recent Questions We’ve Been Getting About Pigging
Having over two decades experience in the process pigging industry, we’re always being asked a host of questions on liquid product recovery (pigging) and distribution systems. So, we’ve listed some of the most recent questions we’ve been getting asked. For reference, previously questions we’ve been asked about pigging can be found on the pigging system FAQs section of our website.
For anyone who is reading this blog and is unfamiliar with pigging technology and how it works, here’s an explanation of pigging.
Also, if you have any other questions that you’d like to ask, please comment on the form at the bottom of this page.
How Long Does a Pigging System Take to Install?
Although pigging systems offer many clear benefits and deliver a high return on investment (ROI), some manufacturers and processors decide not to go ahead and install a system. There are many reasons for this, however, one of the most predominant reasons is due to concerns regarding installation times and downtime of the plant.
It would be great if we could give you a clear-cut answer on how long a pigging system takes to install. However, that’s not possible. That’s because pigging systems are bespoke and designed around the precise requirements and needs of each customer.
Generally speaking, a standard single-pig system with one launch and one receive return, installation including electrical, pneumatic and mechanical, on average takes around 2-3 days. However, please note this could be shorter or longer depending on the customer. Other types of systems such as tank drops offs would take slightly longer to install.
Nevertheless, regardless of the system, we’ll keep downtime to an absolute minimum, limit disruption to operations and work around your schedule.
Does the Length of the Pipeline Determine the Installation Time?
No, the length of the pipelines does not determine the installation time. Installation time is dependent on the amount of equipment being installed and the number of pipelines.
We Manufacture Paint. Are all Pigging Systems Designed Hygienically?
Most HPS pigging systems and components are designed hygienically which reduces cross-contamination and enables fast and efficient cleaning processes.
Many people assume hygienic design is just applicable for food and beverage related manufacture. However, more and more manufacturers such as paint and coatings companies are implementing hygienic pigging systems to reduce the threat of a microbial attack and contamination and ultimately reducing the risks of product recalls.
However, not all pigging systems are designed hygienically as in some cases it’s not needed.
My Product is Not Listed. Does that Mean it Can’t be Pigged?
Even if your product is not listed and your pipeline diameter ranges from 25 mm (approximately 1 inch) to 203 mm (approximately 8 inches), there’s a high chance we can pig it.
Almost any product that can be pumped, can be pigged! So, make sure you send in an enquiry to find out. Our friendly and knowledgeable team will be more than happy to assist you.
How Much Does a Pigging System Cost?
We previously looked at how much a pigging system costs in a blog article, so take a look!
All pigging systems are bespoke, therefore there’s no such thing as a standard pigging system and a standard price. But, generally the price of a pigging system is made up of the following:
- The cost of the system itself
- Installation and commissioning costs
- Software and programming (if applicable)
There’s also the option for additional extras such as service plans, training, and spare part kits.
What’s the Longest Pipeline You Can Clean?
The team at HPS have a wealth of experience in installing long pipe runs. As an example, HPS installed a pigging and liquid distribution system for an Australian winery and the bi-directional pig travels over 3000ft (which is just under 1km). Similarly, HPS installed a pigging system for a bottled water supplier in Canada and the pig also travels a very long distance of 1km.
Importantly, regardless of how long or short the pipe is, the process pig will not get stuck and will effectively travel through the pipelines and recover up to 99.5% of product.
What Information Do I Need to Provide for a Pigging System Quote?
In order to provide an accurate pigging system quote, we’ll need as much information as possible about your processes and project. The most important details we’ll need are the product you are wanting to pig, pipeline inside diameter and length plus the number of product sources and destinations.
Other important details include project objectives such as increasing product yields, reducing waste, reduce cleaning time etc and information on how you currently clean between changeovers and how frequent you carry out changeovers. The more information we have about your project, the more accurate your quote will be. Getting a quote from HPS is quick and easy – please see our request a pigging system quote form.
How Long Do Pigging Systems Last?
If properly designed and maintained, pigging systems will last a very long time. In fact, some HPS systems are still in active use after two decades. That’s because HPS systems are highly effective, durable, reliable and long-lasting.
In order to ensure your system remains in tip-top condition and delivers optimum performance, pigging system maintenance is critical. Nothing lasts forever, so routine replacement of certain components such as pigs and seals will help improve the lifeline of your system. At HPS we offer pigging system service plans which will give you peace of mind and save you money in the long run.
All pigging systems come with a 12-month warranty. However, our pigs are also guaranteed for 30 kilometers or 18 miles of use (subject to terms and conditions). This is a figure which is unmatched by other pigging companies. Our automatic pigging solutions also come with pig usage software, which tells operators when the pig is nearing the end of its working life and needs replacing.
How Could a Pig be Introduced into an Automated System and be Removed Without Manual Intervention?
Automatic pigging systems are often ‘closed’ systems, where the pig is held in a special housing at a launch station (and sometimes a receive station), which enable the system to automatically introduce the pig to the line as and when required.
As well as storing the pig when not in use, HPS launch housings are designed so that the pig can also be cleaned and CIP’d without it being removed, and of course, introduced automatically as required by the pigging sequence.
Please note that even in automatic pigging systems, pigs do need to be removed from time to time for maintenance and inspection.
Any More Questions?
If there’s anything we’ve missed, please don’t hesitate to contact HPS!