CR Furnace Tube and Pipeline Pigging

SETTING NEW STANDARDS

FURNACE TUBE & PIPELINE PIGGING

Specialised Pigging ModulesOur pigging modules range from small containerised units, for easy transport to difficult sites, to trailer mounted 20ft and 40ft units. The units are modular in design, require no additional ancillary equipment for operation, and can be separated and lifted into inaccessible areas when required.Our 40 ft pigging module has a liquid storage capacity of 40,000 litres, making this the only unit in Australasia with the ability to Pigg up to 350 metres of DN 400 (16) in a fully closed circuit while returning all waste streams to the unit.

Permanent Location OptionContract Resources can also provide clients with resident pumping modules on site. This gives the client immediate access to equipment in emergent situations, removing the potential equipment mobilisation lead time should the need arise.

Minimal Client Involvement & Impact on Site Resources The client is only responsible for providing pipeline access to the launch and retrieval point, fresh water supply, and effluent discharge.

Due to the ability to close circuit Pigg, pipeline sections up to 400 metres long can be cleaned in one set up. This minimises line breaks, subsequent mechanical works, and access requirements for overhead lines. Contract Resources supervisors coordinate all operations with the client prior to and throughout the pigging operations to ensure the pipeline has been prepared as required, and that all safety and site specific procedures have been adhered to.

Interior of a 40 ft clean water tank A 40 ft pigging module is completed in a CR engineering bay


Throughout the process, pig travel and pipe cleaning are continuously monitored, and hydraulic driving pressure and flow rate values versus time is recorded. The resulting pressure profile measures the resistance to pig travel, enabling the operator to determine the location of fouled sections and the extent of the deposit build-up. The recorded data of the pig propellant pressure clearly delineates the fouling extent and pig travel. Clean return water with consistent pressure and flow data signifies that the progressive pigging program is completed.

A final pressure profile is obtained and recorded, and compared with the initial pressure profile. This information is available to the operator and client for confirmation that all deposits have been removed from the pipeline.

01. A pressure profile before and after cleaning, showing the increase in pipeline flow rate. 02. A computer model of a Pigging clean inside a pipeline

Continuous Monitoring

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Utilising water as the propellant medium in a closed circuit configuration prevents all spills to grade, and the solid/liquid separation system minimises the generated waste stream. The patented unique closed circuit pigging process presents the least risk to the client, the operators, and the environment available to the market today.

Environmental Advantages

A 20 ft modular container set up onsite for Pigging operations Removal of scale from a pipe section

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The Patented ProcessThe DDT process is the safest, most environmentally friendly method for removing pipeline debris.

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01. Removed scale build-up in front of a DDT Pigg 02-04. Specialised Pigg launchers setup on client pipelines


The DDT process employs a closed loop, self contained hydraulic system and is the holder of 17 patents worldwide. Contract Resources are a licensee for the use of this technology. It is the only pigging technology that is able to remove mineral laydown and hard scale deposits from pipelines.

The process uses no chemicals and works at ambient temperatures, with water being the propellant medium; process water can also be utilised to further reduce any environmental impact. Contract Resources is proud to have played a significant part in the endeavour to reduce unnecessary emissions; we have incorporated environmental considerations into all areas in the design and construction of our cleaning systems and the ensuing operation of our pumping modules.

The pigging process is bi-directional, allowing the cleaning Pigg to traverse the pipeline in both directions. It is the only process that can direct the Pigg to travel repeatedly over an isolated contaminated section of pipeline; this expedites the cleaning process and abates non-productive Pigg runs over unfouled pipeline sections.

01. Different appendages designed to fit into Pigg bodies for different types of scale and build up 02. A selection of Piggs 03. View of the cleaning studs on a Pigg body

The DDT Pigg is a compliant and flexible cleaning device key to the cleaning process. This polymer Pigg is available in diameters from 50mm (2) to 914mm (36). The Pigg can negotiate short radius elbows and U-Bends with ease, obstacles that have long defeated conventional pigs.

Pressurised water, supplied from a pumping module, pushes a flexible pig through the fouled pipeline. In the process, the appendages erode and remove deposits. A controlled amount of the water flows around the pig and past the appendages, flushing the loose deposits ahead of the unit and into the solids separation system.

The DDT Pigg

Pigging Process

Each Pigg carries an array of interchangeable cleaning appendages, each of which is threaded into the body of the Pigg. These cleaning appendages are radially dispersed in a clockwise or counter clockwise configuration to provide a complete, 360 cleaning action. The Pigg size, number of appendages and their specific selection, as well as height are all matched to each stage of a cleaning run.

Liquid bypass around the Pigg removes deposits from the Piggs path, eliminating the possibility of pig blockage - an unparalleled feature of the Pigg. It is also the only Pigg design that incorporates interchangeable appendages, allowing the operator to adapt to any conditions encountered and provide optimum cleaning performance in the shortest possible timeframe.

The appropriate diameter pig, height, type of appendages, and amount of water to bypass the pig is all determined by the operator. A series of valves controls the direction the pig travels.

Since the fouling may not be uniform throughout the pipeline, the Contract Resources operator has the ability to direct the pig to travel over the most fouled section as required. This bi-directional Pigg control method is a patented process. A significant benefit of the directional control is that it also permits the cleaning of pipelines with changing pipe diameters. The DDT process operates nominally in a pressure range of between 75 to 200 psi, eliminating the risks associated with HPW cleaning methods.

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The 40 ft Pigging module set up on site


Chemical Pigg Trains

Clean and Gauge

Chemical Pigg Trains are used to achieve Pre-Commissioned Pipeline Pigging requirements together with the following objectives: Environmentally friendly

Minimisation of the volume and hence the cost of chemicals required

Minimisation of the transport and disposal costs of spent chemicals

Ensure complete internal surface contact with the cleaning chemicals

Offer visual confirmation of pipe wall cleanliness

The cost and environmental benefits of this system are enormous. As an example, to clean 100 meters of 150mm (6) pipe via the traditional method would require 3,200 litres of chemicals per run. With the batching technique, chemical usage is down a massive 96%; to just 128 litres per run. This equates to considerable financial savings for clients in both the purchase and subsequent disposal of chemicals and resultant residues.


Contract Resources provides pre ILI inspections and routine pipeline cleaning programme services to clients across Australasia, with a large inventory of piggs (6 - 30) and tracking equipment in stock in Australia to assist with emergent cleaning runs as required.

Pigg

Pigg Tracking equipment

Cup Pigg

STAGE ONERemoval of heavy Corrosion scales using select pigs and nitrogen gas for propulsion.

Nitrogen (N2)

STAGE TWOChemical Train using

batched chemicals for cleaning, passivation, and

hydrocarbon removal.

STAGE THREEFinal drying and inspection wiping using select drying swabs.

Decoking Fired HeatersThe Pigging System, pioneered by DDT, is the most advanced system for decoking fired process Heaters and Furnaces. It is a fully proven and extremely effective process that removes even the hardest coke and scale from heater tubes.

The DDT Service Complete deposit removal Increased Capacity Greater run-lengths Higher heat fluxes Lower fuel usages Longer tube life Reduced environmental emission

Greater run-lengths are accomplished by polishing the inside surface of the tubes with specially designed appendages. Contract Resources new 40ft unit out- performs all competitor single and two pass trailer units.

Intelligent Pigging DDT International and Contract Resources have worked alongside many of the world leaders in Intelligent Pigging. We are also able to assist with internal inspection of pipelines by means of intelligent pigging.

We have complete confidence in the quality of our service. Our dedicated and qualified service personnel will safely, effectively, and efficiently fulfill all pigging requirements.

The CR guarantee We guarantee the complete removal of pipeline deposits; improving performance while increasing reliability, flow rates, and capacity. DDT has a proven track record, having begun pigging operations in 1991. It is the only company with a patent for selectively cleaning contaminated sections only.

Industry Sectors and Services Facilitated Refinery Heaters Process Heaters Transfer Lines Power Plants Chemical Plants Steel Mills Sewage Treatment Plants Pulp & Paper Mills Mines New Construction Onshore and Offshore Pipelines Removal and conditioning of

Internal Weld Seams in Tubes

A diagram of the Pigging system set up


The process removes this build-up from heater tubes in a series of highly controlled incremental cleaning runs. Because the process is much more effective than steam-air decoking, chemical cleaning, or any other mechanical cleaning method, the economical benefits of an increased run length, longer tube life, lower fuel usage, and improved heater reliability are assured for as long as possible.

DDTs bi-directional Pigg control method facilitates the cleaning of heaters which incorporate reducers and changing pipe diameters, without having to make any modifications. It will also permit closer attention to the most contaminated section of a heater, further optimising the cleaning process.

FOR FURTHER INFORMATION CONTACT // www.contractresources.com

NEW ZEALAND Auckland Office Phone: +64 9 2652 083 Fax: +64 9 2652 084 Email: [email protected]

AUSTRALIA 1300 66 11 91 Sydney Office Phone: +61 2 8723 2111 Fax: +61 2 8723 2199 Email: [email protected]

MIDDLE EAST Abu Dhabi Office Phone: +971 2 5504 355 Mobile: +971 503 790 986 Fax: +971 2 5504 357 Email: [email protected]

SOUTH AMERICA Chile Office Phone: +56 99 8223 894 Fax: +56 32 2133 222 Email: [email protected]

USA +1 855-CHR-4CAT Houston Office Phone: +1 281-538-0529 Fax: +1 281-538-6370 Email: [email protected]

Contract Resources has equipment spread throughout Australia, New Zealand, North and South America, and the Middle East; ensuring fast mobilisation.

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CR Furnace Tube and Pipeline Pigging

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