Projects Engineering Department

Engineering Standard

BES-L007
Pig Launchers/Receivers 01 July, 2006

Contents

1.0 GENERAL INTRODUCTION ........................................................... 3

2.0 LIST OF APPLICABLE DOCUMENTS ............................................ 3
3.0 DESIGN & MANUFACTURE REQUIREMENTS ............................. 4
4.0 INSPECTION AND TESTING .......................................................... 7
5.0 PACKAGING & HANDLING............................................................. 8
6.0 VENDOR’S DOCUMENTATION ..................................................... 8
7.0 REFERENCE DATA SHEETS ......................................................... 9
APPENDIX 1 MAIN DIMENSIONS ....................................................... 10
APPENDIX 2 DATA & DOCUMENTS .................................................. 12

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BES-L007
Pig Launchers/Receivers 01 July, 2006

REVISION RECORD

Date Originator Reviewed Approved Description

01/07/06 ESD AMA NMI For implementation

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BES-L007
Pig Launchers/Receivers 01 July, 2006

1.0 GENERAL INTRODUCTION

1.1 PURPOSE

This standard defines the minimum requirements for the design, manufacture, assembly inspection, factory
testing, vendor documentation, supply and transport to site of pig launchers/receivers in accordance with this
standard and applicable project documents.

1.2 SPECIFIC PROJECT DATA

Data to be provided by PURCHASER to VENDOR

- Line Pipe Specification

- Third Party Inspection Specification PCI030-005
- BES-A002, Basic Engineering Design Data
- BES-A003, Packing & Marking
- BES-A004, Vendor Data & Documentation Requirements
- 1-1-SMA-7, Pipeline Welding Procedure.

1.3 LANGUAGE AND UNITS

All documents, design calculations, drawings and correspondence provided in relation to this standard shall be in
the English language. All units shall be in accordance with the System Internationale (SI) unless otherwise
specified.

1.4 DEFINITIONS AND ABBREVIATIONS

For the purpose of this standard, the following definitions shall apply:

"PURCHASER" means the party or its duly appointed representative, which is contracted to purchase the
materials and/or equipment as described by this standard.
"VENDOR" means the party, which is contracted to manufacture and/or supply, materials, equipment
and services to perform the duties as described by this standard.
NDT Non-Destructive Testing
MT Magnetic Particle Testing
PT Liquid Penetrant Examination
UT Ultrasonic Testing

2.0 LIST OF APPLICABLE DOCUMENTS

The pig launchers/receivers shall comply with the requirements of the documents as listed in codes and
standards, project documents and with those referred to “as applicable”.

2.1 PRIORITY OF DOCUMENTS

In case of conflicting requirements from the documents listed, the following descending order of precedence
shall be taken into account:

1. National or local codes/authority regulations.

2. The purchase order
3. Data sheet(s)
4. This standard
5. Industrial codes and standards referred to in above documents.

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BES-L007
Pig Launchers/Receivers 01 July, 2006

2.2 CODES & STANDARDS

Document No. Document Title

American Society of Mechanical Engineers (ASME)

ASME Boiler and Pressure Vessel Code (BPV)

Section V - Non-destructive Examination
Section VIII - Division I - Pressure Vessels
Section IX - Welding and Brazing Qualifications
ASME B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous
Ammonia and Alcohols
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.34 Valves Flanged and Butt Welding Ends
ASME B16.9 Factory made Wrought Steel Butt Welding Fittings
ASME B36.10 Welded and Seamless Wrought Steel Pipe

American Petroleum Institute (API)

API Spec. 5L Specification for Line Pipe

API Std. 1104 Welding Of Pipelines and Related Facilities

International Organization of Standards (ISO)

ISO 9001 Quality Systems - Model for Quality Assurance in Production, Installation and Servicing
ISO 10474 Steel and Steel Products - Inspection document

American Society for Testing Materials (ASTM)

ASTM - A694 Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves and Parts for High
Pressure Transmission Service
ASTM - A370 Mechanical Testing of Steel Products

National Association of Corrosion Engineers (NACE)

NACE MR-01-75 Standard Material Requirements for Sulphide Stress Cracking Resistant Metallic Material
for Oilfield Equipments.

3.0 DESIGN & MANUFACTURE REQUIREMENTS

Design and manufacture requirements are defined in the documents listed in paragraph 2.0, pig launcher/receiver
data sheet and the specific requirements listed below.

3.1 GENERAL

Pig launcher/receivers are generally located inside the plant area limit and are considered within the scope of the
respective transportation piping code, ASME B31.4/B31.8.

Pig launchers/receivers (including all components) shall be designed and be suitable for continuous outdoor
operation in accordance with site conditions indicated.

The maximum stresses shall be calculated per applicable ASME Code for the design conditions and shall not
exceed the allowable stress based on the design factor. Corrosion allowance shall be as specified in the Purchase
Order or in the design drawings attached to the Purchase Order.

The overall dimensions for pig launchers/receivers shall be in accordance with the drawing specified in the
Purchase Order, or the design drawing attached to the Purchase Order.

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BES-L007
Pig Launchers/Receivers 01 July, 2006

3.2 MATERIALS OF CONSTRUCTION

Material of construction shall be in accordance with the attached data sheets. Cylindrical sections shall be made
from seamless or welded pipe. All materials shall meet the requirements of NACE MR-01-75, with hardness
limited to 200 HB.

Materials supplied by VENDOR for piping elements or structural attachments shall conform to the requirements
of the applicable code and shall be traceable to mill certificates. Material selection may be further limited in this
specification or in the Purchase Order. Used or reclaimed materials or materials of unknown specification are
not permitted.

3.3 BARRELS

The internal diameter of the minor barrel should be the same as that of the main line. However, transitions in the
internal diameter due to wall thickness variations greater than 0.095 inch shall be tapered to 1:5 transition taper
to allow for the smooth passage of a pig.

The reducer between the major and minor barrel shall be eccentric with the bottom of the entire barrel at the
same level. Reducers shall have a nominal wall thickness at least equal to the specified nominal wall thickness of
the matching pipe (of equal yield strength) at the large end.

Appurtenances (valves, pig signallers, pressure safety valves etc), except for the end closure, are to be provided
with the pig launchers/receivers only if noted in the purchase order for pig traps.

Blind flanges are to be provided for each nozzle (except the end closure). Blind flanges should be of the same
rating as the flanges.

3.4 END CLOSURES

The pig launchers/receivers shall be equipped with a quick opening closure, designed to allow one man operation
for both opening and closing, with a pressure interlock to prevent opening of the door while the barrel is
pressurized.

The closure shall be designed in accordance with ASME BPV Code Section VIII, Division 1.

The closure fully closed position shall be marked to aid subsequent closure position. The closure shall use a
single replaceable “O” ring as the sealant element. There shall be no leakage of contents of the pig
launchers/receivers prior to disengagement of the locking element and release of the closure.

Optionally, VENDOR shall propose with his bid alternative types of end closures, which shall meet the
requirements in accordance with this specification.

3.5 BRANCH FITTINGS, FLANGES

Full reinforcements shall be provided on all branch connections.

Branch connections shall either be welded, forged or extruded. Reinforcing pads required by the specified code
shall be fully welded and shall be provided with a vent hole. The vent hole shall be tapped with a 3 mm-6 mm
pipe thread. The tapped hole shall be filled with heavy grease.

All flanges shall be as per ASME B.16.5.

All flanges shall have the same bore as the pipe.

All flanges and branch fittings shall be forged carbon steel fittings with the same specified yield strength as the
pipe.

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BES-L007
Pig Launchers/Receivers 01 July, 2006

3.6 SUPPORTS

The pig launchers/receivers shall be provided with saddle supports. Permanent saddles shall be used to support
and restrain pig launchers/receivers and these shall be designed to carry the weight of the pig launchers/receivers
system filled with water together with the weight of the pigs. Details of saddle supports should be provided to
PURCHASER for designing foundations.

Structural steel used for non pressure containing parts shall be equivalent to ASTM A36, S-1 or better.

The supports under the barrel shall be of the sliding type to compensate for expansion of the unrestrained part of
the pipeline.

3.7 FABRICATION

3.7.1 GENERAL

Fabrication of pig launchers/receivers shall be in accordance with the applicable design code (ASME
B31.4/B31.8) and in compliance with the following specific requirements:

Cutting of carbon steel piping shall be preferably carried out by mechanical means. When flame cutting is
employed, the end shall be ground sufficiently back in order that the bevels are clean and free from defects. All
bevelled ends during fabrication shall be subjected to a 100% UT lamination check and MT when flame cut. End
bevels shall conform to ASME B16.25.

Holes for the attachment of fittings shall be made using drills or a hole saw. Use of flame cutting is prohibited.
Holes shall be drilled prior to welding the fitting.

3.7.2 WELDING

All welding procedures, qualification of welders and welding procedure qualifications, design and preparation of
joints, inspection and testing, standards of acceptability of welding, repairs and radiography shall be fully in
accordance with API 1104 or ASME BPV Code Sec. V and ASME BPV Code Sec. IX, and shall be documented
before fabrication commences.

Single-welded butt joints are permitted for circumferential joints and shall be 100% radiographically tested.
Vendor shall provide ultrasonic tests where radiography produces questionable results.

In the event that welds performed on any forging cannot be 100% radiographed, 100% UT or wet MT shall be
utilised.

UT is required on the shell material where locally reinforced fittings are to be welded. Prior to welding all weld
ends are also to be checked using ultrasonic inspection.

3.7.3 NOZZLES

All nozzles shall be flanged, welding neck type in accordance with ASME B16.5. Facing shall be raised face.

All flanged connections shall be bored full length to match pipe thickness.

Connection neck shall be inserted through the vessel wall. “set on” attachment is not permitted.

All nozzles shall be flush with the inside diameter of the vessel.

3.8 SURFACE PREPARATION AND COATING

All sharp surface protrusions and all weld splatter shall be removed (flush) prior to blast cleaning, to ISO 8501-1
Grade 2 ½.

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BES-L007
Pig Launchers/Receivers 01 July, 2006

The launchers/receivers shall be painted with primer only. All bare surfaces shall be coated with two coats of
alkyd primer. Either the first or second coat shall be tinted with 1 or 2% of black alkyd enamel to ensure that the
two full coats are applied. Both primer coats must be applied by brushing and must be well worked into the
surface. The minimum dry film thickness of each finish coat shall be 25 microns (1mil).

Final coats shall be applied by PURCHASER. Primer shall be applied following satisfactory completion of shop
testing and all functional tests.

4.0 INSPECTION AND TESTING

Third Party Inspection is required for witnessing and certification for non-destructive and other testing and
examination.

The PURCHASER reserves the right to inspect material, manufacturing process, testing etc. Such inspection
does not relieve the VENDOR of the responsibility of suitable design and workmanship.

VENDOR shall submit to PURCHASER a detailed Inspection and Test Plan (ITP) for approval with scheduled
activities and acceptance criteria, before start of manufacturing.

NDT shall be conducted as follows:

UT shall be in accordance with ASME BPV Code Section V, Articles 5 & 23.

X - Ray shall be in accordance with ASME BPV Code Section V, Articles 2 & 22.

MT shall be the wet method and in accordance with ASME BPV Code Section V, Article 7 & 25.

Results shall be reviewed, interpreted, and evaluated in accordance with the following criteria:

X-ray ASME BPV Code Section VIII Division 1 Section UW51.

MT ASME BPV Code Section VIII Division 1 Appendix 6.
UT For welds, ASME BPV Code Section VIII Division 1 Appendix 12.
UT For forging, ASME BPV Code Section VIII Division 2 Section AM 203.2 (c).

4.1 AIR TESTS

If the pig launchers/receivers are provided with welded reinforced attachments, telltale holes shall be provided in
order to test with dry air at 5 barg pressure and checked with foam agent for leaks. This shall be carried out prior
to the final hydrostatic pressure test.

4.2 HYDROSTATIC PRESSURE TEST

Hydrostatic pressure tests shall be carried out by VENDOR at a test pressure based on a fibre stress of 90% of
the specified minimum yield strength (SMYS) in the shell or at the applicable test pressure listed in ASME
B16.5, whichever is the lower.

The temperature of the pig launchers/receivers material and test liquid shall not be less than 50°F during the
hydrostatic test.

Pressure testing is to be conducted using calibrated test gauges. Test pressures shall be held a minimum of 4
hours.

4.3 FUNCTIONAL TESTS

The end closure will be fully operable after pressure cycles have been applied.

No excessive force should be required to be applied to operate the mechanism.

Dimensional inspection to meet the requirements of the approval drawings.

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BES-L007
Pig Launchers/Receivers 01 July, 2006

4.4 QUALITY ASSURANCE/CONTROL

VENDOR shall establish and maintain a quality assurance system in accordance with ISO 9001 or an approved
equivalent. The PURCHASER shall have the right to undertake such audits as he deems necessary to assess the
effectiveness of the VENDOR’s quality system.

5.0 PACKAGING & HANDLING

Packaging and handling shall be in accordance with the requirements of BES-A003, Standard for Packing &
Marking together with the specific requirements listed below:

Each piece of equipment having a nameplate as specified by the purchase order and/or equipment data sheet
shall have the nameplate permanently protected during welding, painting and shipping. The following
information shall be stamped on the nameplate.

Purchase Order Number

Item Name and Equipment Number
Manufacturer
Serial Number
Hydro Test Pressure
Year Built
Maximum Working Pressure
Maximum Temperature
Maximum Test Pressure
Design Code
Material Grades
Nominal sizes

Connections furnished on the equipment shall be identified and shall be tagged to comply with VENDOR’s
connection table or general arrangement drawing.

6.0 VENDOR’S DOCUMENTATION

Vendor data and document requirements are defined in Appendix 2 and BES-A004, Vendor Data &
Documentation Requirements, together with the specific requirements listed below.

Following documents shall be furnished as a minimum requirement.

- Three copies of the certified mill test report showing the chemical and physical properties for each item of
material furnished by the VENDOR shall be provided for PURCHASER’s approval.

- A report of results obtained from MT and X-ray of welds indicating all defects were identified and the
disposition of all repairs shall be provided. All original radiographs shall be available to the
PURCHASER for review upon request.

- Weld identification drawings of the fabrication and the weld number for each weld.

- A certified copy of all hydrostatic test charts shall be provided.

- Two years recommended spare parts list.

- Installation, Operation and Maintenance instructions/manuals covering end closure, and other equipment
supplied in the pig launcher and receiver packages.

- Assembly drawings with corresponding keyed parts lists of all equipment supplied in the pig launcher and
receiver packages.

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BES-L007
Pig Launchers/Receivers 01 July, 2006

7.0 REFERENCE DATA SHEETS

BEF-L006 Pig Launcher/Receiver (Bi-directional) – Data Sheet

BEF-L007 Pig Launcher/Receiver (Bi-directional) – Layout Sketch
BEF-L008 Pig Launcher/Receiver (Instrumented) – Data Sheet
BEF-L009 Pig Launcher/Receiver (Instrumented) – Layout Sketch

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BES-L007
Pig Launchers/Receivers 01 July, 2006

APPENDIX 1 MAIN DIMENSIONS

Sheet 1 of 2 BI-DIRECTIONAL PIG LAUNCHER/RECEIVERS

A
B C

N9 N8 N7 N6 N2 N5 N4 N3 N9 N8 N7

N6 N5 N4 N3
E 300 300 300 150 300 300 300

A
I
I

D2
D1 cL N12 N2
N1 cL

I
A N10
355
N11 G

F = = = = 300 H

N10 N11 Section A-A

NOZZLES
N1 Inlet/outlet/pipeline size.
N2 Kicker/bypass connection.
N3 Vent connection. 2in for line sizes up to 12in and 4in for line sizes 14in and larger.
N4 & N7 Pressure Gauge. 2in connection.
N5 Pressure Safety Valve. 2in connection.
N6 Pig Signaller. 2in connection.
N8 Vent connection. 2in for line sizes up to 12in and 4in for line sizes 14in and larger.
N9 Purge. 2in connection.
N10 & N11 Drain. 2in for line sizes up to 12in and 4in for line sizes 14in and larger.
N12 End Closure

NOZZLE DIMENSIONS
SIZE (in) I (mm)
2 150
3 205
4 230
6 305
8 305

NOMINAL SIZES (in) DIMENSIONS (mm)

MAX PIG
D1 D2 N2 A B C E F G H LENGTH
4 6 2 2980 1380 840 330 450 19 150 710
6 8 2 2980 1380 840 330 450 19 205 710
8 10 3 3185 1405 965 355 450 19 255 815
10 12 4 3285 1455 965 405 475 19 305 865
12 16 4 3285 1455 965 405 475 19 405 865
14 18 6 3310 1480 965 430 475 19 455 865
16 22 6 3310 1480 965 430 500 19 560 865
18 22 6 3385 1505 965 455 500 19 560 915
20 26 8 3565 1535 1015 485 500 25 660 1015
22 26 8 3820 1585 1115 535 500 25 660 1120
24 30 8 4050 1610 1220 560 500 25 760 1220

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BES-L007
Pig Launchers/Receivers 01 July, 2006

APPENDIX 1 MAIN DIMENSIONS

Sheet 2 of 2 INSTRUMENTED PIG LAUNCHER/RECEIVERS
A
B C

N9 N8 N7 N6 N5 N4 N3 N9 N8 N7
N2R N2L
N6 N5 N4 N3
D 300 300 E 150 300 300 200 100 300

A
K
K

D2
D1 cL N12 N2L
N1 cL
N2R

K
A N10
355
N11 I

F G H 760 300 J

N10 N11 Section A-A

Note
1. Pig launchers/receivers in fixed locations shall be fitted with either nozzle N2R or N2L depending on
their function as launcher or receiver.
2. Mobile launchers/receivers shall be fitted with both nozzles N2R and N2L.

NOZZLES
N1 Inlet/outlet/pipeline size
N2L Kicker/bypass connection for launcher.
N2R Kicker/bypass connection for receiver.
N3 Vent connection. 2in for line sizes up to 12in and 4in for line sizes 14in and larger.
N4, N7 Pressure Gauge. 2in connection.
N5 Pressure Safety Valve. 2in connection.
N6 Pig Signaller. 2in connection.
N8 Vent connection. 2in for line sizes up to 12in and 4in for line sizes 14in and larger.
N9 Purge. 2in connection.
N10, N11 Drain. 2in for line sizes up to 12in and 4in for line sizes 14in and larger.
N12 End Closure

NOZZLE DIMENSIONS
SIZE (in) K (mm)
2 150
3 205
4 230
6 305
8 305

NOMINAL SIZES (in) DIMENSIONS (mm)

MAX PIG
D1 D2 N2 A B C D E F G H I J LENGTH
6 8 2 6045 2870 3175 510 1610 510 710 1650 19 205 2870
8 10 3 7720 3710 4010 585 2375 585 635 2490 19 255 3710
10 12 4 8125 3910 4215 610 2550 610 610 2690 19 305 3910
12 16 4 8125 3910 4215 635 2525 635 585 2690 19 405 3910
14 18 6 8125 3910 4215 710 2450 710 660 2540 19 455 3910
16 22 6 8635 4165 4470 785 2630 785 585 2795 19 560 4165
18 22 6 6300 2995 3305 840 1405 840 685 1470 19 560 3000
20 26 8 6805 3250 3555 915 1585 915 610 1725 25 660 3250
22 26 8 6805 3250 3555 990 1510 990 840 1420 25 660 3250
24 30 8 6960 3325 3635 1040 1535 1040 790 1495 25 760 3325

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BES-L007
Pig Launchers/Receivers 01 July, 2006

APPENDIX 2 DATA & DOCUMENTS

(Sheet 1 of 2)

DATA AND DOCUMENTS REQUIRED WITH TENDER

Vendor shall deliver with the Tender the following documents as indicated.

Required Documents Prints With Tender

Prequalification information 3

Reference list of similar jobs (incl. Sub-vendors) 3

Sub vendors names and details 3

Details and drawings of end closures with parts list 3

Quality plan 3

Manufacture, test and delivery schedule 3

List of deviations 3

Completed data sheets 3

Dimensional drawings 3

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BES-L007
Pig Launchers/Receivers 01 July, 2006

APPENDIX 2 DATA & DOCUMENTS

(Sheet 2 of 2)
MECHANICAL DATA AND DOCUMENTS

Vendor shall deliver the following data and documents as indicated.

Number of Number of
Weeks after Weeks after Final
Required documents prints for prints for
Award Approval Documents
Approval Final Issue
Dimensional drawings with weights 2 3 2 3 5

Anchor bolt plan 2 3 2 3 5

Sub-Vendor Drawings with Bill of
2 3 2 3 5
Materials
Equipment Design Calculations 2 3 2 3 5
Equipment Fabrication Drawings
(Shop Detailed Drawings) with 2 3 2 3 5
details of bought out items
Name Plate Details 2 3 2 3 5

Mill Test Reports 2 3 2 3 5

Material Certificates 2 3 2 3 5

Mechanical Test Certificates 2 3 2 3 5

Manufacturer's Data Sheet 2 3 2 3 5

Record Showing Location of Heat
2 3 2 3 5
Numbers
Radiograph Record 2 3 2 3 5

Other Inspection Records / Reports 2 3 2 3 5

Hydrostatic Test Records / Charts 2 3 2 3 5

Air Test Records 2 3 2 3 5

Functional Test Records 2 3 2 3 5

Welding Procedures WPS / PQR
2 3 2 3 5
(including repair procedures)
Q.A. Manual / QC Schedule 2 3 2 3 5

Welders Qualification Records 2 3 2 3 5

NDT Procedure / Techniques 2 3 2 3 5

Inspection & Test Plan 2 3 2 3 5

Performance Test Data / Report 2 3 2 3 5

Manufacturer's Report 2 3 2 3 5
Installation/Operating/Maintenance
2 3 2 3 5
Manual
Spare Parts List (for two year
2 3 2 3 5
operation)
Construction, Start-up &
2 3 2 3 5
Commissioning Spares List
Surface Preparation & Painting
2 3 2 3 5
Procedure

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