Ensuring pipeline integrity and sustained operations is crucial for long-term energy production. A long-standing client in Malaysia faced challenges operating their 231 km offshore-to-onshore pipeline due to an anticipated declining flow rate. In collaboration with the client, ROSEN developed a customized pigging solution capable of running reliably under low-flow conditions.  

This was underpinned by an extensive flow assurance and feasibility studies, supported by rigorous pump testing at ROSEN’s facilities in Germany. A customized pig was design to tailor the low-flow conditions, on top to address the challenges posed by the pipelines multiple bends, vertical expansion loops, and debris accumulation.  

Pump testing simulated various low-flow scenarios, down to 0.01 m/s, to validate the pig’s safe passage, effectiveness, and debris handling capabilities. Six tests confirmed the pig’s robustness, with no critical damage observed, even after clearing approximately 15 kg of sand. The tool demonstrated successful navigation under low-flow and stop-start conditions, with a recommended minimum operational velocity of 0.02 m/s to ensure reliability.  

Through this collaboration, the operator was able to extend the asset’s operation life-span by an additional seven years. This case study highlights how technical expertise and data-driven innovation can overcome operational challenges, setting a benchmark for pipeline management under low-flow conditions. Keywords: Pipeline, oil and gas, low-flow, customized pig, operators.