USER`S INSTALLATION AND MAINTENANCE MANUAL
Contents
1. It is totally the installer s responsibility to couple the valve in the line Place the valve with the ball fully open or fully closed so as to avoid damage to the sealing surface of the seats and of the ball itself Verify that the surfaces of the flanges of the valve and the piping are parallel and properly coupled with the seals If during assembly the exterior painting should get damaged it is necessary to restore the integrity of the coating Take special care during assembly to not let foreign objects of any type or size in line for this could jeo pardize the correct and safe operation of the valve and the system itself Valves with welded ends The connection through permanent joint between the valve and the line is of the person installing the valve in the plant sole responsibility During welding hold the valve in the open position to prevent da mage due to thermal expansion especially the bonding of seats Commissioning The following operations are required before start up e Inspection and testing of the valve and the line e Flushing e Hydraulic test of the line Inspection and testing of the valve and the line Once the valve is connected in line before proceeding to the pressurization of the same it is necessary to e Check if any the presence of caps nipples drain valves and their correct tightening e Check the tightness of bolts and or screws between the body flange and body and lids e Read the instructions2. and any restrictions regarding the use of the actuator if any Flushing The flushing phase is very delicate if not done properly it may affect the functionality of the valve itself The cavities of the valve in fact can accommodate foreign objects and thus influence its proper functio ning In the case in which fluids that carry abrasive materials are being used these can be very dange rous because they can damage the soft seals and the sealing surfaces The valves with soft seal seats Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it 4 onat USER S INSTALLATION AND re lam lt Oe ON MAINTENANCE MANUAL OM aueh EMPOWERED PERFORMANCE Steel ball valves aac ee in fact are designed to intercept clean fluids free of solid and abrasive particles It can be done after completing the installation cleaning the system from inert gases vapors or liquids always checking the compatibility of the fluid that is being used with the valve to remove any residue grease or oil or foreign objects Always use fluids that are compatible with the material of the valve and of the seals especially if the fol lowing materials are being used consider as follows Amine based corrosion inhibitors may damage the O ring which is fluorocarbon based The use of methanol may da
3. ball valve gt PN 100 15000 10000 5000 5000 7 DISPOSAL OF PRODUCTS AT THE END OF THEIR LIFE CYCLE Once that the valve has reached the end of its operating life it can be removed from the system by following the procedures that are suitable to the type of valve and to the operating conditions If the valve intercepts toxic corrosive and or hazardous substances it must first be cleared by an appropriate flushing cycle and the waste is to be disposed of according to the applicable regulations Once removed from the system protect the ends and all the possible openings valve drains nipples etc through an appropriate sealing system in order to prevent the dispersion and the contact by any pollutants or hazardous materials left inside the valve In the case of a fluid leakage from inside the valve occurs it is required to act promptly decontaminate and secure the contaminated environment as required by the relevant laws and regulations The personnel in charge of the product disposal recovery must be qualified and equipped with appropriate personal protective equipment PPE according to the type of fluid intercepted polluting corrosive etc Once disassembled and secured bring the valve to a site that is designated as the storage site and that complies with the requirements of the European national regional and municipal environmental and safety standards The management of waste generated during the installation e
4. specifications also apply IEC 61508 2010 1 7 Functional safety of electrical electronic programmable electronic safety related systems Part 1 7 OMAL S p A reserves the right to change at any time the features and data of its own products to better improve the quality and the duration of said products Revision date 02 2014 The present cancels and replaces any previous documents Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy 1 Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it a x USER S INSTALLATION AND De MAINTENANCE MANUAL iM EMPOWERED PERFORMANCE Steel ball valves UNI CEN TS 764 6 2005 Pressure equipment Part 6 Operating instructions structure and contents It s up to the reader to find his own product and the correct operating conditions possibly referring to the attached drawings Below you will find the safety instructions the minimum information for storage warehousing the installation the commissioning the maintenance and the instructions for disposal of products at the end of their life cycle The Omal valves are CE marked in accordance with the Directives 97 23 CE PED and or 94 9 CE ATEX The company disclaims any liability for damage caused by improper use even if partial respect to the information contained in this manual 2 OPERATION CONDITIONS Every type of
5. valve is described in an accurate way through one or more dedicated drawings The type of valve the maximum permitted operating conditions as well as other important information are shown in a label or are engraved directly on the valve itself the appropriate certification PED ATEX API etc is also indicated The category identification and compliance assessment have been done in conformity with Annex II table 6 of the PED Directive this way the most restrictive conditions have been considered 3 RISK ASSESSMENT Limits of use The Omal valves are suitable for both indoor and outdoor uses The technical characteristics of the val ves such as the type the size the maximum operating pressure the maximum and minimum operating temperature the flange connection the serial number are all indicated body and or on the label Do not use the valves beyond the operating conditions both environmental and performance or beyond the features stated by manufacturer The external surface of the valves in carbon steel is not provided with a protective coating but with simple burnishing treatment It is the end user s responsibility to protect the external surface of the valve against corrosion and wear with a coating that is suitable for the installation environment The stainless steel valves can be used in environmental conditions such as corrosive atmospheres or with low temperature In the case of special installations ex Off shore applicatio
6. EMPOWERED PERFORMANGE inc nou zm 5 DNV GL AUTOMATION jen USER S INSTALLATION AND MAINTENANCE MANUAL Steel ball valves UMAH1000 ENG Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it Z M m a USER S INSTALLATION AND AER res MAINTENANCE MANUAL Iam iz EMPOWERED PERFORMANCE Steel ball valves USER S INSTALLATION AND MAINTENANCE MANUAL Steel ball valves 1 FOREWORD Pag 1 2 OPERATION CONDITIONS Pag 2 3 RISK ASSESSMENT Pag 2 LIMITS OF USE 4 TRASPORTATION AND STORAGE WEARHOUSING Pag 3 TRASPORTATION STORAGE 5 INSTALLATION INSTRUCTIONS Pag 3 HANDLING ASSEMBLY COMMISSIONING SHUTDOWN VALVE REMOVAL INSPECTION SEALING IN CASE OF EMERGENCY 6 MAINTENANCE Pag 6 7 DISPOSAL OF THE PRODUCTS AT THE END OF THEIR LIFE CYCLE Pag 6 8 SPARE PARTS Pag 6 9 TROUBLESHOOTING Pag 7 10 STATEMENT OF CONFORMITY Pag 7 1 FOREWORD The present User s Installation and Maintenance Manual has been edited in conformity with 97 23 CE Directive Pressure equipment PED 2006 42 EC Directive Machinery 94 9 CE Directive Equipment and protection systems designated to be used in potentially explosive atmospheres ATEX The following standards technical
7. INSTALLATION AND re lam lt Oe ON MAINTENANCE MANUAL IOM aueh EMPOWERED PERFORMANCE Steel ball valves mes te Dever cl e Uncontrolled chemical reactions 4 TRASPORTATION AND STORAGE WEARHOUSING Transportation The OMAL valves are properly packaged for an adequate protection during handling and dispatch Since it cannot be excluded that the product could accidentally get damaged during transportation it is recommended to carefully check the same upon receipt before putting it in stock Verify therefore that the packaging upon reception is intact free of damage due to bumps or falls that may have occur red during transportation Also check that the product that has been received corresponds exactly to what had been requested The handling of packages on pallets wrapped in shrink wrap barrier does not require special care if the package is damaged check if the product has been damaged also or if the re s anything missing All handling operations must be carried out with suitable means and by qualified personnel Storage Choose clean sites for storage not excessively humid and with temperatures between 10 and 60 C If the products are to be stored for long periods of time it is best not to remove them from their protective packaging Keep the valves in the package during storage If the valves are not packaged then they must be protected by applying plastic caps to the ends which are usually supplied with the product in or
8. ase needed usually to stop a leak Before proceeding with the sealing operation make sure the sealer is compatible with the materials of the valve and the intercepted fluid so to avoid dangerous chemical reactions that could cause harm to people the environment and to the system Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy 5 Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it ii OMOL A IWEENENWEEN EMPOWERED PERFORMANCE USER S INSTALLATION AND MAINTENANCE MANUAL Steel ball valves The flushing fluids and sealers can be pumped in by a manual or pneumatic pump checking that the nominal pressure of the pump and accessories is higher than the rating pressure of the valve 6 MAINTENANCE The efficiency of the product is the result of a good and careful maintenance check the system efficiency status at least once a year providing for the immediate replacement of parts that are subject to wear in case leaks are found both in the ducts and on the outside of the valves Normally for medium duty applications the replacement time of parts subject to wear for the various types of valves is summarized in the table below Maintenance operations must be performed by quali fied personnel DN 15 25 DN 32 50 DN 65 100 DN 100 200 Steel ball valve lt PN 100 30000 25000 20000 15000 Steel
9. ck the control mechanism Worn seals ball Replace worn components Valve leak Chemical incompatibility with valve structure materials Contact Omal Upper or lower stem seals leak O ring seal damaged Replace worn components Body damaged Replace worn components Stem damaged Replace worn components Valve blocked Drive system failure Contact Omal Ball stem possible binding Contact Omal Stem broken Contact Omal Actuator valve connection broken Contact Omal Increased operating movement time Ball stem possible binding Contact Omal Possible partial binding of actuator Contact Omal Insufficient rotation angle The actuator fails to perform the maneuver Verify actuator dimensions Supply air not enough to produce the required torque Increase supply air Mechanical stop if present is not properly adjusted Adjust the stops to increase the stroke Ball stem possible binding Contact Omal Wrong fixing between actuator outlet hole and valve stem Check fixing and size of the adapter between the valve and the actuator 10 STATEMENT OF CONFORMITY The OMAL ball valves have been designed manufactured and tested to meet the requirements of the following European standards and are marked where provided with the relative CE conformity marking 97 23 CE Directive Pressure equipment PED 2006 42 EC Directive Mach
10. der to avoid liquid or other from penetrating during storage and thus damaging the ball or the seals Should it appear appropriate to apply products for the preserva tion and protection of the valve make sure it is dry also on the inside If the valves are to be stored for long periods of time then they should be inspected periodically check in particular the possible presence of rust oxidation paint nicks or even partial unscrewing of the clo sures It is also recommended to perform a complete dry cycle of opening and closing of the valve The seals in polymer are subject to aging losing their characteristics for this reason after storage periods of more than two years it is recommended to check the functionality and the seals before mounting the valve in the line In the case of flanged valves stored outside the machined surfaces must be protected with anti rust varnish and closed with waterproof wood seals complete with gaskets 5 INSTALLATION INSTRUCTIONS The design of the valve takes into account the loads arising from the line axial forces bending moments etc as required by the reference standards Before the assembly of the valve in line check the conditions making sure of the integrity of all the parts Also check the information on the label or engraved on the valve to ensure the correct operating condi tions Replace any caps on the ends to preserve the valve interior during the handling If the valve is sup plied w
11. inery 94 9 EC Directive Equipment and protective systems intended for use in potentially explosive atmospheres ATEX Regulation EC No 1907 2006 and successive Concerning the Registration Evaluation Authorization and Restric tion of Chemicals REACH Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it
12. ith a bare stem carefully follow the installation instructions provided together with the actuator and possible reducer Such operations must be carried out by an experienced and qualified staff The use of an actuator allows to open and close the valve connected to it without manual operations by means of levers or hand wheels but through an electro pneumatic remote command The normal sizing of the actuators requires to consider an appropriate safety margin in order to guarantee the valve maneuvering The plant design physical or chemical characteristics of the fluids special environmental conditions may require an increase of the safety factor to be applied to the sizing Prior to installation ve rify that valve and the actuator comply with the above described safety standards Furthermore utmost cleanliness is required when connecting the air supply to the actuator All parts of the plant reductions joints plates brackets and equipment must be thoroughly cleaned Before mounting the actuator on the valve be sure that both elements are correctly oriented depending on the rotation direction needed Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy 3 Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it a x USER S INSTALLATION AND De MAINTENANCE MANUAL iM EMPOWERED PERFORMANCE Steel ball valves Always
13. mage some types of O rings Water especially without inhibitors may cause the corrosion of carbon steel parts e Fluids containing fluorine and its derivatives can trigger the corrosion of stainless steel parts Hydraulic test of the line The hydraulic test of the line should be carried out at a pressure that does not exceed 1 5 times the rating pressure of the valve indicated on the nameplate or engraved on the body of the valve itself The test shall be performed with the ball in a half open position so to avoid damaging the seats If the test is performed on valves that are sealed with polymeric material keep the ball in a semi open position du ring the testing time only and no longer than a few hours Should it be necessary to test the valve in the closed position the maximum pressure should not exceed 1 1 times the rating pressure Once the test is over depressurize the line and if possible vent and discharge the valve Once that the previous operations have been carried out the valve is now ready for operation if the valve is manually operated by lever wheel or reducer make at least one complete opening and clo sing maneuver so to verify its proper functioning If the valve is actuated read the instructions carefully check the pneumatic or electric diagrams and then proceed with a complete opening and closing cycle so to verify its proper functioning In order to avoid a functional failure of the valves is recommended to perfo
14. ns it is for the end user to protect the outer surface of the valve from corrosion and wear with a suitable coating The valves with the ATEX configuration can be installed in areas with potentially explosive atmospheres EX Il 22 GD c TX X It is recommended to protect the valve with appropriate devices from overpressure generated by the use of volatile gases or from possible pressure increase due to overheating ex fire The valves are designed for an on off type of use and are not safety valves They must also not be used in an underwater environment and with an external pressure greater than the atmospheric one Always follow the operating conditions printed on the label or engraved on the valve itself do not in any case exceed such limits as exceeding even one of these limits could lead to dangerous situations and impair the functionality of the valve The following are the main hazardous conditions that have not been eliminated Weather Elements wind snow ice etc e Vibrations resulting from the plant or from the fluid passage e Water hammer in case of rapid closure of the valve e Corrosion aggressive atmosphere or valve not suitably protected e Stray current e Shock waves Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it 2 onat USER S
15. read the specific instructions carefully before operating the actuator in order to avoid damage to the valve the plant and the actuator itself Handling The valves must be handled by experts and with adequate protection devices The actuated valves must not be handled through the actuator For valves weighing less than 25 kg handling can also be done through manual means For valves with total weight above 25 kg the unit must be handled with suitable means such as slots eyebolts etc If there aren t any holes or eyebolts you can use the ends appropriately harnessed to move the val ve Be careful not to damage the machined surfaces with chains or hooks Always use approved lifting equipment hooks straps etc to bear the weight of the valve and actuator together this weight is indi cated in the shipping documents However avoid handling suspended loads above people or in places where a possible fall can cause damage Assembly To prevent damage and protect the valve interior remove the caps only upon installation Verify that the inside of the pipe is clean and free of any object or particles that can damage the ball or other parts of the valve If not otherwise indicated the valves are bi directional and can be mounted on either side In the event that the valve is unidirectional an arrow ill show clearly the flow direction In this case make sure that the flow direction coincides with the direction of the arrow Flanged valves
16. rm a partial maneuver at least once a year Shutdown If problems occur on the valve if possible close the valves upstream and downstream and shut the pres sure to the line Then perform a complete inspection of the valve so to identify the fault After a system shutdown before maneuvering the valve empty it out if possible and drain it as well Valve removal Before the valve can be removed from the line it is necessary to e always make sure that the pipeline is not pressurized e actuate the valve by performing an opening closing cycle so to eliminate any residual pressure trapped inside the body Never and in any case use vent plugs or drains to drain out the pressure from the valve body e perform accurate flushing cycles with inert fluids or specific corrosion inhibitors if the valve intercepts substances that are dangerous corrosive explosive etc and ensure safety measures e use suitable personal protective equipment PPE before opening the valve pipe connections After removing the valve from the line thoroughly clean it and protect the ends by covering them with caps Inspection The operating conditions can be very different it is therefore up to the user to establish an adequate inspection interval that is based on the system the intercepted fluid operating conditions etc Sealing in case of emergency Some valves are equipped with injectors in correspondence with the stem and the seals in order to seal the valve in c
17. xtraordinary maintenance or due to the pro duct disposal is governed by the rules in force in the country where the product is installed in any case the following are the general guidelines The metal components aluminum steel can be restored as raw material Seals sealing elements PTFE PEEK NBR EPDM FKM as contaminated by fluids from other materials and lubrication must be disposed of The packaging materials that come with the product should be transferred to the differentiated collection system available in the country 8 SPARE PARTS Use only original spare parts for maintenance always mention when ordering the spare parts the part num ber and date of manufacture stamped on the valve to be sure to receive spare parts that are compatible with the product in the most recent version possible For detailed information on the mounting and dismounting refer to the specific instructions for each type of valve Omal S p A Headquarters Via Ponte Nuovo 11 25050 Rodengo Saiano Brescia Italy Production Site Via San Lorenzo 70 25069 Villa Carcina Brescia Italy Ph 39 0308900145 Fax 39 0308900423 www omal it omal omal it 6 OMoc USER S INSTALLATION AND MAINTENANCE MANUAL AUTOMATION Saw EMPOWERED PERFORMANCE Steel ball valves Rs 9 TROUBLESHOOTING Listed below are a number of main failures with possible causes and possible solutions PROBLEM POSSIBLE CAUSES SOLUTION Ball not completely closed Che
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