Pigging system ALBERT Franck – Regional Sales Manager ANDRE Gwénael – Support Sales Engineer 08/10/2018 DEFINOX 1
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Benefits of pigging system • Less product loss and time-consuming cleaning • Fully hygienic design with Station models certificated 3A (option) • Safe operations philosophy : • Mechanical parts with safety design • No removal of the pig for cleaning operation 08/10/2018 DEFINOX 3
Benefits of pigging system • High customizable solutions supported by engineers team: • Available from DN1’’ to 6’’ on most common standards • (DIN / US / SMS) • Stations customized for precise matching of process • Additionnal accessories item available ( valves, tools and electrical junction box in option) 08/10/2018 DEFINOX 4
How install stations in good position Installation of the station in The pig must be at the bottom -> vertical position OR horizontal Installation of the station in position vertical position Standard station not possible to CIP station (cleaning pig) clean the pig in this station 08/10/2018 DEFINOX 5
How to push the pig, an example : To be welded To be welded Install a reduced TE Install a reduced TE Product / CIP Product / CIP Unit Push pig air Unit Push pig air of or water of or water valves valves Drain air or water Drain air or water 08/10/2018 DEFINOX 6
GENERAL INSTALLATION INSTRUCTIONS 1- Bends must be avoided immediately after the scraping stations (10 D minimum). SCRAPING STATIONS Our scraping stations are designed to be installed vertically unless specified otherwise in the order. The through flow and pressure (over gas) of the actuating fluids must be adjustable to allow the entire assembly to be optimized. Use of a precision pressure regulator is essential for the air, and the range of adjustment must be limited (e.g. 0 to 2 bar) For installation of supply and escape valves, please refer to the valve installation instructions. Check the positioning of the scraper sensors after tests under operating conditions as extra sensors may be require. NB: When undertaking sawing operations, make sure you avoid introducing any splinters or filings into the pipes and flush them out thoroughly so as to avoid any deterioration of the seals when the system is put into operation. STORAGE We recommend that you store your scraping stations for as long as possible away from the pollution generated by the work site (dust, abrasives, impacts, acid or chlorinated products, UV, etc.) and, where possible, assembled, so as to avoid any mixing of components. REPLACEMENT PARTS - VALVES AND SCRAPING STATIONS. On your request, we can supply you with the reference numbers for the component parts of your valves and scraping stations. You can also identify the serial number from the number cold-stamped on the valve actuator. Dismantling the operator is a simple but delicate task calling for the appropriate tools and adherence to the valve's maintenance instructions. We will be happy to obtain these instructions for you or to carry out any maintenance work in our workshops or on your site. EEC CONFORMITY Our valves comply with European regulations (EEC) within the limits of use described in paragraph B. CE mark on the valve indicates the conformity to the following regulations : B- Use limits Use pressure has to be lower than 10 bars for all products. In case of dangerous gas (1) valve diameter (line) must be below 100 mm. For use outside these limits, please contact our technical service. (1) dangerous gas : group 1 gas , identified by a letter on the label and on the security card of the product : E (for detonating gas), O (for fuel), F+, F and R10 (inflammable), T+ and T (toxic). For additional information, please see regulation 1272/2008 "Labelling of dangerous products". 08/10/2018 DEFINOX 7
GENERAL INSTALLATION INSTRUCTIONS 2- To allow you to install your automatic scraping system under optimum conditions, we recommend that your read carefully these notes describing the main steps for commissioning the equipment and the instructions to be followed. OPERATING CONDITIONS Operating conditions for the scraping system are extremely variable (pressure, temperature, viscosity), and consequently you must check that the characteristic features of the entire system correspond with the technical specifications for the relevant process. If you are in any doubt, do not hesitate to contact us. CONDITIONS FOR AIR SUPPLY The actuators are supplied by filtered, dry air at a pressure of 4.5 to 8 bar. The air connections provided for the operator are designed for connection with 4/6 diameter flexible pipes. PRESSURE AND OPERATING CONDITIONS. The system withstands a maximum operating pressure of 8 bar , a maximum scraping pressure with gas of 2 bar (differential pressure of displacement of the pusher between 0.2 at 2 bar), recommended scraping speed 1.2 m / s. INSTALLATION OF SCRAPING STATIONS IN A PROCESSING LINE When installing the assembly in line, so as to avoid damaging the seals, it is imperative that the body to be welded should be disconnected from the rest of the scraping stations. · CIRCUIT DESIGN. Orbital welding is strongly recommended for scraping system lines (undercut and over-thickness less than 0.5). No sharp angles. Pipes provided bare without insulation to allow any repairs required before start up. The elbows should be only 90 ° and with a minimum radius of 3D, (lower beam, to consult us) so as to achieve more regular scraping. The installation of strips is recommended on reduction Tees (refer to drawings below). Check the alignment of the valves the scraper crosses (e.g.: ball on ball valves) The use of self-centring clamp or SMS or DIN connections is essential on scraping system lines (examples of selfcentring connections below) Clamp Plain part Flange Threaded part 08/10/2018 DEFINOX 8
DETECTORS DOCUMENTATION Detector of pig 7008349 Detector of blocking actuator 7008367 Detector of pig 7008349 Detector of clamp 7008348 Detector of connection 7008348 Detector of pushing actuator 7008367 08/10/2018 DEFINOX 9
DETECTORS DOCUMENTATION 7008367 08/10/2018 DEFINOX 10
DETECTORS DOCUMENTATION 7008349 08/10/2018 DEFINOX 11
DETECTORS DOCUMENTATION 7008348 08/10/2018 DEFINOX 12
DETECTORS DOCUMENTATION ATEX zone 2 Detector ATEX of pig 7008208 Detector ATEX of blocking actuator 7008416 Detector ATEX of pig 7008208 Detector ATEX of clamp 7008279 Detector ATEX of connection 7008279 Detector ATEX of pushing actuator 7008416 08/10/2018 DEFINOX 13
DETECTORS DOCUMENTATION 7008416 ATEX 7008416 08/10/2018 DEFINOX 14
DETECTORS DOCUMENTATION 7008208 ATEX 08/10/2018 DEFINOX 15
DETECTORS DOCUMENTATION 7008279 ATEX 08/10/2018 DEFINOX 16
Pig 08/10/2018 DEFINOX 17
North South 08/10/2018 DEFINOX 18
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T Pipe can create 2 problems 08/10/2018 DEFINOX 20
T reduced and rod are needed 08/10/2018 DEFINOX 21
T reduced and rod are needed 08/10/2018 DEFINOX 22
T reduced and rod are needed 08/10/2018 DEFINOX 23
3D or 5D elbow is strongly recommanded ØD 08/10/2018 DEFINOX 24
The propellant pressure must be controlled with air unit automatic volume flow Near stations, the pressure or flow must be decreased If not, the pig will speed-up and can be damaged or damages stations 08/10/2018 DEFINOX 25
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