7
IOM-KHD-21E(a)-110_V1.1_EN
Copyright
©
2022 by KLINGER DIE ERSTE INDUSTRY CO., LTD.
Standard 2-Piece Ball Valve
KHD-21E(a)
IOM-Series 21E(a)-110_V1.1_EN
Copyright
©
2021 by DIE ERSTE INDUSTRY CO., LTD.
6
Standard 2-Piece Ball Valve
Series 21E(a)
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.
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 Series 21E(a) Standard 2-Piece
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
The Series 21E(a) ball valve is designed for man-
ual use instead of pneumatic or electric actuation
without notification. If requests, please consult your
KLINGER DIE ERSTE representative for more infor-
mation.
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.
4.3 Disassembly
1. Depressurized and empty the seal up fluid be-
fore disassembly. Be cautious of the fluid inside
the valve as they can be poisonous and flamma-
ble.
2. Valve should be positioned vertically by resting
body side on clean ground surface, preferably
covered with rubber sheet.
3. Shift the HANDLE (13) so the valve is in the close
position; otherwise, the valve BALL (3) cannot be
removed from the bore later.
4. Remove the HANDLE NUT(11), HANDLE WASH-
ER (10) and the HANDLE (13).
5. Remove the side CAP (2) .
6. Remove the GASKET (6) and SEAT (4).
7. Remove the BALL (3) and the other SEAT (4)
from the BODY (1).
8. Remove the STEM (5) by removing GLAND (9) as
applicable.
9. Push the STEM (3) into the bore and remove it.
10. Remove all stem PACKINGS (8).
11. Remove the THRUST WASHER (7) from the
STEM (5)
12. All the components should be stored in a clean
place.
Note:
Damaged internals to be replaced by KLINGER DIE
ERSTE repair kits only.
4.4 Reassembly
Before reassembly, inspect the valve for any dam-
age on body adaptor and all internals. Note that
after the welding has been broken, it cannot be put-
ting back function.
1. Follow the same step as point 2 mentioned in
Section 4.3.
2. Insert the body SEAT (4) in position.
3. Insert the THRUST WASHER (7) on the STEM (5),
Chapter IV:
Maintenance
4.1 General Notes
With Self-wipe ball and seats, KLINGER DIE ERSTE
valves have a long, trouble-free life, and mainte-
nance is seldom required. However, when neces-
sary, valves may be refurbished, using a minimal
number of components, none of which require ma-
chining. The valves are designed for easy service
and assembly in the field.
Before maintenance, user should check availability
of the service kits for Series 21E(a) Standard 2-Piece
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 dam-
age 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 Series 21E(a) Standard 2-Piece 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 ERSTE for investigation, do not disassemble it.
Clean the valve carefully and flush the valve inter-
nals. If possible, inform us about the medium used
in the valve.
CAUTION:
Do not dismantle the valve or remove it from the
pipeline while the valve is pressurized.
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.
and lastly install the STEM (5) from inside the
BODY (1).
4. Insert the stem PACKINGS (8) and ensure proper
locking of stem with GLAND (9).
5. Align STEM (5) parallel with the body bore.
6. Gently slide the BALL (3) over the STEM (5) and
rotate the BALL (3) so that they are interlocked.
7. Place GASKET (6) and SEAT (4) on the CAP (2).
8. Assemble the valve by putting end CAP (2) on
the BODY (1), tighten the CAP (2). Perform weld-
ing between the end cap and the valve body if
necessary.
9. Place the HANDLE (13), HANDLE WASHER (10)
and HANDLE NUT (11) on the STEM (5). Tighten
the HANDLE NUT (11) with HANDLE WASHER
(10) to secure the HANDLE (13).
10. Ensure smooth operation of valve during open-
ing and closing.
4.5 Troubleshooting
The following table lists the possible malfunctions.
Table 4.1 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
