A Quick reference guide to the installation of Uniflex. Oldham Seals Group Uniflex installation Guide
Uniflex Guide From Oldham Seals Group Introduction: Uniflex systems provide a means of remote Valve operation and the ability to build in secondary operating positions known as remote stations. The Uniflex system is the most versatile, reliable and proven approach to remote mechanical valve actuation available today. It features a 5/8 (16mm) diameter, high-tensile, stainless steel, flexible shaft which is standard in the geared system. The flexible shaft is driven by a geared operator which transmits power to a reduction gear box at the valve. The system can be configured using a range of gear ratios allowing smooth operation in even the longest and most complex installations. A flexible shaft designed for rotary power transmission is ideally suited to remote and safe actuation of valves. Uniflex systems are generally fitted in limited access areas or were valve operation is restricted due to a varied number of reasons these range from but not limited to: Physical accessibility or position of the valve Space limits option to use standard lever or hand wheel Local valve operation poses a threat to life or is somewhat dangerous Secondary operating position required for safety reasons Secondary operating position required by system parameters The addition of a Stow Torque-Limiting Clutch to an operating station (plain or indicating) permits the controlled operation of small plug, ball, diaphragm or instrumentation valves without the operators concern for over-torqueing valve stems or seats. Stow s torque limiting clutch can be easily set to any torque within its range of 0-1000 pounds-inch after installation into a system. The clutch is permanently lubricated and has a repetitive accuracy of approximately 95 h over its full operating range. Hand wheels mounted on torque transmission spindles, wall terminals and floor stands make up the basic operating stations. A 90 gearbox (with indicator) operating station is available to bring high or low wall penetrations to a comfortable chest-high operating height. Stuffing boxes are installed where the rotary flexible shafting penetrates compartment bulkheads or decks. Stuffing boxes serve to maintain the watertight integrity of the bulkhead. The connection to the valve or valve gearbox is made with both rising and non-rising valve couplings and terminal couplings. When the valve is positioned in an accessible location, then a quick-disconnect valve coupling should be installed at the valve location. The quick disconnect coupling allows the valve to be easily disconnected from the remote mechanical Valve actuator system so that the valve may be locally operated at the valve location.
Installation/Assembly: The keyed inner flexible shaft is easily fitted to other components and usually requires only the most basic of tools: Drill Screwdrivers Hammer Pliers The system will be supplied unassembled and pre greased ready for assembly. Due to the systems sealed for life nature it requires no more lubrication than is recommended in the following section. The flexible shaft assembly should be installed using uniform bend radii to optimize efficiency of the system, a minimum bend radius of 12 inches and maximum accumulated degree of bend = 540 Degrees, Torque requirements and 540 max accumulated degree of bend may be exceeded subject to other system parameters. System should be designed and fitted with the minimum number of bends possible. Torque measurements of the valve that the system is to be fitted to should be taken and recorded for future reference for example: Torque to open valve = 20Nm Torque to close valve = 24Nm The following quick installation guide assumes all other components Deck boxes, stuffing boxes and operating stations for example are all fitted in the relevant positions and secure to bulk head or equivalent fixed structure. Due to the number of possible configurations these guidelines may vary. 1. To allow a 90 bend, the flexible shaft will require a minimum of 15 inches from an actuator input shaft or 15 inches away from an operator output shaft, to accommodate fittings and appropriate bend radii. When prohibited by space restrictions, a swivel adapter or 90 adapter can be used. These items interface directly with actuators and operators, and do not require additional mounting brackets. A Deck Box Operator is to be used where flush mount through deck or bulkhead is required. When used in decks it should be limited to clean dry locations and used only if space restrictions prohibit the use of other operators. 2. Uniflex shafts can be connected to components such as deck boxes, remote operators, valve station actuators, gear boxes and valve couplings. To connect the flexible shaft to the output of the remote operator station/valve station start by loosening the screw set in the bronze end sleeve (DC Sleeve). Slide sleeve back to expose inner core keyed fitting, Slide keyed inner core onto output shaft and insert 5/32 roll pin. Slide brass end sleeve on to remote operator output shaft and secure using screws provided. (Casing ferrule should be 1 3/8 to 1 ½ from ferrule sleeve to ensure set screws are located in ferrule groove) The valve station actuator is used as a torque multiplier to increase the output torque of the flexible shaft. The space limited actuator is used when space restrictions prohibit the use of standard actuators.
3. Route the flexible shaft assembly as required. Clamps are to be used to secure the flexible shafting as close to the remote operator or deck box and valve as possible. Clamps are used throughout the flexible shafting run at approximately five foot intervals where convenient. Where radial bends are installed in the flexible shaft run, they are to be made as large as possible to minimize frictional loading. Clamps are to be located at the beginning and end of a radial bend as a minimum, also in the middle of the bend if possible. The stuffing box is used to seal the flexible shaft s penetration though bulkheads or decks. The housing is to be welded in place and the flexible shaft, less the DC sleeve is routed though the stuffing box. Use approx. 12 of 1/8 x 3/16 of packing and torque nut to 108-135Nm to ensure proper seal. It is suggested that a minimum number of clamps are fixed during first routing to allow for possible adjustment later. 4. Turn the remote operator to check general operation, then ensure the remote operator is set to the closed position. The remote operating station serves as an operation point for Uniflex systems. The unit is designed to surface mount though a deck or bulkhead it can also be mounted on a fabricated structure to serve as a deck stand. 5. If applicable turn the intermediate operator to check general operation, the intermediate operator is used when a valve must be operated from two locations or two valves are to be operated from one location simultaneously. Do not forget to set to closed position. 6. Turn any other operators or 90 operators/actuators or swivel adaptors fitted to system to check the general operation. 7. Cycle the valve to ensure it operates as expected. Ensure the valve is in the closed position. 8. Attach the valve actuator to a suitable bracket this is to be secured to a rigid structure. Mount valve actuator assembly to mounting bracket. Align with the centre line of valve. When mounting valve station actuator, Valve actuator needs to be directly above the valve hand wheel to allow for connection of valve hand wheel coupling and Double UJ. Use the two components (hand wheel coupling & Double UJ) to assess the correct position before installing. 9. Connect the flexible shaft to the input of the valve actuator by loosening the screw set in the bronze end sleeve. Slide sleeve back to expose inner core keyed fitting, Slide keyed inner core on to output shaft and insert 5/32 roll pin. Slide brass end sleeve on to remote operator output shaft and secure using screws provided. (Casing ferrule should be 1 3/8 to 1 ½ from ferrule sleeve to ensure set screws are located in ferrule groove)
10. Go to the remote operator and fully cycle the system from closed to open. If operation feels difficult check the cable routing and make adjustments as required. When the best feel has been achieved, return the operator to the closed position. Measure and record torque required to operate the system when disconnected from the valve for example: Clockwise Torque = 12Nm Anticlockwise Torque = 12Nm 11. Assemble double universal joint to valve station actuator with nominated shear pin. The primary purpose of the shear pin is to prevent valve damage from excessive torque. 12. Attach valve coupling to the valve hand wheel using U-bolts (customer supplied) around spokes of the hand wheel. It is important to fix the valve coupling as central as possible to the hand wheel. Excessive run-out will cause operating problems. 13. Attach Double Universal joint (UJ) to valve coupling with key and pin. If applicable this will compensate for misalignment. It is connected to a valve station actuator using a shear pin. The slip end of the double u-joint to valve station actuator should be in the centre of its stroke to allow for movement in both directions. When connecting with a rising hand wheel coupling, position valve hand wheel at its lowest point (closed). Then raise valve station actuator until the valve coupling is in its fully extended position. 14. Go to the remote operator and cycle system to fully open position and temporarily record open position. Cycle system to fully closed position and temporarily record closed position. Repeat cycle to check for consistent in operation. Once satisfied that operation is calibrated permanently mark the open and closed position. 15. Once system is fully installed and operational, open and close system with a torque wrench and record operational torque. Mark this number on system tag for future reference for example: System operating Torque Open = 32Nm System operating torque Close = 36Nm 16. If the system is disconnected from the valve at any time (for maintenance or local operation) it will need to be re-set. While the system is disconnected set the remote operator to the closed position. Set the valve to the close position. Connect the valve coupling to the system. Cycle to the fully open position and check the remote operator indicator shows fully open. Check the valve is fully open, Cycle to the fully closed position, Check valve is fully closed.
Capabilities and limitations: 1. Minimum Bend Radius: 12 inches 2. Max length: 150FT 3. Max torque at valve: 271Nm/200FT-LBS 4. Maximum System Length: 150 feet (subject valve torque requirements) 5. Minimum Length: Approx. 3 Ft 6. Operating Environment: -65 to + 800 F and 0 to 100% Relative Humidity. 7. Fire Test: 1300 F (704 C) 8. No minimum straight length required between bends. 9. Maximum Torque Input at Operator Station: 149Nm 10. Operator Directional Rotation vs. Valve Directional Rotation: Same Direction. Maintenance: A low level of maintenance is required of the Uniflex System due to its Sealed for life & Fit and Forget nature. Only basic considerations during the installation are needed. Ensure fitting ends are free from particles and clean. A very light coat of grease may be applied prior to mating ends. Troubleshooting: Troubleshooting of the flexible shaft and mechanical actuators should be performed by personnel familiar with the system or an Oldham Seals Engineer. Lubrication: Systems should be lubricated once during assembly and do not need to be re-greased. Systems are supplied with grease fitting in case a situation occurs in which lubrication must be added. Standard grease used is: Aero shell 5 for flex shaft assys and Shell Alvania EP #2 for valve station actuator or Nuclear- where there is exposure to radiation: Fosythe MOV Long Life Valve Grease, NLGI-2. Other greases are available according to customer requirements. Note: Do not over lubricate flexible shaft as this may cause binding
Hint & Tips: A double U-Joint is to be utilized in all standard systems except when a Space Limited Actuator is used. Quick release coupling is used on raising and non-rising hand wheel valves; it is attached to the valve hand wheel spokes using U-bolts. U-Bolts are sized to fit around the hand wheel spokes. The threaded leg lengths are sized to protrude through the coupling base and accommodate lock washers and nuts. 300 Adapter allows the flexible shaft to be positioned at any angle from 30 to 300. Try to roll valves that are in awkward places to provide ease of access and aid in the fit of equipment. There will be situations where the 12 minimum bend radius will be hard to achieve before connecting to the operator or before entering an actuator this is where a swivel adaptor should be utilized. From valve manufacturer, obtain torque value that will damage valve, subtract 25% and size down e.g. Torque to damage valve is 200 ft. lbs. - (200 x.25) =150 ft. lbs. Clamps and Standoff Kits are used to support the flexible shaft. Optimally, a shaft should be supported near each end and approx. 5 from bronze DC sleeve and every 3 to 5 in a straight run and at the beginning, middle and end of each radial bend. NOTE: Space Limited Actuators are for special applications. It is configured different than other actuators.
Technical Inquires Lee Dodd Technical Project Engineer Oldham Seals Ltd Gravel Lane Quarry Lane Industrial Estate Chichester West Sussex PO19 8PG Sales Inquires sales@oldhamseals.co.uk M: 07515051368 T: 01243 782296 F: 01243 781933 Email: ldodd@oldhamseals.co.uk www.oldhamseals.co.uk