Index = Page 3 4 5 6 7, 8 8 i oat 12, 43, Note: GD Engineering GD Engineering A guide to the selection and use of pipeline pigging equipment ao, D. coly R [Une plgglng = technical data é acon, peel 7 aoc ee pe ‘Operating sequerice for pig lsunching and receiving — Liquid Operating sequence for pig launching and receiving - Gas ig 1 ent so vvansvewcrenm hid cum ed “gar qh 0 do 1 ay B The following information is given as a quide and typical operation and is not a Training Manual nor should it be used as 2 design manual. 0 Engineering, Ratiord Rose, Worksop. Notts, $80 2PY 1 “Telephone: (91609) 482323 Fa: (01908) 477302 ‘Manufacturers and suppllers of Pipelina & Vessel Closures & Pig Signallers ‘GD ie 8 member of General Signal (UK) Lt.GD Engineering Pig Launching and Receiving Properly designed launchers and receivers are important for any pigging system to ensure safe and efficient handling of rigs. Designs may differ according to the tyne pig, service and system, Sphere launchers may be designed to hancie multiple spheres but would differ in design to a mult! pia launcher (atthough the latter may be used for both types). intelligent pigs on the ober hand would require barrels of larger clametar and length to accommodate them. Most launchers and receivers require @ minimum of four connections plus a closure and an inlat o exit ‘conection. The oversize barrel enables easy pig insertion and removal from the pipeline. If special pigs are ‘ol required the barrel size is normally one size larger than the pipeline up to 12" nominal diameter and two sizes larger 14" and above, (Except in the case of traps designed solely for batching or sphere pigs when the limit Is o7e pipe size). Intoligent pig launchers are usually two to three pipeline sizes lerger to accommodate the inctrumentation attached to them for loading unloading purposes, Whilst concentric reducers are offen used to jain the barrel to the pipeline eccenttic reducers would be the preferred choice of most pigging companies, Such an arrangement keeps the bottom of the launcher / receiver indine with the pipe for ease of pig loading. All trape should be equipped with a quick opening closure to provide essy access during pig loading or removal. Sucn closures should have a safety interlock preventing opening of the closure whilst pressure ie present. The GD Bandlock Il closure has a safety interlock wrich prevent opening of the closure prior to removal of the vent lock, but the inherent design also ensures that even with the bleed screw removed, resiual pressure wil prevent the door from being opened. In addition al closures can be fitted with separate safely interlocks requiring a key to ensure that the main block valve is in a Safe position before being able to release the closure vent screw. ‘The normal trap design requires @ main line valve, vent valve, drain vaive and 2 kicker line or y-pase line valve, See separate typical launcher drawing below. GD Engineering, Retford Road, Worksop, Notts. S60 2°Y 2 Teloshone: (01509) 462328 Fex: (01809) 477902 Manufacturers anc suppliers of Pipoline & Vessei Closures & Pig Signaliers GD is a member of Genecal Signal (UK) LidGD Engineering Pig Launching Systems Moet problems enccurtered wth plogng ayer are lated fo launching procedures, these elude 1. Not pushing he pi for enough nto te launcher barel whieh prevent the pg beng aunched, Eine aver ave opened s beer he marine vave ley open han te oa be ven foward fd become sues of comaged tying to robe he paral opened main ine vane. Launchers are generally designed to handle mest standard Inspection pigs, with the exception of intetigent or special A typical pig launching system Pressure Nee ‘sigan: Pig Signalter Se" 2 Fie. Closure (| “hx a Drain: ‘Mainline Bypass vale rf Remember the following simple criteria when considering a pig launching system for liquid or gas = + The launcher and closure should be designed / manufactured to an International code + Barre! diameter should be 1 to 2 pipe sizes larger than the pipeline to enable easy pig insertion Ensure there is adequate room for pig placement and between pig and kicker line connection > Install a pig signaller downstream of the launcher main Ene vaive io confirm that the pig has lefl the Jauncher and entered the main line. A typical pig receiver system :- Pressure Fig Signaler Vent Gauge he vo p< Mainline By-pass valve “Trap By-pass Valve t GD Enginecring, Rotford Road, Worksop, Notts. S80 2PY 3 ‘Telephone: (01803) 482323 Fax (01909) 477602 Manufacturers and suppiters of Pipeline & Vessel Closures & Pig Signallers GD is a mombor of General Signal (UK) L¢s.GD Engineering Receivers are normally longer than @ launcher with connections at different locations as can be seen by the ‘wo figures. It is not common but pigging problems can also occur at the receipt end of the system, these ste 1. The main line valve remains closed which can cause the pig to be driven into the tee damaging the cups or cleaning brushes / guides 2 Ifthe pipe pup between the main fine valve and receiver barrel is less than one ig lengti it could prevent the pig from fully entering the receiver barrel resuiting in damage to the pig when trying to close the mainline valve, Sphere launching and receiving systems Design of a sphere launcherreceiver often difer ftom pig leunchersfreceivers forthe folowing reasons = > In order to accommotdate muttiple sheres the barra is longer than a pig teuncher. > Sphere launchers are equipped with a pin or shere flap mechanism which enables sheres to be launched one ata tme on a preset schedule or as required. Activation is normally remote to the launcher site at a mother platform or central conti point. Operation of the flap mechanism is controlled by a single hydaulle or pneumatic cylinder. The design Is such thet the flaps can be locked inthe ‘up" postion for launching of inteligent or conventional pigs. > Whilst launchers are normally inclined fo allow the spheres to rol into the pipeline the barrels can also be Vertical te save space, especially on offshore platforms, GD Engineering, Retford Road, Worksop. Notls. S80 2PY 4 “Telestione: (01609) 482323 ex: (01000) 477002 Manufacturers and suppllors of Pipeline & Vessel Closures & Pig Signallers {GD is # member of General Signel {UK} Lid.GD Engineering INFORNATION ‘The following table gives an indication of approximate pressures and flow rates required to propel ‘pig with 2 liquid or gas flow through a pipeline at a given speed. lin the event that your particu'ar application employs pressure and fiow rates in excess of those: ven please consult your local representetive for advice before commencing pigging operations ‘SUGGESTED APPROXIMATE FLOW RATES AND PRESSURES FOR LINE PIGGING TiQUiD FLOW GASEOUS FLOW ] NOMINAL [~ PIG DRIVING TPN. US GPA FLOWREQD FLOWREGD PIPE ID. PRESSURE 8 Kmitir 40KmiHr (Gag in sig Tees sr a EA AT A @ [82 | too-a00_[ rr 7a 150, 7 [oo-ts0_ [7-105 a a 400 [400117 350 © [va [75.125 | 5.88 Sa] 100 [20) 760 [er [ise 1s-100_—1 3: 8 00 180 e 3389 58 2 30, 700) 107 0 a az 30 5 Gi af a0 co 16 aE a5. 18 ae at a5. a 4430 | a 3 [0 45] Es 307 45. 2 7730 a ae eo a | 30743, 403 | 307 45. ero | 50000" a7 _1 a0 cn a os, | seco. 439__| 30 45. 3 895, “34000 60 | 30- as a_| 997 32000. is. 26° as ae foe B00 aoa [80 co The following equations may be used to calculate approximate volumes required to transmit pigs at various speeds: Gas flow ~ Imperial SCFM = 16.94 x Pig Speed (MPH) x Pressure (psi abs.) x Pipe Inside Dia [inches)* ‘Temp. °R CF + 460) Gas Flow~ Metric NM3imin = 0.003825 x Pia Speed (KPH) x Pressure (Bar abs.) x Pipe Inside Dia (mmit Temp. °K CC + 273) Liquid Flow —Imporial Q Gal/Min US) = 3.646 x Pig Speed (MPH) x Pipe Inside Dia. (Inches)? Liquid Flow — metric Q (Litres/Min) = 0.01329 x Pig speed (KPH) x Pipe Inside Dia. (mm)? NOTE: ‘AMotoriSoc = 3.6 KPH = 2.237 MPH = 3.281 FoolScc 1 MPH= 1.6093 KPH GD Engineering, Retford Road, Worksop, Notts $80 2PY 5 Telephone: (01909) 482323 Fan: (01909) 477902 ‘Manufacturers and suppllers of Pipeline & Vessel Closures & Plg Signatiors ‘GD is a member of General Signal (UK) Ltd.GD Engineering PIG TRAP SELECTION itis important to have all the relevant infermation to enable selection of the most suitable tauncher or receiver to meet the customers need, Typical questions to be asked ‘- Pipeline intemal diameter, wall thickness (incliding corrosion allowance) and material. Design and operating pressure range. Design and operating temperature range. Length of pipeline between launcher and receiver. Location of plant facility, e.g. receiving terminal Wil intelligent or inspection pigs be used. What is the pipeline used for, e.g. Crude oil transfer, gas transmission, bitumen etc. Is the system to be operatad manually or automatically. How will the pigs be monitored during taunch or receipt. ‘What type of pigs wil be used, e.g. Cleaning pigs, spheres, foam pigs etc. How will the pig trap be mounted, e.g. by saddles, skid mounted. vyyvvyyyyYyY Typical pig launching and receiving trap sizes. (or guide purposes only) = "F BR ¢ ‘Keine sce NB_[ B= Basra sie | “C= Overal iangih PWG LAUNCHER C= Overall angth PIG RECENER eee obs ‘isan eee ee — oe ee 8 (res ee — oe ie — eget =o. ai ioe ae 2 oe oe on = a ——— ea ie ees = fen — GD Engineering, Reiford Road, Worksop, Notts. S80 2PY Telephone: (0:908) 482923 Fex: (01909) 477902 manufacturers and suppliers of Pipalina & Vesso! Closures & Pig Signallers GD is 2 member of General Signal (UK} LidPIG SELECTION ‘Application Hydrostatic testing Drying De-watering Proving Commissioning Production GD Engineering Pig Selection Cup pig Bidirectional pig ~~ ~-—-f Foam pig. —serenenen Foampig ~ CS Spheres |< aen Birectional pig Foam pig —. Spheres ——esene Bidirectional pig ee eee Cuppig: ann “Wh Bidirectional pig —-—-— rps ann ~ ED Cuppig == cup a brush pig — ~~ PR RP Spheres een = @ op Plough blade pigs =~ GD Engineering, Retford Road, Worksop, Nols. S80 2PY “Teleahone: (01509) 482323 Fax: (01903) 477902 Manufacturers and suppliers of Pipaline & Vaséel Ciosuree & Pig Signalfers ‘GDisa snlber of General Signal (UK) LtdGD Engineering CLOSURES GD Engineering have a range of quick opening closures designed to ensure safe and efficient access to pig traps oF pressure vessels. When selecting a closure it is of paramount importance that issues such as safely, ease of operation, ‘maintainability, compatiblity anc matersls of constructon are considered, Foatures Easy to operate Integral Safety Bleed Screw warns the operator f pressure is stil present in the system before the door is opened. @ Variety of Seat Materials o suit all ow media, Pressure ranges from ANSI 150 up to ANSI 2500, Choice of Materials of construction Low maintenance / Minimal spares are required. Cannot be opened whist the system is oressurised even i the Bleed Serew is removed and all other vent and drain connections are not operational. © Total operator safety is maintained. ‘Special Anti-corrosive coatings are avaiable, ‘Sizo range from 8" (180 mm) to 100" (2540 mm) opening, Bult weld or Flanged end connection. ‘Suitable with Inteligent / Inspection. cigs. Optional hinge handing. Horizontal oF vertical mounting Meets or exceeds most design Code/QA requirements. © ‘Suitable wih all types of pg. vy vvyyy vue yyy Applications For use on Pig launching or Receiving Traps. Fast access door for gaining entry to pipelines. Also Used on strainers, Filters and Pressure Vessels 26 a quick opening access hatch. wvyy @ Bandlock t closure. GD Enginesring, Retford Road, Worksop, Notts, $80 2PY ‘Telephone (01808) 482323 Fax. (01908) 477802 Manufacturers and suppliers of Pipeline & Vessol Closures & Pig Signallers ‘GD le 2 member of Genaral Signal (UK) Ltd.GD Engineering PIG SIGNALLERS Introduction, Pig Signallers provide 2 means of detecting whether Pigs have been Launched into the pipeline, the Receiver, or have passed specific locations In tha pipeline. Selection criteria for most appropriate Pig Signaller will be based on a number of important factors such as :- Pipe Size and Wall Thickness, System Design Pressure and temperature. Materials of construction Proximity ofthe Pig Signaler to the operations / control centre “Type of confirmation preferred, 2.9. Visual Flag, Electrical Signal, or combination unt ‘Whether Pig Signalier is a new unit or is replacing an existng unit. le itnocessary to be able to inetall or remove the Pig Signallar under operating conditons, ‘Type of pigs Daing used in the ine, Frequency af pigging operations Location of Pipeline end / or equipment, eg. Buried pipeline may require special extension type Pig Signallers. vyvvyyyyyy GD Engineering can meet all of the above requirements up to ANS! 2500 with theie ‘Pigalerts’ @ signalier, Features Highly visible Flag, Infine tFeger remains in the neutral position after the pig has passed and operates bi-cieetionally. Manuat resetting of Flag ensures Signal is always operational Electric Proximily Switch for remote signal confirmation. ‘Telemetry System available. ‘Body and Internal parts constructed from 316 Stainless Steal Pressure ratings from ANSI 190 up to ANSI 2500. ‘Combination Wianual reset Flag and Electrical Proximity switch unite avaiable Retrofit units can be supplied for filting directly to competitors signaller base without having to modify or replace parts on the pipeline, Iniegral Valved models enable the Signaller to be safely removed from the line without having to depressurise the system, External shatt available for Pig Signallers connected to buried pipelines. Can de mounted on a Weld Base or Flanged connection. Tee Fiting available for 114° up to 3" pipe sizes. Magnatic Detection systems availabe Temperature rating from ~40°C to +100°C. vevvyyyyy vyvvy ¥ GO Engineering, Rett Road, Worksop, Notts. S30 22Y Telephone: (01908) 482929 Fax: (01808) 477502 Manufacturers and suppliors of Pipoline & Vessel Closures & Pig Signallers ‘GD is 2 member of General Signal (UK) LidGD Engineering PIPELINE CONSIDERATIONS Bends Figs have to negotiate bends anc wil require a minimum, ‘bend radius. One type of pig may be able to negotiate: 21% D bend whilst another will require up to @ 6 D bend. ‘The minimum tend redius is one of the most important factors in pig selection, but this can be avoided if euitable bend radi are incorporated into the pipe design, actus of a bend is measured as the distance from the centre of the radius to the centre tine of the pipe. {n addition to the bend radius, the bend degree is also important ‘Whist a pig may not negotiate a 1% R~ 90° bend it may negoliste @ 114-45" bend, ‘The mest commonly used bend for pipelines that require pigging is 3R as most pigs will negotiate tis beng ‘racius and is the most versatle for plgging operations, although 114R bends are often found in gas pipelines. Pipe bends shouls NEVER be welded back to back, a least two ripe diamater lengths shoul! be welded between bends for normal pigaing. Atleast 6 feet (2 meters) of pipe should be used between bends for most inteligent pigs or corrosion detection pigs. Bend types versus applicable pig types. Tyies [Bendre] Teron Tae ae Tal apciaten tend ie TaDianelet arama bend] Sis possone fon ps Saal eae TR, | “ 7 lussoipiet pina. | THR ‘1% x Diameter | Long radius bend ‘Spheres, foam and sams batching and | Gas ppolines, not | | ei /seanng as || rcormanced % Tw Diente — | Fao end ost pes of pg witvhe posebe | Gae and Laut pipoiaee oxcepten cf Hoten’ oe ” Fania [ran | Faies Apis an linet pie Araites l = Valves Use of valves in piggsble pipelines should be restricted to full bore, full opening types for safe pig passage. Reduced bore valves cannot usualy be pigged, The types of vaive which can be pigged are :~ ‘Through - concult gate valves. Wedge-tyee gate vaives. Bail valves. Check vawves, > > > GD Engineering, Hottore Hoad, Worksop, Nott, $80 2PY 10 ‘Telephone: (01998) 482323 Fax (01803) 477902 Manufacturers and suppliers of Pipsline & Vessel Closures & Pig Signallers GD Is a momber of Sereral Signal (UK} LtdGD Engineering Valves — continued. But there are limitations to the use of wedge-gate valves and some check valves = > The gap in wedge ~ gate vaives can cause some cup and bi-directional pigs to stop in the gap. Pigs for use with this type of valve should be muli-cupped to ensure the pig epans the gap. > Spheros will not negotiste standard check valves, normally they wil stop in the chock valve bow area Lunt displaced by another pi. > Reduced port / bore valves should not be used in plggable line. Tees, ‘Always ensure that pipeline tees are barred to prevent the passage of a pig into the branch, The restriction is not imited to 100% branch, even 75% ean cause problems of trapped pigs. Undarred tees are not to be recommended especially above 59% of the le size. Where spheres are used a special sphere tee isthe only real sclution as a sphere can enter a branch as small as 25% of the line size under certain conditions. itis nol uncommon for spheres to stop on barred tees simply because the propeliing media by-passes the sphere around the side connection. ‘As with bends, tees should never be welded back to back, allow at least 1Wo pipe clameters between each tee. GD Engineering, Rotiow Rood, Worksop, Net's. $80.2 un Telephone: (01803) 482328 Fax (01909) 477902 Manufacturers and suppliers of Pipeline & Vessel Closures & Pig Signallers GD is 2 member of General Signal (UK) LtdGD Engineering Operating sequence for launching and receiving of pigs - for fiquid service - Note - this information is iven as gereral inforation onl and is notinfended as teining ‘or cigning syetem operators, Breseure vant Mainiine Pig Signaller | LAUNCHING jauge e Trap valve — Start condition ‘Closure ) x Flow “Trap io pressurised and Ls A Filled with fiquid, Valves wap kirervane "Xo | Salts Bande re Drain ¢ Mainline closed a Bypass valve aaa — ld Close valves A and ©. Drain the launcher by opening drain valve D and vent vave E to alow the air to dieplace liquid. When the trap is compiotely drained (0 psig) and with valves D and & sill open, open the clasure door and insert the pig such thatthe frst cup forms a tight Min the reducer x. 4. Close and secure the closure door. Close drain valve D but leave vent valve E open. Slowiy fil the trap through valve C allowing airto vent through valve E. When Fling is complete clase valve E to allow the. pressure lo equalise then close valve C. 5, First open valve A then valve C, the pig is now ready for launching. 6. Panially close vaive B which wll increase the liquid ow through valve ¢ and behind tho pig. Continua to lose valve B until the plg exits the irap and into the pipeline which will be indicated by the pig signalle, 7. When the pig leaves the trep ang enters the pipeline fully open valve 8. RECEIVING Pressure Gauge a ig Signalier Vent ‘Starting conditions Mainine Trap is empty at Tap vee q ze atmospheric pressure. J — Valves, and E ae open. | row Gap x Closure ‘Valves A end C are cloeea, a = Closure door is closed anc g secure TrapBypass SOc & Drain ane A Valve By-pass vane wu 41. Close drain valve 0 and stowy open the trap by opening valve C and venting via valve 2° When full close vent vaive & to allow the pressure to equalise trough valve C. 3. Fully open valve c and then vahe A, the trap is now ready to receive pg. 4. When the pig arrives it may step between valve A and the tee (point 29. IFthis happens partly close ‘lve B which in turn wil force the pig into the rep by the Increased flow through vaive C. ‘When the pig arives in the trap, insicated by the pig signaller, open vaWve B fully and close valves A & C. ‘Open drain valve D and vent vaive E to crain the trap. 0 Engirerng, Revors Road, Worksop, Nots. S80 2°Y 2 Telos on: (01908) 402323 Fax (01906) 477902 UManufacturecs and suppliers of Pipeline & Vesesl Closures & Pig Signalers ‘GD Is a member of Genera Signal (UK) Lid.GD Engineering 7. After the trap is fully drained (0 psig) with valves D end E fully open, access the trap through the closure and remove Ne. Close and secure tho closure door after clearing the seal area and greasing the weted door pars, Operating sequence for launching and receiving of pigs - for gas service — [Note his information ie en as general in‘ormatien only and is not intonded as training for aging system cperatore. mice misan? Mainline ig Sig LAUNCHING cs" Q th -_ _ Start condition A ee ‘Trap is pressurised and fo filed with goo. Valves A, x ses eee BF wes. (SE fe Sorbeshesl 4 2. Open valve E to vent the trap to atmospheric pressure Fe ae ee wer went wore arentont the pig such that the first cup forms a tight fit in the reducer X. 4. Close and secure the closure door. Purge alr ftom the trap through valve E by slowly opening valve C. \When purging is compete close valve E to allow the pressure to equalise then clase vaive C. 5. Firstly open valve A then vave ©, the pig Is now reacy for launching, 6. Partially close valve B wich wil increase the gas flow throush valve C and behinc the pig. Continue to close valve until the pig exits the trap and Into the pipeline whien wil be indicated by the pig signaller. 7. When the pig leaves the trap and enters the pipeline fully open valve 8, RECEIVING: Pressure Fig Signaler Vent Gauge Starting conditions Mainline : ‘Trap valve Trap is empty at ql x atmospheric pressure, aves Dene are | row Gop © | [ Cosue ‘open. Vaives A and C are . a closed. Closure door is | ¥ > Lelosed and secure. | ‘Trap By-pass Cc Drain Mainline Wo vas 0 By-pass valve A Close drain valve D ancl slawly open valve C to purge the trap via vent valve E. When fully purged close vent valve E to allow the pressure to equalise through valve C. Fully open valve C and then valve A, the trap is now ready to receive a cig. ‘When the pig arrives it may stop between valve A and the tee (point X). Ifthis happens pactely close valve B which in tum will force the pig into the trap by the increased flow through valve C. ‘When the pig arrives in the trap, indicated by the pig signaller, open valve 8 fully and close valves A & C. ‘Open drain valve D and vent valve E to vent the trap to atmosphere. After the trap is fully vented (0 psig) unth valves D and é fully open, access the trap through the closure ‘and remove the pig GD Engineering, Retford Road, Worksop, Notts. $50 2PY 13 ‘Telephone: (01809) 482523 Fax: (01903) 477302 Manufacturors and suppiiors of Pipeline & Vessel Closures & Pig Signallers, GD Is a membar of General Signal (UK) Ltd.GD Engineering 18. Glose and secure the closure door after cleaning the seal area and greasing the wetted door parts. GD Engineering, Retiord Road, Worksop. Notls. S60 2PY “Toloahone: (01000) 482323 Fex: (01909) 477902 Manufacturers and suppiiors of Pipelina & Vessel Closures & Pig Signallors GO is.a mernber of General Signal (UK) Lid, 14