HPS engineer using HMI control

Pigging Health Software for Effective Maintenance

Maintaining the health of your pigging systems is paramount for operational efficiency and productivity. Pig Health Software, developed by HPS, streamlines maintenance processes, ensuring optimal performance and longevity of your equipment.

The Importance of Pigging System Maintenance

Maintenance and upkeep are key concerns for businesses that invest in capital equipment for several reasons.

Financial Considerations

Firstly, such equipment represents a substantial financial commitment, and ensuring its efficient and effective operations over its lifespan is essential for maximising the return on investment. Proper maintenance is crucial for preventing downtime, as equipment breakdowns can halt production or disrupt services, leading to significant financial losses.

Safety Concerns

Safety is another primary consideration, as malfunctioning equipment can pose hazards to employees and consumers. Regular maintenance helps mitigate these risks by ensuring that equipment operates safely. This reduces the likelihood of workplace accidents and injuries.

Additionally, maintaining equipment extends its lifespan, allowing businesses to delay costly replacements and derive greater value from their investments.

Upholding Quality Standards

Furthermore, equipment performance directly affects the quality of products or services delivered by a business. Through routine maintenance, businesses uphold quality standards by ensuring that equipment operates at optimal levels, consistently producing satisfactory results.

Compliance with regulations and standards is another crucial aspect, as many industries have specific requirements regarding equipment maintenance and safety.

Regulatory Compliance and Reputation

Adhering to these regulations through regular upkeep helps businesses avoid fines, penalties, and legal liabilities.

Finally, preserving the company’s reputation is vital. Equipment failures or production delays due to inadequate maintenance can tarnish a business’s reputation among customers, suppliers, and stakeholders. By consistently maintaining equipment, businesses demonstrate reliability and professionalism, thereby enhancing their reputation in the industry.

The Right Maintenance Strategy for Pigging Technology

Implementing the right maintenance strategy is crucial for ensuring the efficient operation and longevity of the pigging equipment. In industrial contexts, several maintenance approaches are utilised to achieve this goal.

Reactive , Preventative, and Predictive Maintenance Strategies

One common approach is reactive maintenance, also known as run-to-failure. This is where equipment is only repaired when it breaks down or fails. Although this strategy can be cost-effective in the short term, it may lead to increased downtime and higher repair costs over time.

Preventative maintenance is another strategy involving routine inspections, servicing, and repairs at predetermined intervals. The goal here is to identify and address potential issues before they escalate into major problems, thereby reducing the risk of unexpected breakdowns and extending equipment lifespan.

Predictive maintenance takes a proactive approach by using data and analytics to predict when equipment is likely to fail. Various condition monitoring techniques are employed to detect early signs of deterioration.

Whilst there are other strategies that can be utilised, these are not relevant to the maintenance of HPS Advanced Liquid Product Recovery (Pigging) Technology.

What Maintenance Strategy Should You Use for Pigging Equipment?

When it comes to maintaining process pigging equipment, the choice between reactive, predictive, and preventative maintenance strategies depends on several factors.

Criticality and Consequences of Failure

Firstly, the criticality of the equipment and the consequences of failure play a significant role in determining the appropriate maintenance approach. Process pigging equipment that is frequently used in operations may require more proactive maintenance strategies to ensure reliability and minimise downtime.

Reactive Maintenance

Reactive maintenance may be a suitable approach for non-critical components, such as valve seal kits, with low downtime costs (although we do recommend that you stock seal kits, filters, and other such items to enable faster replacement – contact the HPS spares team to order consumables for your pigging systems). However, relying solely on reactive maintenance for pigging equipment could result in significant production disruptions.

Preventative Maintenance

Preventative maintenance involves performing routine inspections, servicing, and repairs at predetermined intervals. This proactive approach is well-suited for maintaining frequently used pigging equipment, ensuring reliability, and minimising the risk of unexpected breakdowns. By conducting regular maintenance tasks such as component replacement, preventative maintenance helps extend equipment lifespan and optimise performance.

Fun fact: The oldest HPS pigging system still in use is almost 30 years old!

Predictive Maintenance

Predictive maintenance relies on data and analytics to predict when equipment is likely to fail, allowing for timely intervention.

Having been in business for almost 30 years, HPS has been able to collect and analyse data regarding the durability of the HPS hygienic (sanitary) pig. The average lifespan of the HPS pig is approximately 30,000 metres (although this can vary depending on specific manufacturing conditions and product composition).

Having collected and analysed this data, we have developed the HPS Pig Health Software to provide operators with indications of how far the pig has travelled and when the best time to replace it is.

HPS Pig Health Software for Pigging System Maintenance

HPS Pig Health Software for pigging system maintenance takes a dual approach to maintenance strategy, lending itself to both preventative and predictive maintenance.

Based on data and analytics, Pig Health Software reminds operators to perform regular checks and changes of their pigs. The most common reason for decreased efficiency and effectiveness during pigging sequences is an overused pig.

Pig Health Software is integrated into PLC systems and automatically records the distance that the pig has travelled by communicating with the HPS AccuTect pig detection system. The distance is then shown on the HMI/SCADA panel and messages are displayed at certain points during the pig’s lifetime indicating when the pig needs to be checked or changed.

Seamless Integration

HPS Pig Health Software is included free of charge in most new automatic pigging systems and can also be retrofitted to existing HPS pigging systems. Our team can do this for you or they can provide you with the necessary code (after performing some compatibility checks).

Regular maintenance contributes significantly to the overall benefits of pigging systems that manufacturers achieve.

By not using worn or damaged pigs, businesses maintain optimal system performance, achieving high product recovery rates and decreasing production downtime. Companies are also able to better schedule maintenance, ensuring operational efficiency.

Get In Touch

To find out more about how HPS Pig Health Software will help you maintain your pigging systems and production efficiency, contact our Spares Team! We’re more than happy to help you through the process of integrating the software into your existing systems.

If you’d like to know more about HPS automated pigging systems and how they’ll benefit your liquid product operations, send an email to info@hps-pigging.com. We work with a variety of industries, including food, beverage, pet food, chemicals, paints, lubricants, personal care, cosmetics, and household products.

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