The Kop-Flex® products continue to innovate the industry with leading solutions such as the evolutionary High Performance Disc 2.0 coupling, torque monitoring systems, and patented ground bearing technology. The strength of the brand lies in its ability to provide a wide range of critical applications; from high speed, High Performance couplings for the Oil and Gas Industry, to high torque gear spindles for Metals and Mining applications.

Introduced in 1920, Kop-Flex® products bring over 100 years of design and application experience to a wide range of industries. Kop-Flex products include gear, disc, diaphragm, resilient shaft couplings and monitoring products.

Kop-Flex Fast’s couplings, the first gear coupling, were introduced in the 1930s.

Kop-Flex offers the broadest range of coupling products available on the market today – from high performance, high-speed disc, diaphragm and gear couplings to off-the-shelf, standard couplings as well as engineered gear, grid, jaw, elastomer, disc, universal joints and customized couplings to meet your unique application challenges. Kop-Flex also offers the Powerlign Torque Monitoring System. With a wide variety of coupling products, Kop-Flex provides a single source for all your demanding application requirements.

Kop-Flex high performance coupling products fulfill customers’ needs for demanding turbomachinery applications such as steam or gas turbines and motor driven trains; compressors, generators; boiler feed pumps and special pumps for industries ranging from petrochemical, refinery, power plants, LNG, gas pipeline, test stands and more.

Kop-Flex also offers coupling products for rolling mills and casters in steel mills, paper machines (both wet and dry ends), mines, liquid handling pumps and motors (for processing or liquid handling applications) and more.

With more customized application designs than any other coupling provider, Kop-Flex products are engineered to meet API 671 and ISO 10441, or API 610 and ISO 13409, as well as your own specifications.

Kop-Flex has facilities in the U.S.A., Canada and Europe and a service centers located in Houston and Florence (U.S.A.) A state-of-art, European manufacturing and service center, based in Nove Mesto, Slovakia serves Europe, the Middle East and Asia.

Unfortunately, no mechanical product can last forever and couplings are no exception. While Kop-Flex products are designed and built to last, many applications are so severe that rapid wear and/or coupling damage may occur. KOP-FLEX SERVICE CENTERS OFFER:

• Repair and refurbishment
• Expert failure analysis
• Cost savings through consultation
• Field technical support

At Kop-Flex® repair facilities worldwide, we have the equipment and expertise to repair your couplings at a typical savings of 50%. In two to six weeks, Kop-Flex engineers and field specialists work with clients to understand your application, make recommendations to improve life, create inspection reports and provide exact repair quotations. All required repairs are completed and returned with a full hardware replacement and an original factory warranty.

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 turbomachinery equipment. Gas turbines and compressors are being designed for increased efficiency by leveraging smaller form factors and higher speeds, creating rotordynamic 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.

IMPROVING COUPLING RELIABILITY

What Trends Are Impacting Couplings?

Data demand has exploded for data and information about how couplings are designed and selected, how they are manufactured, how they operate, how they are maintained, and how they are serviced. The coupling industry is catching up with the rest of the world in the data revolution.

Just like you and I track our orders from Amazon and get regular updates during the process, customers are looking for the same easily accessible live data for couplings. The procurement team needs quick access to product information to make purchases. Project managers are looking at Gantt charts to understand more about the process and status while couplings are being designed and manufactured. Installation and maintenance teams always need access to manuals and service experts. Our Kop-Flex® team is building a complete Digital Customer Experience (DCX) to support these goals.

How About The Hardware Side?

We have been gathering data from couplings that allows plant operators to make smarter maintenance decisions by monitoring performance trends with our Powerlign® torque monitoring system. In addition, our Perceptiv™ intelligence group uses an array of torque monitoring solutions for online monitoring, predictive maintenance and failure analysis. This includes the use of augmented reality tools.

Also, there is definitely a trend to have spares for all critical equipment. This is a lesson often learned after a field issue. Having that spare coupling on hand without having to transport parts across the country or the globe, ready to use, minimizes downtime. Many customers have purchased a spare to install at the next turnaround. They send the main coupling back to our Kop-Flex team for recertification.

What Is Your Coupling Recertification Service?

Disc and diaphragm couplings are not a ‘wear item’ like the seals in a turbine or compressor, which can cause a decrease in equipment performance and are typically replaced on a time-based schedule. Most high-performance couplings are designed to be maintenance-free.

If they are operated within their rated capacities, they can outlast the equipment to which they are connected. To maximize production, each asset, critical or not, should have an appropriate maintenance strategy that is followed, audited for effectiveness, and adjusted as necessary to ensure reliability.

However, equipment upgrades, shifting foundations, process changes, environmental factors and handling can push the coupling outside of its design operating envelope. The recertification service allows end users to evaluate couplings and conduct repairs, if necessary, during scheduled downtimes to prevent unplanned outages. Recertification is targeted at the API 671/ISO 10441 market, but is available for most coupling types.

Kop-Flex has been recertifying couplings for over 15 years and services more than 150 couplings per year. The team does a full teardown and inspection of each component. They replace components as needed with new parts made to the original drawings and design standards. Recertification restores couplings to a like-new condition for about half the cost of a replacement.

What Other Products Might Our Users Be Interested In?

The Kop-Flex Powerlign torque monitoring system allows users to minimize emissions and fuel costs by tracking performance trends in connected equipment. This system can be purchased new with couplings or retrofitted to existing Kop-Flex or other brand couplings.

We also offer a Max-C® resilient coupling that provides damping for applications with shock loading or cyclic torques. The Max-C can be mated to disc or diaphragm couplings to tune the drive train. They are frequently used on synchronous and variable frequency drive motors.

What Products Do You Have In The Pipeline?

Our teams are always working to provide optimal solutions for the most challenging applications. We have a great focus on providing lightweight, cost-effective and highly reliable solutions for the industry.

There are some exciting ideas in the pipeline, and a lot of the ideas are spawned from our Perceptiv™ intelligence team. They are working directly with customers to understand new challenges that arise in the field and finding unmet needs. The beauty of this team is that they support our whole Regal Power Transmission Solutions business. So, we get a lot of benefit from cross-pollination of ideas and economy of scale from other industries that we serve, like food and beverage and HVAC.

What Is The Company Doing To Cope With The Current Slowdown?

Regal® is committed to supporting its associates, customers and communities through the Covid-19 pandemic. It is a rapidly changing situation, and we are working diligently to maintain focus and support essential business while making the best decisions for safety.

KOP-FLEX® SERVICE CENTER COUPLING PROGRAM

Repair Worn Equipment And Save 60% To 90% Of The Cost Of Buying New

It takes knowledge, experience and the proper facilities to repair a highly engineered product.

Kop-Flex® offers:

• Engineers and field service specialists work with your maintenance staff to understand the unique parameters of your application.
• Inspection reports detailing the type of wear and/or damage and recommended action.
• Exact price quotations.
• Repair services for other manufacturers’ couplings include recommendations to improve life through design changes and/or material upgrades.
• Highly skilled and experienced technicians.

Let An Expert Provide You With Both An Analysis And A Recommendation

IUnfortunately, no mechanical product can last forever and couplings are no exception. While Kop-Flex® products are designed and built to last, many applications are so severe that rapid wear and/or coupling damage may occur.

Kop-Flex® has the largest and most experienced engineering staff in the industry, with an arsenal of modern analysis tools at our disposal including FEA, an in-house R&D center, and a staff focused solely on couplings. Let our technical experts go beyond mere failure analysis by providing our recommendations on how to prevent future coupling problems.

Case Study:

At one major Midwest Gas Plant, our management program has reduced maintenance and spare costs by nearly 25%, while at the same time improving reliability and uptime. When you consider the tangible, direct-cost savings, reduced downtime, and extended component life, you can see how coming to Kop-Flex® can reward you with big savings.

Kop-Flex Service Centers Offer:

• Repair and refurbishment
• Expert failure analysis
• Cost savings through consultation
• Field technical support
• Asset Management Program (AMP).
• Coupling Reverse Engineering.

High Performance Gear, Disc And Diaphragm

Avoiding Downtime is Critical in High-Performance Environments

• Kop-Flex® can help you recognize significant savings in these applications
• Petrochemical plants
• Offshore drilling rigs
• Turbo-machinery
• Gas/steam turbine-driven compressor drive trains
• Synchronous motor drives
• Boiler feed pumps
• Generator drives in fossil fuel and nuclear power plants.

Kop-Flex® is the industry authority in turbo-machinery with strong technical representation on API and ISO committees as well as active participation in many technical forums.

Kop-Flex® experts will provide you with objective failure analysis, inspections, and reports. Kop-Flex® team will repair or refurbish any coupling including those manufactured by our competitors and provide you with a warranty and a proactive plan to reduce costs. Our process of inspecting and repairing high-performance couplings is the most extensive in the industry.

High Performance Coupling Inspection and Repair Process

• Kop-Flex® provides the most extensive evaluation, inspection, and repair service in the industry:
• Each component is photographed as received for thorough engineering inspection.
• Couplings are disassembled and all components are tagged.
• Non-destructive test on torque carrying components is conducted using Magnetic Particle Inspection (MPI), Dye Penetrant and X-ray as required.
• Kop-Flex® engineers analyze the data and prepare an inspection report detailing findings and offer their expert recommendation on how to refurbish, repair or replace based on the amount of wear and damage.
• A quotation for performing the work recommended is submitted back to you within two weeks of receiving your coupling in our facility.
• Couplings will be assembled to original specifications, skimmed at assembly, dynamically balanced to API 671 (ISO 10441) or API610 (ISO 13709) – component or assembly – as required by the application and your specifications.
• Quick Turnaround - our complete inventory of flex elements and nitrided gear components speeds the process.

KD® DISC COUPLINGS

Features & Benefits

* CLOSE COUPLED *

KD1 with MT Disc Packs

Size Range 103 to 453

Bore Range .50 - 5.50”

• Unitized Disc Pack replaced without moving connected machines
• Medium Duty Applications

KD10 with HS Disc Packs

Size Range 103 to 905

Bore Range .50 - 11.50”

• Unitized Disc Pack replaced without moving connected machines
• Heavy Duty Applications
• Ratings Similar to Gear Couplings

KD11 with HT Disc Packs

Size Range 103 to 905

Bore Range .50 - 11.50”

• Unitized Disc Pack
• Heavy Duty Applications
• Ratings Similar to Gear Couplings

* SPACER STYLES *

KD2® with MT Disc Packs

Size Range 103 to 453

Bore Range .50 - 7.25”

• "Drop-Out" Spacer Design
• Factory Assembled Center Flex Section
• Medium Duty Applications

KD20 with HT Disc Packs

Size Range 204 to 905

Bore Range 1.00 - 13.50”

• "Drop-Out" Spacer Design
• Factory Assembled Center Flex Section
• High Torque Applications

KD21 with HT Disc Packs

Size Range 053 to 905

Bore Range .50 - 13.50”

• Simple 3 Piece Spacer Design
• Unitized “Drop-Out” Disc Pack
• High Torque Applications

* COOLING TOWER *

KD33 with CT Disc Packs

Size Range 153 to 303

Bore Range .50 - 4.50”

• Cooling Towers with Very Long Shaft Separation
• Stainless Steel/Composite Tubes
• Replaces most competitive Cooling Tower
• Couplings
• Non-lubricated

* SINGLE FLEX & FLOATING SHAFTS *

KD4 with HT Disc Packs

Size Range 103 to 905

Bore Range .50 - 13.50”

• Single Flex
• Unitized “Drop-Out” Disc Pack
• Heavy Duty Applications

KD41 with HT Disc Packs

Size Range 103 to 905

Bore Range .50 - 13.50”

• Floating Shaft Design
• Unitized “Drop-Out” Disc Pack
• Heavy Duty Applications

KD42 with HT Disc Packs

Size Range 103 to 905

Bore Range .50 - 11.50” Flex Half

• Floating Shaft Design
• Bolts Directly to Gear Coupling Rigids
• Unitized Disc Pack
• Heavy Duty Applications
• Ratings Similar to Gear Couplings

KD® Series of flexible shaft couplings provides reliable transmission of mechanical power from driving to driven machine where a low-maintenance, non-lubricated coupling is required.

KD Disc Couplings are specifically designed to accommodate general purpose drive system applications such as centrifugal pumps, compressors, generators, cooling towers, machine tools, printing and pulp and paper machines.

KD Couplings transmit torque and provide for both angular and axial misalignment between shafts with a coupling comprised of shaft mounted hubs connected through flexible disc packs with spacer or sleeve assemblies.

All KD Couplings use stainless steel discs as flexible members, providing high strength and good corrosion resistance. The streamline disk pack design results in the reaction load on equipment bearings being minimized. These disc pack couplings are inherently self-centering; additional provision for limited end float is not required.

Most disc packs are unitized and, along with self-locking nuts, they greatly reduce the number of loose parts, thus simplifying installation and replacement.

KD Disc Couplings are now available in an expanded range of sizes and styles suitable for common installations. Or if you need something special, we can design a coupling to meet your specific requirements.

SERIES H PLUS GEAR COUPLINGS

The Kop-Flex Series H Plus gear coupling has been optimized for use in demanding applications. It features high misalignment capability thanks to crowned hub teeth with flank, tip and root curvature. Additionally, the increased tooth pitch diameter allows for more torque with the same flange size. A large bore capacity accommodates large shaft diameters without increasing coupling size.

Lubrication ports are on the sleeve body, close to gear mesh for easier access. The Buna-N O-ring retains grease and protects against contamination. Kop-Flex KHP coupling grease is recommended to obtain maximum operating life and is required for 4-year warranty eligibility. A 1-year warranty is provided if other approved grease is used.

Kop-Flex Series H Plus Features and Benefits

• Available in sizes 1 through 7
• Maximum bore size of 10.875 in.
• Maximum torque capacity of up to 1,180,000 lb-in.
• Accommodates up to 1.5 degrees of static misalignment.

Download Related PDF Documents for more product information

kopflex h plus

kpflex 10568E