Equipment and Operation
System Design and Installation
Equipment and Operation
Will a pigging system help me to meet my plants Continuous Improvement and Environmental Stewardship Objectives?
Absolutely. Pigging systems are one of the few investments a plant can make, even during tough economic times, which not only provide rapid paybacks but also long term savings and a reduced environmental footprint. Both objectives are accomplished by recovering product, reducing flushing waste, and minimizing consumption of natural resources and energy.
How much residual product will be left in the line as a result of pigging?
Pigging Solutions pigging systems will typically recover tapped product and clean the transfer line with greater than 99% efficiency. There is occasionally a trade-off between system cost and residual product. Pigging Solutions provides the most cost effective system design that meets the tolerable residual product level of each application.
My existing pigging system design makes it difficult for pig inspection and maintenance. Is there a pigging system that will permit my production operator quick and easy access to pigs for inspection and maintenance?
Yes, if provided by Pigging Solutions. Pig Launcher/Receivers provided by Pigging Solutions are equipped with the patented LQC Pressure Locking Safety Access Cap, pig Wiper Disc Relax Chamber, and side air/vent fittings. The LQC safety cap is attached with just a quarter-turn and will not permit operator removal when pressure exists in the transfer line from pumping or pigging. The Relax Chamber allows operators to ergonomically insert and remove pigs easily in less than 30 seconds without "stuffing" or "tugging" the compressed pig from the transfer line. Side air/vent fittings means no disassembly of utility piping to access pigs for service or inspection.
The regulatory and political environmental are placing an increasing focus worker safety. Are pigging systems safe for operators to use?
Yes, if provided by Pigging Solutions. All pigging components supplied by Pigging Solutions are manufactured by Hiltap Fittings, a division of OPW Engineered Systems. OPW is recognized world leader in the supply of fluid transfer equipment and Hiltap Fittings is leader in the manufacturing of pigging components designed for both operator safety and ease of use. Pig Launcher/Receivers are equipped with the patented LQC Pressure Locking Safety Access Cap and pig Wiper Disc Relax Chamber. The LQC safety cap is attached with just a quarter-turn and will not permit operator removal when pressure exists in the transfer line from pumping or pigging. The Relax Chamber allows operators to ergonomically insert and remove pigs easily in less than 30 seconds without "stuffing" or "tugging" the compressed pig from the transfer line.
Why are Short Branch Piggable Tees with pig bars important to trouble free pigging?
To maintain high flow rates, all sides of the tee must maintain the same ID (internal diameter) as the surrounding pipe. Piggable Tees provided by Pigging Solutions have an uniquely integrated (not welded) pig bar across the tee branch opening to prevent pig hang-up in the tee branch and assure smooth transition of the pig through the tee. The Pigging Solutions short tee branch length minimizes the dead leg product residual above the pigged transfer line created by the tee branch.
I have a sanitary transfer application that requires CIP of the transfer system. Is it possible to have a pigging system where the pig is exposed to the CIP process to prevent risk of exposure to microbial growth?
For this unique application, Pigging Solutions provides Pig Launcher/Receivers with CIP Rise Chambers that permit both the pig and pig launcher to be exposed to the CIP process.
How can I be sure my pigging components are reliable and professionally manufactured to the appropriate industry standards?
All pigging components supplied by Pigging Solutions are manufactured by Hiltap Fittings, a division of OPW Engineered Systems. OPW is recognized world leader in the supply of fluid transfer equipment and Hiltap Fittings is leader in the manufacturing of pigging components designed for both operator safety and ease of use. All components are manufactured to the appropriate industry standards such as ASME B31.3 or Sanitary 3A.
I need to routinely conduct both simultaneous transfers and switch transfers between multiple supply sources to multiple destination locations. Is this possible with a pigging system?
Yes. Pigging Solutions supplies safe and easy to use hard piped Piggable Manifolds and 3-Way Piggable Diverter Valves that allow both simultaneous and sequential flow diversion between multiple sources and destinations.
Pigging though hose is not considered safe and is never recommended. However, pigging through hose can be done under certain rigorous conditions. Hoses must have piggable connection fittings on each end, the internal surface must be smooth, and the piping ID must either be schedule 40 or sanitary tube. To provide safety and minimize the risk of kinking, the hose should have armor, be rigid, and the length be kept very short. Pigging Solutions recommends the use of hard piped Piggable Manifolds as a safe alternative to hose pigging. Pigging Solutions does not recommend or supply hose for pigging applications, but will assist clients in evaluating potential applications with limited use of hose pigging.
I would like to eventually have an automated system but prefer to first start with a manual system. Is that possible?
Yes. Most manual components from Pigging Solutions can later be automated if desired.
If I want to see a system in operation, is that possible?
Pigging Solutions has many systems in operation across the USA. A few of these clients will permit Pigging Solutions to show non-competing company representatives these systems in operation.
What is the recommended pig speed?
Pig speeds of between 3-5 feet per second are recommended. Lower pig speeds only slow the pigging process and do not impact pigging performance. High pig travel speeds can result in both pig and system damage. Pigging Solutions assists clients in designing systems that effectively control pigging speeds.
System Design and Installation
Why is it important to have a pigging system professional design my pigging system?
In most cases, potential pigging system clients are not aware of the all the options and full capabilities of pigging systems. There are often trade-offs between cost and system performance levels. Pigging Solutions has the widest array of system options in the industry and works with each client to assure design and supply of a system that is cost effective and appropriate for the application. By working with Pigging Solutions, clients are assured of a properly designed system that performs reliably and does not result in expensive after installation modifications to ultimately achieve the desired level of performance.
Does the pigging application have an impact on system design?
Absolutely. Pigging system design varies depending on such factors as the level of residual that can be tolerated in the line after pigging, the number of input sources and destination locations along the line, flexibility to make simultaneous transfers and cross-connect between multiple supply sources and multiple destinations, chemical and physical properties of the products to be pigged, the pipe schedule to be used, and other factors. Pigging Solutions works with each client to design pigging systems that meets the specific application needs.
Do the products to be pigged have an impact on system design?
More aggressive chemicals, high temperatures, and high viscosity can all have an impact on system design. Pig materials that are more resistant to high heat and chemical attack are also less physically forgiving to bending and flexing. Systems requiring the use of more chemically resistant or heat tolerant pig materials will benefit significantly from system designs that minimize flexing and bending. Similarly, viscous products will also benefit from system designs having more sweeping elbows that lower system pressure required to propel the pig. Pigging Solutions will provide system designs appropriate the products and application.
Does the choice of piping have an impact on the pigging system design and operation?
Only in applications using schedule 10 piping. There are no standard valves having schedule 10 porting. Pigging Solutions can provide system designs that do not use valves or can provide designs using special schedule 10 ported piggable valves available from Pigging Solutions.
Does the orientation of system components have an impact on performance?
Pigging component orientation can have an impact on residuals remaining in the line and ergonomic access for operators. Pigging Solutions will be happy to review installation plans and provide recommendations.
Do I need special valves in a pigging system?
Pigging systems require that all components in the line, including valves, be very close or the same ID (internal diameter) as the piping. For sanitary tube and schedule 40 piping, standard "full port" valves are satisfactory for pigging. However, for schedule 10 piping, special schedule 10 ported valves are required for trouble free pigging. Schedule 10 ported piggable valves are available from Pigging Solutions. Pigging Solutions can also provide system designs for schedule 10 applications that do not require the use of isolation valves.
Do I need special pipe or tubing for a pigging system?
In most instances, whatever piping type and surface finish that is suitable for the product transfer is also suitable for pigging. Sanitary tubing as well as both tubular and seam welded pipe are all suitable for pigged transfer applications.
Do I need to hire a piping contractor experienced with pigging systems?
Prior experience is always a plus but not a requirement. Any quality piping contractor with certified welders can meet the recommendations for piggable pipe welding and installation. Installation recommendations for piggable piping systems are available from Pigging Solutions.
Is it beneficial to have long radius "sweep" elbows in a pigging system?
Though pigs can pass effectively through standard 1.5D radius elbows. However, the use of more sweeping 3D or 5D radius elbows provide benefit by lowering system pressure requirements and increasing pig life. The degree of benefit depends on the nature of the application. Pigging Solutions provides system designs appropriate for the products and applications.
Pigging is key component of a larger project being managed by an engineering firm. How can I assure the pigging system will meet my application needs?
Pigging Solutions routinely works jointly with both engineering firms and end user clients to assure provision of a cost effective and application appropriate design. We recommend Pigging Solutions be permitted to work directly with the client in developing the pigging system. Once the design is approved by the end user client, Pigging Solutions can provide the needed components and desired level of installation and commissioning assistance to the engineering firm managing the overall project.
Is line cleaning recommended prior to pigging system commissioning?
Line cleaning using a combination of brush and foam surfaced pigs help to remove welding and other debris that may have accumulated in the pipe during installation and storage. Though highly recommended for carbon steel pipe, cleaning prior to pigging is often recommended for stainless steel piping as well. Line cleaning components are low cost. Line cleaning components and recommended procedures are available from Pigging Solutions.