CHAODA Pigging Ball Valve User manual

10633 W Airport Blvd. STE 200 Chaoda Group USA Co., LTD Tel: [phone]
Stafford, TX 77477 Fax: [phone]
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Chaoda Group USA Co., LTD
CHAODA Pigging Ball Valve
Installation & Operation Manual

10633 W Airport Blvd. STE 200 Chaoda Group USA Co., LTD Tel: [phone]
Stafford, TX 77477 Fax: [phone]
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Chaoda Group USA Co., LTD
Table of Contents
1. Prior to installation3
2. Installation ...................................................................................................................................... 4
2.1 Flange end valve installation......................................................................................................... 6
3. The operation, Launching and Receiving ........................................................................................ 9
3.1 Launching ....................................................................................................................................10
3.2 Receiving .....................................................................................................................................12
4. Maintenance .................................................................................................................................15
5. Hanging and Supporting................................................................................................................16
6. General Assembly Drawing ...........................................................................................................18
6.1 4’’ Pig valve .................................................................................................................................18
6.2 6’’ and above............................................................................................................................... 21
7. Troubleshooting............................................................................................................................24

10633 W Airport Blvd. STE 200 Chaoda Group USA Co., LTD Tel: [phone]
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Chaoda Group USA Co., LTD
CHAODA Pigging Valve Installation & Operation Manual
This manual provides relevant valve installation, operation, and maintenance
information. All drawings in this manual show standard general construction details.
1. Prior to installation
1. Upon receipt, each valve should be inspected for damage due to transportation and
handling.
2. All packing, packaging, and protection used for each valve should be maintained in
place until the time of installation.
3. End Flange and BW surfaces are properly protected at the factory. End protection
shall be maintained to avoid having foreign material entering the valve body cavity.
4. Make sure the piping system is clean before installing the valve into the pipeline.
Foreign materials, such as sand or welding items will damage the ball and seat ring
seating surfaces.
5. If the valve is stored for a long period of time, all bare surfaces should be coated with
anti-rust oil or lubricant. It is suggested to put the valve in a dry and well-ventilated
location. A valve stored for a very long time should be cleaned and re-pressure tested
before installation.
6. Pig Valve and all accessories MUST be suitable for the service conditions.

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2. Installation
1. It is highly recommended to install the pigging valve with the stem in the vertical
position.
2. Ensure the Pig Valve matches the nominal size and pressure rating of the piping
system.
3. Check and clean all sealing surfaces and they MUST be free of foreign materials or
damage.
4. Identify the ‘’launcher’’ / ‘’receiver” pigging valve and flow direction. On the marking
side of the body (opposite the closure) there is a flow arrow. If the catcher plate (An
indicated tag located on the flange) is installed on the body at the head (point) end
of the arrow it is a receiver valve and if the catcher plate is installed on the body at
the tail end of the arrow it is a launcher valve (please refer to the figure 1). Ensure
the correct flow direction.
5. The valve should be properly supported to not add weight or stress to the piping
system. The added valve weight can cause distortion of the pipeline and/or valve
body.
6. Do not attempt to correct pipeline misalignment by means of flange bolting
adjustments.
7. Do not allow the valves to carry the weight of the pipeline to avoid distortion and
jamming.
8. Pigging Valve MUST be installed in the “Fully Open” position.

10633 W Airport Blvd. STE 200 Chaoda Group USA Co., LTD Tel: [phone]
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The Catcher plate, Launcher and Receiver Options
Figure 1
2.1 Flange end valve installation
1. Make sure that both the flange gasket and fastener are suitable for field operation
2. Insert the valve (fully open position) along with suitable gasket between the mating
flange, align the flange bolt holes & hold it in place.
3. Hold the nut first on the backside of the valve flange and then insert the bolts
4. Tighten all the bolts by finger, use two spanners to tighten the joint in sequence as
shown in figure 2 (Corner across corner)

10633 W Airport Blvd. STE 200 Chaoda Group USA Co., LTD Tel: [phone]
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Bolting Sequence Chart
Figure 2

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3. The operation, Launching and Receiving
The below video shows the Chaoda Pig Valve demonstration.
Caution:
1. Flush the pipeline carefully once more when the valves are mounted to remove all
the possible impurities. Before, and during, flushing keeps the valve in open fully
2. Open and close the valve slowly to avoid the hammering effect on the valve pipeline.
3. Valves should be fully opened and fully closed to prevent damage to the seat and ball.
4. The valve is intended for on-off service only. It should not be used for throttling
service.
5. Chaoda Pigging valve is ninety degrees shut off the ball valve. Valves open by gear
operator handwheel in a counterclockwise and close by gear operator in a clockwise
direction
6. Care must be taken when opening any fittings, plugs or closure. Proper safety
procedures and (Personal Protective Equipment) PPE must be used. Do not pollute
the ground or atmosphere when open the drain valve. Open the fittings slowly and
do not face it directly.

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The Below video shows how to Open and Close the Closure/Entry Cap of Chaoda Pig Valve,
check it out first.
3.1 Launching
1. Fully close the pig valve by using the gear operator to achieve shut-off in both
directions. Slowly open the vent/drain fittings/valves located on the Body of the
valve.
2. Open the secondary safety needle vent/bleed valve located at the front of the
closure door. This will vent any excess pressure, releasing the mechanical stop, and
unlocking the closure door(entry cap).
For 4’’ pigging valve. Turn the handle to fully open the safety needle bleeder on
the closure. Then remove the locking bolt and closure. Only after these safety
devices have been removed (to make sure the cavity vented), the closure can be
opened by turning the handle.
For 6’’ and above pigging valve. Turn the handwheel to fully open the safety
needle bleeder on the closure. Only after these safety devices fully

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opened (to make sure the cavity vented), the closure can be opened by turning
the handle.
3. Open the closure door and insert the Pig.
Note: It won’t let you turn the handle to open the closure if the safety needle valve is
not fully opened.
4. Reinstall the closure -- align and adjust the closure with the entry bore, close it and
turn the handle to lock it. Then, fully close the secondary safety needle valve at the
front of the closure and the vent/drain fittings/valves on the body.
Note: Ensure the safety needle valve is fully closed before going to the next step.
5. Open the pig valve by using the gear operator and the pig will be launched
downstream.

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Launching
Figure 3
3.2 Receiving
1. The Pig enters the pig valve and it will be stopped by the catcher plate in the open
position.
2. Fully close the pig valve by using the gear operator to achieve shut-off in both
directions. Slowly open the vent/drain fittings/valves located in the Body of the valve.

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3. Open the secondary safety needle vent/bleed valve located at the front of the closure
door. This will vent any excess pressure, releasing the mechanical stop, and unlocking
the closure door(entry cap).
For 4’’ pigging valve. Turn the handle to fully open the safety needle bleeder on
the closure. Then, remove the locking bolt and closure. Only after these safety
devices have been removed (to make sure the cavity vented), the closure can be
opened by turning the handle.
For 6’’ and above pigging valve. Turn the handwheel to fully open the safety
needle bleeder on the closure. Only after these safety devices fully opened (to
make sure the cavity vented), the closure can be opened by turning the handle.
Note: It won’t let you turn the handle to open the closure if the safety needle valve
is not fully opened
4. Open the closure and remove the pig.
5. Reinstall the closure -- align and adjust the closure with the entry bore, close it and
turn the handle to lock it. Then, fully close the secondary safety needle valve at the
front of the closure and the vent/drain fittings/valves on the body.
Note: Ensure the safety needle valve is fully closed before going to the next step.
6. Open the pig valve by using the gear operator to resume line flow/receive the next
pig.

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Receiving
Figure 4

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4. Maintenance
1. After installation and the pressure test of the pipeline or the system, the ball must
be fully opened or fully closed.
2. Dust, grease and medium residual tend to accumulate at the surfaces of the body,
and moving parts such as stem, gearbox, the guide of the yoke, etc., wear and erode
the valve, and even generate friction heat that is dangerous in an explosive
atmosphere, and shall be cleaned frequently according to the working conditions.
3. After putting into service, the valve shall be checked and maintained periodically
especially for the condition of seating surfaces and, the age of packing, and the
corrosion of the body. In the event that sealing will be impaired, the valve shall be
repaired or replaced. It is suggested that the inspection and maintenance of the valve
shall be performed every three months provided the fluid is gas, water or oil. For other,
more abrasive media, at least once a month is recommended.
4. When performing Repair/maintenance operations, the user shall use valve O-rings,
gaskets, bolts, and nuts of the same size and material as the original ones. Valve O-
rings and gaskets may be (alignment of all of this)ordered as spare parts for
maintenance and replacement. It is forbidden to open the closure or replace the bolts,
nuts or O-rings when the valve contains pressure. After replacement of O-ring, gasket,
bolt, and nut, the valve shall be closure test prior to reuse.
5. If stem leak develops inject sealant via emergency sealant injection fitting. If the
stem leakage cannot be stopped then replace of stem packing is necessary.
6. If the body seal leak develops, do not overtighten the body end cover stud and nuts.
This may damage the valve. Instead, the body seal should be removed and replaced
by disassembling the affected end connection

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7. If the cover flange leak occurs, do not try to excessively tighten the body and bonnet,
this may damage the valve. Instead, the cover flange should be replaced by a new one.
5. Hanging and Supporting
Proper ways of lifting
Proper way of lifting Improper way of lifting
Figure 5

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Improper method of support Proper method of support
Proper method of support Proper method of support
Figure 6

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6. General Assembly Drawing
6.1 4’’ Pig valve

10633 W Airport Blvd. STE 200 Chaoda Group USA Co., LTD Tel: [phone]
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10633 W Airport Blvd. STE 200 Chaoda Group USA Co., LTD Tel: [phone]
Stafford, TX 77477 Fax: [phone]
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