Our pipeline pigging program consist the manufacture of poly foam pigs, decoking pigs, moni-directional pigs fitted with cups (standard scraper or conical) and bi-directional pigs fitted with discs (soft sealing, hard guiding) and custom made pigs starting at size 2″ upto100″ for poly foam pigs and size 4″ upto60″ for mono / bi-directional pigs.
Mill scale, pipeline corrosion,even rock-hard mineral deposits are no match for rugged poly foam pig cleaners equipped with silicon carbide straps or flame–hardened wire brushes. Made from tough polyurethane foam, the Blue Series (5-7 lbs .cu .ft .density) feature a hard polyurethane criss cross pattern with spirally applied silicon carbide straps.
Use this type for removing hard encrustations in all pipe sizes over medium length runs. The Red Series (8–10 lbs. cu. ft. density) criss cross silicon carbide and wire brush poly foam pigs are recommended for longest runs, multiple turns and toughest cleaning action. The Special Series studded poly foam pigs are used for removal of hard estencrustations and used for decoking of industrial lines.
Blue or red criss cross poly foam pigs feature hard polyurethane bands spirally applied on tough polyurethane foam cores. Density ranges are 5–7 lbs. cu. ft.(Blue) and 8-10 lbs. cu. ft. Both type seasily turn 90 ells, cross tees and slip through valves. The Blue criss cross is ideal for new construction and on-stream cleaning. The Scarlet criss cross models are recommended for extra cleaning or wiping and for long pipeline runs.
When your pipeline maintenance calls for mild scraping, final drying or water removal after hydrostatic testing, select a Yellow Swab, Blue Bareor Red Bare poly foam pig. Bare poly foam pigs are made of durable, resilience flexible polyurethane foam ranging in density from 1 up to 10 lbs .cu .ft. Poly foam pigs resist mild acids, caustic solutions and hydrocarbons. The cylindrical Yellow Swab has a vapor seal on one end. The Blue Bare and Red Bare models are cylindrical with a bullet nose and dished end.
Poly foam pigs are industrial pipeline and municipal water main cleaners and product recovery devices. The basic design consists of a flexible, bullet shaped polyurethane foam cylinder. The rear end of the Poly foam pig is concave in order to allow more pressure to be exerted and create a tighter seal against the pipe wall.
This helps to prevent “by pass” of the propelling agent (water,air or product) and virtually eliminates product contamination. Over all length of Polyfoampigs (Blue and Red Series) are approx 2 times the diameter of the pipeline and over size of the bare pigs varies between 0.25” and 0.75” depending on size of pig and pipe grade.
Fast, safe and economical restoration off low and pressure within pipelines and tubular systems by the use of versatile poly foam pigs to remove unwanted “build-ups”causing restriction of the pipe’s internal diameter.
Excavations kept to a minimum, poly foam pigs can clean long distances in a single run, with out the need for numerous cut-ins that other cleaning systems require. poly foam pigs can clean lines,traveling at speeds up to 3 meter per second.
Contract work or technical supervision is carried out in compliance with Government regulations.
Progressive cleaning technique used, ensures that there is virtually no chance of a poly foam pig become plugged. Low pressures for propulsion of poly foam pigs.
Very short downtime.
Relative low cost of poly foam pigs.
No overtime,weekend, or surcharges.
Little or no disruption to normal production process since time taken is afraction of all other cleaning methods eg. Water jetting, Roding, chemical etc.
Occasional cleaning prolongs the working life-span of pipes.
Cost of water main and supply line cleaning can be reduced by up to 80% mainly as a result of the reduced number of“cut-ins”.
Prior to the use of poly foam pigs in the process industries, removal of residual product from transfer tubes was a long, tedious and expensive operation . The principal methods and their associated problems may be summarized
A) Blow down, using compressed air.
B) Manual brushing.
C) Flushing with water or solvent.
Method A most of the product still remaining adhered to the pipe wall and method B or C had to be used also.
Pipe work had to be dismantled to accomplish this task, involving manyman-hoursand substantial lost of production time.
Time consuming and due to the mixing of product with water or solvent, the residue was diluted beyond use and subsequently dumped into rivers, sewages or drainage systems.
In certain industries, this waste would create BOD (Biological Oxygen Demand), leading to problems with Water Authorities,
River Purification Boards, Environmentalist Groups, etc.
By contrast, industries which have made a small investment by using poly foam pigs, not only operate far more efficiently than their competitors, but can also save thousands of Euros each year.
• Save up to 100% product salvage.
• Reduce lost time on product changeovers.
• Increase production capacity.
• Eliminate BOD fines or bills.
FIGURE 1 Single Point Distribution
• When the mixing tank is empty, valve “B” is closed and “C” is opened.
• Clear compressed air propels the poly foam pig through the line, salvaging product as it travels.
• poly foam pig is then recovered from receiver / catcher.
FIGURE 2 Batching
With certain products it is not necessary to empty the line before running the next product. This can be achieved by means of batching.
FIGURE 3Multiple Point Distribution
Sequence of events.
• Production run of product “A” has finished.
• 1st. poly foam pig has salvaged product through 1st lateral distribution line.
• 2ndpoly foam pig is salvaging product through 2nd distribution line.
• Once the 4thpoly foam pig is located in the catcher, product “B” is ready to be pumped.
Poly foam pig unique ability to cross tees,turn short radius ells,travel through multi dimensional lines and pass through reduced openings (up to 65% reductions) such as valves, fittings, etc. Make it the ultimate cleaning tool, even for complex pipe work systems.
These may be manually operated,or fully automated systems incorporating state of the art electronic and actuator valves.
FIGURE 4 SINGLE PRODUCT TRANSFER LINE
This type of arrangement is mainly used inconstant production lines where build up succor quickly because of the nature of the product. Optimum hydraulic capacity can be maintained using poly foam pigs with out stopping production.
The diagram above shows schematically how the “progressive cleaning technique”works shaving off successive layers of encrustation gradually, so avoiding “plugged” line, while the diagram below illustrates the forces at work enabling the Red poly foam pig to clean efficiently and keep debris a head is a state of suspension.
1. Isolate the section to be cleaned.
2. Open all valves in the system.
3. Check direction of flow with Red Swab.
4. Run full size Red Bare; Measure it to determine true size of opening.
5. Run Red Criss Cross that will justfit opening in build-up with full line size Red Swab behind to ensure seal.
6. Graduate Red Criss Cross diameters in increments until full I.D. is accomplished.
7. Flush system with full sized Red Bare and examine. It should be undamaged and re-usable.