Preparing & Filling Unisphere Pigs
In this third episode of Pigging Insights, we cover the steps and guidelines to preparing and filling TDW unisphere pigs. These seamless liquid cast polyurethane balls are designed for removal of liquid hydrocarbons and water as well as batch separation for pipelines handling different liquids.
TDW PIGGING INSIGHTS - Episode 3
Instructions for the preparation and filling of TDW Unisphere Pigs
TDW Unisphere Pig
TDW Unisphere pigs are seamless liquid cast polyurethane balls. They are designed for removal of liquid hydrocarbons and water as well as batch separation for pipelines handling different liquids. Unisphere pigs are hollow, they can be filled with liquid and also be inflated with pressure to match the pipeline’s ID.
Preparation for Use
Unispheres must be filled with liquid before use. Water/glycol or light lube oil solutions are recommended. It is best to avoid using pure glycol as a filling solution. The 4 inch to 8 inch Unispheres have one filling valve. Larger spheres have two valves; either valve can be used. Other components required are an inflating valve, valve core, pipe plug, filling adapter and valve core extractor.
Filling Procedure (not including inflating with pressure)
1. Remove inflating valve with a 3/8 in Allen wrench.
2. Fill sphere with liquid using funnel or hose.
3. The opening must be at the top and sphere completely filled with air displaced. Rolling the sphere slightly around can help to settle liquid and displace air.
4. Inspect O-Ring on inflating valve for nicks and burrs, and replace if necessary. Apply lubricant to O Ring and threads.
5. Remove pipe plug, and check the tightness of valve. A valve core extractor is available.
6. Install inflating valve and tighten securely.
The above steps are a guide designated to be read in conjunction with TDW Unisphere instructions. Download by clicking on the red button.
TDW PIG RESOURCES
Register for TDW’s e-commerce site and quick-ship Pigs.
To learn more about TDW Pigs or find Resource guides, see the TDW Pig Resource page.
If you have questions, please contact the Kerr Engineered Sales Company who are also available for team for presentations, lunch and learns and customer visits.
USE CASE FOR TDW 3-WAY TEE
A gas operator in PA who was building a compressor station needed to tie in a new branch line to an existing 10 inch natural gas gathering line that was running at 950 psi. The customer did not want to leave a buried flanged connection underground that was in the ground.
TDW 3-WAY TEE IDEAL SOLUTION FOR TIE IN
10”x 10” 3-WAY TEE on the main line with sandwich valve
A gas operator in PA who was building a compressor station needed to tie in a new branch line to an existing 10 inch natural gas gathering line that was running at 950 psi. The customer did not want to have a buried flanged connection underground and were proposing to weld on a standard fitting, add a long pup piece to the fitting, attach a ball valve to the pup piece, and then bolt on the new 10 inch line to the valve above ground level. There were challenges in terms of the stack up. One issue was the length of travel that a tapping machine would have to navigate, the line needed a pup piece to be welded on, and the 10 inch main line was pigged and needed to remain so.
As an alternative, the Kerr and TDW specialists recommended to the operator to use a 10 inch by 10 inch Full Encirclement 3-WAY Tee with LOCK-O-RING ® Flange and LOCK-O-RING® Completion plug with flow through pig guide bars. This solution had multiple advantages. It eliminated the need for a long pup piece. There would not be an issue with the length of travel the tapping machine would have to navigate, and the line would remain piggable. The gas operator agreed.
LOR plug with pig flow through guide bars being attached to the tapping machine.
For this project, TDW technicians performed the welding of the 3-Way Tee fitting and the 10 inch branch line to the side outlet of the fitting. The Technicians operated the 10 inch Hot Tap and set the completion plug with the pig guide bars.
The result for the gas operator was a new branch line tied in with the 10 inch main line able to be pigged. This was the end result the customer required.
A successful result with a new branch line and 10” main that can be pigged.
To learn more about TDW Pigs or find Resource guides, see TDW Pig Resource page.
If you have questions, please contact the Kerr Engineered Sales Company who are also available for team for presentations, lunch and learns and customer visits.
TDW 16 inch Ultra Pig – Purging Excellence
An Ohio Gas and Liquids operator needed a pig for a run on a 16 inch 4-mile condensate line needing to be thoroughly purged, the Kerr team recommended that the line be purged in order for the repairs to take place.
TDW Ultra pig in action
When an Ohio Gas and Liquids operator called for advice on a pig for a run on a 16 inch 4-mile condensate line needing to be thoroughly purged, Kerr and TDW were on hand to support. The line needed purging in order for needed repairs to take place.
After visiting the launch site and discussing with the customer their requirements, the 16 inch Ultra Pig with four Ultra discs was selected. This all-urethane pig (less nuts, bolts, and washers) also carried two transmitters. One transmitter acting as a back-up was secured in the front part of the cavity body during the run.
The design of the discs on the ultra-pig are ideally suited to carry out purge operations due to their shape. A key differentiating factor is that the ultra-disc is thicker than the regular sealing discs. As the ultra-disc wears, it has more urethane touching the pipe wall.
Kerr attended the launch and followed up to see how the run went. The line was successfully purged of the condensate and the repairs on the condensate line were able to proceed.
To learn more about TDW Pigs or find Resource guides, see TDW Pig Resource page.
If you have questions, please contact the Kerr Engineered Sales Company who are also available for team for presentations, lunch and learns and customer visits.
Storing TDW Pigs and Unispheres
TDW Pigs/Spheres are constructed with strength, flexibility, and resistance to hydrocarbons. In Volume 2, we cover guidelines for storing TDW pigs and unispheres.
TDW PIGGING INSIGHTS - Episode 2
Overview of Storage of TDW Pigs and Unispheres
TDW assorted pigs
TDW Pigs/Spheres are constructed with strength, flexibility, and resistance to hydrocarbons. For TDW pigs to do the job they were designed for, they must be stored correctly. This blog gives a brief overview, with areas of consideration.
To learn more about TDW Pigs or find Resource guides, see the
TDW Pig Resource page.
tips for storing pigs
Humidity and temperature can have a negative effect on the shelf life of urethane. Shelf life maximized when temp is 75F and humidity less than 50%.
Assembled pigs are ideally stored on a stand supporting the pig’s weight.
Brush/blade pigs should be stored standing on their end. If they are stored on the side, the blades, springs, cups and the supporting the weight of the pig on the ground can lead to deformation.
Cups can be stacked upside down if the weight is not enough to distort lower stacked cups.
Spheres – new spheres are best left in the shipping carton until use. After use, any liquids can be left in the sphere pressurized.
If pigs are stored long term, before using it is important to inspect them carefully. Look for softened/darkened urethane that will compromise performance. For example, if a flat blade screw can be pushed into the material, it is safest to discard the pig.
If you have questions, please contact the Kerr Engineered Sales Company who are also available for team for presentations, lunch and learns and customer visits.