John Crane Metastream TSK, Metastream TSC, Metastream TSP, Metastream T Series, Metastream TLK Fitting, Operating And Maintenance Instructions

COUPLINGS TYPE TSK – TSP – TSA – TSC - TLK

Fitting, Operating and Maintenance Instructions

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General Specification

The ranges of Metastream couplings covered by this manual, are designed to transmit torque
between the rotating shafts of a driving and driven machine, whilst accomodating the inevitable
lateral, angular and axial misalignment, which will exist between two coupled machines.
The usual extent of supply comprises:

• a hub for the DRIVING machine (motor) shaft

• a hub for the DRIVEN machine shaft

• a factory assembled transmission unit, comprising two packs of flexible metallic dis cs, each

bolted to a “guard ring” and to a common spacer (d istance piece), which separates the two disc
packs, The overall length of the trans mis sion unit is sized to suit the shaf t end separation of the
coupled machines

• a set of fasteners to assemble the t ransmission unit to the two hub flanges.

IMPORTANT
These instructions should be read in conjunction with any application specific general arrangement
drawing which may be supplied with the c oupling.

Selection verification

Although a coupling may be correctly specified at the time of order placement, the duty conditions
can sometimes change prior to the coupling being put into service. Information is available from
John Crane to advise on the selection and limitations of their power transmission products, but the
USER is ultimately responsible for verifying the suitability of the selection for the actual service
conditions.
The coupling and its manner of use must conform to any legal or licensing requirements, and, where
appropriate, meet local health and safety requirements.

IMPORTANT: If the conditions of operations are cha nged without approval from John Crane, then
we would decline responsibility for any cons equent damage and the USER would assume all risks .

Documentation supplied with the coupling should be retained for future reference.

Unpacking and Storage

The coupling should be unpacked and examined for any signs of transit damage. Particular attention
should be paid to hub bores and spigot/ recess local diameters.
If the coupling is not to be used immediately, it should be re-packed and stored in a dry place away from
direct heat.
Documentation supplied with the coupling should be retained for future reference.

Installation

Prior to installing the coupling ensure that the machinery is made safe

• Remove the coupling from its packaging and carefully inspect for signs of damage. Particular attention

should be paid to the hub bores and the spigot/recess location features, which should be free from
burrs and other damage.

• Fit the Driver (1) and Driven (2) hubs to the corresponding machine shafts. Normally, John Crane

supply parallel bored and keywayed hubs, individually machined to give a light interference fit with the
associated shaft. If it i s necessa ry to apply some heating to the hub to assist fitting, then a warm oil
bath will usually be adequate.

Hubs must be adequately supported during installation to avoid accidental damage should

they slip.

It is usual to install the hub such that the hub face and shaft end are flush, but consult the arrangement
drawing, or other particular instruc tions, to check the configuration for individual designs.

Align the centre lines of the driving and d riven machine shafts as follows:

• With one machine firmly bolted down, set the distance between shaft ends (DBSE) according to

drawing or catalogue dimension ‘A’

IMPORTANT: DBSE is usually measured between the inner face of the hubs and should not be
taken as the length of the transmission unit at its maximum diameter

• Align the shaft centre lines both horizontally and vertically by aligning the hub flanges. The John Crane

coupling alignment kit and reverse periphery procedure allows rapid an d ac curate alignment of shafts.

IMPORTANT: The misalignment tolerances quoted in literature and on drawings allow for dynamic
conditions and variations. For the best service from the coupling, John Crane recommend that
installed misalignment is no more than 10% of the maximum allowable misal ignment, allowance being
made for any anticipated movement s which will occur during operation (eg. t hermal movements on
hut pumps).

• Check spigot and recess locations on the hubs and transmission unit for burrs or other signs of damage

and then fit the transmission unit (3) between the hubs.

THE TRANSMISSION UNIT MUST BE ADEQUATELY SUPPORTED DURING INSTALLATION

TO AVOID ACCIDENTAL DAMAGE SHOULD IT SLIP.
It may be necessary to compress the trans mis sion unit whilst sliding it between the hubs, and f ac ilities are

provided to make it easier:

1. on smaller units, lever slots are provided in the hub flanges

2. on larger units, including the TLK, the spacer flanges are drilled so
that the hub bolts (4) may be used to compress the transmission unit
sufficiently to clear the s pigot location (see sketch).
Maximum compression of the gap ‘X’ should not exceed 0.8 times the
coupling maximum axial misalignement value, unless indicated
otherwise on the general arrangeme nt drawing.

IMPORTANT: Always remove the compression bolts as soon as the transmission unit is in position
and before fully tightening the hub bolts.

Fit the hub bolts (4) (and locking washers (5) if supplied) and tighten these evenly to locate the transmission
unit, ensuring that the spigots enter their recess squarely. Bolts s hould be tightened in a “diametrically
opposite” sequence to the values quoted in Table 1. If a general arrangement drawing is supplied with the
coupling, then torque values quot ed on that drawing take precedence.

• Rotate the machinery two or three times sl ow ly to ensure it moves freely.

The coupling i s now ready for continuous and trouble free service.

John Crane Italia SpA
Via Giotto 3
20053 Muggiò (MI)
Tel. [phone]
Fax [phone]

Operation

BEFORE STARTING THE MACHINERY, ENSURE THAT ALL NECESSARY SAFETY
PROCEDURES ARE BEING OBSERVED

When operated within the duty conditions for which they were designed, John Crane Metastream
flexible disc couplings will give long and trouble free service. Routine examination should include
a periodic check on the tightness of fasteners and visual inspection of transmission components
for signs of fatigue or wear.
If the coupled machinery is disturbed at any time, then shaft alignment should be re-checked as a
matter of routine. Alignment checking is also recommended if a deterioration of installation
alignment during service is suspected.

Inspection and Maintenance

MAINTENANCE WORK MUST ONLY BE CARRIED OUT BY SUITABLY QUALIFIED

PERSONNEL WHEN THE EQUIPMENT IS STATIONARY AND HAS BEEN MADE SAFE

John Crane Metastream flexible power transmission couplings are designed to give long and
trouble free service if operated within the conditions for which they were specified. Failures are
rare and can generally be attributed to:-

• excessive misalignment

• severe torsional overload

In all cases of coupling failure, the cause should be identified and corrected before replacing the
coupling.
The usual mode of failure of flexible disc couplings is rupture of the flexing membranes. In such
circumstances, it is possible to repair t he c oupling by fitting a replacement dis c pack assembly.

ATTENTION: When repairing John Crane Metastream flex ible disc couplings, only John
Crane approved parts should be used.

• To replace the transmission unit (3), first remove the hub bolts (4) and then withdraw the

transmission unit using the lever slots in the hubs or compression bolt feature in the spacer as
appropriate.

TRANSMISSION UNIT MUST BE ADEQUATELY SUPPORTED DURING REMOVAL

TO AVOID ACCIDENTAL DAMAGE SHOULD IT SLIP

• Identify the bolts which connect the disc packs to the spacer piece. Slacken and remove

these drive bolts (3C) and nuts (3D) and carefully dismantle the disc pack assemblies from
the spacer piece. Do not attempt to dismantle the disc pack assemblies any further;
replacement disc packs are always s upplied complete with a new guard ring.

• Subsequent refurbishment is dependent on the type of coupling involved and the precise

configuration of the replacement membrane pack. It is recommended that BOTH membrane
packs be replaced, as failure of one inevitably results in some damage to the other.

TSP (TSA) REPLACEMENT PACK

• Complete the removal of the old disc pack assemblies by pressing the washers (3E) out of the

holes in each spacer flange.

• Identify the fasteners which attach the disc packs to the spacer. Disassemble the loosely

assembled nuts (3D) and separate the bolts (3C) and washers (3E).

• Fit new washers (3E) into the spacer.

• Carefully press the protruding sleeves in each disc pack into the holes in the spacer flange,

taking care not to over-strain the flexible discs. Insert the drive bolts (3C) from the guard ring
side and secure using the locknuts (3D). Tighten the locknuts evenly to the correct SPACER
BOLT tightening torque value give n in Table 1.

• Complete the refurbishment of the transmission unit by replacing the second disc pack

assembly.

TSK [TSC] AND TLK REPLACEMENT PACK

• Complete the disassembly of the old disc packs by pressing the sleeves (3F) out of the

holes in each spacer flange.

• Identify the fasteners which attach the disc packs to the spacer flanges. Disassemble the

loosely assembled nuts (3D).

• With the bolts (3C) in position, carefully press on the bolt heads to push the new sleeves

into the holes in the spacer flange. T ake care not to over-strain the flexible dis c s.

• Place a small amount of threadlocking compound (e.g. Loctite 242) on the protruding bolt

threads and then assemble the nuts (3D). Tighten these nuts evenly to the correct spacer
bolt tightening torque value given in T able 1.

• Complete the refurbishment of the transmission unit by replacing the second disc pack

assembly.

• Having rebuilt the transmission unit, it is recommended that the shaft alignment be

checked prior to re-installation.

• The refurbished transmission unit should be installed in accordance with the instructions

for fitting a new coupling.

IMPORTANT Hub bolts should be replaced every time the coupling is dis m ounted.
ATTENTION: REPLACEMENT OF THE DISC PACK ASSEMBLIES INEVITABLY

CHANGES THE INHERENT BALANCE OF THE TRANSMISSION UNIT. HENCE, IF A
BALANCED COUPLING NEEDS REFURBISHING, IT IS RECOMMENDED THAT A
FACTORY ASSEMBLED AND BALANCED TRANSMISSION UNIT BE FITTED TO ENSURE
FUTURE, VIBRATION FREE OPERATION. IF REPLACEMENT DISC PACK ASSEMBLIES
ARE FITTED TO A BALANCED TRANSMISSION UNIT, THEN CONSIDERATION MUST BE
GIVEN TO REBALANCING OF THE REFURBISHED TRANSMISSION UNIT OR IN-SITU
BALANCING OF THE COUPLING.

WARNING

All necessary steps have been taken to ensure, as far as is reasonably practical,
that couplings are designed and manufactured to be safe when properly used.
These instructions are, however, general and it is important that users observe all
statutory plant and other safety requir ements.

All safety requirements must be strictly ad her ed to.
Ensure all precautions are taken to av oid personnel hazards.
Full machinery protection (safety guards) is ensured.
Use protective clot hes.

John Crane will provide advice on the use of couplings, but the following are the sole
responsibility of the User:

• Compliance with statutory plant requi r ements

• Compliance with oth er safety requirements

• Final choice of a co upling for a partic ular duty

Fitting, operating and maintenance operations should be carried out by qualified,
experienced and c ompetent people, for w hom these instructi ons have been written

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METASTREAM CO UPLING TYPE TSK, TSC, TLK GIUNTI METASTREAM TIPO TSK, TSC, TLK

METASTREAM CO UPLING TYPE TSP, TSA GIUNTI METASTREAM TIPO TSP, TSA

Table 1 – STANDARD COUPLING BOLT TIGHTENING TORQUES /COPPIE DI SERRAGGIO BULLONI DI GIUNTI STANDARD

BOLT TIGHTENING TORQUES/COPPIE DI SERRAGGIO BULLONI

HUB BOLTS/BULLONI MOZZO (4)

SPACER BOLTS/BULL ONI S PAZ I ATO RE (3C/3D)

FOR REFURBISHMENT/PER RIPRISTINO

TSK

TSP

TSC
TSA

TLK TSK TSP TSC TSA TLK

COUPLING SIZES

GIUNTO TIPO

N-m lb-ft N-m N-m N-m lb-ft lb-ft N-m
0011 0013 13 7 - 11 - 8 - ­0027 0033 25 14 - 23 9 17 7 ­0060 0075 25 14 - 47 17 35 14 ­0110 0135 25 14 - 75 31 55 26 ­0180 0230 50 26 - 130 31 95 26 ­0260 0350 25 14 - 150 58 110 41 ­0400 0500 50 26 - 205 58 150 41 ­0560 0740 50 26 - 285 145 210 125 ­0750 0930 86 63 - 380 145 280 125 ­1120 86 63 - 490 277 360 220 ­1400 86 63 86 490 - 360 - 380
1850 - - 86 ----490

(Data given on general arrangement drawings takes precedence) (I valori indicati sul disegno sono prioritari)

Mozzo St an dard

Mozzo Largo

Mozzo Standard Mozzo Largo

Spaziatore

REPLACEMENT MEMBRANE PACK

SOSTITUZIONE PACCO MEMBRANA

REPLACEMENT MEMBRANE PACK

SOSTITUZIONE PACCO MEMBRANA

STORAGE AND TRANSPORTATION

METASTREAM COUPLINGS

1. INTRODUCTION

John Crane manufacture and supply Metastream couplings of the highest quality. These are
precision-made pieces of equipment, with faces within hundreds of a mm. allowance. Every care
is taken in their design, manufacture, assembly, and despatch to ensure that they are of the
highest quality, and that they reach their destination to our customer’s satisfaction.

To obtain the optimum performance from our couplings, it is important that they are both fitted
and operated correctly in line with our technical literature. It is also important that couplings are
transported stored, packaged, and handled correctly from the time of delivery to installation in the
equipment.

The following designations are used in this instruction manual to highlight instructions of particular
importance

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NOTE:

Refers to special information on how to install or operate the coupling most efficiently

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ATTENTION:

Refers to special information or instructions directed towards the prevention of

damage to the coupling or to the equipment involved

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Refers to mandatory instructions designed to prevent personal injury or extensive
damage to the coupling

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2. PACKAGING AND TRANSPORTATION

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John Crane chooses a level of packaging appropriate to the item, the method of

transportation, the environment, and its known destination; if this is an intermediate location
the Company must be advised in advance.

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Specialised packaging is available for particular circumstances.

ATTENTION:

Metastream couplings to be transported should always be retained in their original
packaging or an equivalent.

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Equal attention to packaging is needed when transporting couplings when parts are being

returned or reconditioning is planned.
In many instances the original supply packaging is reusable, and if stored appropriately can
be used when moving used parts.

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Transported parts should always be accompanied by documentation confirming the

manufacturer, his identification code, and the reason for the supply.

It is the responsibility of the user to ensure that any parts being sent to a third party

have been appropriately decontaminated and have safe-handling instructions
externally attached to the package.

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On receipt of the package, its contents should be checked against the accompanying

documentation. Minimal disturbance should be applied, and after inspection the parts and all
relevant documentation should be replaced in the original packaging.

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If the package contains a coupling, it will also include an Instruction Manual and/or other

instructions. This information should be read thoroughly before handling the coupling. The
Instruction Manual should remain with the coupling unit until it is installed, and should then be
stored in an accessible and clean area.

• John Crane should be notified immediately if, after checking the documentation, it indicates an

item is missing, doesn’t comply, or there is concern an item has been damaged in transit.

If a part is damaged in transit, the coupling’s integrity may be affected.

ATTENTION:

Any gags should be removed before the start-up.

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No sharp edges likely to cause physical injury should exist, but function or processing may

have necessitated them. Check parts before handling and either avoid risk areas, and wear
appropriate protection

3. STORAGE

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The coupling should be fitted with gags to prevent undue movement of the membranes

during transportation and installation. Even so it must be appreciated that these couplings are
high precision items and should be handled carefully to avoid shock loads. It is also
recommended that couplings are stored horizontally. They should not be stood on end.

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The coupling in its container has been carefully packed to give protection during transport

and storage for a minimum period of two years. It is recommended that the coupling is kept in
this package until it is required for installation.

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If a coupling is removed from its packaging for any reason and not installed, the coupling and

its components must be cleaned and repacked. If the time to installation is so short that
complete repackaging is not considered necessary, then the coupling should be at least kept
in its case, along with technical literature and instructions supplied, until required.

• The benefits of careful packaging are nullified if couplings are badly handled when they reach

their destination.

John Crane Italia SpA
Via Giotto, 3
20053 Muggiò (MI)
Tel. [phone]
Fax [phone]