Flowserve Atomac AKH3.2 User manual

These instructions must be read prior to installing, operating, and
maintaining this equipment.
Atomac AKH3.2
Lined Reduced Port Ball Valve
AKH3.2M (Monobloc) & AKH3.2F (Floating Ball)
FCD ATENIM0001-03 (EN/AQ)
Original Instructions

AKH3.2 User Instruction – FCD ATENIM0001 EN
Copyright
All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system
or transmitted in any form or by any means without prior permission of Flowserve Corporation.
Document Version
Revision 03, 09-August-2022

AKH3.2 User Instruction – FCD ATENIM0001 EN
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CONTENTS
1 General Information ......................................................................................................................... 4
1.1 Scope of manual ........................................................................................................................................... 4
1.2 Disclaimer ..................................................................................................................................................... 4
1.3 Certification instruction .................................................................................................................................. 4
1.4 Units .............................................................................................................................................................. 4
2 Safety Information ........................................................................................................................... 5
2.1 Intended use ................................................................................................................................................. 5
2.2 Safety symbols and description .................................................................................................................... 6
2.3 General hazard sources ................................................................................................................................ 7
2.4 Safety data sheets ........................................................................................................................................ 8
2.5 Qualified personnel and targeted group ........................................................................................................ 8
2.6 Industrial health and safety measures .......................................................................................................... 8
2.7 Potential explosive areas .............................................................................................................................. 9
2.8 Protective equipment .................................................................................................................................... 9
3 Product Description ........................................................................................................................ 9
3.1 General product description .......................................................................................................................... 9
3.2 Scope of delivery ........................................................................................................................................ 10
3.3 Function description .................................................................................................................................... 10
3.4 Connections ................................................................................................................................................ 11
3.5 Accessories ................................................................................................................................................. 14
3.6 Tools, Equipment, and fixtures ................................................................................................................... 14
4 Packaging, Transportation and Storage ...................................................................................... 14
4.1 Unpacking ................................................................................................................................................... 14
4.2 Packaging ................................................................................................................................................... 14
4.3 Transportation ............................................................................................................................................. 16
4.4 Storage ....................................................................................................................................................... 16
5 Installation ...................................................................................................................................... 17
5.1 Fluoropolymer-lined Atomac valves ............................................................................................................ 17
5.2 Inspection and preparation ......................................................................................................................... 18
5.3 Mounting of Lever & Gear ........................................................................................................................... 19
5.4 Installation ................................................................................................................................................... 21
6 Commissioning .............................................................................................................................. 22
7 Operation ........................................................................................................................................ 22
7.1 Normal operation ........................................................................................................................................ 22
8 Maintenance ................................................................................................................................... 23
8.1 Schedule ..................................................................................................................................................... 23
8.2 Required replacement parts for maintenance ............................................................................................. 23
8.3 Disassembly & Assembly Procedure .......................................................................................................... 24
8.4 Maintenance procedure .............................................................................................................................. 27
8.5 Post maintenance inspection ...................................................................................................................... 27

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9 Decommissioning and Recommissioning .................................................................................. 28
9.1 Decommissioning ........................................................................................................................................ 28
9.2 Recommissioning ........................................................................................................................................ 28
10 Returns and Disposal .................................................................................................................... 29
10.1 Returns ....................................................................................................................................................... 29
10.2 Disposal and recycling ................................................................................................................................ 29
11 Technical Data ............................................................................................................................... 30
11.1 Weights ....................................................................................................................................................... 30
11.2 Nameplate ................................................................................................................................................... 30
11.3 Operating limits ........................................................................................................................................... 31
11.4 Torque requirements ................................................................................................................................... 31
Annex A: Declaration of Conformity ................................................................................................... 33
Annex B: Technical Terms, Acronyms, and Abbreviations .............................................................. 37
Annex C: Additional Sources of Information ..................................................................................... 37

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1 General Information
1.1 Scope of manual
These instructions must be kept close to the product’s operating location or directly with the product.
These instructions must be read prior to installing, operating, using, or maintaining the equipment in
any region worldwide. The equipment must not be put into service until all of the safe operating conditions
noted in the instructions have been met. Failure to comply with the information provided in the User
Instructions is considered to be misuse. Personal injury, product damage, delay in operation, or product
failure caused by misuse are not covered by the Flowserve warranty.
English ANSI ASME Units – CL150, NPS 1”-6”.
These instructions are intended to familiarize the reader with the product and its permitted use. Operating
the product in compliance with these instructions is important to help ensure reliability in service and avoid
risks. These instructions may not take into account all local regulations; ensure such regulations are
observed by all, including those installing the product. Always coordinate repair activities with operations
personnel and follow all plant safety requirements and applicable safety and health legislation.
1.2 Disclaimer
Information in this User Instruction is believed to be complete and reliable. In spite of all Flowserve’s efforts
to provide comprehensive information and instructions, sound engineering and safety practices should
always be used. Please consult with a qualified engineer.
Flowserve manufactures products to applicable International Quality Management System Standards as
certified and audited by external Quality Assurance organizations. Genuine parts and accessories have
been designed, tested, and incorporated into the products to help ensure continued product quality and
performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the
incorrect incorporation of such parts and accessories may adversely affect the performance and safety
features of the product. The failure to properly select, install, or use authorized Flowserve parts and
accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Flowserve’s
warranty. In addition, any modification of Flowserve products or removal of original components may impair
the safety of these products in use.
1.3 Certification instruction
• Declaration of Conformity PED 2014-68-EU, English F
• Declaration of Conformity PED 2014-68-EU, German F
• ATEX 2014-34-EU, English F
• ATEX 2014-34-EU, German F
Note: Certificates defined in the Contract requirements are provided with these instructions where
applicable. Examples of the certificates can be found in the Annex of this document. If required, copies of
other certificates sent separately to the Purchaser should be obtained from the Manufacturer for retention
with this User Instruction.
1.4 Units
This document uses the unit: dual unit system F

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2 Safety Information
2.1 Intended use
Flowserve Atomac and Durco are leaders in the design and manufacture of corrosion resistant
fluoropolymer lined valves and that these valves are used in the toughest fluids of the CPI.
Table 1: Applicable intended uses of the AKH3.2
Pulp & Paper Industries:
Steel Industry:
Titanium Dioxide
Production (both
Sulphate and Chloride):
Pharmaceutical
Industry:
Spent Acid
Pickling Line
Chlorine
Solvents
Tall oil
Liquid and Vapor
Acids
Sodium Chlorate
Sulphuric Acid
Alkaline
Sulphuric Acid
Barium Chloride
Mixtures of these
HCL
Calcium Chlorides
Chlorine Dioxide
HCL
Sodium Hypochlorite
Flowserve lined ball valves are pressure containing components in accordance with the Pressure
Equipment Directive (PED). They are designed for shut-off and passage of different fluids, vapours, gases
and liquids of group 1. According to the PED and have a corrosion- resistant plastic lining. Solids can have
a negative effect on the liner and sealing parts of the valve resulting in increased erosion, damage to
surfaces and sealing and to a reduction in the service life of the valve or higher torques.
Before operating under new conditions, the personnel have to carefully examine all information including
provided data from Flowserve and service conditions for the operation whether the valve, accessories and
materials are suitable for the new application (Flowserve Ahaus GmbH can give recommendations).
The product/system must not be operated beyond the parameters specified for the application. If there
is any doubt as to the suitability of the product/system for the application intended, contact Flowserve for
advice, quoting the serial number.
• Installing, operating, or maintaining the Valve in any way that is not covered in this User Instruction could
cause death, serious personal injury, or damage to the equipment. This includes any modification to the
product/system or use of the parts not provided by Flowserve.
• Only operate the Valve when it has successfully passed all inspection acceptance criteria.
• Do not operate the Valve in a partially assembled condition.
• If the conditions of service on the customer’s purchase order change (i.e., pumping fluid, temperature,
or duty conditions) it is requested that the user seeks written agreement from Flowserve before start-up.
• Observe equipment labels, such as arrows designating the direction of rotation, warning signs, etc., and
keep them in a legible condition. Replace any damaged and/or illegible labels immediately.

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2.2 Safety symbols and description
This User Instruction contains specific safety markings where non-observance of an instruction would cause
a hazard. The specific safety markings are:
Table 2: Definition of safety symbols and markings
Symbol
Description
DANGER
This symbol indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
This symbol indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
This symbol indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Safety Instruction
This symbol indicates specific safety-related instruction or
procedures.
NOTICE
This symbol is used to address practices not related to physical
injury.
This is the safety alert symbol. It is used to alert you to potential
physical injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

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Table 3: Additional symbols
Symbol
Description
ELECTRICAL HAZARD
This symbol indicates electrical safety instructions where non-
compliance would affect personal safety and could result in loss of
life.
TOXIC HAZARD
This symbol indicates “hazardous substances and toxic fluid”
safety instructions where non-compliance would affect personal
safety and would damage the equipment or property.
ATEX EXPLOSION PROTECTION
This symbol indicates explosive atmosphere marking according to
ATEX. It is used in safety instructions where non-compliance in
the hazardous area would cause the risk of an explosion.
2.3 General hazard sources
Risk of injury due to ball valve parts in motion!
A ball valve wrench and ball which are in motion may cause crushing and/or amputate fingers.
• Do not reach between the ball valve wrench and the stop.
• Do not reach into the bore of the ball valve.
• Wear appropriate safety gloves.
Risk of injury due to a heavy ball valve!
A heavy ball valve may cause back injury if lifting the ball valve without additional personnel or appropriate
mechanical auxiliary means (hoist or swing crane).
• Perform lifting only in compliance with site safety protocol, local regulations, and industry standards.
• Prior to any attempt to lift the ball valve, first determine the approximate weight and stability of the ball
valve.
• Always handle the ball valve with the assistance of additional personnel or appropriate mechanical
auxiliary means.
• Only lift a ball valve weighing 23 kg (50 lb.) or more using appropriate mechanical means and in
accordance with respectively valid statutory regulations.
• Always wear appropriate personal protective equipment (PPE) during handling.
• Evaluate repetitive ball valve handling of any kind as part of a documented end-user safety program.

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Furthermore, in case of a non-intended use (reasonably foreseeable misuse) the following may occur:
• Failure of the ball valve’s primary functions.
• Damage to the industrial plant or piping system.
• Failure of required maintenance and repair methods.
• General risk of injury to personnel.
• Environment pollution caused by substances leaking from the ball valve.
2.3.1 Mechanical Hazards
Lifting limits and guidelines
Note: The load values mentioned in this section are Flowserve recommendations only. All liftings must be
done in compliance with site safety protocol, local regulations, and related industry standards.
Many precision parts have sharp corners which require appropriate personal protective equipment during
handling. Prior to any attempt to lift an item, employees must first determine the approximate weight and
stability of the load.
• Large, unstable, or awkward loads should always be handled with the assistance of additional personnel
or appropriate mechanical means.
• Loads in excess of 23kg (50 lb.) should only be lifted by appropriate mechanical means and in accordance
with current local legislation or with the assistance of additional personnel.
• Lifting items less than 23kg (50 lb.) may be prohibited without assistance if the lift is repetitive and/or
awkward (i.e., away from the body, above the shoulders or below the knees) thus placing excessive
stress on the personnel.
• Repetitive lifting of any kind should be evaluated as part of a documented end-user safety program.
2.4 Safety data sheets
The following instructions are designed to assist in unpacking, installing and performing maintenance as
required on Flowserve products. Product users and maintenance personnel should thoroughly review this
bulletin prior to installing, operating or performing any maintenance.
DANGER: In most cases Flowserve valves and actuators are designed for specific applications
(e.g., with regard to medium, pressure, temperature). For this reason, they should not be used in other
applications without first consulting the manufacturer.
2.5 Qualified personnel and targeted group
Qualified personnel are people who, on account of their training, experience and instruction and their
knowledge of relevant standards, specifications, accident prevention regulations and operating conditions,
have been authorized by those responsible for the safety of the plant to perform the necessary work and
who can recognize and avoid possible dangers.
2.6 Industrial health and safety measures
Follow industry safety standards including the use of appropriate equipment in required areas.

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2.7 Potential explosive areas
Consideration of Conformity with the Directive 2014/34/EU (ATEX)
The lined and metallic valves of the brands Atomac and Durco produced by Flowserve Ahaus GmbH have
been examined according to DIN EN 13463-1 to determine the danger of ignition. Potential sources of
ignition coming from the valve itself have not been ascertained. This result was confirmed by the
Bundesanstalt für Materialforschung und -prüfung (BAM – Federal Office for Material Research and
Testing).
The valves are intended for usage in areas where explosive atmosphere will be present from time to time.
As no internal sources of ignition were determined, the following statements are valid:
• The valves do not fall within the scope of the Directive 2014/34/EU.
• A corresponding marking is not permissible.
The specifications and instructions of the corresponding Installation and Operation Manuals have to be
obeyed. We would like to point out that potential sources of ignition resulting from operating conditions
and/or the used medium fall under the responsibility of the operating company. These potential dangers
can be minimized or possibly excluded in cooperation with Flowserve with suitable modifications on the
valve e.g., by using conductive lining materials to prevent static charging of the mediums during operation.
2.8 Protective equipment
FLOWSERVE products are often used in problematic applications (e.g., extremely high pressures,
dangerous, toxic or corrosive mediums). In particular valves with bellows seals point to such applications.
When performing service, inspection or repair operations always ensure, that the valve is depressurised
and that the valve has been cleaned and is free from harmful substances. In such cases pay particular
attention to personal protective equipment (PSA) (protective clothing, gloves, glasses etc.).
3 Product Description
3.1 General product description
The AKH3.2M & AKH3.2F are 2-piece fully lined ball valves designed to meet ASME B16.34 requirements.
The face to face is per ASME B16.10 – short pattern with flanges per ASME B16.5 class 150, RF. The
maximum temperature rating is 200°C, refer to our pressure / temperature and vacuum / temperature graph
for more details.
The valve is available in 2 designs:
• AKH3.2M - Monobloc Unit with 1-piece ball and stem.
• AKH3.2F - Floating Ball with 2-piece ball and stem.
Both options offer a tight shut-off per API 598 and DIN EN 12266-1 (leakage rate A):