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ASubsidiary of Kuwait Potroloum Corponrtion

STANDARDS PUBLICATION

STANDARD STANDARD

FOR

PIPELINE PIG TRAP SYSTEMS

DOC NO: KOC-MP-005

STANDARDS TEAM

Page 1 of 41 REV. 1

STANDARDS PUBLICATION

C STANDARD

FOR

PIP LINE PIG TRAP SYST MS

.NO. KOC-MP-005

STANDARDS TEAM

DOC. NO. KOC- MP-005 Page 2 of 41 II REV. 1

KOC STANDARD

FOR

PIPELINE PIG TRAP SYSTEMS

DOC.NO. KOC-MP-005

(Supersedes KOC Engg. Specification 015-IH-1006)

ISSUING AUTHORITY:

STANDARDS TEAM

29.05.12 Issued as Task Force


KOC Standard (TF-MP/19 )
Rev. Date Description Prepared by Snr. Engineer Standards '~. Team Leader Standards
Tel. No. 63693 Tel. No. 61407 Tel. No. 61151
Page 3 of 41 REV. 1

TABLE OF CONTENTS

FOREWORD 5

1.0 6

2.0 EXCEPTIONS 6

3.0 APPLICATION 6

4.0 TERMINOLOGY 6
4.1 Definitions
6
Abbreviations and Acronyms
9

5.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS 10


5.1 National/International Standards and Codes 10
5.2 KOC Standards, Recommended Practice and Specifications 12
5.3 KOC Engineering Group Specifications (015-Series) 13

6.0 GENERAL REQUIREMENTS 13

7.0 SYSTEM DESIGN 14


7.1 Code Break
14
Pig Trap
14
Wall Thickness Transitions
14
7.4 Design 14
7.5 Design Pressure 14
7.6 Design Temperature 14
7.7 External 15
7.8 Cyclic Requirements
15
Corrosion Allowance
15
10 NOT
15
7.11 Internal Lining 15
7.12 Trap Isolation Valve and Other 15
7.13 in the Mainline 15

8.0 PIG TRAP COMPONENTS REQUIREMENTS 16


8.1 Major 16
8.2 Minor Barrel (Neck Pipe) 16
8.3 Reducer 16
8.4 End Door 17
8.5 Pig Trap Nozzles
18
Kicker
19
Balancing (Equalizing) Line
19
8.8 Pressurizing 19
8.9 Blow-down I Vent Lines 20
8.10 Drain Connections
8.11 Purge Connections 20
8.12 Thermal and Pressure Relief Valves and Connection 20
8.13 Pressure Indicator (Gauge) Connection 21
8.14 Signallers (Pig Alerts)
8.15 Chemical Injection Connections 21
8.16 Earthing and Bonding Lugs
8.17 Lifting Lugs 22
Page 4 of 41 REV. 1

8.18 Saddle Supports 22

8.19 Loading and Unloading Arrangements 22

8.20 Catch (Drip at Closure Door


8.21 Skid Mounting

MATERIALS OF CONSTRUCTION 24

9.1 24

9.2 Materials for Trap Components

Materials for Quick Opening Door

10.0 FABRICATION AND WELDING 26

11.0 QUALITY ASSURANCE 28

12.0 QUALITY CONTROL AND INSPECTION


12.1 General

1 Materials 28

12.3 NOT 29

12.4 Closure 30

12.5 Functional Testing 30

12.6 Shop Testing 30

13.0 SURFACE PROTECTION AND PAINTING I COATING 30

13.1 External Coating 30

13.2 Internal Lining 30

14.0 DOCUMENTATION TO BY I MANUFACTURER


14.1

1 Deliverables 31

1 Skid Mounted Pig I Scraper Traps 32

15.0 NAME

16.0 PREPARATION SHIPMENT

17.0 SPARE PARTS 33

18.0 PACKINGA NO MARKING 33

APPENDIX 1: DATA FOR PIG


1: Code for Traps 37

2: Name Plate Pig Trap 38

Figure 3: Dimensions of Pig Trap and Nozzles 39

DOC. NO. KOC- MP-005 Page 5 of 41 REV. 1

FOREWORD

Pipeline pigging is a part of the pipelines operations. The applications of pigging


are needed during construction, operation, inspection, maintenance and repair, during
rehabilitation and decommissioning. To facilitate these activities, pig traps (launchers and
receivers) are needed to be installed at the start and destination points of the pipeline or at
intermediate points where pipe diameter is changed.

This KOC Standard KOC-MP-005 supersedes and replaces the KOC Specification No. 015
IH-1006, which is now withdrawn.

This Standard KOC-MP-005 out to facilitate the following objectives:

a) pipeline filling and dewatering using pigs;

b) pipeline drying, purging, batching;

c) pipeline gauging using gauging plates and/or caliper pigs;

d) implement internal corrosion control of the pipeline;


e) periodic removal of sludge/liquid build-up in line;
f) inspecting the pipeline using smart pigging tools;
g) hydrostatic test for proof of pipeline integrity;
h) performing internal cleaning, passivation and lining;
i) pipeline mothballing;
j) isolation of the pipeline at any point using plugging, stopplings and other
technologies.

Feedback as well as any comments or suggestions from the application of this Standard at
any stage are encouraged and should be directed to:

The Team Leader Standards


(Chairman, Standards Technical Committee)
P.O.Box-9758, Ahmadi 61008
State of Kuwait

The preparation of this Standard has been entrusted by the Standards Technical Committee
(STC) to the Task Force No. (TF-MP/19) comprising of the following members:

Mr. Mohd. Insp. & Corr. (S&E) Task Force No. 63693
Leader/Author
Mr. Santanu Bandyopadhyay Gen. Projects Team Member Tel. No. 61584
Mr. Shabbir Safri & Corr. (S&E) Member No. 61
Mr. Shaya AI-Hajri Opns. Team (N&W) Member Tel. No. 3820270
Mr. Sulaiman AI-Foodari Major (V) Member Tel. No. 61026
PageS of 41 1

1.0

1.1 Standard "KOC-MP-005" specifies the minimum KOC requirements for design,
materials, manufacturing, inspection, testing and supply of pig trap systems for onshore
and offshore pipelines having a diameter of 100 mm to 1500 mm (4 to 60 inch).

1.2 The pig traps supplied to this Standard shall suitable for including
hydrocarbons (crude oil, gas, condensate, etc.) and other services (water, C02, etc.).

1.3 This Standard supplements ASME A, and ASME 831 for pipeline
transportation systems and deSign requirements contained in other KOC Pipeline
Standards. Standard is for permanent and portable pig trap systems.

EXCEPTIONS

This Standard does not apply to:


(a) Offshore underwater launchers and receivers.
(b) launcher valves where pigs can loaded into side the
(c) Temporary launching and receiving facilities including traps employed during
construction that are subject to approval by KOC I project authorities
(Refer to 6.3 for guidance).

3.0

3.1 This KOC Standard is intended to guide the purchaser in the use or creation of a
purpose specification for enquiry or purchasing activity. Data shall be prepared by
the Controlling Team and lor purchaser to provide the specific requirements which
shall be attached to this Standard. A typical data sheet format is provided in Appendix 1
of this Standard.

Compliance with this Standard shall relieve the Contractor of its responsibilities to
supply equipment suited to the specified service conditions and contractual
requirements.

3.3 Where conflict exists between this Standard and drawings, codes, standards and
specifications, subject shall be addressed to KOC Controlling Team resolution
otherwise the stringent requirement shall apply.

4.0

4.1

4,1.1 Use of Language

Throughout this documents, the words "shall", "shOUld" , and "can", when used in
the context of action by KOC and/or by others, have specific meanings as follows:

"Shall" indicates a requirement: It is to indicate requirements strictly to be


followed in order to conform to document and from which no deviation is
7of41 1

"Should" indicates a recommendation: It is used to that among


possibilities one is recommended as particularly suitable, without mentioning or excluding
others, or a certain course of action is preferred but not necessarily required, or that
(in the negative form, 'should not') a certain possibility or course of action is deprecated
but not prohibited.

"May" . It is used to a course of action permissible within


the limits of the document.

"Can" indicates possibility and capability: It is statements of possibility and


capability, whether physical or

4.1.2 Company

The Kuwait Oil Company (KOG)

4.1.3 Controlling Team

Any KOC Team authorized to initiate a request for procurement of material and I or
equipment a KOC project, or any KOC Team that manages and/or controls a KOC
project.

1.4 Factor

Factor applied to hoop stress when calculating the wall thickness or pressure

4.1 Design

Time period for which a pipeline Trap is to be used for intended purpose with
planned integrity management

1.6 Piggable

Capable of passing a pig.

4.1.7 Pig Trap I Scraper Trap

Device allowing entry to a pipeline for the launching and receiving of pigs, inspection
tools and other equipment to be run through the pipeline. Pig Trap is named as Pig
Launcher and trap, Launcher/Receiver and Scraper Trap, all have the
same meaning.

1.8 Pig

propelled through a pipeline by fluid pressure, for cleaning, swabbing, gauging,


or batch etc.
DOC. NO Page 8 of 41 REV. 1

4.1.9 Batching Pig

A utility pig that forms a moving seal in a pipeline to separate liquid from gas media, or
to separate two different products being transported in the pipeline. The most-common
configurations of batching pigs are cup pigs and sphere pigs.

4.1.10 Cleaning Pig

A utility pig that uses cups, scrapers, or brushes, to remove dirt, rust, mill scale, or other
foreign matter from the pipeline. Cleaning pigs are run to increase the operating
efficiency of a pipeline or to facilitate inspection of the pipeline.

4.1.11 Configuration Pig

An instrumented pig that collects data relating to the inner contour of a pipe wall or of
the pipeline. Geometry pigs, camera pigs, and mapping pigs are types of configuration
pigs.

4.1.12 Cup Pig

A utility pig that is supported and driven by cups made of a resilient material such as
neoprene or polyurethane. At least one of the cups forms a piston-like seal inside the
pipe.

4.1.13 Gauging Pig

A utility pig that is permanently deformable by obstructions in the pipeline and thus,
upon retrieval from the line, provides evidence of the worst-case obstruction in a given
pipeline segment.

4.1.14Gel Pig

A utility pig that is composed of a highly-viscous gelled liquid. These pigs are often used
for pipeline cleaning and are sometimes called gelly pigs.

4.1.15 Geometry I Caliper Pig

A configuration pig designed to record conditions, such as dents, wrinkles, ovality, bend
radius and angle, and occasionally indications of significant internal corrosion, by
making measurements of the inside surface of the pipe.

4.1.16In-line Inspection (Ill)

The inspection of a pipeline is done from the interior of the pipe using an in-line
inspection tool.

4.1.17In-line Inspection Tool

The device or vehicle, also known as an 'intelligent' or 'smart' (Ill tool) pig, that uses a
non-destructive testing technique to inspect the wall of a pipe. An in-line inspection tool
is one type of instrumented tool.
Page 9 of 41 REV. 1

4.1.18 Instrumented Pig

A vehicle or device used for internal inspection of a pipe, which contains sensors,
electronics, and recording or output functions integral to the system. Instrumented pigs
are divided into two

(1) configuration pigs, which measure the pipeline geometry or the conditions of the
inside surface of the pipe; and

(2) in-line inspection tools that use non-destructive testing techniques inspect the wall
of the pipe for corrosion, cracks, or other types of anomalies.

4.1.19 Mapping Pig

A configuration pig uses inertial sensing or some other technology to collect the data
that can be analyzed to produce an elevation and plan view of the pipeline route.

1.20 Sphere Pig

Spherical utility pig made of rubber or polyurethane. The sphere may be solid or hollow,
filled with air or liquid. The most-common use of sphere pigs is as a batching pig.

1.21 Utility Pig

Pig that performs relatively-simple mechanical functions, such as cleaning the pipeline.

(Note: Not all the of pigs mentioned above are used in KOC Also some
are not directly related to this Standard. They are provided only for information).

4.2

API American Petroleum Institute


ASME American Society of Mechanical Engineers
ASNT American Society for Non-Destructive Testing
ASTM American Society for Testing and Materials
BS Booster Station
GC Gathering
Dry Film Thickness
III In-Line Inspection
ISO International Organization for Standardization
KOC Kuwait Oil Company
MAOP Maximum Allowable Operating Pressure
Magnetic-Flux I-IJC:;!I'\CII.IIJ
MIG Metal Inert
MT Magnetic Testing
NACE National Association of Corrosion Engineers
NDT Non-Destructive Testing
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RF Raised
RT Radiographic Testing
Page 10 of 41 REV. 1

Ring Type Joint


SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
SMYS Specified Minimum Yield Strength
TIG Tungsten Inert Gas (known also as GTAW)
UT Ultrasonic Testing

5.0

The latest version of the following standards, codes and specifications shall apply.

5.1 National/International Standards and Codes

API5L Specification for Line Pipe

API Standard on Impertection Terminology

API6H Specification on Closures, Connectors and Swivels

ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24.

ASME B16.9 Factory-Made Wrought Butt-welding Fittings

ASME B16.20 Metallic Gaskets for Pipe

ASME 6.47 Large Steel NPS 26 Through NPS 60

ASME B31.3 Process Piping

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and


Other Liquids

ASME B31.8 Gas Transmission and Distribution Piping Systems

ASMEV Non Destructive Examination

ASME VIII Div. 1 Rules for Construction Vessels

ASME IX Welding and Brazing Qualifications

ASTMA36 Standard Specification for Carbon Structural

ASTM A105 Standard Specification for Carbon Forgings for Piping


Applications

ASTM A1 Standard Specification for Forged or Rolled Alloy and


Stainless Steel Pipe Flanges, Forged Fittings, and Valves and
Parts for High-Temperature

ASTM A216 Standard Specification for Steel Carbon, Suitable


for Fusion Welding, for High-Temperature Service
Page 11 of 41 REV. 1

ASTM A234 Standard Specification for Piping Fittings of Wrought Carbon


and Alloy for Moderate and High Temperature
Service

ASTM A350 Standard Specification for Carbon and Low-Alloy


Forgings, Requiring Notch Toughness Testing for Piping
Components

ASTM A388 Standard Practice for Ultrasonic Examination of


Forgings

ASTM A516 Standard Specification for Pressure Vessel Plates, Carbon


Steel, for Moderate- and Lower Temperature Service

ASTM A537 Standard Specification for Pressure Vessel Plates, Heat


Treated, Carbon Manganese-Silicon Steel

ASTM A578 Standard Specification for Straight-Beam


Examination of Rolled Steel Plates for Special Applications

ASTMA662 Standard Specification for Pressure Vessel Plates, Carbon


Manganese-Silicon for Moderate and Lower
Temperature Service

ASTM A694 Standard Specification for Carbon and Alloy Steel Forgings for
Pipe Flanges, Fittings, Valves, and Parts for High-Pressure
Transmission Service

ASTM A707 Standard Specification for Forged Carbon Alloy Steel


Flanges for Low-Temperature Service

ASTMA860 Standard Specification for Wrought High-Strength Low-Alloy


Butt-Welding Fittings

AWS 01.1 Structural Welding Code

BS 10160 Ultrasonic Testing of Steel Flat Product of Thickness Equal or


Greater Than 6 mm (Reflection Method)

BS PO 5500 Specification for Unfired Fusion Welded Pressure Vessels

EN 10168 Steel products Inspection documents - List of information


and description

10204 Metallic products - Types of inspection documents

ISO 10893-8 Non-destructive testing of steel tubes -- Part 8:


Automated ultrasonic testing of seamless and welded
steel tubes for the detection of laminar imperfections
MSS SP-44 Steel Pipeline Flanges

MSS Quality Standard for Steel Castings and Forgings for


Flanges, and Fittings and Other Piping Components
Page 12 of 41 REV. 1

MSS Quality Standard for Steel Castings for Valves, Flanges,


Fittings, and Other Piping Components - Visual Method for
Evaluation of Irregularities

MSS Specification for High Test, Wrought, Butt-Welding Fittings

MSS SP-97 Integrally Reinforced Forged Branch Outlet Fittings

Socket Welding, Threaded, and Butt-welding

NACE MR 0103 Materials Resistant to Sulfide Cracking in Corrosive


Petroleum Refining Environments

NACE MR 01751 Petroleum and Natural Gas Industries - Materials for in


H2S-Containing Environments in Oil and Gas Production
ISO 15156

NACE TM 0177 Standard Test Method - Laboratory Testing of Metals for


Resistance to Sulfide Stress Cracking and Stress Corrosion
Cracking in H2S Environments

NACE TM 0187 Standard Test Method - Evaluating Elastomeric Materials in


Sour Environments

NACE TM 0284 Standard Test Method - Evaluation of Pipeline and Pressure


Vessel for Resistance to Hydrogen-Induced Cracking

SNT-TC-1A ASNT Recommended Practice, Personnel Qualification and


Certification in Nondestructive Testing

KOC Standards, Recommended Practice and Specifications

KOC G-004 KOC Standard for Packing, Marking and Documentation

KOC-G-007 KOC Standard for Basic Design Data

KOC-G-009 KOC Standard for Spare Parts and Maintenance Data

KOC-G-012 KOC Standard for Plant Equipment Identification Nameplates


and Pipeline Markers

KOC-MP-010 KOC Standard for Piping Material

KOC-M KOC Standard for Pressure Relief Devices: 1: Design


Pt.1 and Materials

KOC-MP-027 KOC Recommended Practice for Pressure Relief Devices:

Pt.2 Part Sizing, Selection, Twinning and Installation.

KOC-MS-001 KOC Material Specification - Line Pipe for Sour Service

KOC-MS-004 KOC Standard for Sour


Requirements (under
preparation)
Page 13 of41 1

KOC-P-001 KOC Standard for Painting and Coating of External Metal


Surfaces

KOC-P-005 KOC Standard for Internal Coating of Pipelines

KOC-Q-014 KOC Standard for Project QAlQC Requirements

Under preparation Structural Skids and Base Plates for Packaged Equipment

5.3

015-WH-1003 Inspection of Castings for Service

KOC Drawing Earthing of vessels and exchangers


NO.55-07-21

6.0

6.1 Pig traps shall be required to be installed permanently KOC pipelines when the
following conditions are during the of the pipeline.

(a) To facilitate pipeline filling and dewatering using pigs (1);


(b) To facilitate pipeline drying, purging and commissioning;
(c) To facilitate pipeline gauging using gauging plates and/or caliper pigs (1);
(d) To implement internal corrosion control of pipeline;
(e) To facilitate the periodic removal of liquid build-up in the line;
(f) inspecting the pipeline using smart pigging tools;
(g) To facilitate the hydrostatic for revalidation of pipeline integrity;
(h) To enable KOC in performing internal cleaning, passivation and lining (1);
(i) To facilitate pipeline mothballing (1);
G) To facilitate isolation of the pipeline at any point using plugging, stopplings
and other technologies (1).

Note (1): These ""roTIII""'" may performed using temporary pig that have been
approved by KOC.

6.2 Unless otherwise specified in the Contract documents, the design life of the pig trap
system shall 30 All pig trap systems for sour hydrocarbon fluids shall be
suitable for "sour and tested to the appropriate standards as detailed in this
Standard.

6.3 Unless otherwise waived by KOC, the temporary pig traps required the construction
or service activities a new or existing pipeline may be manufactured on the basis of
the requirements of this Standard. All details such temporary traps shall subject to
KOC approval (design, materials, fabrication, welding, inspection, NOT, testing,
installation, operation, etc.).

6.4 Except for offshore applications, the Pig Trap /Scraper Trap shall be designed
for bi-directional pigging whether or not permanent facilities exist for pumping in both
directions and whether or not the source of propelling fluid may be available either
end of the pipeline.
DOC. NO. KOC- MP-005 Page 14 of 41 REV. 1 I
I

6.5 "
Pig Trap / Scraper Trap stations shall be designed for on-stream scraping (while normal
operation of the pipeline) at the flow rate which corresponds to the maximum
recommended pig velocity, unless the fluid ahead of the pig is to be diverted to a side
stream .

6.6 Pig Trap / Scraper Trap (launching and receiving) for onshore operations shall be
horizontal. Scraper traps for launching from offshore installations shall be of the vertical
type. Pig Trap /Scraper Trap for offshore receiving shall be horizontal type .

6.7 Pig traps should be oriented to allow adequate space (about 6.0 meters), and facilities
should be provided to open the closure and load/unload pigs. The layout and alignment
of pig traps shall be such that other facilities are not sited immediately behind pig trap
doors.

6.8 Pig traps /Scraper Traps including end closure and all other associated components
shall be suitable for continuous operation at desert location under high ambient
temperature and humidity. (Refer to basic design data as per KOC Standard KOC-G
007).

7.0 SYSTEM DESIGN

7.1 Code Break

The pig trap system shall be designed , constructed and tested according to the same
code as the pipeline with the design code break between pipeline code (ASME
831.4/ASME 831 .8) and ASME 831 .3 as shown in Figure (1) of this Standard. This
figure only shows the code break and does not represent schematic of ,Pig Trap
System.

7.2 Pig Trap Doors

Pig trap doors shall be designed to ASME VIII Div. 1 clause UG 35 .2, Appendix 24 and
Appendix FF as applicable, with safety features as provided in clause 8.4 of this
Standard.

7.3 Wall Thickness Transitions

Wall thickness transitions shall meet the welding configuration requirements as


specified in ASME 831 .8 and ASME 831.4 as applicable. Refer also to clause 10.14 of
this Standard .

NOTE: This is particularly important if flanges are to be used in thin walled high grade mainline
pipe sections and might have to be made of high grade material.

7.4 Design Factor

Design factor to be used in calculating the wall thickness of pig trap assembly shall not
be greater (numerically) than 0.6. This includes trap assembly and piping. The intention
is to achieve thicker wall components for higher safety margin.
Page 15 of 41 REV. 1

7.5 Design Pressure

Design pressure of the pig trap system shall not be less than that of the respective
pipeline.

7.6 Design Temperature

Design temperature shall not be less than the respective pipeline maximum design
temperature. Unless otherwise specified in the data sheets, the purchase order or other
project documents, the minimum design temperature shall be the lesser of - 3C (as per
KOC-G-007 "KOC Standard for Basic Design Data") or the minimum pipeline design
temperature. For depressurization/blowdown of pig traps in gas and gas condensate
services, the design temperature shall take into consideration the minimum metal
design temperature that could be reached due to depressurization/blowdown.

7.7 External Loads

Pig trap, supports, anchor bolts etc. shall be designed to resist all external loads such
as wind, seismic loads, platforms, davits, all attachments, connected pipe work etc.
External loads imposed by connected pipework on the nozzles shall also be considered
in the design of the trap.

7.8 Cyclic Requirements

Fatigue from possible cycling loadings (due to frequent pigging operations) requires
fatigue analysis. Additionally the loads from winds, supports, seismic loads, loads at
lifting lugs and during transportation shall be considered.

7.9 Corrosion Allowance

Corrosion allowance of the pig trap assembly shall be the same as per the respective
pipeline. For carbon steel materials, the minimum corrosion allowance shall be 3.2 mm
(1/8").

7.10 NOT

All pig trap assembly shall be 100% examined using X- radiography. Welds other than
butt type which cannot be radiographed shall be 100% examined using ultrasonics and
lor MPI. (Refer also clause 12.0 of this KOC Standard).

7.11 Internal Lining

When so specified in the data sheet, project specifications or the purchase order,
internal lining for corrosion protection shall be applied at the inner surfaces of the
scraper trap (Refer to clause 13.2 of this Standard).

7.12 Trap Isolation Valve and Other Valves

Trap isolation valve shall be of the full bore, tight shutoff, double block and bleed and
having nominal size as the pipeline. Isolation valves in kicker lines, balancing lines,
pressurizing lines, drain lines, chemical injection, vent and blow down lines shall be of
the tight shutoff type.
II DOC. NO. KOC- MP-005 II Page 16 of 41 Jl REV. 1

7.13 Tees in the Mainline

Tees in the mainline shall be barred as per KOC drawing number 55-04-72 . The
distance between the centerline of the branch and the near end of the trap isolation
valve shall be kept to a minimum; and if more than three (3) pipe diameters, it shall be
sloped back to the branch .

8.0 PIG TRAP COMPONENTS REQUIREMENTS

The basic trap components are the major barrel, end closure ,reducer, minor barrel
(neck pipe), branch nozzles, kicker line, balance line, pressurizing line, drain, vent,
blowdown, thermal or pressure relief valve, pressure indicator (gauge) , pig signalers,
supports, lifting lugs, earthling (grounding) lugs, sliding trays.

8.1 Major Barrel

8.1.1 The major barrel 's nominal diameter shall be 4" (100 mm) larger than the pipeline's
nominal diameter. Fig .2 of this Standard provides the KOC preferred dimensions of the
various Trap components. Any justified proposal to deviate from Fig.2 shall be subject
to KOC approval.

8.1.2 The barrel length shall be as per Fig .3 of this Standard and shall be suitable for
launching and receiving conventional cleaning pigs as well as all types of intelligent
pigs. Specific pipeline's design may require longer barrels. This shall be highlighted in
the data sheet, the purchase documents or the Vendor (Manufacturer) proposal.

8.1.3 For horizontal launcherslreceivers the barrel may be sloped to maximum 3 0 down
towards the end closure to improve draining of liquids from the barrel.

8.1.4 Irrespective of the wall thickness design calculations, the major barrel and minor barrel
shall not have final thickness less than 0.375 inch (9.5 mm) .

8.2 Minor Barrel (Neck Pipe)

8.2.1 The length and diameter of the neck pipe (minor barrel) shall be as per Fig . 3 of this
Standard .

8.2.2 The internal diameter of the minor barrel (neck pipe) shall be the same as that of the
main line . If the wall thickness of the neck pipe is 0.1" (2 .5) mm greater than the main
pipeline, a transition in the internal diameter shall be tapered to a maximum angle of
0
14 to the pipe axis to allow the smooth passage of a pig .

8.3 Reducer

8.3.1 The reducer between the barrel and neck pipe (minor barrel) shall be eccentric for
horizontal traps (with the bottom of the entire barrel at the same level) . For vertical
traps, the reducer shall be concentric.

8.3.2 Reducer's nominal wall thickness shall be at least equal to the specified nominal wall
thickness of the matching pipe (having the same SMYS) at the large and small ends.
Page 17 of 41 REV. 1

8.3.3 Concentric and eccentric reducers shall be as per ASME or MSS type.
Reducers shall have smoothly curved transitions and parallel ends.

8.3.4 Material of construction shall be generally from the materials specified in


Table-1 to the service conditions and shall be as specified in the Data

8.4 End Closure Door

8.4.1 The end closure shall be of the quick acting type, lever or hand wheel operated
hinged vertically. All locking components shall completely visible, both in the open
and closed position. locking mechanism shall be of the band lock or clamp
mechanisms. Screwed type end closures are not permitted for all services. C
clamp type quick closure with bolt tightening from both sides of door is not
permitted.

8.4.2 quick acting design should allow opening and closing by one (1) man in
approximately one (1) minute, without the use of additional devices.

8.4.3 The closure shall be designed such that the closure cannot opened while pig
is pressurized. A sequential key interlock arrangement with main pipeline valve,
kicker line valves, drain vent valves shall be provided. Consideration is required
for a design the opening mechanism; specifically the failure of any part of
the opening mechanism shall the door rather than open. Details of the
requirements shall be specified in the Contract and/or Order.

8.4.4 The end closure shall conform to the requirements of ASME VIII Division 1 clause
(quick actuating closures). ASME U-stamp is not required for the closure.
Closures be of the welded end type.

Closure doors shall be supported by adjustable hinges or adjustable davit. The direction
of view for determination the hinge position for horizontal is from the closure
of trap. hinge position shall be on the left-hand unless otherwise
specified in the Purchase Order.

8.4.6 Closure Seals

(a) Closure seals (seal type, dimensions and material) shall proposed at of
quotation and prior to fabrication. Proposed seals shall be resistant to degradation
from the fluid the design temperature. It shall also be decompression
resistant.

(b) Closure seals shall Chevron type or equivalent self-energizing type O-ring
seals having a groove configuration or design prevent O-ring slipping during
the door closure are acceptable

(c) O-ring shall submitted for prior review and approval by KOC.

(d) activation of the seals be such that fluid within the pig trap any
pressure between one (1) bar (abs) and the pig trap design pressure is sufficient for
Page 18 of 41 REV. 1

Closures for installation on vertical scraper traps shall suitably by


counterweights where to limit lifting weight in normal operation to kg
maximum. Other means may be provided for convenient operation subject to prior
approval by KOC.

8.4.8 will require mechanical the when opening


the door and compress the seal when closing the door. All required tools shall
included in the delivery and suitable attachment lugs for the tools shall be provided
where nec:es!;a

8.4.9 Closure Safety: The closure locking mechanism shall provided with a pressure
warning safety interlock device which must be opened before closure mechanism
can unlocked. Closing of pressure warning safety interlock shall not possible
until the closure locking mechanism is fully engaged and locked. The non-bleed type of
warning device is preferred in toxic or sour fluid design shall
ensure that the hinges and locking mechanism are sufficiently robust to withstand
use.

8.4.10 Instruction plate made of stainless 316 shall be fitted end closure with
permanent marking stating brief instructions for the safe operation of the closure.

8.5 Pig Trap Nozzles

8.5.1 Nozzles at pig trap shall be of the welded, forged or extruded type. The type of
nozzle connection shall conform to the applicable design All shall be of
the flanged type and shall not be than nominal size. Ring joints shall the
design requirements and ASME 816.20 standard.

8.5.2 Reinforcing pads required by applicable code shall be fully welded and shall be
provided with a 3-6 mm "Tel-Tale Holes". The tapped hole shall be filled with heavy
before shipping.

8.5.3 trap shall be provided with the as per 3 of this Standard (Sizes shall
be as per design requirement).

Nozzle flanges shall have raised face conforming to ASME 6.5 (for 24" and
below), ASME 6.47 Series-A (for sizes above 24") and MSS (for 22" nozzles
and when connecting flanges to X-grade pipelines).

8. If pig trap is be installed an existing pipeline with flanges made to a different


standard, the new on the pig trap shall match the standard of the existing flange,
as specified in Data Sheet I Project Drawing.
. NO. KOC- MP-005 19 of 41 REV. 1

Table 1 : Nozzle

of Items Numbers of

Two numbers on major barrel

Two numbers (One on major barrel one


on minor barrel)
---
Two numbers (One on major barrel and one
/ Balancing
on minor barrel)

4 Vent I Blow-down Line One on barrel near the end

Thermal I Relief
5 One number on major barrel
Valve

6 Purge Connection One on minor barrel near main valve)

Two numbers (one on the major barrel and


7 Pressure
one on minor barrel)

8 Pig Signaler One number on

9 Water Flushing

10 Other Nozzles As in the data and other i

project drawings and order (e.g.


chemical injection).

11 Additional vent connection 8.9.3 of this

8.6 Kicker Lines

8.6.1 the KOC mandatory requirement is bi-directional Pig (Scraper Trap)


twin (two) Kicker shall be provided. special pipeline design (e.g. offshore
pipelines) requires a uni-directional trap system, then only one kicker line shall
provided.

kicker line connected as possible to the


closure (for launching). For the second it shall be as
as possible to the reducer (for receiving).

Kicker connections not be located 6 o'clock position.


DOC. NO. KOC- MP-005 II Page 20 of 41 I REV. 1

8.7 Balancing (Equalizing) Line

8.7.1 Balancing (equalizing) line shall be provided to enable filling and depressurization of the
barrel on both sides of the pig at the same time . It also prevents any possible pressure
differential across a received pig . Balancing line nozzles are required on both the
launcher and receiver traps .

8.7.2 The balancing line shall be connected to the minor barrel as close as possible to the pig
trap valve and also be connected on the major barrel as close as possible to the closing
door.

8.7.3 Size of the balance line shall be as per the pig trap dimensions Figure (3) of this
Standard.

8.8 Pressurizing Line

8.8.1 Pressurizing line should be provided around kicker valve to assist the speed of
operation, to control the barrel pressurization and to avoid damage to the kicker valve
seats or other internals. Pressurizing line around bypass valves should also be provided
for equalizing possible high differential pressures.

8.8.2 Pressurizing line size should be smaller than the balancing line size but not less than 2"
nominal diameter.

8.9 Blow-down I Vent Lines

8.9.1 For gas systems, 2" or larger (Refer nozzle N3 in Figure 3) nominal diameter blOW-down
line shall be provided at the major barrel for controlling depressurization. Provision of
plug valve, globe valve or restriction orifice should be considered . For gas systems, a
vent line shall be branched at upstream side of the blow-down isolating valve. Another
vent line shall be provided at the minor barrel near the trap neck end flange to ensure
depressurization behind the pig in case it becomes stuck in the Minor Barrel (neck
pipe).

8.9.2 For liquid systems, two (2) vent nozzles shall be provided, one at the major barrel and
the other at the minor barrel to ensure depressurization behind the pig in case it
becomes stuck in the minor barrel (neck pipe).

8.9.3 BlowdownNent lines shall be connected to the blowdown/flare system where available;
otherwise the vent discharge shall be routed to a safe location at a height of about 3.0
meters from ground level and be provided with bug screen at the vent outlet. Where
venUblowdown lines are connected to a flare header, additional vent connection shall
be provided on the major barrel for final depressurization to atmospheric pressure.

8.10 Drain Connections

8.10.1 Drain points shall be provided on both launchers and receivers near the end closure
and on the neck pipe near the end flange to drain any liquid accumulated in the barrel.

8.10.2 For vertical launchers a single drain point shall be provided on the neck pipe near the
end flange. The size of the drain nozzles shall be as provided in Figure 3 of this
Standard .
Page 21 of 41 REV. 1

8.11

(1) purge connection shall be provided near the end at highest


Another one (1) to be on the minor near the main valve. Each
connection shall have one isolation valve and one check valve with blind flange.

8.12 Thermal and Pressure Relief Valves and Connection

8.12.1 A relief valve be installed shut-in of trapped fluid could


exceed the design as a result of expansion of static fluid.
are not normally required for or multiphase pipelines, but should
liquid pipeline systems.

8.1 relief valve capacity and setting shall comply with the pipeline code
and 520/API as applicable. Valve shall determined on the
governing case (Fire blocked outlet, thermal expansion). Respective on
the trap shall match the valve

8.1 If specified in the data sheet, purchase order or other technical a pressure
relief valve shall provided and shall sized for case. Relief shall meet
the requirements of KOC-MP-027, Pt.1 & 2.

8.13 Pressure Indicator (Gauge) Connection

8.1 1 Pressure indicator connections shall installed at following locations:

(a) On the major barrel near the end


(b) On the minor barrel near the end flange;
(c) On bypass line on pipeline side of the bypass valve.

8.1 The diameter of pressure indicator connections shall be 2", although isolation
may be reduced diameter.

8.13.3 Piping shall include instrument that allow change-out of the


gauge without depressurizing the pig trap.

1 The pressure should clearly visible the operator from the end
activation point.

8.14

1 1 Two (2) signallers shall installed one on side of


purpose of signallers is provide confirmation that the pig been successfully
launched from the launcher or ''''''';>1\/'''''' at the and has successfully passed
through the pig trap valve.

8.14.2 For launchers, the signaller on the downstream side of pig trap valve should be
located on pipeline at a distance from main tee of the length of the
maximum length pig to be This Signaller will confirm that successfully
passed both pig trap valve and main tee.
Page 22 of 41 REV. 1

8.14.3If an ESD valve is installed in the mainline the launcher location, this signaller
moved downstream of the by a distance of at least the maximum
to confirm that the pig has through the ESD valve.

8.14.4 For receivers the signaller located on should be at a from


pig trap valve of at least the length pig to be used.

8.1 Pig signallers may be of the or of the non-intrusive type. The


latter are preferred in certain as toxic and unstable fluids or where
pigging is infrequent. Limit provided for the pig signallers for remote
indication if specified in data

8.14.6 Set-in mechanical signallers may or indirect (magnetic) mechanisms.


Isolation valve shall be installed under the to allow removal under pressure.

5 Chemical Injection Connections

When chemical injection is required, as in the purchase order or data sheets,


a flanged connection or proprietary fitting with an isolation valve shall be provided. The
connection should be located on the bypass line between the isolation valve and the
kicker line tee.

8.16

Earthing connections shall be provided to


drawing No. 55-07-21 (Earthing of Vt-!!-iSt-!1
The details shall be provided by

8.17

on the pig trap assembly lifting of the complete


installation stage.

8.1 Trap Assembly, four (4) Nos. lifting lugs shall be provided on the
lifting of the skid assembly, in addition to the lifting lugs on pig trap. The
to handle the total weight of the skid including pig trap,
and other equipment with a design factor as specified in 8.1

8.17.3 All lugs for 1.5 times the weight of the trap assembly I skid.

8.18

8.18.1 Adequate shall be provided for each trap with bolt


to the . . . ,...~,,+'" foundation and shall allow for some longitudinal
assembly in sliding supports shall be provided

8.18.2 The design of shall be based upon the combined loading


assumed full of together with the maximum weight of any pig
(instrumented pig) piping External load shall be considered for deSign of the
support.
il DOC NO KOC- MP-005 II Page 23 of 41 REV. 1
II

8.18.3 Saddle Supports shall be designed, fabricated and attached to traps by means of
appropriate welds to meet the requirement of BS PD 5500 clause G.3.3.2 and figure
G.3.3-7 of the same.

8.18.4 Unless otherwise speci'fied in the contract or dictated by the detailed engineering, the
bottom line of trap shall be at least one meter (1.0 m) above the finished grade level or
top of skid level for skid mounted pig traps.

8.19 Pig Loading and Unloading Arrangements

8.19.1 Pig loading and unloading arrangements shall be supplied for traps with the pipeline
size of 12 inches and larger.

8.19.2 The equipment shall be furnished with cradle unit to suit pigs and corresponding
scraper trap barrel sizes as specified in the purchase order or data sheet.

8.19.3 The equipment shall facilitate pig inserting into the full length of launching barrel and
retracting from the full length of receiving barrel.

8.19.4 The equipment shall include a Jib Crane system to facilitate pig handling. The
ContractorNendor shall submit deSign, fabrication, installation and inspection/testing
details including SWL for KOC review and approval.

8.19.5 The jib crane shall be suitable for operation at desert location under high ambient
temperature and humidity as specified in KOC Standard KOC-G-007.

8.20 Catch Pit (Drip Pan) at Closure Door

8.20.1 For skid mounted trap assembly, the skid shall include a drip pan underneath the
closure and a drip pan underneath the skid as integral parts of the skid.

8.20.2 The drip pan shall have a slope of 1 inch in 10 feet.

8.20.3 The drip pan shall have a 2-inch, class 150, flanged drain connection.

8.20.4 The drip pan and skid shall extend beyond the pig trap closure a minimum of 150 mm
(6-in.).

8.20.5 The drip pan drain shall be positioned as low as practical.

8.20.6 For launchers/receivers wrlich are purchased without a skid or drip pan and which will
be installed directly on concrete foundation at Site, a containment concrete pit shall be
constructed underneath the closure door. The containment area shall drain into the
drain system of the pig trap area.
Page 24 of 41 REV. 1

8.21 Skid Mounting

8.21.1 When skid mounting is specified in the Contract, order or data sheet,
the skid shall and fabricated in with KOC Specification
"Structural Skids Plates for Packaged and shall have
following

The Vendor shall dynamic forces, as well as forces, when designing


the skid.

The skid adequate structural support the pig trap and other
to transmit the forces to the foundation.

The skid shall be with sufficient stiffness and so the trap assembly
can be mounted leveled with no bending or twisting.

Skid layout and shall be such that access is not


hindered. Access ladders platforms shall also be provided.

Structural steel for of skid shall new, quality and


traceable to chemical and mechanical properties. Material test (MTC) shall
be provided.

supports and directly on the skid through penetrations


grating.

packaged skid shall deSigned to accommodate the lifting lugs specified in


clause 8.17.2 ofthis Standard.

1 10 All piping and valves on skid shall be in accordance with KOC-MP-010 and be
terminated with a flange along of the skid.

1.11 Welding procedures and welders shall be qualified in accordance with AWS 01.1
All skid welds shall be visually inspected and examined MPI.

8.21.12 Drip pan shall be provided as of Standard.

1.13 and suitable platforms with ladders/stairs shall be provided on the


access to all eqUipment, instruments, flange jOints,
and maintenance purposes.

9.0

9.1

9.1.1 sour and non-sour service, materials for trap components shall as provided
2 & 3 of this Standard. Where sour is specified, all materials
manufacturing of pig trap assembly satisfy NACE MR01 /
requirements and KOC-MS-003 (KOG Standard under preparation); and
for HIC and SSCC. HIC testing and acceptance criteria for pipe,
and component made from end closure door) shall be
III DOC. NO. KOC- MP-005 II
Page 25 of 41 II
REV. 1

as specified in the NACE MR0175 IISO 15156 and NACE TM0284. The SSCC test
shall be made as per NACE TMO 177. The pig trap assembly shall also satisfy both
the NACE MR0103 and NACE MR0175/1S0 15156 when it is to be installed inside a
facility (Refinery, GC, BS, etc.)

9.1.2 Materials from stockists shall have been manufactured and tested as per the
applicable standards with test certificates in accordance with EN 10204-3.1 type
certificates. Clause 16 and Appendix (I) of KOC Standard KOC-Q-014 shall be
adhered to.

9.1.3 Subject to KOC approval, the Vendor may propose for KOC acceptance of other
materials that are compatible with the respective pipeline and meet the design and
operational requirements.

9.1.4 All materials to be used for the fabrication of pig traps shall be new, certified and
traceable to heat numbers as well as chemical and mechanical properties. Stock
materials may be proposed for KOC review subject to conditional acceptance or
rejection.

9.1.5 All Pig Trap items shall be compatible with the main pipeline line pipe with respect to
weldability, wall thickness I material grade transitions and dimensions. Dimensional
considerations include actual internal diameter, ovality and wall thickness transition
taper angles.

9.2 Materials for Pig Trap Components

Table 2 : Materials for Pig Traps


Trap Component Material (General) Remarks

Major and Minor 1. If made from pipe: KOC MS-001 / For sour se rvice (See also Note
Barrels API 5L seamless or longitudinally 11
welded to match respective pipeline
(Note 1). 1. Refer KOC-MS-004 (under
preparation) Otherwise:
2. Perform HIC testing on SAW
2. If made from plate: ASTM A516, welded pipes and plates. (Note
A662, A537 class 1 or class 2 2). Ensure hardness on base
metal and Weldments not to
exceed BHN 237.
3. Perform SSC as per NACE TM
0177 .

Reducer and other Reducers shall be eccentric to ASTM For sour service
Fittings A234 WPBIWPC or ASTM A 860 in Hardness not to exceed BHN 197
accordance with ASME B16.9 / MSS for A234WPB and WPC. For other
SP-75 (Note-3), or ASTM A420 WPL6 materials, it shall not exceed BHN
237 .
End closing door See Table 3 For sour service
See Table 3
Flanges ASTM A 105N, ASTM A694N in For sour service
accordance with ASME B16.5/ ASME Hardness not to exceed BHN 187
B16.47/ MSS SP-44 . (Note 3), or for A105 .
ASTM A350N LF2.
Page 26 of 41 REV. 1

Remarks

not to exceed 0.025%.


2) Hardness not to exceed BHN
187 for A 105N and BHN 237
for others.

ASTM A216 Grade WCB or better.


ASTM A352 Gr. LCB/LCC.
I Elastomeric materials See Table 2 See Table 2

SAWL or seamless pipes (as per KOC ! Sour service as per KOC-MS-001
MS-001), ASTM A1 MSS-SP 97.
Nozzles up to and including 20" size
shall be made from seamless pipe.
Extruded nozzles and
reinforced forged nozzles are

Process pipes As per Sour service as per KOC-MS-001


ASTM A106
Reinforcing Plates to match barrel No sour service requirements

. Saddles for Same material used for major barrel No sour service requirements
i supporting

Structural Steel AST M A36 or better

Unless otherwise in project documents and data the


of class 150, 300, and 600 flanges shall be raised face. The facings of
in class 900, 1500 and 2500 shall be of joint type. They shall
also match the pipeline and connected in of type and facing

1. Note 1: SAW pipe more than one seam is not eH"',,,,::j.IICllm::.


2. Note 2: and plates should have been manufactured from materials designed and
manufactured from HIC and SSC resistant materials. Proposal to test stock materials
to approval the KOC Inspection & Corrosion Teams.
3. Note 3: Material shalf be selected compatible with the barrel material.
4. Note 4: For sour service, the completed pig trap shall be PWHT at 11000 F (595 C)
DOC. NO. KOC- MP-005 II Page 27 of 41 II REV. 1

9.3 Materials for Quick Opening Door

Table 3: Materials for Quick Opening Door

Hub ASTMA 105 N ! ASTM A 350N LF2! ASTM A694N F52-F60-F65


(Material shall be selected compatible with barrel material)

Door ASTM A 516 Gr. 70N! ASTMA105 N! ASTM A 350N LF2! ASTM A 694N
F52-F60-F65.
(Material shall be selected compatible with barrel material).

316 Stainless Steel.


Segments

Vent! bleeder
316 Stainless Steel
screw

Seals Nitrile! Vi ton (Resistant to H2 S).Explosive decompression resistant

10.0 FABRICATION AND WELDING

10.1 Fabrication of pig traps shall be made only at the fabrication shops of the KOC
approved Vendors.

10.2 Fabrication and welding (including the qualification of welding personnel) shall meet the
requirements of ASME IX and the applicable pipeline code.

10.3 Acceptance criteria for weldments shall be in accordance to ASME 831.4 or ASME
831.8 as applicable.

10.4 Fabrication and welding shall not be commenced until the following drawings and
documents are submitted and KOC's approval is obtained."

(a) GA drawings;
(b) Detailed shop drawings;
(c) Design calculations;
(d) Fabrication procedure;
(e) Welding procedures and qualification records;
(f) Welding/NOT map;
(g) NOT procedures including hardness;
(h) Heat treatment procedure.
(i) Painting/Lining Procedure

U) Inspection & Test Plan (ITP)

10.5 Welding shall be carried out using procedures and operators qualified in accordance
with ASME IX and approved by KOC. The following welding processes only are
allowed:
(a) Submerged Arc Welding (SAW)
(b) Gas Metal Arc Welding (GMAW)
(c) Gas Tungsten Arc Welding (GTAW)
Page 28 of 41 1

(d) Shielded Metal Arc Welding (SMAW)

10.6 The inside of the trap barrel shall free from obstructions which could prevent the free
travel of pigs.

10.7 All main seam welds and nozzles shell welds shall be full penetration. Set-on small
nozzles are acceptable when barrel diameter is too small to internally examined.

10.8 Hot formed ferritic steel material shall be normalized at a temperature not exceeding
1050"'C after forming.

10.9 closure may fully machined or part machined before attachment by welding to
the trap barrel. The Vendor shall provide details of the proposed option for KOC review.
Vendor shall ensure welding and post weld heat treatment will not trap
dimensional stability, metallurgical and surface condition, mating and sealing surfaces
Le. holding/locking ring, mating groove, ring gasket groove and all gasket mating and
sealing surfaces.

10.10 Post weld heat treatment (PWHT) on the completed trap shall made after
completion of all welding on the major and minor barrels (inclusive of attachments,
and if any). All flange and threaded connections shall be
adequately protected during heat treatment. Method of protection shall provided in
PWHT procedure.

10.11 Heat Treatment procedures to applied shall in accordance with ASME VIII,
Division 1 Part UW-40.

10.12 Id repairs shall not be allowed after heat treatment without approval by KOC.
Repaired welds shall be heat treated.

10.13 Acceptable butt welded joint design for equal and unequal wall thicknesses shall be as
Fig. 434.8.6-1 and 434.8.6-2 of the 831.4 code for traps designed to ASME
831 For traps designed to ASME 1.8, the acceptable butt welded jOint design for
equal and unequal wall thicknesses shall be as per Fig. 1-4 and 1-5 of the 831
code.

10.14 Welding of appurtenances (for ladders, saddles, supports, etc.) shall be a continuous
fillet seam with legs of at 0.75 % of thinnest section in the joint

10.15 Supports and saddles shall not be welded directly to the barrels. Transition plates of the
same barrel material shall be The Vendor may propose compatible alternative
material for KOC review and approval.

11.0

11.1 Verification of the Vendor's quality system is normally part of the pre-qualification
procedure, and is therefore not in the core text of this Standard.

11 Vendor shall and be prepared to quality system to the


Purchaser. The quality system shall ensure that technical and QNQC requirements
in the enquiry and purchase documents, Contract as well as in KOC-Q-014
DOC. NO. KOC- MP-005 Page of 41 1

Standard, are applied to all materials, equipment services provided by sub-


Contractors, sub-Vendors, suppliers and to any free issue materials.

11.3 Responsibilities of the Purchaser as specified in KOC Standard KOC-Q-014 shall


strictly adhered to during all of work.

12.0 QUALITY CONTROL AND INSPECTION

12.1 General

1 1.1 Quality control and inspection activities shall satisfy the design code B31.4 I
ASME .8 for and VIII Oiv.1 for the end closure) in addition to
requirements this Standard.

1 1 The Vendor I Manufacturer shall submit its Quality Plan and Inspection and Test Plan
(lTP) KOC approval in line with KOC-Q-014.

12.1.3 Fabrication shall not started until any required pre-inspection meeting held
with KOC attendance and minuted to the satisfaction of KOC.

1 1.4 Inspection and shall performed before any coating or paint is applied.

12.1 All personnel performing NOT activities shall be competent, qualified and certified to
requirements of SNT-TC-1A or equivalent, with at level II. The Manufacturer
have least one level III person to manage and control the NOT activities

1 Materials

12.2.1 Material certificates (MTC) meeting EN 10204 Type 3.1 all trap component,
shall be reviewed and accepted by KOC Inspector the of fabrication
activities. of information that may included in the MTC shall be in line with
EN 10168. MTCs shall be provided for all the trap components.

1 Chemical analysis and mechanical and impact are required for the barrel,
reducer neck pipe for trap in accordance with the design These
items shall tested ultrasonically in accordance with article 5 of ASME Code 5

1 For sour service ultrasonic examination in accordance with ASTM A578 (level B) shall
be performed for pig trap components of plates.

1 For steel HIC testing as NACE TM 0284 shall be out for all heats
(NACE TM 0177). Acceptance criteria shall as follows:

CLR: s 15%
CTR: S
S2%

1 Sulphide corrosion Cracking (SSCC) shall be made as per NACE TM0177


solution A using the four pOints procedure and shall be performed with a
constant load stress equivalent to 90% actual SMYS of base metal. shall be no
failure at any stage the test.
Page 30 of 41 REV. 1

1 All components including major barrel, reducer and minor barrel (neck pipe) shall be
visually examined in accordance with ASME V Article 9. All materials shall be free of
defects and imperfections including laminations. and API 5T1 shall be
applied in inspecting components. internal surfaces and of the
completed trap shall be flush and from any restrictions that obstruct the
smooth pig ",,<A'''''''''H

12.3

1 1 Non-destructive tests shall include visual, magnetic particle examination and


radiography. Surface examination shall be carried out using wet particle
including fluorescent magnetic type.

1 All butt welds on the trap and pig signaler shall examined by 100% radiography
(RT). In addition, carbon steel welds shall receive 100% magnetic particle examination
(MT) and steel welds shall receive 100% liquid penetrant examination (PT).

12.3.3 RT be in accordance with ASME V Articles 2 and with acceptance criteria in


accordance with ASME B31,4 I B31.8 as applicable. MT shall in with
ASME V, article 7 and 25, with criteria in accordance with ASME .4 I
1.8 as applicable. shall in accordance with V, Articles 6 and
with acceptance criteria as per ASMEB31,41 ASME B31.8 as applicable.

12.3,4 Radiographic examination shall be made using X-ray. thick material e.g. greater
than 30 mm, ultrasonic examination is an acceptable alternative subject to KOC
approval.

1 Forgings shall be UT examined as per A388.

12.3.6 Hardness testing be as part of the Welding Procedure Qualification also


on production welds. Hardness shall not exceed BHN on welds, HAZ or base
metal. Hardness traverse measurements shall be made as per NACE MR0175 I ISO
15156-2 Figure 4 and 5.

1 All KOC acceptance non-destructive examinations shall be carried out after post
weld heat treatment (PWHT). N made by the manufacturer before PWHT shall be
considered as part of internal control.

12.4

1 1 For the end closure, all mating clamp and flange machined door hinges, hinge
attachments and locking mechanisms shall be subject to magnetic particle inspection
(or dye penetrant inspection if fabricated from non-magnetic material). Any defects shall
constitute a basis for rejection. Disposition of such defects shall subject to review
and approval by KOC.

1 End closure components (hub, door forging, shall be examined by ultrasonic to


ensure freedom from internal gross defects and cracking.

12.4.3 Interlock system shall subject to detailed inspection and functional testing to ensure
that it is functioning as
IIm nnl'"
~ ......... ~.....
~
.........
~ ,p
--- Page 31 of 41 REV. 1

12.5 Functional Testing

A functional test shall be performed to demonstrate that closure door, pig signaler,
loading and unloading devices function satisfactorily.

12.6 Shop Hydrostatic Testing

12.6.1 The trap shall be hydrostatically tested to 1.3 times the design pressure but shall not be
less than that of the installed pipeline. The test pressure shall be held for a period of at
least 4 hours. The test is considered acceptable if there is no leakage or loss in
pressure.

12.6.2 The test shall be carried out with clean fresh water, at a temperature not lower
than10C.

12.6.3 Any gaskets to be supplied with the pig trap shall be replaced with new ones after the
hydrotest.

13.0 SURFACE PROTECTION AND PAINTING I COATING

13.1 External Coating

The launcher and receiver traps shall be externally coated as per KOC-P-001 System
A1-1, blast cleaned to SA 2.5 and coated with the following system:

(a) Zinc Rich Epoxy (75 microns, OFT)


(b) High Build Epoxy (MIO) (125 microns, OFT)
(c) Aliphatic Polyurethane (50 microns, OFT)

13.2 Internal Lining

13.2.1 Internal lining for launcher I receiver traps shall be carried out for internally lined
pipelines or when specified in the data sheets or purchase specification.

13.2.2 For effluent water lines, Fusion Bonded Epoxy shall be applied as per KOC-P-005.

13.2.3 For other services (i.e. crude oil, gas .etc.), phenolic epoxy shall be applied as per
KOC-P-005 if the pipeline is internally lined.

14.0 DOCUMENTATION TO BE PROVIDED BY VENDOR I MANUFACTURER

14.1 General

14.1.1 All correspondence, instructions, Oata Sheets, drawings, calculations, procedures or


any other written information shall be in English language. In case of dual languages,
one language shall be English.

14.1.2 All dimensions, units of measurement, physical constants etc. shall be in SI units,
unless otherwise specified.
Page of 41 REV. 1

14.1.3In addition to hard copies, all final documents such as specifications, data sheets,
drawings, procedures and inspection reports shaH be provided in software
formats (Latest versions Microsoft Word, Excel, and AutoCAD).

14.2 Deliverables

As a minimum, the Vendor/Manufacturer provide following documents for KOC


review and approval. Additional documents may be submitted as specified in Purchase
Order/Contract.

(a) General Arrangement (GA) Drawings of Trap showing materials of Construction


to be used and other data;
(b) Drawing for Closure and Pig Signaller;
(c) Details of the key interlock system;
(d) Drawings showing Details of attachments welds;
(e) Data Sheet for Trap and Signaler;
(f) Data for pressure safety thermal relief valves, pressure
pressure and any instruments or electrical parts.
(g) Jib Crane details.
(h) Design calculations for all components, supports and lugs. same shall be
included for skids if skid mounting is part of the purchase order;
(i) Detailed attachment drawings showing welding details;
G) Welding/NOT map showing weld procedure to be used for and the
and procedure to applied;
(k) Welding Procedures Specification (WPS) Procedures Qualification Records
(PQR);
(I) NOT Procedu
(m) PWHT Procedure;
(n) Hydrostatic Testing Procedure;
(0) Painting/Lining Procedure;
(p) Inspection and Plan;
(q) All certified Reports / Certificates including Material Test Certificates and
Inspection Report;
(r) Packing and shipping procedure
(s) Installation Procedure;
(t) Operations and Maintenance instructions including the end closure and pig
signallers;
(u) Manufacturing Record Book (MRB) as specified in KOC-Q-014 Standard.

14.3

For skid mounted pig trap design including piping and valves, the following documents
shall also be provided for KOC review and approval.

(a) Skid General Arrangement Drawing;


(b) Skid piping layout drawing;
(c) Specifications for pipe, fittings and flanges;
(d) Valves Data Sheets;
(e) Manufacturer's Drawings for Valves showing materials of construction;
(f) Inspection and Plan (ITP) for Valves
(g) Testing Procedures for Valves;
(h) NOT Procedures for Valves;
DOC. NO. KOC- MP-005 Page of 41 REV. 1

(i) Test Certificates including Material Test Certificates for pipe, fittings, flanges and
valves;
(j) Material Test Certificates for Skid structural members.

15.0 NAME PLATE

1 1 A nameplate made of stainless steel 316 or Monel shall be attached securely with
stainless steel or Monel fasteners on a support continuously welded to the scraper trap.
The location shall be such that the nameplate data can be read from the normal
position near the closure. The nameplate shall marked by raised letters or by die
stamping.

1 As a minimum requirement. the nameplate shall include the following:

(a) Manufacturer's name and location;


(b) Purchase Order number and date;
(c) Serial number and Date of manufacture;
(d) Name and KOC number of the Pipeline in which the trap is installed
(e) Class of flange connections;
(f) Design Pressure
(g) Maximum allowable operating pressure (MAOP);
(h) Sour or non-Sour service;
(i) Hydrostatic test pressure;
(j) Design code;
(k) Empty weight.

15.3 Figure 2 provides a typical name plate acceptable to the KOC. The Vendor may
propose a different design as long as the main information required in 15.2 is included.

16.0

16.1 Flange facings shall protected during shipment.

16.2 Machined surfaces shall be suitably coated to prevent corrosion, and be protected
against damage during transport, storage and installation.

16.3 Welding shall fitted with threaded steel bar stock plugs. All plugs shall be
given graphite and lubricating oil paste coating installation. Wooden plugs shall
not be used.

16.4 Scraper traps shall stencil marked with Kuwait Oil Company Order number, project
title, item number, nominal line and pressure class rating.

17.0

requirements for spare parts and maintenance are specified in "Spare and
Maintenance Data" KOC-G-009 and shall be followed as applicable. Contract
documents and/or purchase order may specify other requirements.

18.0 PACKING AND MARKING

For packing, marking, shipping documentation and other relevant requirements, refer to
the KOC-G004 "KOC Standard for Packing, Marking and Documentation".
Page 34 of 41 REV. 1

APPENDIX 1: DATA SHEET FOR PIG TRAP

KOC - MP-005

Document No. : Data Sheet for Pig sl"r'~r,,"r Trap)

._ _-"""""
--....-
.................
.. (Launcher I Receiver)

Prl"li""l"t No. : Equipment No. :

Project Title: Contractor:

Design Temperature (Min I Max)

Corrosion Allowance Inch (mm)

Design Factor

Flange Rating/Standard

Wall Thickness of Major Barrell Minor Barrel


Inch (mm) 3)

Service Fluid

I Design Code (Pig Trap) D ASIVIE B31.4 D ASME B31.8

Design Code (End Closure) VIII - Div. 1 - UG 35 & App. EE. I

Key Interlock DYes D No I

I CompHance to NACE MR0175/1S0 15156 DYes D No

, Compliance to NACE TM-0284 (HIC


DYes D No
Testing) and NACE TM0177 (SSCC)

Compliance to NACE MR0103 DYes D No I

Type of Pig Signaller


I
.. I
Note. Limit sWitches shall be provided for the pig
I signallers for remote indication.

Radiography .%

I MT/UT/PT %

Hardness Requirement For BHN Max.


Page of II 1
I

KOC - MP-005

Document No. : ~~ Data Sheet for Pig Trap (Scraper Trap)


~

(Launcher / Receiver)
IfJUfit:: fIl:S

nyuIUl~;:'l Pressure Psig

PWHT (0 requirement o Service Requirement) DYes D No

Insulation DYes D No

Fire Proofing of saddles/supports DYes D No

External Painting As KOC Std. KOC-P-001

Internal Lining As per:

MATERIALS OF CONSTRUCTION OTHER INFORMATION

Pipeline Material Skid Mounting

Major and Minor Barrel: Saddle

Reducer: Platform
i
Nozzles: Lifting

Flanges: Earthing

Forged Fittings: On-skid


instruments

Bolts & Nuts: Weight (Empty) (Note 3)

Reinforcement Pad: Weight (Full of water) (Note 3)

Supports:

Saddle Plate:

Lifting Lugs:

Gasket (on Closure):

Earthing Cleat:

Name Plate:

Pig Signaller: Body: Wetted Parts:

NOTES

! 1 Trap shall designed for all of pigs including intelligent pigs

I 2 The Vendor shall provide all supports, lifting lugs, earthing bosses, name plate etc.
Page 36 of 41 1

KOC MP-005

Document No, :
.
~_
__ ~QOc-tl'
....
........ 4v"-' ....................... _
Data Sheet for Pig

(Launcher/R~vclvcl
Trap)

I
3 To be furnished by the Vendor.

4 The Vendor shall comply with KOC -MP-005- latest revision


i
5 Pig signaller shall be removable type during normal operation with visual flag.

Revision No tus P Checked Approved


DOC. NO. KOC- MP-005 Page 37 of 41 REV. 1

Figure - 1 : Code Break for Pig Traps

ASME VIIH

Ty
f------,- , - - - - - - r - -'-- -'-- - , - - - - - - j 10 1 ASM:-B31.4/B31.8

tI -TI - -- - --U- -r - --
I ASME -B31.3 (*l

* Refer KOC Standard ( KOC-MP-OIO ) for piping classes/details


KOC - MP - 005 - Rev-l CODE BREAK FOR PIG TRAP SYSTEM

Note on figure 1: When the piping marked ASME 831.3 in Figure 1 ofthis Standard, extends
to a slug catcher, then the pipe portion up to slug catcher shall be designed and constructed
to ASME 831 .8 even though that piping part extends inside the fence of a plant or refinery
(Refer to ASME 831 .8 Fig. 02) .
DOC. NO. KOC- MP-005 Page 38 of 41 REV. 1

Figure 2: Name Plate for Pig Trap


Items in Clause 15.2 to be included

___ _ _ _ _ _ _ _ _ _ _ _ __.. ____ _____--'1-=-50"-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--1

~_~1'5
I ..
I
.
40

'I'
58.5 I

1
SPACEFORNAMEAND rl----------~'r-~-t~
11 10 15
1
I 2 THK-ST-ST.316
R=6

+
ADDRESS OF MANUFACTURER \

",L I ~ ~

r --
CD

=.... ~

~
~

= ~

4.5
:=========:ICJi"$C~
ICD 2.5 e
I============ill psi I TYP

F=============~II~

-
-
170
I
I' 1

T
~ ~ ::;;
1F +---~1-K
It
-5- -
'
INSUL. OR VESSEL

EXT.SURFACE
"1' -~ - -, NOTE 3

:[0 -~- ol:


o
~
'I'
: ,
I
'I nr1'I" ST.ST .316
[ :Lq __ -+- __ ~.J: Rivets

FOR INSULATED AND NON INSULATED VESSELS

General Notes,

1) Basic data as shown shall be engraved.AII other data shall be stamped

using 3.5 mm letteling

2) All dala blocks and lettering shall be embossed 0.5 mm on black back

ground

3) Nameplale support (same ma1.as shell) shall be welded onlo vessel (before

heat treatment if any) using continuous fillet weld on both extemal sides.

Nameplate shall be located on v8ssel near quick opening door nearest to

ground and shall also be easily legible from platfonn or ladder

KUWAIT OIL COMPANY

Drawn
MANUFACTURER'S
Scale

Microfilm code
NAMEPLATE FOR PIG TRAP
Rev. Dale Description Check Appr.
Project Unit 1 1 Doc. Account class& progressive I I Sheet Rev.
DOC. NO. KOC- MP-005 Page 39 of 41 II REV. 1

Figure 3: Dimensions of Pig Trap and Nozzles

~ A ~Y Et
\ ! i! ) ,
, I I I ! I
-~--___
--~--=-*- ---~-}
\. ffi ~

,
m -/ /

I,
(NJ(",~ II!i ~ -----iJ3l
- ~r

I
I
I
(@ 4=J
PIG LAUNCHERJRECEWER
~3t@
s:crroN A-A

PIG TRAP DIMENSIONS NOZZLE DESIGNA TION


VOl.VO. QIY. O!sc lIPtIJU
INESlZ 4" 6" 8" 10" 11" 14" 16 " 18 " 10" ll" l4" 16 " l8" 30" 3l" 34" W 38" 40' 41" 44" 46" 48 " 50 " Sl " 54 " W 60"
HI 11lor . K!l:K!liBYPI\II
A 3~3~~h3~~~Um~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ III '1 }Jr." DUJN'
ll) l)lt ~IIBLOWWW'
B 3~~~3~~h~h3~~ ~ ~ ~ h h ~ ~ ~ ~ h ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
lit 2l:lof , lIJ...Ulft!
8" 10" 11 " W 16 " 18" 20" ll" l4" ltS" 18" 30" 3l" 34" 36" 38" 40" 4l" W 46" ' 8" 50" 5l" 51" 56" 58" 60 6'
10 '1 UN . Pll!UUl!.GAOO!
I) 4" 6" 8" 10' ll" 14" 16" 18" 20" ll" l4 ' ltS " l8" 30" 3l" l4" l6" 38" 40' ll ' 44 " 46 " 48 " 50" 51" 54 ' ;6" 60 "
1" I )I. PIG 1X;1lAL
N i l" l" 3" 4" '" 4" 6" 6" 8" 8" 8" 10 " 10" la' Il" Il" Il" l4" l4" 14" 16" 16" 16' 18 " 18" 18" lO" lO" V7 Ill. l!U!P'Vll'J!. *
N1 l" l" l" 3" 3" 3' 3" 3" 3" 4" 4" 4' 4" 4" 4" 4' 6" 6' 6' 6" 6" 6' 6" 6" 6" 6" 6' 6" llMl9 tll.,. DlUY.a:JtLt

N3 l" l' l' 3" 3' 3' 3' 3' 3" 4" 4" 4' '" 4' 4" '" 6" 6' 6" 6" 6" 6' 6" 6' 6' 6" 6" 6" HI'
lilt I ll. 1.111\.1 I!l.Pll)',enro
N4 l' l' l' l" l' l" l' l" l" l" 3" 3' 3' 3" 3" 3" 3" 3" 3" 3' 6" 6" 6" 6" 8' 8" 8" 8"
N5 l' 1" l' l' l" l" l' l" l' l" l" l' l' l" l' l" l" l" l' l' l" l" 1" 1" l' l' l' 1" Nota:-
N6 1" l" l' l" l' l' 1" l' 1" l' l' l" 1" l' l' l" l' l" 1" l' l' l' l' 1" l' l' l' l" Nazzle location & orientation to be
N1 1" 1" 1" 1" l" l' 1" 1" 1" l" 1" l" 1" 1" 1" l' l' 1" l' 1" l' l' 1" 1" 1" 1" l' l' finalized as per lht respective P&lD
NIO 1" l" 1" l' l" l' 1" 1" l" 1" l" l" l" l' l" l' l' 1" 1" l" 1" 1" 1" 1" 1" 1" 1" l" Project drawings.
Nll l" 1" 2" l' " l" l" l" 1" ," " " l' ," ," " " " l" ," ," 1" l" l" 1" l" ," "
* N7 siu to be finalized based on
relief design eel cul.ti ons
DOC. NO. KOC- MP-005 Page 40 of 41 REV. 1

ACKNOWLEDGEMENT

This Standard has been approved by the Standards Technical Committee (STC) consisting of
the following :

Mr. Hamzah Ahmad Standards Team Chairman


Mr. Mohd Emam Insp. & Corr. Team (S&E) Deputy Chairman
Mr. S. Kumar Standards Team Secretary/Member
Mr. A. Unnikrishnan Standards Team Member
Mr. N. Ramanathan Major Projects IV Member
Mr. Daniel Pino Utilities Team Member
Mr. Abdul R. AI-Shamari Insp. & Corr. Team (N&WK) Member
Mr. Haithem Aboughaith Gen . Projects Team Member
Mr. Gopal Murthy Opns. Tech. Svcs. (WK) Team Member
Mr. Mohd. Aslam Imadi Design Team Member
Mr. G. Unnikrishnan Design Team Member
Mr. Fahad AI Qattan HSE System Team Member
Mr. Abdulla AI-Yousef Project Mgmt. Team (NK) Member
Mr. Richard Arthur Info. System Planning Team Member

The draft of this Standard had been circulated to the KOC User Teams for review and the
responses were received from the following:

MAJOR PROJECTS GROUPS (I & II) INDUSTRIAL SVCS. GROUP

Team Leader Project Support Team Leader Insp. & Corr. (S&E)

ENGINEERING GROUP Team Leader Insp. & Corr. (N&W)

Team Leader Design TECHNICAL SERVICES DIRECTORATE

SUPPORT SERVICES GROUP (S&E) Team Leader HSE (TS)

Team Leader Gen . Projects OPERATIONS SUPPORT GROUP S&EK

GAS MANAGEMENT GROUP Team Leader OTS (S&EK)

Team Leader Gas Opns. (S&EK) Team Leader HSE (S&EK)

Team Leader Opns. Tech . Svcs. (Gas) HSE GROUP

Team Leader HSE Systems

OPERATIONS GROUP (NK) SUPPORT SVCS. GROUP (WK)

Team Leader Opns Tech Svcs. (NK) Team Leader HSE (WK)

EXPORT AND MARINE OPNS. GROUP

Team Leader Export Tech. Svcs.


DOC. NO. KOC- MP-005 II Page 41 of 41 II REV. 1

Task Force Responsible for This Standard

The Standards Technical Committee (STC) has entrusted the preparation of this Standard to
the Task Force No . (TF-MP/19) consisting of the following members:

Mr. Mohd. Emam Insp. & Corr. (S&E) Task Force Tel. No. 63693
Leader/Author
Mr. Santanu 8andyopadhyay Gen. Projects Team Member Tel. No. 61584
Mr. Shabbir Safri Insp. & Corr. (S&E) Member Tel. No. 61527
Mr. Shaya AI-Hajri Gas Opns. Team (N&W) Member Tel. No. 3820270
Mr. Sulaiman AI-Foodari Major Projects (V) Member Tel. No. 61026