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04 Pigging Valve Operation Procedure 247-17-OGS-16A/P02

1.0 INTRODUCTION

This manual covers the standard operation of valves for launching and receiving of pig during pigging
operation. This manual can be used in conjunction with clients operating procedure for the safe
launching and receiving of pig.

1.1 OPERATIONAL LIMIT

Prior to performing the valve operation, it is necessary for the Pipeline Operator to obtain all current and
historical data on the pipeline sections to be inspected.

Further details of the pipeline history must be supplied to the Pipeline Operator to avoid unnecessary
problem during the surveys. Romstar personnel will directly liaise with Client personnel for coordination
of the work throughout the entire contract session.

Launcher and receiver conditions that are not capable of accommodating the survey tool should be
properly assessed and/or modified to suit the pigging requirement.

1.2 RESPONSIBILITIES

Romstar Sdn. Bhd. personnel are NOT authorized to operate any pipeline facilities or interfere with
launch or receive trap valves, closures or fittings. Unless otherwise specified, it is a contractual
requirement that the client or the client’s appointed representative operate launch and receive trap
valves, and all associated activities. This document is therefore only intended as guidance information
which the client (or pipeline operator) may wish to consider in conjunction with their safety procedures
and operating procedures. Romstar personnel will provide guidance as required during the operation.

1.3 AUTHORIZATION

No operations should commence until written permission from client’s representatives is received.
Permission is granted by signing off the Permit to Work and/or Operational Commencement Form.

2.0 PREPARATION

2.1 ASSUMPTION

(1) Launcher and receiver are suitable for safe launching and receiving of the pig. Proper assessment
shall be conducted regarding specific technical specification of the pig.
(2) All hazardous substances (e.g. Mercury, H2S, pyrophoric dust) incorporated with the product and
the working conditions (e.g. confined space, hanging object, and oily condition, dusty) have been
identified and necessary precautions have been applied.
(3) All necessary equipment is available at the place of work.
(4) Client personnel are available to conduct operation of the pipeline, operate the valves and
provide, control and monitor the required product to propel the pig as per contract.
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(5) Proper coordination and communication plan has been established as per agreed.
(6) All required paperwork (e.g. work permits, certification, commencement form etc.) are available
and comply with the client’s working practices and safety requirements.
(7) Pipeline facilities such as instrument, valves and appurtenance are installed, functioning and in a
good working condition.
(8) Product profile such as flow, pressure and temperature as required for safe and successful
operation comply with agreed condition. Any consideration that will affect run condition shall be
highlighted prior mobilization.
(9) The client has ensured that all waste generated is disposed of in a safe, timely, efficient, cost
effective manner and compliance with safety and all environment policies and regulation.

2.2 SAFETY PRECAUTIONS

(1) Operation of the valve during opening and closing should not be too quickly.

(2) Launch and receive trap shall be isolated and all valves required to isolate the barrel from the
live pipeline shall be isolated or locket out. Check for bypass and pressure build up in the trap to
assure trap is properly isolated.

(3) All operations in the vicinity of the trap are subject to the safety regulations of the client who will
have specific information as to the hazards associated with his product and installation. The
working area associated with the launch and receive traps may be regarded by the client as a
hazardous area in terms of electrical and other potential sources of ignition.

(4) Should there is a possibility for existence of explosive substance due to mixture of oxygen and
gas in the trap, Client is recommended to purge the trap (preferentially with nitrogen) prior to
opening a trap, whilst the trap is open, and after the trap has been closed.

(5) Continuous monitoring for any hostile condition and hazardous substance while the closure door
is open.
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3.0 LAUNCHING OPERATION

Prior to implementing this work instruction refer to section 2.2, Safety Precautions and be familiar with the
requirements.

A typical launch trap installation is show below for reference purposes only.
DRAIN VALVE 'F'
(UNDERSIDE)
PG
N2 PURGE PIG SIGNAL

VALVE 'B'

VENT VALVE 'E'

VALVE 'D'
VALVE 'A'

BALANCE LINE

KICKER LINE

VALVE 'C'

PLAN VIEW

3.1 LAUNCHER ISOLATION AND VENTING/DRAINING

Prior insertion of pig into the launcher, the following instruction should be carried out.
(1) Assure the launcher is isolated. If the trap is NOT already isolated, close valves ‘B’ and ‘C’ (the
kicker valve). Assure there is no valve passing and leaking.
(2) Depressurize the launch trap.
Gas product – slowly remove pressure in the trap to atmospheric pressure by slowly venting using
valve ‘E’. Drain any liquid from the trap through valve ‘F’. Close valve ‘F’ (to prevent nitrogen loss
when purging). Leave valve ‘E’ open.
Liquid product - depressurise the trap by slowly opening the drain valve ‘F’. Fully open valve ‘F’
then open the vent valve ‘E’ to enable the trap to drain. When the trap has fully drained, close valve
‘F’ (to prevent nitrogen loss when purging). Leave valve ‘E’ open.
(3) Hazardous environment situation should be taken care in according with client’s preferred practice
at client discretion.
(4) Open launch trap door.
Ensure the trap is fully depressurised by checking the trap’s pressure gauge, drained and vented
prior to opening the trap door. Slowly open the launch trap door according to the manufacturer’s
manual. Constant monitoring of any hazardous condition should be carried out until the door is
closed. A procedure for continuous elimination of any possible hazardous environment within the
trap is suggested in section 5, which may be used in conjunction with the client's own procedures at
his discretion. The launch trap is now ready for insertion of the pig.
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3.2 LAUNCHING OF PIG

Once the pig has been inserted, complete the following steps:
(1) Close the launch trap door.
(2) In accordance with the clients procedure (or that given in section 5), reduce the risk of any
hazardous environment within the trap through vent 'E'. When the trap has reached the required
safety level, close the vent valve 'E'.
(3) Pressurise the launch trap.
Bringing up the pressure slowly prevents damage to the tool and lessens the chance of running
the tool into the Launcher Valve ‘B’ or the closure door. If the trap is not fitted with a balance line
the pressurisation of the trap must be performed more slowly until the pressure across the pig is
equalised.

Gas product - open body vent in valve 'B'. Open valve ‘D’ in the balance line. Slowly crack open
valve ‘C’ and allow the trap to become pressurised to the same level as that in the pipeline. When
the trap is fully pressurised fully open valve ‘C’, and close valve ‘D’.

Liquid product - open body vent in valve 'B'. Open valve ‘D’ in the balance line, and reopen the
vent valve ‘E’. Slowly crack open valve ‘C’ and allow the trap to fill with liquid. When the trap is
full close vent valve ‘E’ and allow the trap to become pressurised to the same level as that in the
pipeline. When the trap is fully pressurised fully open valve ‘C’, and close valve ‘D’.
(4) Assure there is no leak or passing on the valves and closure. The client is responsible for sealing
any leaks.
(5) Assure that the pressure inside the trap and pressure of the line is equal (verify by checking the
pressure gauges). Close the body vent in valve ‘B’, de-isolate and open valve ‘B’.
(6) Notify the central control that the pig is ready to launch. Also confirm that the receive trap and
receiver team is ready to receive the pig.
(7) Reset the pipeline pig signals, if fitted.
(8) Slowly close valve ‘A’, to divert product through valve ‘C’ into the trap behind the pig and drive the
pig out of the launch trap and into the pipeline. This will take about 1-2 bar differential pressure
depending on the size of the pig.
(9) After the pig has passed the tie-in loop, re-confirm that the pig has left the launch by checking the
pig signal or audible sound of the pig moving off.
(10) Fully open valve ‘A’.
(11) Start isolation of the launcher trap by fully close valves ‘B’ and ‘C’.
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4.0 RECEIVING OPERATION

Safety precautions should be implemented and all personnel should be familiar with the operation
requirement before proceeding with this operation. Refer to section 2.2 for safety Precautions.
A typical receive trap installation is show below for reference purposes only.
DRAIN VALVE 'Z'
PIG SIGNAL N2 PURGE
(UNDERSIDE)
PG

VALVE 'W'

VENT VALVE 'Y'

VALVE 'V'
VALVE 'X'

BRIDLE LINE

PLAN VIEW

4.1 RECEIVE OF PIG

Depending on the dimension of the receiver trap and the condition of the receiver, there are generally
two (2) options available for receiving a pig. The standard operation is to drive the pig straight into the
trap or to drive the pig slowly into the trap after pig been stop at the main off-take.

4.1.1 DRIVING THE PIG STRAIGHT INTO THE TRAP

This method is suitable if the trap dimension passed the minimum requirement for standard receiving
operation:
 The length of the nominal section is greater than the distance between the driving cup and the
end of the pig. This is to assure that valve ‘W’ during isolation of the trap.
 The distance between the bridle off take and the closure door is equal to or greater than the
distance between the front of the pig and the driving cup. This is to avoid the front of the pig
from hitting the closure door.
 The bridle pipe diameter is of sufficient diameter to divert the pipeline flow through the trap.
If the trap is considered suitable implement the following steps, otherwise refer to section
4.1.2.
(1) The receiver normally is fully isolated during standard operational condition. All valves shall be
closed except the main off-take line valve ‘V’.
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(2) Before the pig arrive, valves ‘W’ and ‘X’ must be set in full open condition, and close valve ‘V’.
This will allow the flow to go through the trap into the bridle line. The pig will proceed through
mainline valve into the trap.
(3) Confirm the tool has passed valve ‘W’. Begin trap isolation.

4.1.2 STOPPING THE PIG AT THE MAIN OFF-TAKE

This method is not preferred as it may result to the damage of the pig. It should only be applied if the trap
dimension NOT passed the minimum requirement for standard receiving operation, i.e.:

 The distance between the closure door and the bridle off-take is too small and there is a possibility
that the pig may be driven into the receive trap door.

 The diameter of the bridle is too small such that the flow through the trap and bridle line is limited.
(1) Initial valve positions.
If the trap is isolated, the initial valve positions are:
VALVE ‘V’ : Open
VALVE ‘W’: Closed
VALVE ‘X’ : Closed
VALVE ‘Y’ : Closed
VALVE ‘Z’ : Closed

(2) Prepare for pig receiving.

Before the pig arrive, fully open valve ‘W’. Once pig arrives at the off-take, the flow will be
diverted into main off-take and the pig will stop at the off-take.

(3) Confirm the location of the pig.

(4) Depending on the pipeline condition and configuration of the facilities piping, there are two
possible methods to drive the pig into the oversize barrel.

Method 1: Full open valve ‘X’ and slowly close valve ‘V’ diverting the flow into receiver. Pig will be
slowly pushed into the receiver. Once the rear of the pig passed valve ‘W’, fully open valve ‘V’.

Method 2: Assure the venting line is connected to proper containment and slowly vent the
product from the receiver via Valve ‘Y’. This will create a differential pressure across the pig. Pig
will move slowly into the receiver. Once the rear of the pig passed Valve ‘W’, close Valve ‘Y’.

(5) Confirm the tool has passed valve ‘W’ and begin trap isolation.
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4.2 ISOLATION OF RECEIVER

Sections 4.1.1 or 4.1.2 must be completed prior to implementing the following instructions.
(1) Isolate the receiver by closing valve ‘W’ and valve ‘X’. Assure valve ‘V’ is fully open to maintain
product flow.
(2) Vent the receive trap.
Gas product - slowly open valve ‘Y’ to vent the gas till pressure inside receiver is atmospheric.
Slowly open valve ‘Z’ to drain any trapped liquid via drain line. Close valve ‘Z’ (to prevent nitrogen
loss when purging). Leave valve ‘Y’ open.

Liquid product – Slowly open drain valve ‘Z’ to drain the liquid. Once valve ‘Z’ is fully open, open
valve ‘Y’ to avoid vacuum effect in the receiver When the trap has fully drained, close valve ‘Z’ (to
prevent nitrogen loss when purging). Leave valve ‘Y’ open.
(3) Prior opening the receiver, any hazardous environment shall be properly addressed. Hazardous
environment situation should be taken care in according with client’s preferred practice at client
discretion.

For live survey tool, allow the pig to be in the receiver until the ‘latch time’ has elapsed prior opening
the receiver. Pressure purge shall not be executed during this time.
(4) Assure the receiver is fully depressurized and pressure inside receiver is atmospheric. At the
discretion of the client, procedure as suggested in as section 5 may be used in conjunction with
client’s own procedure. Then, slowly open the receiver door.
(5) Pull the pig out from the receiver and secure pig on tray.
(6) Close the receiver door and reinstate the receiver according to the client’s procedure.

5.0 TRAP PURGING

The purging process should be that as defined by the client’s operating practices. The following procedure
is for guidance only and may be adopted by the client at his discretion. It is recommended to do launcher
and receiver purging with nitrogen to eliminate explosive environment prior opening, whilst the door is open
and after the door is closed. This procedure requires that:
(1) Launcher and receiver have been fully depressurized.
(2) Inert gas normally nitrogen and associated piping connection is available.
(3) A suitable measuring device to detect and measure combination of oxygen and hydrocarbon
substance and personnel to operate the device.
(4) The client is aware of the explosive limits for the product in the pipeline.
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5.1 PURGING PROCEDURE

The following procedure shall serve as guideline to be executed by client in conjunction with client’s
own safety procedure at client’s own discretion. Prior performing purging procedure, the launcher or
receiver shall be fully isolated to avoid ingression of hydrocarbon product into the trap. Depending
on the situation and requirement, two methods are described below:
5.1.1 FLOW PURGING

Inert gas normally nitrogen is injected into the trap using suitable intake line and vented
out via the vent line. The point of injection shall be the lowest intake point of the trap.
Continue the flow of nitrogen until the level of oxygen or hydrocarbon fuel is below the
explosive limit of the product.

5.1.2 PRESSURE PURGING

Nitrogen or inert gas is injected into an isolated trap until pressure is slightly above
atmospheric, normally about 3 to 4 bar. Then, venting line valve is open to allow nitrogen
to be released. The operation is repeated until the level of oxygen or hydrocarbon is
below the explosive limit of the product.