One question that we get asked a lot is “are your pigging systems compatible with our existing pipelines?” And the answer to that question is usually “yes”. So, here’s an explanation of how our pigging systems can integrate into existing pipelines and some of the things that might need to be changed.

The most important thing for you to know is that we want to make everything as easy as possible, with minimal disruption. The earlier you talk to us about your requirements, the better!


HPS Product Recovery Solutions work with a large range of pipe codes and standards, including ASME, ASTM, API, BS, ISO, and DIN.

The most important thing about the pipelines is that they are free from dents and damage, and that they are of a consistent diameter throughout the piggable length. The vast majority of existing (and new) installations are already in good condition, so it usually isn’t something that you’ll have to worry about.

Our expert team will check that the pipelines are suitable for use with a HPS pig before installation and will make recommendations regarding any upgrades that need to be made to ensure the success of an HPS pigging and product recovery system.

The existing layout of your pipes and equipment will also be taken into consideration when we design your pigging system (remember, all HPS pigging systems are bespoke!). HPS have over 27 years of experience in designing and commissioning pigging systems and will be able to guide your chosen installer every step of the way. We will provide 3D renders of the pigging equipment to be installed and be available for consultation throughout the process.


The welding of the pipeline is also key to the success of a pigging system. We strongly recommend orbital welding for your pipe connections as these shouldn’t pose any obstacles to the installation of an HPS pigging system, however HPS will use a special foam pig to ensure that your pipelines are free of any welding burrs or other intrusions, significantly decreasing the risk of damage to the pig and any potential contamination of the product.


Valve types are an important consideration to make when integrating an HPS pigging system into an existing production line. While many types of valves are compatible with pigging, there are a few that aren’t and would require an alternative replacement. Typically, valves that aren’t piggable have an internal obstruction, such as butterfly valves. The best replacement for a butterfly valve would be a ball valve, which performs the same function and enables a pig to pass through it.

Companies that use matrix valves may find that they would benefit from replacing their existing matrix valves with HPS max-yield matrix valves, which will enable production lines with multiple connected source and destination points to recover the maximum amount of product quickly and efficiently.


Unlike other companies, HPS does not require any specialist bends. The flexibility and shape of the HPS pig enable full body contact to be maintained, even when going around a 1.5D bend. This means that the installation of a HPS pigging system is faster, simpler, and more cost effective than other suppliers, who may require bends to be changed for their pig to travel along the length of the pipe without risk of obstruction.


Another concern we frequently come across is how the operational technology that powers the pigging system will be integrated into the PLC. Many companies are concerned that they will have to install an extra PLC panel & HMI to facilitate the pigging system, however HPS do not require this. Our dedicated team will write the necessary code and integrate it into the existing production PLC code, ensuring a seamless transition from product transfer to pigging and back to product transfer.


HPS have over 27 years of experience installing pigging systems into existing pipelines, making us process system experts.

Contact us to find out more about how we can help your company increase product recovery rates without causing major inconvenience to ongoing production.

Remember, the sooner you get us involved, the better!

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