Considerations In Pig Trap Design

is essentially part of the pipeline,

it is important that it be capable of
withstanding the pipeline conditions
such as pressure, temperature and
the effects of the service medium
i.e., corrosion.
The trap or vessel incorporates
By Duncan Warriner, a number of nozzles at suitable
Pipeline Engineering, locations for the diversion of flow,
North Yorkshire, UK draining, venting and monitoring.
The diversion of flow provides
ig trap design choices can be vitally the motive force to move the tool
important in ensuring that the opera- through the vessel neck and into
tional unit is practical and safe to the pipeline flow. The vessel neck
use. It is useful to review what is is critical in that it must be of a Rapid opening closure.
expected from a pig trap and the role of the compatible internal diameter to the
various key trap components. Pig traps provide pipeline itself. opening can take the form of a simple flange-
a means of loading and unloading pipeline Once it has been isolated, the vessel can be blind flange arrangement or a more complex
tools, including intelligent pigs, into pipelines. opened in order to either load or unload a pipe- quick opening hub-door arrangement more
They take the form of a vessel that can utilize line tool. The opening is at the other end of the commonly known as a quick opening closure.
diverted flow for either launching or receiving. vessel from the neck to the pipeline connection For subsea applications, the same basic
The vessel can be isolated from the pipeline and is generally of a larger diameter than the principles apply. However, the trap may
to facilitate the loading and unloading of neck to provide ease of loading for launching require additional protection for the valves
pipeline tools. Because the trap when in use and an increase in bypass for receiving. This and pipework in the form of a shielding frame

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Pipeline & Gas Journal / August 2008 / www.pgjonline.com 71
to reduce the risk of damage from fishing nets B31.3, B31.8, AS2885 et al. While essentially still be a bad design for several reasons. It may be
and ships’ anchors. attached directly to the end of a pipeline as costly, dangerous, wasteful, etc. Codes have an
It is beneficial for subsea traps to be either an isolatable extension, the trap can often be important role in securing minimum standards
temporary or removable to facilitate loading designed to a vessel code rather than a pipeline for protection of the community, but should not
and maintenance. code. This in itself can often provide a signifi- be forced into roles they were not intended.
In addition, for unmanned or particularly cant challenge in meeting the pipeline internal Pressure. This can be client-specific
hazardous or frequent pigging operation appli- diameter with a thicker calculated vessel wall. or based upon the ASME/ANSI Pressure/
cations it is often advantageous to consider In this case, we have what is called a specifi- Temperature Class tables. The design pressure
multiple launching capabilities. This can be cation “break” between the pipeline and trap; should never be less than that of the pipeline.
via multiple valve/mechanical methods or by in other cases the trap can be designed to the Temperature. The design would take
more recent AMPL-type technology. same code as the connecting pipeline. account of the maximum design temperature,
Whichever approach, the designer must but also the minimum design temperature in
Mechanical Design ensure all appropriate loadings and condi- terms of material selection.
Considerations tions are addressed to produce a safe working Materials. Often specified by the client,
In the first instance we need to understand design. Typical basic design parameters to however, where possible it is better to allow
the applicable design code. As pig traps are consider include design code, design pressure, the trap manufacturer to select materials that
pressure vessels, pressure vessel design param- design temperature, materials, external load- are compatible with the pipeline materials and
eters must apply. However, unlike pressure ings and cyclic requirements. It is useful to run meet the design specification requirements.
vessels, pig traps must be capable of retaining through each of these parameters. This approach ensures that the most suitable,
pressure while allowing tools to be launched Design Code. This can be any of the cost-effective and readily available materials
and received. It is these tools which determine national or international standards and either a that fully meet the design requirements are
the overall trap dimensions. Certain tools such specific pressure vessel code or pipeline code. selected. It is important that the line product is
as the metal-bodied intelligent pigs are both However, we should ask ourselves what a code specified and whether it is sour, toxic or cor-
heavy and long and must be considered, along is for. A code is a statement of the minimum rosive. This will influence the selection of not
with the internal pressure requirements, when requirements needed to protect the commu- only the metallic elements, but also the elas-
designing supports, lifting lugs and assessing nity. “Community” is generally interpreted to tomeric materials, which typically constitute
foundation loadings. include the users of the equipment, the general the closure-sealing element. All components
Trap design must also satisfy applicable public and the wider environment. in sour service should be specified to meet
codes, whether it be PD5500, EN13445, A code is not a complete guide to design. A the requirements of NACE MR 01 75 for sour
ASME VIII (Div 1 or 2), ASME B31.4, design can meet the requirements of a code and service and where the product is very sour, con-

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sideration should be given to specifying that the sion liquid, gas or both? Will the tool(s) be Practical Design
materials should be HIC/SSCC-tested. Finally, used for cleaning, stabilization, separation or a Considerations
any material must be compatible with its mating combination thereof? How frequently will the In addition to mechanical and process con-
material in respect of weld ability, wall thick- tool have to travel and how far? What is the siderations, the trap designer must consider
ness, chemical and mechanical properties. performance of the line-pumping systems? practical issues such as location, layout, envi-
External loadings. These loads consist of Often it is necessary to consider the suitabil- ronment and logistics.
those imposed by attaching pipework acting ity of industry norms to specific applications,
upon nozzles. In addition, external pressure particularly with regard to such parameters Trap Components
due to water depth in a subsea application as nozzle sizing. Industry norms for nozzle The basic trap components are barrel,
could fall into this category. sizing do not always consider the practical reducer, neck pipe, branch nozzles, kicker,
Cyclical requirements. Should the unit be issues associated with the service medium. drain, vent, blowdown, balance line, pres-
subject to frequent pigging operations, this For instance, the number and size of drain surizing line, thermal relief valve, pressure
may in turn create sufficient cyclical loading nozzles will differ for a dry gas medium as indicator (pressure gauge), supports, lifting
to warrant fatigue analysis. In addition, we compared to a waxy crude medium. In the case lugs, earthing (grounding) lugs, end closure
need to consider support loads, wind, blast of waxy crude it may be necessary to consider and pig signaller.
and seismic loadings, loads induced during larger drain nozzles located at the closure and Barrel. This is the major section of the
transportation of the units and any subsequent reducer end of the major barrel. trap and the means by which the loading and
lifting lug requirements. The pigging philosophy itself may also have unloading of pigs can be carried out with com-
an impact on the nozzle size. For instance, parative ease and safety. It is usually equipped
Process Design when receiving, if the pig is not stopped at the with an opening closure at one end while its
Considerations bypass barred tee and brought into the vessel other end is welded to a reducer. For conven-
As specialist pigging designers we look at at a lower velocity than that of the medium tional pigging its diameter is usually a nominal
the requirements from several angles. In addi- (with partial bypass via the line barred tee), the 50 mm above the line size, while for intelligent-
tion to an examination of pipeline configura- bypass line may not be of sufficient diameter type pigs it is recommended that it be at least a
tions, pressures and diameters, the product and to carry the flow. In this case, the bypass size nominal 100 mm above the line-pipe diameter.
its temperature and flow rates, we will seek to may need to be increased. The barrel length is dependent upon the operat-
define precisely what the systems have to do. Many questions have to be considered before ing procedures, service, type of pigs, available
Will the tool(s) travel in one direction only, a design solution begins to emerge. A thorough space, etc., but in general for launchers deploy-
forward or backward, or is two-way motion analysis is essential to design traps capable of ing conventional pigs - 2 x pig length, while for
needed? Other questions include: Is propul- absorbing all the necessary forces and loadings. receivers - 3/3.5 x pig length.

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 When deploying intelligent-type pigs, the at the closure end in the case of launchers, and Blowdown. On high-pressure gas systems
barrel length should be decided only after near the reducer end in the case of receivers. consideration should be given to the provision
consultation with the pig manufacturer. In the case of universal (bi-directional) traps, of a blowdown line, incorporating a globe
Reducer. This is welded at its larger diam- a single connection midway along the barrel valve or restriction orifice, for controlled
eter to the other end of the barrel, and can be or twin connections, one in the launch position depressurization. Size should not exceed two
eccentric or concentric. Generally, horizontal and one in the receive position, can be fitted. inches ns.
units use eccentric on launchers, concentric Kicker connections should not be positioned at Balance line. This can be provided on
on receivers. Vertical units use concentric the 6 o’clock position; historically, this posi- launchers to enable filling and – pressuriza-
throughout. tion causes damage to the pigs. tion of the barrel on both sides of the pig at
Neck Pipe. This is the minor diameter sec- Drain. This nozzle should be situated near the same time. This is to prevent a pig which is
tion of the pig trap and is welded at one end the closure end for horizontal traps and near ready to be launched from moving forward and
to the smaller diameter of the reducer and the neck flange on vertical launchers. For thereby hitting and possibly causing damage
terminates in either a butt weld end prepara- receivers, a drain point near the barrel reducer to the trap valve, or backwards and losing the
tion or flange at its other end. Dimensionally is recommended, or alternatively on the neck seal in the reducer. Consideration should also
it is usually very short - one pig length + 10%, pipe near the end flange. For receivers which be given to the provision of a balance line on
however, in the case of intelligent pig receivers are sloped for spheres, two drain points should the receiver to prevent any possible pressure
it could be as long as four meters. ideally be specified and located together differential across a receiving pig. Size should
Branch Nozzles. On the simplest of traps near the closure end, but separated by half a be in the region of two inches ns.
there can be as few as four nozzles - kicker, vent, sphere diameter, this prevents the drains being Pressurizing line. This may be required
drain and pressure indicator. On more complex blocked by the spheres. Size of drain connec- around kicker valves for several reasons -
traps, additional nozzles are incorporated for, tions should be not less than two inches for speed of operation, control of barrel - pressur-
blowdown, balance, equalizing, pressurizing traps up to 14 inches line size and four inches ization and/or damage to the kicker valve seats
and thermal relief valves. Other nozzles may be for traps above that. or other internals. Similarly, a pressurizing line
fitted in accordance with the clients’ specific Vent. This nozzle should be situated near around bypass valves should also be consid-
requirements, but consideration should be given the closure end or highest point; a further con- ered, for equalizing possible high-differential
to the design requirements regarding proxim- nection may be considered near the trap neck pressures. Size should be smaller than the
ity of welds etc. Running through the various end flange to ensure depressurization behind balancing line connection.
nozzles, the size and positions are generally in the pig in case it becomes stuck in the neck Thermal relief valve. This can be provided
accordance with the following. pipe. Size of vent connections should not be at locations where it is anticipated shut-in or
Kicker. This nozzle is situated on the barrel less than 1/2 inches ns. trapped fluid could exceed the design pres-

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sure. Size would be as dictated by design lethal workplace. If the accumulated static is at a minimum with a safety bleeder device,
conditions. suddenly discharged within a hazardous atmo- forming part of the door-locking mechanism,
Pressure indicator. This should be fit- sphere, the resulting spark may easily act as the to safeguard personnel before and during door
ted toward the closure end and visible to the ignition source for an explosion. opening. An interlocking system between the
operator, may be incorporated with the vent End closure. This can be as simple as a various valves and the closure may be consid-
connection. Size should be in the region of 1/2 flange and blind, but is more commonly found ered as an additional feature.
inch to one inch, threaded, with four inches or in the form of a quick opening door, an assem- Pig signaller. This is also known as a pig
six inches dial size. bly which provides a quick, easy and safe detector, a device set on or into the pipeline
Supports. Required to permanently support access to the barrel when open and seals the which indicates the momentary presence of a
and restrain the pig trap, supports should be bore when closed. The closure should be fitted pig at a precise location. Signallers should be
designed to carry the weight of the pig trap system
filled with water (or other fluid if their density is
greater), together with the weight of the associated
heaviest pig. Supports under the barrel should
normally be of the sliding type to compensate for
expansion of the unrestrained part of the pipeline.
Other supports may be fixed if design calculations
indicate that sufficient flexibility is incorporated
in the pipework to compensate for any axial and
transverse movements.
Lifting lugs. These are required to facilitate
lifting of the complete trap during the instal-
lation stage.
Grounding lugs. These are required to
reduce the build-up of static electricity. Static
is a seriously under-estimated yet ever-present
hazard. Being invisible to the naked eye, it tends
to be ignored. Yet, an undischarged build-up of
electrostatic can take hours, even days, to relax Pig signaller-set, left, and pig signaller-
back into equilibrium, resulting in a potentially Rapid End Closure tripped, right.

Pipeline & Gas Journal / August 2008 / www.pgjonline.com 77

installed on both sides of the trap valve. For
launchers, it should be positioned on the main
pipeline at a distance from the trap valve of at
least the length of the longest pig anticipated.
For receivers, it should be positioned on the trap
neck pipe at a distance from the trap valve, again,
equal to the anticipated longest pig length.

Generic Types
A pig trap can take a number of forms but
generally falls into the generic types such as bi-
directional, vertical launcher, vertical receiver,
horizontal launcher, and horizontal receiver.

Innovations
Clearly at the forefront of any design consid-
erations is the issue of health, safety and envi-
ronment. Any reduction in manual intervention
or potential environmental risks is advanta-
geous and we should look to achieve this where
possible for very frequent pigging operations or
those in very remote/hazardous locations. This
reduction in the number of times the vessel
needs to be opened can be achieved by the use
of multiple launching/receiving capabilities. Pig launcher
There are four main systems available:
Valve type Pig Launcher. Valve Type Multiple Pig Launcher. The launched individually as required. Although
Vertical Multiple Pig Launcher. trap is fitted with a set of launch valves for a very reliable system, the additional valve
Automatic Sphere Launcher. each pig in the launcher. This allows line pres- requirement adds considerable cost to the sys-
Automatic Multiple Pig Launching (AMPL). sure to be directed behind each pig in turn and tem, especially when fitted to a large-diameter

78 Pipeline & Gas Journal / August 2008 / www.pgjonline.com

pipeline, due to the high cost of the large Vertical Multiple Pig Launcher. This sys- er. This pig is then launched. Subsequent
valves required for the multiple kicker lines. tem is based around the space-saving solution pins are then retracted as and when further
This system is used predominantly in of a vertical pig launcher used on many pigging runs are required.
subsea applications with either a diver or offshore installations. It is basically an As mentioned earlier, this is a very
ROV operating the valves as required, or extended standard launcher, but with the reliable multiple pig launching system.
the valves are fitted with remotely operated addition of hydraulically operated launch However, the initial cost outlay can be
actuators which adds to the overall cost. It pins that protrude into the oversize barrel quite high due to the launch pins and the
is also retrofitted to existing installation pig of the launcher. The f irst pig is loaded into hydraulics required to operate them. Extra
launchers if an automatic launching require- the throat of the launcher, and then the f irst maintenance is needed to ensure the launch
ment is later identified. or lowest launch pin is extended. Another pins operate correctly. They also require
pig is then loaded regular inspections to ensure they have not
— that is — held become bent due to excessive forces.
up by the launch Automatic Sphere Launcher. Although
pin. Subsequent not strictly a pig launcher by definition, the
pins and pigs are principles are the same. Spheres are regularly
then inserted until used when large numbers of cleaning runs are
the trap’s capacity required, but the efficiency is not critical, usu-
is reached. ally where the removal of unwanted fluids is
The f irst pig the primary cleaning requirement.
is launched in the Automatic sphere launchers operate similarly
normal way. When to the Vertical Multiple Pig Launcher, utilizing
another pigging run launch pins, but with the trap on a slight decline
is required, the low- from the horizontal. Spheres are loaded with the
est launch pin is front pin extended and the rear pin retracted.
retracted, and the pig When a launch is required, the rear pin extends,
above it falls into the holding back the remaining spheres. The front
Multiple Pig Launcher throat of the launch- pin retracts, allowing the lead sphere to roll

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 Pipeline Engineering to meet the compliance by manufacturing inspection, it
need for a multiple pig-launching sys- is important to inspect and maintain the units
tem that can be retrofitted to existing during operation.
launcher facilities without the need
for costly trap modifications. ACKNOWLEDGMENT:
The system operates in a simi- This article is based on a presentation at the 20th
lar way to standard pigging equip-
international Pipeline Pigging & Integrity Management
ment. The pigs are either pre-
Conference sponsored by Clarion Technical Conferences,
loaded into a specially designed
cassette, which is then inserted Feb. 13-14, 2008, in Houston, TX.
into the standard trap, or they are Author: Duncan Warriner is general man-
loaded into the trap in which the ager of metal products at Pipeline Engineering
cassette has already been fitted. in the UK. He is a Chartered Mechanical
The number of pigs in the cas- Engineer with 19 years of experience dealing
sette is pre-determined by the
with the mechanical requirements and materi-
length of the trap.
Sphere Launcher als used in the oil and gas, construction and
Inspection service industries, with specialist knowledge
into the pipeline. When the downstream signal- Having made all the necessary consider- in pipework and pressure vessel design, fabri-
ler indicates the sphere has been successfully ations during the design phase and ensured cation and material selection.
launched, the front pin extends, the rear pin
retracts, the remaining spheres roll forward and
the system resets itself for the next launch.
Although widely used, this system is pre-
dominantly used for fluid removal and not for
physical line cleaning due to the sphere only
having one sealing face, and therefore a ten-
dency to ride over solid residue in the pipe.
Automatic Multiple Pig Launching System
Automatic Multiple Pig Launcher
(AMPL). This system has been developed by

82 Pipeline & Gas Journal / August 2008 / www.pgjonline.com