Pigging-PIPELINE PIGS & PIGGING

Design and Application Manual
PIPELINE PIGS & PIGGING
CONTENTS - SECTION 1.0
1.1 Tools and Techniques
1.1.1 Description (What are Pigs?)
1.1.2 Function (What do pigs do?)
1.1.3 Description of Pigging Functions
1.1.4 Method (How do pigs work?)
1.1.5 Selection (How do I choose a pig?)
1.2 Pipeline Design Factors
1.2.1 Internal Conditions (Conditions inside the pipe)
1.2.2 Pipeline Specifications (Dimensions & materials)
1.2.3 Fittings & Equipment (Components fitted to the pipe)
 Copyright 1999 Page 1 Section 1

Pipeline Engineering & Supply Co. Ltd
TOOLS AND TECHNIQUES

1.1.1 DESCRIPTION (“What are Pigs?”)
1.1.1.1 OVERVIEW
Pipeline Engineering’s formidable reputation is based on the high specification and

quality of its pigs, traps and related equipment – which have been used to maintain
pipelines world-wide for many years.
But, what is a ‘pig’. The name refers to a mechanical device that can be inserted into
a pipeline and used to carry out pre-defined tasks (depending upon its construction)
at critical points, or along the full length of the pipeline.
Pigs are driven by pressurising the pipeline behind them or, in most cases, inserting
them into the existing product flow, using specialised laundering equipment.
Whilst the potential applications for pigs are limited only by the imagination of the
specifier and the manufacturer, most tasks have now been defined and accepted
design characteristics are used by all the major suppliers.
Pigs and spheres must be suitably equipped to carry out a function or ‘task’. These
tasks are given names (cleaning, gauging, separation, drying, etc.) but the demands
of any individual task may require very different qualities from the pig depending upon
the stage in the development of the pipeline (pipeline development stage) at which
the pig is to be used (construction, pre-commissioning, commissioning, etc.)
Pipeline design factors influence the overall design of the pig and the types of seals
and fittings to be used.
1.1.1.2 PIG TYPES
The chart in fig. 1 shows the way in which pigs are generally classified:
Fig. 1
Pipeline Pigs
Utility Pigs In-Line Inspection (ILI) Tools
Metal-Bodied Pigs Solid Cast Pigs Foam Pigs Spheres Special Pigs
(Mandrel Pigs)
Bi-Directional Uni-Directional Hard Medium Soft Solid Inflatable

(Disc) (Cup)
Standard Conical

There are two types of pigs at the highest level:
1. In-line inspection tools (‘Intelligent Pigs’)

2. Utility pigs
1. In-Line Inspection Tools (I.L.I)
Because of the complexity of these pigs (which make extensive use of on-board
electronics, they fall outside the scope of this manual.
2. Utility Pigs
Utility pigs include all categories except intelligent pigs. They can be divided into 5
sub-groups based on their construction characteristics:
1. Metal bodied pigs (often referred to as ‘mandrel’ pigs) – sealing components

axially mounted on a tubular or solid metal body.
2. Solid cast pigs – single piece polyurethane casting – usually ‘dumb-bell’ shaped
3. Foam pigs – moulded polyurethane foam, usually in 3 ‘densities’: soft; medium;
hard.
4. Spheres – manufactured from cast polyurethane and various rubbers according
to task
5. Special pigs – construction is similar to metal bodied pigs.
Specialised categories are allocated according to function (the task, or type of work
that the pigs will be required to perform). Although functions are referred to
collectively (cleaning, gauging, etc.) operating conditions will vary according to the
pipeline development stage. This will influence parameters such as component rates
of wear which will, in turn, effect the quantity of spares or complete pigs required to
complete the task.
1.1.1.3 CONSTRUCTION CHARACTERISTICS
Overview
The length of metal-bodies, solid cast and foam pigs is approximately 1½ - 2 x

nominal diameter of the pipeline in which they will be operating. Special pigs may not
confirm to this formula due to other factors that may effect their design. Spheres are,
obviously, spherical.
There are 3 elements to be considered with regard to pig construction:
• The pig body

• The type of seal
• The fittings
Only metal-bodied and special pigs have independent bodies onto which seals and
fittings can be attached. These bodies are usually made from carbon steel, although
polyurethane can be specified in some types of pig for improved flexibility.

Solid cast pigs are constructed entirely from polyurethane whilst spheres can be mad
from several types of elastometric material:
• Polyurethanes
• Rubbers: Neoprene; Nitrile; Silicon; Viton Seals
There are 3 types of detachable seal:
• Discs
• Standard Cups
• Conical Cups
Seals made from polyurethane are specified for most pigging functions – it possesses
excellent physical characteristics which can be formulated for specific applications.
However, there are good reasons for specifying some rubbers, which are given later.
Careful formulation of urethanes allows characteristics such as harness, tear

strength, abrasion resistance, hydrocarbon and hydrolysis resistance, flex life and
compression set to be modified.
There are 2 types of polyurethane:
• Ethers (Good hydrolysis resistance; high resilience; low compression set).

• Esters (Better physical properties than ethers).
As a general rule, it is not always possible to specify and formulate a particular

urethane, unless all the operating conditions are taken into account. Although
urethanes work in applications where rubbers could not, they must be carefully
selected, especially for very critical tasks.
Pipeline Engineering was one of the first companies to use polyurethane for pig seals
in the late 1960’s. The company developed its own polyurethane, known as
‘Omnithane®’ that was very successful and is still being specified by clients.
However, the drive for technical excellence led to the development of ‘Super
Omnithane®’ an ester/MDI/diol system and ‘Hyper Omnithane®’ a TDI/amine system.
These formulations are used for the seals of some of the most durable pigs in use
today.
Fittings
Fittings are those items other than seals which can be attached and removed from
the pig body; these include: brushes; scraper blades; plough blades; transmitter
housings; gauging plates; magnets and any item not usually found on a standard pig.
1.1.1.4 PIG CHARACTERISTICS BY TYPE
Metal-Bodied Pigs
This is the only pig type in which the 3 construction elements can be identified
separately. This form of construction allows the specifier to develop a pig that
accurately meets the demands of the task.

The pig body is manufactured from steel tube in pigs 8” and above and a steel bar in
pigs below 8”. Other materials, including aluminium and polyurethane, are also used.
Flanges are welded to the body at both ends of the pig for seals and spacers; studs
and pads are provided for attachment of fittings.
These pigs incorporate discs, standard cups and conical cups, manufactured
primarily from polyurethane, although discs can also be supplied in several types of
rubber, as previously described. The quantity and type of seal depends upon the
pigging function and operating conditions.
Metal-bodies pigs allow the greatest range of fittings to be attached. This range
covers fittings of all types and includes brushes, scrapers, plough blades, transmitted
housings, gauging plates, magnets and many other types necessary for specific
tasks.
Solid Cast Pigs
These pigs are made from a single polyurethane casting. Therefore, the sealing
elements are not interchangeable or replaceable. All seals are disc-type and
comprise 4 sealing and 2 support discs. They are designed, primarily, for small-bore
pipelines of approximately 2” to 12” nominal diameter.
The one-piece construction method limits the choice of fittings. However, brushes,
gauging plates and magnets (for tracking and location purposes) can be fitted to this
type of pig.
Foam Pigs
Foam pigs are often specified in similar circumstances to metal-bodies pigs.

However, they employ very different design characteristics. The pigs are normally
bullet shaped and moulded from open cell polyurethane foam which is available in
several densities (designated soft; medium; hard). External coats are applied to
increase the pigs’ effectiveness in specified operating conditions.
They have no independent sealing elements. The pig is compressed in the pipeline
by the pressure and forced against the pipe wall to form a seal.
The density of the pig is matched to the pigging function and operating conditions.
‘Hard’ pigs are tougher and last longer; ‘soft’ pigs are more commonly known as
‘swabs’ and are used for drying and other specialised tasks.
A thin polyurethane coating is often applied to bare pigs to help increase the
efficiency of the pig with respect to its function: ‘cross-cross’, spiral or fully coated. A
coating of polyurethane is also applied to the base (the flat end) of most bar pigs.
Although there are many options for foam pigs, there are relatively few fittings.
Specialisation is controlled at the moulding stage when options are ‘built-in’: gritted
bands, brushes, jetting holes, magnet inserts (for tracking and location), transmitted
cavities, ropes, studs for gauging plates, stud inserts for scraping are some of the
options available. Some fittings are removable and include magnets, gauging plates,
transmitters and studs for scraping.

Spheres
The spherical elastomeric body of a sphere forms a single-line seal in the pipe.
Therefore, there are no independent sealing elements to consider. Spheres do not
accept fittings (with the exception of some spheres which have magnets cast into
them for tracking and location purposes).
There are 2 types of sphere (with typical uses given):
• Solid – automated pigging programmes; batching; condensate removal

• Inflatable – meter proving; batching; condensate removal
Once the type has been decided, the characteristics of the pig are dependent upon
the formulation of the material from which the spheres are constructed. This will
influence properties such as sealing efficiency, rate of wear, operating temperature
limits and chemical resistance.
Inflatable spheres have a removable valve and are usually filled with water or a
water/glycol mixture. Meter proving spheres are produced in hardnesses of 65-70°
Shore A while, for most other operational purposes, spheres tend to be specified with
hardnesses of approximately 65 – 75° Shore A.
Special Pigs
‘Special pigs define those pigs – usually metal-bodies – which have to be significantly
modified (relative to the ‘ideal’ standard in terms of dimensions and seal
configurations) in order to pass through the limitations imposed by the pipeline design
factors which exist for that specific pigging application.
Special pigs include:
• Dual diameter pigs

• Articulated pigs
• High differential pigs
By definition, special pigs must cope with increased problems imposed by the
pipeline design factors. Therefore, their design is much more critical. Body, seals
and fittings may use standard components, but it is much more likely that they will
include characteristics which will require detailed information on all aspects of the
pipeline and its design factors.

1.1.2 FUNCTION – (What Do Pigs Do?)
1.1.2.1 OVERVIEW
Pigs must first be selected to carry out a specific function (task). This results in a pig
which can generally be described by its function type. e.g cleaning pig, gauging pig,
de-watering pig (section 1.4.0 explains this principle in more detail). For now, the
scope of pigging functions is set out as follows:
1.1.2.2 PIGGING FUNCTIONS
As a result of the experience gained in pigging operations world-wide, most functions

are now pre-defined and can be found somewhere within the following list:
• Debris removal
• Cleaning
• Gauging
• Filling
• De-watering
• Drying
• Separation (batching)
• Condensate removal
• Meter proving
• Product displacement
• Product conversion
• Gel pigging
• Coating application
These pre-defined functions all rely on one (or a combination of) the following
aspects of the pig’s design characteristics (the ability(s) required to complete the task
successfully):
• Ability to SEAL
• Ability to CLEAN
• Ability to GAUGE
• Ability to ABSORB
• Ability to RETAIN PRODUCTS
Some of the characteristics may need to be enhanced in order to provide the best pig
for the task (e.g more – or improved – seals and fittings may be required). All will be
influenced by the pipeline development stage.

1.1.2.3 PIPELINE DEVELOPMENT STAGE
Pigging function depends upon the stage in the operational life of a pipeline at which
the pig must carry out its task. Most stages in the development of a pipeline can be
found in the following list:
• Construction
• Pre-commissioning (including hydrostatic testing)
• Commissioning
• On-line operations
• Inspection
• Maintenance and repair
• Renovation and rehabilitation
• Decommissioning
Some pre-defined functions can take place at several stages in the development of
the pipeline. However, pigs designed to carry out tasks at one stage of pipeline
development may not possess features that are suitable to enable them to carry out
the same task at other stages. This is due to a combination of the following factors:
• Pigging distance
• Frictional resistance of the materials in contact
• Lubrication
• Pigging speeds
These factors are dealt with later when we consider pipeline design factors and the
operating conditions that apply. However, for now we can consider what is involved
in each of the pigging functions previously listed.
1.1.2.4 DESCRIPTIONS OF PIGGING FUNCTIONS
1.1.3.1 DEBRIS REMOVAL
Debris removal is generally the first operation to be considered. It occurs at the

construction stage and involved the clearance of the constructor’s waste, rocks, sand,
dead animals, etc. These items must be removed prior to cleaning and gauging
operations at the pre-commissioning stage. This particular task is extremely
demanding and requires a robust, well specified pig. Bi-directional pigs – either foam
or metal-bodied – are required as it may be necessary to reverse them if they
become stuck.
The nature of the operation varies depending on whether it is carried our on land of
offshore/sub-sea. Sub-sea operations are more complex and may involve the use of
‘lay-down heads’ with the pigs being pre-loaded for operations after the line is ‘tied-
in’. Debris removal onshore usually involves pigging with compressed air between
‘test-ends’ (temporary pig traps).

Compressed air operations impose several conditions on the pig – no lubrication is

available and pigging occurs in a series of high speed ‘excursions’ between localised
restrictions. The pig stops and the pressure builds until there is sufficient energy to
launch the pig past the obstacle. As the pig moves forward rapidly, the pressure is
dissipated until the pig reaches the next restriction, causing the process to be
repeated.
1.1.3.2 CLEANING
The specification of cleaning pigs depends upon the pipeline development stage at
which cleaning is required – usually at one of the following:
• Pre-commissioning
• On-line operations
• Inspection
• Renovation and rehabilitation
• Decommissioning
Cleaning at each stage imposes a different set of demands on the pig. This could,
but would not automatically, require variations in pig design. There are 2 main
requirements for cleaning – irrespective of the type of pig.
1. Pigs must be fitted with cleaning devices – brushes (circular or spring mounted;
scrapers; ploughs.
2. ‘By-pass’ must be introduced across the pig and, in particular, the brushes.
Cleaning operations are usually carried out by either metal-bodied or foam pigs. Both
have advantages, although metal-bodied pigs can be more readily adapted to suit
specific conditions.
Liquid flows improve cleaning efficiency by allowing the pig to maintain a constant
velocity. Unfortunately, a liquid flow is not always available (at the construction
stage, for example). Cleaning then has to be done with compressed air, where the
efficiency is diminished as the pig speed cannot be easily controlled.
Cleaning included the removal of ‘scale’ (mill scale, silica, coke, calcium) which often
requires a much more aggressive pig. Conversely, pigs can be fitted with nylon
brushes for cleaning pipes that are internally lined. Foam pigs are often used for this
task – ‘hard’ foam pigs have inserts for studs integrally moulded into the pig body.
These studs are made from steel and are available in several types to suit the
operating conditions. Metal-bodied pigs are available with steel scraped blades and
special pigs (such as the pin-wheel pig) have also been developed for this purpose.
Old pipelines, or those which have never previously peen pigged, require a special
approach. A progressive pigging programme must be carried out to avoid the risk of
a more robust pig becoming stuck in a pipeline which cannot be accurately evaluated.
This approach involves the step-by-step use of progressively harder, more
aggressive foam pigs, run until the pipeline is considered acceptable for metal-bodies
pigs to be used.

1.1.3.3 GAUGING
Gauging is commonly carried out at the following stages:
• Construction
• Maintenance and repair
• Decommissioning
It is necessary for 2 reasons:
• To check that there are no unintended intrusions into the Pipeline Engineering
• To confirm that the ovality of the pipeline is within acceptable limits (tolerances)
Metal-bodied pigs (uni-directional or bi-directional) are fitted with a circular aluminium

gauging plate (steel plates can also be used), which is usually machines to 95% of
the smallest internal pipeline diameter. Foam pigs can also be adapted to accept
gauging plates but they are not often used for this purpose.
At the construction stage, gauging operations are usually conducted with compressed
air. As with all other operations using compressed air as the pigging medium, it is
extremely dangerous and less effective.
1.1.3.4 FILLING
Filling is carried out at the following stages:
1. Pre-commissioning
2. Commissioning
1. Pre-Commissioning
Filling is carried out in order to evacuate air and fill the line with a solid column of
water prior to hydrostatic testing. The most important characteristic required is the
ability of the pig to maintain an effective seal against the pipe wall in order to
minimise leakage. For this reason metal-bodied bi-directional pigs using multiple
sealing discs are specified.
Pigs are run in front of the water column, evacuating the air from the pipeline that is
vented at the receiver. It is extremely important that all pipeline design factors that
apply are considered in order to produce a pig which is capable of travelling through
the pipeline system successfully.
2. Commissioning
Filling is carried our in order to bring the pipeline to the point of operation – when it
has been filled with product. Several metal-bodied, disc-type pigs are required as
filling involves ‘slugs’ of other liquids e.g methanol, glycol, held between pigs
preceding the pipeline product. Commissioning is complex and required
considerable expertise.

1.1.3.5 DE-WATERING
After hydrostatic testing the water must be removed from the pipeline prior to drying
and subsequent commissioning. This is done by a series of pigs pushed through the
pipeline using compressed air.
The same qualities are required for de-watering as for filling – the most important
characteristic again being the ability to maintain an effective seal in order to minimise
leakage. All relevant pipeline design factors should be considered.
Soft foam pigs (swabs) are often run after de-watering to swab away any water
remaining on the pipe walls, or which has accumulated at low points in the pipeline.
1.1.3.6 DRYING
In on-shore pipelines, foam swabs are pigged with extremely dry compressed air (-
90°F atmospheric dew point temperature). Together with pigs and the air pick up the
remaining water leaving behind a dry pipeline. However, it takes more than one
swab to do this and is, of course, dependent on the length of the pipeline. Several
hundred swabs may be required to fully dry a pipeline.
After the pipeline is dry, brush pigs must be run to remove the rust, mill scale and any
deposits that have settled out from the hydrostatic test. Again, several hundred
swabs may be required to remove the material loosened by the brush pigs. These
swabs will then be run until the air reaches a specified dewpoint.
1.1.3.7 SEPARATION (BATCHING)
Batching is a technique used during on-line operations, primarily on multi-product

pipelines that transport different products in the same line at the same time.
In order to minimise ‘interface mixing’ (caused when two products being transported
in the same line come into contact with each other), the pig has to be inserted into the
pipeline at exactly the right time. This task can be automated by using spheres pre-
loaded into magazines. They can then be automatically inserted into the pipeline
when required.
1.1.3.8 CONDENSATE REMOVAL
Condensate removal is a constant activity during on-line operations in untreated gas

lines. It settles out in low spots in the pipeline, reducing efficiency. As it builds up,
the condensate is pushed along the line by the flow until it reaches the receiver. The
resulting slug can be so large that it frequently exceeds the capacity of the slug
catcher set up to receive it.
Sphering provides the ideal solution. Automatic launching from pre-loaded

magazines allows un-manned pigging activity over extended periods. Spheres do not
have to seal in the pipe – their purpose is to move the condensate into the slug
catcher at the receiver.

1.1.3.9 METER PROVING
Meter proving describes the procedure for calibrating flow meters (e.g turbine and
positive displacement meters) in which pigs are used to batch a known volume of
product through the meter. This volume is then compared against the volume
indicated by the meter.
Early meter provers were simply a ‘measured mile’ of pipe in which batching pigs
were used to push the product through the meter in one direction only. When the
pigs had completed the task they were transported back to the launcher to be used
again. To save on transportation and handling costs, bi-directional pigs began to be
used as these pigs could be returned simply by reversing the flow of the pipeline.
The next development saw spheres used in a continuous pipeline loop with an
interchange valve closing the top from the bottom. These interchange valves
subsequently proved to be inadequate and bi-directional meter provers became
standard.
In their simplest forms, meter provers consist of an internally coated pipe containing
an inflatable sphere. Electrical pig signallers and a scraper trap (for launching and
receiving spheres) are installed at each end of the pipe. The volume of product
contained in the pipe between the detectors is accurately calibrated against certified
columetric tanks and the meter to be proved s connected in series with the meter
prover system.
Outputs from both signallers and the flow meter are connected to a counter. When
the pig trips signaller 1, pulses from the flow meter are counted. When the pig trips
counter 2, counting stops and the count is recorded. The signal count is compared
against the known volume to obtain a factor which can then be used to calibrate the
meter.
Only inflatable spheres with a hardness of between 65° - 70° Shore A are specified
for use in meter prover loops.
1.1.3.10 PLUGGING
Plugging is carried out during the maintenance and repair phase of a pipeline’s life.
The plug is most commonly a modified metal-bodied, bi-directional, disc-type pig in
which the sealing elements not only seal but cause the pig to be an extremely tight fit
in the pipeline.
Depending upon the diameter of the pig, pressures of up to 8 bar may be required to
move it in the pipeline – higher pressures are required to reverse the pig and ‘flip’ the
discs.
Plugging is often carried out in ‘trains’ where the pressure that a single pig can
withstand s cumulative and which therefore allows a series of pigs to withstand
greater differential pressures.


1.1.3.11 PRODUCT DISPLACEMENT
The same qualities are required for displacement as for filling and de-watering duties.
Product displacement is carried out whenever the pipeline contents have to be
evacuated, particularly at the decommissioning stage.
1.1.3.12 PRODUCT CONVERSION
This involves ‘sterilising’ the pipeline prior to running other products which may
become contaminated. Pigs used for this purpose require similar quantities to pigs
used for filling and de-watering duties.
1.1.3.13 GEL PIGGING
This technique does not involve utility pigs. A jelly-like substance is either injected
directly into the pipeline or moulded into cylindrical ‘pigs’. The jelly picks up and
holds within it deposits found in the pipeline. It is bio-degradable and can be broken
up under pressure.
1.1.3.14 COATING APPLICATION
There are 2 pigging phases involved in the application of ‘in situ’ pipeline coatings:
1 Cleaning
2 Coating application
1. Cleaning
Cleaning prior to coating application requires as much debris to be removed from the
pipe wall as possible. Therefore, it is usually done using methods other than cleaning
pigs. e.g: grit blasting techniques). Pigs are then used to remove loosened deposits
from the pipeline.

1.1.4 METHOD – (“How Do Pigs Work?”)
1.1.4.1 PROPULSION METHODS
Pigs travel through the pipeline under pressure from the pigging medium being
pumped behind them. This medium takes on of two forms:
1 Gas
2 Liquid
Whatever the medium is – gas or liquid – has a dramatic effect on operational pigging
characteristics, especially in terms of the pig’s velocity profile.
Irrespective of the type of pigging medium, pig velocity has a profound effect on
pigging efficiency. Pigs are designed to work most efficiently within a limited velocity
range which may be difficult to achieve, depending upon the pigging medium or other
factors, such as the ability to regulate existing product flow rates.
1.1.4.2 PIGGING WITH A GAS
A stationary pig requires increased pressure to start it moving. Once this pressure is
reached, the pig moves forward very quickly as the pressure begins to decrease
behind it. Eventually the pig comes into contact with an obstruction, such as a weld
bead, the pressure is insufficient to keep it moving forward and the pig stops. The
cycle then begins again.
This velocity profile is typical when pigging with gasses, due to their ability to be
compressed. Once the pig begins to move this energy is released very rapidly. Pigs
have been measured at speeds in excess of 100mph and have been know to burst
out of thin walled pipes at bends in the pipeline.
Aside from the safety aspects, pigging in this manner is inefficient, increases wear on
the pig seals and brushes (if used) and is generally more destructive to the pig.
1.1.4.3 PIGGING WITH A LIQUID
This method is much more efficient. Velocities can be maintained, within limits. They
are lower and controllable at the pump. Seal wear rates are also reduced as the
product or pigging medium acts as a lubricant.
The pressure required to move a pig depends upon a number of factors:
• The pressure in front of the pig

• Condition of the pipe wall surface
• Pressure exerted by the seals on the pipe wall (the ‘fit’ of the pig in the pipe)
• The presence of a lubricant
Pigs move in the pipeline under the influence of the ‘differential ‘pressure across
them. That is to say, the pressure behind the pig (P1) minus the pressure in front of
the pig (P2). This differential pressure (‘delta P) gives the pig a velocity. (i.e. It gives
the pig both speed and direction). Obviously if P1 is less than P2 the pig will move
backwards – which is only of benefit when using bi-directional pigs (refer to
illustrations on page 14).

The differential pressure contributes to the efficiency of pigging operations in the

following ways:
• It improves sealing efficiency by forcing the seals against the pipe wall, making
them act like non-return valves.
• It is used as ‘by-pass’ in cleaning operations
1.1.4.4 BENEFITS OF BY-PASS
‘By-Pass’ is the controlled flow of pigging medium, gas or liquid, through and/or past
the pig. It has two effects:
• It reduces the pressure (P1) behind the pig and hence the differential pressure
(delta P) across the pig – variations in the differential pressure effects the speed
of the pig. The pig slows down as the differential pressure decreases.
• It provides a very necessary jetting action which increases the efficiency of

cleaning pigs by preventing brushes from becoming blocked with loosened
deposits and holding these deposits in suspension in front of the pig rather than
allowing them to form into a solid ‘slug’. These slugs are difficult to deal with at
the receiver but, more importantly, may cause the pig to become stuck.
Studies have shown that it is better to drive the pig in the pipe using the front seals
only, the rear seals act as support. Pluggable by-pass ports are built into the pig
body for this purpose and allow the pressure to flow through the pig body and be
directed into the space between the two sets of seals.
More ports can be added to create flowpath right through the pig. This reduces the
pressure P1 behind the pig and the differential pressure (delta P) across the pig.
Consequently, the pig can be driven at slower speeds in pipelines with fixed flow
rates.
The relative importance of by-pass depends on the task which the pig has been
designed to perform. These tasks can be divided into 2 groups:
1. Sealing
2. Cleaning
1. Sealing
If the pig is used for operations where its ability to seal in the pipe is most important
(e.g filling, de-watering) then the principle benefit of by-pass is to allow the pig to be
driven from the front set of seals. However, in addition, it is thought that by-pass may
help prevent the formation of slugs of solids building up in the liquid which the pig
would then tend to ride over and leave behind in the pipeline.

2. Cleaning
During cleaning operations, especially was removal, the deposits on the pipe wall
very quickly build up in the brush reducing its effectiveness. To prevent this
happening, limited by-pass can be used to create a flow path of pipeline product
through and around the brushes. This tends to prevent the deposits removed from
the pipe wall from building up in the brush by holding them in suspension within the
product flow created by the by-pass.
Pigs are often fitted with jetting nozzles (also known as ‘spider noses’) which are
positioned in front of the leading set of seals. The nozzle jets are directed back
towards the leading discs or brushes (depending on the pig type) and again are used
to create a flow of product that is designed to hold in suspension any deposits
removed from the pipe wall.

1.1.5 SELECTION – (“How Do I Chose A Pig?”)
1.1.5.1 OVERVIEW
There are 3 fundamental questions to ask when selecting the appropriate type of pig:
1. What is the function, of task of, the pig?

2. At what state in pipeline development will the task be performed
3. Which pipeline design factors are relevant and to what extent will they influence
pig design
This approach will establish:
1. The most suitable type of pig and consequent arrangement of body, seals and
fittings
2. The extent of any modifications and additions to the body, seals and fitting of
standard pigs (resulting in the basis of a design or a special pig).
All pre-defined tasks will be carried our by one of the following 5 types of pig:
1. Metal-bodied pigs
2. Solid cast pigs
3. Foam pigs
4. Spheres
5. Special pigs
The construction characteristics of each type of pig influences its suitability for a
particular task. Some types (metal-bodied and foam) include within their range pigs
suitable for most tasks while others (solid cast and spheres) are themselves
specialised and are limited in the number of options they can offer. Special pigs are
those pigs which have had their body and seal configurations significantly modified as
a result of pipeline design factors or which belong to no pre-defined category.
In order to carry out the function for which they were designed, many pigs are
equipped with fittings of some type. The range of fittings, and hence the range of
tasks, are limited by the type of pig specified.
Metal-bodied pigs, other than those specified solely for their sealing qualities, may
incorporate any of the fittings listed below:
• Blades
• Brushes
• Scrapers
• Magnets
• Gauging plates
• Jetting nozzles
• Transmitters

The way in which some fittings are mounted will influence the pigging direction. The
following table refers to those fittings which do influence the pigging direction:
Uni-Directional Bi-Directional
Brushes ‘U’-spring mounted Circular

Cantilever Mounted Arch-spring mounted
Blades ‘U’-spring mounted Arch-spring mounted

Cantilever Mounted
Scrapers ‘U’-spring mounted Arch-spring mounted

Cantilever Mounted
Each pig type incorporated very different design characteristics which are examined
in more detail below:
1.1.5.2 METAL-BODIED PIGS
Metal-bodied pigs are divided into 2 groups according to their directional ability within
the pipeline. This can be selected or, more likely, will be imposed by the operating
conditions;
• Uni-directional pigs travel through the pipeline in one direction only

• Bi-directional pigs travel through the pipeline in either direction
The directional ability of a metal-bodied pig depends upon 2 factors
• Seal type
• Fittings
Seal Type
There are 3 types of seal which are further classified by their suitability for use with
regard to pigging direction:
• Discs – bi-directional
• Standard cups – uni-directional
• Conical cups – uni-directional
Discs
Discs increase the scope of the pig to be used for a more diverse range of
applications. They allow it to be reversed, they provide a scraping/swabbing action
and are lighter and cheaper. However, they wear more quickly, are more prone to
damage and are less able to pass obstructions and reductions in the pipeline than
conical cups.

Cups
• Standard – cost effective design

• Conical – greater flexibility of use
Selection depends on the pipeline design factors detailed in section 2.0.0. However,
conical cups do offer one particular advantage over standard cups – an increased
ability to pass restrictions in the pipeline (up to 20% of minimum pipeline internal
diameter compared to 5% with standard cups).
Other Factors
After ensuring that the pig will travel through the pipeline, selection is based on the
pigging function, particularly when the function relies on the qualities of the seal (e.g.
de-watering, filling, pigging long distances)
Unless operating conditions dictate otherwise, the pig body will be constructed
relative to the diameter and length of the pig. This ratio is as follows and varies
between pig types – it does not include spheres:
Length of pig = nominal pipe diameter x ‘n’

(The value of n varies between approximately 1.4 – 2.0 according to pig type)
Fittings will then be sized and configured to match the pigging function. All of the
fittings listed earlier in this section are available for selection for use with metal-
bodied pigs.
1.1.5.3 SOLID CAST PIGS
These pigs have limited application as they cannot be readily adapted to suit complex
operating conditions. They are often used in the food process industry because they
can be manufactured from a single piece of polyurethane that complies with food
hygiene standards. They are typically supplied in diameters from 2” to 12” and the
integrally moulded disc seals offer low leakage and high scraping efficiency
compared with spheres. They are bi-directional and can have a limited range of
brushes, gauging plates and magnets fitted (for tracking and location).

1.1.5.4 FOAM PIGS
Foam pigs are initially selected according to pigging functions – the following types
are commonly available for the task specified:
• Bare – swabbing displacement

• Fully polyurethane coated – displacement
• Criss-cross polyurethane coated – displacement/light cleaning
• Wire brush – spiral pattern – cleaning
• Wire brush – fully covered – cleaning (long run)
• Silicon gritted – heavy cleaning/scale removal
The characteristics of foam pigs are more closely matched to the task by specifying
the density of the open cell polyurethane foam:
• Soft – approximately 2lb/ft3

• Medium – approximately 5lb/ft3
• Hard – approximately 8lb/ft3
‘Hard’ foam pigs assist aggressive cleaning whilst ‘Soft’ foam pigs improve swabbing
characteristics.
Foam pigs are often specified as an alternative to metal-bodies pigs as they have
several advantages.
• They are relatively cheap

• They can pass through tight bends (ID depending on density and type)
• They are easier to handle than comparable metal-bodied pigs
• Softer, non-brush types do not require specialised launching facilities
• Swabs can be used for testing blockages in a pipeline (if they become stuck they
will disintegrate under increased pressure)
• As a product group, they form the basis of a progressive pigging programme ( a
vital approach for pipelines which have never been pigged previously).
Not all foam pigs are bi-directional but most can be suitably adapted at the design
stage. Several types of fitting are available:
• Jetting holes
• Magnet inserts
• Transmitter cavities (for tracking and location)
• Ropes for pulling (or being pulled)
• Studs for gauging plates
• Stud inserts for scraping

1.1.5.5. SPHERES
Spheres play a vital role in pigging operation due, particularly, to their shape. It
allows them to be pre-loaded into launcher magazines and used to carry out
automated pigging operations (e.g. batching, condensate removal in untreated gas
lines) where the launching facilities are un-manned for long periods.
There are 2 types of sphere:
• Solid
• Inflatable
Solid spheres can be made from various elastomer materials:
• Polyurethane
• Nitrile rubber
• Neoprene rubber
Solid spheres are used for batching and condensate removal from unmanned
launching stations
Inflatable spheres – made from polyurethane – are always specified for use in meter
prover loops because the sphere can be precisely inflated to give a constant seal as
the sphere wears with use. Meter prover spheres are softer than standard spheres
(65-70° Shore A compared to 70 – 75° Shore A for standard spheres). Making the
sphere softer improves the quality of the seal.
Rubbers such at nitrile and neoprene allow spheres made of the materials to be used
within a much greater temperature range than is available with spheres made from
the standard formulations of polyurethane. However, polyurethane formulations do
exist which greatly improve the sphere’s ability to operate in temperatures up to
150°C
The best polyurethane spheres are of seamless construction which, although it is

more technically difficult to achieve and requires significant investment by the
manufacturer, results in a sphere of much higher quality.
Due to their construction and sealing characteristics, spheres cannot accept fittings
however, some spheres do have magnets incorporated during the moulding process
for tracking and location purposes.

1.1.5.5 SPECIAL PIGS
If standard pigs must be modified to such an extent that they no longer comply with
an ‘ideal’ standard model in order to perform a function, then a ‘special’ pig must be
designed.
This usually involves changing the dimensions of a pig relative to the nominal pipeline
diameter. The body dimensions may be changed or constructed in two modules
(articulated), and the fittings and seals may also be suitably adapted. In some
instances, the dimensions of the pig remain unchanged with modifications being
confined to altering the specification of the materials used in the construction of the
pig.
Pigs designed for one-off tasks (tasks for which there is unlikely to be any further
demand) can also be classified as special pigs.


PIPELINE DESIGN FACTORS
1.2.1 INTERNAL CONDITIONS (“What Are Conditions Inside the Pipe?”)
This section considers the potential problems posed by factors such as the chemical
compatibility of the pipeline product with the materials used in the construction of the
pig. It also considers the contributory effects of temperature, pressure, flow and
pipeline deposits on the pig and its components.
1.2.1.1. PIPELINE PRODUCTS
Most pipelines carry one or more of the products listed below:
• Hydrocarbons
• Petrochemicals
• Chemicals
• Water
• Food Products
• Gases
Each of these product groups has an effect on polyurethanes and rubbers to a

greater or lesser extent. (Pig body materials are also effected by pipeline product).
The typical effect of chemical incompatibility with polyurethanes and rubber leads to
blistering, cracking and chemical breakdown (Material is described as having a
‘cheese-like’ consistency).
Whilst it is extremely important to select a material which has good compatibility with
the pipeline product, a compromise will almost certainly have to be made because
the most compatible material with the product is unlikely to have the necessary
physical characteristics.
Most rubbers can be moulded into spheres or supplied in sheet form (hence can be
supplied as discs) but they cannot be economically moulded into more complex cup
shapes. Therefore, the choice of seal materials may have great effect on the overall
pig design.
1.2.1.2 TEMPERATURE
Internal pipe temperatures primarily effect elastomeric components and, in particular,

pig seals. Temperature increases the effect that product incompatibility has on
elastomeric components. Elastomers, in this instance rubbers and polyurethanes,
operate most effectively within specified limits. These limits are much wider in
rubbers (Nitrile, Silicon, Neoprene, Viton) than they are in polyurethanes, which have
relatively low upper operating limits.
In almost all instances, rubbers withstand high temperatures better than

polyurethanes but have significantly inferior physical characteristics, resulting in
inferior wear rates, material strength, etc.

1.2.1.3 PRESSURE
Pressure does not have a significant effect on the construction of utility pigs which
contain no sealed units. In-Line (I.L.I) pigs do have sealed units and pipeline
pressure has a much more significant effect on this type of equipment.
The general effect of pressure is to move the pig in the pipeline. If this movement is
smooth and constant then pigging will be much more efficient. In pipelines
transporting liquids, this characteristic movement is not difficult to achieve. However,
it is much more difficult in gas pipelines or where pigging is being carried out using
compressed air.
Minimum pressure levels need to be achieved in order to keep pigs moving past
obstacles (typically weld beads) without stopping. IF a pig does stop, pressure will
increase until it is sufficient to launch the pig past the obstacle. Initial acceleration will
be rapid and overall velocity will be high with consequent safety implications, possible
damage to pipelines and fittings and much lower pigging efficiency. These problems
can be relieved by pressurising the pipeline ahead of the pig and venting at the
receiver.
Recommended minimum pigging pressures are often requested but are not easy to
supply as they are a compound of many factors: function, pipeline, condition,
deposit, lubricant, seal material and type, liquid or gas pigging.
1.2.1.4 PRODUCT FLOW
Maximum pigging efficiency id dependent upon a constant product flow that, by

definition, is usually only available in on-stream applications. There are guidelines
giving approximate pigging speeds for different types of pig however, the speed is
dependent on the velocity of the product flow and may not be changeable.
The main consideration is t move the pig smoothly at a constant speed through the
pipeline. Pigging in gas lines is less efficient and moor likely to result in ‘speed
excursions’. This is more destructive to the pigs as the higher speeds and more
abrasive conditions cause greater wear on the pig components. Increased speed
also causes a decreased pressure differential across the pig which, in turn, results in
decreased sealing efficiency.
1.2.1.5 DEPOSITS
The main types of deposit are as follows:
• Condensate (untreated gas lines)

• Water (most lines)
• Waxes (oil lines)
• Scale
• Mineral deposits
• Rust
The type of deposit to be removed influences the type of seal and cleaning elements
required for carrying out the work most effectively.


Condensates and water are swabbed our using pigs with seal discs, spheres or foam
pigs.
Polyurethane ploughs and scrapers are recommended for removing soft and hard
waxes respectively. Scale and mineral deposits often have to be removed using
foam stud pigs to break up the hard scale initially then followed using cleaning pigs
equipped with brushes.
Rust (corrosion) can be removed using brush-equipped cleaning pigs, possibly with
magnets fitted to pick up the ferrous debris. Foam pigs gritted with silicon carbide
can be used to burnish the pipeline, which will improve frictional losses and which, in
turn, lead to increased pipeline output.

1.2.2 PIPELINE SPECIFICATIONS (“What Are the Pipeline Dimensions and

Materials?”)
1.2.2.1 PIPELINE LENGTH
It is not the overall pipeline length that is of interest but the maximum pigging
distance – the distance between launching and receiving stations. This factor
influences the wear rate of the seals along with several other factors:
• Pipe wall condition

• Pipe wall lining (if any)
• Product compatibility
• Seal material
• Pigging medium
• Presence of lubricant
• Pigging speed
Throughout the world, pigging distances range from a few metres to hundreds of
kilometres. Whilst the pig design for the two extremes may possibly involve similar
characteristics, it is essential that, along with the factors mentioned above, the
maximum pigging distance is specified.
1.2.2.2 PIPELINE DIAMETER
Most pipelines have a constant external diameter while their wall thickness changes
to accommodate design pressure, etc. This variation in wall thickness can greatly
effect the function of the pig, whether it is batching, cleaning or gauging. At the
extremes, the variation in wall thickness is equivalent to specifying a dual diameter
pig and many ‘standard’ pigs would possibly become stuck in the narrower bores.
The other aspect relating to pipeline diameter is the tolerance on ovality, particularly
important to consider when gauging.
1.2.2.3 MULTIPLE PIPELINE DIAMETERS
Pipeline systems can include pipes of two or more nominal diameters (say 8” and 10”
for example). This can result in a very significant narrowing of the internal diameter
of the pipe. In order to overcome this problem, dual-diameter pigs are available
which are usually designed to cope with two changes in pipe diameter (e.g. 10” to
8”; 12” to 10”).
Ideally, pigging should be carried out from the large diameter into the small diameter
pipe. To assist the pig, the transition from diameter to diameter should be smooth
and gradual. Reducers should be concentric with a taper no steeper than 1:5.

1.2.2.4 PIPELINE MATERIALS
Pipelines are made from many different materials:
• Steel, including stainless steel.

• Cast iron
• Wrought iron
• Cement
• Reinforced concrete
• Plastic
Whilst there are many reasons for selection of the line pipe, compatibility with the
proposed product is extremely important. If the product is particularly aggressive, the
pipe can be lined (this also improves the flow characteristics of the product in the
pipe.
1.2.2.5 INTERNAL LININGS
Linings minimise corrosion of the pipe walls and improve the flow characteristics of
the product. They can be applied when the pipe is constructed or after it has been
laid.
There are several types of lining:
• Epoxy linings
• Concrete linings
• Plastic lining (sleeve)
Pigs must be carefully chosen for use in lined pipe – all points of contact with the pipe
(brushes, seals) should be constructed from non-metallic materials (polyurethane,
nylon, etc.).
1.2.2.6 EXTERNAL COATINGS
External coatings do not directly influence pig design but can influence the reception
of signals from pig mounted transmitters fitted for tracking and location purposes.
Any external coating and the depth and nature of ground cover should be made
known to the pig manufacturer who can then offer advice on suitably powerful
transmitters, should they be required.
1.2.2.7 FLEXIBLES
1. Smooth bore – plastic lined for chemical/water injection systems

2. Rough bore – for flowlines, jumpers, risers.
Smooth bore pipelines are not suitable for pigging and any metal-to-metal contact
with pigs should be avoided in rough bore pipelines.


1.2.2.8 BUNDLES
Bundles allow several pipes to be laid together. The operational pipelines are
contained within a large conduit that is laid as a single pipeline in the normal manner.
Bundled pipelines do not present any problems to utility pigging.
1.2.2.9 RELATIVE POSITION FEATURES
This refers to the minimum distance between any two significant pipeline features
that might influence the efficiency of a pig or cause it to become stuck.
These features are as previously listed and are particularly relevant to the positioning
of:
• Valves
• Offtakes (tees and laterals)
• Bends
The general rule is that a minimum distance of 3 x pipeline diameters should be

allowed between any two features.


1.2.3 FITTINGS AND EQUIPMENT (“What Components Are Fitted to the
Pipe?”)
1.2.3.1 VALVES
Valves present major obstacles to successful pipeline pigging. There are several
types:
• Ball valves
• Gate vales
• Check valves
• Butterfly valves
• Plug type valves
Some types cannot be pigged but others can. Certain features can be included in the
valve design to assist pigging. Only those valves which can be pigged are illustrated,
with relevant features noted.
There are two types of valve that cannot be pigged:
• Butterfly/Plug type
There are three types of valve that can be pigged:
1. Ball valves
2. Gate vales
3. Check valves
Valve design should include the following features:
1. Ball valve:
• Solid ball
• Full bore
• Concentric bore
• Smooth, shallow transitions between valve bore and pipe
2. Gate valve (Through-conduit only)

• Full bore
• No gaps or intrusions
• Concentric bores
3. Check Valve
• Full bore
• Concentric bores
• Contoured (shaped) valve clapper
• Side hinged valve clapper improves piggability

Possibly the single most important factor applies to all valves, irrespective of type.
They must all be OPEN. Appropriate mechanisms or checking procedures must be
in place to ensure that this happens as the consequences of not doing so involve
great expense.
Valves should always be fully specified as there will usually be some compromise
with regard to the most effective pig design for the function. Specialised components
may need to be added to the pig to improve its ability to pass safely through any
valves.
1.2.3.2 OFFTAKES
All offtakes present a potential hazard to pigging. It is easy for pigs, especially
spheres, to be diverted into an offtake and become stuck or continue their journey
down the offtake with obvious and expensive implications. Alternatively, if the size
and relative positioning of offtakes are not offered for consideration at the pig design
stage, it is possible that the pig may stall at the offtake as a flowpath opens up for
product/pressure to bypass the pig. Spheres are particularly vulnerable as they
incorporate a ‘single line seal’ (the circumference of the sphere I contact with the
pipe).
Offtakes are sub-divided into 2 groups:
1. Offtakes which connect to the main pipeline at 90° - ‘Tees’

2. Offtakes which connect to the main pipeline at other anges – ‘Laterals’
1. Tees
There are three types of tee:

• Unbarred
• Barred
• Sphere (or flow)
Unbarred Tees
Most pigs can pass tees where the inside diameter (ID) is less then 70% of the main
pipeline ID. However, spheres would undoubtedly be lost at this point. It is always a
good practice, therefore, to install guide bars when designing pipelines for pigging.
Always make the presence of unbarred offtakes – tees or laterals – known to the pig
designer.
Barred Tees
This is the preferred condition of all tees in a pigging system (except sphere tees).
Sphere (Flow) Tees
Sphere tees have been designed for use in pipelines that are regularly pigged with
spheres. If spheres do not disappear into an offtake, they are highly likely to stall
opposite the offtake. This is because their spherical shape results in a single line
seal in the pipe. When the pig reaches an offtake, the seal is broken and flow
bypasses the sphere.

Sphere Tees allow product flow into and out of the offtake through slots around the
inner sleeve preventing the sphere from pushing into the offtake.
2. Laterals
Laterals are offtakes that connect to the main pipeline at angles other than 90°. They
are either barred or unbarred although, when designing pipelines for pigging, they
should always be barred. Laterals present an increased opening when compared to
Tees. Therefore, pig design must take account of this. Pigs have to be made long
enough to span the opening to prevent stalling.
1.2.3.3 WYES
For the purpose of pigging, wyes join two lines together, both of which must be
pigged. The pig emerges from a branch pipeline into the main pipeline (‘main’ and
‘branch’ do not imply any difference in pipe diameter) where it changes direction by
bouncing off the opposite wall of the pipeline into which it has emerged. The
convergence angle between the two pipelines is between 22° - 30°.
Wyes can be pigged on one direction only and there is therefore no requirement for
the pigs to be bi-directional although disc-type pigs offer the most popular solutions.
There are two types of wye, each of which requires a pig possessing different design
characteristics:
1. Wyes with parallel bores

2. Wyes with over-size bores
1. Wyes with Parallel Bores
The pig must be long enough to emerge into the main pipeline whilst still being driven
in the old pipeline. As with laterals, the convergence angle extends the opening at
the junction of the two pipes which allows product/pressure to bypass the pig before it
seals in the new pipe. Articulated pigs are usually specified to overcome this
problem.
2. Wyes with Over-size Bores
Standard size pigs are used and are intended to ’float’ into the main pipeline. The pig
is driven out of the branch pipeline under pressure and into the over-size bore where
product/pressure bypasses the seals. The pig then drifts on the flow until it hits the
wall of the main pipeline where it seals again and continues its journey.
In both examples, pigs are equipped with special polyurethane bumper noses to
assist with shock absorption and to help locate the pig correctly in the main pipeline.


1.2.3.4 DIVERTERS
Diverters are designed to guide pigs from a main pipeline into a branch (lateral) – the
opposite of wye pigging. The pipeline product is not diverted – only the pig.
Most diverters use mechanical methods but some divert pigs by means of magnets
which attract the metal bodied pigs.
1.2.3.5 BENDS
There are three types of bend:
1. Forged (or factory) bends

2. Field bends
3. Mitred bends
1. Forged (Factory) Bends
Forged bends are classified according to their ‘bend radius’ which is expressed in
terms of ‘diameters or ‘D’. Standard sizes are produced as follows:
• ID or ‘short radius bend’ should not be included in a system designed for pigging.
However, if they are present, it may be possible to manufacture special pigs to
cope.
• 1½D or ‘long radius bend – suitable for: spheres, foam pigs, specified metal
bodied pigs
• 3D – most utility pigs are suitable
• 5D – all pigs are suitable
• 10D – all pigs are suitable
2. Field Bends
These are ‘cold’ bends made by machine before laying. Bend radii are extremely
large and will not cause problems for pigs – localised pipeline deformation as a result
of bending/laying is a much greater problem.
3. Mitred Bends
Mitred bends are sections of pipe cut and welded at an angle in order to change the
direction of a pipeline. They are not recommended as part of a piggable pipeline
system. However, it may be possible to design a pig for some applications but
detailed specifications of the bend would need to be supplied to the pig manufacturer.
Bends have other characteristics that influence pig design:
• Bend angle – 22°; 45°; 90°.

• Increased wall thickness in forged bends
• Ovality in forged bends
• Distance between bends in a pipeline system (Minimum 3 x pipeline diameter).


The minimum bend radius is almost always the first piece of information requested by
the pig manufacturer after establishing the pipeline diameter and pigging function. It
is important that as much relevant information as possible is made available.
1.2.3.6 TRAPS AND PIG HANDLING EQUIPMENT
To some extend, pig design is dependent upon the type of launching and receiving
equipment installed. Some systems will only accept their own specially designed
pigs and some systems will allow pig design within the limits of the trap dimensions.
These systems may be specified in applications where complex industrial pigging
strategies are necessary or where trap size must be restricted because of space
limitations.
Where there are no such restrictions, the following points should be considered:
• Are handling facilities adequate for pig types and weights?

• Are the traps sufficiently oversize to allow the pigs to be properly
launched/received?
• Are the traps large enough to meet the requirements of the pigging programme?
• Do the traps have the necessary characteristics for launching and receiving?
• Are the traps suitably equipped for automated pigging programmes?


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Design and Application Manual

PIPELINE PIGS & PIGGING

CONTENTS - SECTION 1.0

1.1 Tools and Techniques

1.1.1 Description (What are Pigs?)

1.1.2 Function (What do pigs do?)

1.1.3 Description of Pigging Functions

1.1.4 Method (How do pigs work?)

1.1.5 Selection (How do I choose a pig?)

1.2 Pipeline Design Factors

1.2.1 Internal Conditions (Conditions inside the pipe)

1.2.2 Pipeline Specifications (Dimensions & materials)

1.2.3 Fittings & Equipment (Components fitted to the pipe)

 Copyright 1999 Page 1 Section 1

PIPELINE PIGS & PIGGING

TOOLS AND TECHNIQUES

Pipeline Engineering’s formidable reputation is based on the high specification and

1.1.1.2 PIG TYPES

Utility Pigs In-Line Inspection (ILI) Tools

Bi-Directional Uni-Directional Hard Medium Soft Solid Inflatable

 Copyright 1999 Page 2 Section 1

PIPELINE PIGS & PIGGING

There are two types of pigs at the highest level:

1. In-line inspection tools (‘Intelligent Pigs’)

1. In-Line Inspection Tools (I.L.I)

1. Metal bodied pigs (often referred to as ‘mandrel’ pigs) – sealing components

1.1.1.3 CONSTRUCTION CHARACTERISTICS

The length of metal-bodies, solid cast and foam pigs is approximately 1½ - 2 x

There are 3 elements to be considered with regard to pig construction:

• The pig body

 Copyright 1999 Page 3 Section 1

PIPELINE PIGS & PIGGING

There are 3 types of detachable seal:

Careful formulation of urethanes allows characteristics such as harness, tear

There are 2 types of polyurethane:

• Ethers (Good hydrolysis resistance; high resilience; low compression set).

As a general rule, it is not always possible to specify and formulate a particular

1.1.1.4 PIG CHARACTERISTICS BY TYPE

 Copyright 1999 Page 4 Section 1

PIPELINE PIGS & PIGGING

Solid Cast Pigs

Foam pigs are often specified in similar circumstances to metal-bodies pigs.

 Copyright 1999 Page 5 Section 1

PIPELINE PIGS & PIGGING

There are 2 types of sphere (with typical uses given):

• Solid – automated pigging programmes; batching; condensate removal

Special pigs include:

• Dual diameter pigs

 Copyright 1999 Page 6 Section 1

PIPELINE PIGS & PIGGING

1.1.2 FUNCTION – (What Do Pigs Do?)

1.1.2.2 PIGGING FUNCTIONS

As a result of the experience gained in pigging operations world-wide, most functions

 Copyright 1999 Page 7 Section 1

PIPELINE PIGS & PIGGING

1.1.2.3 PIPELINE DEVELOPMENT STAGE

1.1.2.4 DESCRIPTIONS OF PIGGING FUNCTIONS

1.1.3.1 DEBRIS REMOVAL

Debris removal is generally the first operation to be considered. It occurs at the

 Copyright 1999 Page 8 Section 1

PIPELINE PIGS & PIGGING

Compressed air operations impose several conditions on the pig – no lubrication is

 Copyright 1999 Page 9 Section 1

PIPELINE PIGS & PIGGING

Pigging-PIPELINE PIGS & PIGGING

Pigging-PIPELINE PIGS & PIGGING