OMC RD10 User manual

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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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 nr.9190.OMC2 - FIRST ISSUE 1994/08/04
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INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
Self-operated pressure reducers
RD10 / RA10

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under nr.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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TABLE OF CONTENTS
1.0 SAFETY INFORMATION
1.01 INTENDED USE
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 WORKERS
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 INSTALLATION OF THE VALVE ON THE PIPE
2.02 PRESSURE PIPE
2.03 PRESSURE GAUGES
2.04 SHUT-OFF VALVES
2.05 SAFETY VALVE
2.06 WATER SEAL POT
3.0 DOWNSTREAM PRESSURE CALIBRATION
4.0 MAINTENANCE
4.01 TIGHTENING TORQUES
4.02 TIGHTENING SEQUENCE
4.03 REPLACEMENT OF THE ACTUATOR
4.04 REPLACEMENT OF THE DIAPHRAGM GROUP
4.0.5 REPLACEMENT OF THE BELLOWS GROUP/PLUG
5.0 AVAILABLE SPARE PARTS
6.0 MALFUNCTIONING: SYMPTOMS, CAUSES AND REMEDIES
7.0 PRESSURE/TEMPERATURE RELATIONSHIP OMC-TUV-00
8.0 REFERENCES OF THE EUROPEAN DIRECTIVE FOR PRESSURE EQUIPMENT
2014/68/EU
9.0 PLATES
9.01 VALVE IDENTIFICATION PLATE
9.02 ACTUATOR IDENTIFICATION PLATE
9.03 “EC” PLATE PURSUANT TO DIRECTIVE 2014/68/EU

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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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 nr.9190.OMC2 - FIRST ISSUE 1994/08/04
ENGLISH
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 controlling:
- that the material of which the valve is made up of is compatible with the process fluid;
- that the valve is suitable to the pressures and temperatures of the process fluid;
- to have arranged a suitable safety device which prevents, in case of valve malfunctioning, any hazardous
overpressures or overtemperatures.
The 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.
1.02 ACCESS
Ensure a safe access and, if required, a safe working platform (with a suitable protection) before operating on the
product. Arrange the suitable lifting means, if required.
1.03 LIGHTING
Ensure a lighting which is suitable to the required type of work.
1.04 HAZARDOUS FLUIDS IN THE PIPE
Take account of the content of the pipe or anything it may have previously contained. Be careful to: flammable
materials, substances hazardous for the health, temperature extremes.
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.
May the intended measure put the other parts of the system or the personnel at risk?
Make sure that the shut-off valves are gradually activated in order 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.
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.

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under nr.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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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.
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 WORKERS
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 WRONG
1.13 FREEZING
Protect the products against frozen in environments with temperatures 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
For the disposal respect the legislation in force in the State/Country/Nation where the product should be disposed
of.
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.
CORRECT

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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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 nr.9190.OMC2 - FIRST ISSUE 1994/08/04
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2.0 INSTALLATION
All works must be performed and supervised by skilled, trained and competent personnel.
The OMC valves highlight the flow direction, the nominal passage, the maximum operating pressure and the
material. Before installing the valve, make sure that the pipe which channels the process fluid is clean, by
performing, if required, an energetic blowing with steam or compressed air.
The OMC pressure reducers have been specifically designed for use on steam, water,
compressed air, industrial inert gases and other fluids included in Group 2 of the Pressure
Equipment Directive 2014/68/EU.
The reducer must be vertically installed on a horizontal pipe.
For any use of fluids with a temperature lower than 90°C the reducer can be installed with its head pointed either
upward (Pic.1) or downward (Pic.2). For any use with steam or fluids with a temperature higher than 90°C, the
reducer must be installed with its head pointed downward and its water seal pot installed on the line downstream
the reducer by making sure to respect the distances and the pressure pipes shown in Pic.2. During the start-up,
slowly open the "7" shut-off valve upstream to prevent any possible water hammer.
2.01 INSTALLATION OF THE VALVE ON THE PIPE
To ensure a uniform load and a uniform alignment, the flange bolts must be gradually tightened in criss-cross
sequence, as shown in Pic.D (paragraph 4.02)
Prevent any excessive tightening. Use the recommended tightening torques.
Prevent any pipe misalignment.
2.02 PRESSURE PIPE (Pic.1 and Pic.2)
The line of the actuator’s signal must be directly connected to the downstream pipe.
To obtain a good adjustment signal the downstream sensitive point must be far at least 1 meter or 15 times the
diameter of the pipe from the reducer "3" or from changes in the flow direction.
The pipe "4" of the actuator’s signal must be made of copper or stainless steel, its diameter must be equal to 8mm
and its minimum length must be 1m .
2.03 PRESSURE GAUGES (Pic.1 and Pic.2)
To activate the reducer "3" and keep the operating conditions under control you must install a pressure gauge "2"
both upstream and downstream "6".
2.04 SHUT-OFF VALVES (Pic.1 and Pic.2)
To ensure future maintenance operations on the reducer "3" you should install a shut-off valve "1" upstream and a
7" one downstream the reducer.
2.05 SAFETY VALVE (Pic.1 and Pic.2)
It's recommended that an appropiate safety valve "5" on the downstream side in order to protect the plant from
any overpressure. The valve "5" must be set to open at a lower pressure than the safety of the equipment and
dimensioned to discharge the entire reducer capacity "3", if it fails in the fully open position. The safety valve
outlet pipe must be discharged in a safe and secure place.
Pic. 1

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ATTENTION!!! Any excessive weight of the valve might damage the system’s structure. If
required, support the valve by using suitable devices (Pic. A and Pic. C) and/or ropes (Pic. B
and Pic. D)
Fig. A
Fig. C
Fig. B
Fig. D
ATTENTION!!! The reducer balancing bellows (Pic.8 Pos.15) and the actuator’s diaphragm
(Pic.6 Pos.9) are subjected to wear. Do not install the reducer in zones where any leakages of
the process fluid, due to breaks of the above-mentioned components, may injure people and/or
animals and/or damage things.
2.06 WATER SEAL POT (Pic.2)
For installations on steam lines use an “8” water seal pot mounted between the pressure tap and the reducer’s
actuator. The "8" vessel must be filled with water before activating the valve. Remove the cap "9" and fully fill it
with water. Put the cap back.
Fig. 2

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
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3.0 DOWNSTREAM PRESSURE CALIBRATION (Pic.3)
The reducer is supplied uncalibrated with the spring pushing plate in its lowest position. The required downstream
pressure must be calibrated in zero-flow rate conditions or in normal operating conditions according to the
requirements of the application and by taking account of the proportional deviation. The required downstream
pressure is obtained by rotating the spring pushing plate "1" until the pressure gauge "6" Pic.1 and 2 indicates the
required value.
The adjustment can be carried out by using a simple 17 mm fixed wrench. By compressing the adjustment spring
the downstream pressure increases while, vice versa, the pressure decreases by reducing the spring tension.
Pic. 3

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under nr.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]
ENGLISH
4.0 MAINTENANCE
Note: before starting any maintenance operations consult the “Safety Information” in chapter 1.
Before operating the reducer:
 depressurize the system
 close the upstream shut-off valve (Pic.1 and 2 Pos. 1)
 fully unload the calibration spring by acting on the ring nut “1” Pic.3.
 close the downstream shut-off valve ( Pic.1 and 2 Pos. 7)
 wait until the whole pressure reducer reaches the ambient temperature
The reducer is not subjected to ordinary maintenance, but it is recommended to disassemble it every 12/18
months for a precautionary control of the components. The parts which show signs of wear must be replaced.
Specifications of the Spare Parts are provided in paragraph 5.0.
Before performing any controls or installing the spare parts, make sure that the valve is intercepted and that the
upstream and downstream pressure is relieved to zero; then rotate the spring pushing plate "1" Pic.3 so as to fully
unload the spring.
The pipe "4" Pic.1 and 2 of the downstream sensing line must be detached from the actuator.
ATTENTION!!! The balancing bellows provided inside the reducer (Pic.8 Pos.15) is
designed to support 10,000 cycles. Any break would let the fluid contained in the pipe
go out. It is recommended to periodically replace the bellows, according to the actual
use of the reducer. Do not install the reducer in zones where any leakages of the
process fluid, due to a break of the bellows, may injure people and/or animals and/or
damage things.
ATTENTION!!! The diaphragm provided in the actuator (Pic.6 Pos.9) is designed to
support 10,000 cycles. Any break would let the fluid contained in the pipe go out. It is
recommended to periodically replace the diaphragm, according to the actual use of the
reducer. Do not install the reducer in zones where any leakages of the process fluid, due
to a break of the diaphragm, may injure people and/or animals and/or damage things.
4.01 TIGHTENING TORQUES
VALVE DIAME-
TER
SEAT (Pic.8
Pos.17)
Nm ±10%
BODY NUTS
(Pic.8 Pos.2)
Nm ±10%
DN15 - 1/2” 190 30
DN20 - 3/4” 190 30
DN25 - 1” 240 30
DN32 - 1” 1/4 350 30
DN40 - 1” 1/2 570 50
DN50 - 2” 570 50
DN65 - 2”1/2 700 100
DN80 - 3” 700 100
DN100 - 4” 850 100
ACTUATOR BLOCKING RING NUT
(Pic.4 Pos 4)
Nm ±10%
300
300
300
300
300
300
300
300
300
NUTS
(Pic.6 Pos 8)
Nm ±10%
40
40
40
40
50
50
ACTUATOR
MODEL
AR085
AR100
AR120
AR150
AR205
AR265

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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4.02 TIGHTENING SEQUENCE
To ensure the uniformity of the load and the alignment, the bolts must be gradually tightened and in criss-cross
sequence, as indicated in Pic.E
Prevent any excessive tightening. Use the recommended tightening torques
Pic. E
4.03 REPLACEMENT OF THE ACTUATOR
 depressurize the system
 close the upstream shut-off valve (Pic.1 and 2 Pos. 1)
 fully unload the calibration spring by acting on the ring nut “1” Pic.3.
 close the downstream shut-off valve ( Pic.1 and 2 Pos. 7)
 wait until the whole pressure reducer reaches the ambient temperature
 loosen the ring nut "4" (Pic. 4)
 grab the actuator "5" (Pic. 4) and rotate it counterclockwise until it is completely unscrewed.
ATTENTION!!!! TO THE ACTUATOR WEIGHT
 set the ring nut "4" in the position shown in Pic.5
 completely screw the new actuator with the ring nut "4".
 tighten the ring nut "4"
Pic. 4 Pic. 5
4.04 REPLACEMENT OF THE DIAPHRAGM GROUP
 separate the actuator from the reducer as described in chapter 4.0.3
 separate the lid "6" from the lid "7" by unscrewing the nuts "8" (Pic.6)
 replace the diaphragm group "9" with the new diaphragm group
 re-assemble the parts by following the indications of chapter 4.01 and 4.02
 re-install the actuator on the reducer as described in chapter 4.03

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OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
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Pic. 6
4.05 REPLACEMENT OF THE BELLOWS GROUP/PLUG
 separate the actuator from the reducer as described in chapter 4.03
 fully decompress the spring "10" by acting on the ring nut 1 (Pic.7)
 remove the ring nut "4" and remove the pin "11"
 remove in sequence the ring nut "12", the spring "10" and the bearing "13"
 unscrew the nuts "2" Pic.8 and remove the bonnet "14"
 remove the bellows group/plug "15"
 if required replace the seat "17" by tightening it as described in chapter 4.01
 replace the gasket "16"
 install the new bellows group/plug by following the operations in the reverse order.
For the tightening operations follow the indications of chapters 4.01 and 4.02
Pic. 7 Pic. 8

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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under nr.9190.OMC2 - FIRST ISSUE 1994/08/04
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5.0 AVAILABLE SPARE PARTS
DESCRIPTION PICTURE POSITION
Complete actuator 4 5
Diaphragm group 6 9
Bellows group / actuator 8 15
Seat 8 17
Body gasket 8 16
Calibration spring 7 10
Spring supporting bearing 7 13
6.0 MALFUNCTIONING: SYMPTOMS, CAUSES AND REMEDIES
Note: before starting any maintenance operations consult the “Safety Information” in chapter 1.
To disassemble this product you must first depressurize the system and wait until the reducer’s temperature is
equal to the ambient temperature
SYMPTOM CAUSE REMEDY
The downstream pressure exceeds the
required calibration one
Actuator not properly dimensioned Control the design data and, if requi-
red, replace it (Chap. 4.03)
Sensing line pipe (Pic.1 pos.4)
obstructed Disassemble the pipe and clear it
Actuator diaphragm (Pic.6 pos.9)
damaged Replace (Chap. 4.04)
Plug or seat damaged Replace (Chap. 4.05)
Bellows group damaged Replace (Chap. 4.05)
In full-load conditions the downstream
pressure is lower than the required cali- Actuator not properly dimensioned Control the design data and, if requi-
red, replace it (Chap. 4.03)
The actuator is properly dimensioned but
the reducer does not provide the maxi-
mum flow rate
The reducer is not properly dimen-
sioned
Control the design data and, if requi-
red, replace it
The downstream pressure pipe is
too close to the valve or some
turbulences
Make sure about the proper installa-
tion of the reducer (Chap. 2.0)
The pressure reduction ratio is too
high.
Consider two valves in series to de-
crease the reduction ratio
Pressure pipe (Pic.1 pos.4) too
sensitive Reduce the pipe section.
The downstream pressure fluctuates
ATTENTION!!! The OMC reducers are univocally identified by a serial number applied on the reducer
and a serial number applied on the actuator, to order the spare parts or for any other need, always refer to
such serial numbers.

Installaon, Use and Maintenance RD10‐RA10‐en Rev.08/2018
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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under nr.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]
ENGLISH
7.0 PRESSURE/TEMPERATURE RELATIONSHIP
For the pressure regression in relation to the temperature refer to the document:
- OMC-TUV-00
The actual use of the valve depends on the combination of the materials of which it is made up.
8.0 REFERENCES OF THE EUROPEAN DIRECTIVE FOR PRESSURE
EQUIPMENT 2014/68/EU
VALVE BODY OF THE REDUCER RD10
PN16 PN25 PN40 CATEGORY FLUIDS
DN15÷DN50 DN15÷DN40 DN15÷DN32 Art. 4 Par.3 Group 2
DN65÷DN100 DN50÷DN100 DN40÷DN100 1 Group 2
EC MARKING
NO
YES
PROCEDURE OF CONFORMITY EVALUA-
TION
Art. 4 Par.3
A
VALVE BODY OF THE REDUCER RA10
ANSI 150 ANSI 300 CATEGORY FLUIDS EC MARKING PROCEDURE OF CONFORMITY EVALUA-
TION
1/2”÷2” 1/2”÷1” Art. 4 Par.3 Group 2 NO Art. 4 Par.3
2”1/2 ÷ 4” 1”1/2 ÷ 4” 1 Group 2 YES A
ACTUATORS
CATEGORY FLUIDS EC MARKING PROCEDURE OF CONFORMITY EVALUATION
Art. 4 Par.3 Group 2 NO Art. 4 Par.3

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9.0 PLATES
9.01 VALVE IDENTIFICATION PLATE
All OMC valves are provided with an identifiction plate for the identification unique of the valve.
LEGEND
NUMBER TEXT DESCRIPTION
1 Mod. Reducer model
2 Nominal diameter and nominal pressure of the valve
3 P.Max. Maximum input pressure
4 Trim Material of seat/plug
5 Serial Valve serial number
6 T Maximum and minimum allowed temperatures of the process fluid
7 Fluid Process fluid
8 Kv Outflow coefficent of the valve
9 Yr: Year of manufacture
10 Fluid Direction Direction of the process fluid’s flow
9.02 ACTUATOR IDENTIFICATION PLATE
1
2
3
4 5
6
7
8
9
10
9.03 “EC” PLATE PURSUANT TO DIRECTIVE 2014/68/EU
If planned (see paragraph 8.0) the valve is provided with an “EC” plate containing the following data
LEGEND
NUMBER TEXT DESCRIPTION
11 Diaph Material of the actuator’s diaphragm
12 Range Actuator’s scale range
13 Serial Actuator serial number
11
12
13
LEGEND
TEXT DESCRIPTION
CE It indicates the conformity to all manufacturer’s obligations
Module: A Procedure of conformity validation
DIRECTIVE
2014/68/EU European directive concerning pressurized equipment 2014/68/EU