Training Module

Pig Gathering
System Pipelines

Human Development
Consultants Ltd.
 Pig Gathering
System Pipelines

© HDC Human Development Consultants Ltd.

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ISBN 1-55338-025-8

Canadian Cataloguing in Publication Data

1. Pipeline pigging. 2. Petroleum Pipelines—Cleaning. 3. Natural Gas Pipelines—Cleaning.

I. HDC Human Development Consultants.
TJ930.P456 2001 665.5’44 C2001-900446-X

This training kit consists of the following parts:

♦ Training Module and Self-Check ♦ Blank Answer Sheet
♦ Knowledge Check and Answer Key ♦ Performance Check

Published by HDC Human Development Consultants Ltd.

Published in Canada

HDC Human Development Consultants Ltd.

Website: www.hdc.ca
E-mail: marketing@hdc.ca
Phone: (780) 463-3909

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 Human Development Pig Gathering
Consultants Ltd. System Pipelines

Contents
Training Objectives 1

1 Introduction 1

2 Internal Line Corrosion and Reduced Flow Rates 2

3 Pigs 4

Pig Launchers and Receivers 8

4 4.1 Pigging Valves 8
4.2 Pig Injector Tees 10
4.3 Wire Mesh Basket Receivers 12
4.4 Barrel-Shaped Pig Launchers and Receivers 13
4.5 Closures 14

Operating Practices 18
5 5.1 Safety and Environment 18
5.2 Launcher/Receiver On-Line or Isolated 19
5.3 Draining and Venting 22
5.4 Venting Trapped Air 23
5.5 Purging 23
5.6 Removing Pigs 23
5.7 Key Interlock Systems 23
5.8 Other Practices 24

Pigging Practices 24
6 6.1 General Considerations 24
6.2 Pig Launching Practices 26
6.3 Pig Receiving Practices 32
6.4 Pig Cleaning 36

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Contents (continued)

7 Stuck and Lost Pigs 38

8 Batch Treating 41

9 Line Gauging, Testing, Internal Inspection 43

10 Self-Check 45

11 Self-Check Answers 50

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Training Upon completion of this training kit, you will be able to:
Describe the purpose and importance of pigging
Objectives operations for gathering system maintenance
Describe reasons for pigging gathering systems
Describe causes of internal corrosion
Describe different types of pigs and their uses
Describe pig launching and receiving equipment
Describe pig launching and receiving practices
Describe methods used to clean a pig
Describe methods used to locate and free stuck pigs
Describe inspection pigs
Launch and receive pigs

1 Introduction
The produced fluids from many oil and gas fields contain a
mixture of hydrocarbon liquids and gases, wax (paraffin), water,
and sediment. As these fluids flow through the flow lines, wax is
deposited on the inner walls of the flow lines and hinders fluid
flow. In addition, wax, water, and sediment may create
environments where internal line corrosion can occur. To
reduce the buildup of wax, water, and sediment in a flow line
and to reduce the effects of corrosion, companies regularly
carry out pigging and batch treating.

Figure 1—
Pig in a Line

In pigging, a cleaning tool, called a pig or scraper, is inserted

into a flow line to scrape wax deposits and to remove water or
sediment from the inner surfaces of the line.

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In batch treating, pigs are used to apply batches of chemicals

to the inner surfaces of a flow line. The chemicals limit
corrosion and kill colonies of bacteria.
Additional uses of pigs in gathering system lines include the
following:
After the line is built, pigs may be used to remove
construction dirt and debris, to aid in testing the new line,
and to thoroughly dry the line before use.
During the lifetime of a line, pigs may be used to inspect the
line for dents, buckles, cracks, and damage, and to gauge
the internal surface.

This training kit presents describes the safe and effective use of
pigs to clean flow lines and control corrosion:
the contribution of wax, water, and sediment to internal pipe
corrosion and reduced fluid flow in gathering system lines
the effect of pigging to remove wax, water, and sediment
deposits from gathering system lines
different types of pigs, pig launchers, and pig receivers
practices and procedures for loading, launching, and
receiving pigs
batch treating to inhibit corrosion

2 Internal Line Corrosion and

Reduced Flow Rates
Internal flow line corrosion seldom occurs unless water is
present. Water in a reservoir’s produced fluids can separate
from the fluids and collect in the low-lying areas of a flow line.
Liquids tend to pool in the dips and valleys of the line.

Pooled liquids in gas lines can lead to the following problems:

Pooled liquids eventually restrict gas flow in the line if the
flow velocity is not sufficient to sweep the liquids from the
dips or valleys. Such restrictions cause pressure drops and
are prime areas for hydrate plug formations.
Pooled liquids in gas lines may travel through the line as
slugs (known as water hammer), which are very difficult to
handle when they arrive at a compressor station or gas
plant. Pigging gas lines removes these pooled liquids, so

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that the line’s flow rate stays more consistent, allowing the
gas plant to handle the liquids more efficiently.
Pooled liquids (especially water) provide an environment
where corrosion may occur. Pigging gas lines assists in
corrosion control by removing the pooled liquids and
allowing corrosion inhibitors to contact the pipe.

Corrosion can occur in areas where the pooled water has

prevented corrosion inhibitors from reaching the metal
underneath the water. Corrosion can also occur in areas where
the pools of water have become breeding grounds for bacterial
colonies. For example, bacteria known as slimers form colonies
at the bottom of the line. Colonies of sulfate-reducing bacteria
(SRB) may form underneath these slimers, creating an acidic
environment that causes corrosion pitting of the pipe.

In gas gathering systems, corrosion primarily occurs as a result

of electro-chemical processes. These processes begin when
rust forms a cap or crust over a corrosion pit in the line.
Together, the rust cap and corrosion pit become a galvanic cell.
The electrical flow from this galvanic cell deepens the pit and
can eventually cause the pit to enlarge and form a hole through
the flow line wall.

In oil gathering systems, wax deposits build up when the wax

hardens and clings along the inner surface of a flow line. Over
time, the wax deposits may build up to such a degree that the
flow of oil is hindered or blocked. In addition, wax may be a
contributing factor in line corrosion. The wax deposits prevent
corrosion inhibitors from coating the metal beneath the wax,
reducing the effectiveness of the inhibitors. The deposits
provide an environment in which under-deposit corrosion can
take place or sulphate-reducing bacteria can thrive.

Cathodic control methods are used to minimize the external

NOTE
corrosion caused by galvanic action. Refer to the training kit
Describe and Adjust Cathodic Protection Systems for
additional information.

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Methods to Control Internal Line Corrosion and

Improve Flow Rates
Several methods are used to control internal flow line corrosion
and improve flow rates. These methods include injecting
chemicals, pigging, and batch treating.

Specific chemicals are used to address problems such as

bacteria, internal corrosion, scale, or wax. A unique chemical or
combination of chemicals is chosen according to the
characteristics of the producing system. For example:
biocides are injected to kill bacteria
scale inhibitors are injected to prevent the buildup of scale
wax dispersants are injected to reduce wax formation or
soften wax deposits
corrosion inhibitors are injected or batched to adhere to the
metal and protect the metal from corrosion

Special equipment is used to regularly inject chemicals into the

line so that the chemical mixes with the produced fluids.

Pigging removes wax deposits, pooled water, and rust caps

that hinder fluid flow or create environments which cause line
corrosion. Pigging is described in Sections 3 to 6 of this module
and in the performance checklist.

In batch treating, chemical inhibitor is batched between two

pigs. The first pig removes produced fluids, wax, water, or
sediment deposits and cleans the inside of the pipe. Chemical
inhibitor, isolated from the produced fluids in the line by the two
pigs, adheres to the bare metal and protects the line. Batch
treating is described in Section 8 of this module.

3 Pigs
Pigs for gathering system maintenance come in many different
shapes, materials, and sizes:
spheres—Most sphere pigs are made of polyurethane and
are filled with a water/glycol mixture.

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foam pigs—Most foam pigs are made of an open cell

polyurethane foam. Foam pigs may be coated with wire
brush straps, silicone carbide chips, or steel studs.
mandrel pigs—Discs are mounted on a central mandrel.
The discs can be replaced or reconfigured, allowing for
changing job requirements. Some discs have brushes to
provide more scraping edges; these are called disc scraper
pigs. Some disc pigs have specialty tools attached for
gauging or inspection. Some disc pigs have strong magnets
to remove ferrous debris.
solid cast pigs—Solid cast pigs are similar to mandrel
pigs, but are cast in one piece.
gel pigs—Gel pigs are viscous gelled fluids used alone or
in conjunction with mechanical pigs.

Figure 2—
Mandrel Pig Sphere Pig
Types of Pigs

Cast Pig Foam Pig

Common Uses of Pigs

The type of pig is chosen according to the specific
requirements of the line. Common uses for each type of pig
are:
spheres—sealing: batch separation, hydrostatic line
testing, line maintenance (dewatering, dewaxing, batch

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treating), meter proving. Sphere pigs are particularly useful

for negotiating tight 90° bends.
foam pigs—sealing and cleaning: drying, wiping,
dewatering, scraping (especially when coated with brushes,
chips, or studs)
mandrel pigs—sealing and cleaning: brushing, dewaxing,
descaling, gauging, inspecting
− when fitted as gauging pigs: determining internal
diameter, locating dents and slope changes
− when fitted as inspection pigs: detecting metal loss,
including corrosion and cracks
− when fitted as magnetic pigs: removing ferrous debris
such as welding rods and mill scale after construction or
before running an inspection pig
solid cast pigs—sealing
gel pigs—cleaning: picking up deposits and debris scraped
off inner pipeline walls by mechanical pigs

Pig Size and Fit

Pigs must be able to:
negotiate bends, curves, and dents in the pipeline
pass check valves and tees without buckling, tearing, or
shredding
resist rapid wear and wear evenly

Pigs come in standard sizes to fit tightly into standard diameter

mainline pipelines. Pigs must fit tightly in the line for several
reasons:
A tight fit prevents produced fluids from flowing past a pig.
Product builds up pressure behind a pig: the upstream
pressure (behind the pig) becomes greater than the
downstream pressure (in front of the pig). This difference in
line pressure across a pig (differential pressure) pushes the
pig down the line.

On disc pigs, the upstream pressure pushes the discs

forward. This action forces the discs tightly against the pipe
walls. For disc pigs, the greater the differential pressure, the
tighter the seal.

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A tight fit permits the edges of the pig to firmly scrape along
the inner surface of the flow line, scraping off wax and
sediment deposits. The scraped-off deposits collect ahead
of the pig, as illustrated in Figure 3. Some pigs are
equipped with bypass holes. Because of the pressure
differential across the pig, the holes create a jet action: fluid
from behind the pig pushes through the holes, keeping the
scrapings ahead of the pig.
For batch treating, a tight fit prevents the corrosion
inhibitors, which are batched between two pigs, from mixing
with the normal production stream and/or with the material
that is being scraped off the inner surfaces of the flow line
(see Section 8—Batch Treating).
A disc pig used for line gauging is typically equipped with a
metal gauge plate that is approximately 90% to 95% of the
internal diameter of the pipeline.

Figure 3—Pig Effectiveness

peeling or flaking cast pig

liquid
flow

wax deposit being removed wax deposits

scraped off walls carried in liquid

liquid smearing sphere pig

flow

wax deposit being removed wax deposits

scraped off walls carried in liquid

Both ball pigs and disc pigs are commonly used for dewaxing.
Disc pigs are more effective than ball pigs for dewaxing for the
following reasons:
The trailing edges of the disc pig are designed to peel the
wax off the walls of the pipe, whereas the ball pig tends to
pack the wax and deposits onto the walls of the pipe.

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The ball pig tends to elongate as it encounters heavy or

hard deposits and may not remove these deposits.
Disc scraper pigs (with stainless steel wire brushes
attached to the back disc) scrape the pipe clean and disturb
corrosion cells.

4 Pig Launchers and Receivers

To send a pig, a pig is inserted into the pig launcher. Pig
launchers are located at the upstream end of the flow line,
usually at the wellsite, satellite, or battery. Each section of flow
line which has a pig launcher at the upstream end must also
have a pig receiver at the downstream end to catch pigs after
they have traveled through the flow line. Pig receivers are
commonly called pig traps.

The basic types of pig launchers for gathering system

maintenance are pigging valves, pig injector tees, and barrel-
shaped pig launchers. Common pig receivers are pigging
valves, wire mesh basket receivers, and barrel-shaped pig
receivers. Pigging valves, pig injector tees, and basket
receivers are commonly used for smaller gas and liquid
hydrocarbon lines (two- to six-inch diameter). Barrel-type pig
launchers and receivers are used for gas and liquid lines, from
two-inches diameter and up.

To allow passage of the pig, the downstream isolation valve on

launchers and the upstream isolation valve on receivers must
be full opening (full port). Butterfly valves and needle valves
cannot be used at these locations.

4.1 Pigging Valves

Pigging valves (commonly known as Barber valves) are used to
launch and receive small, sphere- or bullet-shaped pigs.
Pigging valves are commonly used to launch pigs from gas or
liquid hydrocarbon wells and to receive the pigs at a satellite,
battery, or gas plant. Pigging valves are designed to reduce
time and labor associated with launching pigs: when using a
pigging valve to launch a pig, the well normally does not need
to be shutdown.

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The pigging valve is positioned directly in the flow line, and

consists of a specially designed valve body.

Review the installation and operation of each brand of pigging

WARNING
valve from site P&IDs and manufacturer manuals. Some
pigging valves block off the flow when launching a pig; other
types of pigging valves bypass the flow during pig launching.

Figure 4—Pigging Valve on a Flowing Well

safety pressure switch

upstream pigging downstream
tubing head isolation valve isolation valve
pressure gauge (ESD) valve (full opening)

hammer cap

master valve This arrangement is identical

on flowing and pumping wells

casing valve

In the open position, fluid flows through the pigging valve. In the
closed position, the valve’s side entry cap can be opened.

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Figure 5—Pigging Valve in Open and Closed Position

pigging lever pigging lever

Valve in Open Position (through flow) Valve in Closed Position (no flow)

To insert a pig, the pigging valve is closed, the side entry

cap is opened, and the pig is inserted. A funnel may be used
to insert the pig if the pig has swelled. To launch a pig, the
side entry cap is replaced, and the pigging valve is opened.
To receive a pig at the receiving end of the line, the pigging
valve is left open. To remove the pig, the pigging valve is
closed, and the side entry cap is opened.

Pigging valves that are equipped to handle sphere pigs may be

retrofit (using kits from the valve manufacturer) to
accommodate bullet or disc pigs.

For launching disc pigs from pigging valves, make sure you
CAUTION
insert these pigs in the correct orientation. If the pig is inserted
backwards, the pig may get stuck in the flow line.

4.2 Pig Injector Tees

Pig injector tees are used to launch small two-, three-, or four-
inch pigs into the line near the wellhead of a gas or liquid
hydrocarbon well. Pigs sent from this type of pig launcher are
used to clean the lines from the wellsite to the satellite or to the
central battery.

To insert a pig into the body of the pig injector tee, the cap must
be removed. Most caps associated with this type of pigging tee
have an O-ring seal and a drilled port(s). The port allows
trapped pressure to escape when the cap breaks contact with
the O-ring and the O-ring seal is broken.

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Some pig injector tees may have an additional safety feature

known as a pressure warning valve. The pressure warning
valve prevents the cap from being removed until the seating
screw is removed. There are many different types of
installation; make sure you are familiar with each type of
launcher in use at your site and follow the operating directions
set out by the manufacturer and your company.

End of Sample
A full licensed copy of this kit includes:
• Training Module and Self-Check
• Knowledge Check and Answer Key
• Blank Answer Sheet
• Performance Check

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