Trimteck OPTIMUX OpDx Technisches Datenblatt

Product Instruction Manual

Leading Technologies

For Control

OpDx

Butterfly Control Valve

INTRODUCTION

Scope of Manual

This instruction manual includes installation,

maintenance, and parts information for the

OptimuxTM OpDx control valve. Refer to

separate manuals for information regarding

installation, operation, and maintenance of

additional features such as actuators,

positioners, special accessories, fail-safe

systems, etc. Only qualified persons should

install, operate, and maintain an Optimux OpDx

valve. Any questions about these instructions

should be directed to your Optimux sales office

or sales representative before proceeding.

This publication does not contain information on

Optimux positioners. Refer to the appropriate

manual for information on positioner installation,

operation, maintenance, and calibration.

Note:

Selecting the proper fastener material is

the responsibility of the customer. Typically,

the supplier does not know what the valve

service conditions or environment may be.

Optimux's standard body bolting material is

B7/2H. B8 (stainless steel) is optional for

applications above 800• F and with stainless

steel or alloy body valves. The customer

therefore must consider the material's

resistance to stress corrosion cracking in

addition to general corrosion. As with any

mechanical equipment, periodic inspection

and maintenance is required. For more

information about fastener materials, contact

your local Optimux representative or factory.

Unpacking

1. While unpacking the valve, check the

packing list against the materials received.

Lists describing the valve and accessories

are included in each shipping container.

2. When lifting the valve from the shipping

container, position lifting straps to avoid

damage to tubing and mounted accessories.

TABLE OF CONTENTS

INTRODUCTION

Scope of Manual ............................ pg. 1

Safety Information ..........................pg. 1

Unpacking ...................................... pg. 1

INSTALLATION .............................. pg. 2

Quick-Check .................................. pg. 2

MAINTENANCE ............................ pg. 3

ASSEMBLY AND DISASSEMBLY

Valve Removal from Line .............. pg. 4

Actuator Removal .......................... pg. 4

Body Disassembly.......................... pg. 5

Body Reassembly .......................... pg. 5

REMOUNTING ACTUATOR .......... pg. 6

SAFETY INFORMATION

WARNING: Indicates a potentially

hazardous situation, which, if not

avoided, could result in death or

serious injury.

CAUTION: Indicates a potentially

hazardous situation, which, if not

avoided, could result in minor or

moderate injury and/or property

damage.

Note: Indicates a potential situation,

which, if not avoided, may result in an

undesired result or state.

OpDx Butterfly Control Valve

Valves up through 14-inch may be lifted by

the actuator lifting ring. On larger valves, lift

the valve using lifting straps or hook

through the yoke legs and outer end of the

body.

3. In the event of shipping damage, contact

your shipper immediately.

4. Should any problem arise, contact your

Optimux representative.

INSTALLATION

1. Before installing the valve, clean the line of

dirt, scale, welding chips, and other foreign

material. Clean the gasket surfaces

thoroughly to insure leak-proof joints.

2. Check flow direction to be sure valve is

installed correctly. Fail-closed valves

should be installed with the shaft upstream

only on gas service. It is preferred that

liquid service valves must be installed with

the shaft downstream regardless of air

failure action. However, under certain flow

conditions the valve can flow shaft

upstream. Consult factory if the valve must

be mounted with the shaft upstream in

liquid service. Fail-open valves should be

installed with the shaft downstream.

WARNING: When installing the

valve in-line between flanges,

make certain the flange face

gasket covers both seat

retainer and body and

surface. Failure to do so will

cause excessive leakage

downstream. Refer to “Seat

Insert/Snap-ring Configuration”

in Figure 1.

3. Fully close the valve before and during the

installation process.

WARNING: Keep hands, hair,

clothing, etc. away from the

rotating disc and the seat when

operating the valve.

CAUTION: Because of

Optimux’s self-centering seat,

there is no reason to open the

valve at any time during

installation. Therefore, the

valve should remain closed

until it is fully installed.

4. Connect air supply and instrument signal.

Throttling valves are usually equipped with

valve positioners. Two connections are

marked for the air supply and for the

instrument signal. Cylinder actuator is

suitable for 150 PSI air supply. An air filter

is recommended unless the supply air is

unusually clean and dry. All connections

must be free of leaks.

CAUTION: On valves equipped

with air filters, the air filter bowl

must point down; otherwise,

the air filter will not perform

properly.

Note:

In some rare cases, the air supply must

be limited to 100 PSI rather than 150 PSI. In

this case, a sticker found near the upper air

port on the cylinder will indicate this and an

air regulator should be installed to insure the

supply pressure does not exceed 100 PSI.

5. Make sure proper clearance exists

internally in the mating piping to permit

proper disc rotation.

6. Apply recommended torque values to line

flange bolting for proper sealing (see Table I).

Quick-check

Prior to start-up, check the control valve by

following these steps:

1. Check for full stroke by making the

appropriate instrument signal change.

Observe disc position indicator plate

mounted on the transfer case. The disc

should change position in a smooth, rotary

fashion.

Product Instruction Manual

2. Check all air connections for leaks. Tighten

or replace any leaky lines.

3. Evenly tighten the packing nuts to slightly

over finger-tight.

CAUTION: Do not over-tighten

packing. This can cause excessive

packing wear and high shaft friction,

which may impede shaft rotation.

After the valve has been in operation

for a short time, check the packing

nuts to make sure they are just over

finger-tight (readjust if necessary). If

packing box leaking occurs, tighten

the packing nuts only enough to stop

leakage.

4. To observe the valve failure mode in case

of air failure, position the valve to midstroke

and shut off the air supply or disconnect the

instrument signal. By observing the

indicator plate, the disc should either fail

open or closed. If incorrect, refer to the

“Actuator Action Reversal” section in the

appropriate Spring Cylinder Actuator

Instruction Manual.

MAINTENANCE

At least once every six months, check for

proper operation by following the preventive

maintenance steps outlined below. These

steps can be performed while the valve is in

line and, in some cases, without interrupting

service. If an internal problem is suspected,

refer to the Disassembly and Reassembly

section.

1. Look for signs of gasket leakage through

body and line flanges. Tighten flange

bolting if necessary.

2. Note if any corrosive fumes or process

drippings are damaging the valve.

3. Clean valve and paint any areas of severe

oxidation.

4. Check packing box bolting for proper

tightness. Packing nuts should be slightly

over finger-tight; however, tighten as

necessary to prevent stem leakage.

CAUTION: Do not over-tighten

packing.

5. If valve is supplied with a lubricator, check

lubricant supply and add lubricant if

necessary.

6. If possible, stroke valve and check for

smooth, full-stroke operation by observing

the disc position indicator plate mounted on

the transfer case. Unsteady movement of

the disc could indicate an internal valve

problem (jerky motion is normal whenever

Grafoil packing is used).

Valve Size

(inches)

Rating

150

300

600

150

300

600

150

300

600

150

300

600

150

300

600

150

300

150

300

150

Torque

(ft./lbs.)

118

209

118

209

337

209

505

209

337

728

337

505

337

728

505

728

1009

Table I: Flange Bolting Torques

OpDx Butterfly Control Valve

7. Check positioner calibration by observing

the gauges and the disc position indicator

plate. Make sure the positioner is calibrated

to the correct range.

8. Remove transfer case cover plate and

make sure the positioner linkage and

internal actuator parts are securely

fastened. Also, check for air leaks through

actuator stem seal, using a soap solution.

CAUTION: Never apply air to the

actuator without the cover

plate installed; otherwise, the

unsupported shaft may sustain

damage.

9. Be sure that all accessories, brackets and

bolting are securely fastened.

10. If possible, remove air supply and observe

stroke plate for correct fail-safe action.

11. Spray soap solution around the cylinder

retaining ring and the adjusting screw to

check for air leaks through the O-rings.

12. Clean any dirt or other foreign material

from the exposed portion of the shaft.

13. If an air filter is supplied, check and replace

cartridge if necessary.

ASSEMBLY AND DISASSEMBLY

Valve Removal from Line

If an internal valve problem is suspected with

the valve and disassembly is required, remove

the valve from the line by proceeding as

follows:

WARNING: Depressurize line to

atmospheric pressure, drain

all process fluids and decontaminate

the valve (if caustic or hazardous

materials are present).

1. Make sure valve is fully closed.

Note:

On valves with fail-open action, air

pressure must be supplied under the

actuator piston to close the valve. If the valve

is supplied with a handwheel, it can be used

to close the valve.

2. Attach a hoist or some means to support

the valve.

3. Remove the line bolting. Do not attempt to

pry line flanges apart by pushing or pulling

on valve actuator.

4. Slide the valve carefully from the line. To

avoid damage to gasket surfaces, do not

twist the valve.

5. After the valve is completely removed from

the line, slowly relieve air pressure from the

actuator.

Actuator Removal

In most cases, both the body assembly and the

actuator are easier to disassemble with the

actuator removed from the body. To do so,

proceed as follows:

1. Support actuator assembly by the lifting

ring before disconnecting it from the body

assembly.

2. Remove the transfer case cover bolts.

Carefully pry or slide the cover plate from

the end of the shaft.

3. On Optimux actuators with a clamping lever

arm design, loosen the linkage bolt.

4. Loosen the actuator adjusting screw to

release spring pressure.

5. Remove the bolts connecting yoke to the

actuator subassembly.

6. Slide entire actuator assembly off the shaft.

For Optimux actuators with a clamping

lever-arm design, it may be necessary to

wedge the halves of splined lever arm apart

to loosen it from the shaft splines.

Product Instruction Manual

Body Disassembly

To disassemble the body, refer to Figures 1, 2

and 5 and proceed as follows:

1. On Optimux valves supplied with seat

retainer screws, remove the seat retainer

screws and retainer clips. Lift the seat

retainer out of the valve body. (Refer to

Figures 1A, B, C).

2. On valves supplied with retainer snap-ring

configuration, carefully insert a screwdriver

in the key slot provided in the retainer; pry

the retainer and snap ring out of the valve

body. (Refer to Figure 1D).

3. Remove the gland flange by removing both

packing nuts. It is not necessary to remove

the studs.

4. Drive the taper pins out of the disc by

tapping on the small end of the pins using a

punch and hammer.

5. Remove the end plug (optional bolted

flange and seal if applicable).

6. Remove shaft by inserting a press or a

nylon rod (or similar material) into body’s

blind end, and using a hammer, carefully

tap the shaft through the body.

CAUTION: Take special care not

to damage the splined end of

the shaft during disassembly.

To prevent scratching the sealing surface of

the disc while removing the shaft, place

supports underneath the disc. This also

prevents the shaft from binding in the body

as the shaft comes off the bearing surfaces.

7. Push the packing and bearings out of the

body using a dowel of appropriate

diameter. Push the packing from the center

of the valve.

Body Reassembly

To reassemble the body subassembly, refer to

Figures 1, 2, 3, and 5 and proceed as follows:

1. Clean all parts.

2. Check the disc seating surface to make

sure it is smooth and free of scoring and

scratches.

CAUTION: Damaged or dirty

seat surfaces can cause

excessive seat wear and high

torque requirements. Damaged

discs should be replaced.

3. Inspect shaft for scratches or galled

surfaces. For maximum performance,

Optimux shafts are machined to a very

smooth finish. If damage exists, replace the

shaft or contact factory representative.

Note:

Disc and shaft are interchangeable in

recent designs. Replacing the disc does not

require replacing the shaft. Earlier designs

require that the disc and shaft be machined

together. Contact the factory for matched

disc and shaft.

4. Insert new sliding stem shaft bearings into

the body. (A press may be required with

some designs.)

Note:

Earlier Optimux designs require the

disc to be aligned in the body in such a way

that it can rotate properly. Align the shaft

bearings on either side of the disc and insert

the shaft through the body, bearings and

disc.

5. Position the disc in the body, making sure it

will rotate in the proper direction with

respect to the body’s internal disc stop.

Slide the shaft through the body, bearings

and disc.

CAUTION: Exercise care while

sliding the shaft into the sliding

stem shaft bearings to avoid

damage to both the shaft and

bearings.

OpDx Butterfly Control Valve

6. Insert new taper pins and drive them firmly

into place in the side opposite the stop.

7. Slide the packing retainer, lower packing,

packing spacer, upper packing, and

packing follower over splined end of the

shaft and into the body. Typical packing

configurations are shown in Figure 3.

Note:

Always use new packing whenever

rebuilding the packing box.

CAUTION: Since the sealing on

V-ring packing takes place at

the feather edge, it is important

to avoid damage to that edge.

8. Reinstall the end plug (or replace the end

seal and reinstall the bolted flange).

9. Reinstall the gland flange and packing nuts.

Tighten packing evenly to slightly over

finger-tight.

CAUTION: Do not over-tighten

packing. This can cause

excessive packing wear and

high shaft friction, which may

impede shaft rotation.

10. All seat configurations with screw/clip

retainers require a gasket (item No. 55)

installed in the appropriate groove. This is

accomplished by pressing the gasket into

the appropriate groove.

11. If the seat retainer is the screw/clip type

and has a soft or dual seat, press the soft

seat into the soft seat retainer or metal

seat. (There should be an interference

between the soft seat and the retainer.)

With the valve in the closed position,

secure the retainer or metal seat in place

by tightening the retainer clips and screws.

This allows the seat to align with the disc,

permitting tight shutoff.

12. If the seat retainer is the screw/clip type

with a metal seat design, a gasket will need

to be installed in the metal seat prior to

clipping the seat in place with the seat clips

and screws.

Note:

Optimux valves of earlier design may

require that the disc be open while installing

the soft seat into the body. (Refer to Figure

1D.)

13. If an early design Optimux seat retainer

has an indexing groove to accept a soft

seat, press the corresponding seat into the

retainer groove. Install the seat retainer

subassembly into the body.

14. On valves supplied with the retainer snap-

ring configuration, install the snap-ring into

the groove around the retainer (or metal

seat). Start the retainer into the body with

the open ends of the snap-ring in the body

groove. Gently press the snap-ring into the

retainer until both the retainer and snap-

ring slip into the body. (Refer to

Figure 1D.)

15. On early design Optimux valves supplied

with seat retainer screws, install the insert

and retainer into the body with the disc

open. Loosely install the retainer screws,

then close the disc. Tighten the screws

after the closed disc has centered the seat.

This allows the seat to align with the disc,

permitting tight shutoff.

REMOUNTING ACTUATOR

Before mounting an Optimux actuator on the

valve body, verify that the disc rotation

matches the actuator rotation and complies

with the air failure requirements. Procedure for

mounting the actuator is as follows:

Product Instruction Manual

1. Slide the entire actuator assembly onto the

shaft. If necessary on Optimux actuator

designs with clamping lever arm design,

wedge the splined lever arm apart to loosen

it on the shaft splines. For full rotation of the

disc, marks provided on the end of the shaft

and on the lever arm should be aligned.

2. Bolt the actuator yoke to the valve body. Be

certain the stroke indicator plate is

positioned properly to accurately indicate

the valve's rotation.

3. Position the actuator lever arm on the shaft

so the actuator stem is centered in the

transfer case. Firmly tighten the linkage

bolt, on clamping lever arm actuators.

CAUTION: On clamping lever-

arm actuators, do not apply air

to the actuator without

the cover plate installed;

otherwise, the unsupported

shaft may sustain damage.

4. Adjust the actuator stroke stop bolts until

the disc is parallel to the seat surface, but

not resting on body disk stop.

CAUTION: Actuator stroke stop

bolts must be properly

adjusted, to prevent the valve

disc from overstroking. If

incorrectly adjusted the valve

shaft may be twisted or sheared

off.

5. Install valve in line as outlined in

Installation

section.

A – Dual Seat B – Metal Seat C – Soft Seat D – Seat Insert / Snap-ring

Note: Item numbers correspond directly to the bill of material.

Refer to the bill of material for specific part numbers.

Figure 1: Seat Retainer Configurations

OpDx Butterfly Control Valve

Figure 2: Body Assembly

Note: Item numbers correspond directly to the valve's bill of material.

Refer to it for specific part numbers.

Shaft

Plug

(Item No. 122)

Disc

(Item No. 50) Shaft Bearing (Item No. 83)

Taper Pins (Item No. 52)

Shaft (Item No. 51)

Inner Packing (Item No. 88)

Outer Packing (Item No. 88)

Packing Follower (Item No. 87)

Packing Spacer(s) (Item No. 93 - 95)

Packing Retainer (Item No. 85)

Seat Retainer Clip (Item No. 123)Seat Retainer Bolt (Item No. 124)

O-ring

(Item No. 61) Shaft

Bearing

(Item No. 83) Disc Stop

Body

(Item No. 1)

Seat

Figure 3: Typical Packing Configurations

Standard Square Standard Single "V"

Standard Single "V"

Twin "V"

PTG

(Packing studs rotated 45 degrees)

PT PTG / PT

Fire-safe Option

(Live-loading omitted)

Product Instruction Manual

424 42422

333

3Left-hand

Mounting

Right-hand

Mounting

Style A

Fail-closed

Air-to-open

Shaft Upstream

Style B

Fail-closed

Air-to-open

Shaft Upstream

Style C

Fail-closed

Air-to-open

Shaft Downstream

Style D

Fail-closed

Air-to-open

Shaft Downstream

Right-hand Mounting

Facing Downstream

Left-hand Mounting

Facing Downstream

1111

Style C Style D Style B Style A

FLOW

Figure 4: Transfer Case Mounting

Note: Orientation 1 is standard. Orientation positions 2 and 4 are not available

in some actuator sizes. Contact Optimux representative or factory.

OpDx Butterfly Control Valve

Item No. Description

1 body

20 hard seat

21 seat insert

22 seat retainer

50 disk

51 shaft

52 taper pins

55 seat gasket

61 O-ring

80 gland flange

83 shaft bearing

85 packing retainer

87 packing follower

88 packing

93 packing spacer

109 packing box stud

117 packing box nut

122 shaft plug

123 clip

124 screw

122 61

83 52

20/22

124

123

109

117

Figure 5: Exploded Body Sub-Assembly

Note: Item numbers correspond directly to the bill of material. Refer to it for specific part numbers.

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