Pig Ball Valve Maintenance & Safe Use Instructions

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API 6D Split Body Floating Trunnion Ball Valve API 6D Double Block and Bleed (DBB) Ball Valve API 6D Pig Ball Valve Launcher and Receiver API 6D Fully Welded Ball Valve High Pressure Wafer Type Ball Valve Burak Type Wafer Mono-Block Ball Valve Natural Gas Ball Valve EU Ball Valve High Pressure European Norm Ball Valve Cast Iron Water Ball Valve 3 Way Ball Valve Jacket Ball Valve

This Pig Ball Valve Maintenance guide summarises Batusan’s API 6D pig launcher and receiver valves: technical features, design and testing standards, the procedure for launching and receiving the scraper pig, and the 17-step maintenance procedure.

Pig Ball Valve, normally consists of Pig Launching & Pig Receiving valve, is a device for loading and receiving cleaning pigs and detecting tools to clean the internal pipe periodically, and it is especially widely used in Oil & Gas pipeline industry. The field tested pig valve offers durability, reliability service for oil and gas applications to improve the piping transportation efficiency. It can be easily and safely used with most of the popular pig styles, either one-piece molded pigs or the spherical pigs that are intended for use in pig ball valves.

Pig Ball Valve Maintenance and use instructions

Features

The technical features below set the scope of Pig Ball Valve Maintenance:

Dimensions: 2″ – 24″
Connection types: RF / RTJ
Working pressure: CLASS 150 / 300 / 600 / 900 / 1500 / 2500 (PN 20 / 50 / 100 / 150 / 250 / 420)
Working temperature: -29 °C…+180 °C / -46 °C…+180 °C
Operation: lever / gear box
Design standards: API 6D / ISO 17292 / ISO 14313 / ASME B 16.34
Dimensions and connections: ASME B 16.5
Fire-safe: API 6FA / API 607 / ISO 10497
Testing: API 6D / API 598 / ISO 14313
Isolation type: DBB / DBB-1 / DBB-2

Advantages over traditional pig launcher systems

Compared with a conventional launcher barrel, Pig Ball Valve Maintenance is simpler for the following reasons:

Smaller footprint reduces the space required for pigging facilities.
Simple configuration means a reduced requirement for infrastructure and decreases field construction time.
Less equipment and functionally simple design means fewer valves and controls to operate, minimizes training and Pig Ball Valve Maintenance costs.
Built-in features means safer operations for operations personnel and less man power.
Reduce emissions by more than 80% compared to traditional pig launching methods, saving the valuable medium.
Overall Pig Ball Valves allows cost savings ranging between 25% to 60% over traditional pig launcher and receiver systems.

Batu pig ball valve advantages

Batu Pig Valves can be customised to match customer requirements: customisable face-to-face lengths, customisable ball sizes to accommodate different pigs, or other special features can be implemented. Design details that make Pig Ball Valve Maintenance easier and safer:

Batu Pig Valves are CNC machined from forged steel.
Batu Pig Valves have oversized balls that accommodate longer pigs which allows wider range of pig selections.
Batu Pig Valves have a guide implemented to restrain pinching of the pig and to avoid obstructing of the system during loading.
Double Block and Bleed construction allows it to be used as a traditional block valve reducing the number of valves required in the pigging facility.
Designed in accordance to NACE for sour service.
Alternative materials are available for different conditions.
All Batu Pig valves are equipped with ROTORK gearboxes.
Batu Pig valves are constructed with 100% European origin materials and 100% manufactured in Turkish facilities.

Batu Pig ball valves have a top pressure releasing valve, have a bottom liquid and debris drain valve and most importantly have a visibly placed manometer to observe inside pressure during operation for extra safety measures. Grease injectors allow longer service life by making regular Pig Ball Valve Maintenance easier and can also be used for emergency sealant injection to seal leaks. Batu Pig ball valves also use a special guiding piece that ensures the pigs are not pinched during operation and provides smooth operation during use. Extra safety measures are taken to make the Batu Pig Valves leak free. Robust cap design allows easy and leak free operation.

Design and testing standards

Batu Valve is committed to safety and quality. Our pig valves conform to the design and testing standards below, and Pig Ball Valve Maintenance is carried out in accordance with them:

API (American Petroleum Institute) — SPEC. 6D Specification for Pipeline Valves · SPEC. 6FA Fire Test for Valves · STD. 607 Fire Test for Quarter-turn Valves and Valves Equipped with Nonmetallic Seats · STD. 598 Valve Inspection and Testing · SPEC. Q1 Specification for Quality Programs for the Petroleum and Natural Gas Industry
ANSI / ASME (American National Standards Institute / American Society of Mechanical Engineers) — B1.20.1 Pipe threads, general purpose · B16.5 Pipe flanges & flange fittings · B16.34 Valves – Flanged, Threaded and Welding End · B31.3 Process Piping
ISO (International Organization for Standardization) — ISO 9001 Quality Management Systems · ISO 15156 Materials for use in H2S containing environments in oil & gas production · ISO 10497 Testing of valves – fire type-testing
NACE (National Association of Corrosion Engineers) — MR0175 Materials for use in H2S containing environments in oil & gas production

Launching the scraper pig

Launching is the first operation covered by these Pig Ball Valve Maintenance instructions.

Before opening any fittings or removing the closure make sure the ball is in the closed position. Caution must be used when opening any fittings or the closure. Venting gases or draining the valve may be hazardous and care must be taken not to pollute the ground or atmosphere. Use proper safety precautions. When opening all vent fittings and drains, make sure to do it slowly.

- Step 1 — Close the pig valve to achieve positive shut off in both directions. Slowly vent the body cavity and watch the manometer to see the pressure drop to zero.
- Step 2 — Remove the entry cap, insert the pig into ball cavity.

- Step 3 — Reinstall the entry cap. Close all bleed valves and pressure releasing valves.
- Step 4 — Open pig valve. Flow and pressure moves the pig downstream.

Receiving the scraper pig

Receiving the pig follows the same Pig Ball Valve Maintenance safety rules:

Before opening any fittings or removing the closure make sure the ball is in the closed position. Caution must be used when opening any fittings or the closure. Venting gases or draining the valve may be hazardous and care must be taken not to pollute the ground or atmosphere. Use proper safety precautions. When opening all vent fittings and drains, make sure to do it slowly.

- Step 1 — Receive the pig. Slowly vent the body cavity and watch the manometer to see the pressure drop to zero.
- Step 2 — Close the pig valve to achieve positive shut-off in both directions.
- Step 3 — Remove the entry cap. Remove the pig from the ball cavity. Open the drain plug and remove the debris.

- Step 4 — Reinstall the entry cap. Close all bleed valves. Open the pig valve into the flowing position.

Operational configuration

The launcher and the receiver both come with baffles, which does not change the Pig Ball Valve Maintenance sequence. This way they can be used both in left side operational configuration or right side operational configuration. The drawings in the manual show the left to right flow direction with operation from the left side, in each case with a launching pig ball valve with baffle and a receiving pig ball valve with baffle.

Pig Ball Valve Maintenance instruction

The 17 steps below make up the full Pig Ball Valve Maintenance procedure.

- Step 1 — Turn the valve to the closed position by turning the handwheel.
- Step 2 — The pressure in the valve must be completely relieved. In order to release the pressure, the blind plug of the vent valve on the valve is removed and the pressure is released by opening the vent valve. You can see from the manometer on the valve that the pressure is completely relieved.
- Step 3 — Fully open the safety lock by turning it counterclockwise with the handle supplied with the valve. The safety lock is integrated into the locking mechanism.
- Step 4 — Remove the locking mechanism and open the drain valve at the bottom of the body and make sure that the valve is completely cleaned.
- Step 5 — Open the drain valve and make sure that the valve is completely cleaned.
- Step 6 — Insert the on-off lever on the side of the valve into the shaft on the body and make sure that the threads are engaged.
- Step 7 — Turn the opening-closing lever clockwise so that the pig cover can be opened.
- Step 8 — You can turn the flywheel at the top counterclockwise to open the lid securely.
- Step 9 — Pig Ball Valve Maintenance of the O-rings on the cover is of great vital importance. O-rings are checked carefully. If there is a wear, replace with a new O-ring. All sealing elements and machined surfaces must be checked to be clean by Pig Ball Valve Maintenance personnel. Cover O-rings and all machined surfaces must be lubricated with grease oil.
- Step 10 — It must be ensured that the closing surfaces on the body are clean. All machined surfaces must be carefully lubricated with grease oil.

- Step 11 — The quick-release lid is now ready to be closed. The staff should align the lid and start turning the flywheel clockwise.
- Step 12 — Carefully return the cover to the closed position by turning the opening-closing lever counterclockwise.
- Step 13 — Insert the locking mechanism back into the slot.
- Step 14 — Carefully check the ventilation seal on the safety lock. Replace the worn gasket with a new one. Insert the safety lock into the slot and turn it clockwise, tighten the safety lock with the help of the handle provided.
- Step 15 — Turn vent and drain valves to closed position and install blind plugs.
- Step 16 — You can lubricate the shaft by removing the housing of the lubrication nipple located in the throat of the valve. As part of annual Pig Ball Valve Maintenance, the drive shaft should be lubricated once a year. We recommend that you choose the type of oil according to the environment in which the valve is used. After the lubrication process is finished, put the housing back in place to keep the nipple clean.
- Step 17 — There are emergency sealing system nipples made of steel material on the covers on both sides of the valve. BATUSAN has designed all of its valves as fully sealed so that no additional sealing material is required. However, foreign and solid materials that may be present in the installation may enter between the sphere and seat and damage the sealing surfaces. In such a case, the problem can be temporarily eliminated by using VALTEK sealing material. The sealing material can be injected through the emergency sealing nipples located on both covers of the valve. This is the last step of Pig Ball Valve Maintenance.

About this Pig Ball Valve Maintenance guide

This page is a summary of Batusan’s Pig Ball Valve Maintenance instructions. For sizes, pressure classes and the valve family, see the API 6D pig ball valve launcher and receiver product page. For the general handling, storage, installation and periodic check procedures that apply to all Batusan ball valves beyond Pig Ball Valve Maintenance, see the API ball valve use and maintenance instructions.