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1. INTRODUCTION ............................................................................... 2
1.1. PURPOSE .......................................................................................... 2
1.2. DEFINITIONS ...................................................................................... 2
1.3. ABBREVIATIONS ...............................................Error! Bookmark not defined.
2. EXECUTIVE SUMMARY ....................................................................... 2
3. SCOPE .......................................................................................... 2
4. PIGGING REQUIREMENTS ................................................................... 3
4.1. PRE-COMMISSIONING AND COMMISSIONING ................................................... 3
4.2. OPERATIONS AND MAINTENANCE .............................................................. 4
4.3. INSPECTION ....................................................................................... 6
4.4. PIGGING FACILITIES.............................................................................. 9
5. RECOMMENDATION ........................................................................ 11
APPENDIX 1: PWRI PIGGING ASSESSMENT TABLE ......................................... 14
APPENDIX 2: VENDOR INFORMATION (MFL/EC TOOLS & PIG VALVE) .................. 15
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1. INTRODUCTION

1.1. PURPOSE

It is to note that this document is only a guideline on pigging but shall form the basis for relevant
responsible parties to develop more detailed procedures at a later stage of this project.

1.2. DEFINITIONS

Should Defines a desirable or recommended outcome or action.

Will Defines an intended outcome or action.
May Defines freedom of choice.

2. EXECUTIVE SUMMARY

3. SCOPE
The scope of the pigging philosophy will cover the following materials:

1. Carbon steel with CA / Carbon Steel with CA + CI

2. Carbon steel with internal coating (i.e. FBE and Liquid Coating)

3. Carbon steel with internal lining

4. CS + CRA Clad

5. Full CRA pipe

6. Non-metallic pipe (GRE/TCP pipe)

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4. PIGGING REQUIREMENTS
Pigging is a process where a device called pig is forced through a pipeline for the purpose of
cleaning, separating different products, displacing fluids or for inspection of the pipeline.
Depending on application types and pipeline conditions, different kind of pigs are chosen to
minimize the cost of pigging operations.

The pigging system shall be design for the following phases of pipeline:

1. Pre-commissioning and commissioning

2. Operations and maintenance

3. Inspection

The following sections of this document will provide the requirements for pigging based on above
phases.

4.1. PRE-COMMISSIONING AND COMMISSIONING

Brush pigs may be selected if some time has passed between the line being laid and this pre-
commissioning operation, in order to produce a more aggressive cleaning action.

After cleaning is completed, the pipeline shall be gauged. A bi-directional gauging pig with 2 sets
of separate guiding and sealing discs shall be fitted with 1 or 2 aluminium gauging plates to check
for any reductions in the pipeline internal diameter and any pipeline deformations which might
occur due to pipeline buckles, bends, and dents.

Dummy launcher/receiver and pig trap valves shall be used for pre-commissioning activities. All
pigs shall be inspected prior to insertion into the launcher to ensure their fit for use.

Pigging during commissioning will require a pig train consist of multi-lipped conical cups, whereby
the multi-lipped cups have independent sealing lips on each cup which significantly improves their
ability to maintain a seal between the pre-commissioning water and the product. For the bare
carbon pipe using CI, a pig train should be run during commissioning with slugs of corrosion
inhibitor in between the individual pigs to inhibit corrosion of the pipeline.

The recommended pig types for pre-commissioning and commissioning pigging are:

1. Foam Pig

2. Bi-Di Brush Cleaning Pig

3. Bi-Di Pig with Magnet

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4.2. OPERATIONS AND MAINTENANCE

The operations and maintenance pigging should be performed without interrupting the flow of the
product in the pipeline. The following purposes will be served with regular pigging:

1. Cleaning and improving flow efficiency

Being part of pipeline integrity management, the operational pigging requirement is to maintain
the pipeline cleanliness and allow the line to operate at its optimum capacity and minimizing
risk of pipeline blockage.

2. Chemical treatment of pipeline

Chemicals used in treating the pipeline such as corrosion inhibitors and biocides should be
coupled with regular operational pigging to enhance their performance and efficiency. By
removing water hold-up and debris, pigging activities will allow chemical inhibitors to effectively
reach the pipeline wall to coat the whole internal surface of the pipe at regular intervals.

Pig batching or pig train method to be adopted to ensure that the chemical coats the internal
pipe wall by retaining a slug of inhibitors between two batching pigs within a period of retention
of time.

The recommended pig types for operations and maintenance pigging are:

1. Foam Pig

2. Bi-Di Brush Cleaning Pig

Normally pigging frequency for each individual pipeline regardless of its services will be determine
based on risk assessment to ensure pipeline integrity is protected through operational i.e. cleaning
with the optimum cost. In general, typical frequency for operational pigging is tabulated in
APPENDIX 1. This can be determined in the next stage once the specific pipeline material has
been identified/selected and risk assessment is finalized.

The operations and maintenance pigging should be performed without interrupting the flow of the
product in the pipeline. The following purposes will be served with regular pigging:

3. Cleaning and improving flow efficiency

Being part of pipeline integrity management, the operational pigging requirement is to maintain
the pipeline cleanliness and allow the line to operate at its optimum capacity and minimizing
risk of pipeline blockage.

4. Chemical treatment of pipeline

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Chemicals used in treating the pipeline such as corrosion inhibitors and biocides should be
coupled with regular operational pigging to enhance their performance and efficiency. By
removing water hold-up and debris, pigging activities will allow chemical inhibitors to effectively
reach the pipeline wall to coat the whole internal surface of the pipe at regular intervals.

Pig batching or pig train method to be adopted to ensure that the chemical coats the internal
pipe wall by retaining a slug of inhibitors between two batching pigs within a period of retention
of time.

The recommended pig types for operations and maintenance pigging are:

3. Foam Pig

4. Bi-Di Brush Cleaning Pig

Normally pigging frequency for each individual pipeline regardless of its services will be determine
based on risk assessment to ensure pipeline integrity is protected through operational i.e. cleaning
with the optimum cost. In general, typical frequency for operational pigging is tabulated in
APPENDIX 1. This can be determined in the next stage once the specific pipeline material has
been identified/selected and risk assessment is finalized.

The operations and maintenance pigging should be performed without interrupting the flow of the
product in the pipeline. The following purposes will be served with regular pigging:

5. Cleaning and improving flow efficiency

Being part of pipeline integrity management, the operational pigging requirement is to maintain
the pipeline cleanliness and allow the line to operate at its optimum capacity and minimizing
risk of pipeline blockage.

6. Chemical treatment of pipeline

Chemicals used in treating the pipeline such as corrosion inhibitors and biocides should be
coupled with regular operational pigging to enhance their performance and efficiency. By
removing water hold-up and debris, pigging activities will allow chemical inhibitors to effectively
reach the pipeline wall to coat the whole internal surface of the pipe at regular intervals.

Pig batching or pig train method to be adopted to ensure that the chemical coats the internal
pipe wall by retaining a slug of inhibitors between two batching pigs within a period of retention
of time.

The recommended pig types for operations and maintenance pigging are:

5. Foam Pig
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6. Bi-Di Brush Cleaning Pig

Normally pigging frequency for each individual pipeline regardless of its services will be determine
based on risk assessment to ensure pipeline integrity is protected through operational i.e. cleaning
with the optimum cost. In general, typical frequency for operational pigging is tabulated in
APPENDIX 1. This can be determined in the next stage once the specific pipeline material has
been identified/selected and risk assessment is finalized.

4.3. INSPECTION

During operations, pipeline inspection from the interior of the pipeline is required for integrity
monitoring. A variety of in-line inspection tool may be employed for pipeline inspection purposes,
including detection of dents and buckles, corrosion pitting, cracks, spanning and burial, and
measurement of pipe wall thickness.

In-line inspection is intrusive, involving the insertion of the tool into the pipeline. Depending on the
operational criticality of the line, in-line inspection may cause some interruption to normal pipeline
operation. However, the advantage of ILI is that metal loss information is obtained for the entire
length of the pipeline.

Techniques available for the in ILI of metal loss based on pigging technology include:

1. Magnetic Flux Leakage (MFL)

Magnetic flux leakage (MFL) pigs are the most common technology for pipeline metal loss
inspection. The technology is based on magnetising the pipe wall and sensing the leakage of
magnetic flux as a result of the presence of metal loss defects and/or other flaws. From the
MFL signal patterns it is also possible to identify other defect features such as girth welds,
seam welds, valves, fittings, adjacent metal objects, gouges, dents, mill defects, girth weld
cracks and large non-metallic inclusions.

Current technology has been made available to combined tools i.e. MFL with IEC (Eddy
Current Inspection) as attached in APPENDIX 2.

2. Ultrasonic Testing (UT)

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Ultrasonic pigs utilise ultrasonic transducers that have a standoff distance to the pipe wall. The
transducers emit sound pulses, which are reflected at both the inner and outer surface of the
pipe wall. The time elapse detected from these two echoes gives a direct measurement of the
remaining wall thickness of the pipe. A typical UT pig has accuracy to within ±1mm of wall
thickness and 3-8 mm of defect size.

During operations, pipeline inspection from the interior of the pipeline is required for integrity
monitoring. A variety of in-line inspection tool may be employed for pipeline inspection purposes,
including detection of dents and buckles, corrosion pitting, cracks, spanning and burial, and
measurement of pipe wall thickness.

In-line inspection is intrusive, involving the insertion of the tool into the pipeline. Depending on the
operational criticality of the line, in-line inspection may cause some interruption to normal pipeline
operation. However, the advantage of ILI is that metal loss information is obtained for the entire
length of the pipeline.

Techniques available for the in ILI of metal loss based on pigging technology include:

3. Magnetic Flux Leakage (MFL)

Magnetic flux leakage (MFL) pigs are the most common technology for pipeline metal loss
inspection. The technology is based on magnetising the pipe wall and sensing the leakage of
magnetic flux as a result of the presence of metal loss defects and/or other flaws. From the
MFL signal patterns it is also possible to identify other defect features such as girth welds,
seam welds, valves, fittings, adjacent metal objects, gouges, dents, mill defects, girth weld
cracks and large non-metallic inclusions.

Current technology has been made available to combined tools i.e. MFL with IEC (Eddy
Current Inspection) as attached in APPENDIX 2.

4. Remote Field Testing (RFT) for HDPE Lining

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RFT inspection tools provide an improved probability of detection (P.O.D.) and exceptional
accuracy for sizing of corrosion pits and internal and external damage for pipelines lined with
cement, epoxy or polyethylene. This RFT method is to replace conventional tools that use Magnetic
Flux Leakage (MFL) that require intimate contact with the pipe wall in order to achieve acceptable
flaw sizing. During operations, pipeline inspection from the interior of the pipeline is required for
integrity monitoring. A variety of in-line inspection tool may be employed for pipeline inspection
purposes, including detection of dents and buckles, corrosion pitting, cracks, spanning and burial,
and measurement of pipe wall thickness.

In-line inspection is intrusive, involving the insertion of the tool into the pipeline. Depending on the
operational criticality of the line, in-line inspection may cause some interruption to normal pipeline
operation. However, the advantage of ILI is that metal loss information is obtained for the entire
length of the pipeline.

Techniques available for the in ILI of metal loss based on pigging technology include:

5. Magnetic Flux Leakage (MFL)

Magnetic flux leakage (MFL) pigs are the most common technology for pipeline metal loss
inspection. The technology is based on magnetising the pipe wall and sensing the leakage of
magnetic flux as a result of the presence of metal loss defects and/or other flaws. From the
MFL signal patterns it is also possible to identify other defect features such as girth welds,
seam welds, valves, fittings, adjacent metal objects, gouges, dents, mill defects, girth weld
cracks and large non-metallic inclusions.

Current technology has been made available to combined tools i.e. MFL with IEC (Eddy
Current Inspection) as attached in APPENDIX 2.

RFT technology works by detecting changes in an AC electromagnetic field generated by the

tool. As the field passes through the pipe wall it is attenuated and delayed (it becomes stronger
in areas of metal loss and the time delay is less). The field interactions are measured by on
board detectors, and subsequently processed on the tool itself using A/D converters and DSPs.
Once all the data is acquired, sophisticated analysis software is applied to generate accurate
information on the wall thickness of the line. Figure 1 (below) schematically shows the magnetic
coupling path between the exciter section of the tool and the detector array
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Figure 1: Magnetic Coupling Path between Excitor and Detector

6. Eddy Current for CRA

Eddy current testing is almost like RFT method. The main differences between RFT and
conventional eddy-current testing (ECT) is in the coil-to-coil spacing. The RFT probe has widely
spaced coils to pick up the through-transmission field. The typical ECT probe has coils or coil
sets that create a field and measure the response within a small area, close to the object being
tested.

4.4. PIGGING FACILITIES

For the water pipeline, temporary pigging facilities is recommended instead having a permanent
pigging facility as the frequency for the pipeline pigging is lesser compared to oil or gas pipeline.
The pigging facilities will depend on the pressure rating for each pipeline, as this will affect on the
major barrel and minor barrel thickness, valve and flange size.

For the normal operational pigging i.e. cleaning, temporary pigging facility can be accommodated
by providing enough space inside the plant boundary where pigging operator will assemble
portable pigging launcher/receiver to perform the activities as and when required.

As for the inspection and monitoring pigging activities, it will be based on the Risk Assessment i.e.
Risk Based Inspection (RBI), that will dictate what type of pigging facilities required. Typically,
when inspection and monitoring activities are required, larger space may be needed to
accommodate combined ILI inspection tools i.e.;

- Metal-loss / corrosion detection;

- Photographic inspection;
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- Crack detection;

- Wax or scale deposition measurement;

- Leak detection;

- Product sampling, and;

- Mapping

Compare to operational pigging requirement, only smaller space is required for the temporary
pigging facilities. Pig Valve can be considered to save space with optimum cost should only
operation pigging for cleaning is required. Pig Valve information is attached in APPENDIX 2.
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5. RECOMMENDATION
Summary of the recommended pigging requirement for varies of pipeline material option are tabulated as below. Details including typical
pigging requirement for industry is attached in APPENDIX 1

Carbon Steel Carbon Steel Carbon Steel

Non-Metallic
Criteria with CA / Carbon with Internal with Internal PE CS + CRA Clad Full CRA
Pipe (GRE/TCP)
Steel with CA + CI Coating (1) Lining
Cleaning & Cleaning &
Cleaning & Cleaning & Cleaning &
Pre-Commissioning Function Gauging (if Gauging (if Cleaning
Gauging Gauging Gauging
required) required)

Function Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning

Foam Pig, Low Foam Pig, Low

Friction - brush Friction - brush
Foam Pig, Low Foam Pig, Low pig using Nylon, pig using Nylon,
Foam Pig, Bi-Di
Maintenance Pig Type Friction - pig Friction - pig urethane blade urethane blade Spheres
Brush Pig
brush using Nylon brush using Nylon or other or other
equivalent non- equivalent non-
ferrous material ferrous material
Periodic 3 to 6 months Once a Year Once a Year Once a Year Once a Year Once a Year
Maintenance (Cleaning) (Cleaning) (Cleaning) (Cleaning) (Cleaning) (Cleaning)
MFL / UT - May
require depends
Remote Field
the failure rate of
Internal Inspection Type MFL / UT Testing (RFT) if MFL / IEC UT Not Required
internal coating
required
for/within 25year
Design Life

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Carbon Steel Carbon Steel Carbon Steel

Non-Metallic
Criteria with CA / Carbon with Internal with Internal PE CS + CRA Clad Full CRA
Pipe (GRE/TCP)
Steel with CA + CI Coating (1) Lining
1. Baseline survey
1. Baseline survey 1. Baseline survey
after
To be based on after after
commissioning To be based on
risk assessment commissioning commissioning
2. Periodic risk assessment
Periodic Survey i.e. Failure Rate 2. Periodic 2. Periodic Not Required
survey: every 5 i.e. Failure of the
of the Internal survey: To be survey: To be
years or to be Internal Liner
Coating based on risk based on risk
based on risk
assessment assessment
assessment
Temporary / Temporary / Temporary / Temporary / Temporary /
Pigging Facilities Pig Valve
Offline Offline Offline Offline Offline
Note:

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Figure 2: Typical Pigging Facilities Arrangement

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APPENDIX 1: PWRI PIGGING ASSESSMENT TABLE

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APPENDIX 2: VENDOR INFORMATION (MFL/EC TOOLS & PIG VALVE)

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