Technical Directorate Technical Services Department
Technical Directorate Technical Services Department
Technical Directorate Technical Services Department
- Revision A -
; Pesign, Manufacture, Testing and Supply of Pig Si~naller(Intrusive Typc)
ES.5.06.0024 Rev A
Page 2 of 17
CONTENTS
Introduction
Custodian
Pu: ,pose
4.0 Application
6.0 Malerials
Glossary
Int -oduction
Thi- engineering standard (ES) specifies the minimum requirements for the design,
mat~ufacture,testing and supply of intrusive (set-in mechanical) type pig signallers
equipped with a probe that intrudes into the pipeline / pig trap, for permanent installation
on QP onshore and offshore (except sub sea) carbon steel pipeline systems.
The purpose of the signaller is to provide feedback that the pig has been successfully
launched or arrived at the receiving station / that the pig has successfully passed through
the pig trap valve.
Pig signallers should normally be installed on both sides of the pig trap valve, as a
mir ;mum, as indicated in the enclosed schematics, Annexure-A.
The signaller on the downstream side of the pig launcher should be located on the
pip line at a distance from the main tee of at least one length of pig to be used, usually of
the intelligent pig.
For pig receivers one signaller should be located on the minor barrel at a distance from
the pig trap valve of at least one length of the pig to be used, usually of the intelligent
pig
Wf erever there are nearby flange joints / opening devices, example pig signallers located
on the pig trap equipment and it's surrounding, the intrusive type pig signaller can be
used. Intrusive type pig signallers can also be used on pipelines which will be routinely
pig ;ed at intervals of 6 months or more frequently, except as stated below, to avoid
sig ialler getting stuck in the line. The connection for intrusive type is via 2"NB branch
into which the pipeline fluid will enter and pressurize the housing of the pig signaller.
Thr intrusive types shall not be used in cases where the fluids are toxic and unstable
(like ethylene), in which cases the selection shall be to use non-intrusive type. The
decision on what type of pig signaller is to be used shall therefore be decided during
PE FD / P&ID stage.
For non-intrusive (clamp-on / strap-on with local / remote sensing capabilities) type of
pig signallers (where the locations can be moved on the pipeline) refer to ES.5.06.0023.
Any detail or item not n:::ntio.i,I,! in this ES, but rrquird Q thc Systsm 1 Cc~?ifis;ltix
Agency / Regulatory Bodies, are to be included in the scope of supply.
All work shall be carried out in compliance with this ES, Codes, Standards and
Spmifications listed unless otherwise stated in the pig signaller data sheet &/or project
spc cification. In case of conflicting requirements the Manufacturer shall follow the more
strr ngent, and such issues shall be brought to the notice of QP in advance and shall be
agreed in writing.
Application
De!iign Code
5.1.1 Thc design methodology as described in ASME VIII, Division 1 shall be used for the
design calculation of the pig signaller pressure housing.
Co ~nponentDescription
A trigger penetrating into the main bore of the pipe which will be moved by a
passing pig;
A transfer mechanism to transfer the movement of the trigger causing the trip of
a mechanical indicator and/or electrical switch;
A pressure housing, containing the transfer mechanism connected with the
trigger, having a flange of 2"NB for installation on to the pipeline;
A mechanical and/or electrical indicator mounted externally on the pressure
housing.
5.2.2 Additionally, for pig signallers on pipeline sections, which cannot be depressurised for
pig signaller maintenance or where installed on pipelines at buried locations:
A flanged ball valve of 2"NB, with or without a flanged extension, to isolate the
pig signaller from the pipeline;
A portable jacking tool for safe lifting of the transfer mechanism complete with
the trigger through the isolating valve with the main pipeline under pressure.
This shall be treated as an optional item while procurement of pig signaller, or if
an existing tool is to be used, manufacturer's confirmation must be obtained to
check the suitability of the tool with reference to the pig signaller model.
Functional Requirements
The trigger shall trip the mechanical indicator for local indication or an
electrical switch for remote indication or both when a pig passes the pig
Design, Manufacture, Testing and Supply of Pig Signaller (Intrusive Type)
ES.5.06.0024 Rev A
Page 5 of 17
signaller in any direction, per description stated in the respective pig signaller
data sheet.
After the pig has passed the pig signaller, the internal mechanism shall re-set
automatically to the position required for indicating the passage of the next pig.
Resetting of the signal mechanical indicator shall be undertaken manually only.
Resetting of the electrical switch shall be automatic;
The mechanical signal flag or the electrical switch shall not be triggered by the
flow or pressure of the pipeline fluid;
The trigger shall not obstruct or damage a passing pig and the trigger shall not
be damaged by a passing pig;
The penetration of the trigger into the trap / main pipe shall be kept to a
minimum to avoid unnecessary obstruction of the fluid flow;
The trigger shall be corrosion resistant over a 25 year design life of the signaller.
5.2 Se -viceRequirements
5.2.1 The pig signaller shall be designed for maintenance free operation and permanent
installation in an open atmospheric environment. For the location / its environmental
co~iditionsrefer to the respective pig signaller data sheet.
Pii signallers shall be suitable for installation vertically at the 12 o'clock position for
hor izontal pig trap equipment and in any horizontal position for vertical pig trap
equipment, with or without an isolation valve.
Pig signallers designed for replacement with the main pipe under pressure shall have a
lift able internal mechanism to allow the closing of the isolating valve and to allow safe
rekase of the pressure of the isolated part when the valve is closed.
Th: trigger and the transfer mechanism shall be suitable for a passage through a branch
wilh a minimum ID of 38mm.
In!tallation requirements
Th pig signaller shall be mounted on the main pipe / trap via a branch terminating in a
rai ;ed face (unless otherwise specified in the respective pig signaller Data Sheet) flange
of size 2"NB for pipeline diameters equal or greater than 8"NB, connected through a
weldolet, a weld neck flange, and a pup piece wherever required. For trap 1 pipeline size
i ~ l . LC tluuugil a icducing tee where practical, otherwise through
-4'NB t h L ~ u l l ~ c iLa11
a 2"NB weldolet.
Bolting and gaskets for the field installation of the Pig Signaller should also be included
as )art of the pig signaller scope of supply, unless otherwise agreed in writing with QP.
Th: required pressure / temperature rating of the pig signaller and the design criteria I
patameter of the pipeline / pig trap shall be stated in the pig signaller Data Sheet.
Th: minimum wall thickness of the pig simaller pressure housing and any cxteniion
I besign, Manufacture, Testing and Supply of Pig Signaller (Intrusive Type)
ES.5.06.0023 Rev A
Page 6 of 17
sha I be 4.8mrn, excluding of any corrosion allowances. The corrosion allowance
requirement shall be taken per the pig signaller Data Sheet.
Where stated on the data sheet pig signallers shall be fitted with a micro switch for
rerrote indication, which is hermetically sealed and compatible with intrinsically safe
des gn. In addition, the micro switch shall be weatherproof and explosion- proof. The
r a t i ~ gof the micro switch shall be indicated in the data sheet, based on the area
cladication. The recommended minimum is "Eex ed IIC T6 IP65".
The, electrical switch shall be made of corrosion resistant materials, e.g., salt water
resistant materials for offshore installations.
In case of any electronics assembly, the enclosure should be covered with removable
typ: of sunshade for easy maintenance access, and shall be made of either U-V resistant
fib1e-glass reinforced epoxy or stainless 3 16 grade materials. Details shall be discussed
and agreed upon during bid negotiation stages.
Iso ation valve of the pig signaller shall be a ball valve, with flanged ends.
Pig signallers shall be bi-directional type, having pivot less tumbler mechanism and
lan inated trigger blades.
De;;ign of pig signallers shall be such that any possibility of the signaller being triggered
by line pressure is eliminated. The pig signaller shall be fitted with an integral valve
ensbling controlled retrieval and installation of the signaller mechanism under full line
pressure. The trigger mounting mechanism should permit extension or retraction into the
ma in body.
Pig signallers shall be provided with a visual flag-type indicator to indicate the passage
of pigs, by means of spring loaded metal shaft. The arm shall lock in down position
when manually reset. The linkage between the internal cam / shaft and external flag
shz :l be either magnetic or mechanical.
Aboveground or below ground application shall be stated on the data sheet. For
belowground applications the pig signallers shall be provided with an extension, suitable
for installation on the buried pipeline.
5.5.10 Proven history of succe:._;fulinstallations is mandatory requirement for the pig signaller.
A1 the materials of construction shall be selected in accordance with the selected design
and construction code of the pig trap / pipeline, and are to be indicated in the pig
signaller data sheet. QP may accept alternative material than what was specified in the
design code, subject to agreement, if they satisfy the other international practices.
Carbon steel materials used for all components shall be fully killed.
Tes specimens that have been subjected to the same heat treatment as the completed
vessel shall represent the respective material specifications. The term "heat treatment"
sha::also include any heating above the critical range for hot forming.
Aur tenitic stainless steel parts exposed to weather conditions of offshore installations
sha 1 be used only after obtaining a written approval from QP.
Attachments that are essential to the structural integrity shall be of material meeting the
tou;:hness requirements of the design code / ASME Sec II-A. Lightly loaded
attachments shall meet ASME Sec II-A requirements for a minimum design metal
temperature lower than minus 10 deg C.
Unl :ss otherwise specified in the data sheet or project specification, all the bolting shall
be ully threaded stud bolts with UNC series threads (8UN for bolt sizes 1" and above)
ma1 merial confirming to ASME SA320 Grade L7 and the nuts to ASME SA194 Grade 7,
del vered with charpy impact tested according to SA194 section S4.1. Nuts shall be SF
and heavy hexagon type. All the bolting and nuts shall be either hot spun galvanised to
AS TM A123 or to IS0 1461 to a DFT of 43 microns (with extra clearances provided on
the threads to allow for the coating thickness) OR alternately the bolting shall be
fluorocarbon coated to an approved specification OR alternately apply grease and
provide caps, with no galvanizing or coating. These details shall be discussed by the pig
g Supplier and included in data sheet 1 drawings for approval by QP.
s ~ :aller
Un.ess otherwise specified in data sheet or project specification, gaskets in 1500# and
higher shall be octagonal ring type R, material to Incoloy 825, soft annealed to obtain a
ma ltimum hardness of 155HB.
Elastomeric materials for ring seals shall resist explosive decompression and shall be
suitable for the long term exposure to the transported fluid at the design pressure and
temperature conditions. The cross-section of the seals shall not exceed 7mm diameter
for design pressure of 150barg and above.
Al! materials of the pig signaller shall be certified to minimum 3.1B certification
acc ording to BS EN 10204.
6.10 Where the pig signaller is for use in Sour service, the additional requirements of
document no. QP-STD-R-001 (,QP Technical Standard for Materials for Sour Service)
shr 11 be met for all the pressure retaining and load-bearing parts including end closure
C/F with its accessories. This includes meeting requirements of NACE MR 01-75 also.
Fabrication
A1 pressure-containing welds shall be full fusion, full penetration butt-welds.
Machined surfaces and all gasket contact surfaces shall be protected against scaling.
Fa ~rication,welding, weld repair, testing shall meet the requirements of the design code
of construction. Any repair work carried out shall be pre-approved and recorded. The
repair weld shall be re-examined by the originals method to ensure freedom from defects.
Tk e requirement for the pig signaller to be post-weld heat treated shall be determined in
I lesign, Manufacture, Testing and Supply of Pig Signaller (Intrusive Type)
ES.5.06.0014 Rev A
Page 8 of 17
Thn -aded connections shall not be used in any of the pressure containing components
exccpt when required to facilitate the removal of the internals of the pig signaller, in
whi ,h case a pre-approval shall be taken from QP. If used, threads shall be of NPT type
(tapx pipe threads) secured by a locking ring / pin or a retaining strip. The threads shall
be in accordance with ASME B1.20.1. Threaded connections shall have a gasket or an
O-ring above and below the thread.
Inspection and testing shall be performed before any paint or coating is applied.
All components shall be visually examined in accordance with ASME VIII, Division 1,
and Part UG-93. Visual examination methods shall be in accordance with ASME V,
Art zle 9.
A fmctional test shall be performed to demonstrate that the trigger mechanism trips the
met hanical indicator or the electrical switch.
Each weld shall be examined by 100% radiography. In addition, carbon steel welds shall
recc ive 100% magnetic particle examination and stainless steel welds (if any) shall
recc-ive 100% liquid penetrant examination. The above tests shall be in accordance with
AS V' IE V, with acceptance criteria per ASME VIII.
The assembled pig signaller, including the isolation valve, shall be submitted to a
hyc rostatic pressure test prior to any painting or coating. The test pressure shall be 1.5
tim:s the design pressure (at ambient temperature) stated on the data sheet or per the
rating class of the signaller - whichever is higher. The test pressure shall be held for a
per od of at least 4 hours. The acceptance criteria are no leakage or loss in pressure.
On y clean tap water with a chloride content not exceeding 200mgkg shall be used.
Autenitic stainless steel materials, if any used, shall be flushed with condensed or
derlineralised water to reduce the chloride content to 2mgkg if the pig signaller will not
be ~!riedimmediately after the completion of the hydrostatic pressure test.
Supplier shall state to what extent the spare parts and service assistance for the Supply
are available, as well as a list of contact perbonnel for normal wvicc i111dfur 24 hours
ser :ice must be provided, and included in the data book. The statement is to include for
an]. repair work or to replace critical and major components.
Spare gaskets and any such seal.ing devices shall be separately boxed, shipped with each
vessel, and clearly identified for future use / field installation.
The pressure housing of the pig signaller shall be stamped with the pressure class rating
as indicated on the data sheet. If sour conditions are specified, the signaller shall be
sta nped "SOUR SERVICE".
8.10 Witness inspection certificates shall be provided for dimensional checks, pressure test
and functional checks.
Design, Manufacture, Testing and Supply of Pig Signaller (Intrusive Type)
ES.5.06.0024 Rev A
Page 9 of 17
8.11 The pig signaller Manufacturer shall provide a user manual detailing the requirements
f o ~installation, inspection and preventive maintenance of the pig signaller. A list of
rec omrnended spare parts and details of the jaclung tool shall be also provided by the pig
signaller Manufacturer.
8.12 Su )plier shall be responsible for the technical integrity of the pig signaller complete with
its accessories, including design, materials, manufacture, assembly, testing, performance,
and for the engineering services. All these activities are to be in accordance with this
ES, data sheets, project I job specifications, applicable codes / standards, and interface
information. Neither anything contained in this ES nor the possible QP approval of
pkns, drawings, calculations, etc., shall relieve the Supplier from the said responsibility.
The Supplier shall also be responsible for the integrity of all items supplied by their Sub-
Su )pliers.
A list of required documents and other details should be agreed with the Supplier prior
to xder placement and shall be stated in the project specification.
a) Sectional drawings, material details and relevant calculations for pressure containing
parts.
b) Assembly drawing with overall dimensions and the interconnection drawings.
c) Welding, heat treatment, testing, inspection, installation, pre-commissioning &
commissioning procedures
d) Micro switch details, including cable connection details and cable specification
e) Quality control manual and Quality control plan.
Ar.y changes in design, material and method of manufacture shall be implemented only
after subsequent and specific approval of the Purchaser in writing.
The Purchaser reserves the right to conduct a Quality Audit at the Manufacturer and sub-
SU) lpliers facilities at any stage during manufacture.
Afler completion of the hydrostatic pressure test the pig signaller shall be dried
internally. All exterior and interior surfaces shall be dry and shall be free from grease or
oil, and shall be certified accordingly.
A1 external carbon steel surfaces except machined surfaces shall be cleaned, primed and
finish painted in accordance with the QP standard QP-SPC-L-002 (Specification for
Painting and Wrapping of Metal Surfaces, New Construction and Maintenance).
The equipment shall be suitably preserved to maintain in good condition throughout the
ph ses of storage until ready to be operated.
Surfaces of stainless steel items (if any used) shall be pickled and passivated.
Tk :. pig signaller shall be protected against damage and corrosion during transport and
stcaage. The transfer mechanics with the trigger outside the pressure housing shall be
Design, Manufacture, Testing and Supply of Pig Signaller (Intrusive Type)
ES.5.06.0024 Rev A
Page 10 of 17
pro~ectedby plastic covers. Machined surfaces (e.g. Flange faces) shall be suitably
treated (with substances like hard grease for easy removal at the time of installation) to
prevent corrosion, and protected against damage during transport, storage and
inst allation.
A corrosion resistant metal tag shall be permanently attached with each unit, with the
following marking, die stamped or deep engraved:
a) Project title
b) Manufacturer's name
c) Pipeline / Pipe Trap Size & Service
d) ASME Pressure Rating
e) Purchase Order and Item Number
f) Tag Number of the Pig Signaller
Se~~arate
or loose parts shall be completely boxed with identification tag.
Approval to Deviate
Str it compliance with this ES is required. Any deviation must obtain prior written
apy roval from the custodian.
GI1 Jssary
Within the context of this ES the following words shall have the meanings stated:
General definitions
'n ~ustlshall' Indicates a mandatory requirement.
'should' Indicates a preferred course of action / recommendation.
'r.lay' Indicates one acceptable course of action.
Purchaser The organisation responsible for carry out the purchasing function,
e.g. OP or a. QP appointed Contractor, Conwltant or Ayent.
Supplier or The supplier of materials or equipment - not necessarily the
\ endor Manufacturer.
Manufacturer 1 The company responsible for the manufacture - not necessarily the
Fabricator Supplier
"Data sheet" - The form where data can be filled in the standardized sheet, used while
pro ming a pig trap or a system or a component.
"Pi ;" - A device, which can be propelled through a pipeline by fluid flow and is
normally used for various internal activities such as separating fluids, cleaning, batching,
inspection or other activities.
"Pig signaller" - A device set onto or into a pipe which gives an indication of the
passage of a pig. This is also called as "sphere detector" or "pig alert".
"Pig trap" - An ancillary item of pipeline equipment comprising a barrel, end closure
anc instruments, for introducing a pig into a pipeline or for removing a pig from the
pipeline.
"Pig trap system" - A pig trap together with all associated piping, valves, supports and
ins mments.
"Piping" - Pipe work associated with the pipeline but not part of the main line.
"project or job specification" -. the specific procurement specification issued with the
requisition.
"Sl lhere tee" - A jacketed tee-piece with a perforated inner pipe allowing flow to enter
the side branch, but preventing entry of a sphere in the side branch.
- Engineering Standard
- Quality Assurance
- QP, Technical Services
The following standards, codes and specifications, to the extent specified herein, shall form
pa-t of this ES. Except where a specific edition or revision is identified by date or
revision/edition number, the edition in effect at the time of the contract shall govern.
Ns,tional/International Standards
B 4 1640 Part 3 - Carbon Steel Butt-Welding Pipe Fittings for Petroleum Industry
ASME B 16.20 - Metallic gaskets for Pipe Flanges - Ring Joint, Sprial-wound
and jacketed
NACE MR-01-75 - Sulphide stress cracking resistant metallic materials for oil field
equipment
A <ME SA 193 - Alloy steel & SS bolting materials for high temperature service
A <ME SA 194 - Carbon & alloy steel nuts for bolts, for high pressure and high
tempi'rature scrvice.
A {ME SA 320 - Specification for alloy steel bolting materials for low-
: Design, Manufacture, Testing and Supply of Pig Signaller (Intrusive Type)
ES.5.06.0024 Rev A
Page 13 of 17
temperature service
-+
Re J. No. Remarks
Design, Manufacture, Testing and Supply of Pig Signaller (Intrusive Type)
ES.5.06.0024 Rev A
Page 15 of 17
F otes:
1) XI(1) = Pig Signaller (Intrusive Type)
2) SR& SL= Minimum length equal to one length of the pig (usually intelligent pig)
3) This sketch shows both flanged and butt-weld end valves, for representation sake.
Design, Manufacture, Testing and Supply of Pig Signaller (Intrusive 'I'ype)
ES.5.06.0024 Rev A
Page 17 of 17
RELIEF
1 '4 VAL-
b-otes:
1) XI(1) = Pig Signaller (In~rusiveType)
2) SR& SL= Minimum length equal to one length of the pig (usually intelligent pig)
3) This sketch shows all flanged end valves, for representation sake.