.com http://www.vulkan24.com http://www.vulkan24.com/

G5310 BR2100-2200 englisch.doc Respon-sibility 25.05.04 25.05.04 Version: 001 TB 10 Simonetta Marschall Jürgen Kestermann Page: 2/9

Contents:

1. General safety instructions

1.1 Symbol for industrial safety

1.2 Attention remark

1.3 Safety regulations

2 Generalities

3 Design of the flexible part

4 Design of the membrane dimension group

5 Installation of the coupling

5.1 Assembly for series 2100, 2200

6 Commissioning

7 Maintenance

7.1 Operating performance considering the mechanical properties of the Elastomer material

7.2 Operating performace considering the chemical properties of the Elastomer material

8 Replacement of the flexible part

8.1 Disassembly of the flexible part

8.2 Assembly of the flexible part

9 Service and spare parts

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1. General safety instructions

1.1 Symbol for industrial safety

This symbol is added to all passages in this documentation concerning industrial safety and including a risk to people's life and limb. Please follow these instructions and handle with the utmost caution in these situations. Hand over all industrial safety instructions to other users as well.

1.2 Attention remark

Attention!

This "Attention!" remark is added to passages in this documentation which should be specially noted in order to stick to the guidelines, regulations, instructions and correct flow of work and to prevent any damages or destruction of the coupling.

1.3 Safety regulations

A coupling shield has to be provided, according to the accident prevention regulations.

According to EN 292, part 1 „Safety of Machines“, a shield against mechanical movements of ma-chine parts (protection against accidental contact) is permissible, if a „usage according to the re-gulations“ is guaranteed during all working conditions. At the same time a good ventilation of the coupling has to be ensured (use of perforated plates).

If the possibility of exceeding the permissible speed of the coupling, nkmax, cannot be excluded com-pletely, e. g. in case of an incident or because of a failure of the over-speed-trip in the system, the coupling shield has to be so designed that possible coupling fragments cannot escape to the surrounding environment.

For coupling applications in fast ships (Dynamically Supported Craft), the safety regulations of publi-cation A373 of IMO (International Maritime Organisation) are valid. Dependant on the construction, these machine arrangements contain components with a high rotating energy. When the coupling runs outside of a casing, an external protecting device has to be provided to keep off possible coupling fragments in any case.

2 Generalities

The highly-flexible VULKAN-RATO-S coupling is a rubber coupling, flexible in all directions. Its es-sential parts are the flexible part, the membrane dimension group and the connecting parts.

All connecting elements of the coupling are arranged without clearance. The coupling must be pro-tected against permanent influence of oil and against the radiation of heat. Oil mist and oil splashes are not detrimental. The flexible part is fit for use at ambient temperatures comprised between -50°

(C) to +70° (C). The segmental construction form of the flexible part guarantees good heat dissi-pation properties. The free-of-play torque transmission in the coupling and the large sectional rubber area of the flexible element provide good noise attenuation.

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Basically, the connection surfaces and the fitted bores as well as the finish bores of the coupling are protected by Tectyl. Before installation, these surfaces have to be cleaned with conventional solvents.

Pay attention to wear protective clothes (gloves, safety glasses etc.) while working with solvents.

When the cleaned surfaces are completely dry, they must be greased slightly.

On behalf of the classification societies we herewith give the following instruction:

The torsional vibration behaviour of the driving system has to be checked and approved by the clas-sification society. The expected and satisfactory behaviour is guaranteed only, provided that all com-ponents comply to the values, the torsional vibration calculation is based upon. With respect to the coupling, this means to exactly keep to the dynamic stiffness and damping according to the nominal values including tolerances.

In case of a replacement of the elements, only original VULKAN elements with coordinated technical data approved by the classification societies must be used!

As the highly-flexible VULKAN RATO-S coupling is delivered in the partially assembled condition, it will not be necessary to carry out any extensive disassembly work in order to carry out the installation.

To guarantee faultless function and optimum usage of the highly-flexible RATO-S coupling, certain installation instructions have to be observed.

Attention! Basically, each bolt connection participating in the transmission of the torque must be tightenend by means of a torque spanner.

The individual tightening torques are given in the corresponding execution drawing of the coupling.

In case of a flexible mounted system, please coordinate the alignment with the manufacturers of engine, coupling and gearbox.

When using 10.9 bolts, hardened washers should be provided.

3 Design of the flexible part

The flexible part consists of 1 flexible element. The flexible element is divided into four flexible seg-ments (please refer to the following sketch).

The position of the flexible segments towards each other is marked.

Further information with respect to the marking can be taken from drawing EG...

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4 Design of the membrane dimension group

The membrane part consists of a number of ring-shaped membranes which are rigidly clamped at their outer circumference. The membrane dimension group is arranged behind the flexible part and allows a displacement in axial direction.

Distance sheet

5 Installation of the coupling

As the coupling is delivered in the partially assembled condition, no extensive disassembly procedure will be required for the installation.

During transportation, please pay attention to a sufficient carrying force of the lifting devices. Only use approved transportation elements.

Thoroughly fix the transportation elements to the attaching devices.

Attention! While lifting the flexible elements, take care not to damage the flexible elements and the add-on pieces.

5.1 Assembly for series 2100, 2200

The hub (item 5) with the connected parts is fixed to the connecting part of the corresponding machine.

If a connection with a free shaft butt end should be made, and a heating of the hub at the membrane part should be required, the temperature must not exceed +150°C.

After the connection with the respective machines has been made, both machines have to be erected according to the installation dimension of the coupling. Possible thermal expansions are to be considered (for alignment instructions please refer to enclosed sheet S / R-A- 1/3 - 5/3).

After the drive system has been aligned, you can start to assemble the flexible part.

Attention! The centre bars in the upper part of all segments must not be used as suspension arrangement for the transport of elements or segments resp.

Disk

Membranes

Hexagon bolt

Clamping ring Distance sheet

X X

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For assembly, the individual segments have to be hung into a lifting device using suitable aids. First the segments arranged opposite to the membrane part must be inserted one after the other and must be linked to the connecting part at the driving side by the corresponding fastening elements. The prescribed tightening torque must be kept. When using 10.9 bolts, hardened washers have to be provided.

In order to insert the segments, the membranes must be deflected. This deflection can be carried out using an appropriate traction device. For this purpose, first the two ring bolts have to be screwed into the threaded bores radially arranged in the clamping ring, one besides the other.

After having applied a suitable traction device which has to be connected with the two ring bolts, the membrane package can be deflected as far as to allow installation of one segment.

Attention! The total deflection of the membrane package is not allowed to exceed the ∆Ka value given on page „technical data“.

When the segment has been inserted using suitable aids, and after it has been put in the right position, the connection with the clamping ring has to be established. The nuts have to be tightened keeping the prescribed tightening torque.

Attention! During the tightening process, please check if the respective segment is at its outer circumference in metallic contact with the centering of the connecting part!

The same sequence of operations has to be carried out with the remaining segments.

Then the connection of the individual centre bars with the links and the provided fastening elements have to be established (please refer to the following figure).

links fastening elements

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The fixation elements are to be tightened keeping the prescribed tightening torque.

6 Commissioning

Press „EMERGENCY SHUTDOWN“ in case of danger.

Do not tough any rotating parts.

Equip the coupling with a sufficient protection device against contact.

Attention! Make sure that the coupling is protected against contact with oil, solvents and other chemicals.

We would like to point out that before commissioning you have to make sure that all assembling auxiliaries have been removed from the coupling and that the centre bars of the segments are connected with the links.

A coupling shield has to be provided, according to the accident prevention regulations. If there are no other objections having priority, these shields have to be made of perforated plates or expanded metal to ensure a good ventilation of the coupling as well. Please refer to safety regulation paragraph 1.3.

7 Maintenance

Stop the system for maintenance work.

Safely protect the system against unintentional starting resp. rotation.

Function and service life of highly-flexible couplings are decisively determined by construction and design, but also by the elastomer material selected and its resistance against environmental influ-ences.

7.1 Operating performance considering the mechanical properties of the Elastomer material

Basically, the highly-flexible RATO-S coupling does not require maintenance. In many cases, however, the highly-flexible RATO-S coupling is an indicator for malfunctions in the system.

We recommend a check of the highly-flexible part in case of exceptional incidents, e. g. propeller ground contact, short circuit, disturbance of synchronization, governor hunting or emergency cut-off.

Criteria for this purpose are given in document S/R-CRIT-1/1a up to 9/1a:

• Specification of limit values for the permissible permanent set depending on the size.

• Evaluation of surface cracks caused by ageing and their treatment including additional measures according to document S/R-COAT-1/2 – 7/2.

In addition to a check of the flexible part it is recommended to carry out an alignment control within the scope of the engine inspection intervals.

Standard values are given in document S/R-A-1/3 up to 5/3.

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7.2 Operating performace considering the chemical properties of the Elastomer material

Caoutchouc (NR) is mainly used as elastic material in highly-flexible Elastomer couplings. Because of its excellent dynamic properties (stablility / elasticity), actually there is no equivalent alternative material available. Caoutchouc (NR) belongs to the DIEN caoutchoucs, however, it is subject to various environmental influences, known under the collective noun „ageing“.

The immediate surrounding of the highly-flexible coupling in the system should be ventilated well in order to prevent high ambient temperatures. To prevent early ageing, however, it should be ensured that no „airflow“ will occur directly onto the rubber surface (especially waste air from generators).

An air swirl occurs closely above the coupling’s rubber surface which is desired because of its cooling effect on the one hand, and on the other hand, however, continuously providing fresh air (O2). To pro-tect the Elastomer material of the VULKAN couplings against these environmental influences, they are equipped with the most progressive ageing protecting agents available for the rubber industry. Ageing protecting agents which are chemically dispersed in the material’s matrix, however, use up when ful-filling their purpose.

In order to significantly improve the long-time protection of highly-flexible couplings, an additional sur-face protection is used.

Once a year or after special incidents this protective coating has to be checked with respect to da-mages. Conservative paintings after longer periods of operation and repairs are possible without any problems in form of local coating of damaged spots. Advice for this purpose is given in document S/R- COAT-1/2 up to 7/2.

8 Replacement of the flexible part

The elements of VULKAN RATO-S couplings can be removed and installed without the driving or driven machine having to be displaced.

Now we would like to explain the replacement of the flexible part in detail:

8.1 Disassembly of the flexible part

The individual segments can be disassembled using a lifting device. First of all the segments installed at the membrane side have to be removed. For this purpose, the membrane package must be deflected sufficiently.

Attention! The total deflection of the membrane package is not allowed to exceed the ∆Ka value given on page „technical data“.

After having removed the fixation elements arranged at both sides of each segment, all segments can be disassembled one after the other.

Please note: If a damage occurs to one of the segments, it is a basic requirement to replace all remaining segments of the respective flexible element.

When ordering spares for the flexible part or for the flexible elements, the following information has to be given with respect to the coupling:

• order no.

• drawing no.

• partslist no.

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8.2 Assembly of the flexible part

Before starting the assembly, a new alignment control should be carried out at the driving system.

The assembly of the segments has already been described in paragraph 5.1.

After completion of the assembly, the drive system is ready for operation, as far as the coupling is con-cerned.

9 Service and spare parts

Contact address:

VULKAN Service dept.

Heerstraße 66

D-44653 HERNE

Phone: +49 (0)2325 922 179

FAX: +49 (0)2325 71110

Mobile: +49 (0)1782922179

S/R-A-1/3

Ausrichthinweise für hochelastische VULKAN-RATO-S/R-Kupplungen

Alignment Instructions for highly flexible VULKAN RATO-S/R Couplings

Es wird vorausgesetzt, daß die Kupplung gemäß der auftragsbezogenen mitgelieferten Einbau- und Be-triebsanweisung ohne das elastische Teil in die Anlage eingebaut ist. Nur die Anschlußflächen sind von dem vor dem Versand zur Konservierung aufgebrachten Tectyl gereinigt.

Vor dem Einbau des elastischen Teils ist eine Aus-richtkontrolle durchzuführen. Hierbei ist die radiale, axiale und winklige Ausrichtung mit geeigneten Meß-geräten zu überprüfen.

Wir empfehlen, bei der Ermittlung der einzelnen Meßwerte beide Wellen jeweils um 90 Grad weiter-zudrehen, da bei dieser Meßmethode Rundlauf- und Planlauffehler nicht mitgemessen werden. Je genauer die Anlage ausgerichtet wird, desto größer sind die Reserven der Kupplung für die Aufnahme von Verlagerungen während des Betriebes.

RATO-Kupplungen sind in der Lage, große Verlage-rungen der angeschlossenen Maschinen auszuglei-chen, ohne größere Reaktionskräfte zu erzeugen und an Lebensdauer einzubüßen. Wir empfehlen im Nor-malfall eine praxisgerechte Ausrichtgüte anzustreben.

Unter praxisgerecht soll hier eine Ausrichtung ver-standen werden, die ohne erhöhten Arbeits- und Meßgeräteaufwand erreicht werden kann. Die ent-sprechenden Ausrichtwerte sind der folgenden Tabelle zu entnehmen.

Bei Anlagen mit zu erwartenden großen Verlagerungen empfehlen wir, die zulässigen Ausrichttoleranzen mit den Erstellern der Anlage abzustimmen.

It is assumed that the coupling metal parts have been installed without the flexible element assembly as stated in the VULKAN "Installation and Operating Instructions". The connection faces need to be cleaned to remove the Tectyl preserving agent.

Prior to installing the flexible part, an alignment check must be carried out. The radial, axial and angular alignment must be measured, using appropriate measuring instruments.

We recommend that both shafts are rotated by 90 deg before each measurement in order to eliminate any inbuilt errors due to eccentricity and non-parallelism.

The accuracy of the alignment determines the reserves the coupling will have to accomodate misalignments during operation.

RATO couplings are able to accommodate high misalignments of connecting machines, without generating high reaction forces or reducing service life.

We recommend to work out an alignment- quality for the normal case oriented on practicability. Usually the required alignments may be achieved with normal alignment measuring equipment without having to use sophisticated or time consuming procedures. The recommended alignment tolerances can be taken from the following table:

With respect to installations where high misalignments are expected we recommend to coordinate the permissible alignment tolerances with the supplier of the assembly.

Alle Werte gelten für den betriebswarmen Zustand1) / All data are valid for service-warm condition1) empfohlene Ausrichttoleranz / recommended alignment tolerance [mm] radial axial2) winklig / angular3)

Baugruppe Dimension group elastisch aufgestellt elastic mounted starr aufgestellt2) rigid mounted

K 4010 - K 5710 G 1210 - G 1340 + 0,5 5,0

0,1 − ± 0,25 ± 0,25 ± 0,35

G 1410 - G 2340 + 1,0 0,1

− ± 0,5 ± 0,5 ± 0,35

G 2510 - G 3140 G 0310 - G 0520 + 1,0

0,1

− ± 0,5 ± 0,6 ± 0,5

G 3310 - G 3440 G 0810 - G 0820 + 1,5

0,1 5,2

± 0,7 ± 0,8 ± 0,6

G 3610 - G 7340 + 1,5 0,1 5,2

− ± 1,0 ± 0,8 ± 0,6

1.) Für Neuausrichtungen im kalten Zustand gelten anlagenspezifische Werte, die vom Ersteller der Anlagen zu ermitteln und zu berücksichtigen sind.

2.) Siehe Montagekontrollmaß 3.) Bezugsdurchmesser = Schwungradrezeß bzw.

Kupplungsaußendurchmesser

1.) Installation depending values are valid for service cold conditions. These values must be determined by the supplier of the assembly and have be to taken into account.

2.) please refer to the assembly control dimension 3.) relating diameter = flywheel recess respectively outer Diameter of the coupling

S/R-A-2/3

Beispiel: Example:

Ohne Durchdrehsicherung

Without torsional limit device radial axial winklig/angular

Mit Durchdrehsicherung With torsional limit device radial axial winklig/angular

Ziel jeder Ausrichtung muß sein, für den betriebs-warmen Zustand eine möglichst ideale Fluchtung zu erreichen. Für die im kalten Zustand auszurichtenden Maschinen kann sich u.a. aus Gründen der Wärme-dehnung ein Fluchtversatz ergeben (siehe hierzu Fußnote 1 in der Tabelle), dem die angegebenen Toleranzen zu überlagern sind.

Einen Sonderfall stellen Anlagen mit elastisch gela-gerten Motoren dar. Hier werden die Motoren gegen-über dem Getriebe auch betriebswarm um einige Millimeter höher gestellt, um die zeitabhängige Setzung der Gummielemente zu berücksichtigen. Die Kupplung läuft also zumindestens anfänglich mit einem gewollten Radialversatz. Wegen dieses relativ großen Versatzes, aber auch wegen der Schwierigkeit, den gewünschten Versatz gezielt einstellen zu können, werden bei derartigen Anlagen die Ausrichttoleranzen entsprechend erhöht.

The alignment should aim at the best possible ideal alignment in the warm operating condition.

For machines to be aligned in the cold condition a misalignment can occur due to thermal expansion (please refer to note 1 in the table) which should be superimposed by the tolerances given.

Installations with elastic mounted engines should be given special consideration since these engines may settle relative to the gearbox in the warm condition due to the creep characteristics of the rubber mounts. In such installations it is normal to set the engine some millimetres high to offset settlement. The mounting supplier should advise the expected settlement figure to enable the installation to be adjusted. This adjustment will mean that the coupling will have a higher radial displacement initially and this has been considered as set out in the table.

S/R-A-3/3

Beispiel für starr aufgestellte Anlage:

Hochelastische VULKAN-Kupplung Größe RATO-S 2521 Radiale Ausrichtung - ohne eingebautes elastisches Teil.

Example for rigid mounted engine plant:

Highly flexible VULKAN coupling size RATO-S 2521 Radial alignment - without installed flexible part.

mm06,175,075,0R

RRR

mm75,0

5,2370,236

R-RR

mm 0,75

236,1237,6

RRR

Dieser Wert ist größer als die empfohlene Ausrichttoleranz in der Tabelle, deshalb muß mit den Erstellern der Anlage eine Abstimmung über die resultierenden Belastungen in den Anschlußebenen erfolgen.

This value exceeds the recommended tolerance in table. Therefore it is necessary to coordinate the resulting loads in the connected surface planes with the builders of the system.

S/R-A-4/3

Axiale Ausrichtung-ohne eingebautes elastisches Teil. Axial alignment - without installed flexible part.

( ) ( ) mm3,190

0,916,914,912,91X

XXXXX a 4a3a2a1a a =−

Dieser Wert ist größer als die empfohlene Ausrichttoleranz in der Tabelle, deshalb muß mit den Erstellern der Anlage eine Abstimmung über die resultierenden Belastungen in den Anschlußebenen erfolgen.

This value exceeds the recommended tolerance in the table, therefore it is necessary to coordinate the resulting loads in the connected surface planes with the builders of the system.

Für elastisch aufgestellte Anlagen und komplett montierte Kupplungen kann die axiale Ausrichtung nur über die Gesamteinbaulänge "L1"- NICHT am Membranpaket - kontrolliert werden.

Die radiale Ausrichtung kann mittels Meßuhr am Außendurchmesser des Spannringes kontrolliert wer-den.

For flexible mounted systems and completely mounted coulings, the axial alignment can only be checked over the complete installation length of the coupling "L1" and NOT at the membrane package.

The radial alignment can be checked by means of a measurement gauge at the outer diameter of the clamping ring.

S/R-A-5/3

Winklige Ausrichtung - ohne eingebautes elastischesTeil

Angular Alignment - without installed flexible part mm32,030,010,0X

XXX

mm30,0

6,900,90

XXX

mm10,0

2,904,90

XXX

w

4,3w

2,1ww

4w3w 4,3w

1w2w 2,1w

Der Winkelversatz ist in Ordnung, da er unter dem gemäß Tabelle 1 zulässigen Wert liegt.

The angular displacement is correct as it is below the permissible value in the table 1.

Criteria for inspection S/R-CRIT-1/1a

Criteria for the inspection of VULKAN-RATO-S/R couplings

The outer surface of a rotating coupling is continuously in contact with the surrounding air. This ensures a good ventilation of the coupling but also gives rise to permanent contact with oxygen, ozone and especially aggressive exhaust gases. This, in combination with the temperature, humidity and UV-radiation, causes irreversible changes in the material structure at the rubber surface. This unavoidable process is generally known as AGEING.

Due to the fact that AGEING is a combination of various influences it is impossible to simulate under laboratory conditions. VULKAN has therefore examined RATO elements, with a long operational life, to investigate the influence of AGEING on the operational-safety of the coupling.

The results of these investigations can be summarized as follows.

Due to the constructional design of the elements, and the different types and values of stresses, the elements will, after a certain period of service, show indications of having undergone operational service. The most frequent symptoms are:

To determine the permanent set of a RATO-S segment the dimension „s“, measured at the outer diameter of the rubber element, is determined (figure 1). The permanent set „s“ of a RATO-R element can be measured through the deformation of the rubber roll (figure 2).

If the permanent set „s“ exceeds the criteria in the following table, the flexible parts must be replaced; otherwise the flexible parts are suitable for further service provided there are no other indications of a damage.

1. Permanent set

Figure 1 Figure 2

S

S

Criteria for inspection S/R-CRIT-2/1a

Permissible permanent set for a RATO-S segment

Size X = 1 S [mm]

X = 2 S [mm]

X = 7 S [mm]

X = T S [mm]

X = Z S [mm]

X = W S [mm]

X = Q S [mm]

X = Y S [mm]

141 X 19,0 12,0 20,0 – – – – – 151 X 23,0 16,0 23,0 – – – – – 161 X 24,0 17,0 26,0 – – – – – 171 X 26,0 18,0 27,0 – – – – – 191 X 28,0 19,0 30,0 – – – – – 211 X 30,0 20,0 34,0 30,0 32,0 28,0 27,0 – 231 X 32,0 22,0 36,0 32,0 34,0 30,0 29,0 – 251 X 36,0 22,0 38,0 36,0 35,0 32,0 30,0 – 271 X 37,0 24,0 38,0 37,0 41,0 35,0 33,0 – 031 X – – – 55,0 – 61,0 – – 291 X 41,0 26,0 44,0 41,0 44,0 38,0 37,0 – 311 X 49,0 28,0 51,0 49,0 53,0 45,0 44,0 – 051 X – – – 65,0 – 71,0 – – 331 X 53,0 31,0 51,0 53,0 54,0 49,0 48,0 – 341 X 58,0 33,0 59,0 58,0 58,0 54,0 53,0 – 081 X – – – 75,0 – 82,0 – – 361 X 62,0 36,0 64,0 62,0 – - – – 381 X – – – 90,0 – 95,0 – – 391 X 67,0 38,0 67,0 67,0 – – – – 431 X 73,0 42,0 76,0 73,0 – – – – 451 X – – – 105,0 – 112,0 – – 461 X 34,0 20,0 41,0 34,0 – 36,0 – – 481 X 67,0 40,0 82,0 67,0 66,0 65,0 61,0 – 491 X 36,0 22,0 44,0 36,0 – 38,0 – 32,0 511 X 72,0 43,0 78,0 72,0 80,0 75,0 65,0 – 531 X – – – 120,0 – 130,0 – 130,0 541 X 39,0 23,0 48,0 39,0 – 41,0 – – 561 X 88,0 47,0 95,0 88,0 85,0 80,0 69,0 – 581 X 94,0 56,0 103,0 94,0 90,0 85,0 – 64,0 601 X 47,0 28,0 52,0 47,0 52,0 47,0 – – 621 X – – – 85,0 100,0 93,0 – – 631 X – – – 85,0 – 93,0 – – 651 X 51,0 30,0 56,0 51,0 56,0 51,0 – – 681 X – – – 103,0 – 113,0 – – 701 X 55,0 33,0 60,0 55,0 60,0 55,0 – – 731 X – – – 110,0 – 125,0 – –

It is advisable to determine and eliminate the reasons for the permanent set, that is in excess of the permissible values given in the table, before renewing elements.

Criteria for inspection S/R-CRIT-3/1a

Permissible permanent set of one RATO-R element

Size X = 1 S [mm]

X = 2 S [mm]

X = 7 S [mm]

X = 5 S [mm]

X = Z S [mm]

X = W S [mm]

X = T S [mm]

X = Y S [mm]

K401 X 24,0 14,0 26,0 22,0 – – – – K491 X 27,0 16,0 30,0 25,0 – – – – K541 X 40,0 24,0 44,0 36,0 – – – – K571 X 40,0 24,0 44,0 36,0 – – – – 161 X 23,0 14,0 25,0 21,0 – – – – 171 X 25,0 15,0 27,0 22,0 – – – – 191 X 27,0 16,0 29,0 24,0 29,0 27,0 27,0 – 211 X 29,0 18,0 32,0 27,0 32,0 29,0 24,0 – 231 X 31,0 19,0 35,0 28,0 35,0 31,0 28,0 – 251 X 35,0 21,0 39,0 30,0 39,0 35,0 30,0 – 271 X 38,0 23,0 42,0 34,0 42,0 38,0 34,0 – 271 X2 23,0 14,0 26,0 22,0 – 23,0 32,0 – 291 X 40,0 24,0 45,0 36,0 – – – – 291 X2 25,0 15,0 27,0 24,0 – 25,0 – – 311 X 45,0 27,0 50,0 41,0 50,0 45,0 41,0 45,0 331 X – – – – – 50,0 50,0 – 331 X2 30,0 18,0 33,0 27,0 33,0 30,0 27,0 – 341 X2 39,0 23,0 42,0 35,0 42,0 39,0 35,0 – 391 X – – – – – 65,0 65,0 58,0

23-row elements

It is advisable to determine and eliminate the reasons for the permanent set, that is in excess of the permissible values given in the table, before renewing elements.

Criteria for inspection S/R-CRIT-4/1a

2. Cracks

„AGEING“ gives rise to a hardening of the surface rubber. Due to the reduced elasticity at the outer surface, cracks can be formed when the elements are deformed during service. Cracks (X/Y) with a depth LESS than the permissible value are acceptable (figure 3, figure 4).

According to our experience, for a RATO-S/R flexible part cracks with a depth up to 5 % of the radial rubber thickness are to be considered acceptable if they occur around the whole surface (figure 3, depth X).

If cracks are predominantly in the outer rubber surface including the radius area, an equivalent crack depth up to 8,5% of the radial rubber thickness is acceptable (figure 4, depth Y, Z).

If cracks are predominantly on the front side of the segments, a depth of 8,5 % of the radial rubber thickness is acceptable as well (figure 4, depth Y).

Cracks should be ground out as soon as possible. This procedure, usually used for steel cast components, can also be used for rubber elements.

Figure 3 Figure 4

Criteria for inspection S/R-CRIT-5/1a

Dimension Group

Depth X [mm]

Depth Y [mm]

Depth Z [mm]

1410 5,0 8,5 22 1510 5,5 9,5 24 1610 6,0 10,0 26 1710 6,5 11,0 28 1910 7,0 12,0 30 2110 7,0 12,0 33 2310 8,0 13,5 36 2510 9,0 15,5 38 2710 9,5 16,0 42 0310 9,5 16,0 42 2910 10,0 17,0 45 3110 11,0 19,0 49 0510 11,0 19,0 49 3310 12,0 20,5 52 3410 13,0 22,0 57 0810 13,0 22,0 57 3610 14,0 24,0 61 3910 15,0 25,5 66

Dimension group

Depth X [mm]

Depth Y [mm]

Depth Z [mm]

3810 15,0 25,5 66 4310 16,0 27,0 71 4610 18,0 30,5 77 4810 18,0 30,5 77 4510 18,0 30,5 77 4910 19,0 32,5 83 5110 19,0 32,5 83 5410 20,0 34,0 90 5610 20,0 34,0 90 5310 20,0 34,0 90 5810 22,0 37,5 97 6010 22,0 37,5 97 6210 23,0 39,0 103 6310 23,0 39,0 103 6510 24,0 41,0 105 6810 25,0 42,5 111 7010 25,0 42,5 113 7310 28,0 47,5 125

Dimension group

Depth X [mm]

Depth Y * [mm]

K4010 3,0 5,5 K4910 3,0 5,5 K5410 3,0 5,5 K5710 4,0 6,5 1610 6,0 10,0 1710 6,5 11,0 1910 7,0 12,0 2110 7,0 12,0 2310 8,0 13,5 2510 9,0 15,5 2710 9,5 16,0 2910 10,0 17,0 3110 11,0 19,0 3310 12,0 20,5 3410 13,0 22,0 3910 15,0 25,5

* Cracks in the area of the outer diameter / inner diameter free from cracks

Permissible crack depth of a RATO-S coupling

Permissible crack depth of a RATO-R coupling

Criteria for inspection S/R-CRIT-6/1a

2.1 A guidance for VULKAN-RATO-S/R couplings:

• Cracks should be ground out as soon as possible. This can be done by a VULKAN service engineer, or by the operator using the working instructions for „grinding“, refer to section 2.3.

• When a crack is noticed, the depth and length must be marked in order to monitor it.

• It is important to check if the installation is operating / or has operated abnormally.

• In many cases the coupling acts as an indicator of installation malfunctions. When no system malfunction can be determined, the couping has to be checked at shorter intervals.

• When the cracks formed are due to an overloading of the coupling and this is not corrected, the crack will continue to grow.

• An „unique event“ can damage the coupling. This, however, does not infer, that when the installation operates „normally“ that the damage situation will not get worse.

• If the crack depth exceeds the permissible depth, we recommend replacing the re-levant row as soon as possible.

2.2 Interval for checking RATO couplings:

• When, after checking a RATO coupling, surface cracks have been found which have a depth LESS than the maximum value given in the table, a „2nd measurement“ of the crack dimension should be made at an interval of about 3 months in order to check crack growth.

• Assuming that the coupling itself is subjected to permissible load levels, the crack can be defined as being the result of AGEING, when the crack dimensions do not significantly change in the interval between the tests. Subsequent checks every 6 months can be made.

• After a system „unique-occurance“, cracks can appear in couplings that normally operate within their permissible limits. The reason for the malfunction must be investigated and corrected. A check should be carried out after 3 months or in case of a new system malfunction.

• If a crack reaches the permissible depth, the respective element have to be restored.

Actions to be taken: Grinding off the cracks and applying of Coating 113. Details:

see 2.3.

• If cracks reoccur, repeat step 2 twice.

The element must however be replaced as soon as possible.

Criteria for inspection S/R-CRIT-7/1a

2.3 Working instruction „grinding“

This working instruction is one component of the criteria for the inspection of RATO-S/R couplings. The rework of the cracks in the rubber of the segments/elements can be done with a suitable belt grinder.

Belt grinders are available in specialist shops as electric and pneumatic belt grinders. The abrasive belts are available in three different coarseness (fine, medium, rough).

When grinding you should take care that the temperature is not too high at the final end of the grinding procedure and the material rubber not hardened.

The moulding of the cracks should be, if possible, very accurately rounded and should not show sharp corners.

During and after grinding it is not allowed to use French chalk or similar substances to smooth the surface. A subsequent treatment with the system COATING 113 requires clean, fat-free and oil-free surfaces.

Subsequently the machined surface as well as the surface of the flexible elements must be treated with COATING 113.

Advice concerning this treatment is given in document S/R-COAT-1/1 - 7/1.

The following photos show tools and reworked segments.

Criteria for inspection S/R-CRIT-8/1a

Photo 1: Grinding tools

The rework of the cracks can be done with a suitable belt grinder. The abrasive belts are available in three different grades of coarseness (fine, medium, rough).

Photo 2:

Criteria for inspection S/R-CRIT-9/1a

Photo 3: Segment corners reworked

Photo 4: Additionally protection of the surfaces with "Coating-113"

Surface protection COATING 113 S/R/DS-COAT-1/2 Modification 2 Herne, 22.05.2003 COATING 113 e_2.doc

Surface Protection COATING 113 for

VULKAN RATO- S/R/DS Couplings

To supplement the chemical ageing protection included in the Elastomer material, the outer surfaces of the highly-flexible VULKAN coupling elements are equipped with a protecting coat consisting of liquid Elastomer. This Elastomer offers a better protection against en-vironmental influences, especially against the influence of atmospheric oxygen which causes an „ageing“ of the near-surface zones on the couplings‘ elements.

Basically, the system COATING 113 consists of two components:

PRECOATING 113-1

COATING 113-2

Both protective coatings consist of the same elastomer material. PRECOATING 113-1, which is more liquid, is used for the priming coat of a pretreated surface according to regulation

S/R-CRIT-1/1-7/1,.

For both main coats COATING 113-2 is used.

RATO-S couplings are coated on the outer surface including the radius passings to the front surfaces per segment. It is not required to disassemble the segments.

With RATO-R/DS couplings, the complete outer rubber surface is coated.

Processing instructions for the application of

COATING 113

Surfaces of highly-flexible elements which have been ground crack-free within the scope of inspections according to the „criteria for inspection“.

1.) The surfaces of highly-flexible elements should be ground with a belt grinder on the complete surface in order to optimally prepare them for the priming coat with

PRECOATING 113-1.

This special surface treatment guarantees an optimum cleaning and removes possi-ble existing microcracks at the same time.

If the surfaces are in good condition, sufficient cleaning can be reached by careful brushing (brass brush).

2.) The surfaces are properly cleaned from grinding dust by blowing-off with compressed air. In order to keep the surfaces dry and free from grease, the compressed air must be almost free from oil and condensates.

Surface protection COATING 113 S/R/DS-COAT-2/2

COATING 113 e_2.doc

3.) The priming coat is made with PRECOATING 113-1. The drying time is approx. 30 minutes. The coat is dried if it is not tacky when touched by hand.

4.) The first main coat is made with COATING 113-2. The drying time is approx. 30 mi-nutes. The coat is dried if it is not tacky when touched by hand.

5.) The second main coat is made with COATING 113-2 as well. The procedure is the same as described under 4.).

All coatings are to be applied thinly, but totally covering the segment.

The waiting time until recommissioning of the coupling should be at least one hour after having applied the last coating.

COATING 113 can be used for approx. 8 weeks providing it has been stored in a sealed tin.

The safety regulations according to the following safety data sheet (93/112/EG) are to be observed.

Surface protection COATING 113 S/R/DS-COAT-3/2

COATING 113 e_2.doc

Safety data sheet (93/112/EG)

PRECOATING 113-1 10099544

COATING 113-2

valid from: 19.11.1999 subst. version from: NEW current date: 27.09.2001

1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY

COMPOSITION / INFORMATION ON INGREDIENTS

1.1 Precoating 113-1

precoating solution for coating 113-2

1.2 Coating 113-2

Company:

Phoenix AG Hannoversche Strasse 88 D-21079 Hamburg

+49 / 40 / 76 67 22 33

2 COMPOSITION / INFORMATION ON INGREDIENTS

2.1 Precoating 113-1 CAS no.: 108-88-3

90 % Toluene EINECS no. 203-625-9 TLV: 380 mg/m3

2.2 Coating 113-2 R-phrases: 11,20

70 % Toluene Hazard symbol

3 HAZARD IDENTIFICATION

R11 : highly flammable R20 : harmful by inhalation R36/37 : irritating to eyes and respiratory system

4 FIRST AID MEASURES

Remove soiled or soaken clothing immediately.

AFTER INHALATION

Remove the casualty into fresh air and keep him calm.

In case of breathing difficulties or no breathing give oxygen. Summon a doctor.

AFTER INGESTION

Induce the patient to vomit only if fully conscious. Summon a doctor.

AFTER SKIN CONTACT

Wash thoroughly with water and soap. The solvent of the product has a strong degreasing effect, therefore use a skin protection cream afterwards.

AFTER EYE CONTACT

Rinse with plenty of water for several minutes, keeping the eyelid open. Call or go to a doctor.

ADVISE TO DOCTOR

Surface protection COATING 113 S/R/DS-COAT-4/2

COATING 113 e_2.doc

5 FIRE-FIGHTING MEASURES

SUITABLE EXTINGUISHING MEDIA

Water, foam, extinguishing powder, carbon dioxide

UNSUITABLE EXTINGUISHING MEDIA

Full water jet

HAZARD ARISING FROM COMBUSTION PRODUCTS

Danger of formation of toxic pyrolysis products.

Use self-contained breathing apparatus.

6 ACCIDENTAL RELEASE MEASURES

Keep people away and stay on the upwind side. Do not discharge into the drains, surface waters or groundwater.

Take up with absorbant material (e. g. sand, general-purpose binder). Do not use sawdust or other combustible materials.

7 HANDLING AND STORAGE

Use only in well-ventilated areas.

Keep away from ignition sources – do not smoke.

Take precautionary measures against static discharges.

Wear shoes with conductive soles. Vapours can form an explosive mixture with air.

Provide solvent-resistant and impermeable floor.

Keep container tightly closed. Keep in a cool place. Protect from frost.

8 EXPOSURE CONTROLS AND PERSONAL PROTECTION

INGREDIENTS WITH EXPOSURE LIMITS TO BE MONITORED

Toluene CAS no.: 108-88-3 EINECS no.: 203-625-9 TLV: 380 mg/m3

Hazard symbol: F, Xn R-phrases: 11,20

Do not eat, drink, smoke during work. Wash hands thoroughly with water and soap before breaks and after work. Use barrier skin cream.

RESPIRATORY PROTECTION

Unsufficient ventilation, short term mask with filter: solvents

HAND PROTECTION

Solvent-resistant gloves

EYE PROTECTION

Framed protective goggles

BODY PROTECTION

Surface protection COATING 113 S/R/DS-COAT-5/2

COATING 113 e_2.doc

9 PHYSICAL AND CHEMICAL PROPERTIES

FORM

liquid

COLOUR

black

ODOUR

aromatic

BOILING POINT (DEG. C)

111,000

FIRE POINT (DEG. C)

6,000

FLASH POINT (DEG C)

535,000

SELF IGNITIONABILITY

EXPLOSIVE LIMITS

1,0 / 7,0 VAPOR PRESSURE (hPa at 50 DEG. C)

12,300 DENSITY (kg/l at 20 DEG. C)

1,000 SOLUBALITY (at 20 DEG. C) VISCOSITY (at 50 DEG. C)

1600 cP

CONTENCE OF SOLVENTS (%)

CA. 80

CONTENCE OF SOLIDS (%)

CA. 20

10 STABILITY AND REACTIVITY

None, if used correctly.

Hydrogen halides are formed in contact with flames, and, under unfavourable conditions, toxic pyrolysis products.

11 TOXICOLOGICAL INFORMATION

The values of the preparation are not determined.

CLASSIFICATION RELEVANT VALUES

Values of the single components Toluene, LD 50 (oral, rat) 5000 mg/kg Frequent persistant contact with the skin can cause skin irritation.

12 ECOLOGICAL INFORMATION

Danger to drinking water is possible if large quantities penetrate into the subsoil and natural waters.

Surface protection COATING 113 S/R/DS-COAT-6/2

COATING 113 e_2.doc

13 ADVICE ON DISPOSAL

PRODUCT

Can be disposed of together with household refuse after compaction in accordance with the regulations and after consultation with the disposal agency and the relevant authorities.

EAK No.

080402

PACKAGING

Recommendations:

The package units should be completely emptied (drop-free, cleaned with a towel).

The packing material should preferably be recycled or reused, in accordance with the relevant, applicable local/national regulations.

14 TRANSPORT INFORMATION

TRUCK TRANSPORTATION (ADR)

Dangerous good class 3 figure 5c ADR UN 1133 Adhesives, containing solvents with a fire point under 23 deg. C packing group III ADR-Label 3 written instruction K1

SHIPMENT BY SEA (IMDG-CODE)

Dangerous good class 3.2 UN 1133 Adhesives, containing a inflammable liquid Packing group III IMDG-Label K3

EMS: 3-05

MFAG: 330

SHIPMENT BY AIR (IACO/IATA – CODE)

Dangerous good class 3 UN 1133 Adhesives, containing a inflammable liquid PkgGr III PkgInst 309 IATA-Label: Inflamm.liquid

15 REGULATORY INFORMATION

HAZARD

Toluene

CLASSIFICATION ACCORDING TO EEC DIRECTIVES

F: highly inflammable Xn: harmful

CONTAINS

R PHRASES

R11 : highly inflammable R20 : harmful by inhalation R36/37 : irritating to eyes and respiratory system

Surface protection COATING 113 S/R/DS-COAT-7/2

COATING 113 e_2.doc

S PHRASES

S9 : Keep container in a well-ventilated place S16 : Keep away from sources of ignition – No smoking S23 : Do not breath vapor/spray S33 : Take precautionary measures against static discharges S51 : Use only in well-ventilated areas

SPECIAL LABELLING FOR CERTAIN PREPARATIONS

Only for industrial users

Refer also to point 8

A1

16 OTHER INFORMATION

The information given here does not represent any guarantee or properties. Please refer to our technical leaflets.

Service and spare parts