Sees Au Asou Picewe eee The design of pipelines and facilities for conventional and intelligent pigging and a guide to pig selection, operation and maintenance and to pipeline pigging services 5 Jim Cordell, C.Eng, M.I.MechE. & Hershel Vanzant, ConsultantAu Asout Picea First Edition Published August, 1995 Reprinted February 1996 Reprinted April 1996 Reprinted September 1996 Reprinted January 1997 ¢ Second Edition August 1997 ; Third Edition August 2000 Published by: On-Stream Systems Ltd, P O Box 66, Cirencester, Gloucestershire. GL? ZF. UK. ‘Telephone: (44) 1265 65006] ~ Fax: (44) 1285 650008 and Hershel Vanzant & Associates, Consulting Engineers, 141 Claremore, OK 74017, USA. Telephone: (1) (918) 341 6601 ~ Fax: (1) (18) 343 9409 Choctaw Pi. Copyright © 1995 - On-Stream Systems Limited and Hershel Vanzant & Associates All rights reserved. No part of this publication may be reproduced, stored in a retrteval system or transmitted in any form or by any means electronic, mechanical or by photocopying, in whole or in ‘part, without permission of the publishers ISBN 0 9526448 2 7 ~ 3 revised and updated edition (SBN 0 952448 1 9 - 2" edition SBN 0 9526448 0 0 ~ 1" edition)oper f See ping ete Mids Au. Asout Picame IMPORTANT NOTICE, ‘The purpose of this publication is to inform the reader of general pigging practices in moder pipeline operations. It is not intended to be an instructional manual, but rather a general guide to pigs and Pigging practices. In general, the practices outlined in this book will be applicable up to 2 point; but inthe final analysis, specific programs will have to be tailored to meet the specific purpose, the line conditions and company operating policies and procedures iitAu Asourt Picea FOREWORD ‘This manual is an invaluable source of information for all those involved with pipeline design, construction, operation and maintenance and covers every aspect of pipeline pigging in a logical and easy to use format. It will provide guidance for the design of pipelines and pigaing systems, as well as for the selection and operation of all types of pipeline pigs. However, because every pipeline contains certain unique features, this manual is, not intended to be, neither must it be considered as, a definitive work on the subject. It is a guide only and independent professional advice must be obtained before ‘making a commitment to any particular course of action, ‘The Publishers would welcome any suggestions which, in the opinion of the reader, would make future editions of the manual more ‘user friendly’ About the authors: Jim Cordell has been actively involved with pipeline pigging, maintenance and inspection since the mid 1960's at both practical and managerial levels. He founded On- Stream Systems Ltd, in 1985 to provide completely impartial consulting services on all matters relating to pipeline pigging. In 1990 he founded the Pigging Products & Services Association (PPSA), and has served as its Executive Secretary ever since. Virtually all of the major pigeing related companies throughout the world are now Members of PPSA. the contact details for which will be found in the appendices. Hershel Vanzant worked 38 years for one of the world’s leading pipeline equipment manufacturers. He worked in the Engineering, Research and Management areas of the company. During his years in the Research Department he designed and assisted with the design and testing of pigs and related pigging equipment. He also traveled to many areas of the world 10 work onsite assisting pipeline operators with their pigging applications, In 1996 he started his consulting services concerning pigging and other pipeline maintenance applications.Au. Asout Picene CONTENTS 1.0 BACKGROUND 2.0 THE PURPOSE OF PIGGING 2.1 WHY PIG A PIPELINE? 2.1.1 Safeguarding assets and optimizing efficiency 2.1.2 Regulations, Safety and the Environment 2.1.3 Practical needs 2.2 PIGGING DURING PIPELINE CONSTRUCTION 2.2.1 General 2.2.2 Cleaning 2.3 ACCEPTANCE TESTING 2.3.1 Gauging 2.3.2. Hydrostatic testing 2.4 PRE-COMMISSIONING 2.4.1 Dewatering He 2.4.2 Drying 9 2.5 COMMISSIONING 2.5.1 Water pipelines 2.5.2 Products pipelines 2.5.3 Natural gas pipelines 2.5.4 Crude oil pipelines 2.5.5 Other pipelines 2.6 BASE LINE SURVEYS 2.7 OPERATIONAL PIGGING 2.7.1 Water pipelines 2.7.2 Products pipelines 2.7.2.1 Cleaning 2.7.2.2 Products Separation 2.7.3 Natural Gas pipelines 2.7.3.1 Cleaning 2.7.3.2 Swabbing 2.7.3.3 Batch Inhibition 2.7.4 Cade Oil pipelines 2.7.4.1 Cleaning 2.7.4.2 Batching 2.7.5 Plant Piping systems 2.75.1 Cleaning 2.7.5.2 Swabbing, Separating, Batching 2) 2.8 INLINE INSPECTIONAut Asout Picane 3.0 PIPELINE DESIGN FOR PIGGING 3.1 PIPELINE DIMENSIONS 3.1.1 Length 3.1.2 Diameter and Wall Thickness 3.1.3 Dual diameter pipelines PIPELINE MATERIALS 3.2.1 Base materials 2.2 Linings 3.2.3 Coatings 3.3 BENDS 3.3.1 Forged bends Field bends 3.3 Miter bends 3.4 OFFTAKES 3.4.1 Unbarred tees 3.4.2 Barred tees 3.4.2 Sphere or Flow tees 3.4.4 Laterals 3.5 WYE JUNCTIONS Convergence angle 3.5.2 Bores 3.6 DIVERTERS 3.7 VALVES 3.7.1 Inline block valves 3.7.2 Check valves 3.8 RELATIVE POSITION OF FEATURES 3.9 FLEXIBLES 3.10 BUNDLES 3.11 OPERATING CONDITIONS 3.11.1 Product 3.112 Pressure 3.11.3 Temperature 3.11.4 Fluid velocity’ or flow rates 4.0 PIG STATIONS 4.1 BASIC CONFIGURATION 2 LAUNCHING TRAP DESIGN and DIMENSIONS 4.2.1 For wtlity pigs For in line inspection tools For spheres 4.3 RECEIVING TRAP DESIGN and DIMENSIONS For utility pigs For in line inspection tools, For spheres 4.4 PIG TRAP CLOSURES viAu Asour Piconc 44.1 Basic types 4.4.2 Closure design 4.4.2.1 Safety 4.4.2.2 Operation 4.4.2.3 Protection 44.24 Seal 44.25 Hinges 4.43 Installation 4.4.4 Selection 44.4.1 Safety 4.4.4.2 Operability 4.4.4.3 Maintainability 44.4.4 Adaptability 4.5 PIPEWORK LAYOUT and CONNECTIONS 4.5.1 Kicker and bypass connections 4.5.2 Drain Points 4.5.3 Pressure balance 4.54 Signalers 4.5.5 Vents or blow down piping 4.5.6 Optional connections 45.6.1 Purge 4.5.6.2 Injection point 4.5.6.3 Valve bypasses 4.5.6.4 Instrumentation connections 4.6 AUTOMATIC PIG LAUNCHING AND RECEIVING 4.7 PIG HANDLING 4.7.1 Handling area 4.7.2 Lifting equipment 4.7.3. Access 4.7.4 Safety 4.8 OFFSHORE - TOPSIDES 4.9 OFFSHORE - SUBSEA 5.0 UTILITY PIGS 5.1 DESCRIPTIONS 5.1.1 Mandrel cleaning pigs 5.1.2 Mandrel sealing pigs 5.1.3 Foam pigs 5.14 Solid cast pigs 5.1.5 Spheres 5.2 PIG DESIGN 5.2.1 Pig body 5.2.2 Cups and seals 5.2.2.1 Materials 2 Design 5.2.3 Bypass ) 324 Canny clones vilAut Asour Picene 5.3 PIG SELECTION 5.3.1 The Selection Process 5.3.1.1 Setting the Objective 5.3.1.2 Operational Conditions 5.3.1.3 The Pipeline 5.3.1.4 Selecting the Pig 5.3.2 Pig Selection for Construction 5.3.3 Pig Selection for Maintenance 5.3.4 Pig Selection for Surveys 5.4 PIG MAINTENANCE and STORAGE 54.1 Cleaning 5.4.2 Maintenance 5.4.2.1 Disassemble and inspect 3.4.2.2 Cups and Seals 5.4.2.3 Cleaning Elements 5.4.2.4 Body, Springs and other metal components 5.4.3 Storage 3.4.3.1 Pigs 5.4.3.2 Metal Components and Spares 5.4.3.3 Elastomer Components and Spares 6.0 PIGS FOR MAINTENANCE and REPAIF. 6.1 MAGNETIC (FERROUS DEBRIS) PIGS 6.2 PLUGGING or ISOLATION PIGS 6.2.1 History and development 6.2.2 Design Considerations 6.2.2.1 Pipeline Diameter 6.2.2.2 Working Pressure 6.2.2.3 Pipe Wall Thickness 6.2.2.4 Pipe Wall Condition 6.2.2.5 Weld Bead 6.2.2.6 Pipe Content 6.2.2.7 Control Systems 6.2.3 Existing plugging pigs 6.2.3.1 IPSCO Plugging Pig HydroTech 'HydroPhig" ‘TeenoMarine Systems Plugging Pig Pipeline Products & Services 'PAPlug 6.3 HYPERBARIC SPHERES 64 HIGH DP AND SECONDARY BARRIER PIGS. 6.4.1 High DP pigs 6.4.1.1 BJ Pipeline Inspection Services 6.4.1.2 Inpipe Products 6.4.1.3 Acurite ‘ARC’ sphere 6.4.2 Secondary Barrier pigs viii ig Ab ate eaeAut Asour Picanc 2) 6.5 SOLUBLE PIGS 6.6 OTHER SPECIALIST PIGS 6.6.1 Pressure by-pass pig 6.6.2 Pin-wheel pig 6.6.3 Shunting pig 6.64 Spray pig 7.0 GEL PIGS AND PIGGING 7.1 FLUID GELS 7.1.1 Sealing and Separation gels 7.1.2 Debris pick-up and Cleaning gels { 7.1.3 Carrier and inhibitor gels - 7.2 PRE-CAST GEL PIGS 7.3 SPECIAL GEL "PIGS" 7.3.1 Plugging gels 7.3.2 GELBLOK Valve Sealant 7.3.3 Foamed fluids 8.0 IN-LINE INSPECTION PIGGING 8.1 GENERAL 8.2 METAL LOSS SERVICES o 8.2.1 General ) 8.2.2 Technologies 8.2.2.1 Magnetic flux leakage (MFL) 8.2.2.2 Ultrasonics (UT) 8.2.2.3 Eddy currents 8.2.3 Services using MFL tools 8.2.3.1 Linalog (Tuboscope Vetco Pipeline Services) 8.2.3.2 MagneScan (Pipetronix GmbH) 8.2.3.3 Corrocontrol (TRAPIL) 8.2.3.4 Corrosion Detection System - “CDS” (H Rosen Engineering GmbH) 8.2.3.5 On-line Inspection (OLI) Pig (BG-Pipeline Integrity Intemational) 8.2.3.6 MFL Inspection Tool (BJ Pipeline Inspection Services) 8.2.3.7 Picolo tool (3P Services GmbH) 8.2.4 Services using UT tools 8.2.4.1 UbraScan WM@Pipetronix GmbH) 8.2.4.2 Ultrasonic Inspection Tool (NKK Corporation) 8.2.4.3 Ultrasonic Too! (BI Pipeline Inspection Services) 8.2.5. Services using Eddy Current tools 8.2.5.1 "Corrolog" (Syminex) 8.2.5.2 Internal Corrosion Pig - "ICP" (H Rosen Engineering GmbH) 8.3 GEOMETRY SERVICES 8.3.1 General 8.3.2 Technologies 8.3.2.1 Electro-mechanical ixs Aut Asout Picome 8.3.2.2 Eddy currents 8.3.3 Services using electro-mechanical tools 8.3.3.1. "Kaliper" Pig (TD. Williamson Inc.) 8.3.3.2 CalScan (Pipetronix GmbH) 8.3.3.3 Electronic Gauging Pig (Enduro Pipeline Services Inc.) 8.3.3.4 Geocontrol (TRAPIL) 8.3.3.5 Deformation/slope Tool (Tuboscope Vetco Pipeline Services Inc.) 8.3.3.6 Inertial Geometry Pig - GEOPIG (BJ Pipeline Inspection Services) 8.3.4 Service using Eddy current tools 8.3.4.1 EGP (H Rosen Engineering GmbH) 8.4 CRACK DETECTION 8.4.1 General 8.4.2 Technologies 8.4.3 Services using UT tools 8.4.3.1 SCC (BG Pipetine Integrity Intemational) 8.4.3.2 UltraScan CD Pipetronix GmbH) 8.5 PROFILE MONITORING AND MAPPING 8.5.1 General 8.5.2 Technologies 8.5.2.1 Gyroscopes 8.5.2.2 Pendulums 8.5.3 Services using gyroscopic tools 8.5.3.1 Inertial Geometry Geopig Pig (BJ Pipeline Inspection Services! 8.5.3.2 ScoutScan Pig (Pipetronix GmbH) 8.5.4 Service using other technology 8.5.4.1 Deformation/stope Tool (Tuboscope Vetco Pipeline Services Inc.) 8.6 LEAK DETECTION AND LOCATION 8.6.1 General 8.6.2 Technologies 8.6.2.1 Ultrasound 8.6.2.2 Metering 8.6.23 Radioactive tracers 8.6.3 Service using ultrasound 8.6.3.1 MLD (H Maihak AG) 8.6.3.2 LeakScan (Pipetronix GmbE) 8.6.3.3 Leak Detector Pig (EDAG) 8.6.4 Service using flow meters 8.6.4.1 Leak Detection Pig-LDP (H Rosen Engineering GmbH) 8.6.5 Service using radioactive tracers 8.6.5.1 Leak Detection System (ICI Tracerco Ltd.) 8.7 BEND MEASUREMENT 8.7.1 General 8.7.2 Technologies 8.7.2.1 Mechanical 8.7.2.2 Electrical transducers 8.7.3 Services using mechanical methods 8.7.3.1 Bend Locator (Enduro Pipeline Services Inc.)Aut Azout Piccc 8.7.3.2 CalScan/Bend Measurement Too! (Pipetronix GmbE) 5 PLyE Siig tipan ona 8.7.4.1 RMT Surveyor (T D Williamson Inc.) 8.8 PHOTOGRAPHIC AND VIDEO INSPECTION 8.8.1 General 8.9 LINE COVER AND SPANNING 8.9.1 General 8.9.2 Technologies 8.9.2.1 Acoustics 8.9.2.2 Radioactive emissions 8.9.3 Service using radioactive emission 8.9.3.1 Burial & Coating - B+C Tool (BG Pipeline Integrity Intemational) 8.10 MISCELLANEOUS ILI TOOLS 8.10.1 General 8.10.2 Metal loss tool (Uitrasonic) 8.10.2.) RPIT (Rontgen Technische Dienst bv) 8.10.3 Geometry tools 8.10.3.1 Caliper Plus (Réntgen Technische Dienst bv) 8.10.4 Profile monitoring 8.10.4.1 Gyrosystem (H Rosen Eng GmbH) 8.10.5 Other ILI tools and services 8.10.5.1 Sampling Pig (Pipetronix GmbH) 8.10.5.2 Wax Deposition Survey (H Rosen Eng GmbH), 7 8.10.5.3 Variable Speed Pig (GRM Fluid Controls) ) 8,10.5.4 Pig Pilot (Smart Pipeline Services) 8.10.55 Data Loggers 8.10.5.6 Fluid Tagging Pig 8.11 SURVEY SELECTION AND PREPARATION 8.11.1 Selection criteria 8.11.2 Information required 8.11.2.1 General 8.11.2.2 Pre-survey questionnaire 8.11.3 Preparing the line 8.114 Survey results 9.0 PIG SIGNALING, LOCATION AND TRACKING 9.1 PIG SIGNALERS 8.1.1 Types 9.1.1.1 Intrusive 9.1.1.2 Non-intrusive 9.1.2 Applications 9.1.3 Selection 9.2 PIG LOCATION AND TRACKING 9.2.1 Noisemakers 9.2.2 Isotopes 9.2.3 Transmitters 9.2.4 PingersAut Asour Picema 9.2.5 Transponders 9.2.6 Magnets 9.2.7 Acoustics 9.28 ELF, Systems 10.0 OPERATING PROCEDURES 10.1 GENERAL 10.1.1 Operating efficiency 10.1.2 Pig effectiveness 10.1.3 Pigging log 10.1.4 Cost benefits 10.2 PRE-RUN CHECKS 10.2.1 Pig inspection and maintenance 10.2.2 Signaters 10.3 PIG LAUNCHING AND RECEIVING 10.3.1 Launching procedures (typical) 10.3.2 Receiving procedures (typical) 10.4 PIGGING THROUGH A PUMP STATION (typical) 11.0 INDUSTRIAL PIGGING SYSTEMS 11.1 INTRODUCTION 11.2 BASIC SYSTEM DESIGN 11.2.1. One pig and two pig systems 11.2.2 Propelling medium 11,3 PIG DESIGN 11.4 VALVES AND FITTINGS 11.5 PIPEWORK 11.5.1 General 11.5.2 Pipes 11.5.3 Bends 11.54 Joints 1154.1 Flanged 115.42 Screwed 115.43 Butt welded 115.44 Welding rings 11.5.5. Branch connections 11.5.6 Hangers and brackets 11.6 CLEANING AND COMMISSIONING 12.0 ANCILLARY PRODUCTS AND SERVICES 12.1 TETHERED TOOLS 12.1.1 Metal loss (corrosion) inspection 12.1.1.1 Ultrasonics 12.1.1.2 Real time radiography 12.1.1.3 Eddy currentsAut Asour Picene 12.1.1.4 Magnetic flux leakage 12.1.2 CCTV (Video) inspection 12.1.3 Pipeline isolation 12.1.4 Internal pipeline alignment 12.1.5 Cleaning 12.2 INSITU INTERNAL COATING 12.3 SCALE REMOVAL 12.4 CHEMICAL CLEANING 12.5 DRAG REDUCING AGENTS 12.6 GEOGRAPHICAL INFORMATION SYSTEMS 12.7 FITNESS FOR PURPOSE ASSESSMENT 12.7.1 Background 12.7.2 Defect assessment 12.7.3 Fitness for purpose 12.8 DECOMMISSIONING 13.0 APPENDICES 13a, Pig Maintenance Records 13b. Pig Log Sheets and Run Records 13c. Terminology used in the Pipeline Pigging Industry 13d. Abbreviations and Acronyms 13e. Descriptions of Pipeline Imperfections and Conditions 13f. Pigging Test Loops - World-wide 13g. Useful Conversion Tables 13h Typical Differential Pressure Required to Drive a Pig 14.0 ANECDOTES (PIGGING STORIES) 15.0 ACKNOWLEDGMENTS AND FURTHER READING 15.1 Acknowledgments 15.2 Further Reading 16.0 BUYERS GUIDE 16a. Buyer's Guide Classifications 16b. Products and Services 16c. Companies Supplying Products and Services xiiAu: Azour Picane Background 1.0 BACKGROUND "Pig" is now the most widely accepted term for any device which is inserted into a pipeline and which travels freely through it, driven by the product flow. A pig is in effect a free moving piston, Occasionally other words are used, such as rabbit or mole and in some countries, they may be referred to by their function e.g. scraper, swab, tool, etc. The term "pig" originated in the United States, but why the word was chosen has never been satisfactorily explained. There are various theories, but the most widely accepted explanation is that the screeching sound made as the early pigs traveled through the pipeline, together with their brushes and their appearance when they emerged covered in crude oil, in many ways resembled the farmyard pig. The suggestion that PIG was an acronym for Pipeline Inspection Gauge is highly unlikely as the term was used long before inspection became a significant factor. Pigs were originally used exclusively for cleaning a pipeline. There is no documented evidence of when the first pig was run, but it was probably during the early days of crude oil pipelining in America, although it is possible that the water industry could claim to have been first. These early pigs are believed to have been made on site from straw wrapped with barbed wire. Other stories tell of the earliest ‘pigs’ being simply bundles of rags. These itis said were replaced by bundles of leather because this was not only stronger, but would swell when it was wetted and so gave 2 good seal in the pipe, Further details of the history of pigging will be found in Section 14 Early purpose built mechanical pigs were made without any consideration of possible damage to the pipeline and comprised hardened stee! scraper blades, stee! spur wheels and leather driving cups, They eamed the name of *Go- Devil” and such pigs are still occasionally used today to clean short pipes which are caring 2 high percentage of soft solids in suspension, 23 may be the case for example in china clay quarries. Even here however, there are more modem pigs which could generally perform the tasks significantly better. Today there are over 350 pigs of all types, a large number of specialist services and several thousand related products. Selection of the correct ones and the design of an optimum igging system will depend upon a great many, often seemingly unimportant factors. There are at present no recognized national ot imemational standards for the design, construction or operation of pigs or pigging systems, But there are industry "norms" which have resulted from long experience and which, if they are understood and followed, will contribute to trouble-free operation ‘These norms and some of the experiences have been the subject of various papers but these documents are not always readily accessible and are far from comprehensive. This manual is intended to resolve many of these problems ‘The terms and phrases used in this manual are those normally used in the pipeline pigeine industry. For those who are not entirely familiar with this, itis strongly recommended that reference be made to the definitions included in the Appendices before referring to the main sections