SIL3 and ATEX Certified Omal Actuated Valves

Otkonsaş has continued the venture it started 32 years ago by providing both sales support and technical support today. With 30 employees and serving as the sole representative for many products in Turkey, the company serves Turkish industry. As with improvements to operating facilities, Otkonsaş continues to be a solution partner for investors, engineering firms and contractors in new investments. The selection, supply and commissioning of industrial valves demanded by heavy industry is Otkonsaş's primary objective, with particular focus on challenging industrial processes such as chemistry, petrochemistry, and paints. Not only in valve and actuator supply, but with a broad product range spanning from safety systems to valve locks, switches and transmitters, to tubes and pipe fittings, Otkonsaş serves Turkish industry with reliable and long-lasting products; products that aim to reduce work load, lower costs and eliminate possible dangers and risks.

Otkonsaş's First Turkish Representative: Omal Automation

Having signed its first representation agreement in Turkey with OMAL in 1988, Otkonsaş has been successfully representing OMAL in Turkey for over 30 years. OMAL S.P.A., with Scotch Yoke pneumatic actuators, ball and butterfly valves, has served many sectors for many years. Particularly in recent years, OMAL SIL3-certified pneumatic actuator ball valves, in accordance with Seveso requirements demanded by petrochemistry, chemistry and paint facilities, easily provide solutions for these sectors' SIL certification needs.

Double Acting and Spring Return Pneumatic Actuators

Heavy Duty Carbon Steel Pneumatic Actuators

As mentioned above, OMAL, through its Scotch Yoke Design actuators, has become the first choice actuated valve manufacturer for many firms worldwide by providing the long service life most end users desire and minimizing maintenance costs, while enabling joint certification of valves and actuators for SIL3 and ATEX.

Reasons Why Scotch Yoke Design Actuators Are Advantageous Over Rack&Pinion Design Actuators

The Scotch Yoke Design that OMAL uses in pneumatic actuator production has a much longer service life compared to Rack&Pinion Design (rack and pinion gear) actuators. The main reason for this is that the equipment inside Scotch Yoke actuators does not work by metal-to-metal contact; as a result, friction and wear are minimized. Since the Rack&Pinion design mechanism operates with a rack and pinion gear system, these wear and friction cause more damage to the actuator, especially with each opening and closing. The most typical failure seen in Rack&Pinion actuators due to this wear is gear breakage. Of course, this situation creates additional costs for end users because it generates production, maintenance and spare parts purchasing needs. End users using OMAL's Scotch Yoke Design actuators do not need any maintenance thanks to the device's self-lubricating pin. Another advantage of Scotch Yoke Design actuators over Rack&Pinion actuators is that they are much more compact and lighter. Furthermore, because Scotch Yoke actuators contain a pneumatic piston instead of rack and pinion gears inside, actuators with this design produce much more torque compared to Rack&Pinion (max. 8000 Nm). While Scotch Yoke actuator torque curves follow a parabolic curve, Rack&Pinion actuator torque curves are linear. The parabolic nature of the curve indicates lower air and energy consumption. This is because, as is known, in ball valves, torque is most needed during valve opening, that is when separating from the seal, and during closing.

After the valve ball separates from the seal, it rotates freely with less torque; Scotch Yoke Design actuators minimize air and energy losses by providing the lower torque required when the ball operates freely. OMAL actuators undergo quality control of initial samples before series production begins

(dimensionally and materially); if the product passes testing after control, Production Department approval is given to continue production. Each actuator is tested both after production and during assembly. Approval is given only after leak and torque are 100% tested. Actuators are marked with traceable production reference. OMAL continuously conducts durability and life-span testing in its own laboratories to ensure OMAL's reliability. Actuators are run in test facilities that generate actual valve torque until the end of their service life (over 1 million opening/closing cycles). OMAL, through its Double-Single and Staged actuators, places importance on quality and long service life in its production policy and, as noted above, is the preferred choice for many chemistry, petrochemistry and paint facilities and maintains an extensive reference list.

Scotch Yoke Design

Magnum & Thor

OMAL began production of SIL3-certified Magnum and Thor model valves approximately 5 years ago due to the need for SIL-certified products in recent years in the chemistry and paint sectors in accordance with Seveso requirements, as mentioned in this article. Magnum model ball valves have a monobloc body; Thor model ball valves are two-piece and are manufactured with flange connections. Both models are manufactured according to both DIN and ASME standards. These valves, which also have Fire Safe certification, demonstrate through Fugitive Emissions Certification that they prevent the release of toxic gases present in production lines into the environment and nature. Manufactured in DN15-DN200 sizes, these valves meet requirements up to PN63 – ANSI1500 pressure class as needed. Through the Antistatic Device they possess, valves prevent electrical charge buildup between the MIL and body, enabling valve use in hazardous areas. They are also highly resistant to thermal shock and wear thanks to their special sealing. Generally manufactured as Carbon Steel and Stainless Steel, these valves can also be produced as Duplex – Super Duplex and Nickel alloys as needed. TFM1600 seal (polytetrafluoroethylene derivative) seal production exists (Max. 180°C), but to meet higher temperature demands, they can also be manufactured with RPTFE – DEVLON and PEEK seals.

Magnum

Thor

Certifications

With an extensive certification list (SIL3, ATEX, FUGITIVE EMISSION, FIRE SAFE), OMAL is one of the rare manufacturers in the market that produces valves and actuators together. This ensures that valves and actuators work in harmony; quality control testing is performed for both products together. OMAL also manufactures the assembly kits between valves and actuators itself, providing relevant certifications for both products. OMAL's quality and safety sensitivity in valves and actuators is the most important reason for its preference in the paint and chemistry sectors.

Service and Maintenance

Through Enkosaş, which it established in 2016, Otkonsaş provides on-site maintenance, repair, online and offline testing, certification, calibration, assembly and supervising services. Emre Cingöz Sales Engineer Otkonsaş