Components
The pigging system/product recovery system required some key components associated with the operation of the pigging system. Our pigging systems are designed to provide optimum benefits and cost balance for clients. Without sacrificing operator safety or utility.
1. Pipeline Pig
The purpose of the technology is to recover or remove residual remaining in the pipelines. This is achieved by using a specialist projectile (Pipeline Pig). The pipeline pig is an integral part of a pigging system. A “pig” is a tool that is sent down a pipeline and propelled by the pressure of the product flow in the pipeline itself.
2. Piggable Pipe
For the pigging process, special seamless pipes are used as the internal diameter of the pipe is the most crucial part of the system. A pipe is inspected to minimise defects like ovality, surface dents or dimensional defects. For the smoother operation of pig, various polishing operations are performed on the internal diameter of the pig
3. Valves
In a pigging system, valves are used for mainly two reasons:
1. To isolate the piggable pipeline.
2. To redirect the flow in the pipeline.
Piggable valves are specially designed to have a bore of the same size as the pipeline that it is attached to, so that pig can pass through without any obstructions, when fully opened.
The pigging system involves mainly 3 types of piggable valves:
1. 2Way Piggable Ball Valve
2. 3Way Piggable Ball Valve
3. T Port Valve
4. Bend
Piggable long radius bends are specially fabricated to provide smooth pig passage with minimal increase in pressure requirements. Piggable bends can be provided for any pipe size, schedule, and material construction. Piggable bends are specially fabricated to meet stringent ovality tolerances. Elbows are provided with a straight face on each end to guarantee a smooth transition of the pig through the elbow.
5. Tee
The Piggable Tee is designed in such a way that they allow pigs to pass through. The Piggable Tee provides supply and discharge points in the pigged transfer line. The design of the piggable tee assures smooth passage of the pig through the tee without hang-up in the tee branch and minimizes residual product trapped in the tee branch’s dead leg.
6. Pig Detector
A pig detector is a sensing tool used to detect the movement of a pig in a pipeline during pigging operations. The detector is installed on the exterior of the pipe and consists of an indicator (such as a LED light) that alerts operators to the pig’s proximity.
The pig detector is the most important sensor for the automation of the system.
Pig detectors are usually placed near the launching and receiving stations, and they are useful for confirming the progress of the pig through the pipeline.
7. Welding Sleeve
To maintain the surface ID of a piggable pipeline, welding of two pipelines is done differently.
Instead, if two pipes are welded directly, it can lead to damage to the ID surface at the welding region, hence the Pigging system uses welding sleeves.
Welding sleeves allows making weld joints on the outer surface of the pipe without any structural loss or leakage in the pipeline. It also helps to make a joint structure stronger than a direct joint.
FAQ
What is a pipeline pig, and what are its primary functions?
A pipeline pig is a device inserted into a pipeline that travels through it, driven by air or the flow of the product within the pipeline. Pipeline pigs are used for various purposes including recovery, cleaning and maintenance.
What are the benefits of using piggable pipes?
Using piggable pipes offers numerous benefits across various industries. Firstly, they enhance operational efficiency by facilitating the easy and cost-effective cleaning of pipelines, which helps maintain product quality and integrity. Piggable pipes also enable efficient pigging operations for product separation, batching, and reducing downtime and maximizing productivity.
Can pigs effectively navigate bends in a pigging system?
Yes, pigs can navigate bends in pigging systems, but the design of the bends is crucial for effective pig passage. The bends should have a sufficient radius to prevent the pig from getting stuck or damaged. Typically, a bend radius of 1.5 times the pipe diameter (1.5D) is recommended for smooth and effective pigging operations. 3D or 5D bends are also used for better movement of pigs in certain processes. Using specially designed pigs that are flexible and capable of handling various pipe configurations can also improve their ability to navigate bends.
What types of pigs are suitable for pipelines with multiple bends?
For pipelines with multiple bends, flexible monobloc pigs are generally more suitable. Foam pigs, bi-directional pigs, and spherical pigs are commonly used in such scenarios.
How do you ensure that the valve selection in a pigging system is appropriate for the application?
Ensuring appropriate valve selection in a pigging system requires a comprehensive understanding of the system’s requirements and constraints. Firstly, evaluate the specific needs of the application, considering factors like pipeline size, pressure, temperature, process and the nature of the product being transported.
What are the common materials used for tees in pigging systems?
Tees in pigging systems are typically made from materials that offer high durability and corrosion resistance to handle various fluids and environmental conditions. Common materials include carbon steel, stainless steel, and sometimes special alloys depending on the specific requirements of the application, product & pipeline.
How do you maintain tees in a pigging system to ensure long-term reliability?
Maintaining tees in a pigging system involves regular cleaning, and repairs as necessary. Cleaning involves removing any buildup or debris that could obstruct the flow or damage the pig.
What types of pig detectors are available, and how do I choose the right one for my system?
There are several types of pig detectors, including magnetic, acoustic, pressure-based, and electronic (RFID) detectors. The choice depends on factors such as pipeline material, pig type, operational environment, and specific detection requirements.
How do I install and calibrate a pig detector in my pigging system?
Installation typically involves mounting the pig detector at strategic locations along the pipeline, such as launchers, receivers, or critical points where pig tracking is essential.
What materials are welding sleeves typically made from?
Welding sleeves are commonly constructed from durable materials such as stainless steel or carbon steel, chosen for their resistance to corrosion and ability to withstand the operational demands of the pigging process.