Pigging - Concept, Installation & Operations: Presenters: Uma Maheswar Gali & S. Chellasamy - Completions Department

PIGGING – CONCEPT, INSTALLATION & OPERATIONS
Presenters: Uma Maheswar Gali & S. Chellasamy – Completions Department
By
Petrofac Engineering Services (P) Ltd., Chennai
Date: 05.05.2011
Agenda for the Presentation
• Pigging – Requirement and Advantages
• Applications
• Basics of Design
• Concept – Launcher, Receiver,
Combination of Launcher /Receiver &
Temporary Launcher & Receiver
• Pigging - from Pre-commissioning to Operations
• Types of Pigs
• Principle of Pigging Operations
• Safety in Pigging – With mechanical Interlock
Key locking system
• Trouble shooting Operations
• Explosions in Pigging – Case Studies
• Video on Pigging (typical)
Pigging – Concept, Installation & Operations – Completions

2
Terminology and Definition
Terminology: “PIG”
“THE MOST WIDELY ACCEPTED EXPLANATION COMES FROM THE SCREECHING SOUNDS
MADE BY THE EARLY PIGS AS THEY WENT THROUGH THE HISTORY OF INTELLIGENT
PIGGING LINE”
“Pig – Pipeline Inspection Gauge”
Definitions:
• PIG: A tool propelled through a pipeline to perform a function.
• PIG Train: Several pigs launched in a set order to perform a specific task.
• PIG Trap: Pressure vessel used for launching and receiving pigs.
• Utility PIG: Non-autonomous pig used to carry out simple tasks, e.g. cleaning
• Intelligent PIG: A generic name given to a pig that utilizes power to perform a specific
task or log specific information. Intelligent Pigs are also referred to as inline inspection
tools.
• GEL PIG: Pig created by gelling.

3
Requirement and Advantages
Why is Pigging Required?
1.Pipelines are the most economical means to transport oil and gas, and one of the most
valuable assets in the industry.
2.Pipe line Pigging improves product quality, reduces pumping demands (Energy),
restores full flowing capacities and reduces downtime.
3.Pigs are used in the maintenance of pipelines to maximize flow and minimize operating
costs and, more importantly, to enhance chemical corrosion control efforts.
Advantage of Pigging
• They are non-destructive to the pipe.
• Pigs are used in all types of pipe construction material (steel, plastic, and epoxy lined).
• Pigging is proven as an extremely cost-effective method of cleaning lines.

4
Types of Propellant
Liquid Medium- Propellant

• Liquid- preferred medium for propelling pigs .
• Incompressible liquids provide maximum control over pig speed as well as lubrication
for the pig seals, minimizing wear, and maximizing seal effectiveness and life.
• Liquids such as water, crude oils, or process products and chemicals can be used as
propelling mediums.
Gas Medium- Propellant
• As gasses are compressible, the amount of stored energy behind a pig propelled with
gas is far greater than that of a similar pig propelled with liquid.
• Pig movement can also be affected by improper use of a compressible gas as a
propulsion fluid.

5
Uncleaned Pipeline
Pigging is an operation to remove debris or
unwanted deposit build up in a pipeline
Build up of deposit can:
• Restrict fluid flow/increase pressure
• Damage pumps
• Prevent chemicals accessing pipe wall
• Encourage corrosion
• Prevent assessment of pipeline integrity
The materials typically found in pipelines are:
•Organic: Paraffin wax, asphaltene and other hydrocarbon residues.
•Inorganic: Sodium Chloride, Calcium carbonate, Magnesium hydroxide, Barium
Sulfate, Iron Sulfide, Iron carbonate, Iron oxides and sand

6
Frequency
• Pigging Frequency
Pipeline pigging frequencies and pig types are based on the fluid handled in the pipe line,
field and industry experience, and the type of fluids that are handled in each line.
Recommended Frequency :
 Hydrocarbon Liquid lines : once in 2 months
 Hydrocarbon Gas lines : once in 4 months
 Generally : Company Past Experience/wax content in well fluid
 Critical Pigging – Offshore pipeline due to temperature gradient/length of pipe.
• Effectiveness of Pigging / Performance Indicators
Criteria of measurement:
 Total solids removed
 Estimated slug

7
Basic Design
• Pigs are designed so that sealing elements provide a positive interference with the
pipewall. Once inserted into a line, pigs are driven through the line by applying pressure
in the direction of required movement.
• A pressure differential is created across the pig, resulting in movement in the direction
of the pressure drop. In operational lines, this pressure is applied by the line product,
whereas, in un-commissioned lines, the propelling medium can be chosen to suit the
task being carried out, e.g. water for flooding /hydro testing or dry air/nitrogen gas for
dewatering.

8
Pig Launcher and Receiver

9
Pig Launchers/Receiver – Operating Guidelines
Normal Launcher/Receiver
PSV Launcher/
PAHH
Receiver to
UA Separator
PIT
RO
ESD PIT
PIT
PALL
Brackish Vent
Water from PI PI
205-TP-004
XI
HS
PI
M ROV PI
SC
Slug Catcher
TSV
By pass
HCV HCV
TI PI
HS
TIT PIT
ESDV
M
TW PI PI
ROV
Gas from
Metering Skid
To Burn
Pit Flare
To Dedicated
Drain Pit

10
Design Considerations
 Mechanical design
1. As pig traps are pressure vessels, pressure vessel design parameters must apply. The
pig determines the overall trap dimensions.
2. Certain Pigs such as the metal-bodied intelligent pigs are both heavy and long and
must be considered, along with the internal pressure requirements, when designing
supports, lifting lugs and assessing foundation loadings.
3. Trap design must also satisfy applicable codes, whether it be PD5500, EN13445,ASME
VIII (Div 1 or 2), ASME B31.4, B31.3, B31.8, AS2885 etc.
4. The trap can often be designed to a vessel code rather than a pipeline code. This in
itself can often provide a significant challenge in meeting the pipeline internal
diameter with a thicker calculated vessel wall.

11
Design Considerations (Contd.)
PROCESS PARAMETERS – For Design
• Pressure: The design pressure should never be less than that of the pipeline.
At times, Client-specific or based upon the ASME/ANSI Pressure/Temperature Class
tables.
• Temperature: The design would take account of the maximum design temperature, but
also the minimum design temperature in terms of material selection.
• Materials: Often specified by the client, however, where possible it is better to allow
the trap manufacturer to select materials that are compatible with the pipeline
materials and meet the design specification requirements.
• Corrosion: It is important that the line product is specified and whether it is sour, toxic
or corrosive. This will influence the selection of not only the metallic elements, but also
the elastomeric materials, which typically constitute the closure-sealing element. All
components in sour service should be specified to meet the requirements of NACE MR
01 75 for sour.

12
External loadings:
• Loads consist of those imposed by attaching pipe work acting upon nozzles.
• In addition, external pressure due to water depth in a subsea application .
• Loads due to support loads, wind, blast and seismic loadings.
(lifting lug requirements.)
General Pipe line Loading:
Pipe line is anchored and the load is not transferred to Pig traps/ Bypass Pipe line
Blast Wall: A protection Concrete wall is provided at about 20 meters to stop pig, if
blasted through closure door
Operator platform:
Access and operating plat form is provided
Crane: Jib or EOT cranes are provided

13
Brief on Design Considerations of PIG Trap/Barrel
• This is the major section of the trap and the means by
which the loading and unloading of pigs is carried out .
• It is usually equipped with an opening closure at one end
while its other end is welded to a reducer.
• Pig Barrel Diameter :
 For conventional pigging - nominal 50 mm above the
line size,
 Intelligent type pigs- it is recommended that it be at
least 100 mm above the line-pipe diameter.
• Barrel Length: The barrel length is dependent upon the
operating procedures, service, type of pigs, available
space, etc.
 Launchers : conventional pigs - 2 x pig length,
 Receivers - 3/3.5 x pig length.

14
Brief on Design considerations of PIG Trap/Barrel (Continue)
• Reducer: This is welded at its larger diameter to the other end of the barrel, and can be
eccentric or concentric. Generally, horizontal units use eccentric on launchers, concentric
on receivers. Vertical units use concentric throughout(Offshore).
• Neck Pipe: This is the minor diameter section of the pig trap and is welded at one end to
the smaller diameter of the reducer and terminates in either a butt weld end preparation
or flange at its other end. Dimensionally it is usually very short - one pig length + 10%,
however, in the case of intelligent pig receivers it could be as long as four meters.
• Branch Nozzles: On the simplest of traps there can be as few as four nozzles - kicker,
vent, drain and pressure indicator. On more complex traps, additional nozzles are
incorporated for, blow down, balance, equalizing, pressurizing and thermal relief valves.
• Blowdown: On high-pressure gas systems consideration should be given to the provision
of a blowdown line, incorporating a globe valve or restriction orifice, for controlled
depressurization. Size should not exceed two inches.

15
• Drain : This nozzle should be situated near the closure end for horizontal traps and near
the neck flange on vertical launchers. For receivers, a drain point near the barrel reducer
is recommended, or alternatively on the neck pipe near the end flange. Size of drain
connections should be not less than two inches for traps up to 14 inches line size and four
inches for traps above that.
• Vent: This nozzle should be situated near the closure end or highest point; a further
connection may be considered near the trap neck end flange to ensure depressurization
behind the pig in case it becomes stuck in the neck pipe. Size of vent connections should
not be less than 1/2 inches.
• Balance line. This can be provided on launchers to enable filling and – pressurization of
the barrel on both sides of the pig at the same time. This is to prevent a pig which is ready
to be launched from moving forward and thereby hitting and possibly causing damage to
the trap valve, or backwards and losing the seal in the reducer. Consideration should also
be given to the provision of a balance line on the receiver to prevent any possible
pressure differential across a receiving pig. Size should be in the region of two inches.

16
• Pressurizing line: This may be required around kicker valves for several reasons -speed
of operation, control of barrel – pressurization and/or damage to the kicker valve seats
or other internals. Similarly, a pressurizing line around bypass valves should also be
considered, for equalizing possible high-differential pressures. Size should be smaller
than the balancing line connection.
• Thermal relief valve: This can be provided at locations where it is anticipated shut-in or
trapped fluid could exceed the design pressure.
• Lifting lugs: These are required to facilitate lifting of the complete trap during the
installation stage.
• Supports: Required to permanently support and restrain the pig trap, supports should
be designed to carry the weight of the pig trap system filled with water (or other fluid
if their density is greater), together with the weight of the associated heaviest pig.
Supports under the barrel should normally be of the sliding type to compensate for
expansion of the unrestrained part of the pipeline.

17
• Pressure indicator: This should be fitted toward the closure end and visible to the
operator, may be incorporated with the vent connection. Size should be in the region of
½ inch to one inch, threaded, with four inches or six inches dial size
• Grounding lugs: These are required to reduce the build-up of static electricity. If the
accumulated static is suddenly discharged within a hazardous atmosphere, the
resulting spark may easily act as the ignition source for an explosion
• End closure: This can be as simple as a flange and blind, but is more commonly found in
the form of a quick opening door, an assembly which provides a quick, easy and safe
access to the barrel when open and seals the bore when closed.

18
Pig Signaler: This is also known as a pig detector,

a device set on or into the pipeline which
indicates the momentary presence of a pig at a
precise location.
Signalers should be installed on both sides of
the trap valve. For launchers, it should be
positioned on the main pipeline at a distance
from the trap valve of at least the length of the
longest pig anticipated.
For receivers, it should be positioned on the trap
neck pipe at a distance from the trap valve,
again, equal to the anticipated longest pig
length .

19
Type of PIGS
Utility or Maintenance Pigs:
1.Mandrel Pigs
Mandrel pigs consists of a steel mandrel body with
replaceable sealing elements (cups and discs). The
advantage of steel pigs is the ability to replace the wearing
components.
2.Solid Cast Pigs
Solid cast pigs are often used in short to medium distance
small diameter pipelines and in plant pipe work with
multiple changes in direction for removing products,
keeping lines clear of wax or deposit build-up and pigging
pipelines when metallic
components can not be considered.

20
Type of PIGS (Contd.)
3. Foam Pigs
 Foam pigs are generally used for liquid removal, drying,
product separation and many cleaning duties.
 Foam pigs are often suited to Pipeline Systems with very
tight radii or mitred bends and where significant
reductions in internal diameter exist.
 Foam pig selection will be dependent on the operation to
be performed and foam pigs capable of travelling up to
300 miles.

21
Pigs – Accessories
Cleaning pigs consists of a standard body to which any combination of accessories can
be mounted, including high-wear resistant polyurethane cups and discs.
•Gauge Plate : Determine whether large obstructions exist which would block passage of
an inline inspection tool.
•Spider Nose : create turbulence to avoid accumulation of debris and wax in front of the
tool.
•Brushes : Scrape solid debris from the pipe wall
•Magnets : Collect loose metal components and carry them out of the pipeline.
•Transmitter : Measure exact tool passage time or pinpoint a lost tool.

22
4. Gel Pigs
• Gel pigs are series of gelled liquid systems which have been developed for use in
pipeline operations, either during initial commissioning, or as a part of a continuing
maintenance program.
The Principle pipeline applications for Gel Pigs:
1. Debris removal
2. Dewatering & Drying
3. Line filling / Hydro testing
4. Product Separation
5. Condensate removal from gas lines.
6. Special Chemical treatment
7. Pipeline freezing

23
Type of Intelligent or Smart PIGS
1. MFL (Magnetic Flux Leakage) Pigs : Basic
• MFL pigs work by magnetizing the pipe wall and
measuring changes in flux outside the pipe.
• Changes in flux occur at metal loss and some
changes in the pipe material properties.
• The amount of flux leakage depends on the size
and shape of the metal loss region or change in
material properties.

24
Type of Intelligent or Smart PIGS (Contd.)
2. Ultrasonic Pigs : Basic
• Ultrasonic pigs detect corrosion by sending a high
frequency sound wave toward the pipe wall. One
reflection comes from the inner wall, one from the
outer wall or an planar
discontinuity between two walls
 A planar discontinuity is a break-caused by a crack
or separation between grains of the steel.
 Some inclusions(e.g., dirt in the steel) can also
cause reflections.
• Signal interpretation is easy.

25
Type of Intelligent or Smart PIGS (Contd.)
3. Geometry /Deformation /Caliper Tools:
 Tools are designed to give an indication with
changes in a pipe bore.
 Need to measure < OD
 Systems with inertial can also map pipe
directional changes and give GPS information.
 It measure buckle and a field bend wrinkle.

26
Pigging Operations
Pigging of a pipeline is required at various stages of a pipeline’s life for a variety of
reasons.
1. Pre commissioning Phase
•When new pipelines are built, they generally need to be cleaned of construction debris
and prepared for hydrostatic testing. This is generally done by utilizing a pig train
consisting of cleaning, gauging, and batching pigs to flood the line.
•Depending on the medium to be transported in the line, further pigging may be required
for dewatering and drying operations.
2.Commissioning Phase
•As the product is introduced into the line, a batching pig or pigs can be used to separate
the product from the medium currently in the line.

27
Pigging Operations (Contd.)
3. Operational Pigging
During the life of a line, operational pigging is a cheap effective way of maintaining flow
and minimizing back pressure. Pigs can be used to mechanically clean waxes and
other hydrocarbon build-ups, or chemicals can be batched between pigs to provide
chemically enhanced cleaning. Inline inspection is generally carried out as part of a
routine maintenance plan.
4. Decommissioning
Pig is also used in decommissioning of Pipe lines – Removal of products , fluids from pipe
line before handing over to maintenance/Repair.

28
Offshore Pigging Operations
Pigging subsea pipe line from Riser of Platform A to Riser of Platform B

29
Offshore Pigging Operations (Contd.)
Pigging of subsea pipe line :

30
Offshore Pigging Operations (Contd.)
Pigging of subsea pipe line to Platform Riser :

31
Pig Launchers/Receiver – Operating Procedure
Typical Launcher/Receivers

32
Pig Launchers/Receiver – Operating Procedure (Contd.)
Ball valve
(isolation) C2
Globe valve C1 A
(throttling) C3
PI H PI H
PI H
E G2 G1
F
B
A - By-pass valve
D B - Main isolating valve
I Balance Line
C1 - Kicker valve
D - Drain valve
E - Vent valve
F - Door
Typical launcher/receiver G1,G2 - Pig alerts
(pigsigs)
H - pressure gauge

33
Launcher: Lining up to Launch PIG
Step-1 Ensure kicker valves (C1 + C2 +C3) and isolation valve (B) are closed while valve
(I) is open.
Step-2 Open drain valve (D) and vent valve (E) to drain and depressurise the launcher
barrel. Confirm zero pressure.
Step-3 Open door (F) in accordance with manufacturer’s procedures.
Load pig into barrel, ensuring that the front driving cups are in contact with the reducing
portion of the barrel.
Step-4 Check door seal - clean and lightly oil mating surfaces. Close door. Close drain valve (D).
Ensure that door is securely locked.
Step-5 Ensure that the balance valve (I) is open (if fitted) across the barrel eccentric reducer in
order to prevent the pig coming into contact with the main isolation valve, whilst pressuring
up the barrel. Open kicker valve (C2) then slowly crack kicker valve (C3) open. As oil/gas
enters, air will be displaced from the barrel through the vent valve (E).

34
Step-6 When barrel is full of oil, close vent valve and allow the barrel to pressurise fully. In the
case of a gas pipeline, air will be replaced by gas. Continuous readings shall be taken until
100% gas is detected at the vent valve.
Note 1: Ignition sources shall be removed from the area and continuous atmospheric
monitoring within the area shall be carried out.
Note 2: In H2S designated areas the procedures for entering and working in an H 2S area
must be followed.
Step-7 Check that all pressure gauges give the same reading. Close kicker valves (C2)
and (C3).
Step-8 Close balance valve (I).
Step-9 Set the pig signallers (G1) and (G2). Open main isolating (barrel) valve (B) fully.
Step-10 Open kicker valve (C1) fully.
Step-11 Slowly close by-pass valve to force oil flow through the launcher until pigging (G2)/(G1)
trips showing that the pig has left the barrel and is travelling through the pipeline. Reset
the pig signaller.

35
Step-12 Open by-pass valve (A).
Step-13 Close kicker valve (C1).
Step-14 Close main isolating (barrel) valve (B).
Step-15 Drain and depressurise.
Step-16 Close drain valve (D) and vent valve (E).
Clean and Closed Drain Drum.
Step-17 Complete 'Pipeline' and 'Launch' sections of the Pigging Log sheet.

36

37

38
Ball valve
(isolation) C2
Globe valve C1 A
(throttling) C3
PI H PI H
PI H
E G2 G1
F
B
A - By-pass valve
D B - Main isolating valve
I Balance Line
C1 - Kicker valve
D - Drain valve
E - Vent valve
F - Door
Typical launcher/receiver G1,G2 - Pig alerts
(pigsigs)
H - pressure gauge

39
Pig Receiving Procedure
(Refer to Figure, Typical Launcher/Receiver Arrangement)
Step-1 At the start, by-pass valve (A) is open, main isolating valve (B) and kicker valves (C1), (C2),
(C3) are closed.
Step-2 Ensure that drain valve (D) is closed and that the door (F) is secured as per
manufacturer’s procedure, and that the balance valve (I) is open.
Step-3 Open vent valve(s) (E).
Step-4 Open (C2), crack Open (C3), and fill the barrel while air is being vented via (E).
Step-5 In the case of a gas pipeline, air will be replaced by gas. Continuous readings shall be
taken until 100% gas is detected at the vent valve.
Note: Ignition sources shall be removed from the area and continuous atmospheric
monitoring shall be carried out for hydrocarbons.
Step-6 In H2S designated areas the procedures for entering and working in an H 2S designated
location must be followed. (PR-1078)
Step-7 When the barrel is full of fluid, close vent valve(s) (E) and allow the barrel to pressurise
fully. Check that the barrel pressure gauge shows the same value as the line pressure gauge.

40
Step-8 Open kicker valve (C1) fully and open main isolating valve (B). This allows fluid to flow
through the receiver.
Note: In the case of low flow there is a risk of the pig stopping across the by-pass tee. If
two kicker lines and valves are installed stoppage of the pig can be avoided by closing the
by-pass valve (A) to divert all the oil through the receiver.
Step-9 Confirm there is no leakage from the door seal and fittings before leaving the site.
Step-10 Arrival of the pig is shown initially by pig alert (G1) being activated. Pig alert (G2) should
activate shortly afterwards to show that the pig has entered the barrel. If (G2) does not
activate, the by-pass valve (A) must be closed or throttled to force the pig into the barrel.
Step-11 Once pig is 'home' in the barrel, open by-pass valve (A) fully.
Step-12 Close main isolating valve (B).
Step-13 Close kicker valve(s) (C1), (C2) and (C3).
Step-14 Drain and de-pressure through drain valve (D) and vent valve(s) (E). Ensure that the
balance line (if fitted) across the reducer is open. Confirm that pressure is zero.
Step-15 If no fluid flows through the bleed screw, remove bleed screw. Airflow into the trap
indicates that fluid is still flowing from the trap via the drain. When the airflow stops the
trap is fully drained and the door may be opened.

41
Note: A number of older doors may not be fitted with bleed screws. In this case
additional precautions shall be taken before opening the door, e.g. confirm by visual observation
that drain has stopped.
Step-16 Open door (F) and remove pig.
Step-17 Clean out receiver barrel and take sample of debris, if quantity is greater than 20kg or if
specifically instructed. A sample sheet shall be completed and sent with the sample to the
appropriate laboratory. Check door seal, - clean and lightly oil mating surfaces.
Step-18 Close door (F), drain valve (D), and vent valve (E). Ensure door (F) is secured as per
manufacturer’s procedures.
Step-19 Inspect pig for damage and action refurbishment and/or return ready for its next use.
Step-20 Ensure that 'retrieval' section data is passed to launch supervisor for completion of the
Pigging Log sheet.
Step-21 Complete the pigging log sheet.
Step-22 Empty and clean the saver pit and cross check the valve positions before leaving the site.

42
Safe Operation of Pig Launchers/Receiver
Pig Launchers / Receiver – Mechanical Key Interlocks:
According to statistics, “70% of the reported incidents in the oil and gas industry world wide are
attributable by human error“
“Mechanical key interlocks are introduced in the 1890’s when they were used on the French Railway
Systems to control track switching operations. Key Interlock Systems for the Oil and Gas Systems
did not emerge until the early 1980’s”.
1. The Installation and use of key interlocks has the potential to eliminate the possibility of human
error in the operation of critical valves such as the ones involved in a pig launcher/receiver system.
2. The locking system prevents the operator from operating
a valve when it is not allowed and the valve can only be
operated with the designated key. Each lock is operated
by two keys, one released in the open position and one in
the closed position.

43
Mechanical Key Locking System
Task 1 : To load the Pig
1. Vessel Status : Isolated / Depressurized.
2. Production : online
3. Permit key ‘A’ into PSV block valve to unlock
and close-releasing key ‘B’
4. Key ‘B’ into atmospheric vent valve to unlock
and open-releasing key ‘C’.
 Residual s vent to atmosphere
5. Key ‘C” into drain valve to unlock and open
to clear any accumulated liquids.
6. Close drain valve again releasing key ‘C’
 Vessel is now depressurized /venting.
7. Key ‘C” into closure to unlock and open-
commence loading.

44
Mechanical Key Locking System (Contd.)
Task 1 : To Re-pressurize and prepare for Launch
1. Vessel Status : Isolated / Depressurized.
2. Production : online/ Pig Loaded
3. Key ‘C’ into atmospheric vent to unlock and close-
releasing key ‘B’
4. Key ‘B’ into PSV block valve to unlock and open-
releasing key ‘A’.
5. Key ‘A” into mainline valve ‘M1’to unlock and
open- releasing key ‘D’
6. Key ‘D’ into kicker valve ‘K1” to unlock and open-
releasing key ‘E’
7. Key ‘E’ into kicker valve ‘K2” to unlock and crack
open slowly to pressurize.
8. After substantial or complete pressurization, open
fully releasing key ‘F’
9. Key ‘F’ mainline valve M2 to unlock and open.(Key
‘F’ remains trapped).
Now loaded, pressurized & ready for launch.
45
Mechanical Key Locking System (Contd.)
Task 1 : To Launch Pig and Depressurize
1. Vessel Status : Ready for Launch.
2. Restrict flow on line valve ‘L1’ (not interlocked0 by
inching closed.
3. Back pressure through kicker line will effect pig
launch. Fully re-open line valve ‘L1’.
4. Close mainline valve M2 and lock closed, releasing
key ‘F’.
5. Key ‘F’ into kicker valve ‘K2’ to unlock and close-
releasing key ‘E’
6. Key ‘E’ into kicker valve ‘K1’ to unlock and close-
releasing key ‘D’.
7. Key ‘D’ into mainline valve ‘M1’to unlock and
close- releasing key ‘A’
8. Permit key ‘A’ into PSV block valve to unlock and
close-releasing key ‘B’
9. Key ‘B’ into atmospheric vent valve to unlock and
open-releasing key ‘C’.
10. After venting, close atmospheric vent valve
releasing key ‘B’
11. Key ‘B into PSV block valve to unlock and close -
releasing key ‘A’
Vessel is now depressurized and Isolated.
46
Pig Launching and Receiving –Typical Procedure
PIG LAUNCHER “A” PIG RECEIVER “B”
LP Flare Header HP Flare Header
Air/N2 Hose
PI PI
N1 Pig Indicator 1 Pig Indicator 2 Pig Indicator 2 Pig Indicator 1 N11

PI PI
Above
M M Ground M M
Pig Launcher Pig Receiver
Drip Tray Drip Tray
A1 A2 B2 B1
BV1 BV11
K1 Below K11
A3 Ground
M
B3
M
P2 P12
Closed Drain Closed Drain
K2 K12
P1 P11
Production Header To Separator
Engineering Excellence – Completions

47
Pig Launchers/Receiver – Operating Guidelines (Contd.)
Pre-Requisite:
1. Risk assessment
2. Radio Communication
3. Flare System is in-service
4. Closed drain and open drain are in operation
5. Check availability of N2
6. PTW or Informed to Control Room
7. Wash Water System
8. Request Plant operation team reduce plant load to 40% load.
Launching of Pigs:
1. Receiver is to be made ready for receiving pig.
2. Check the pipeline operating pressure at launcher and Receiver side.
3. Follow up Mechanical key interlock procedure for valve opening.

48
Launching of Pigs (Contd.)
4.Take opening first key from Control room.
5.Ensure that main valve (MOV) is closed.
6.Depressurize and drain the launcher barrel.
7.Open the enclosure door with mechanical key.
8.Insert the pig - with Jib crane or EOT
9.Close the enclosure door.
10. Close drain valve and check pressure at local gauge.
11. Check that TSV/PSV is lined up.
12. Check pig signaler /indictor in right position(flap closed).
13. Ensure that Receiver is ready to receive pig.
14. Inform to Control room the pig launching activity.
15. Reduce the feed supply to plant up to 40% and maintain pigging velocity up to 2
to 3 ft/sec.

49
Launching of Pigs (Contd.)

16. Check Receiver pressure is less than at the launcher (< 2 bar).
17. Line up Launcher by opening kicker valve, partially closing bypass valve& opening
main isolation valve.
18. Check pig signaler indication at launcher and roughly estimate pig receiving time.
19. Monitor travel of pig by its transmitter signal in off shore and installed pig
signalers on pipe line at on shore.
20. Monitor the pig receiving signal at Receiver.
21. Follow receiving procedure and unlock the receiver.
22. Restore the feed supply to plant.
23. Remove all the debris from the launcher and keep ready for next operation.

50
Implications:
1. Downstream plant load get affected.
2. Heavy slug flow causes operation imbalance in Slug catcher.
3. Plant venting due to upset of operation.
HSE:
1.Disposal of debris.
2.Pyrophoric scale deposits.

51
Gel Pigging Operations

52
Temporary Pig Launcher/Receiver
To HP Flare
Header
PG
PG Pig
DBB
Signaller
DBB
Temporary Pig Launcher/

Production Receiver
Header
Bypass
Line
Drain Line

53
Troubleshooting
How to Remove "Stuck" Pigs :
There are two types of "stuck" pigs that an operator will encounter when pigging. Once
it is understood why a pig becomes "stuck", it is easier to avoid the problem rather than
having to overcome it.
Two types of problems:
1.First type of "STUCK" PIG :
The first type of "stuck" pig is when a pig loses seal.
Reason: Excessive wear of pig, due to too long of a pig run, dual-diameter applications or
abrasive conditions in the line, and torn pigs due to partially closed valves or other
destructive debris. In this case, the pig has lost its seal and is allowing the propelling
medium to bypass the pig instead of propelling it.
Solution : the following options may recover the "stuck" pig:

54
Troubleshooting (Contd.)
• Increase pigging volume: By increasing the volume of propelling medium, the amount
not being bypassed may be enough to propel the pig.
• Run a line-size swab: Running a swab (2 pound density foam) in a line where a pig has
lost seal will re-establish the lost seal by the first pig. The swab will try to bypass the
pig as the propelling medium is doing, but instead will seal off this area of bypass, and
the propelling medium will once again start to push the "stuck" pig.
• Reverse flow direction: By reversing the flow of the propelling medium, we can have
the pig retreat a few feet and then reapply pressure behind the pig to try to send
through pipe. Note: This will not work for unidirectional pigs (cup pigs and the like).

55
2. Second type of "stuck" pig :
• The pig that has encountered obstructions that it cannot negotiate. This will include excessive
debris build-up in front of the pig, partially closed valves, and various obstructions, such as,
lunch boxes, tools, etc. For removing this type, the following options may prove helpful:
• Increase pigging pressure: The increased pressure equates to increased force, which may be
enough to allow the pig to push the obstruction.
• Increase / decrease pigging pressure (Alternating fashion): By increasing and decreasing the
pressure in a quick on-and-off fashion, may give it the proverbial "kick in the rear" to help the
pig to negotiate the obstruction. This option works very well in smaller internal diameter
fittings and valves, as well as, tight-bend ells.
• Remove pressure and volume (Allowing the pig to recover): As with the lost-seal type, this
procedure is useful for the same reasons, allowing the pig to recover its shape after
encountering an obstruction.
• Reverse flow direction: Reversing flow direction is very effective for removing this type of
"stuck" pig. In most cases, the pig cannot negotiate or push the obstruction and reversing the
flow allows the pig to be retrieved from the line. Note: This will not work for unidirectional
pigs (cup pigs and the like).

56

57
3. Sphere jammed in Off take
• Sphere jams into a branch line due to flow diversion and causes a jam.
• Require to provide a bar arrangement in receivers or special flow/sphere tees in the
pipeline. This can also occur with standard pigs where there is flow from branch lines.
The barring arrangements should be checked.

58
4. Incorrect Valve/Valve not fully open
• Use of the incorrect valve in line (valves need to be full bore ball valves or through-
conduit gate valves, ideally), or when the valves are not fully opened.
This is a problem especially in smaller diameter lines at 12” and smaller and has been
known to severely damage the pig.
• Checks in the operating procedure should be in place to check the opening of the
valves,

59
5. Short Pipe Bend Radius

• Insufficient information regarding the design of the pipeline can be a problem,
especially with older pipelines.
• For instance, small radius bends can cause problems with longer pigs. The pig must be
designed for the line. If such information is unknown, then some conservative
assumptions must be made and agreed.

60
6. Plugging with wax

• Wax build up in front of pigs can plug a pipeline. The wax is scraped off the pipe wall,
gathers in front of the tool, hardens and eventually plugs the line. The cost of
rectifying this situation should it occur is potentially huge, especially offshore: -
• This can be avoided by correct selection of pig and the correct bypass rates through
the pig to allow the debris to be maintained in suspension downstream of the pig.

61
7. Debris in the line

• Debris such as sand can damage a pig as it can lift the pig up and cause rapid wear to
the top of the pig.
• Again, the most effective way around this is to provide sufficient bypass through the
pig. The bypass must be strong enough however, to move the debris along in front of
the pig.

62
Explosions in Pigging Case Studies
Cause
The deaths of the two Chevron operators were the result attempt to open the launcher
closure lid while the launcher contained gas that was pressurized to 1020 psi. The
findings indicate that, as one of the yoke bolts was turned at most two full turns, the yoke
containment of the lid was lessened to the degree that the lid broke free of the
containment, was torn from the hinge, and then propelled through the overhead deck.
The resultant sudden release of the pressurized gas, which was isolated in the launcher
by the previously mentioned 4 inch and 16 inch valves, caused the injuries to the
operators, which resulted in their deaths.

63
Explosions in Pigging Case Studies (Contd.)

64

65
Case -2
• Stuck Pig - Inside the Receiver
• locked up pressure between Pig and Receiver neck-no pressure gauge
• Sudden release of Pig, causing damage to wall & fence

66
Pigging – Video Simulation
• Video - Pigging

67
THANKS

68
ANY QUESTIONS?

69

Pigging - Concept, Installation & Operations: Presenters: Uma Maheswar Gali & S. Chellasamy - Completions Department

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PIGGING – CONCEPT, INSTALLATION & OPERATIONS

Presenters: Uma Maheswar Gali & S. Chellasamy – Completions Department

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Liquid Medium- Propellant

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pig Signaler: This is also known as a pig detector,

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

LP Flare Header HP Flare Header

N1 Pig Indicator 1 Pig Indicator 2 Pig Indicator 2 Pig Indicator 1 N11

Production Header To Separator

Engineering Excellence – Completions

Engineering Excellence – Completions

Engineering Excellence – Completions

Launching of Pigs (Contd.)

Engineering Excellence – Completions

Engineering Excellence – Completions

Pigging – Concept, Installation & Operations – Completions

Temporary Pig Launcher/

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions

Pigging – Concept, Installation & Operations – Completions