Overview
A Middle Eastern client approached AISUS with an urgent operational challenge on a Well Head Platform in Qatar. A PIG had become lodged approximately 7 metres beyond the PIG launcher, within the first isolation value of a 38″ wet gas line, leaving no established method for safe retrieval. Recognising the critical nature of the issue, AISUS rapidly mobilised engineering resources to assess the challenge and develop a safe, practical and fully engineered retrieval solution. Within 10 days of the issue being reported. AISUS had designed, fabricated and tested a bespoke remote PIG retrieval tool, together with a detailed deployment methodology, ready for execution.
Requirement
The client required a safe means of retrieving the stuck PIG without personnel entry into the launcher. The solution needed to be operated remotely over a distance of approximately 7 metres while generating sufficient force recover the obstruction. Given the operational impact and the critical nature of the pipework, the solution also needed to be designed, approved and ready for deployment within an exceptionally short timeframe.
Challenges
The project presented a unique engineering challenge. The PIG was located within the first isolation valve in critical live pipework with only a single isolation in place, creating significant constraints around intervention methods. No existing tooling was available that could safely complete the task, requiring a completely bespoke approach. The retrieval system also needed to deliver up to 14 tonnes of pulling force while maintaining safe remote operation.
Solution
AISUS responded immediately, working closely with the client to develop a fit-for-purpose retrieval system tailored to the operational conditions. A brand-new remote PIG retrieval tool was designed, engineered and fabricated in-country specifically for the scope, significantly reducing lead times and enabling rapid deployment readiness.
To support client review and approval, AISUS supplied detailed 3D models and animations, allowing the proposed methodology to be visualised and assessed before mobilisation. The completed system underwent onshore testing to verify performance and ensure operational readiness, while a comprehensive scope of work and deployment plan were prepared to support execution.
By combining engineering expertise from Aberdeen with established Middle East operations and personnel, AISUS was able to transform an urgent client challenge into fully engineered, tested and deployment-ready solution in just 10 days.
Benefits to Client
The project demonstrated AISUS’s ability to respond rapidly to complex operational challenges, developing bespoke technology where no conventional solution existed. Through local fabrication, detailed engineering validation and clear visualisation of the proposed methodology, the client was provided with a safe practical and technical robust retrieval solution within an accelerated timeframe.
Client Testimonial
“AISUS’s regional technical lead Andy, was extremely responsive, professional and a brilliant problem solver throughout the project”
