Introduction to Propipe Limited

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Helena Lambert
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Introduction to Propipe Limited Propipe manufactures and supplies a wide range of pipeline pigs and pipeline plugs to leading offshore and onshore companies

Our pig-supply scope covers all types of pipeline pigs; foam pigs, disc pigs, cup pigs and on to more complex articulated and multi-diameter designs, capable

Every pig from Propipe is designed to meet specific requirements of the pipeline.

experience in the use of dual and multi-diameter pigs.

Long Run The yard-stick used to measure the performance of a pig manufacturer.

1 Introduction to Propipe Limited Propipe manufactures and supplies a wide range of pipeline pigs and pipeline plugs to leading offshore and onshore companies throughout the world. Our pig-supply scope covers all types of pipeline pigs; foam pigs, disc pigs, cup pigs and on to more complex articulated and multi-diameter designs, capable of running line lengths in excess of 700 km. Since our launch in 1998, Propipe has achieved phenomenal year-on-year growth. Every pig from Propipe is designed to meet specific requirements of the pipeline. Designs have been developed, tested and field-proven in some of the most difficult applications known for pigs: - Multi-Diameter Propipe has extensive experience in the use of dual and multi-diameter pigs. As well as common sizes such as 8 x 10 and 10 x 14, Propipe has pigs that work in size range such as 26 x 20, 24 x 20 and 22 x 18. Long Run The yard-stick used to measure the performance of a pig manufacturer. Using only the highest quality polyurethane wear parts, Propipe has supplied pigs for many large projects with long trunk lines. Project such as Gulfstream in the Gulf of Mexico (36 x 450 miles), Nam Con Son in Vietnam (26 x 230 miles) and West Natuna in Indonesia (26 x 250 miles) have all been successfully completed. Articulated With the ever increasing need to tie-in marginal fields to one main trunkline, wye connections are becoming common. Articulated pigs offer safe solutions to pass through wyes, whilst still negotiating tight radius bends. Propipe has several proven joint designs and has used these on sizes from 6 up to 48.

Facilities Factory:- 1700m² manufacturing space & 8000m² external pig testing facility

manufacturing capability Foam pigs from 0.

plugs and testing equipment In-house Polyurethane manufacture Piggability Testing

2 Facilities Factory:- 1700m² manufacturing space & 8000m² external pig testing facility (with new 500m² fabrication facility under construction for 2013) Propipe Ltd 24 hour manufacturing capability Foam pigs from 0.25 to 72 diameter Disc pigs 4 to 60 diameter Cup pigs from 6 to 48 diameter Pipeline plugs and testing equipment In-house Polyurethane manufacture Piggability Testing Piggability Testing Full machining and welding facilities Hydrotesting CAD with 3D modelling Finite element analysis 3D CAD & Analysis Facilities

3 Foam Pigs 1/4 to 72 diameters Available in densities 2lb/cu. ft up to 22lb/cu. ft Supplied bare, spiral wound, criss-cross or fully coated Wire brushes available in mild steel, stainless steel, nylon and carbide coated Optional towing eyes, jetting ports, pinger cavities, gauge plates, magnets or hardened studs Chemical resistant coatings Bi-directional capabilities Disc Pigs Dual-diameter Multi diameter Check valve passage Articulated Magnetic Wye passing Sampling Pressure relief HD Sweeping Scraping Brushing Jetting Pipeline Plugs & Testers Compression Plugs Grip tight plugs Welding Pigs Flange Weld Testers Internal Joint Testers Inflatable Stoppers Pipeline Recovery Tools J-Tube Plugs Heat Exchanger Plugs Subsea Plugs (Diver or ROV) Operated Pipe Abandonment Plugs

BI-DIRECTIONAL DISC PIG SPECIFICATION Application Propipe Bi-Di pigs are used for a wide variety of applications, such as for flooding and dewatering, as well as cleaning and gauging

Pig configurations can also be modified to run a dual diameter and multi-diameter pipelines as well as through difficult features such as Wyes, Unbarred Tees and Swing Check Valves

which are listed below:- Cleaning Brushes Dewaxing / Descaling Pads Gauging Plates Locating and Tracking Device Long Run Support / Guide Discs Support Wheels Jetting Heads Magnet Packs

4 BI-DIRECTIONAL DISC PIG SPECIFICATION Application Propipe Bi-Di pigs are used for a wide variety of applications, such as for flooding and dewatering, as well as cleaning and gauging operations. Pig configurations can also be modified to run a dual diameter and multi-diameter pipelines as well as through difficult features such as Wyes, Unbarred Tees and Swing Check Valves Propipe has a reputation for high quality, reliability and expertise and excels in pig design for difficult pipelines General Information Various optional extras are available, some of which are listed below:- Cleaning Brushes Dewaxing / Descaling Pads Gauging Plates Locating and Tracking Device Long Run Support / Guide Discs Support Wheels Jetting Heads Magnet Packs Size range All sizes from 3 to 72 Number of Discs Bore Passing Minimum Bend Radius Materials Typically, 4 Sealing Discs, 2 Support / Guide Discs Up to 10% bore restrictions (greater with changes in disc configuration) 3D minimum (1.5D specials available) Metallic parts Carbon Steel / Stainless Steel / Aluminium Pigging Discs High Grade Polyurethane Elastomer

COMPLETED PROJECT DETAIL Project Name End Customer Gulfstream Offshore pipeline project

pre-commissioning and commissioning the Gulfstream offshore pipeline in 2002.

large changes in diameter due to wall thickness changes throughout the pipe length.

5 COMPLETED PROJECT DETAIL Project Name End Customer Gulfstream Offshore pipeline project Gulfstream Operating Company Project Description Propipe supplied 36 articulated pigs for pre-commissioning and commissioning the Gulfstream offshore pipeline in The pigs were developed for flooding, cleaning, drying, gauging and commissioning operations for the 36 offshore pipeline. The dry uncoated pipeline runs for more than 700 km and connects Alabama, Mobile bay to Florida, Tampa Bay. As well as the long distance and uncoated pipe, the pigs were also designed to cope with large changes in diameter due to wall thickness changes throughout the pipe length. The Gulfstream pipeline is the largest pipeline in the Gulf of Mexico. It is also the first new natural gas transportation system to serve Florida in more than 40 years. The system is expected to supply Florida with approximately 1.1 billion cubic feet of natural gas per day.

Bi-Di Pig Design Options for multi-diameter pipelines A conventional bi-directional pig has guide discs sized below the

For example, a pig sized to suit a 24 OD x 25.4mm WT (558.

8mm x 99% = 553mm OD Sealing Disc OD = Pipe ID x 105% = 558.8mm x 105% = 587mm OD Fig.

6 Bi-Di Pig Design Options for multi-diameter pipelines A conventional bi-directional pig has guide discs sized below the minimum pipe internal diameter (ID) (typically 99%) and sealing discs sized above the maximum ID (typically 105%). For example, a pig sized to suit a 24 OD x 25.4mm WT (558.8mm ID) pipeline would be sized as follows:- Guide Disc OD = Pipe ID x 99% = 558.8mm x 99% = 553mm OD Sealing Disc OD = Pipe ID x 105% = 558.8mm x 105% = 587mm OD Fig. 1 Standard Bi-Di Pig Layout The term multi-diameter or dual-diameter is mostly applied to lines with definite changes in outer diameter (say 8 x 10 ). This usually requires pigs similar to those in figures 1 and 2 below. Fig x 20 Dual-Diameter Pig Fig x 14 Dual-Diameter

Changes in pipe wall-thickness or fittings (valves, tees etc) can also create situations similar to those seen in true dual-diameter or multi-diameter pipelines.

To do this we see if the sealing discs can be increased (to a maximum of 8% over the minimum line ID) or if the guide discs can be reduced.

7 Changes in pipe wall-thickness or fittings (valves, tees etc) can also create situations similar to those seen in true dual-diameter or multi-diameter pipelines. When designing a pig to suit more than one ID, we first look to see if a conventional pig design can be used. To do this we see if the sealing discs can be increased (to a maximum of 8% over the minimum line ID) or if the guide discs can be reduced. However, if the seals are too large, we run the risk of them creasing in the smallest ID, causing a leak path. Similarly, if the guide discs are too small, the pig sits lower in the large ID s, leading to a potential leak path at the top of the pig (as the seals are sitting too low in the pipe too). If the changes in pipeline ID mean that conventional seal and guide arrangements cannot be used, then we must adopt a multi-diameter approach to the pig design. There are two basic possibilities: - Leave the design as normal, but cut slots around guide discs, so that they can bend easily in the smaller ID (as figure 4). Fig. 4 - Slotted guide pig Use guide discs sized below the minimum ID, seals sized above the maximum ID and intermediate discs to provide sealing or support backup (as figure 5). Fig. 5 - Pig fitted with intermediate disc

It is also possible to use a number of other techniques, such as flaps and wheel support (as figures 1 and 2), or combinations of the options above (figure 6). Fig.

8 It is also possible to use a number of other techniques, such as flaps and wheel support (as figures 1 and 2), or combinations of the options above (figure 6). Fig. 6 - Combination design, with both slotted discs and intermediate discs The decision on which option to use is not based purely on the minimum and maximum pipe ID, but also where those diameters occur within the pipeline system. For example, if the line ID is the minimum ID, but bends are at the maximum, the pig will be different from one for a line where the bends are a smaller ID than the pipeline. Propipe produces all styles of pigs, but has found that the intermediate disc design is best suited to applications where the changes in ID are significant, but not sufficient enough to be classed as fully dual-diameter. The intermediate discs can be made as flexible sealing discs, thinner guiding discs (able to deflect) or a mid-hardness disc that can act as both sealing disc and guide disc. The slotted guide arrangement is ideal for applications where the majority of the line ID is within a short range, but where short, large reductions in ID are present. It is not suited to long distance running in many applications, as the slots themselves can make the guide disc more flexible and can also lead to increased wear. Selection of the correct pig design is always done specific to the pipeline and is dependant upon the number if ID changes and their location within the pipeline. Propipe experience and commitment to providing the correct pig is essential, to ensure safe, reliable performance.

Example Images below (figures 7 and 8) show pigs that were supplied to the Gulfstream Project in 2002.

The majority of the line ranged from 863mm to 877.7mm. The guide discs were sized at 855mm and it was accepted that the guides would deflect sufficiently to pass the short sections at 850.9mm and 844.

9 Example Images below (figures 7 and 8) show pigs that were supplied to the Gulfstream Project in These pigs were used during flooding, cleaning, dewatering and gassing-up operations for a line over 700km long (and uncoated internally). The pipe ID range for Gulfstream was from 844.5mm to 872.7mm. The majority of the line ranged from 863mm to 877.7mm. The guide discs were sized at 855mm and it was accepted that the guides would deflect sufficiently to pass the short sections at 850.9mm and 844.6mm. Sealing discs could not be made in one size, to cover the entire ID range, so two sizes were used, at 891mm and 917mm OD s. This design accepts that the pig will sit lower in the larger pipe ID s (because of the smaller guide discs), but compensates for this by using seals to cover the increased ID range caused by the pig sitting down. If the pig had used larger, slotted guide discs, this would not have removed the need for two seal sizes, but would have added loading to the guide discs, due to their reduced rigidity and increased risk of tearing. Fig. 7 Front end, Gulfstream 36 pig Fig. 8 Overview three pigs Fig. 7 Pig condition, post run

ARTICULATED PIG SPECIFICATION Application Articulated pigs designed for negotiating Wye connections, bridging

This type of pig is also highly efficient in long run dewatering/flooding operations as well as dual-diameter

. General Information The details shown are for common pigs, however various optional extras are available, some

10 ARTICULATED PIG SPECIFICATION Application Articulated pigs designed for negotiating Wye connections, bridging line features and pigging around various bend radiuses. This type of pig is also highly efficient in long run dewatering/flooding operations as well as dual-diameter applications.. General Information The details shown are for common pigs, however various optional extras are available, some of which are listed below:- Cleaning Brushes Dewaxing / Descaling Pads Gauging Plate Polyurethane Bumper Nose or Retaining Flange Tracking Device Long Run Support Discs High Performance Polyurethane Stainless Steel Body Support Wheels Pluggable Bypass Ports Jetting Head Magnet Pack

PROJECT DETAIL Project Name Customer End Customer Nam Con Son Pipeline Project BJ Process and Pipeline Services BP (Vietnam) Project Description Propipe Limited supplied 26

The 26 articulated pigs were developed for the pigging of a subsea wye piece, during flooding, cleaning and dewatering operations.

11 PROJECT DETAIL Project Name Customer End Customer Nam Con Son Pipeline Project BJ Process and Pipeline Services BP (Vietnam) Project Description Propipe Limited supplied 26 articulated pigs to BJ Process and Pipeline Services Vietnam for commissioning the 372-km Nam Con Son gas pipeline in The 26 articulated pigs were developed for the pigging of a subsea wye piece, during flooding, cleaning and dewatering operations. Because the pig was required to endure stopping and starting operations the pig needed to weigh less than conventional pigs in order to prevent seal damage. A new design of articulated wire rope & polyurethane joint was developed to withstand twice the calculated load and to reduce the pig weight.

12 PROPIPE CHECK VALVE PIG Previous application Used by Shell on the Goldeneye Project - to traverse a 20 ns check valve in reverse, as shown in fig.1. (Figure ns Uni-Di pig traversing check valve in reverse)

PROPIPE HIGH FRICTION ISOLATION PIG APPLICATION High Friction

isolation of pipelines, during maintenance intervention work,

They can be sized from 8 up to 48 and are able to be run up to

In many instances, especially where divers / operators are

perform verification testing prior to finalisation of the pig

TYPICAL VALUES Size range Currently 8 to 48 Pressure Ability

Nominally 1 bar per pig can be up to 5 bar if accounting for

pressure 10 Sealing Discs and 2 Support / Guide Discs Up to 5%

13 PROPIPE HIGH FRICTION ISOLATION PIG APPLICATION High Friction Pigs are primarily used to provide a low-pressure, high seal isolation of pipelines, during maintenance intervention work, as well as during pipelay flooding and dewatering. They can be sized from 8 up to 48 and are able to be run up to 5 or 10 km prior to use and over 600km after use. In many instances, especially where divers / operators are expected, Propipe will produce a short pigging spool and perform verification testing prior to finalisation of the pig design. TYPICAL VALUES Size range Currently 8 to 48 Pressure Ability Number of Discs Bore Passing Minimum Bend Radius Materials Nominally 1 bar per pig can be up to 5 bar if accounting for flip pressure and depending upon line size and direction of pressure 10 Sealing Discs and 2 Support / Guide Discs Up to 5% bore restrictions (greater with changes in disc configuration) 3D Metallic parts Carbon steel or stainless steel Pigging Discs Diprane 54 Polyurethane elastomer

PROPIPE SMART GAUGE PIG OVERVIEW The Propipe Smart Gauge Pig is designed to allow the condition of a pipeline to be assessed without the need to recover the pig, saving significant time and costs.

14 PROPIPE SMART GAUGE PIG OVERVIEW The Propipe Smart Gauge Pig is designed to allow the condition of a pipeline to be assessed without the need to recover the pig, saving significant time and costs. The design of the smart gauge allows the detection of multiple pipeline flaws - such as a buckle, a dent or excessive weld penetration. Multiple flaw detection allows multiple pipeline defects to be detected rather than just the most severe. FEATURES Multiple pipeline flaw detection (Such as buckles, dents or excessive weld penetration) Pipeline flaw data - Indication of position & size upon data download High Resolution sensor system Sensitive for detecting gauge disc deflection. Options for both Acoustic and Electromagnetic signal SMART GAUGE DETAILS The smart gauge pig is of standard bi-di pig design with the addition of a smart gauging disc. The smart gauge disc is manufactured using a conventional aluminium gauge plate, housed in a polyurethane disc. High resolution sensors on board the pig detect any deflection in the gauging disc. An acoustic pinger or electromagnetic transmitter is fitted to the smart gauge pig and is configured to change signaling mode upon the detection of a pipeline flaw. Furthermore, data such as location, clock position and size of deflection can be downloaded to provide valuable information in such event. The smart gauge pig is rated up to 450 barg, allowing it to remain in the pipeline during hydrotest. Contact us for more information about our smart gauge pig.

15 TECHNICAL SPECIFICATION Size Range 6 upwards Smart Gauge Disc Standard Constructed from Aluminium & Slotted Options: Dual Composite Disc - Aluminium / Polyurethane For use as a true multi-hit gauging disc All Polyurethane (for Multi-diameter pipelines) All discs are combined with a sensor ring fitted with a minimum of 8 Independent High-Resolution Sensors (to detect any deflection of gauge plate) Drive discs Configured with discs, capable of Bi-Directional operation. (Note, gauging can only be performed in the forward direction) Bend Passing 3D bend passing for all sizes of pig. Scan Pitch Data capture from the sensors is triggered by internal clock pulses. Scan rate will be 200 scans/ second. Data Storage Data stored in solid state memory. Survey Speed 0 to 3m/s. Accuracy Gauge Sensing +/- 1mm Clock Position +/- 15 Tilt +/-5 Operating Pressures 250 bar standard 450 bar (high pressure version) Battery Life (Acoustic Pinger) 200 hours run time from activation. Beam Pattern (Acoustic Pinger) Omni Directional ± 2 db Frequency 20khz 40khz Pinger Detection Will be compatible with both manual and ROV receiver systems. Start-up Options Mechanical or sea water contact start Data Download Data download will be via USB2 link to a standard laptop or PC.

PIPELINE PIGS types of mechanical pigs. Pig length (inches) = 1 and ½ pipeline diameters.

PIPELINE PIGS types of mechanical pigs. Pig length (inches) = 1 and ½ pipeline diameters. PIPELINE PIGS A cleaning pig is any free traveling cleaning device that is sent through a pipeline by product flow to scrape and brush foreign deposits, rust and dirt and fluids from the inside surface