Instrumentation and Pigging

Oil and Gas Pipeline Design,
Maintenance and Repair

Dr. Abdel-Alim Hashem
Professor of Petroleum Engineering
Mining, Petroleum & Metallurgical Eng. Dept.
Faculty of Engineering Cairo University
aelsayed@mail.eng.cu.edu.eg
ahshem2000@yahoo.com
Part 7: Instrumentation and Pigging
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
PIGGING OPERATIONS
INTRODUCTION
Devices that are inserted into and travel
throughout the length of a pipeline driven
by a product flow.
Developed to remove deposits which
could obstruct or retard flow through a
pipeline.
Today are used during all phases in the
life of a pipeline for many different reason
REASONS FOR PIGGING

Batch or separate dissimilar products
Displacement purposes
Internal inspection.
PIG CATEGORIES
Utility Pigs, which are used to perform functions
such as cleaning, separating, or dewatering
In Line Inspection Tools, which provide
information on the condition of the line, as well
as the extent and location of any problems.
Gel Pigs, which are used in conjunction with
conventional pigs to optimize pipeline
dewatering, cleaning, and drying tasks.
SELECTION CRITERIA
The purpose:
Type, location, and volume of the
substance to be removed or displaced in
conventional pigging applications,
Type of information to be gathered from an
intelligent pig run,
Objectives and goals for the pig run
SELECTION CRITERIA
The line contents
The contents of the line while pigging,
Available vs. required driving pressure,
Velocity of the pig.
SELECTION CRITERIA
Characteristics of the pipeline
The minimum and maximum internal line
sizes,
Maximum distance pig must travel,
Minimum bend radius, and bend angles,
Additional features such as valve types,
branch connections, and the elevation
profile.
UTILITY PIGS
Cleaning Pigs, to remove solid or semi-solid
deposits or debris from the pipeline
Sealing Pigs, used to provide a good seal in order
to either sweep liquids from the line, or provide an
interface between two dissimilar products within the
pipeline.
Within these two groups, a further subdivision can
be made to differentiate among the various types or
forms of pigs:
Mandrel pigs, which have a central body tube, or
mandrel, and various components which can be
assembled onto the mandrel to configure a pig for a
specific duty;
UTILITY PIGS
Foam pigs, which are molded from
polyurethane foam with various
configurations of solid polyurethane strips
and/or abrasive materials permanently
bonded to them;
Solid cast pigs, which are moulded in one
piece, usually from polyurethane, and;
Spherical pigs or spheres, which are of
either a solid composition or inflated to their
optimum diameter with glycol and/or water.
10
UTILITY PIGS
Mandrel pigs
Foam pigs
11
UTILITY PIGS
Solid cast pigs
Spherical pigs or spheres
12
IN LINE INSPECTION TOOLS

In Line Inspection provides information on
the condition of the pipe and/or its
contents.
With few exceptions, the In Line Inspection
Tool itself is simply the tool which gathers
the data, which is then analyzed by the
engineers and technicians to determine
and report on the condition of the line.
13
IN LINE INSPECTION TOOLS
14
INFORMATION FOR IN LINE

INSPECTION TOOLS
Diameter/geometry measurements;
Curvature monitoring
Pipeline profile;
Temperature/pressure recording
Bend measurement
Metal-loss/corrosion detection
Photographic inspection
Crack detection
Wax deposition measurement
Leak detection
Product sampling
Mapping.
15
ULTRASONIC INSPECTION TOOLS
16
GEL PIGS
Gel pigs are a 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.
Most pipeline gels are waterbased, but a range of chemicals,
solvents, and even acids can be
gelled.
Some chemicals can be gelled as
the bulk liquid and others only
diluted in a carrier.
Gelled diesel used as a carrier of
corrosion inhibitor in gas lines.
17
TYPES OF GEL
Batching, or separator gel

Debris pickup gel
Hydrocarbon gel
Dehydrating gel
18
PRINCIPLE APPLICATION OF GEL PIGS
Product separation
Debris removal
Line filling/hydro testing
Dewatering and drying
Condensate removal from gas lines
Inhibitor and biocide lay down
Special chemical treatment
Removal of stuck pigs
19
DUAL DIAMETER PIGS
20
DUAL DIAMETER PIGS
21
DUAL DIAMETER PIGS
22
MULTI DIAMETERS PIGS
23
WHY DO PIG STUCK?

Pigs plug a pipe and cause a blockage
Build up of wax in front of a pig causing a wax plug
Unidirectional bypass leading to a stuck pig with
product flowing past to it
Jack knifing of a dual module pig
Excessive wear leading to failure of seals and drive
Mechanical damage
Failure due to environment material selection
Others that do not fail in the categories above
24
SPHERE JAMMED IN OFF TAKE

Cause
Due to flow diversion, Flow
from branch line
Solution
Require to provide a bar
arrangement in receivers or
special flow/sphere tees in
the pipeline
The bearing arrangement
should be checked
In dual diameter line, special
bearing arrangement may
be necessary
25
INCORRECT SIZED PIG COMPONENTS

Cause
Oversized guider can cause pig to misalign and jam in
launcher reducer
Solution
Pig component should be resized to the actual pipeline
with an allowance for wear and other such factors
Guiders need to be sized correctly to 99% of the
smallest internal diameter and then seals sized to suit
Avoid sealing locking on guiders as this may lead to
rapid wear and seal damage
26
INCORRECT SIZED PIG COMPONENTS
27
INCORRECT VALVE/VALVE NOT OPEN

Cause
Use of incorrect valve in line, valves are not fully open
Happens in smaller diameter line 12 in and smaller
Solution
Checks in the operating procedures should be in place to
check opening the valve
Pig design should consider this eventually
28
INSUFFICIENT INFORMATION
(wrong bend radius)
Cause
Insufficient information
regarding pipeline design,
especially older one
Solution
Pigs must be designed for
the line
Some conservative
assumptions must be made
and agreed
29
PIG PUSHING ON PIG IN FRONT

Cause
when one pig pushes into the rear of another pig. It acts
on the seals, forcing them harder against the pipe wall
Solution
Have a bumper noses, both front and rear
This be provided even if it is not only planned to have
one pig in the line
30
COLLIDING PIGS
Causes
Possibility of pigs to meet at
wyes or tees in complex lines
Solution
Good communication and
pigging operation procedures
One pig may be made
sacrificial
31
HIGH FRICTION PIGS

Cause
Change from thin wall to
thick wall pipe, lead to
serious damage of the
seals
Solution
All pigs should be
designed to deal with all
internal diameters of the
line and if in doubt, a test
performed
32
PLUGGING WITH WAX

Cause
Wax build up in front of
pigs
Solution
Correct selection of pigs
and correct bypass rates
to allow debris in
suspension
33
DEPRIS IN THE LINE

Cause
Depris such as sand lift the pig up and
cause rapid wear
Solution
Provide strong and sufficient bypass to the
pig
34
FLOW AROUND THE PIG

Cause
Pipeline features such
as branches and
offtakes, wyes etc.
which can lead to a
stalled pig if the
bypass system is
incorrect
Solution
Consider the position
of the offtakes
35
INSUFFICIENT SEALING LENGTH

Cause
Components such as wyes and tees
Solution
A dual pig should be used to span the
component
36
NOSE DOWN
Cause
It happens the large diameter line
Solution
Modern support techniques should be
employed and seals sized appropriately
37
REVERSAL
Cause
Reversing the flow of the line which causes interaction
between pipe seal and pipe wall
Solution
Consider the interference of pig component such as
seals and guide discs in reversing pigs
38
PROXIMITY OF COMPONENTS
Cause
Too close line components which makes a risk of bypass
as the sealing is incorrect
Solution
The configuration of the pig must be considered and
sufficient length between line components should be
allowed
39
BUCKLING OF SEALS
Cause
Buckling of sealing
disks
Solution
Appropriate
selection of the
seal geometry and
flange selection
40
REDUCER LENGTH
Cause
When the diameter of the pipe is reduced from a large
diameter to a smaller diameter
Solution
The reducer length should be as long as possible with
inspection pigging compared with utility pigging where it
should be as short as possible
41
BYPASS WITH REDUCTION IN FLOW

Cause
When a standard bypass pig is in a pipeline an
d there is a sudden reduction in fluid flow
Solution
Perform the the necessary calculations to allow
the correct bypass to be selected
42
DRIVING DUAL MODULE PIG ON REAR

Cause
Bends makes the pigs
tend to move laterally,
results in seal flapping
Solution
Pressure should be
transferred to the front
module via bypass
ports on the rear
This allows the rear
module to be towed
43
DUAL MODULE PIG WITH LEAKAGE

Cause
Low density gas leaks
through a dual module
pig, differential
pressure is set up
across the pig and
lateral movement can
result
Solution
Use better support for
the pig and correct
sizing of the seals
44
WEAR
Cause
Abrasion cause wear due to large distance
Solution
Determine the maximum piggable distance
depending on: pig velocity, fluid type, pig
differential pressure, pipeline nominal
diameter, pipe surface type
45
VELOCITY EXCURSIONS
Cause
Large acceleration
and velocities due
to the
compressibility of
the system
Solution
Take into
consideration
during pig
selection
46
COUPLING DAMAGE
Cause
In dual module pig,
compression and tension
on coupling between
module
Solution
Strong coupling selection
Joint must be capable of
opening to the correct
angle to allow the pig to
negotiate the line
features
47
TRAPPED CAVITIES
Cause
Cavities in pig cause collapse under high pipeline
pressure or during testing
Solution
Balance all cavities
If cavity is required, it should be designed as an
externally pressurized container and subject to
qualification
48
TEARING SEALS OUT OF BOLTHOLES

Cause
Highly oversized
sealing discs
Solution
Oversize needs to be
carefully selected and
the bolting
arrangement such that
the discs is properly
clamped to the pig
49
PIGS IN FREE FALL

Cause
Steep sections such as
risers, lead to high
velocity
Solution
Slow the pig down
50
ENVIRONMENTAL ISSUES
Cause
Line temperature (degradation of the seal
materials, expansion of metallic parts
Line pressure (Cavities, explosion, decompression)
Line contents (incompatibility with the seal
materials)
Immersion time
Solution
Check such aspects with pig suppliers
51
UNUSUAL DAMAGE TO 10 X 16 PIG

DURING TESTING
As an example of the need to Expect the
Unexpected, the following photograph
shows a 10 x 16 pig stuck in the straight
10 line at a flange and offtake
52

DURING TESTING
53

DURING TESTING
54
PIG MOTION ANALYSIS

A pig moves through the pipe at constant
velocity Vp
Due to large contact friction between the pig
and the pipe, Vp is smaller than the mean flow
velocity V
The flow creates a drag force FD on the pig
2
1
FD = C D A (V V p )
2
55
PIG MOTION ANALYSIS

Pipe Wall
Pig
Vp
P1
P2
Ff
56
PIG MOTION ANALYSIS (Cont.)

The drag force is equal in magnitude but
opposite direction of the contact friction force
FD = F f = N
V p = V Vd
Where
Vd =
2 N
C D A
The equation shows that the pig velocity is

smaller than fluid velocity by Vd
57
PIG MOTION ANALYSIS (Cont.)

C
4k
4
d
1 k
2
d
Dd
The leakage ratio is given by:

Leakage = 1-Vp/V
Where
CD = Drag coefficient
A
= Area
= Fluid density
= Contact friction coefficient

N
= Angular speed, rpm
kd = Diameter ratio of the disk
58
Example
A pig with two end disks having an
effective disk diameter of Dd=0.98 D is
used in a 10 in steel pipe for cleaning the
pipe interior. The fluid is water flowing at 6
fps. The pig being squeezed into the pipe
exerted a total normal force of 400 lb on
the pipe wall and the contact friction
coefficient between the pig and the pipe is
o.6. Find the velocity of the pig and the
percentage of the leakage flow
59
Solution
Given
= 0.6
N = 400 lb
= 1.94 slug/ft3
V = 6 fps
A = 0.545 ft2
kd = 0.98
Required
Vp, Leakage
Solution
CD = 2353
Vd = 0.439
Vp = 5.56 fps
Leakage = 1 (5.56/6)
= 0.073
60

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Oil and Gas Pipeline Design,

Maintenance and Repair

Part 7: Instrumentation and Pigging

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

REASONS FOR PIGGING

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Solid cast pigs

Spherical pigs or spheres

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

IN LINE INSPECTION TOOLS

IN LINE INSPECTION TOOLS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

INFORMATION FOR IN LINE

ULTRASONIC INSPECTION TOOLS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Batching, or separator gel

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PRINCIPLE APPLICATION OF GEL PIGS

DUAL DIAMETER PIGS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

DUAL DIAMETER PIGS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

DUAL DIAMETER PIGS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

MULTI DIAMETERS PIGS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

WHY DO PIG STUCK?

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

SPHERE JAMMED IN OFF TAKE

INCORRECT SIZED PIG COMPONENTS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

INCORRECT SIZED PIG COMPONENTS

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

INCORRECT VALVE/VALVE NOT OPEN

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PIG PUSHING ON PIG IN FRONT

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

HIGH FRICTION PIGS

PLUGGING WITH WAX

DEPRIS IN THE LINE

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

FLOW AROUND THE PIG

INSUFFICIENT SEALING LENGTH

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

BYPASS WITH REDUCTION IN FLOW

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

DRIVING DUAL MODULE PIG ON REAR

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair