HIGH-PERFORMANCE DISC COUPLING 2.0

FOR THE OIL & GAS INDUSTRY


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OVERVIEW

Kop-Flex® high-performance couplings have been supplied to the global oil and gas industry for over 30 years and have amassed over one billion hours of reliable operation in API 671 applications. Leveraging this experience, the next generation of disc coupling was developed to enable continued improvements in the turbo-machinery equipment. Gas turbines and compressors are being designed for increased efficiency by leveraging smaller form factors and higher speeds, creating rotor-dynamic challenges. To achieve the best weight and power density possible, a more compact coupling was designed and optimized for the torque requirements of the application. Building on our foundation of reliability, safety and exceptional performance, the Kop-Flex High-Performance Disc Coupling 2.0 was created for your highly engineered equipment. 

 

 

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ADVANTAGES

  • Optimized disc geometry improves stress distribution and reduces reaction loads.
  • 15-30% weight reduction compared to our previous generation coupling.
  • Lowest overhung moment available.
  • Reduced coupling diameter decreases windage effects.
  • 22 sizes available to align with common inch and metric shafts.
  • Weight reduction decreases imbalance forces on equipment.

The next generation Kop-Flex disc coupling is an evolutionary design developed using cutting edge analysis tools and techniques, including:

 

  • Advanced finite element analysis.
  • In-house static and dynamic testing.
  • Fatigue life testing.

Development leveraged our in-house R&D facility, which includes state-of-the-art test stands and precision instrumentation specifically designed for the development of next-generation coupling products. Analysis and testing complexity ranged from individual components to complete couplings to determine the product ratings met requirements. These improved analysis techniques enable technical details and in-depth analysis of application-specific designs to be delivered quickly and confidently.

 

 




 

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PRODUCT LINE OVERVIEW

The High-Performance Disc Coupling 2.0 product line consists of two reduced moment styles: the RMS and RZS. The RMS is a full-featured disc coupling providing a reduced windage design and interlocking flanges for additional protection in the event of a disc pack failure. The RZS coupling provides a more cost effective solution, with non-interlocking flanges. Optional coupling features also include:

 

  • Powerlign® torque meter
  • Lateral and torsional tuning
  • Electrical insulation
  • Shear device
  • Corrosion-resistant material
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OPTIMIZED COUPLING SELECTION

Shaft diameter drives the selection of reduced moment couplings for most high-speed equipment. The product line was designed with 22 sizes to match the most common inch and metric shafts, providing an optimized coupling selection for each application. The Kop-Flex® High-Performance Disc Coupling 2.0 is designed to be the lightest coupling available on the market, enabling the highest performance in critical applications.

 

disc coupling 

 

SELECTION EXAMPLE

Compressor train for top oil and gas producer’s offshore project:

 

Application Info

Equipment

Gearbox to Compressor

Driver Rated Torque - lb-in (N-m)

28,000 (3,164)

Max Continuous Speed (rpm)

13,000

Coupling Details

Previous Generation

Disc Coupling 2.0

Spacer Material

Titanium

Alloy Steel

Max OD - in. (mm)

6.56 (166)

5.86 (149)

Driving Half Weight - lb (kg)

17.1 (7.76)

14.6 (6.62)

Driven Half Weight - lb (kg)

17.1 (7.76)

14.6 (6.62)

 

The Kop-Flex High-Performance Disc Coupling 2.0 selection enabled the customer to use a more cost-effective alloy steel spacer while still achieving a 15% weight reduction and meeting all application requirements.

 

LIGHTEST WEIGHT COUPLING

Average weight reduction of over 30% compared to the previous generation.

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RMS Disc Coupling (inch)

 

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RMS Coupling Selection Data

 

Size

(1)
Normal Bore
Capacity
(in)

(4)
Max.
Continuous
Torque
Rotating
(lb-in)

(5)
Max.
Momentary
Torque
Rating
(lb-in)

(6)
Maximum
Speed (RPM)

(6)
Total Weight
(lb)

(6)
Total
WR2
(lb-in2)

(6)
Half
Coupling C.G.
(in)

(6)
Torsional
Stiffness K
(E6 lb-in/rad)

2103

1.6

12000

19000

34300

13

25

1.6

0.4

2504

1.7

22000

35000

33000

17

45

1.7

0.5

3004

2.0

30000

48000

30800

19

55

1.8

0.7

3304

2.3

39000

62000

29400

22

75

2.0

0.9

3604

2.5

53000

85000

26700

27

110

2.3

1.3

4104

2.8

76000

121000

23700

34

180

2.6

1.7

4304

3.0

90000

144000

22500

39

230

2.7

2.1

4704

3.3

115000

184000

20700

48

330

2.8

2.8

5104

3.5

147000

235000

19100

62

500

3.0

3.5

5504

3.8

180000

288000

17800

74

680

3.3

4.6

5804

4.0

215000

344000

16800

88

910

3.4

5.4

6204

4.3

268000

428000

15600

106

1300

3.7

7.1

6504

4.5

301000

481000

15000

120

1600

3.8

8.3

6904

4.8

367000

587000

14100

145

2100

4.0

10

7404

5.1

425000

680000

13200

170

2900

4.4

13

7904

5.5

527000

843000

12300

218

4300

4.6

16

8604

6.0

670000

107000

11300

272

6400

4.9

21

9404

6.5

842000

135000

10400

341

9300

5.6

28

10104

7.0

1020000

1630000

9700

434

14000

5.9

35

10804

7.5

1270000

2030000

9000

524

19000

6.2

45

11604

8.0

1550000

2480000

8400

655

28000

6.6

55

12404

8.6

1880000

3010000

7900

779

37000

7.0

69

 

Axial Data

 

Size

(7)(8)
Maximum Continuous
Axial Displacement
(in)

Maximum
Force
(lb)

2103

+/- 0.080

120

2504

+/- 0.060

210

3004

+/- 0.070

240

3304

+/- 0.080

300

3604

+/- 0.090

360

4104

+/- 0.105

470

4304

+/- 0.110

530

4704

+/- 0.120

610

5104

+/- 0.130

690

5504

+/- 0.140

830

5804

+/- 0.150

940

6204

+/- 0.160

1100

6504

+/- 0.170

1300

6904

+/- 0.180

1400

7404

+/- 0.190

1600

7904

+/- 0.205

1900

8604

+/- 0.225

2100

9404

+/- 0.240

2400

10104

+/- 0.260

2800

10804

+/- 0.280

3400

12404

+/- 0.320

4400

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RZS Disc Coupling (inch)

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RMS Disc Coupling (metric)

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RZS Disc Coupling (metric)

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