POLMAZ LIMITEDMETHOD STATEMENT OF PIPELINE PIGGING SERVICES

INTRODUCTION

This report covers pipeline operation (routine) pigging for pipeline maintenance as is the practice in modern pipeline operations. This technical report can also be made a procedure document providing clearly defined and structured guidelines for safe and efficient operations during pipeline pigging and related activities on all liquid, gas pipelines to minimize risk and negative impact upon client’s facilities and the environment.

WHAT IS A’ PIG’?

Pigs are devices, which are inserted into, and travel throughout the length of a pipeline, during the product flow. They fall into two categories: ‘UTILITY’ PIGS which perform a function such as cleaning, separating or dewatering the pipeline, and in-line inspection or more simply, ‘ILI TOOLS’ (sometimes referred to as ‘intelligent pigs’ or ‘smart pigs,) – which provide information on the condition of the lines as well as the extent and location of any problems.

WHY PIG A PIPELINE

A pipeline is arguably the most efficient method yet devised for transporting fluids-whether gases or liquids. Its relative’s efficiency though depends upon two fundamental requirements:

a) It must operate continuously; andb) The required throughput must be obtained with the least capital investment and the

lowest operating costs.

Pigs play a major role in both obtaining and maintenance the ‘two fundamentals’.

1. They help to ensure continuous operation by:- removing any substance which might damage the pipeline process systems;- helping to prevent the formation of corrosion cells;- providing timely information of any developing problems;- providing data on any perceived problems to enable informed decisions to be

Made- providing an alternative to shutting down for statutory periodic testing.

2. They help to ensure maximum efficiency by:

- removing any debris or foreign matter in the line;- removing any deposits, either liquid or sold, which might otherwise build up and

restrict the flow;- monitoring the operating and/or physical conditions of the line.

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PIPELINE PIGGABILITY

PROGRESSIVE PIGGING

Pipelines that have never been pigged or have not been pigged for some time may have substantially reduced bores due to build up of deposits/debris. These deposits may consist of sand, corrosion products, wax and/or scale.

The progressive pigging operation under high flow conditions (above 1m/s) should consist of three (3) steps:(a) To ensure that there are no major obstructions one (1) or (2) soft (foam) pigs should

be run.(b) To check piggability, a cup with open bypass ports and gauging plate should be run(c) To fully dislodge and suspend the debris, bi-di pigs with open bypass ports should be

run

If hard scale is present in a pipeline, then studded foam pigs should be used.

RECOMMENDED ROUTINE MAINTENANCE PIGS

Foam Pig

Least aggressive of all pig types, Foam pigs are normally used for providing, batching or swabbing. It is a pig made of open cell polyurethane foam. It is available in variety of foam densities to suit various applications. It is available with polyurethane coating for added durability and also available with wire brush mats for more aggressive cleaning qualities.

Basic Scraper Pig

An industry standard coming in a variety of forms, they are uni-directional and are propelled by conical polyurethane cups, which tend to ride over debris in the pipeline. Spring-loaded wire brushes improve cleaning ability.

Bi-Directional Pig (Bi-Di)

This type of Piggs are an industry standard with improved qualities over foam and scrapper pigs. They are versatile pigs, which can be used for the removal of loose debris, soft wax and liquid batching in pipelines. They are bi-directional and are propelled by discs that are efficient at removing debris from the pipeline. They are available with spider nose by-pass facility to reduce risk of the line blockage due to debris accumulation.

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Intelligent Pig

They are electro magnetically / ultrasonic coded tools (pigs) which provide information on the condition of the pipeline internal as well as the extent and location of any problems. Hence, they confirm the pipeline status and integrity.

Pig Tracking

A technique used to monitor a pig moving through a pipeline. In the event that the pig becomes immobilized due to restrictions in the pipeline, or periodic tracking is required, using a pig tracker which is a transponder capable emitting a signal, and shall be fastened securely to the pig prior to launching. This signal is readily identified from a hand held detector from above ground.

WORK PRACTICE(Refer to the attached pig flow chart and simplified pig trap)

PRE-LAUNCH ACTIVITIES

For all routine maintenance pigging using approved cleaning pigs and with velocity not less than 0.5m/s, 50% of the available by-pass ports shall be left opened. However, for cases of where the velocity is less than 0.5m/s, all by-passed ports shall be closed to ensure sufficient pressure differential is maintained across the pig.

All solid body pigs shall be fitted with a pig tracking/locating device/transmitter ensuring that batteries are sufficiently charged for the entire run duration.

Pigging facilities at both ends shall be inspected and certified suited for safe pigging operations. Any threat or unsafe condition observed to the pigging operations shall result in suspension of pigging.

All intermediate pipeline valves including river crossing ball valves shall be checked to ensure that they are in fully open position. In the event that any intermediate valve is struck in partially closed position, the pig launch shall be suspended until the affected valve is repaired.

There shall be diesel transfer pumps, vacuum trucks and trucks/environmental barges of adequate capacity for liquid handling prior to line-up of pig receiver.

It shall be ensured that for delivery lines, the producing flow station was not shut down within the last 24 hrs and that for all cases there is enough production to provide the minimum specified fluid velocity required to drive the pig to the receiver. No pig shall be launched if it will not be recovered prior to any planned shut, down of station.

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Availability of functional communication system between the work site and base shall be ensured, in the event of emergency.

PIG RECEIVER BARREL LINE-UP

There shall be calibrated and functional pressure gauges with enough range to cover the maximum allowable operating pressure (MAOP) of the pipeline to be pigged. The gauges shall have a current test certificate. It shall be verified that no unsafe conditions exist that could affect the HSE aspects of the operation.

Ensure that the barrel door (F) is properly secured with no leaks. Barrel door seals shall be replaced for all cases of leaking doors.

Verify that drain lines are free from blockage.Verify that the vent valves (E) are fully closed without leaks.

Gradually crack open the kicker line valve (C) to pressurize the barrel using the vent Valve (E) to vent all trapped gas/air. The vent valves (E) shall be closed once all gas/air has been vented from the trap. The barrel shall be fully pressurized when the pressure gauges on the barrel and mainline are reading same valves.

Fully open kicker line valve (C) and main line valve (B)

Close the by-pass valve (A) to 75% closed position to cater for backpressure in the event of high debris build-up in the barrel.

PIG LAUNCHING

For manifold over water, a mini boom shall be deployed around the barrel and saver pit areas.

Certified pressure gauges shall be installed on each side of the barrel isolation valve (B) the gauges shall be such that the expected working pressure falls approximately mid way on the gauge range.

Connect a pressure recorder to the pipeline such that pressure/time may be monitored throughout the travel time of the pig. The range of the recorder shall be such that the expected working pressure falls approximately mid way on the recorder range.

Fully open the by-pass valve (A)

Both mainline valve (B) and kicker line (C) shall be in fully closed position.

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Gradually open the drain valve (D)

The vent valves (E) shall be gradually opened to depressurise the barrel while the drain valve (D) shall be used to completely drain the launcher into the drain pit. Confirm that the barrel pressure is zero using the gauge on the launcher barrel prior to gradual and sequential opening of the launcher door (F).

Test pit – tracking equipment to ensure proper working conditions exist.

If the pig cannot be manually loaded safely, load the approved pig into the barrel using the lifting facility provided on the manifold. Load the approved pit into the barrel ensuring that the pig nose is in front and the front drive cup in contact with the reducer section of the launcher barrel. (A push rod or ram is to be used to position pigs in long barrels)

Close the barrel door (F) taking care not to damage the door seal and secure all locking devices tightly.

Close the drain valve (D)

Gradually crack open the kicker line valve ( C) to fill the barrel with the liquid while leaving the vent valve (E) open to displace the air in the launcher barrel until all the air is displaced.

Closed the vent valve (E) and fully pressure gauges on both the launcher barrel using the kicker line valve (C ) and mainline indicate the same reading.

Gradually open the main line valve (B) until it is fully opened. Main both kicker line valve (C) and mainline valve (B) in fully open position.

Gradually closed the by-pass valve (A) to direct fluid flow through the launcher barrel until the pig signalers turn to indicate pig travel out of the launcher barrel through the above ground pipeline section into the underground section.

Reset both signalers

Return the launcher barrel to normal operating made by opening the by-pass valve (A) close the kicker line valve (C) and close the mainline valve (B) in the sequence indicated.

Depressurise and drain the launcher barrel by opening the drain valve (D) follow by the vent valve (E) in sequence. Zero pressure in the barrel shall be confirmed using the pressure gauge and the end closure safety bleed device prior to opening of the barrel door.

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Open the barrel door (F) to confirm that pigs were actually launched. Check the door seal for damages replace the seal if damaged or grease it if in good condition. Close the barrel door (F) the drain (D) and vent valve (E) properly.

Drain pit shall be evacuated and waste disposed of safety.

PIG RECOVERY

When the pig arrival is confirmed in the receiver by the operation of the pig signalers and/or the pig tracker, the recovery procedure shall be activated.

Ensure that the receiver barrel is properly line up with no tampering.

Ensure the drain pit has adequate capacity to accept full barrel contents during pig recovery.

In the event that the pig has not fully entered the receiver barrel, the by-pass valve (A) shall be throttled until the pig is fully received in the barrel.

Both mainline valve (B) and kicker line valve (C) shall be fully closed in that sequence.

Depressurise and drain the receiver barrel using the drain (D) and vent vale (E) in that sequence.

Continue from above until zero pressure is confirmed on the gauge installed on the barrel and no liquid is coming out of the drain valve (D).

Ensure that no personnel are directly in front of, or near the hinged side of the end closure (F).

Undo the safety locking device and reconfirm the barrel is depressurized.

Gradually open the end closure (F), recover the debris and recover the pig. If the pig stops any distance from the barrel door, an extension rod shall be used to put the pig to within arms reach. For pig sizes of 16” and above a recovery tray or the lifting facilities shall be employed during recovery.

Small samples of both the debris and the liquid shall be taken to the laboratory for analysis.

Inspect door seal, clean and grease if in good condition or replace if damaged. Thereafter close the barrel door (F) and properly lock it.

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Drain pit shall be evacuated and waste disposed of safely.

Inspect the recovered pig for possible damage, record any observation and return to base for appropriate action.

ENVIRONMENTAL / WASTE HANDLING

It shall be ensured that the environmental impact of pigging operation is not neglected. All activities shall be performed such that liquid and solid wastes are treated according to the guidelines set out below.

WASTE HANDLING AND DISPOSAL

All liquid waste shall be drained from the barrel via the drain line into the manifold saver pit.

There shall be adequate haulage in the savour pit overflowing.

Transfer of liquid waste from the barrel to the savour pit shall be accomplished with moderate pressure such that splashing does not occur.

The savour pit shall completely evacuated before leaving site. At locations not having an automated recovery system, all liquid waste shall either be collected in suitable watertight seal-able containers, collected by vacuum tanker or re-injected into the pipeline sing purpose built diesel drum pumps.

On no account shall separated water be evacuated into the environment.

Only suitable hand or diesel driven pumps shall be used for the transfer of saver pit waste. Decanting from buckets is not encouraged.

There shall be absorbent materials for mopping up operations in the event of a minor spill.

All solid waste shall be collected, categorized and weighed on site. These shall be evacuated to approved and licensed facility.

ENVIRONMENTAL CONTIGENCY

During all pigging operations, contingencies for the unexpected release of product into the environment shall be put in place.

For all swamp operations a boom shall be deployed such that the entire water surface around the pigging platform is encompassed.

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Absorbent materials shall be readily available to remove any traces of oil failing onto the water surface from the platform.

Any traces of product shall be cleaned from the manifold structure on completion of operations using absorbent material.

PIPELINE PIGGABILITY

Prior to commencement of a pigging operation, it must be ensued that there are no pipeline features that would impede the travel of the pig. For the entire pipeline system route that a pig will travel (i.e. launcher to receiver), the following physical aspects should be checked before the pigging is approved. These checks should be conducted before the pig is ordered, so that the information can be passed on the pig supplier and suitable pigs can be obtained.

Pipeline Feature What to Check forInternal diameter of the following features:

* Flanges* Tees* Bends* Valves* Riser & topsides piping up to pig trap* Reducers* Narrow pig trap barrels

The internal diameter should be checked to ensure that the pig selected will be able to pass through. Pigs should be able to traverse the followings (subject to confirmation by supplier):

* Bi-di pigs – up to 10% of nominal ID * Cup pigs – up to 15% nominal ID* Foam pigs – up to 20% nominal ID* Bi-di cast pigs – up to 15% of nominal ID* Cup cast pigs – up to 20% of nominal ID

Design of tees For spheres, sphere tees should be installed

For other pig types, barred tees should be installed for branch sizes larger than 50% of nominal line size. Most conventional pigs can transverse branch sizes up to 70%, and intelligent pigs, sizes up to 60%.

Design of valves Gate and ball valve on the pipeline should not have bores smaller than 90% of the nominal line size.

Mitred bends Mitred bends should have angles of no more than six degrees

Opening of valves The correct setting of end stoppers shall be checked to ensure that valves are fully opened for the pig runs. Any

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valves not fully opened may damage both pig and valve.

Pipelines with internal coating

Pigs with wire brushes may damage internal coating.

Launcher and receiver lengths

Lengths of the launcher and receiver barrels should be checked to ensure they are adequate, especially in the case of intelligent pigs.

ROUTINE PIGGING ACTIVIITES

The internal of the candidate pipelines will be cleaned on monthly routine basis. This will include pipelines ranging from 8 inches. Occasionally, provisions shall be made for the cleaning of pipelines with gas or crude oil medium for line sizes of 4”, 6” and 48” when the need arises.

For the routine pigging of pipelines, the under listed pigs will be used.

(a) Form Pig(b) Scraper Pig(c) Bi-directional Pig

The Form Pig will be used to pig lines that have not been pigged for a long time or lines in which hard scales exist. This will reduce the changes of stuck pig in the line. Form pig is used as a compromise where scraper or Bi-di pigs cannot be used in the first run.

Scraper Pigs are mandrel pigs with conical cups and blades or brushes, they perform better than foam pigs in removal of debris from pipelines but they are not as aggressive as bi-di pigs. Pipeline that are not de-scaled are pigged with scraper and or foam pigs. They only move in one direction hence they are unidirectional.

Bi-Di pigs are most efficient and preferred pigs for pigging of new or descaled pipeline. A bi-di pig comprises of a mandrel with guide and sealing discs. They are very aggressive in with by-pass nozzles for jetting debris away from the front of the pig.

GENERAL PROVISION OF WORK SUPPORT EQUIPMENT/TOOL/ PERSONNEL

Mobile House Boat Ramp Barges Tug Boats Crane 20 tons Pig Trackers Pigs Personnel, etc.

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Routine Pigging of pipelines and pig maintenanceAuxiliary pumping of low flow pipelinesValve greasing / maintenanceGreasing / stroking of manually operated valves (MOV)Inspecting / reports of shallow creeksReporting of sabotage of client facilitiesSpill containment – drums, water, pumps, buckets, boats, canoe, shovels, pick-up car and Personnel

Premobilisation

Arrangement of the base Setting up a mini-workshop for the cleaning of pigs and related equipment Procurement of hand tools and box Procurement of personal protective equipment and 2 first aid boxes Confirming the date of inspection from CLIENT Definitions of the various personnel involved / organization Field job reporting formats and activities updates Safely training of the technical crew

Mobilization

Selecting the actual leasers and inspecting their units before client inspection Orientation of the Supervisor / foremen on facilities inspection and data gathering Grouping of the cells for the work proper