In this second part of our interview with our product recovery experts, we cover how effective pigging system design impacts efficiency and performance, is customisable and innovative, and the support that HPS offers before, during, and after implementation.
Efficiency and Performance
Peter Elgar, Director
What are the typical efficiency gains and product recovery rates that can be expected from an HPS pigging system?
HPS pigging systems have a phenomenal product recovery rate of up to 99.5% from full pipelines – it’s actually the best quantified recovery rate on the market.
The patented design of the HPS hygienic pig is responsible for the recovery rate being so high – unlike other pigs, the HPS pig doesn’t have a solid magnet in the core but has a magnetised silicone core which enables flexibility, even around 1.5D bends. It also doesn’t have fins or wipers or discs, which means that product isn’t getting caught in the pig itself, and the uniform profile of the pig gives full body contact with the pipeline and prevents product bypass.
In terms of efficiency, the pig travels very quickly through the pipeline and speeds up changeover and cleaning times by about 80%, depending on product viscosity and pipeline length and diameter.
How does the design of a pigging system contribute to reducing environmental impact and operational costs?
The environmental benefits are many, and they influence the operational costs of the pigging system, and production in general.
As a rule of thumb, manufacturers can expect a waste and water reduction of about 20%, again depending on factors such as product viscosity and pipeline measurements. Pigging also saves energy, cuts effluent, and reduces effluent-related transport, treatment, storage, and disposal costs.
The reduction in the amount of product to be removed from the pipelines during changeovers and cleaning also means that clients are saving money on chemicals, energy, and non-productive labour. This is a significant amount of cost savings for some companies, particularly if they do hot flushes, which are energy intensive.
And, finally, the best environmental benefit of all, is that pigging cuts scope two carbon emissions! We did a carbon study with one of our clients, a paint manufacturer, and a carbon measuring company back in 2022, and the results blew me away. We’d kind of figured that HPS pigging technology reduced carbon emissions but seeing the report and finding out that pigging actually reduces carbon emissions by up to 99.3% was brilliant.
Customisation and Innovation
Dennis Stewart, VP of Technology Solutions
How does HPS tailor pigging systems to meet the needs of different industries?
We work with a really wide range of industries, from food and beverage to chemicals and paints, so there are certain things that we have to consider when designing the systems, such as the client’s objectives, internal pipeline diameter, number of changeovers, and product composition.
It’s the product composition that mainly influences how we design a pigging system. If a client needs to meet a high standard of hygiene, then we might, for example, propose a different valve then we would for a client who doesn’t need to reach such high standards.
Different industries require different types of pigs as well, so we look at the product, do some testing, and then select the most suitable pig for the process.
What recent innovations have been developed by HPS to enhance system performance?
We released the second generation of the HPS AccuTect pig detection system a couple of years ago. This version of the AccuTect has an IP67 rating and LED lights for increased visibility throughout the plant, plus we made some modifications to the detection technology that enables faster detection and communication with control systems.
We also designed a new piggable valve called the “Max Yield Valve”. This valve eliminates dead pockets, increasing product recovery and reducing cross contamination. It’s now become one of our most popular valves to be included in pigging system designs.
Implementation and Support
Cathal O’Sullivan, Engineering Manager & Andrei Cox, Client Support Director
What is the typical timeline for designing and implementing a custom pigging system?
We work with the client’s engineering team to ensure that the technical details align with the customer’s process requirements. Achieving clarity on items such as equipment and pipeline connection standards, material compatibility with the product and/or chemicals used in the system, the device communication protocols, and so on is important, as these all have an impact on the design of the pigging systems.
Communication to achieve this level of detail and process understanding is characteristic of our service. There’s no need for a client to purchase “off the shelf” assemblies, should there be a requirement for a more bespoke design.
Our design team then finalise the pigging systems general arrangement drawings, which we then share with the customer to ensure eventual onsite integration between the transfer pipeline and HPS equipment is seamless once the pigging system is delivered. We can also supply 3D modelling of the system for the client to integrate into a plant/factory model.
The lead time on HPS pigging systems varies based on the level of customisation required, however we do always aim to have the systems delivered as soon as possible, ready for installation and commissioning at the client’s convenience.
What kind of training and support does HPS provide to ensure the successful operation of a pigging system?
To begin with, every client gets a full training course for operators during commissioning. This training is given onsite and is both classroom and pipeline based. The commissioning HPS engineer goes through every aspect of the pigging system, including general controls operation, fault finding and troubleshooting, and the “dos and don’ts” of pigging system operation.
Optional training is also available after commissioning, so clients can receive periodic operator top-up training and pigging system maintenance training. We also offer maintenance support if needed and we have a dedicated client support team who are available to assist with technical queries and consumables ordering.
On top of that, we also have “how-to” videos that clients can access. These videos cover things like how to check a pig for wear and how to change the seals on different valves.
Find Out More
If you’d like to find out more about HPS Product Recovery Solutions pigging systems, please get in touch!
You can reach us via email, telephone, or contact form, and a member of our team will be in touch with you as soon as possible. We look forward to hearing from you!