KLINGER KHD-311FF Instruction manual

KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
3-Piece Flanged
Ball Valve
KHD-311FF
Installation, Operation,
& Maintenance Manual

KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 2
3-Piece Flanged Ball Valve
KHD-311FF
Table of Contents
Chapter I
Introduction
1.1 Contact Information 3
1.2 General Notes 3
1.3 Precautions and Warnings 3
1.4 Storage 4
Chapter II
Installation
2.1 General Notes 4
2.2 Installation of Ends 5
2.3 Pneumatic and Electrical Connections 5
Chapter III
Operation
3.1 Handling 6
3.2 Cleaning 6
3.3 Manual Operation 6
3.4 Remote Operation 6
Chapter IV
Maintenance
4.1 General Notes 8
4.2 Maintenance Frequency 8
4.3 Disassembly 8
4.4 Reassembly 8
4.5 Troubleshooting 9
4.6 Technical Data and Product Information 10

3
KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
3-Piece Flanged Ball Valve
KHD-311FF
Chapter I
Introduction
The manual is provided to ensure proper instal-
lation, operation & maintenance for KHD-311FF
3-Piece Flanged Ball Valve, manufactured and sup-
plied by KLINGER DIE ERSTE INDUSTRY CO., LTD.
The valves are identified by marking on the body or
on a name plate or both.
1.1 Contact Information
For information concerning warranties, or for ques-
tions pertaining to installation, operation or mainte-
nance of KLINGER Die Erste products, contact:
KLINGER DIE ERSTE INDUSTRY CO., LTD.
5F-1, No.936, Sec. 4, Wen-Xin Road,
Taichung City, Taiwan 406
Phone: [phone]
Fax: [phone]
Email: [email protected]
To order replacement parts, contact KLINGER Die
Erste sales at address listed above.
1.2 General Notes
The following instructions refer to KHD-311FF
3-Piece Flanged Ball Valve as described in the
KLINGER Die Erste current catalog.
Keep the protective covers in place until the valve is
ready for installation. Valve performance depends
upon prevention of damage to ball surface. After re-
moving the cover make sure that the valve is com-
pletely open and free of obstructions, dirt, particles
or any materials that may cause seat or seal dam-
age.
Valves may contain a silicon-based lubricant for
transportation, which aids in the assembly of the
valve. Lubricant may be removed with a solvent if
found objectionable. Alternatively valves can be or-
dered free of lubricants upon request.
Certain ferrous valves contain phosphate material,
and are oil dipped during the course of manufac-
ture. However, the processes used are completely
non-toxic.
1.3 Precautions and Warnings
Choose the correct material of valve for different
applications before obtaining the valve. The user
should be aware of the operating situation, fluid
properties, and the possible outcomes when imple-
menting valves into the pipeline system. KLINGER
Die Erste suggests that the user should make esti-
mation beforehand.
Fluid undergoes property changes with respect
to outside factors, particularly fluid left inside the
sealed cavity. When temperature and pressure ex-
ceed allowable value, valve failure may occur. De-
spite the KHD-311FF 3-Piece Flanged Ball Valve of-
fers the pressure-relief function to prevent pressure
buildups, users should be aware of that excessive
pressure and temperature at nearby pipeline sys-
tem can also cause valve failure as well.
The Series KHD-311FF 3-Piece Flanged Ball Valve
are generally not recommend for throttling services,
due to both fluid flow and ball leading edge may
damage or deform the resilient ball seats, and con-
sequently causing leakage problem. Further, high
fluid velocity or the presence of solid particles in
suspension will further reduce seat life in throttling
applications.
Do not attempt to remove the bonnet from the body
during operation, especially with the presence of
high pressure in the pipeline system.
For safety concern, unstable fluid should not be
used in the pipeline system, unless otherwise spec-
ified with the category III in Declaration of conformi-
ty.
CAUTION:
Before removing valve from pipeline, operator
should be aware of that: media flowing through
the valve may be corrosive, toxic, flammable, or
of a contaminant nature. Where there is evidence
of harmful fluids having flowed through the valve,
the utmost care must be taken. It is suggested
that the following safety precautions should be
taken when handling valves.
1) Always wear eye shields.
2) Always wear gloves and footwear.
3) Wear protective headgear.
4) Ensure that running water is readily accessible.
5) Fire extinguisher must be obtainable if media is
flammable.

KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 4
3-Piece Flanged Ball Valve
KHD-311FF
Chapter II
Installation
Flush the pipeline carefully before installing the
valve. The particles of dirt or debris or welding may
damage the ball sealing surface and seats. Also, be-
fore installing, check all valve and mating flanges to
ensure gasket surfaces are free from defects.
CAUTION:
Do not exceed the valve performance limitation.
CAUTION:
Before installing, make sure the line pressure has
been relieved, and any hazardous fluids have been
drained or purged from the system.
2.1 General Notes
1) Direction
Standard ball valves are bi-directionally sealed un-
less otherwise specified.
NOTE:
If requested, valves with upstream hole in ball are
one-way valves.
2) Position
The body, cap and gasket are in the connection area
of ball valve and pipeline. The bear weight ability
and gradient are very important to the pipe instal-
lation. Do not make the pressure from the pipeline,
and stress to concentrate on the connecting area of
body and cap. Ball, seat, and stem will be damaged.
Consequently, deformation and leakage may occur.
NOTE:
Most of the valves do not restrict the flow direction
when installing the KHD-311FF. However, KLINGER
Die Erste suggests vertical or horizontal position to
maximize sealing and reduce the accumulation. In
the case of vertical installation, upstream pressure
should be located above, since in the floating ball
design, the ball helps the sealing effects.
3) Fittings
Select the correct size of fittings according to the
pipeline specification. Tighten the valve to the pipe-
Check the line gauge to ensure that no pressure is
present at the valve. Ensuring media is released by
operating valve slowly to the half open position.
Ideally, the valve should be decontaminated when
the ball is in the half open position.
These valves, when installed, have body connec-
tors which form an integral part of the pipeline
and the valve cannot be removed from the pipeline
without being dismantled.
1.4 Storage
If the valves are not to be installed immediately,
please store the valve carefully before installation,
preferably indoors in a dry and clean place.
Also, the valve ports should be sealed by plastic
caps to prevent dirt from entering and damaging in-
ner parts.

5
KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
3-Piece Flanged Ball Valve
KHD-311FF
line adequately with appropriate threads or bolts.
Do not attempt to correct pipeline misalignment by
means of flanged bolting.
Note:
Over tightening of any side may cause leakage.
4) Systems hydrostatic test
Before delivery, valves are tested 1.5 times the al-
lowable pressure at ambient temperature in OPEN
position. However, after installation, the piping sys-
tem may subject to system tests, as condition not
to exceed the marking pressure.
5) Pre-Installation Wash
Before the valve installation, clean the pipeline sys-
tem to remove any foreign deposits by water. Clean
the connecting flanged end surfaces as well to en-
sure tight sealing.
2.2 Installation of Flanged Ends
1. Before installing the valves, make sure the
flanges and the pipe are free from grit, dirt or
burrs.
2. The flanges must be aligned and parallel with
the correct distance to allow the valve face-to-
face dimension and gaskets to fit between.
3. Tighten the flange bolts in a crossover pattern,
with a torque values determined by the gasket
manufacturer, other variables like gasket type
and material, bolt, flange and lubricant affect the
tightening torque values.
4. Note that the bolts tightening must be uniform
in order to create a parallel movement of the
two flanges and uniform deformation of the
gasket in between them.
5. Before pressure testing the valves, bring the
valves to the half OPEN position to ensure pres-
sure reaches the stem seals and to avoid unnec-
essary loading of the seats. Fail-to-close actu-
ated valves should be brought to the half-OPEN
position.
NOTE:
Do not fasten supports to the flange bolting or the
actuator.
2.3 Pneumatic and Electrical Connections
Due to the design structure of the valve, we don’t
recommend the valve is applied to actuation auto-
mation. If frequent ON/OFF operation is required
in the application of the valve, please contact your
KLINGER Die Erste personnel.
Also, if the valve has been installed online without
handle or lever, please identify the ON/OFF status
of the valve according to the indication of the top of
stem as Figure 2.1.
Figure 2.1 The top graph indicates an OPEN valve, and the
bottom one represents a CLOSED valve
OPEN
CLOSE

KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 6
3-Piece Flanged Ball Valve
KHD-311FF
Chapter III
Operation
For manual operation, shift the handle in clockwise
direction for CLOSED and counter-clockwise for
OPEN.
If the handle is in parallel position with the flow di-
rection, the valve is OPEN. If the handle is in right
angle position with the flow direction, the valve is
CLOSED.
When installing actuator or the valve is operated
with removable handle, the user should ensure the
position of the valve whether open or close. The line
on the top of the stem indicates whether the valve
is in OPEN or in CLOSED position. Figure 2.1 and the
below Figure 3.1 provides the visual understanding
of above explanation.
Figure 3.1 Rotation Direction for
CLOSED and OPEN position
3.1 Handling
During the ball valve installation, it must follow the
procedure to handle at the both side of the bodies.
If using cable for big size valve, make sure the cable
must be strong enough to ensure the safety during
the installation.
Never lift the valve package by the actuator, posi-
tioner, limit switch or their piping. The Valve damage
or personal injury may occur from falling parts.
3.2 Cleaning
Even though the valves were transported under a
clean environment, operator must check if there
is any foreign body or dusts inside the bore. If
yes, clean the valve before installation. Operator
may clean the valves by water, compression air, or
steam. However, valve automation devices shall be
cleaned only with water or steam, using compres-
sion air to clean the valve automation devices is
strictly prohibited. For cleaning operation, first step
is put the valve bore perpendicular to the ground
and clean, ensure all the dusts are be removed from
the bore. The second step is to check and clean all
the connecting pipe bore and connection area. No
flush, rust and foreign bodies are allowed to avoid
the blocking and leakage.
3.3 Manual Operation
KLINGER Die Erste KHD-311FF 3-Piece Flanged
Ball Valve have ¼ turn operation opening in a count-
er-clockwise direction. When the handle is posi-
tioned across the pipeline, this indicates that the
valve is closed. When the handle is positioned paral-
lel with the pipeline, this indicates the valve is open.
3.4 Remote Operation
Where manual operation is not required, valves may
be automated for remote operation, instrument
controls etc. KLINGER Die Erste offers a wide range
of pneumatic and electric actuators for different
working conditions.
When an actuator is used, no stop plate is fitted
to the valve since end stops are an integral part of
the actuator. Operation will be in accordance with
KLINGER Die Erste Installation, Operation and Main-
tenance Instructions for the relevant actuator.
CLOSE
OPEN
FLOW
FLOW

7
KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
3-Piece Flanged Ball Valve
KHD-311FF
CAUTION:
Keep hands, other parts of the body, tool and oth-
er objects out of the open flow port. Leave no for-
eign object inside the pipeline. When the valve is
actuated, the ball segment act as a cutting device.
Also, the segment position may change when the
valve is moved. The failure may result in damage
or personal injury.

KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 8
3-Piece Flanged Ball Valve
KHD-311FF
4.3 Disassembly
CAUTION:
Pipeline and valve must be depressurized by shut-
ting off the valve and bleed line, cycle the valve
once and leave it half open to relieve the pressure
from the body cavity.
1. Depressurized and empty the seal up fluid in the
cavity before disassembly. Be cautious of the
fluid inside the valve as they can be poisonous
and flammable.
2. Valve shall be positioned vertically by resting
body side on clean ground surface, preferably
covered with rubber sheet. Shift the Handle (13)
so the valve is in the partial close position; oth-
erwise, the valve ball cannot be removed from
the bore later.
3. Remove the Handle (13) by removing the Handle
Nut (11) and Handle Washer (10).
4. Loosen the Body Bolt Nuts (17) in diagonal pat-
tern and remove one of End Caps (2) from the
Body (1).
5. Remove the Body Seal (5) and Ball Seat (4) and
then the Ball (3) from the Body.
6. Remove the other End Cap (2), Body Seal (5) and
Seat (4).
7. Loosen and Remove the Gland Nut (9).
8. Remove the Stem (6) from the side of body by
pushing it from the top.
9. Remove Thrust Washer (7) from the Stem.
10. Remove Stem Packing (8).
11. All the components should be stored in a clean
place.
4.4 Reassembly
Before reassembly, inspect the valve for any dam-
age on body and all internals. Damaged internals
can be replaced by genuine KLINGER Die Erste valve
part from the service kit.
1. Follow the same step as point 1 mentioned in
Section 4.3.
2. Apply suitable coat to Bolts (14) to prevent from
corrosion.
3. Insert the Thrust Washer (7) thru the Stem (6).
4. Install the Stem (6) from inside the Body (1).
Chapter IV
Maintenance
CAUTION:
Do not dismantle the valve or remove it from the
pipeline while the valve is pressurized.
4.1 General Notes
With Self-wipe ball, seats, and pressure equalizing
slots, KLINGER Die Erste valves have a long, trou-
ble-free life, and maintenance is seldom required.
However, when necessary, valves may be refur-
bished, using a minimal number of components,
none of which require machining. The valves are de-
signed for easy service and assembly in the field.
Before maintenance, user should check availability
of the service kits for KHD-311FF 3-Piece Flanged
Ball Valve. We strongly recommend using the genu-
ine service kit produced directly from the manufac-
ture facility. For more information, please contact
your KLINGER Die Erste representatives. Service
kits may be available locally; however, KLINGER Die
Erste is not responsible for any of the valve damage
caused by using non-genuine spare parts.
4.2 Maintenance Frequency
The maintenance frequency is determined based
upon the application of the valve. User should con-
sider the following factors when determining the
maintenance time internal: fluid type, flow velocity,
operation frequency, pressure and temperature.
Note:
For the KHD-311FF 3-Piece Flanged Ball Valve,
KLINGER Die Erste recommends inspecting the
valve at least every (1) year.
Note:
Please use the original spare parts to ensure the
valve functions well.
Note:
When sending back the valve to KLINGER Die Er-
ste for investigation, do not disassemble it. Clean
the valve carefully and flush the valve internals. If
possible, inform us about the medium used in the
valve.

9
KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
3-Piece Flanged Ball Valve
KHD-311FF
5. Insert the Stem Packing (8).
6. Tighten the Gland (9).
7. Align Stem (6) parallel with the body bore.
8. Gently slide the Ball (3) over the Stem (6) so that
the stem and the ball are interlocked.
9. Insert Ball Seats (4) and Body Seal (5) in position
on both side of Body.
10. Position Body Bolts (15) then assemble the
valve by putting End Caps (2) to two side of Body
(1) together with the center piece.
11. Insert Washers (16) and Nuts (17) then tighten
the Nuts (17).
12. Place the Handle Washer (10) and the Handle
(13) on the Stem (6) and tighten the Handle Nut
(11).
13. Ensure smooth operation of valve during open-
ing and closing.
4.5 Troubleshooting
The following table lists the possible malfunctions.
Table 4.5 Troubleshooting Table
Symptom Possible fault Actions
Leakage through a
closed Valve
(Internal Leakage)
Damaged ball sur-
face Replace the ball
Damaged seats Replace seats
Ball might not be
fully closed Realign the ball
Irregular ball move-
ment
Fluid accumulated
on the surface.
Flush the ball from
inside
Ball or seat dam-
aged
Clean or replace the
ball or seat
Valve leaking from
stem
(External Leakage)
Stem nut are loos-
ened
Tighten the stem
nut
Parts are worn or
damaged
Replace the neces-
sary parts
Valve leaking from
body and cap joint
(External Leakage)
Damaged or break-
age of gasket Replace gaskets
Relaxation of studs
due to gasket creep
Re-tighten the
studs evenly
Valve too hard to
operate
Damaged seats Replace seats
High pressure Confirm the pres-
sure rating
Foreign particles in
valve Clean the internals

KIOM-KHD-311FF-112_V2.1_EN
Copyright © 2023 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 10
3-Piece Flanged Ball Valve
KHD-311FF
4.6 Technical Data and Product Information
NO PART NAME MATERIAL
1 Body 1.0619 / 1.4308 / 1.4408
2 Cap 1.0619 / 1.4308 / 1.4408
3 Ball 1.4308 / 1.4408
4 Ball Seat PTFE / MG1241
5 Body Seal PTFE / MG1241
6 Stem SS316
7 Thrust Washer PTFE / MG1241
8 Stem Packing PTFE
9 Gland SS304
10 Handle Washer SS304
KHD-311FF
NO PART NAME MATERIAL
11 Handle Nut SS304
12 Locking Device SS304
13 Handle SS304
14 Handle Sleeve PLASTIC
15 Body Bolt SS304
16 Body Bolt Washer SS304
17 Body Bolt Nut SS304
1
2
13
7
10
17
3
15
16
4
14
9
12
6
11
8
5