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OPERATIONS CONTROLLED DOCUMENT

DISOUQ PIGGING PROCEDURE


Document No:

Custodian:

Supersedes

Revision no: 0

Revision no:

Filename:

Date:

Date: 28/11/2015

Administered by: Verified: Date:


O-90

O-91

Verified: Date:

Approved: Date:

Approved: Date:

O-1

Date:

Reason for revision: The document is in new format and updated.

This document contains proprietary information and is intended for use by SUCO staff only.
The contents of this controlled document shall not be changed without formal approval of the
document custodian.

Rev 1

PIGGING PROCEDURE

CONTENTS
1. INTRODUCTION................................................................................................................................................... 3
2. RESPONSIBILITIES.............................................................................................................................................. 3
3. PIGS TO BE USED................................................................................................................................................. 4
4. GRADED CLEANING PROCEDURE.................................................................................................................... 4
5. LAUNCHER/RECEIVER SAFETY PRECAUTIONS.............................................................................................. 5
6. PIGGING PROCEDURE......................................................................................................................................... 5
6.4. LAUNCHER/RECEIVER SCHEMATIC............................................................................................................... 8
7. PIPELINE PIGGING LOGSHEET.......................................................................................................................... 9
8. ADDITIONAL INFORMATION............................................................................................................................ 10
8.1 PIPELINE INFORMATION.................................................................................................................................. 11
8.2 SLUG CATCHER / PIGGING OPERATION OF 12 TRUNKLINE......................................................................12

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PIGGING PROCEDURE

1. INTRODUCTION

Routine pigging is carried out to prevent a build-up of debris within the pipeline and to remove free water which
may accumulate at the bottom of the pipeline. Deposits can cause an effective reduction of pipeline diameter
and hence increased back pressure to the export system, both debris and stagnant water can give rise to
increased corrosion of the pipeline and reduce the efficiency of corrosion inhibitor.
1.1 OBJECTIVE

Pipelines cross boundaries of area responsibility and various parties are therefore involved in the launch and
receipt of pigs. This document seeks to provide a common procedure such that efficient operation is achieved
during pigging activities and pigging is carried out in a controlled safe manner.
1.2 SCHEDULING
Oil/Gas/Water transport lines
The minimum frequency of pigging product transport lines is given in section 9 of this procedure.
Note: Deviations from stated frequency in section 9 may be required and will be set by the Pipeline Integrity
Management authority. Deviation may be initiated by the Production Manager.

2. RESPONSIBILITIES

- The Area Field Manager is the Asset custodian for those oil/gas and water lines that originate from a
station/facility in his area.
- It is the responsibility of the Asset custodian to ensure that pigging is carried out at regular intervals in
accordance with this procedure.
- It is the responsibility of the Asset custodian to ensure that the responsible supervisor of the pig receiving
area is informed and has given his consent prior to pig launching.
- The responsible supervisor of the receiving area will arrange retrieval of the pig from the pig receiver and fills
in relevant section of the pigging report (see section 7).
- It is the responsibility of the supervisor of the receiving area to inform Inspection section prior to opening the
pig receiver because internal inspection of the receiver is a requirement.
-

The person in charge of the pigging activity is responsible for;


- that all pigging material used to pig a line is in a fit for purpose condition, and that the proper type of
pig is used.
- checking the launcher/receiver configuration, and that all valves are in good sealing condition.
-

transport to the launcher and initiation of the pigging report upon launching.

- The receiver is responsible for the forwarding/return of the pig to the launcher department. He also completes
the pigging report and forwards the report to Corrosion Department and launching supervisor. If required, the
receiver is to make alternative arrangements for the return of the pig.

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PIGGING PROCEDURE

- Upon retrieval of the pig at the receiving end, the production supervisor is responsible for sampling debris
and handing the sample over to the Area Corrosion Engineer who will assess quality and quantity and submit
appropriate samples to the laboratory for further analysis. The analysis results are sent to O-90 when
obtained from the laboratory (copy Chemical Engineer Cairo).
- The launcher is responsible for the return of the pig to the workshop and reporting of the required information
in the pigging report.
2.1 REPORTING
The pigging report (see section 7) is completed by the supervisor responsible for the launch and shall include
all necessary information from the receipt activity. The completed report is then routed to the area Corrosion
Engineer who will log the pigging frequency on a data base en will send a copy of the pigging report to the
Chemical Engineer in Cairo for data analysing who will inform the asset holder if pigging frequencies need to
be adjusted. The data will be put on the area data file server which is read only accessible.

3. PIGS TO BE USED
For routine pigging of pipelines it is recommended to use BI-DIRECTIONAL pigs. Pipelines with bore variations
larger than 5% shall be pigged with CUP TYPE PIGS. (In SUCO only CUP PIGS are used)
For pipelines which have to be pigged for the first time or have not been pigged for a long time a graded
cleaning procedure as described below must be followed. (Not to be used for sales gas pipelines)
For additional information on pigs see section 8 of this procedure.
NOTE: The diameters of discs of BI-DI pigs have to be checked prior to launching.
Seal disc OD to be approx 4% larger then the ID of the pipeline to be pigged.
Support discs OD to be approx the same as the ID of the pipeline to be pigged.
For pipeline diameter information refer to section 9.

4. GRADED CLEANING PROCEDURE


- Run High Density foam pig with smooth polyurethane cover. For pig launching and receiving refer to section
6.1, 6.2 and 6.3. Note: No Foam pigs to be used in export gas lines which deliver gas to point of
custody transfer! In this case reduced size cup pigs may be used instead of HD foam pigs.
- Estimate volume of debris received and take sample.
- Continue to run HD foam pigs until consecutive runs produce similar amounts of debris, or no debris.
- Run High Density foam pig with criss-cross braided wire brushes.
Continue to run wired foam pigs until consecutive runs produce similar amounts of debris, or no debris.
- Estimate volume of debris received between runs and take sample.
- Run steel bodied BI-DI pig or CUP pig with urethane discs/cups.
- Estimate volume of debris received between runs, take sample and continue until a run produces no
significant debris.
- Run BI-DI pig or cup pig fitted with 95% diameter-6mm thick aluminium gauge plate.
NOTE:

Gauge plates are used to demonstrate that pipelines are free of any major obstructions. The best
location of a gauge plate is just in front of the rear sealing cups or discs. In this position the chance is
reduced that the plate will be damaged due to minor obstructions, bends, loose debris etc.

- Run BI-DI pig or CUP pig with full size discs/cups and brushes until a run produces no significant debris.
CAUTION
Foam pigs can absorb hydrocarbons. Care should be take when handling them after pigging, especially in
combination with pyrophoric dust (FeS). Immerse the foam pig in water upon retrieval if pyrophoric dust is
present.
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PIGGING PROCEDURE

5. LAUNCHER/RECEIVER SAFETY PRECAUTIONS


General
Blockages of drain and vent valves by pig cups or large quantities of debris is possible. Similarly, pressure
gauges are sometimes faulty or blocked. At least two pressure gauges should be fitted to the barrel at different
locations, where possible, to guard against this event.
However, if there is any doubt that the barrel is not at zero pressure, close vent and drain valves and repressure the equipment. Observe very carefully the changes in pressure that are indicated, particularly when
the barrel is pressurized again. Depressurise and once satisfied that barrel is fully depressurized, proceed with
door opening.
When opening the door of a launcher or receiver, NEVER stand in front of the door or at the side where the
hinge is fitted. Ensure that NOBODY stands directly in line with the door.
The receiver shall always be lined up prior to launching a pig and the proper operational valves ascertained.
Pyrophoric dust
Special precautions need to be taken on receiving pyrophoric dust. Before opening the receiver the barrel
should be damped down with a water source.
Note:

Fire extinguisher and/or running fire hose to be on site when iron sulphide (FeS) is expected.

NORM
This procedure shall be read in conjunction with procedure No XXXXX Radiological safety precautions for
pigging operations

6. PIGGING PROCEDURE
6.1.

LINING UP OF THE RECEIVER (refer to section 6.4) Launcher/receiver schematic)

6.1.1

Ensure drain valve D is CLOSED and that the door F is secured.

6.1.2

OPEN vent valve(s) E.

6.1.3

OPEN pressurizing valve G and balance valve H (if installed) or crack kicker valve C. As the pipeline
fluid enters the receiver, air will be displaced through vent valve(s) E.

6.1.4

In the case of a gas pipeline air will be displaced by gas. Continuous gas readings should be taken until
100% gas is detected at the vent valve.

NOTE: Ignition sources should be removed from the area.


6.1.5

When the barrel is full of product, CLOSE vent valve(s) E and allow the barrel to pressurize fully.
Check that the barrel pressure gauge shows the same value as the line pressure.

6.1.6

OPEN kicker valve C fully and OPEN pig trap valve B. This allows fluid to flow through the receiver.
In case of low flow there is a risk of the pig stopping across the by-pass tee.

6.1.7

Confirm there is no leakage from the door seal and fittings before leaving site.

6.2.

PIG LAUNCHING (refer to section 6.4 Launcher/receiver schematic)

6.2.1

Ensure kicker valve C and pig trap valve B are CLOSED.


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PIGGING PROCEDURE

6.2.2

OPEN drain valve D and vent valve E to drain and depressurize the launcher barrel. Confirm zero
pressure. Unseat bleed screw on door. If no fluid flows through the bleed screw, REMOVE bleed screw.
Air flow into the trap indicates that fluid is still flowing from the drain. When the air flow stops the trap
is fully drained and the door may be opened.

NOTE: A number of older doors may not be fitted with bleed screws. In these cases additional precautions
should be taken before opening the door e.g. confirm by visual observation that draining has stopped.
6.2.3

OPEN door F.

6.2.4

Load pig into barrel, ensuring that the front driving cups are in contact with the reduced bore part of the
barrel.

6.2.5

CLOSE door F. CLOSE drain valve D. Ensure that door is securely locked.

6.2.6

OPEN pressurizing valve G if installed or crack kicker valve C. As oil enters air will be displaced from
the barrel through vent valve E.

6.2.7

When the barrel is full of product, CLOSE vent valve and allow the barrel to pressurize fully. In case of
a gas pipeline, air will be replaced by gas. Continuous readings should be taken until 100% gas is
detected at the gas vent valve.

NOTE: Observe note under 6.1.4.


Check that all pressure gauges give the same reading.
6.2.9

OPEN receiver isolation valve B

6.2.10 OPEN kicker valve C fully. CLOSE balance line H if installed.


6.2.11 Slowly CLOSE by-pass valve A to force product flow through the launcher until pig signaller X1 trips
showing that the pig has left the barrel and is travelling through the pipeline. Reset the pig signaller.
6.2.12 OPEN by-pass valve A.
6.2.13 CLOSE kicker valve C
6.2.14 CLOSE pig trap valve B.
6.2.15 Drain and depressurize as under 6.2.2 above
6.2.16 OPEN door F and confirm that pig has been launched. Check seal, clean and lightly oil mating surfaces
6.2.17 CLOSE door F and ensure that it is secure as per manufacturers procedure.
6.2.18 CLOSE drain D and vent E valves. Clean, empty saver pit.
6.2.19 Complete "PIPELINE" and "LAUNCH" sections of the pigging log sheet.
6.3.

PIG RECEIVING (refer to section 6.4 Launcher/receiver schematic)

6.3.1

The receiver has been lined up as per section 6.1.

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PIGGING PROCEDURE

6.3.2

Arrival of the pig is shown initially by pig alert X2 being activated. X1 should activate shortly
afterwards to show that the pig has entered the barrel. If X1 does not activate, the by-pass valve A must
be closed or throttled to force the pig into the barrel.

6.3.3

Once the pig is HOME in the barrel, OPEN by-pass valve A fully.

6.3.4

CLOSE pig trap receiver valve B.

6.3.5

CLOSE kicker valve(s) C.

6.3.6

Drain and Depressurise as under section 6.2.2.

6.3.7

OPEN door F and remove pig.

6.3.8

Clean out receiver barrel and take sample of debris if >20 kg, or if specifically instructed. A sample sheet
shall be completed and sent with the sample to the laboratory. The sample taking must be recorded on the
log sheet. (for info XXXX). Check door seal, clean and lightly oil mating surfaces.

6.3.9

CLOSE door F, drain valve D and vent valve E. Ensure door F is secured as per Manufacturers
procedures.

6.3.10 Inspect pig for damage and action refurbishment and/or return ready for next use.
6.3.11 Ensure "retrieval" section data is passed to supervisor for completion of the pigging log sheet.

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PIGGING PROCEDURE

6.4. LAUNCHER/RECEIVER SCHEMATIC


Vent

PI

Vent

PI

Relief
valve

XL

Pig trap valve

XL

ESD

B
Enclosure

To Closed drain
system

Main Line

Launcher/receiver

drain valve

PI
Balance valve
Kicker
valve

Pressurisation
line and
valves

By-pass
valve

A
G

kicker line
Isolation
valve

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PIGGING PROCEDURE

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7. PIPELINE PIGGING LOGSHEET

SUCO PIPELINE PIGGING LOGSHEET

DATE:

PIPELINE CODE:

FROM:

TO:

SERVICE: OIL /GAS/WATER

LENGTH:

km

DIAM:

inch

LAUNCH INFORMATION
DATE/TIME PIG LAUNCHED:

ETA:

PRESSURE (before/after):

TYPE OF PIG: CUP/BI-DI

BY-PASS (open/closed):

NUMBER OF CUPS:

NUMBER OF PINS (per disc):

CUP MATERIAL(mesc)

CIRCUMFERENCE OF CUPS:
NUMBER OF DISCS: GUIDE

SEAL

CIRCUMFERENCE OF GUIDE DISCS:

DISC MATERIAL(mesc)

CIRCUMFERENCE OF SEAL DISCS:

DISC MATERIAL(mesc)

BRUSHES (y/n type):

BRUSH CONDITION
NAME:
SIGNATURE:

PIG RETRIEVAL INFORMATION


DATE/TIME PIG ARRIVED:

PIG RUN TIME:

AVERAGE PIG SPEED:

m/sec

DEBRIS RECOVERED:

dm3

SAMPLE TAKEN IF DEBRIS > 0.5KG

TYPE OF DEBRIS:

(Y/N)

CIRCUMFERENCE OF GUIDE CUPS


CIRCUMFERENCE OF SEAL DISCS

hrs

(indicate wear):

(indicate wear):

BRUSH CONDITION:
PIG DAMAGE:
REMARKS:
Gauge plate:
1) Cover pigs against sunlight.
2) Place pigs in brackets during transport.
3) Clean pigs directly after use.
4) check tightness nuts/bolts.

NAME:
SIGNATURE:

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PIGGING PROCEDURE

8. ADDITIONAL INFORMATION
Efficient Swabbing Pig Velocities.
- Efficient pigging speeds for CUP pigs in swabbing debris from pipelines range from 0.2-1.6 m/sec. Optimum
speed 1.0 - 1.2 m/sec.
- Efficient pigging speeds for CUP pigs in swabbing fluids from pipelines range from 0.2-4.5 m/sec. The lower
the speed the better the efficiency.
- Efficient pigging speeds for BI-DI pigs for swabbing debris from pipelines range from 0.2 m/sec to well above
3 m/sec. Optimum speed is above 2.0 m/sec.
- Efficient pigging speeds for BI-DI pigs swabbing liquids from pipelines range from 0.2 to well above 6 m/sec.
The lower the speed the better the efficiency.
- Pigging at low speeds (0.2 m/sec) with BI-DI pigs is still reasonable effective. There seems to be no real
reason for a minimum pigging speed.
Amount of oversize of seal discs.
Medium overzise seal discs (4%) on BI-DI pigs seem to be most efficient. 2% oversize discs create a too wide
gap; 6% oversize disc start to act too much as a cup pig, will require a higher driving pressure and will wear
down fast.
Indications of typical tolerable bore variations.
- Foam Pigs
- Spheres
- Cup Pigs
- Bi-Di Pigs

20-60%
20-30%
10-15%
5-10%

High Temperature Pigs.


For pipelines operating above 60 C consideration should be given to deteriation of disc and cup materials.
- For Temp < 60 degr. C
- For Temp > 60 degr. C < 100 degr. C
- For Temp >100 degr. C

Polyurethane discs and cups.


Neoprene discs and cups.
Viton discs and cups.

Cup Disc material


In general Polyurethane with a hardness of 70 Shore A is recommended as disc/cup material.
NOTE 1: Certain types of polyurethane may suffer up to 30% swelling if they come in contact for longer
periods with methanol. It may also result in rapid loss of elasticity and shore hardness therefore if methanol is
used material selection of cups and discs is critical.
NOTE 2: The sizes of all pipelines are identified by the Nominal Pipe Size NPS, which is seldom equal to the
true bore (Internal Diameter) of the pipe. The differences in some instances is large. Pipes with a NPS of 14
and above have an Outside Diameter which is equal to the NPS. If the exact ID of the pipeline is not known or
if the ID varies over the length of the pipeline then BI-DI pigs must not be used. In this case use CUP pigs
which can cope with a larger variation in pipeline bore.

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PIGGING PROCEDURE

8.1 PIPELINE INFORMATION


Service

Start

End

Sales gas from TPF

TPF BVS 2

Tie-in NTS Gasco

Length
KM
19

Dia.
Inch
16

Sales gas from CTP

CTP

Tie-in NTS Gasco

40.3

16

Sales condensate
from TPF

TPF Block valve


station

Tie-in NTS PPC

19.4

Sales condensate
from CTP
Raw gas/ Multiphase
Raw gas/ Multiphase
Raw gas/ Multiphase

CTP

PPC Tie-in

40.7

NWK 1-1 manifold


NWK 1-1 manifold
NWK 1-2

1.4
0.25
1.5

6
6
6

Raw gas/ Multiphase


Raw gas/ Multiphase
Raw gas/Multiphase
Raw gas/ Multiphase

NWK 1-3 *
NWK 1-1 *
NWK 1-1 *
manifold
TPF *
NWK 1-2 *
NWK-1-4*
NSG-1-1

Via Mobile
arrangement
from CTP
Via Mobile
arrangement
from CTP
Via Mobile
arrangement
From CTP
Via Mobile
arrangement
No
No
No

0.2
0.5
5
2.0

8
6
8
6

No
No
Yes
Yes

Raw gas/ Multiphase


Raw gas/ Multiphase

NSG-1-2
SSG-1-1

0.25
9.57

6
6

No
Yes

Raw gas/ Multiphase


Raw gas/ Multiphase
Raw gas/ Multiphase
Raw gas/ Multiphase
Raw gas/ Multiphase
Raw gas/ Multiphase

SSG-1-2
NWSG 1-1A
NSG 2-3
NSG 2-1
SSSE-3-1
NSG 4-1

Tie-in 16
TPF manifold
NWK 1-2 Manifold
NSG-1-1
Manifold / CTP
NSG-1-1 Manifold
SSG-1-1 Manifold
-CTP
SSG-1-1 Manifold
CTP Manifold
CTP Manifold
NSG 2-3 Manifold
NSG 1-1a Manifold
CTP Manifold

1.21

6
12

No
Yes
Yes
No
No
No

Piggable

* These wells currently produce into the RPF at NWK 1-2 and from the TPF into the 16Sales as line.

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PIGGING PROCEDURE

8.2 SLUG CATCHER / PIGGING OPERATION OF 12 TRUNKLINE


The 12 Trunk Line between NWSG 1-1 and the CTP has a low gas velocity and hence liquid
volumes during pigging operation are expected to be between 39 and 104 m 3.
These volumes cannot be handled by the existing slug catcher without further adjustments.
Slugs during normal operations will be handled by the slug catcher
Liquid volumes during pigging operations from the other pipelines can be handled by the slug
catcher. Based on the simulations the liquid consists of 1/3 Hydro carbons and 2/3 reservoir
fluids.
To avoid overflow and shut down of the slug catcher during pigging operations the by-pass
valves G in the 2 by-pass line across valve C shall be used while valve C is closed (see
sketch pig receiver).
Pressure regime has to be adjusted via the choke valve on the wellhead.
Pig velocity is very low. All other trunk lines are in normal operation.

8.3 Modification:

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PIGGING PROCEDURE

Due to current situation for slug catcher as it is operated manually we add some modifications to ensure
normal pigging operation for 12" pipe line:
1- Before pigging start up, keep water level at the slug catcher at high level (+/- 2000 MM) to
ensure condensate carry over to condensate part at the other side.
2- At the day of pigging before start pigging by +/- 0.5 hr., start to drain water & condensate level
until reach to LL level on condensate compartment and to low level (+/- 900 MM interface and
+/- 1200 top liquid level )on water compartment that ensure no condensate escaping with water
to water degasser vessel.
3- Its possible to perform override to LAHH 5010 & XZV 5014 at slug catcher due to malfunction
of water control loop and for any faulty transmitter if required.
4- Inst. crew must check level transmitters and level glasses of water and condensate at slug
catcher before start pigging.
5- Mechanical crew must check strainer of pumps at water degasser and condensate stabilizer unit
before start pigging.
6- The expected time for pig arrival is about 2 hrs , so after 1.5 hr keep close monitoring for level
inside slug catcher .
7- To avoid overflow and shut down of the slug catcher during pigging operations the by-pass
valves G in the 2 by-pass line across valve C shall be used while valve C is closed (see
sketch pig receiver). depending on level on slug catcher its possible to complete closing Valve
G or closing wells NWSG 1-1 and SSSE 3-1 if required
8- We must keep monitoring for level and pressure at LTS A&B and condensate stabilizer unit.
9- We can reduce pressure at 1st stabilizer to provide more volume at vessel and to help for liquid
drain from slug catcher and LTS A/B.
10- Observe and monitor pig receiver alerts at manifold area to check pig arrival.

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