OMC VD10, KA20, KD10, KA10, KD20 Maintenance Manual

Installaon, Operaon and Maintenance VL10/…‐en Rev.08/2018

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

ENGLISH

Globe Valves

SERIES

VD10 - KD10 - KA10

KD20 - KA20

Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04

OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

Page 1

Installaon, Operaon and Maintenance Manual VL10/…‐en Rev.08/2018

TABLE OF CONTENTS

1.0 SAFETY INFORMATION

1.01 INTENDED USE

ENGLISH

1.02 ACCESS

1.03 LIGHTING

1.04 HAZARDOUS FLUIDS IN THE PIPE

1.05 ENVIRONMENTAL SITUATIONS

1.06 TEMPERATURE

1.07 SYSTEM

1.08 PRESSURIZED SYSTEMS

1.09 TOOLS AND CONSUMABLE PARTS

1.10 PROTECTION CLOTHES

1.11 QUALIFICATION OF OPERATORS IN CHARGE OF THE WORKS

1.12 HANDLING

1.13 FREEZING

1.14 OTHER RISKS

1.15 DISPOSAL

1.16 RISK OF CORROSION AND/OR EROSION

2.0 INSTALLATION

2.01 ASSEMBLY OF THE VALVE ON THE PIPE

3.0 ACTUATOR CONNECTION

3.01 PNEUMATIC ACTUATOR CONNECTION

3.02 ELECTRIC ACTUATOR CONNECTION

4.0 MAINTENANCE

4.01 VALVE/ACTUATOR SEPARATION

4.02 REPLACEMENT OF THE PLUG SEAT OF THE STANDARD VALVE

4.03 REPLACEMENT OF THE PLUG SEAT WITH QUICK CHANGE SEAT

4.04 REPLACEMENT OF THE PLUG SEAT OF THE BALANCED VALVE

4.05 REPLACEMENT OF THE PLUG SEAT OF THE VALVE WITH BELLOWS

4.06 REPLACEMENT OF THE STEM PACKING GLAND

5.0 TIGHTENING TORQUES

6.0 SIZES OF PLUG CONNECTION

7.0 PERIODICAL OPERATIONS

8.0 AVAILABLE SPARE PARTS

9.0 PRESSURE/TEMPERATURE REPORT OMC-TUV-00 Rev.03/2018

10.0 REFERENCES OF THE EUROPEAN DIRECTIVE FOR PRESSURE EQUIPMENT
2014/68/EU

11.0 PLATES

11.01 IDENTIFICATION PLATES

11.02 “EC” PLATE PURSUANT TO DIRECTIVE 2014/68/EU

Page 2

OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04

Installaon, Operaon and Maintenance VL10/…‐en Rev.08/2018

1.0 SAFETY INFORMATION

The safe operation of this product is ensured only if it is installed, commissioned, used and maintained in an
appropriate way by qualified personnel in compliance with the operating instructions.

1.01 INTENDED USE

Verify that the valve is suitable for the intended use and application by checking:

- that the material of which the valve is made up of is compatible with the process fluid;

- that the valve is suitable for the pressures and temperatures of the process fluid;

- that a suitable safety device is fitted to the system to prevent any hazardous overpressures or overtemperatures
in the system.

OMC valves are not intended to withstand any external stresses which can be induced by the systems in which
they are inserted. The installer must take account of these stresses and take the appropriate measures to prevent
them.

1.02 ACCESS

Ensure safe access and, if required, a safe working platform (with a suitable protection) is provided, before
operating or installing the product. Arrange the suitable lifting means, if required.

1.03 LIGHTING

Ensure the area around the valve is adequately lit and is suitable to safely work on the valve.

1.04 HAZARDOUS FLUIDS IN THE PIPE

Take account of the content of the pipe (process fluid) or anything it may have previously contained. Take special
safety precautions where flammable, hazardous substances are present, or where fluid pressure or temperature
may be hazardous to health.

ENGLISH

1.05 ENVIRONMENTAL SITUATIONS

Take account of: areas at risk of explosion, lack of oxygen (such as tanks, wells, etc.…), hazardous gases,
temperature limits, high or low temperature surfaces, risk of fire (for example during welding operations),
excessive noise, moving machines.

1.06 TEMPERATURE

Wait until the temperature normalizes after the interception to prevent any risks of burn or freezing.

1.07 SYSTEM

Take account of the possible effects on the whole expected working system.

In particular, you must assess any proposed actions and the consequences that may result in any other
part of the system, You must ensure the system remains safe at all times.

Make sure that the control valve is isolated via shut-off valves to prevent any abrupt variations to the system.

1.08 PRESSURIZED SYSTEMS

Make sure that the pressure is isolated and discharged to the atmospheric pressure in safe conditions. Take
account of a double insulation (double block and vent) and the blocking or the labelling of the closed valves. Do
not consider the system depressurized even if the pressure gauge indicates zero pressure. The depressurization
process should include taking the valve through its full stroke, to ensure all pressure is allowed to exhaust to
atmosphere.

During the operation the valve is pressurized. Before performing any maintenance operation or action on
the flanges and closing caps, make sure that the line is depressurized (0 bar) and at ambient temperature.

Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04

OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

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Installaon, Operaon and Maintenance Manual VL10/…‐en Rev.08/2018

1.09 TOOLS AND CONSUMABLE PARTS

Before starting the work, make sure to have at your disposal all the tools required to perform it, do not make use
of inappropriate tools. Use only OMC original spare parts.

ENGLISH

1.10 PROTECTION CLOTHES

Take account of whether you and/or others need some clothes against the hazards, such as chemical products,
temperatures, radiations, noise, fall of objects, risks for eyes and face.

1.11 QUALIFICATION OF THE OPERATORS IN CHARGE OF THE WORKS

All works must be performed and supervised by some skilled, trained and competent personnel.

1.12 HANDLING

Use suitable lifting means for the handling of the products by assessing all the risks concerning the lifting, the
environment load, the individual and the circumstances of the work which is about to be performed.

CORRECT

CORRECT WRONG

1.13 FREEZING

Protect the product in freezing environments where temperatures are lower than the freezing point of the process

fluid.

1.14 OTHER RISKS

During the operation, the external surface of the product can be at temperatures which are hazardous to touch.
Take account of this risk.

1.15 DISPOSAL

The product should be disposed of in accordance with local legislation. This may be different in each State/
Country/Nation. It is the users responsibility to dispose of the product according to local requirements.

1.16 RISK OF CORROSION AND/OR EROSION

Periodically verify any phenomena of internal and/or external corrosion and/or erosion as they may
significantly damage the pressurized parts by locally reducing the thickness and as a consequence the
safety degree.

Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04

Page 4

OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

Installaon, Operaon and Maintenance VL10/…‐en Rev.08/2018

2.0 INSTALLATION

All work must be performed and supervised by skilled, trained and competent personnel.

The valve body casting is marked with an arrow showing the direction of flow and its normal flow path. The
casting also has markings which show the type of material and maximum operating pressure.
Before installing the valve, make sure that the inside of the is clean, by performing, if required, an energetic
blowing with steam or compressed air.This should be done with caution.
The installation of a filter (pos. A Pic. 1) upstream the valve will prevent dirt entering the valve.
To allow periodical maintenance of valves that are installed on continuously operating systems, it is

recommended to install two Isolating valves, located upstream (pos. B Pic. 1) and downstream (pos. C Pic. 1) of
the control valve, and a by-pass one (pos. D Pic. 1). Use the by-pass valve (pos. D Pic. 1) to manually regulate
the process when the control valve is temporarily disconnected. The two shut-off valves must have the same
internal diameter of the control valve. During the installation of the valve, make sure that the flow in the pipe goes
in the same direction as indicated by the arrow on the valve body.

B C E

Pic. 1 Installation diagram

ENGLISH

A

D

The assembling position of the valve does not limit its operation, but it is recommended to assemble the valve
with the actuator pointed upward (pos. E Pic.1) as other positions may allow the accumulation of any impurities
which are contained in the fluid thus damaging the valve itself.

2.01 FITTING THE VALVE TO THE PIPE

To ensure a uniform load and a uniform alignment, the flange bolts must be gradually tightened in criss-cross
sequence, as indicated in Pic.2

Prevent any excessive tightening. Use the recommended tightening torques. Prevent any pipe
misalignment. Choose the flange gaskets according to the operating conditions.

ATTENTION!!! For valves with braze-on connections, the welding operation must be performed
only by qualified personnel and, in order to prevent any damages to the valves, keep the valve
body cold during the above-mentioned operation.

Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04

OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

Pic. 2 Tightening sequence

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Installaon, Operaon and Maintenance Manual VL10/…‐en Rev.08/2018

ATTENTION!!! Any excessive weight of the valve might damage the system structure. If required,
support the valve by using suitable devices (Pic.3) and/or ropes (Pic.4)

ENGLISH

Pic. 3 Installation with
supports on the ground

Pic. 4 Installation with
lifting ropes

3.0 ACTUATOR CONNECTION

3.01 PNEUMATIC ACTUATOR CONNECTION

The pneumatic actuator is provided with two 1/4"NPT connections, one of which is closed by a filter. Connect the
control air pipe to the connection which has remained free. The control air must be clean, dry and free from oil
and grease and must not exceed an allowed maximum pressure. The signal required to control the valve is
provided on the plate fixed on the actuator’s yoke. If the valve is provided with a pilot positioner, refer to its
manual.

For the maintenance operations of the OMC pneumatic actuators, refer to the specific manual.

3.02 CONNECTION OF ELECTRIC ACTUATOR

For the connection of the electric actuator refer to its specific manual.

Page 6

OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04