Chapter

6
Dewatering
6.1 Introduction
This chapter describes bulk dewatering and residual dewatering. Dewatering is
the removal of as much water as possible before the pipeline is conditioned and
the product is introduced.

Pipelines that can be dewatered as the product is introduced are discussed in

Chapter 7.

This chapter is organized into the following main parts:

• The Overview introduces dewatering to readers who have no previous

pipeline experience.
• The General Preparations for Dewatering, Detailed Preparation for
Dewatering, and Stages of Dewatering sections describe and explain in
detail the engineering and operational procedures that may be required
for some clients. These sections are designed to help engineers prepare
documentation.
• The Final Reporting section contains details of information typically
required for the Final Report to the client.

6.2 Overview
The Overview will discuss the following topics useful for understanding dewa-
tering:

• Pig train design

• Selecting the propelling medium
• Effect of dewatering on conditioning operations
• Dewatering requirement (acceptance criteria)
• Velocity of Dewatering Pig Train
• Accumulated Heads

January 1997 Chapter 6 6-1

 Dewatering removes as much of the fill water as possible from a pipeline after
successful completion of hydrostatic testing and before the pipeline is dried for
introduction of the product.

Dewatering is achieved by propelling a train of pigs, and in long lines sealing

gels, through the pipeline, with air or nitrogen as the propellant. In some cases,
such as when an oil line or wet gas line is being dewatered, the pipeline product
itself can be used as the propellant.

The terms dewatering and drying are somewhat interchangeable; however, when
used interchangeably, the terms could be confusing. For this manual, the follow-
ing definitions apply:

• Dewatering describes two procedures: bulk dewatering and residual

dewatering.
• Bulk dewatering describes the removal of the main body of water left in
the pipeline after hydrotesting.
• Residual dewatering describes the operations conducted after bulk
dewatering. It concerns the removal of as much free water from the
pipeline as possible, either before introduction of product into the
pipeline, or in preparation for drying.
• Drying describes the steps conducted after dewatering that prepare the
pipeline for introduction of product.

Different levels of drying are determined on the basis of the type of product to
be carried. For example, a pipeline for wet gas does not need to be conditioned
to the same level of dryness as one for dry gas.

6.2.1 Pig Train Design

When a dewatering pig is designed, the emphasis should always be placed on
dewatering. If the client requires cleaning or gauging pigs in the dewatering
train, these should be additional to the dewatering pigs.

Sealing gels are used in dewatering pig trains to increase the efficiency of
dewatering. These gels increase efficiency by reducing both the amount of
bypass water in the reverse direction and air or nitrogen in the forward direction.
Sealing gels also help lubricate the pig discs that will be traveling in a dry
atmosphere. The lubrication reduces the amount of wear and bypass on the pigs.

For pipelines that are filled with seawater, a batch of fresh or potable water is
often included between two of the pigs to wash out salt deposits.

The simplest pig train consists of two bidirectional pigs separated by the propel-
ling medium. Selecting the propelling medium is discussed later in this chapter.
The first pig removes the bulk of the water, while the second pig sweeps some of
the remaining pools of water through and out of the pipeline. A simple pig train
can be used in short pipelines or pipeline sections, both subsea and on land. The
simple pig train can be followed by more pig trains that incorporate foam pigs to
pick up residual water without too much additional time required for dewatering
to be completed. In long pipelines, where propelling a pig train through the
pipeline can take considerable time, the pig train is designed to complete bulk

6-2 Pipeline Commissioning Manual January 1997

dewatering and remove as much residual water as possible in one pass.

The distance between pigs in a train is critical. If the distance is too short, a pig
may collide with the pig in front of it. A collision occurs when the propelling
medium bypasses the front pig.

There is no definite rule available for calculating the distance to allow between
pigs. As a guideline, allow 1% of the pipeline length between pigs to ensure that
the pigs will not collide. However, if the internal surface of the pipeline is
abnormally rough and could produce excessive wear on the pig discs, increase
the distance between pigs to 1.5% of pipeline length. For short pipelines, a
minimum distance of 200 m (650 ft) between pigs is recommended. Examples
of dewatering pig trains are shown in Figure 6.1.

C ~~j B ~~I
:~,
A ~
PT1 PT1

Basic Two-Pig Dewatering Train

PT3 PT3 PT2 PT2 PT1 PT1 PT1

~ G ~~, G ~~, E ~~~ F ~~, F ~~, E ~~, D ;~I

:~, A
~
One-Pass Cleaning, Gauging and Dewatering Pig Train

A- Line Fill Water Pig Types

B - Dry Air or Nitrogen PT1 - Bidirectional Pig
C- Dry Air or Nitrogen PT2 - Bidirectional Brush Pig
D- Potable Water PT3 - Bidirectional Gauge Pig
E - Water-Based Gel Sealant
F - Water-Based Gel Pick-Up
G - Dry Air

Figure 6.1-Typical Dewatering Pig Trains

6.2.2 Selecting the Propelling Medium for Pig Trains

Four propelling media are available to dewater pipelines before the pipeline is
conditioned and the product is introduced:

• Clean, dry, oil-free air

• Nitrogen
• Oil on an oil pipeline
• Wet gas on a pipeline that does not require drying

In certain cases, nitrogen must be used to dewater a pipeline. For example, when
methanol will be used as a swab in the drying operation, air may be used as the

January 1997 Chapter 6 6-3

 propellant, but it must be replaced with nitrogen once dewatering is complete to
make the pipeline inert and ready for safe swabbing with methanol.

The selection of the propelling medium depends primarily on cost. For short
pipelines, nitrogen may be less expensive because of the volumes involved. The
availability of air compressors, air dryers, and ancillary equipment may prove to
be cost-prohibitive in these situations. However, if the pressure of the dewater-
ing train is high because of accumulated heads and changes in elevation of the
terrain, compressed air might be the most economical way to dewater the
pipeline. The volume of nitrogen needed could also be prohibitive, especially on
offshore locations where space for equipment is not available. Furthermore, for
long pipelines, nitrogen may not be available in large enough quantities. Using
compressed air, or other means of inerting the pipeline must be addressed.
Therefore, designers and clients should determine the cost of all alternatives
before deciding which propellant to use.

6.2.3 Effect of Dewatering on Drying Operations

It is easier and less expensive to remove water during dewatering than it is to
remove it by any of the drying techniques. The efficiency of dewatering deter-
mines the time required to dry the pipeline. The less water left in the pipeline
after dewatering, the shorter the time required to reach the specified level
of dryness.

6.2.4 Dewatering Requirement (Acceptance Criteria)

In a successful dewatering operation, the pipeline is bulk dewatered, and as
much of the residual water as possible is removed from the pipeline. This
requirement cannot be tested, but an indication can be obtained based on the
amount of water brought into the pig trap and the condition of the pigs.

6.2.5 Velocity of Dewatering Pig Train

Unless specified otherwise, the most suitable velocity for a dewatering pig train
is 0.6 mls (2 ft/sec).

6.2.6 Accumulated Heads

An accumulated head is a phenomenon by which several broken water columns
occur within the pipeline. The normal head is the differential pressure of the
pipeline that occurs when the starting section and ending section of the pipeline
are at different elevations. This elevation change can occur throughout the
pipeline profile, so the profile of the pipeline must be known. The differential
pressure can change during dewatering of the line because of the profile and can
be calculated to determine the pump or air pressure required during dewatering
or filling.

An accumulated head can occur if a pipeline is partially filled. The pipeline can
be partially filled because (1) it is being repaired, (2) a wet buckle during
offshore construction occurred, or (3) a change in service from a liquid line to a
gas line occurs. These heads are actually gaps in the fluid column with air or gas
being moved or propelled to create differential pressures within the line (Figure
6.2). If these gaps in fluid occur, the pressure required to move the medium in

6-4 Pipeline Commissioning Manual January 1997

the pipeline would be the sum of the differential pressures plus the total differ-
ential pressure of the pipeline. Because heads hi' h2' and h3 in Figure 6.2 are
cumulative, the total head Ph may exceed the capacity of the pump or air com-
pressor used to move the water.

Head Pressure
With Air and Water Ph = 0.433 (h, + h2 + h3)
With Water only Ph = 0.433 h
h is expressed in feet

Ph~__~________~____________________________________________- - L

Figure 6.2-Accumulated Heads Caused by Undulating Elevation Step Changes

When determining the pumping equipment and/or air compressor equipment,

designers must know if any accumulated heads could occur. This knowledge
could playa significant role on the type and size of the equipment to use,
especially on land lines where a mountain range must be crossed with the
pipeline.

CAUTION Never attempt to release the head of water before pigging.

Always maintain a backpressure during dewatering opera-
tions.

6.3 General Preparation for Dewatering

Dewater after hydrostatic testing but before drying.

The equipment required for dewatering depends on the choice of propelling

medium. In some cases, both air-compressor and nitrogen-pumping equipment
may be required. Potable and freshwater pumps and gel mixing and pumping
equipment may also be required.

The preparatory steps required for dewatering vary depending on the client's
needs. Typical preparatory steps for Halliburton operations appear below:

• Planning
• Engineering
• Preparing procedures
• Selecting equipment and instrumentation
• Inspecting and using testing equipment

January 1997 Chapter 6 6-5

 6.4 Detailed Preparation for Dewatering
Complete the following steps when preparing for dewatering:

1. Prepare an overall schedule.

2. Begin engineering.
3. Produce a preliminary equipment list and layout drawing.
4. Produce a detailed equipment and instrumentation list.
5. Produce a detailed equipment layout drawing.
6. Produce a piping and instrumentation diagram.
7. Prepare the procedures.

These steps are discussed in detail below.

IMPORTANT Read the contract; make sure the contract covers all aspects
of the job. Pay particular attention to the scope of work and
specifications.

6.4.1 Prepare an Overall Schedule

Show the amount of time required for the following tasks:

• Engineering, including pig train design

• Producing procedures, including quality plans and safety procedures
• Assembling equipment and instrumentation
• Mobilizing
• Performing the work
• Demobilizing
• Producing final documentation

The dates for submitting key documents and for finishing the work are agreed
upon with the client and are available in the contract. An example of an overall
schedule is shown in Appendix B.

6.4.2 Begin Engineering

To begin engineering, calculate the following:

• Pipeline volume
• Volume per linear meter (or foot) of pipeline
• Pressures required to launch pigs and propel the pig train through
the pipeline
• Friction losses
• Elevation differentials

6-6 Pipeline Commissioning Manual January 1997

 • Flow rates required to propel the pig train through the pipeline at a
specified speed
• Gel ingredient quantities, if required
• Nitrogen volume, if required

Formulas and examples for these calculations are available in Chapter 13.

6.4.3 Produce a Preliminary Equipment List and Lay-

out Drawing
Create a preliminary equipment list based on the information discussed earlier in
this chapter. Then produce a preliminary layout drawing based on this list. From
the calculations made in the previous step, size the equipment and instrumenta-
tion. Figure 6.3 shows a typical equipment layout in which nitrogen is used.

,-------------------------------

N2 N2 N2
Tank Tank Tank
,-----------'
I
I
I
___________ I'
I I {
I
I
I
I
I

Discharge
1/4·in. Instrument Line Hose
1·in. N2 Hose
Secured

(
I--
I Spare I
I I cassion:
I
I / I
I
: Pig Launcher l
I '-
IL _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Subsea Manifold
____________ l
I

Figure 6.3-Dewatering Equipment Layout Using Nitrogen

6.4.4 Produce a Detailed Equipment and

Instrumentation List
Compare the preliminary list with the equipment and instrumentation that
Halliburton has available.

CAUTION Do not oversize or undersize equipment or instrumentation.

The client's specification contains a section on equipment and instrumentation.

In this section, the pressure and flow rate ranges for the main pieces of equip-
ment are specified. If it is not possible to locate a piece of equipment that is

January 1997 Chapter 6 6-7

 within the specified range, notify the client of the additional cost for the known
piece of equipment. It is permissible to list two or more pieces of equipment for
one purpose if you are not sure which piece will be available at the time of
mobilization. Obtain full data sheets for all pieces of equipment, and include
them with the procedure.

6.4.5 Produce a Detailed Equipment Layout Drawing

A detailed equipment layout drawing is similar to the preliminary drawing, but
it contains specific items of equipment.

Make sure the piping between the air compressors or nitrogen pumps and the
pipeline includes a check valve to ensure that the full pressure in the pipeline
cannot back up into the pumps. Include a double block-and-bleed system
between the air compressors or nitrogen pumps and the connection to the
pipeline. Include a pressure safety valve in the system as near as possible to the
pipeline.

6.4.6 Produce a Piping and Instrumentation Diagram

The diagram should show the equipment and instrumentation connection points
to the permanent pipework. Mark up a copy of a piping and instrumentation
drawing (P&ID) supplied by the client. The client may supply a marked up copy
showing the preferred connection points for your information. If the client does
supply a drawing indicating these connection points, use it. If one is not sup-
plied, request a P&ID.

If the pipeline has not been tied in to the platform, connection points will be
available on the temporary subsea head. A sample piping and instrumentation
diagram is shown in Figure 6.4.

,-------------------------------
N2 N2 N2 N2
Tank Tank Tank Tank 1------------.,
I
I
I
----------- /
: I I
Temporary
Pig Receiver

Flow Meter 0 0

Discharge
1·in. N2 Hose Hose
Secured

(
- -- A
1-- _/ I
I Spare I I
I
I
Cassion i i
I I I
I I I
I
I
IL____________________________
Subsea Manifold II
l
" ---- /'
1

Figure 6.4-Typical Piping and Instrument Diagram

6-8 Pipeline Commissioning Manual January 1997

6.4.7 Prepare Procedures
NOTE Use simple language in your procedures; short statements
are best.

Follow the steps below to begin preparing the procedures:

1. Write a simple introduction stating the project title, project description,

and the scope of Halliburton work.
2. Copy the section listing the relevant national codes and standards and
the client's specifications directly from the contract document.
3. Prepare a detailed schedule of operations, including an employee
schedule.
4. List the pipeline parameters including length, diameter, and wall
thickness. These parameters are located in the specification.
S. Use the formulas and example calculations in Chapter 13 to list the air
compressor or nitrogen pumping rate needed to propel the pigs at
approximately 0.6 mls (2 ftlsec). List gel injection rates and the esti-
mated total volumes.
6. List the pressures estimated for launching and propelling the pigs.
7. Include the equipment layout and connection point drawings.
8. Include detailed lists of equipment and instrumentation.
9. Include a list of the items that the client is expected to supply. For
example, water, electricity, light, air, and other consumables, such as
diesel are usually supplied by the client. Information on what the client
should supply is available in the contract.
10. Include valve checklists. These lists should show the position of all
valves before the beginning and after the completion of each operation.
The Halliburton superintendent and the client's representative should tour the
area immediately before startup to check that the valve positions are correct.
Both parties should sign the checklists.

Writing the Method Statement

Some clients furnish an outline method statement in the specification. Make
sure that all the points mentioned in the specification are included in the
method statement.

Write the method statement using command statements, similar to the

following:

• Check that the pig trap is isolated and depressurized.

• Open the pig trap door.
• Insert the pig into the launcher.
• Ensure that the front discs of the pig are securely entered into the throat
of the launcher.

January 1997 Chapter 6 6-9

 • Close the launcher door.
• Check that the valves are in the launching position.
• Check that the instruments are connected and working.
• Check that all recorders have sufficient time left on the charts.
• Obtain the client representative's permission to begin operations.
• Start the compressors or nitrogen pumps.
• Launch the pig.

If it is necessary to operate a permanent valve or other piece of permanent

equipment, include the following statement in the procedure:

"Permanent valves or other equipment, such as pig trap closure doors, will be
operated only under the supervision and control of the prime client's operation
staff. Halliburton will provide labor assistance."

NOTE Operations cannot begin until the client gives permission.

Copy the operation acceptance criteria from the specification. Remember that a
quality plan showing witness and hold points is not always required. However, if
a quality plan is needed, an example is given in Table 6.1, Page 11.

Safety
Include the following points in the Safety section:

• Erect safety barriers and warning signs forbidding entry to unauthorized

personnel. Be vigilant; some people ignore the signs and attempt to
enter and work inside the restricted area.
• Involve the site safety personnel.
• Announce on the public address system that operations are about
to begin.
• Prohibit flexible pressure hoses inside control cabins.
• Suitably protect hoses passing over walkways.
• Tie down all hoses at regular intervals to prevent whip in case of
hose rupture.
• Include any details specific to the dangers associated with the use of
compressed air and nitrogen.

6.5 Stages of a Dewatering Operation

Dewatering can include some or all of the following main stages:

• Bulk dewatering with air-propelled pig trains

• Residual dewatering with air-propelled pig trains
• Dumping treated fill water

6-10 Pipeline Commissioning Manual January 1997

ru:J
§ Table 6.1 - Halliburton Onshore Quality Plan
~ (Document No. EA-024-001)
......
~ Control Procedure
Acceptance
'J Activity Criteria Verifying Primary Pipeline Owner
Number Activity Responsibility (EA·024-007) (HQ·A·SF·OO8) Document Halliburton Contractor Inspection
4.23 DeriQ hydrotest equipment T RF.001 M M M
5 Dewatering - OEl-l, II and Gel

5.1 Connect all dewatering equipment T 4.4.1 RF.001 M M M

Confirm that receiving and launch
5.2 crews are ready to begin. T RF.001 M M M
5.3 SiQn recordinQ charts. Tand C TCR HandW HandW M
Get client approval before starting
5.4 'ob Tand C RF.001 H HandW W
OEl-1 - propel flooding pig from RF.001
5.5 PlEM to TIM T 4.4.8 PCR M M M
OEl-1i - propel flooding pig from RF.004
5.6 PlEM to TIM T 4.4.14 PCR M M M
GEL - propel flooding pig from land RF.004
5.7 end to TIM T 4.4.20 PCR M M M

OEl-l, II and GEL propel dewatering 4.4.23 RF.004

5.8 pigs to PlEM (land) ends T 4.4.24 PCR M M M
OEl-1 - Disconnect the PlR (PlEM)
5.9 and fig the TlR for dryinQ RF.001 M M M

Daily Operations Report - RF.001 Leak Check and Repair Log - RF.OO? W - Witness
Pig Launch and Receive Register - RF.002 Pressurization Report - RF.008 H - Hold
Chemical and Dosing Report - RF.003 Pressure and Temperature Log - RF.009 M - Monitor
Pipeline-Pigging Report - RF.004 Hydrotest Report - RF.010 T - Halliburton Services Test Engineer
Q Gauge Plate - RF.005 Air-Inclusion Report - RF.011 C - Client
~ Instrument Calibration Check-List - RF.006 Test-Acceptance Certificate - RF.012
(b -TCR Pressure-Chart Record -PCR
..., Temperature-Chart Record
0)

'tl
......
 • Inerting the pipeline with nitrogen
• Receiving the pigs into the pig trap
• Removing the pigs from the pig trap after each pigging operation
• Accepting the operation
• Recording and reporting data

6.5.1 Bulk Dewatering (With Air)

To bulk dewater the pipeline, a train of pigs, potable water, and gels are pumped
through the pipeline, with air as the propelling medium. The pigs may need to be
inserted by the use of temporary pig launchers.

It is good practice to build up and maintain a backpressure in front of the pig

train. This pressure prevents the water in the pipeline from moving ahead of the
pig train and creating accumulated heads.

6.5.2 Residual Dewatering

After the bulk dewatering train has been received, residual dewatering pig trains
are propelled through the pipeline with air as the propellant. Pig train movement
can be controlled if backpressure is maintained. In most cases, the residual
dewatering train contains foam pigs, which absorb and remove water from the
pipeline.

In both bulk and residual dewatering operations, if there is a doubt that the pigs
have been received, continue pumping until an agreed, predetermined volume
has been pumped (e.g., 10 % of total pipeline volume). In long pipelines, it can
take a long time to depressurize the pipeline to check the number of pigs re-
ceived and repressurize the pipeline to initiate movement of the pigs; therefore,
it is important to continue pumping to a predetermined volume.

Depressurizing of the pipeline is necessary because isolation valves cannot be

closed if a pig is sitting across a valve. Damage can occur to the pigs during
repeated initiation of movement. Such damage can lead to the propellant being
bypassed and the pig becoming stuck in the pipeline.

6.5.3 Disposing of Treated Fill Water

Disposing of treated water is regulated or controlled in many different ways. The
government regulations that control these procedures differ from country to
country. It is our responsibility to find the proper means of disposal because the
contractor we work with might not have the regulations in hand.

On land, disposal might be as simple as letting the fill water run across the
landscape, or it might need to be treated to remove the chemicals that were
placed in the treated water for corrosion control, oxygen scavenging, or bacteria
control. In large-volume pipelines or large sections between pipeline testing
stations, the process of making the water safe for disposal might need to be
accomplished in-situ. Instead of being held for treatment, the water might be
treated on the fly and then dumped into the approved area.

6-12 Pipeline Commissioning Manual January 1997

On offshore locations, dumping the water overboard from the platform is a
common practice as long as it meets with the approval of local governments,
fisheries, and environmental regulators. When performing this type of disposal,
consider the platform, stand-by boats, and supply boats. The freshwater makers
can be damaged when taking on water during the fill water disposal operations.
Make sure the platform and support vessels are topped off with the potable
water tanks before the fill water from the pipeline is dumped into the sea. Some
time needs to pass before the freshwater makers are started again to have
sufficient time for the currents of the ocean to dilute the fill water.

IMPORTANT Each case is different. Do not take the last disposal criteria
and apply it to the next job without checking. Each project
has its own set of specific criteria that must be met.

6.5.4 Inerting with Nitrogen

To inert a pipeline dried with a hydrocarbon such as methanol, propel a pig
through the pipeline using nitrogen as the propellant, or simply pump nitrogen
into the pipeline until <2% oxygen is detected at the receiving end. The use of a
pig reduces the amount of intermixing between the air and the nitrogen. An
oxygen level below 2% is usually required before hydrocarbons can be intro-
duced into the pipeline.

6.5.5 Receiving Pigs into the Pig Trap

For all pigging operations, check how many pigs the pig trap can accommodate.
Pumping may need to be stopped so that pigs may be removed from the trap to
make room for more pigs. The number of pigs used in a train may be limited by
the size of the temporary pig receivers. The compartment size between the pigs
can also be altered to prevent the pig train from stopping. If the pig receiver is
manifolded to allow fluids to bypass during pig retrieval, the compartment fluids
between the pigs can be bypassed around the pig trap while the pig is being
removed or when the operator is preparing the pig trap to receive the next pig.

Receipt of pigs into the pig trap is usually verified by pig signalers fitted to the
approach pipe and to the throat of the trap. Receipt can be further verified by
careful observation of changes in the pumping and backpressures. The approach
of the pig train to the receiving facility can also be signaled by pig tracking
devices fitted to the pigs.

6.5.6 Removing Pigs from the Pig Trap

Generally, pig trap barrels are oversized to make removal of the pigs simple.
However, temporary pig trap barrels may have the same internal diameter as the
pipeline, and winches may be required to remove the pigs.

6.5.7 Accepting the Operation

The operation is accepted when all pigs are out of the pipeline and as much
water as possible has been removed from the pipeline.

For pipelines requiring inerting with nitrogen, acceptance occurs when the level
of oxygen mixed with nitrogen received at the venting end is negligible, typi-
cally less than 2%.

January 1997 Chapter 6 6-13

 6.5.8 Recording and Reporting Data
Recording and reporting data during dewatering is vital for the following
two reasons:

• The data assist in tracking the progress of the pig trains and determining
the integrity of the batches of liquids in the pig train compartments.
• The data determine if a pig is bypassing or if it has become stuck and,
if so, where.

Table 6.2 lists the data collected during dewatering, which should all be included
in the final report.

Table 6.2-Data Collected During Dewatering

Charts Pipeline pressure
Logs Events
Volume and time to propel the pig trains through pipeline
Volumes of potable water and gels used
Pressure and time at the pumping end
Pressure and time at the receiving end

6.6 Final Reporting

Compile the final report and present the original and the specified number of
copies to the client. The Final Report is the only record the client has of the
dewatering results. The report should contain the following information:

• Summary of the operations

• Copies of all charts
• Copies of all manual records
• Pig condition reports
• Photographs of the received pigs
• Equipment and instrumentation calibration certificates
• Operation acceptance certificate

6-14 Pipeline Commissioning Manual January 1997