February, 2009 Pigging Industry News the newsletter of the ... the newsletter of the Pigging Products & Services Association August, 2000 Pigging Industry News ... a geophone is recommended

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Pigging Products & Services Association is at:PO Box 2, Stroud, Glos GL6 8YB, UK

tel: (+44) (0) 1285 760597 fax: (+44) (0) 1285 760470e-mail: [email protected]

web: http://www.ppsa-online.com

February, 2009

THE PPSA held its 10th annualpigging seminar in Aberdeen

on 28th November, 2008, whichonce again proved a great success(see photos, right). Some veryinteresting papers were presentedby PPSA members and thenumber of exhibitors was up onprevious years as were thedelegates – 127 people from 16different countries. The nextseminar takes place on 18thNovember, 2009, at the MarcliffeHotel in Aberdeen, UK.

PPSA members will be backtogether again at the Houstonpigging conference on 11th - 12thFebruary. The annual golftournament is planned forMonday 9th February with theAGM on the 10th at the MarriottWestchase Hotel Houston at 3.30.The meeting is open to all –members and non-members alike– and provides the opportunity foropen discussion as to how PPSAshould proceed in the coming year.An election for two USA directorswill be held at the meeting. Onlyfull members are entitled to voteand can do so, either at themeeting, or in advance by e-mail,fax, or post. The directors electedwill take over from Brent Cross ofN-Spec, retired President, andKevin Scott who left BakerHughes last year, thus creating asecond vacancy on the Board. Ourthanks go to Brent for his greatcontribution to PPSA over the pastfew years.

Anyone wishing to play at the golftournament should visit the PPSA

web site www.ppsa-online.comand follow the links through fromthe home page, top left handcorner.

John LambleyPresident

Full

Pipeway International Inc, USA

Optimess Engineering GmbH,Germany

PNS – Pipeline NitrogenServices bv, Netherlands

Individual

Stephen Mayo, Pipelines 2 Data(PLD) Ltd, UK

New Members

President’s letter

Pigging Industry News2

IndustrynewsBJ Servicesopens in Houston

BJ Services Co has expandedits US-based pipeline

inspection services by opening anew facility in Houston, Texas.The 20,000-sqft facility, which isdedicated to providing pipelineinspection services, represents anexpansion of the operations anddata analysis services in theUnited States, and will furthercomplement the services suppliedby the pipeline inspection servicesoperation centre in Calgary for thepast 20 years. The new locationwill enhance support for continuedgrowth in the US market,providing strategic operations anddata analysis for all of thecompany’s pipeline inspectionoperations throughout the region.

“The new base in Houstondemonstrates the company’sgrowth and commitment toproviding unparalleled service toall of our highly valued pipelineinspection services customers inNorth America, while acting as acentral hub from which continuedbusiness development efforts willbe carried out in the UnitedStates,” Dave Latto, BJ Services’technical sales manager, said.“The expansion of our operation inthe US allows us to bolstersupport for the North Americanmarket from two full operationsbases.”

The facility features offices foradministrative support, sales andmarketing, data analysis, andoperations personnel, as well as alarge maintenance workshop andwarehouse that house acomprehensive suite of specialist

pipeline inspection equipment. Afull complement of state-of-the-artpipeline inspection equipment willbe based permanently on-site,including the new fleet of combotools featuring the high-resolutioncapabilities of BJ Services’industry-leading magnetic fluxleakage and GEOPIG tools.●

Tips for better tracking

JACK Rankin, manager ofengineered solutions and new

products with T.D. Williamson’sPigging Products Division,provides guidelines for success intracking and locating pipelinepigs.

Tracking and/or locating a pigstuck in a pipeline can present achallenge. A little preparation andproper tracking techniques,however, help ensure success.There are many applications inwhich it is important to track theprogress of a pig as it travelsthrough a pipeline, including:

Commissioning

• running a smart pig• conducting a nitrogen purge

with pigs• running a pig with a

transmitter to locate a stuckpig

There are also several situationsthat can result in a pig gettingstuck in the line, such as:

• excessive by-pass when the pigis in a bend

• excessive debris build-up infront of the pig

• an obstruction such as a bucklein the pipe or a partially-closedvalve

Manpower

First, plan to have an adequatenumber of two-man crews with

each crew consisting of a pipelineoperator who knows, and hasaccess to, the pipeline right-of-way(ROW), as well as a contractorwho is experienced in trackingequipment and procedures. Thenumber of crews needed dependsupon a variety of factors,including:

• is the ROW accessible byvehicles?

• how long is the run fromlauncher to receiver?

• what is the velocity of the pigunder expected conditions?

• is the pig propelled with gas orliquids?

• is there a contingency plan ifthe pig gets stuck and can, orcan’t be located?

Job preparation and training

The pipeline operator shouldprovide suitable maps andalignment sheets, and bethoroughly familiar with thepipeline ROW and access tovarious tracking locations. Thecontractor should possess anoperating manual and bethoroughly familiar with theoperation and maintenance of thetracking equipment. Crews shouldpractice with the equipment so thesignal can be observed, recorded,and interrogated before everlaunching the pig. For practicepurposes, the transmitter shouldbe positioned a few meters awayfrom the electronic receivers andmoved parallel to the receivers atvarious velocities to demonstratewhat the signal will sound andlook like. For training, thetransmitter should be placed outof sight. The trainee, following theinstructions in the operator’smanual, should walk along a linethat is parallel, but about 3mfrom, the transmitter at its closestpoint. This exercise should beconducted in a field withovergrown vegetation whereconditions are less favourable.

Pigging Industry News 3

Inline Services Inc. Tel: +1 (281) 401-8142

Fax: +1 (281) 401-8147

Email: [email protected]

Manufacturers of

“built-for-purpose”

pigging equipment

www.inlineplc.com

Equipment

Electronic tracking systems usean electromagnetic-pulsetransmitter (mounted on the pig)and an electronic receiver system.The transmitter should be selectedbased on the specific application,considering size and wallthickness of the pipeline, and theamount of time that it may take tolocate the pig should it get stuck.Lithium batteries will provideextended life (though there maybe some restrictions on the use oflithium batteries in some areas).The tracking equipment shouldprovide audible, visual, andrecorded indication of the pigpassage. In addition to theelectronic receiver, a geophone isrecommended as it amplifies thesound being made by the cups,discs, and brushes as the pigtravels through the line, allowingthe crew to hear the pig comingwell in advance of its scheduledarrival time at the trackinglocation.

Once the crew or crews are inplace, confirm that all mainlinevalves are fully opened and thatflow is going through the receiverbarrel. Each crew should havespare batteries as needed, and a

laptop computerwith variableproject inputs anda spreadsheet forrecording data andnotes. Whenpositioning thetracking systemreceiving antennaand geophoneprobe, each crewshould have a pipelocator to confirmit is over thepipeline. A sparereceiving systemshould be carried

by one of the tracking crews. If thepipeline goes through a casing, thereceiver antenna should bepositioned a bit upstream ordownstream of the casing pipe sothat the signal doesn’t have totravel through two pipes. Wherepossible, pigs should be tracked atapprox. 2-km (1.5-mile) intervals.Avoid areas with a lot of traffic,railroad crossings, and high-voltage power lines as these mayinduce ‘noise’ in the trackingsystem receivers.

Communication

Communication is critical.Everyone involved in the trackingprocess must have accurateinformation at all times to knowwhen the pig is expected to arriveat a particular location.

Should a pig pass a given trackingstation (station 73, for example)but not arrive in a timely mannerat the next station (station 74), thecrew at station 74 should wait forthe late-arriving pig. Perhaps thepig was damaged and is stillmoving but is by-passing flow, orone of the units (compressor orpump) may have shut down,causing it to be late. The crewshould proceed as though nothinghas changed, assuming that thesignal was simply missed for somereason.

If, after diligent tracking effortsall the way to the receiver, thecrew has not heard/recorded pigpassage at any location, includingthe receiver barrel and associatedvalves and fittings, it would beassumed that the pig is stucksomewhere between station 73and 74. At this point, one personequipped with an antenna andreceiver would start at eachstation walking toward each otheruntil the stuck pig is found. If theROW can be cleared in this area itwill make the job easier andsuccess more likely. If there areany fittings, valves, etc., betweenthe two stations, they should besearched first. The receiver andassociated valves and fittingsshould be checked on a regularbasis (every few hours isrecommended) until the pig islocated.●

IMS to help operatorsmanage pipelines

GE Oil & Gas’ PII PipelineSolutions has introduced an

integrity-management system(IMS), said to be a first-of-its-kindpipeline integrity managementsoftware system, to help pipelineoperators more effectively managethe integrity of their pipelines.The company has launched itsIMS as part of PipeView Integrity,its rapidly-expanding portfolio ofintegrated pipeline integritymanagement and engineeringsolutions and services to help theoil and gas industry comply withincreasingly stringent integrityreporting and maintenanceregulations.

By using the new system, GE saysthat operators can manage allaspects of their pipeline-integrityprocess, from setting integritygoals and assessing pipelineconditions and risks to planningand tracking mitigation,assessment and maintenanceactivities. Encompassing both

Pig tracking in progress.

Pigging Industry News4

PIPELINE PIGGING, TESTING, ISOLATION & ANCILLARY EQUIPMENTPIPELINE PIGGING, TESTING, ISOLATION & ANCILLARY EQUIPMENTINPIPE PRODUCTS, registered as ‘International Pipeline Products Ltd.’,has become one of the leading European suppliers of pigging and pipelinetesting equipment. This has been achieved by a combination of quality,realistic prices, quick deliveries and innovative engineering that offers aflexible approach to a client’s requirement. We serve the internationalcompanies working in the Onshore and Offshore Hydrocarbons, Oil & Gaspipeline industries.For further information, please contact us via email: [email protected] by telephoning: +44 (0)1748 834577 www.inpipeproducts.com

E N G L A N D , U K

data analysis and practicalintegrity management, IMSincludes modules that can assess apipeline’s condition, determinerisks, and evaluate, create andmanage integrity plans. Thisincludes determining appropriatemitigation activities and assigningmitigation and maintenanceactivities to the appropriatepersonnel, complete withnotification and approvalmechanisms.

The system offers the requiredfunctionality to support theoperator during internal andregulatory audits, including theability to link proceduralinstructions and document thecompletion of activities. “The IMSis the pipeline industry’s firstsoftware solution that trulyintegrates integrity managementand integrity engineering into asingle, seamless environment,”said John Bucci, general manager.“It offers all the enhanced supporttools needed to drive assetavailability and empower theoperator’s staff to dramaticallyimprove the way they managetheir pipeline assets.”●

“Next-generation”inspection tools

GE Oil & Gas’ PII PipelineSolutions has launched its

new, enhanced EmatScan CD,which it describes as a ‘next-generation’ inspection tool. Thetool’s technology is designedspecifically to provide pipelineoperators the necessary levels oftool performance and confidencein stress-corrosion crack (SCC)and individual crack detectionanalysis and mitigationmanagement in gas pipelines.

The new tool applies electro-magnetic acoustic transducer(EMAT) technology to the

demands of in-line inspection runsin gas pipelines by detecting andmeasuring what the company saysis a greater range of defectscompared to existing technologies.The system can detect cracksdown to 1.97in (50-mm) lengthand as shallow as 0.079in (2mm)while utilizing PII’s softwarecapabilities and reportingtechniques.

The company says that thanks toits new sensor technology,developed by project partner GEInspection Technologies, thisthird-generation EMAT tool alsooffers operators greaterdiscrimination of serious and non-serious flaws in a given pipeline.Unlike conventional ultrasonicinspection methods, the new tooldoes not require a liquid mediumfor its signals to reach a pipe’swall. As a result, operators nolonger need to invest in costly pre-inspection preparation or subjecttheir lines to contamination byliquids, in order to obtain therequired inspection medium tosupport conventional ultrasonicdata collection. The tool has beendesigned to offer operators othercritical technical and economicbenefits, including the ability todetect even sub-critical SCCcolonies, and enhanced dataaccuracy.

The company is also introducingits new MagneScan ‘next-generation’ magnetic-flux leakage(MFL) pipeline inspectiontechnology. The new toolincorporates an improvedmagnetizer design and advancedsensor technology; using the 6-intool as an example, the new sensordesign includes 216 low-noiseHall-effect sensors, and readingsare taken on the axial, radial, andtransverse vectors every 2 mm.This new three-dimensionalsensor configuration has beendesigned to provide 100% coverage

of a line and to optimize theaccuracy of defect sizing for width,length and depth.

With its comprehensive sensorarray, the new MagneScancombines several types ofinspections in a single run. Thetool is equipped with a fullyintegrated high-resolution caliper,EMAT sensors to measure wallthickness for more accurate defectsizing, and also offers GISmapping technologies as astandard option for improved dataalignment. The corrosion detectionis now 5% of wall thickness at 90%POD, while the depth-sizingaccuracy is 10% at 90% certainty.Offering multiple inspections in asingle run greatly reduces anyinterruptions in pipeline servicefor the operator and overallinspection project costs.●

Integrity softwarecustomization contract

HOUSTON-based Rosen USAhas been awarded a contract

in customizing its asset integritymanagement software (RoAIMS)for Equistar Chemicals. Theproject includes customization ofthe software package to integratethe with Equistar’s existingdatabase structures, and to offer acollection of interoperablesoftware tools to assist theoperator in maintaining itspipelines in a safe, reliable, andcost-effective manner.

The primary objective of RoAIMSis to assist pipeline operators inapplying their integrity-management strategy to thespecific conditions of their assets.Rosen has projects in place fordelivering and maintaining thecustomized software package forcustomers in South America,North America, and EasternEurope.●

Pigging Industry News 5

Double-block pipelineisolation in Austria

TDW Offshore Services hassuccessfully completed an

onshore pipeline isolationoperation for OMV Gas GmbH inAustria, in conjunction with thecompany’s Trans-Austria gaspipeline (TAG) expansionprogramme. One of the keydevelopments of the expansionprogramme is the newly-constructed compressor station inEggendorf, Austria, to which OMVGas needed to safely re-route theexisting pipelines. To achieve this,TDW carried out pipeline isolationservices on the 38-in importpipeline that runs approx. 70kmfrom Baumgarten to Eggendorf,and on the export pipeline thatruns approx. 70km fromEggendorf to Grafendorf.

TDW isolated these pipelines byusing its remote-controlled 38-inSmartPlug trains to create double-block isolations against the gaspressure. Both plugging trainswere launched and pigged withproduction gas into excavatedsections of the pipelines, travellingapproximately 100m from thelaunchers to the work positions.Using its wireless through-wallcommunication system, TDWmanoeuvred each plug train intoplace, and set them in theexcavated area of the pipeline.While the plug trains were inplace and isolated pipeline

sections, OMV Gas carried out thenecessary modifications and re-routed the two pipelines to thenew compressor station. Once thiswas completed, TDW released theSmartPlug trains and piggedthem back to the launcher andreceiver using gas pressure fromthe pipelines. The pipelinepressures for both pipelines were50bar during the isolationoperations. While each SmartPlugtrain isolated the pipeline sectionsfor three days, the entire isolationoperation took 10 days fromTDW’s arrival on site in Austriathrough to demobilization.

In order to help the two pipelinesections cope more effectively withthe additional internal pressureexerted by the plug trains, TDWdeveloped eight custom-madetension belts specifically for theoperation. Although traditionalbelts can be cumbersome andtime-consuming to attach to thepipelines during onshore isolationoperations, TDW designed thetension belts in such a way thatthey were quickly and easilymounted. As a result, thecontractor was able to reduce thetime and effort required to attachthe belts and progress morerapidly to isolating the pipelinesections in order that the

Fig.1. One of the 38-in SmartPlugtrains on its way into the launcher.

Fig.2. The SmartPlug train is situatedjust below the custom-made tensionbelts. The pipeline contains gas with apressure of 50bar held back by theplug train while work continues safelyto connect to the new pipeline.

Fig.3. Mounting the tensionbelts onto the pipeline.

modifications couldbe made, and thepipelines safely re-routed. Throughoutthe operation, theplug trains werecontinuouslymonitored usingTDW’s SmartTracksystem that interacts

with the transceiver systems thatare featured as standard in allSmartPlug trains.

“As a result of our ability toeffectively isolate the pressure inthe two pipelines so efficiently,OMV Gas was able to initiatemodifications to the system soonerthan anticipated which was highlybeneficial, reducing the overallpipeline re-routing programmeschedule,” said Rune Haddeland,general manager for TDWOffshore Services. “Coupled withthe fact that the pipelines wereisolated with minimal venting ofproduct in accordance with OMVGas’ environmental policy, weconsider it a real testament to thededication and innovative spirit ofthe TDW team,” he added.●

Pigging Industry News6

Movement of blackpowder in pipelines- Part 2by Dr John Smart

BLACK POWDER, or sediment in pipelines, can move from fluid dragin pipelines, or can be swept clean by pigging. Knowing the velocity

required to move loose powder can help plan the cleaning of a pipeline,helping to prevent sticking of pigs by solids accumulation in front of apig. This paper presents some design information on movement of blackpowder in oil, water and gas in pipelines, and gives a velocity criterionto indicate when progressive pigging, jetting devices or gel pigs arerequired to allow safe passage of pigs through a pipeline in oil, water orgas pipelines.

In the first part of this paper, published in the November, 2008, issue, DrSmart discussed pipeline cleaning and some aspects of modelling thetransport of particulate solids by pipeline.

Case 3: iron compoundsin 20oAPI oil

The calculated velocity to moveiron compounds in 20oAPI oil byvelocity alone is even higher thanfor 40o oil, as shown in Fig.4. Oilvelocities from 10ft/sec to over15ft/sec are required, plus the 10-15% safety margin for uphill flow.

However, for very small particles,in the range of 1-5 mils, the oilvelocity only has to be 2-6ft/serespectively, as the velocityrequired to move the particles

compound is relatively-inexpensive and available, andmuch of it can be recovered orsold. The velocity for entrainmentof the same iron compounds isshown in Fig.5.

Lines using No 2 diesel shouldalso be treated with caution, aslarger particles will collect in frontof the pig and will need to bepushed by it. This means thatdiesel is not a particularly goodfluid to use when cleaning verydirty pipelines. Also, with thesafety margin added in for uphillflow, these numbers may be a bitoptimistic. Therefore, by-pass pigswith jetting nozzles, progressivepigging, or gel pigging are moreconservative for lines with ironoxides, sulphides, etc. in them.

Case 5: black powder innatural gas pipelines

Figure 6 shows the effect ofpipeline operating pressure on thevelocity required to move 1-mildiameter and finer black powderparticles in an 8-in pipeline as afunction of pipe diameter andpressure. The term black powderis used as a catch-all phrase toinclude iron oxides, sulphide andcarbonate particulates inpipelines, and can also includesand, clay, mineral scale, weldspatter and flex, and ironshavings.

Gas velocity is 9ft/sec in 8-in lines,up to 13.6ft/sec in 48-in lines at1000psi, plus 10-15%. Natural gaspipelines can very in their flowvelocity depending on the season,and may cycle above and belowthis number. If the pipeline wereoperated in a corrosive condition,even just enough to causemillscale to flake off the insidewall, large amounts of blackpowder could result that couldpossibly be delivered to customersor, at the least, require substantialfiltering before delivery.

increases more slowly withparticle size. Thus, if a pipelinecontains fine powder, it should beable to be safely cleaned bypigging even at these lowervelocities. Use of heavier, more-viscous, oils will result in muchlonger particle settling times tothe pipe bottom, if stirred up byturbulence in front of the pig.

Case 4: iron compoundsin No 2 diesel

Diesel is sometimes used forcleaning pipelines as the

Fig.4. Velocity tomove iron

compounds in20oAPI oil.

Pigging Industry News 7

EMPOWERED BY TECHNOLOGY

www.roseninspection.netINNOVATION.

These results explain why gaspipeline compressor stations needto have filters installed in front ofcompressors to catch black powdercoming down the pipeline.Pipeline operators report that asblack powder is transported downa pipeline, it fractures andbecomes very fine, with a size inthe range of 1 micron; extremelyfine powder like this can passthrough normal pipeline filters.They also report that extremelyfine powder such as 1 micron canbe tolerated by reciprocatingcompressors, but can damageturbine compressors, even withfilters in place.

These velocities also illustrate thecleaning requirements when crudeoil pipelines are converted tonatural gas service. One techniqueto keep the amount of blackpowder flowing down a pipeline isto treat the line with corrosioninhibitor which puts a tacky filmon the wall of the pipe to whichthe black powder sticks, making itimmobile.

Figure 7 shows the effect ofpipeline operating pressure on theflow rate required to move 1-mildiameter and finer black powderparticles in natural gas pipelines.

Discussion

Conversations with pipelineoperators reveal that whenpipelines are cleaned for suchpurposes as ILI inspections, usingchemical cleaning initially resultsin a clean line. However, aftersome time, black powder isusually found coming down theline again when the lines are dry.Further, many gas pipelines arenot dry, however, but containcompressor lubricating oil andpossibly other liquids such asglycol which can adhere solids tothe wall of the pipe and keep themfrom moving. One commontechnique to keep black powder

Fig.6. Black powderin natural gaspipelines.

Fig.7. Velocity tomove black powderparticles in an 8-inpipeline as afunction of lineoperating pressure.

Fig.5. Ironcompounds in No 2diesel: theproperties of thediesel used forcalculations were32oAPI diesel at60oF, with aviscosity of 200cp.

from moving is to treat the linewith a corrosion inhibitor:inhibitors are tacky compoundsand can “glue” powder in place.

Operators also report that whenblack powder solids move down apipeline, they tend to fracture andbecome very fine, in the range of 1

Pigging Industry News8

micron, and these particles aremore easily moved down a line.One advantage for fine powder inpig cleaning is that it settles muchmore slowly than coarse powder,and can be kept fluidized moreeasily by turbulence.

Another problem reported byoperators is that moving powdercauses problems with ultrasonicflowmeters.

Conclusions andrecommendations

1. Solids can move through apipeline either by velocity aloneor during pigging operations.

2. Pigging can dislodge sedimentfrom the bottom of a pipeline

and the upper walls of the pipe,which can accumulate as largeplugs in front of the pig.

3. If the velocity required to movethe solids in front of a pig ishigher than the pig velocity,solids can accumulate in frontof the pig and it can becomestuck.

4. Knowledge of the velocityrequired to move solids in apipeline is an important designparameter in a piggingprogramme.

5. If the velocity of a pipeline isless than the velocity to moveparticulates, the steady-statebed height of black powder canbe estimated which can be an

indicator of the amount ofsolids in a pipeline.

6. When the velocity to movesolids is greater than the pigspeed, the pigging programmeshould be designed toaccommodate the presence ofthese solids by progressivepigging, by-pass pigs, andjetting nozzles in front of thepig, or the use of gel pigs.

References

1. Iraj Zandi, Ed., 1971. Transportof solids at low concentration inhorizontal pipelines. In:Advances in solid-liquid flow inpipelines and its applications.Pergammon Press, New York,pp101-124.●

Pigging SolutionsTDW provides the world’s pipeline industry with a comprehensive

selection of innovative pigging products and technologies ranging

from durable, cost-effective cleaning tools to leading edge corrosion

management applications. For more information, call:

® Registered trademarks of T.D. Williamson, Inc. in the United States and in foreign countries. ©2009 T.D. Williamson, Inc