Knowledge Kit
Emergency Foam Pig Deployment – Scarborough Wet Buckle Recovery
Project: Scarborough Pipeline Recovery – Wet Buckle Incident
Client: Saipem (EPC Contractor)
Location: Offshore Western Australia
Date: March 2024
Product Supplied: High-Density Fully Coated Foam Pigs
Lead Time: 7 Days – From Design to Site Delivery
Challenge
Following a wet buckle incident during offshore pipelay operations on the Scarborough Project, a section of the subsea gas export pipeline was flooded with raw seawater. This posed a critical integrity risk. Saipem required urgent displacement of seawater from the pipeline to prevent long-term contamination and resume offshore operations.
Key operational requirements:
- Immediate displacement of raw seawater from 68 km of pipeline
- Foam pigs suitable for subsea recovery, with high abrasion resistance
- Foam pigs to be fully coated for protection and structural durability
- Fast-track delivery to Karratha site, utilising only Australian resources
Solution
Royal Poly Products custom-designed and manufactured a high-density, fully coated polyurethane foam pig, optimised for:
- Maximum structural integrity under high flushing volumes (13.9 m³/min)
- Debris push-out effectiveness
- Compatibility with subsea ROV recovery
- Resilience across 68 km of continuous flushing
Key operational requirements:
- Use of impact-resistant coating to prevent foam degradation
- Designed for controlled collapse under extreme hydraulic push, avoiding premature failure
Rapid Response Execution
Royal Poly Products custom-designed and manufactured a high-density, fully coated polyurethane foam pig, optimised for:
- Raw material (coating resin) was air-freighted from Melbourne.
- Pigs were manufactured in Perth and sent to Karratha via hot-shot road transport.
- Delivery achieved in 7 days, exceeding project emergency expectations.
- Entire supply chain of the rescue pig managed by Royal’s WA-based team, leveraging Australian supply chain.
- First ever such pig manufactured in Australia for Australian waters.
Outcome
Royal Poly Products custom-designed and manufactured a high-density, fully coated polyurethane foam pig, optimised for:
- The foam pig successfully traversed the flooded pipeline section and was recovered offshore.
- Surface markings indicated impact from debris as expected, validating design integrity.
- Debris displacement was achieved, enabling progress toward pipeline reinstatement.
Key Highlights
Royal Poly Products custom-designed and manufactured a high-density, fully coated polyurethane foam pig, optimised for:
| Metric | Result |
|---|---|
| Pipeline Distance Covered | 68 km |
| Flowrate During Operation | 13.9 m³/min |
| Delivery Time (Design to Site) | 7 days |
| Foam Pig Condition Post-Use | Recovered intact with surface marks |
| Operation Status | Successful |
Why It Matters
This project demonstrated Royal Poly Products’ ability to rapidly engineer, manufacture, and mobilise emergency pigging solutions, supporting critical offshore timelines. It also highlighted Australia’s local manufacturing and response capability in high-stakes subsea operations.