KLINGER KHD-SGF Instruction manual

IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
Installation, Operation,
& Maintenance Manual
V-Notch Segment Ball Valve
KHD-SGF

IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 2
V-Notch Segment Ball Valve
KHD-SGF
Table of Contents
I Introduction
1.1 Contact Information
1.2 General Notes
1.3 Precautions and Warnings
1.4 Storage
II Installation
2.1 General Notes
2.2 Installation of Wafer Ends
2.3 Pneumatic and Electrical Connections
III Operation
3.1 Handling
3.2 Cleaning
3.3 Manual Operation
3.4 Remote Operation
3.5 Techinical Data
IV Maintenance
4.1 General Notes
4.2 Maintenance Frequency
4.3 Disassembly
4.4 Reassembly
4.5 Troubleshooting
4.6 Technical Data and Product Information
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4
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5
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7
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IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
V-Notch Segment Ball Valve
KHD-SGF
Chapter I
Introduction
The manual is provided to ensure proper installa-
tion, operation & maintenance for KHD-SGF, the
Wafer Type and Flanged V-notch Segment Ball Valve
with metal seat and soft seat, manufactured and
supplied 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 KLINGER Die Er-
ste Wafer Type and Flanged V-notch Segment Ball
Valve with soft seat and metal seat 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. User
should be aware of that excessive pressure and
temperature at nearby pipeline system can also
cause valve failure as well.
Wafer Type and Flanged V-notch Segment Ball
Valves are generally recommended for throttling
services as well as on-off functions.
Do not touch the valve surface when high tempera-
ture fluid is flowing through the valve.
Do not attempt to open the bonnet and the cap
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.
NOTE:
1. KHD-SGF Wafer Type and Flanged V-notch Seg-
ment Valves are installed between flanges. The
body is in one part; the shaft and segment ball are
separated.
2. The valve is either soft or metal seated. De-
pending on customers' requirement, the structure
of the supplied valve may be different.
3. The valve is designed for both control and shut-
off applications.
4. Actuators and accessories are only discussed
briefly. Please refer to individual manuals for fur-
ther information on their IOM manuals.
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

IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 4
V-Notch Segment Ball Valve
KHD-SGF
Chapter II
Installation
Flush the pipeline carefully before installing the
valve. The particles of dirt or debris or welding may
damage the segment sealing surface and seats.
Also, before installing, check all valve and mating
flanges to ensure gasket surfaces are free from de-
fects.
2.1 General Notes
1) Direction
The valves are designed with a preferred flow di-
rection. Install the valve according to the direction
marked on the valve body. Valve installed with re-
versed flow direction will not seal properly.
Figure 2.1 Flow Direction Indication
In the case of valve automation with actuators, in-
stall the valves with the actuator at or above the
centerline of the horizontal piping, as shown in Fig-
ure 2.1.
CAUTION:
Do not fasten supports to the flange bolting or the
actuator.
NOTE:
User should avoid installing the valve so that the
shaft point downwards because impurities travel-
ing in the pipeline may enter the body cavity and
damage the gland packing.
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.
Note:
1. The valve is delivered in the closed position. Be-
fore storing, check to see that the valve is in the
CLOSED position in order to avoid damage to the
seal.
2. The surface of the valves should be greased
properly for protection.
that the following safety precautions should be
taken when handling valves.
1) Always wear eye shields.
2) Always wear eye shields.
3) Always wear gloves and footwear.
4) Wear protective headgear.
5) Ensure that running water is readily accessible.
6) Fire extinguisher must be obtainable if media is
flammable.
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 connectors
which form an integral part of the pipeline and the
valve cannot be removed from the pipeline without
being dismantled- see DISMANTLING section for
reference.
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.

5
IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
V-Notch Segment Ball Valve
KHD-SGF
্্
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Figure 2.2 Proper position while piping
NOTE:
When installing horizontally, the support of the ac-
tuator must be strengthened to avoid valve leak-
age caused by valve stem deflection.
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.
3) Fittings
Select the correct size of fittings according to the
pipeline specification. Tighten the segment valve
to the pipeline adequately with appropriate bolts.
Do not attempt to correct pipeline misalignment by
means of flanged bolting.
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 wafer end surfaces as well to ensure
tight sealing.
2.2 Installation of Ends
1) Wafer End
1. Verify valve is in the fully OPEN position.
2. Use the appropriate size bolt and heavy hex nut
(not included) as recommended for flange size
and class.
3. Do not over tighten the joints bolting.
4. Place gasket on each flange connection (not in-
cluded).
5. Follow gasket manufacturer’s recommended
practice for tightening flange bolts.
2) Flanged End
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

IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 6
V-Notch Segment Ball Valve
KHD-SGF
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.
2.3 Pneumatic and Electrical Connections
When installing the actuator, make sure that the
valve-actuator combination functions properly. The
valve OPEN and CLOSED position are indicated by a
groove at the top of valve shaft. See Figure 2.2.
FLOW
FLOW
Figure 2.3 The top graph indicates an OPEN valve,
and the bottom one represents a CLOSED valve
If possible, install the valve so that the actuator can
be disconnected without removing the valve from
the piping.
Please refer to the appropriate instruction manual
shipped with the automation devices for the in-
stalled actuator, positioner, filter/regulator, solenoid,
and/or limit switches.
When making pneumatic connections, it is recom-
mended that PTFE tape or paste is used on thread-
ed joints, unless otherwise specified by the com-
ponents instruction manual. The pneumatic supply,
such as dry air or nitrogen, should be clean. When
making electrical connections, wiring of components
should be in accordance with any and all applicable
local and national codes and standards.
Before installing the actuator, use an adjustable
wrench to manually rotate the valve stem sever-
al times. This rotation breaks the torque that may
have built up during long-term storage.
NOTE:
When the valve is in a bare-stem state, be careful
not to rotate the valve ball OVER the FULLY OPEN
and FULLY CLOSED positions. Operation over the
positions may restrict the valve ball from returning
to the normal operation.

7
IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
V-Notch Segment Ball Valve
KHD-SGF
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 direction, 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.
3.1 Handling
During the segment 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 V-notch Segment Ball Valves
have ¼ turn operation opening in a counter-clock-
wise direction. When the handle is positioned across
the pipeline, this indicates that the valve is closed.
When the handle is positioned parallel with the
pipeline, this indicates the valve is open.
In cases where it is difficult to operate a manual
valve due to large torque requirements, it is recom-
mended to provide a gear operator for the valve.
The hand wheel on the gear box indicates the open-
ing and closing direction of the valve. Generally
speaking, the clockwise direction of the handwheel
is the closing direction, and the counterclockwise
direction is the valve opening direction. As shown in
Fig 3.2 below.
Figure 3.2 Handwheel Rotation Direction
for CLOSED and OPEN position of a gear box
NOTE:
Due to the spring structure, when manually oper-
ating the soft-seated segment ball valve, be sure
not to over-rotate the segment ball. Opening more
than 90 degrees may cause the segment ball to
deviate from the effective path of the spring, mak-
ing it impossible to use it normally.
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.

IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 8
V-Notch Segment Ball Valve
KHD-SGF
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.
3.5 Technical Data
3.5.1 Pressure-Temeprature Chart
Temperature (°F)
Temperature (°C)
Pressure ( psig ) Pressure ( barg )
250
300
200
150
100
50
350
20
10
15
5
25
50 150 250 350 450 550 650 750 850
0
50 100 150 200 250 300 350 400 450
0
0
PTFE PACKING
KHD-SGF-CL150
GRAPHITE PACKING
Temperature (°F)
Temperature (°C)
Pressure ( psig ) Pressure ( barg )
250
300
200
150
100
50
350
20
10
15
5
25
50 150 250 350 450 550 650 750 850
0
50 100 150 200 250 300 350 400 450
0
0
KHD-SGF-PN16
PTFE PACKING
GRAPHITE PACKING
3.5.2 Flow Coefficients
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
VALVE STROKE
NORMALIZED FLOW COEFFICIENTS
DN NPS Max. Kv Max. Cv
DN25 1" 23 27
DN32 1-1/4" 40 46
DN40 1-1/2" 60 69
DN50 2" 94 109
DN65 2-1/2" 145 168
DN80 3" 240 277
DN100 4" 403 466
DN125 5" 600 694
DN150 6" 668 772
DN200 8" 1473 1703
DN250 10" 1800 2081
DN300 12" 3256 3764
DN350 14" 5515 6375
DN400 16" 7292 8430

9
IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
V-Notch Segment Ball Valve
KHD-SGF
Chapter IV:
Maintenance
4.1 General Notes
Due to the nature of the control valve, the segment
ball valve has different maintenance requirements
than normal ball valves. When necessary, valves
may be refurbished using a minimal number of
components, and none of which require machining.
KLINGER Die Erste valves are designed for easy ser-
vice and assembly in the field.
The following aspects should, however, help to ex-
tend valve life.
CAUTION:
Do not dismantle the valve or remove it from the
pipeline while the valve is pressurized.
4.2 Maintenance Frequency
KLINGER Die Erste Segment Ball Valves must un-
dergo a scheduled inspection based on the appli-
cation. The maintenance frequency is determined
based upon the application of the valve. User should
consider the following factors when determining the
maintenance time interval: fluid type, flow velocity,
operation frequency, pressure, and temperature.
If the application requires intensive valve opening,
closing, and fine adjusting, then the valve should be
inspected frequently.
Note:
KLINGER Die Erste recommends inspecting the
valve at least every one (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.
4.3 Disassembly
1. Valve shall be positioned vertically by resting
body side flanges on clean ground surface (pref-
erably covered with rubber sheet).
2. Turn the valve to CLOSED position.
3. Remove the handle, lever or gear box if applica-
ble.
4. Loosen the BRACKET BOLTS (15) and detach
the BRACKET (16) from the mounting pad of the
valve.
5. Loosen the bottom bolts and remove the TRUN-
NION CAP (5) and THRUST WAHSER (4) out of
the valve.
6. Loosen GLAND NUTS (19) evenly, remove
GLAND (17), and remove GLAND STUDS (18)
from mounting pad of the valve.
7. Put the downstream end of the valve upward
and lay it flat on the desktop
8. Remove the pins locking between SEGMENT
BALL (8), UPPER STEM (13) and LOWER SHAFT
(2) either by grinding or using a spindle. Detach
the pins (7) by drilling.
Note:
Be careful not to damage the original bores of the
pins.
9. Place the valve on the table with the down-
stream end up. Use a flat-blade screwdriver
and soft hammer to push the UPPER STEM (13)
away from the SEGMENT BALL (8).
10. Pull the UPPER STEM (13) and V-Ring STEM
PACKING (14) out of the valve from the stuffing
box.
11. Push the LOWER SHAFT (2) from the ball cavity
away and the lower end of valve. At this time,
the SEGMENT BALL (8) can be taken out from
the downstream port of the valve.
CAUTION:
For the soft-seal valve seat, since there are sever-
al compression springs between the inner wall of
the upstream end and the segment ball, it should
be noted that when the lower shaft is removed,
the segment ball may pop out of the valve body
and cause personal injury.
Note:
Please make sure that the Segment Ball (8) is not
going to fall out of the valve and been damaged.

IOM-KHD-SGF-111_V1.4_EN
Copyright © 2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD. 10
V-Notch Segment Ball Valve
KHD-SGF
12. Inspect the Segment Ball (2) for any damages.
13. Put the upstream end of the valve up and lay
it flat on the table. Tap the METAL SEAT (10) or
SOFT SEAT RING (10A) on the upstream end of
the valve with a soft hammer to move it out of
the other end. Note that this step may cause
damage of the seat when it hits the tabletop.
Make sure that the tabletop is protected and
clean.
14. For metal-seated model, use a flat-blade screw-
driver to tick out SPRING (9); the upper and
lower BUSHINGS (3) can be hooked out to be re-
placed.
15. Replace the O-RING (11) on METAL SEAT (10) or
SOFT SEAT RING (10A) if necessary.
16. For soft-seated model, replace the SOFT SEAT
(10B) from the SOFT SEAT RING (10A).
17. Clean carefully and inspect all parts for wear
and damage. Make sure all gaskets and packing
residue is thoroughly cleaned before valve is re-
assembled. KLINGER Die Erste recommends all
sort parts should be replaced.
4.4 Reassembly
Before reassembly, inspect all the valve for any
damage on body and all internals.
Note:
Damaged internals to be replaced by KLINGER Die
Erste repair kits only.
1. Insert upper and lower BUSHINGS (3) from the
top of the stuffing box and the bottom of the
valve respectively.
2. Place O-RING (11) on the groove of SEAT (10)
and apply lubricating oil.
3. Put the downstream end of the valve upward
and lay it flat on the desktop.
4. For metal-seated model, put the MEAL SEAT
(10) with O-RING (11) into the valve cavity and
push it toward the upstream end for position-
ing. Put the SPRING (9) into the groove between
the SEAT (10) and the upstream end with nee-
dle-nose pliers.
5. For soft-seated model, put the SOFT SEAT RING
(10A) with compressed SPRINGS (9A), O-RING
(11) and SOFT SEAT (10B) into the valve cavity
and push it toward the upstream end for posi-
tioning.
6. Put the KEY (12) into UPPER STEM (13), and
check whether this KEY (12) is matching SEG-
MENT BALL (8), UPPER STEM (13). And lubricate
them.
7. Carefully insert the SEGMENT BALL (8) into the
valve cavity with the valve closed. At the same
time, push the UPPER STEM (13) with KEY (12)
from the stuffing box to match the valve stem
with SEGMENT BALL (8).
8. Push in the LOWER SHAFT (2) from the bottom,
tap the bottom of the valve stem lightly to align
the upper end of the LOWER STEM with the
lower hole plane inside the SEGMENT BALL, as
shown in the figure.
9. Tap the top of the UPPER STEM (13) to align the
bottom end with the upper hole plane inside the
SEGMENT BALL, as shown in the figure.
10. Lock the pins with UPPER STEM (13) and LOW-
ER SHAFT (2) to the SEGMENT BALL (8).
Note:
If the SEGMENT BALL (8) has been disassembled
by drilling before, please confirm the size of the pin
hole and use the corresponding PIN (7).
11. Put the inverted V-shaped PACKING (14) into the
stuffing box.
12. Screw the GLAND STUDS (18) into the valve
mounting flange. Install the GLAND (17) and fas-
ten the GLAND NUT (19).
13. Insert the TRUST WASHER (4) to the bottom of
the valve and install the TRUNNION CAP (5) with
the O-RING (6) with bolts.
14. Check that it is assembled correctly and in the
CLOSED position.
15. Install the BRACKET (20) to the valve with BOLTS
(15) and WASHER (16). Install the handle or au-
tomation devices if applicable.