Manufacturers of liquid and wet products use pipelines with a wide range of internal diameters and lengths, primarily determined by their product and facility layout.
HPS Product Recovery Solutions, a leading provider of Advanced Liquid Product Recovery (Pigging) Technology, frequently receives enquiries from companies seeking pigging equipment for pipelines ranging from 1.5-inches to 8-inches in diameter.
The length of these pipeline networks also varies significantly in length, spanning from just a few metres to several hundred metres. Typically, HPS receives enquiries for pipelines between 100 metres and 500 metres. But that doesn’t mean that longer pipelines aren’t pigged.
Pigging: A Quick Overview
Pigging, more formally known as liquid product recovery technology, is a method of product recovery used by manufacturers in many different industries.
Through physical and controls integration, HPS automated pigging systems work by inserting a specialist projectile called a pig into the pipeline. The pig is then propelled through pipeline using a suitable propellant, pushing any residual product to the destination.
HPS pigging systems have the best proven product recovery rate on the market, with up to 99.5% of product being recovered, ready for further processing, packaging, and sale.
Pigging for “Standard” Length Pipelines
Pigging for pipelines of up to 500 metres is generally quite simple and straightforward. The pig’s journey through the pipeline is relatively quick and fewer components are required.
Here are some key characteristics of pigging for shorter pipelines:
- Fewer pig detectors: Shorter pipelines typically require only two AccuTect pig detectors – one at the launch station and one at the receive station. These pig detectors allow operators to keep track of the pig’s location and inform the controls system of when to increase and decrease the propellant pressure.
- Simpler automation: The control system for shorter pipelines can be less complex, as there are fewer variables to manage during the pigging process.
- Faster product recovery: Due to the shorter distance, the pig can complete its journey more quickly, leading to faster product recovery and shorter changeover times. In one HPS pigging system, the pig travels 200 metres every sixty seconds!
- Lower pressure requirements: Shorter pipelines generally require less propelling force to move the pig through the system, resulting in reduced resource consumption.
The return on investment varies for every manufacturer, meaning HPS never sells a system that won’t prove their worth. If you have a pipeline of short length but you process a high-value product, get in touch – we’ll help you however we can!
Pigging for “Longer” Pipelines
Pigging for longer pipelines of over 500 metres can present additional challenges and require more sophisticated solutions.
- Multiple pig detectors: Longer pipelines benefit from additional AccuTect pig detectors installed periodically along the line. This provides more precise tracking of the pig’s location and quick communication with the PLC ensures that the propellant pressure remains consistent.
- More complex automation: Longer pipelines often require more advanced control systems to manage the increased number of variables and ensure efficient operation.
- Higher pressure considerations: Longer pipelines may require higher pressures to propel the pig effectively, necessitating more robust equipment and safety measures.
- Extended product recovery time: Although the pigging process for longer pipelines takes a bit more time, the process is usually faster than flushing or pipeline dismantling.
Regardless of pipeline length, HPS pigging systems offer significant benefits, including increased product yields, reduced waste, and improved sustainability. The company’s expertise in designing custom solutions ensures that you can implement an efficient and effective pigging system tailored to your specific needs, no matter the pipeline length.
By understanding these differences, manufacturers can better appreciate the complexities involved in implementing pigging systems for various pipeline lengths and make informed decisions about their product recovery processes.