Effective Date Section

10/10/2017 Operation
Revision Page Number
0 Page 1 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location 247-17-OGS-16A /P03
Recovery

STUCK PIG PROCEDURE

1.0 SCOPE

The following is a general guideline used to communicate, verify and deal with a potential
stuck pig operation. Specific procedures related to pipeline operations are to be determined
by the pipeline operator.

2.0 NOTIFICATION

The client's Project Manager or Lead Engineer may communicate a notification of a possible
stuck pig to Romstar Field Crew or any other employee may communicate a notification of a
possible stuck pig to the client Project Manager or Lead Engineer.

In the event a notification of a possible stuck pig has been communicated to either party both
parties will work together to undertake the following guidelines and produce specific
procedure related to dealing with the stuck pig operation.

3.0 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.

4.0 FACT FINDING & CONFIRMATION

The following items are to be checked to determine if indeed a pig is stuck:

1. Normal operating conditions such as flow rates and pressures are reviewed and
confirmed
2. Current operating conditions such as flow rates and pressures are reviewed and
confirmed
3. Branch line (on-takes and off-takes) conditions are reviewed and confirmed
4. Pig launch procedures and documentation are reviewed to establish the time of
launch and conditions
5. All valve positions are checked and confirmed as required by the pig launch
procedures
6. All pig signals, if available, are checked to verify pig passage
7. Review all SCADA system data, which may lead to confirmation is reviewed
8. Launch and receiver pig barrels are drained and opened to verify if the pig is there

Confirmation of a stuck pig is determined by this time. If confirmation cannot be confirmed by

reviewing the above items, the client is requested to continue flow the pipeline at the current
operating conditions until such time that confirmation can be made.

 
 Effective Date Section
01/04/2017 Operation
Revision Page Number
01 Page 2 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location RSB-PL-03/P03
Recovery

5.0 DEALING WITH A STUCK PIG (WITH OR WITHOUT BYPASS)

Upon confirmation of a stuck pig one or more of the following steps

may be required.

Step 1:
Increase the flow rate and line pressure, but do not exceed the safe limits of the pipeline.
Normally, pigs which are considered stuck are only lodged can be easily moved by this
method.

Step 2:
If step 1 fails to dislodge the pig, remove pressure from the line and vent or drain in the
direction of the pig launcher. Removing the line pressure allows the pig to relax and return to
its normal shape. Allow the pressure to dissipate for 15 to 30 minutes. Re-pressure the line
to drive the pig through the obstruction. Repeat 2 to 3 times if necessary.

Step 3:
If the pig still fails to move, run a soft foam pig behind the stuck pig to create a positive
driving seal and repeat Step 1.

Step 4:
If Step 3 is unsuccessful, consider ways to back the pig out of the line, returning it to the pig
launcher. This will require pressuring and flowing in a reverse condition from the trap end of
the pipeline.

Step 5:
If all else fails, the pig will have to be physically located and removed by cut out operations.

PIG LOCATION & RECOVERY

1.0 GENERAL

This document is a general guideline for pig location and recovery. The document lists the
course of action to take when it becomes apparent that a pig is overdue at the receive end
and suspected to have stopped in the pipeline. A 'pig' is reference in this document is taken
to imply any type of pig, e.g. gauge pig, cleaning pig, inspection pig etc.

This document is not intended to replace procedures that a pipeline operator have in place.
In the event of disagreement, the contract proper shall hold precedence.

 
 Effective Date Section
01/04/2017 Operation
Revision Page Number
01 Page 3 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location RSB-PL-03/P03
Recovery

1.1 ACTIVITIES PRIOR TO INSPECTIONS

Several precautionary actions can be taken to safeguard against any pig from stopping or
lodging in the pipeline. This includes:

(1) Ensuring all available information on the targeted pipeline is readily available in order
that a thorough assessment can be carried out well in advance of the actual run of
the pig. Any obstructions in the pipeline are removed prior to pigging.

(2) Proving the pipeline. An essential part of pigging is to initially prove the pipeline to
verify that any intended pig will pass through the pipeline safely:

• Run a customary low density foam pig if the line has never been pigged before.
• A final check should be made to confirm that all valves in the pipeline, between the
launch and receive trap, are fully open. Run Gauge plate to establish the general
minimum bore throughout the intended pipeline:
• Geometry survey to detect and record the actual location of bore variations
(restrictions, dents, ovality etc.), and obstructions.
• Run cleaning pigs to remove debris that can potentially stop the pig in its journey. In
some situations, an enhanced cleaning programmed may be necessary using a
range of progressively aggressive pigs until all damaging debris are removed to allow
smooth passage.
• Profiling with dummy tool. Running a purpose designed pig that mimics the actual
inspection pig.

(3) Ensuring that the optimum running parameters and conditions (product pressure, flow
rate and temperature) are in place, monitored and controlled throughout the pig run.

1.2 COMMUNICATIONS & LOCATING DEVICES

Effective communications must exist between all sites, including 'listening posts'. An
emergency reporting structure between Operator/Client and Contractor must be established
to prevent confusion and ensure that information is relayed to the right personnel as quickly
as possible.
Uncertainty concerning the location of a pig can be minimized if pig tracking is used. In some
instances, e.g. offshore pipelines, the use of pig location equipment may be impractical and
cost prohibitive.

However, in the event of deploying a rescue pig', a location device is essential (a rescue pig
is used to confirm the location of, or drive out, a lodged pig). For offshore pipelines, ship
mounted acoustic ranging equipment may be considered. Monitoring the progress of a pig
as it passes through the pipeline is recommended, such that in the event of it stopping, the
approximate location can be determined. Pig tracking can be achieved by both physical and
theoretical methods

 
 Effective Date Section
01/04/2017 Operation
Revision Page Number
01 Page 4 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location RSB-PL-03/P03
Recovery

1.3 PHYSICAL METHODS

Several methods can be used to detect passage of the pig:

(1) Pig signalers

It is accepted practice to install pig signalers in launch and receive traps as a means of
confirming that the pig has left the launch trap or has arrived in the receive trap.

Before each run, checks should be made to ensure correct operation of the pig signalers.

(2) Listening points

These can be set up at specific points along the pipeline, e.g. valve stations, to audibly
detect the passage of the pig. This can be done manually or by attaching instrumentation to
the pipeline, e.g. 'geo-phones', that will detect the passage of the pig.
Recording the time of passage can be used to confirm the pig speed and run duration.

(3) Magnetic field detection

For pigs fitted with magnets, e.g. an inspection pig, portable magnetic detectors can be
placed at specific points on the pipeline (on the pipe surface or on the ground in the case of
buried pipelines). Magnetic detectors, including a simple compass, can also be used to
confirm that the pig has left the launch trap or arrived in the receive trap.
Magnetic detectors are not normally practical for offshore pipelines due to the logistics of
having to deploy the devices at several locations.

(4) Other devices.

Various devices can be fitted to pigs to monitor their progress and confirm location, e.g. low
frequency transponders and radioactive sources, however both have their drawbacks.

Transponders are suitable for off shore pipelines but require a seagoing vessel to carry the
acoustic ranging equipment to track the pig. Radioactive sources require detailed logistical
planning, and HSE control.

Other systems include pressure pulsing whereby the product is used as a medium to
transmit a pressure pulse that is bounced off the pig in a similar fashion to radar

1.4 THEORETICAL METHOD

Theoretical tracking is normally based on:

(1) Monitoring product flow rate:

Product flow rate should be carefully monitored during pigging in order to calculate the
approximate location of the pig, the estimated run duration, and estimated time of arrival
(ETA) at receiver. The pipeline operator should ensure that pressure and flow measurement

 
 Effective Date Section
01/04/2017 Operation
Revision Page Number
01 Page 5 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location RSB-PL-03/P03
Recovery

instrumentation is in good working order, and communication arrangements are set up.

MINIMUM PIG RUN TIME (hrs) =

MINIMUM PIG RUN TIME (hrs) = 1.1

(2) Monitoring product pressure.

An indirect means of tracking is to monitor the differential pressure (DP) across the pipeline
during the run. DP should remain relatively steady; however, any significant changes may
indicate erratic movement of the pig or stoppage. It is possible that pressure fluctuations due
to operational reasons are sufficiently large to mask increased DP caused by the pig.

Under normal circumstances, a DP across the pig of approximately 1bar is sufficient to

propel the pig in a steady state condition. If the pig starts to stick, the DP across it will rise
causing the flow through the fixed bypass to increase. If the DP across the pig exceeds 3 bar
the driving elements are designed to 'blow over', allowing much greater flow past the pig
whilst at the same time reducing the driving force until the DP builds up again.

The occurrence of this event, along with the time since launch can be used as a means of
estimating the location of the pig.

2.0 TROUBLESHOOTING

In normal circumstances, the estimated time of arrival (ETA) at the receive trap should be
within the maximum calculated run time. The following may be used as troubleshooting
guidelines:

2.1 DP EVIDENCE

If at any time during the run, the DP across the pipeline suddenly increases and throughput
decreases, this may indicate that the pig may have stopped or lodged. If this happens the
pressure at the launch end of the pipeline should be monitored and controlled. The flow rate
should be maintained for a time equal to the 'Last ETA' + 3 hours where possible. If receipt
of the pig is still not confirmed, consideration should be given to the following options

(1) Pipelines transporting liquid.

If pipeline operation is not affected, increase flow rate to as high as practical but not
exceeding 4 m/s. Maintain the increased rate for the full run duration time and monitor for

 
 Effective Date Section
01/04/2017 Operation
Revision Page Number
01 Page 6 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location RSB-PL-03/P03
Recovery

any change in DP that may signify that the pig has moved. If the DP has not reduced, the
flow rate should be returned to a level required to meet operational demand as the pig may
be snagged e.g. collision with a partially open valve, or lodged in a thick wall section of the
pipeline, or an obstruction. When the pig's drive cups/discs have been 'blown over' normal
production can be maintained, the DP over the pipeline will however show an increase.

In such instances the next course of action would be to commence a search. If the pig has
lodged but is subsequently moved by the increased DP across it, this will be recognized by a
reduction in pressure at the launch end of the pipeline together with a slight increase in flow
rate.

(2) Pipelines transporting gas.

Create an artificial DP across the pipeline by reducing the pressure in front of the pig
(through diversion or venting) and monitor for any increase in flow rate that may signify that
the pig has moved. If after a time, no evidence of pig movement has been confirmed, the DP
should be stabilized to a level required to meet operational demand. This situation would
indicate that the pig has been snagged as mentioned in (1) above, or has stopped due to
adverse wear of the pig's drive cups/discs, especially applicable in dry pipelines containing
abrasive debris. In either event, normal product throughput should still be possible.

Commencing a search program would normally be the next step to take.

2.2 PIG OVERDUE

If no run problems were encountered and arrival of the pig at the receive end is overdue, the
recommended course of action is to:

(1) Wait until the 'Last ETA + 3 hours' has passed.

(2) Confirm if the pig has left the launch trap:

If the pig signaler' downstream of the launch trap has not tripped, or no noise was heard
indicative of the pig moving off, or no other positive confirmation was obtained that the pig
may not have left the launch trap, use a magnetic detector; compass or other instrument to
confirm suspicions for magnetic pigs. If there is positive evidence that the pig has not left the
launch trap, the following should be considered:

• Check that the launch trap valves are in the correct position, i.e. all product flow is
passing through the trap.

• If possible check any valves, or off takes immediately downstream of the launch
trap for evidence of the pig.

• Increase the DP across the pig to generate more drive. This should be tried more
than once, if unsuccessful consideration should be given to checking inside the trap.

Opening the trap is only possible if it is certain that the pig is not lying across the launch trap

 
 Effective Date Section
01/04/2017 Operation
Revision Page Number
01 Page 7 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location RSB-PL-03/P03
Recovery

isolation valve(s). Close the launch trap isolation valve(s), vent/drain the trap in accordance
with normal procedure and open the door. Carefully check the position of the pig; whether or
not the drive cups/discs are in the engaged position to enable the pig to be driven forward
(the pig may also have been pushed backwards during pressure balancing the trap).
Pushing the pig further in maybe all that is required. If there is any uncertainty, the pig
should be pulled out from the trap backwards and examined to establish the cause of launch
failure.

Although highly unlikely, if indications suggest that the pig has stopped across the launch
trap isolation valve(s) then dislodgement attempts should be undertaken. Check that the
valve is fully open, under no circumstance try to close the valve(s). Increase the DP across
the pig and monitor for movement. If the pig fails to move, check if product throughput is
being maintained. Obtaining positive confirmation of the pig's position, e.g. radiography,
should be the next course of action prior to considering removal logistics.

(3) If it has been confirmed that the pig has left the launch trap but has not arrived in the
receiver trap and no run problems were experienced, i.e. no significant changes of DP or
flow rate were detected, then the ETA should be extended by 3 hours.

If after this period, the pig has still not entered the receive trap, consideration should be
given to increasing the DP across the pipeline for short periods or continuously by a
combination of reducing the receive pressure and increasing the production rate. If possible
the higher production rate should be held for another 3 hours.

If the pig has still not been received its arrival could have been delayed by intermittent
stoppages due to damage/wear of the drive cups/discs. Consideration should be given to
opening the receive trap. However unlikely, the pig may have stopped in the vicinity of
the receive trap isolation valve(s) hence this area must be checked prior to closing the
valve(s).

If it is certain that the pig is not bridging the receive trap isolation valve proceed to isolate,
vent/drain the trap and check for the pig. Reducing production rate is recommended to
prevent inadvertent receipt whilst the receive trap is isolated. If the pig is not in the trap, a
search should commence.

2.2 SEARCH & RECOVERY

If the pig loses drive through damage/wear or becomes lodged somewhere in the pipeline it
should be possible to maintain a reduced level of throughput pending confirmation of the
pig's location.

The initial search should concentrate on the most likely areas - valves, off-takes, thick-wall
sections etc. Reference to the pipeline maps will benefit at this stage. Attention should be
given to checking the main off takes at launch and receive sites, especially if 'adjacent tees'
are present.

 
 Effective Date Section
01/04/2017 Operation
Revision Page Number
01 Page 8 of 8

Document Level Subject: Document Number

03 Stuck Pig Procedure & Pig Location RSB-PL-03/P03
Recovery

Pipeline history records should be checked to confirm whether or not the off takes have pig
bars
fitted (a protruding pig bar can obstruct a pig's passage). If the pig is suspected to be
located in a valve, offtake etc., the use of radiography should be considered as a means of
verification.

If the approximate location is known from pig tracking information, and the search program
enables the exact location to be confirmed, a plan of action will need to be carefully drawn
up to enable recovery of the pig.