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  POWERLIGN® TORQUE
   MONITORING SYSTEM



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Powerlign® Performance Torque Monitoring System
for Coupling Applications


From the invention of the Fast®’s coupling – the world’s first gear coupling – to today’s
high-performance couplings, Kop-Flex® has a rich industry background and a reputation
for solving customer problems.

 

Faced with rising fuel costs and increasing environmental concerns such as Nox(nitrous oxide) emissions standards, torque-meters are increasingly being used to measure power, speed, and torque on critical rotating machine equipment.

 

Torque differentials can indicate performance problems such as blade fouling and over-torque can lead to coupling shaft or equipment failure. When performance declines, more fuel is burned and Nox emissions increase. Torque-meters provide a cost-effective method for diagnosing these problems early on so you can make the necessary adjustments to
your system for a proactive maintenance plan. 

 

 


Key Benefits




  • All new, digital phase-shift, non-strain gauge system
  • As a single source supplier of couplings and torque-meters, Kop-Flex®
    eliminates coordination and design integrity issues that occur with multiple
    suppliers
  • Simplicity of design reduces margin for error– with accuracy within ±1%
  • Safety and reliability – unlike other torque measuring devices, no electronics
    or electrical power is present in the coupling or in the coupling environment
  • Seamless integration – connect the Powerlign® conditioning unit directly
    to a DCS like the DeltaV system or others running public or private MODBUS
    protocol, reducing the cost of setting another box or training your operator to
    use a new system
  • Retrofit - For most applications, a new instrumented spacer can be inserted
    without disturbing the existing flex half couplings
  • Specially configured MODBUS communication protocol available to fit with
    your existing DCS
  • Significant cost savings – considering that a 40MW gas turbine consumes
    $8,000,000/year in 2003 fuel costs, a one percent increase in efficiency equates to
    $80,000 in annual savings
 

Powerlign® Performance Torque Monitoring System
for Coupling Applications


From the invention of the Fast®’s coupling – the world’s first gear coupling – to today’s
high-performance couplings, Kop-Flex® has a rich industry background and a reputation
for solving customer problems.

 

Faced with rising fuel costs and increasing environmental concerns such as Nox(nitrous oxide) emissions standards, torque-meters are increasingly being used to measure power, speed, and torque on critical rotating machine equipment.

 

Torque differentials can indicate performance problems such as blade fouling and over-torque can lead to coupling shaft or equipment failure. When performance declines, more fuel is burned and Nox emissions increase. Torque-meters provide a cost-effective method for diagnosing these problems early on so you can make the necessary adjustments to
your system for a proactive maintenance plan. 

 

 


Key Benefits




  • All new, digital phase-shift, non-strain gauge system
  • As a single source supplier of couplings and torque-meters, Kop-Flex®
    eliminates coordination and design integrity issues that occur with multiple
    suppliers
  • Simplicity of design reduces margin for error– with accuracy within ±1%
  • Safety and reliability – unlike other torque measuring devices, no electronics
    or electrical power is present in the coupling or in the coupling environment
  • Seamless integration – connect the Powerlign® conditioning unit directly
    to a DCS like the DeltaV system or others running public or private MODBUS
    protocol, reducing the cost of setting another box or training your operator to
    use a new system
  • Retrofit - For most applications, a new instrumented spacer can be inserted
    without disturbing the existing flex half couplings
  • Specially configured MODBUS communication protocol available to fit with
    your existing DCS
  • Significant cost savings – considering that a 40MW gas turbine consumes
    $8,000,000/year in 2003 fuel costs, a one percent increase in efficiency equates to
    $80,000 in annual savings
 

From Simple Diagnostics to True Control


As the only company in the world that has developed an integrated
coupling-torque-meter the solution, Kop-Flex® introduces the newly
designed, digital Powerlign® Performance Torque Monitoring System.

 

As the most reliable, accurate torque-meter available in today’s
marketplace, the digital Powerlign® replaces the proven, analog
Powerlign® the system that has served the market for the last ten years.
Powerlign® features a patented, unique architecture that allows for more
advanced system control with full integration support for distributed control
systems (DCS) or PCs and laptops for analyzing system data.

 

Powerlign® acts as an important part of a closed loop system by
establishing certain thresholds that can be configured to trigger an alert or
alarm. Powerlign® can also be used as a control system to shut down
equipment or direct them in the flow of gas or fuel to maintain load and
efficiency.

 

 

 

 

 

 

 

  • Aids in environmental compliance efforts by helping to reduce
    Nox emissions through improved fuel monitoring.
  • Completely interchangeable components and no need for
    re-calibration.
  • Highly flexible – fewer components, easier to install and no need
    to disturb or modify any vents, drains, filters, etc.
  • ATEX, CE and CSA certification for explosion proof sensors (Div I),
    intrinsically safe conditioning unit and display unit (Div II) operation.
  • RS-232 digital, RS-485 digital and 4-20m analog output.
  • Decreased lead times.
  • Reduced wiring cost.
  • Uses existing coupling guard.
  • User configurable imperial inch or metric (SI) units.
  • Built-in, automatic temperature compensation; sensors operate at
    temperatures as high as 350° F (177°C) to accommodate the most
    demanding environments.



No Other Torque meter System Offers
Consistent Accuracy


The accuracy rating is determined as a root sum of the squares series of all the individual errors possible, both electrical and mechanical.The mechanical inaccuracies
include allowances for the inevitable movements of the coupling in relation to the guard-mounted sensor, during hot and cold cycles of equipment operation. These are the
radial gap and axial movement errors. Other mechanical errors are possible from the various calibrations and set-ups. Electrical items include sensor variation and
conditioning unit variation. Note that because these errors are included in the overall budget, sensors and boxes from the factory or stock can be swapped out in the field
without degradation of accuracy. Powerlign® and Powerwheel are accurate to within one percent.

 

 

Powerlign® and Powerwheel Covering a Range of Application


Powerwheel features the same patented design as Powerlign® in a smaller footprint with a specifically profiled double-sided wheel, where teeth mounted to the outer
diameter of one wheel move relative to teeth mounted on the mating wheel. Similar to Powerlign®, sensors detect this movement but instead, deflection occurs in profiled
spokes in each wheel in combination with a short, tubular section that connects the wheels.

 

 

The Origin of Powerwheel

To develop Powerwheel, Kop-Flex® modified the same, proprietary, numerical analysis used for Kop-Flex® diaphragm couplings then proved the design software with
FEA, R&D and field tests. One back-to-back test connected a Powerlign® torque meter directly to a Powerwheel torque meter, loaded with torque at high speeds. Each meter
had a separate probe and an independent electronic system. Correlation results were excellent, within 0.3% of full-scale torque.

 

 




How Powerlign® and Powerwheel Work





Mechanical wheel or spacer – Powerlign® includes intermeshed, pick-up teeth mounted on a spacer on the coupling. The applied torque causes the spacer and wheel, to torsionally deflect, resulting in torsional twist. In the Powerwheel design, the “twist for torque” measurement occurs in a compact, specifically profiled double wheel, where teeth mounted to the outer diameter of one wheel move relative to teeth mounted on the outer diameter of a mating wheel.

 

Sensors – two, monopole sensors, from reference points on the wheel, pick up this torsional twist. The sensors are mounted on the existing coupling guards by welding a boss plate to the guards, hence they do not rotate with the coupling and the pick-up teeth. The
sensors are inserted into the boss plates and the gap is set with a depth micrometer or feeler gauges. The boss plate orientations are usually installed at a 45° angle to avoid conflicts with drainpipes, vents, etc. As each set of teeth passes the sensor, a waveform is
created.

 

Conditioning unit – the waveform is transmitted to a processor within the conditioning unit,
which translates the twist into torque based on a series of measurements and constants. It also monitors the coupling’s speed and temperature. Internal circuits continuously use temperature information to automatically compensate for temperature-associated changes in coupling stiffness. Because processing occurs close to the sensors, greater accuracy results due to reduced wire transmission. The conditioning unit is mounted within 500 feet of the sensors and transmits data via cable, RS- 485 and a public MODBUS protocol (an industry standard format, recognizable by most DCS). Powerlign® can also be configured to
transmit data over wireless networks or other communication protocols. (Contact Kop-Flex® for details.) The conditioning unit also automatically checks and corrects itself every 24 hours for any electronic drift, eliminating the need for field calibration.

 

Standalone display unit – the standalone unit receives the digital signal and displays (but
does not store) torque, speed, and temperature data at approximately one-second intervals.
Powerlign® can transmit 4,000 feet whereas competitive designs only transmit up to 1,000
feet. This provides a greater range for signal transmission to the standalone display unit or the DCS, eliminating the need for expensive, cross-site cabling and providing flexibility in
locating the diagnostic system. The display unit provides RS-232 digital and 4-20 mA analog output signals.

 

DCS (in lieu of display unit) – the conditioning the unit can connect directly to your DeltaV or other DCS, via RS-485 cable or wireless (as an option) using public or private MODBUS protocol.

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