Flexible Gear Drive System (DGN)

Uniflex-stow remote valve operating systems
Flexible shaft system with integrated geared system
1. INTRODUCTION
The purpose is to provide the user with basic information for the specification,
installation, operation, maintenance, repair of the Uniflex-stow rotary flexible
shafting mechanical geared system.
Remote mechanical systems for the operation of valves are to be fitted where:
a. The standard lever or handwheel cannot be fitted or operated due to the

restricted space or the position in which the valve has to be sited.
b. A requirement for operation from more than one position is specified in the
building specification.
c. The valve is located in a physically difficult to access position or
hazardous/restricted environment
d. Where local operation raises a safety issue
e. When manual mechanical systems are required for reasons of back-up
(redundancy and diversity)
Selection of a suitable Uniflex-stow solution
The Uniflex-stow range features three systems;
Uniflex-stow flexible shaft system with integrated gearing

Uniflex-stow flexible shaft
Uniflex-stow rigid rod
In general Uniflex-stow flexible shaft systems should be selected for longer and/or more complex
routings.
If, when considering a rigid rod installation, the routing is longer than 20 ft and/or, regardless of length,
has more than two 90 degree gearboxes then select a flexible shaft system.
2. CAPACITY INFORMATION
The rotary flexible shafting mechanical actuator described herein is designed for an input torque of 10
to 110 ft.-lbs. dependent on length and routing of the system. The operating station housing contains a
gear ratio of 1:2.8 or 2.69. The valve station actuator contains a combination of planetary gears and
constant speed interval gear which are available in the following system ratios; 2:1, 4:1, 6:1, 9:1, and
15:1.
Resulting in available output torques up to 250 ft.-lbs. at the valve (additional system ratio’s available,
contact DG Energy).
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www.dupillgroup.com - T (724) 845-7300 - 1057 State Route 356, Leechburg, PA 15656
3. FUNCTIONAL DESCRIPTION.
The rotary flexible shafting mechanical actuator is designed to receive input torque (rotary motion
by manually turning a handwheel or tee wrench) at the operator station and to effectively deliver
this torque (rotary motion) to a remotely located valve station actuator. The torque moves through
a single flexible inner core rotating in a conduit (casing) between the two stations. The core is
directly connected at both ends and operates in a rotary motion. The flexible shaft is 5/8” diameter
and different torque capability is achieved using different ratio gearboxes. The relatively small
diameter flexible shaft makes routing and installation both flexible and easy.
4. SYSTEM DESCRIPTION.
The rotary flexible shafting mechanical actuator uses four basic assemblies:
1) The remote operator with a 1:2.8 or 1:2.69 ratio. (speed increaser)

2) The flexible shaft
3) The valve station actuator (speed reducer with ratio’s 6:1, 11:1, 17:1, 25:1 and 43:1)
4) The valve coupling
Basic Uniflex-stow geared system
REMOTE OPERATOR and HANDWHEEL
The handwheel or tee wrench of remote operator or deck box connects directly to an input spindle
which drives a large spur gear which in turn drives a smaller spur gear (1:2.8 / 2.69 ratio). The latter
spur gear is part of the output spindle. The inner core assembly of the flexible shaft is drilled and
pinned to the output spindle. Then the D.C. terminal, or direct connect terminal, which is part of the
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rotary flexible shafting casing assembly, is connected to the hub using three washerhead
handscrews. The inner core assembly is then connected to the valve station actuator in the same
manner as the rotary flexible shafting was connected to remote operators and deck boxes. This
completely seals the rotary flexible shafting assembly. The flexible shafting relays the rotary motion
which is transmitted to the valve station actuator which produces system wide ratio’s of 2:1, 4:1,
6:1, 9:1, and 15:1. All components of the rotary flexible shafting system are noncorrosive;
nonmagnetic materials optional.
Penetrating a Shield Wall or Floor
There are several types of shield wall and floor penetrations that are installed by utilizing either the
cast-in-place or grout-in-place construction methods. (These are typical methods for the new
construction or retro fit applications in Nuclear power plants where Radiation shielding is required.)
Cast-In-Place: This method is

recommended when schedules
permit advance planning of the
penetration location. The cast-in-
place type housing is attached to
the concrete forms and becomes
a permanent part of the wall at
the time the concrete is poured.
Grout-In-Place: This method is

generally specified when the
exact number and location of
penetrations is not known prior
to the pouring of the shielding
wall. Usually, several possible
locations are selected and six (6) inch diameter, schedule 40 pipe is embedded when the wall (or
floor) is poured. Later, the grout-in-place type housing can be inserted into one of the pipes and set
in place with high- density grout. An alternate method is to core-drill a hole through the shield wall,
insert the grout-in-place type housing and set in place with high-density grout.
Both types of shield wall and floor housings are designed with a compensating spindle length that
will accommodate plus or minus one-half (1/2) inch from nominal wall thickness.
The shielded penetration is 100% serviceable from the “cold side” of the shield wall, including seal
replacement. Spindle bearings on the “hot side” of the wall are oil- impregnated sintered bronze
and highly resistant to the effects of radiation.
Operating Stations for Shielded Penetrations
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The addition of a Torque-Limiting Clutch to an operating station (plain or indicating) permits the
controlled operation of small plug, ball, diaphragm or instrumentation valves without the attendant
concern for over-torquing valve stems or seats. The torque limiting clutch can be easily set to any
torque within its range of 0-1000 inch-pounds after installation into a system.
The clutch is permanently lubricated and has a repetitive accuracy of approximately 95° over its full
operating range.
Operating Stations for Nonshielded Penetrations
Handwheels 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.
A geared operator unit will connect to the output spindle of wall and floor penetrations.
INNER CORE AND CASING
The inner core and casing (rotary flexible shaft

assembly) is the driving link between the remote
operator or deck box assembly and the valve. The
inner core is supplied with an end fitting that is
attached to the output spindle (via a terminal
coupling) of the remote operator assembly and
the input spindle of the valve gearbox. The casing
assembly is connected to the hub of mating
assemblies using a direct connect terminal. The
direct connect terminal produces a watertight
seal as well as a direct connection between
casing and hub of remote operator, deck box and
valve gearbox. The rotary flexible shaft assembly (inner core and casing) is supported by clamps and
mounting brackets which are bolted or tack welded to the rigid structures. Clamps secure the rotary
flexible shafting as close to remote operator or deck box and valve as possible. Clamps are used
throughout the rotary flexible shafting run at approximately five foot intervals where convenient.
Where radial bends are installed in the rotary flexible shafting 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 inner core is precision
manufactured using a high tensile stainless steel wire wound in layers of opposing directions upon a
single center wire. The casing that supports the core during operation is manufactured from
corrosion resistant stainless steel and other carefully chosen material to withstand the effects of
dust, oil, moisture, abrasion and temperature extremes; such as a flash fire or other severe
conditions.
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VALVE INTERFACE COMPONENTS
The connection to the valve or valve

gearbox is made with both rising and
non-rising valve couplings. The valve
station actuator assembly consists of
a split housing with top and bottom
sections bolted together. This housing
contains an input spindle, pressed
into a ball bearing and keyed to an
eccentric bearing assembly. This
bearing assembly drives a cycloid disc.
The cycloid disc oscillates around an
outer ring and drives the output shaft
by producing a gear ratio as it rotates
around shaft rollers. The output shaft
is then connected to a double
universal joint assembly, with a properly sized shear pin. This double universal joint assembly,
which can compensate for misalignment due to thermal or mechanical movement, is then pinned to
a valve coupling. To insure smooth rotary motion to the valve stem, actuator must be firmly
mounted over the center line of valve.
The double universal joint mates the valve station actuator with both rising and non-rising valve
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.
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5. CALCULATION OF LENGTH
Use the above as an aid. However, the flexible length does not need to be precise but it must be
long enough to connect each end. An assessment of length up to 10% longer than precisely
required is usually workable. It is recommended that lengths be measured on site where possible.
Tip: using a flexible plastic hose pipe is an effective way of assessing the required length.
6. ASSEMBLY TOOLS
Rotary flexible shafting (core and casing) comes completely assembled. Simple tools such as hand
drills, hammers, and screwdrivers are used to connect the rotary flexible shafting assembly to
remote operators, deck boxes and valve station actuators.
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7. SYSTEM INSTALLATION
The rotary flexible shafting mechanical actuator system is usually supplied unassembled. This
system consists of four basic sub-assemblies. The remote operator or deck box, valve station
actuator, double U-joint, and valve coupling are installed first. Then these components are
connected with the rotary flexible shaft assembly. The approximate length of the flexible shafting
should be calculated before ordering. This allows the rotary flexible shaft assembly to be
preassembled. Once the system components are attached to each other; the system is complete.
The casing should be installed using uniform bend radii to optimize efficiency of the system. Once
the system has been secured using proper clamping techniques, the system is then complete.
Once the system is completely installed, it may be desirable for future reference to determine and
record the frictional load of the system. This is the torque required to operate the system with the
valve fully disconnected.
This is an example of a typical installation procedure;
1. Mount remote operator or deck box assembly.

2. Attach and route flexible shafting assembly.
3. Attach brackets, clamps, and stuffing box where required. Assemble valve station actuator to
double universal joint with shear pin and attach to valve coupling with key and pin.
4. Mount valve station actuator assembly to mounting bracket; be sure to align with the center
line of valve when mounting valve station actuator. The slip end of the double u-joint, to valve
station actuator, should be in the center of its stroke to allow for movement in both directions.
When connecting with a rising handwheel valve coupling, position valve handwheel at its lowest
point (closed). Then raise valve station actuator until the valve coupling is in its fully extended
position. Cycle system once more to assure indicator is properly showing valve position.
5. Position valve and indicator mechanism in desired position ie; cycle valve closed, and then
position indicator to read closed position
6. Attach valve coupling to valve using u-bolts around spokes of the valve handwheel.
7. Cycle system to fully open position and record open position. Cycle system to fully closed
position and record closed position. On deck boxes write corresponding numbers on indicator
gasket.
8. 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.
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8. CONSTRAINTS and CHARACTERISTICS
The proper function of the rotary flexible shafting mechanical actuator system is limited by the
following constraints:
(1) Minimum Bend Radius : 12 inches

(2) MaximumSystemLength : 150 feet (subject valve torque requirements)
(3) Max. Accumulated Degrees of Bend : 540 (1. subject valve torque requirement; 2. May exceed maximum
subject to other system critrea)
(4) Operating Environment : -65° to + 800°F and 0 to 100% Relative Humidity.
(5) Minimum Length : Approx. 3 Ft
(6) Fire Test .: 1300°F
The functional characteristics of the rotary flexible shafting mechanical actuator are as follows:
(1) Shock : System meets requirements of MIL-S—901D Grade A Class I.

(2) Minimum Life Cycles 60,000 at full load.
(3) Maximum Torque Input at Operator Station....110 ft.-lbs.
(4) Maximum Capacity at Valve : 250 ft.-lbs
(5) Operator Directional Rotation vs Valve Directional Rotation : Same Direction.
(6) Vibration : System Meets Requirements of MIL-STD-167
(8) Leakage (Immersion) : Components maintain watertight integrity per MIL-810-E
(9) Leakage (Pressure): Components maintain watertight integrity per MIL-S-16059 tested at depth
of 65ft
(10) Corrosion : All exposed components are non corrosive materials. No components including
internal items shall exhibit noticeable corrosion after being exposed to 10,000 hours salt fog test
per MIL—STD-810-E Section 590.3.
(11) Maintenance : Shall not require scheduled maintenance beyond that outlined here
(12) Rated output torque can be achieved with less than 180 degrees input deflection on all systems
(Recommended less than 90 degree where achievable).
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9. SPECIFICATION
Data required for the proper specification of a remote operating system;
Valve Data Route of flexshaft Operator

• Type : • Ball, Plug, Butterfly • Length • Vertical or horizontal handwheel
• Gate, Globe • Estimated total degrees of bend • Indication required
• Other • Number of 90 degree bends • Floor or wall mounted
• Number of wall/floor penetrations
• Handwheel • Rising, non-rising, Environment
rising stem • Shock
• Current size of handwheel/lever • Vibration
• Siesmic
• Valve size • Submerged
• Valve Manufacturer and model • Corrosive
• Gearbox operated • Radiation
• Total number of turns to open/close • Temperature range
• Input torque required, either to • Other
valve or valve gearbox
• Breakout torque
• Normal operating torque
Not all data is essential. Minimum data required is valve type, hand-wheel or torque, routed length
and estimated bends
.
Calculations for operating force, system deflection and shear pin
The operating force is the force necessary to cause operation of the valve or other device by the
Uniflex-stow system.
The system deflection can be defined as the amount of motion applied to a hand wheel or tee
wrench before actual output motion occurs on the valve or device to be operated. This can also be
referred to as “lost motion”. Recommended not to exceed 90 degrees.
There are three major variables that will define the amount of operating force and the amount of
deflection in a system.
They are:
1.) Maximum anticipated valve torque (max valve operating torque +25% degredation factor.
2.) Total degrees of bends in system.
3.) Flexible shaft length.
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Example:
Maximum valve operating torque value of 60 ft. Lbs. (+ 25% degradation)= 75ft. Lbs.,
Flexible shaft length will be 516.17 inches or 43 feet
Total degrees of bend will be 180.
We will try to utilize a 6:1 uniflex system. If the maximum system deflection exceeds 90 degrees or
the operating force exceeds 60 lbs., we will proceed to a 9:1 system.
1.) Determine maximum output torque of flexible shaft:

a.) Torque reduction caused by u-joint (appendix 1 table III approx. 98% efficient): 75 ft.lbs. ÷ .98 = 76.53 ft.lbs.
b.) Since this is a 6:1 system the reduction actuator ratio is 17:1 : 76.53 ft. Lbs. ÷ 17=4.50 ft.lbs. (appendix 1 table III
: actuator is approx. 82 % efficient.)
4.50 ft. Lbs. ÷ .82 = 5.49 ft. Lbs. Which will be the required output torque of the flexible shaft.
2.) Determine input torque to flexible shaft:
a.) Torque reduction caused by 180 degree bends (appendix 1, table I : 94% efficient): 5.49 ft. Lbs. ÷
.94 = 5.84 ft.lbs.
b.) Torque reduction caused by 43 foot length (appendix 1, table II : 53 % efficient): 5.84 ft. Lbs. ÷
.53 = 11.02 ft.lbs. Which is the required input torque to the flexible shaft.
3.) Determine the operating torque and operating force:
a.) Operating torque is the input torque to the flex shaft multiplied by the operator ratio of
1:2.69. (appendix 1, table III : 75% efficient)
11.02 ft.lbs.x 2.69 = 29.64 ft. Lbs. ÷ .75= 39.52 ft. Lbs. Which is the required input torque
to the remote operator handwheel (value cannot exceed 75 ft. Lbs.).
b.) Using appendix 1, table IV you can select a 12” handwheel or above.
4.) Determine maximum system deflection
Recommended not to exceed 90 degrees. System deflection is calculated using the average of the
input and output torques of the flexible shaft, multiplied by the length of the flexible shaft,
multiplied by the deflection factor (0.4°per ft per ft.lb.), divided by the input gear box ratio of
1:2.69.
A.) Average torque: (11.02 ft.lbs. + 5.49 ft.lbs. ) ÷2=8.26 ft.lbs.
B.) Deflection: 8.26 ft.lbs. X 43 ft. X (.4°/ft/ft.lb.) = 142° ÷ 2.69 = 52.80 degrees.
5.) Determine shear pin:
Max valve breakaway torque= 75 ft.lbs. 75 ft. Lbs. X 2=150 ft.lbs. (see catalog: size up to 188 ft.lbs;
use 22021-188)
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A software calculator for the above calculator is available from DG Energy on request.
10. MAINTENANCE
The purpose of maintenance is to insure that the rotary flexible shafting system continues to
operate at optimum levels.
The following schedule of maintenance must be performed on a regular basis in order to keep the
rotary flexible shafting mechanical actuator system in normal operating condition.
Note: Do not disassemble valve station actuator housing. Housing assembly is composed of many
small precision components which could be easily lost or damaged. Improper disassembly could
cause a loss in efficiency.
INNER CORE AND OUTER CASING
Inspect entire run of rotary flexible shafting for damaged casing which could affect system
operation. Replace damaged casing if it cannot be repaired. If system shows appreciable
increases in torque, then inner core should be removed and inspected. If no damage is
found, regrease inner core and insert into outer casing. Retest if the increased torque is still
present; remote operator or valve station actuator will have to be replaced.
ROTARY FLEXIBLE SHAFTING SUPPORT CLAMPS
Inspect entire run of flexible shafting for correct location, required number, and type of all
support clamps. Replace all missing clamps and tighten all loose clamps. Visually inspect
flexible shaft run when system is under torque to look for any undesirable bends or helix.
MOUNTING
Inspect mounting brackets, flanges, actuator housing, and mounting to handwheel for
missing and loose bolts. Replace missing bolts and tighten all loose bolts.
TROUBLESHOOTING
Troubleshooting of the rotary flexible shafting mechanical actuator should be performed by

personnel familiar with the system.
ISOLATION OF PROBLEM
If during normal use of the rotary flexible shafting mechanical actuator system there are no
indications that there has been a significant increase in applied torque, then system is in
good working order. If an appreciable increase in torque is noticed, make the following
check: (I) Completely disengage the rotary flexible shafting mechanical actuator system
from the valve coupling. This can be accomplished through the use of the quick disconnect if
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installed. If no quick-disconnect has been installed, then valve coupling can be unbolted
from handwheel of valve. (2) While the valve is completely disconnected, operate the rotary
flexible shafting mechanical actuator. It should be free from binding through its complete
operation in both directions. (3) If torque is considered too high (compare with initial recorded
system friction load, if available) and system appears to be undamaged, regrease. If inner core
appears damaged, replacement of the complete flexible shafting assembly may be necessary. If
regreasing flexible shafting will not return system to an acceptable condition, test the remote
operator or deck box with flexible shafting disconnected. Its torque to operate should be
approximately 25 in-lbs maximum. If this value is exceeded; the unit must be replaced. If
acceptable, then test valve station actuator with flexible shafting removed. Its torque to operate
through input side should be approximately 15 in-lbs maximum. If all tests do not reveal a problem,
consult DG Energy customer service.
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DISASSEMBLE
The system once installed may be disassembled in the reverse order of Installation Procedure.
Individual components are made of non-corrosive material and do not need to be disassembled.
Note: Do not disassemble Valve Station Actuator Housing. Housing assembly is composed of many
small precision components which could be easily lost or damaged. Improper disassembly could
cause a loss in efficiency.
TESTING AFTER RE-ASSEMBLY
Units should be tested for ease of operation, torque values should be taken and compared to values
taken when units were originally installed.
INSPECTION
Systems should be inspected and operated on a regular basis to insure proper working order.
CLEANING
Rotary flexible shafting system is made of noncorrosive materials and may be cleaned with any
common solvents such as soap and water or if needed any common degreasing agents.
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;
Aeroshell 5 for flex shaft assys and Shell Alvania EP #2 for valve station actuatorNuclear; 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 since it may cause binding.
REPAIR
If repairs are needed, spare parts may be purchased from DG Energy.
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11. COMPONENT DETAILS AND DRAWINGS
Please consult the latest Uniflex-stow catalog for a complete list of system components, general
dimensions and materials
12. APPENDIX
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Table III – Component Efficiency
Item Part Efficiency

Item Description Supplemental Information
Number Factor
Double Universal Joint Offset Angle 0° to 5° NQ1306-100 0.98
Double Universal Joint Offset Angle 6° to 20° NQ1306-100 0.9
Valve Station Actuator (VSA) Ratio = 6:1 NQ1303-100 0.82
Valve Station Actuator (VSA) Ratio = 2.8:1 NQ1303-105 0.85
Intermediate Operator Ratio = 1:2.69 NQ1311-112 0.75
Remote Operator Ratio = 1:2.8 NQ1311-113 0.85
90° Gear Box Remote Operator Ratio = 1:2.69 NQ1311-117 0.75
Deck Box Remote Operator (Without Weld Sleeve) Ratio = 1:2.8 NQ1311-123 0.85
Deck Box Remote Operator (With Stl Weld Sleeve) Ratio = 1:2.8 NQ1311-108 0.85
Deck Box Remote Operator (With SST Weld Sleeve) Ratio = 1:2.8 NQ1311-109 0.85
Deck Box Remote Operator (With Brz Bolt Sleeve) Ratio = 1:2.8 NQ1311-110 0.85
Deck Box Remote Operator (With Alum Weld Sleeve) Ratio = 1:2.8 NQ1311-111 0.85
Valve Station Actuator (Space Limited) Ratio = 4:1 (use with below Operators) NQ1303-106 0.75
Operator, Remote, 10 Turns Ind. Ratio = 1:1 (use with 22203-4) NQ1311-113 0.98
Operator, Remote, 90° Gear Box, Weld, 10 Turns Ind. Ratio = 1:1 (use with 22203-4) NQ1311-114 0.8
Operator, Remote, 90° Gear Box, Bolt Ratio = 1:1 (use with 22203-4) NQ1311-115 0.75
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Flexible Gear Drive System (DGN)

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Flexible Gear Drive System (DGN)

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Uniflex-stow remote valve operating systems

Flexible shaft system with integrated geared system

a. The standard lever or handwheel cannot be fitted or operated due to the

Selection of a suitable Uniflex-stow solution

The Uniflex-stow range features three systems;

Uniflex-stow flexible shaft system with integrated gearing

1) The remote operator with a 1:2.8 or 1:2.69 ratio. (speed increaser)

Basic Uniflex-stow geared system

REMOTE OPERATOR and HANDWHEEL

Penetrating a Shield Wall or Floor

Cast-In-Place: This method is

Grout-In-Place: This method is

Operating Stations for Shielded Penetrations

Operating Stations for Nonshielded Penetrations

INNER CORE AND CASING

The inner core and casing (rotary flexible shaft

The connection to the valve or valve

This is an example of a typical installation procedure;

1. Mount remote operator or deck box assembly.

(1) Minimum Bend Radius : 12 inches

(1) Shock : System meets requirements of MIL-S—901D Grade A Class I.

Data required for the proper specification of a remote operating system;

Valve Data Route of flexshaft Operator

1.) Determine maximum output torque of flexible shaft:

2.) Determine input torque to flexible shaft:

3.) Determine the operating torque and operating force:

4.) Determine maximum system deflection

5.) Determine shear pin:

INNER CORE AND OUTER CASING

ROTARY FLEXIBLE SHAFTING SUPPORT CLAMPS

Troubleshooting of the rotary flexible shafting mechanical actuator should be performed by

TESTING AFTER RE-ASSEMBLY

Standard grease used is;

Other greases are available according to customer requirements.

If repairs are needed, spare parts may be purchased from DG Energy.

11. COMPONENT DETAILS AND DRAWINGS

Table III – Component Efficiency

Item Part Efficiency

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