The address for pigging technologyI.S.T. Molchtechnik … · fittings and test pigging Installation Maintenance ... an interlock device and as a pig launching and receiving station

I.S.T. Molchtechnik GmbHThe address for pigging technology

Experience in pigging technology for more than 25 years

The principle of pig cleaning

Description of a typical pig cleared process flow system

Contacts

Product overview

I.S.T. provides the following services

I.S.T. Headquarters, Hamburg

recommend that you seek further advicefrom I.S.T.'s qualified project engineers andbenefit from their many years experience inthis specialised field. A full list of all contact addresses can befound at the front of our catalogue.

We endeavour to provide a very high levelof customer care and after sales service toall our clients. With this in mind we recom-mend that I.S.T. service engineers are uti-lised for start-up, commissioning and train-ing works. This will ensure that the piggingsystem is installed correctly and operates toyour total satisfaction.

P I G G I N G T E C H N O L O G Y

The pipeline contents are recovered by aspecial contoured plug, the "pig", which ismoved by a propellant. This method ofbatch separation is used in many industrieson a wide variety of products. All I.S.T. pigsand fittings are manufactured to thehighest possible standards, in order to en-sure that the optimum pigging results arealways achieved.

This catalogue provides outline details forall I.S.T. components and should enableyou to plan the initial configuration of theproposed pigging system. However, fordetailed system design and planning we

Pigging technology is the most cost effective and environ-mentally friendly method of simultaneous product handlingand pipework cleaning. This technology can be applied toalmost all types of industry.

The principle of pig cleaning

Description of a typical pig cleared process flow system.

This flow scheme gives an overview of how the range of equipment in the Catalogue could be con-nected together at a "typical" plant installation.

The pig loading and unloading stations (T 29 & T 39) are positioned at the pig launching stations.Tee-pieces (T 10), Tee-sleeve valves (T 01), Tee-ring valves (T 09), Three-way valves and differentmanifolds interconnect the product inlet points with the piggable distribution system.

The discharge of the products can then take place through barrel filling valves (T 50), Tee-ringvalves, Three-way valves, Tee-pieces and Loading arms (T 91) with a piggable filling head (T 02).Individually, all these units can also be used as Pig launching and receiving stations.

The choice of the correct piece of piggable equipment depends on several factors. Examples of thisare the characteristics of the products to be transferred, plus the required cleanliness / minimalcontamination aspects of the finished pipework. Experienced Engineers from I.S.T. are availablewith advice as required. This will ensure that the optimum selection of equipment, on both a costand suitability basis for your application, is chosen.

T H E P I G G I N G T E C H N O L O G Y

T H E C O M P A N Y

I.S.T. Headquarters, Hamburg

Engineering

Production /welding shop

Commercial orderprocessing

Technical orderprocessing

Design department

Production /machining

Qualitymanagement

Pig grinding

Assembly and repair

TechnicalSupport

R A N G E O F S E R V I C E S

I.S.T. provides the following services:

I.S.T. manufactures a wide range of bothwelded and cast fittings, providing a veryflexible product range.

• Welded fittings can be manufacturedaccording to individual customer require-ment.• Cast fittings are available in many diffe-rent designs to suit various functions. Allfittings are proven designs and providereliable operation and long service life forall parts (incl. seals).

In this catalogue you will find a résumé ofall fittings, pigs, accessories and servicesavailable from I.S.T

Technical data for standard product range:

Available diameters: DN 25 / 1" up to DN 250 / 10" (other sizes on request)Flanges: DIN or ANSIPressure: PN 16 / 150 lbs (other pressure stages on request)Temperature: up to 80°C (higher temperatures on request)Materials: carbon steel and stainless steelSeals: NBR, FKM, PTFE, AU (other materials on request)

◗Planning and conception of complete systems◗Retrofitting and modification of existing systems◗Piggable fittings and manifold systems◗Pipework◗Control systems◗Accessories◗Technical support◗After sales service – commissioning, training, etc.

T H E C O N T E N T S

Contents

Product group Type no. Description Section

Station, T-Shape 01 T-Sleeve valve AT 1Station, T-Shape 09 T-Ring valve AT 1Station, T-Shape 10 T-piece AT 2Station, T-Shape 10.3/4 T-piece as launching and receiving station AT 2Station, T-Shape 26 Filter as launching and receiving station AT 3Station, T-Shape 35 Pig launching and receiving station AT 3Station, T-Shape 43 Plunger valve AT 3

Filling station 02 Loading lance for tank trucks and tank wagons AB 1Filling station 91 Loading arm AB 1Filling station 50 Loading valve AB 1

Fitting, straight form 14 Pig receiving station with pig catcher ring AG 1Fitting, straight form 16 Pig launching and receiving station AG 1Fitting, straight form 17 Pig trap AG 1Fitting, straight form 29 Pig loading and unloading station AG 2Fitting, straight form 39 Pig loading and unloading station, swivelling AG 2

Three way valve 41 Three way valve, cylinder AW 1Three way valve 42 Three way valve, ball AW 1

Manifold 06 Rotary manifolds 1 to 6, 12 or 18 and 2 to 12 or 18 VT 1Manifold 06 Plug in manifolds VT 1Manifold 08 2/2 way valve VT 2Manifold 51 1 to 4 manifold VT 2Manifold 54 Modular multi direction manifold VT 3Manifold 57 Full system manifold VT 4

Pigs 19 DUO-pig M 1Pigs 19 DUO-Lip pig M 1Pigs 19 DUO-Lip pig with replaceable lips M 2Pigs 19 Jet pig M 2Pigs 19 Special pigs M 2

Connecting element 99 Product hose VE 1Connecting element 04 Swivel arm VE 1

Accessories 20 Pressure relief vessel Z 1Accessories 27 Sliding coupling Z 1Accessories 31 Pig sensor/Manual pig locator Z 2Accessories 32 Pig stop/Pig retainer Z 3Accessories 33 Swivel joint Z 3Accessories 34 Welding rings Z 3Accessories 45 Inline Blender Z 4Accessories 48 Control units Z 5Accessories 59 Pipeline and pipe bends Z 5Accessories 92 Measuring instruments Z 6Accessories 97 Air pressure booster Z 6

Service Engineering S 1Service Site supervision S 1Service Test pigging S 1Service Commissioning S 1Service Training S 2Service Repair and maintenance S 2Service Technical support S 2

Subject to alteration

Internationalrepresentativesfor I.S.T. pigging technology can be found in:Europe, USA, Canada,Asia and Africa.

U s e d A l l O v e r T h e W o r l d

If you are interested in a no commitmentquotation, and would like further informationabout the benefits of this kind of system,perhaps including detailed comparisons withother systems, please do call us. We will bepleased to send you more detailed information,or to give you advice at a more personal level:

Whether you require partialretrofitting or a completely newsystem, I.S.T. pigging technologywill suit your needs:System planningDesignPartial and complete solutions, i.e. pigging fittings, pipe layingand control systems, piggingfittings and test piggingInstallationMaintenance… all from one supplier.

■ = I.S.T.-Sales offices

• = I.S.T.-Representatives

USA / Canada / MexikoI.S.T. Pigging Systems431 Ohio Pike, Suite # 211 NCincinnati, Ohio 45255-3375Phone: + 1 - 5 13 - 5 28 49 49Fax: + 1 - 5 13 - 5 28 49 94e-mail: [email protected]

U.K. / IrelandI.S.T. Molchtechnik GmbHUnit 4B, Barrowmore Enterprise Estate,GB – Great Barrow, Chester CH3 7JSPhone: +44 - 18 29 74 15 55Fax: +44 - 18 29 74 18 88e-mail: [email protected]

I.S.T. Molchtechnik GmbHSchierenberg 74D-22145 HamburgPhone: +49 - 40 - 67 99 47-0Fax: +49 - 40 - 67 99 47 10e-mail: [email protected]: www.piggingsystems.com

I.S.T. Sales Offices:

BeneluxI.S.T. Molchtechnik GmbHMax Planckstraat 31NL – 2041 CX ZandvoortPhone: + 31 - 23 - 5 73 00 97Fax: + 31 - 23 - 5 73 03 96e-mail: [email protected]

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T-sleeve valve T 01

F I T T I N G S

The T-sleeve valve is a highly versatile fitting. Itserves as a piggable T-piece, an interlock deviceand as a pig launching and receiving station.This patented valve is available both as manual(with hand lever) and automatic version (withactuator).The T-branch can be locked with a sliding sleeveand the straight passage can be pigged pocket-free. The sliding sleeve is simple in operationand the seals are designed to have a long servicelife.The T-sleeve valve functions as a pig launchingand receiving station when a pig stop insert isinstalled. This station can be equipped with con-tamination control and other accessories (piglocators, pig sensors, pressure relief etc.).

Available diameters: DN 80 - DN 100 (3" - 4")

T-ring valve T 09

The T-ring valve has three functions: Piggable T-piece, product isolation valve and pig stop. Itis possible to use it as a single fitting or as a part of a manifold assembly. The T-ring valve isoperated automatically. Its straight through pas-sage can be pigged pocket free when the valveis closed. The T-branch is opened by the slidingring that also serves as pig catcher. Moreover,contamination is avoided by a spring-balancedseal design.


1.1 T-shape (incl. pig launching and receiving stations)

AT 1

T-piece T 10

F I T T I N G S

The T-piece is piggable in the straight passage.During the pigging process the special T-branchis completely sealed by the lips of the pig. Thefitting can also be equipped with a pig stop thatserves as a buffer for one and two pig systems.The T-piece is a welded fitting, especially suit-able for non standard designs, inner diameters,heating jackets etc.

Available diameters: DN 25 - DN 300 (1" - 12 ")

T-piece as pig launching and receiving station T 10.3

This pig station is applicable for one and twopig systems. It can be operated both manuallyor automatically. It is equipped with a pig stopinsert that catches the pig. This insert can be re-moved for pig change. Sockets for propellant aswell as electrical and manual pig sensing can beinstalled individually. In order to avoid the pigbeing pulled out of its position due to productturbulence a pig retainer can be mounted.

Available diameters: DN 25 - DN 300 (1"-12")


AT 2

Filter with pig launching and receiving station T 26

F I T T I N G S

This fitting combines the functions of a filter, apiggable T-piece and a pig launching and receiv-ing station. Pigging is possible up to the filter in-sert. The filter is a reversible-flow filter that canbe changed quickly. Moreover, it is available invarious mesh sizes.


Pig launching and receiving station T 35 with 90° branch

In principle, this station has the same functionas the T 10.3. The difference is that the T 35 hasno removable pig stop insert and therefore thestation cannot be opened. This has the effect ofreduced unpigged volumes. The risk of conta-mination is reduced. The station has a relative-ly low weight. This station is often used for hoseconnections where unloading of the pig is notnecessary.

Available diameters: DN 25 - DN 300 (1"- 12")

Plunger valve T 43

The Plunger valve T 43 can dose single productcomponents into the piggable line. The flow inthe branch is controlled by a piston. In theclosed position the piston closes exactly to thepipe's inner wall and thus leaves a pocket freepassage for the pig. The Plunger valve has adouble acting pneumatic actuator with springreturn so that in case of emergency an imme-diate closing of the station is guaranteed. Thenon-piggable branch can easily be cleaned byspecial rinsing connections.



AT 3

Loading lance T 02 and loading arm T 91

F I T T I N G S

Straight shape

Loading valve T 50

The loading valve is designed for filling ofdrums and other containers with a bunghole > 60 mm. The pig pushes the product directlyinto the filling station. Thus the contents of thenon-piggable area are fully drained. The load-ing valve can handle various filling operationssuch as top level, bottom level and bottombunghole filling. This valve design allows a fullyautomated piggable filling plant to be achieved.


AB 1

The loading lance is a fitting for application inpiggable filling plants. It is mounted at the end ofa loading arm and allows pipeline piggingthrough the complete loading arm. The pig cantransport the product into the loading lance orback into the initial source tank.The fitting is equipped with a level control switch.This enables the product to be transported backto the tank after loading and overfilling of tanktrucks or wagons etc. is avoided. Due to the factthat the loading arm is fully piggable, it is possibleto fill several different products through the sameloading arm. Product flow is controlled by a sli-ding sleeve installed in the loading lance. Thissleeve is operated by instrument air (positionsopen/closed/throttle). In case of emergency airfailure, the loading lance is closed automaticallyby spring.The loading lance achieves optimum functiontogether with the piggable Loading arm t 91.(below)

Piggable Loading arm T 91.

With the loading arm T 91 pigging through thearm into the filling valve is possible. It has largepositioning possibilities that can be adapted indi-vidually. Special constructions for top level andbottom level filling are possible, as well as a suc-tion device for the filling process. The loadingarms are available with mechanical or pneumaticlevel balancing.


Pig launching and receiving station T 16

F I T T I N G S

This station can also be used for both one andtwo pig systems. It is equipped with a pig stop in-sert. Internal and external bypasses can be fit-ted to allow rinsing/drying of pigs at the end ofthe pigging sequence. With help of the I.S.T.sliding coupling it is easy to connect the T 16 tothe pig loading and unloading station T 29.


Pig trap T 17

The pig trap is designed to catch the pig withinthe pipeline. With this simple fitting the pig canbe stopped at any desired position. Thus, it isalso possible to pig only parts of the pipeline. Itcan be applied to both one and two pig systems.It can be operated manually (hand lever), orautomatically.


Straight shape

Pig launching and receiving station T 14

The product can flow straight through this fit-ting whilst the pig is retained by the internal pigstop ring. It can be applied to both one and twopig systems. In order to rinse the pig the stationcan be equipped with internal and external by-passes. Thus, it is possible to clean the pig aswell as the non piggable area. After the fillingand cleaning process the pig is propelled backinto the launching station.


AG 1

Pig loading and unloading station T 29

F I T T I N G S

This station ensures safe loading and unloadingof the pigs. On the loading/unloading side it isequipped with I.S.T. sliding couplings (maleand female part) that facilitate a quick and safeunloading. After opening the pig can easily beremoved from the oversize section of the sta-tion. In order to avoid an unauthorised openingof the station it can be locked mechanically orpneumatically. With special accessories it can besecured by a safety control. The pipeline sidecan be equipped either with a flange or a fe-male sliding coupling. For safety reasons I.S.T.recommends the use of this station.


Pig loading and unloading station T 39

With this station the loading and unloading ofthe pig from a pipe system is also easy, fast andsafe. A part of the station can be swivelled out ofthe pipeline. Thus, a pressure free loading orunloading of the pig is ensured. So the processof pig exchange is made easier and operationalerrors are avoided. The pipeline side can be equipped with aflange. For safety reasons I.S.T. recommends theuse of this station.


Pig loading and unloading stations

AG 2

Three way valve T 41 (cylinder)

F I T T I N G S

This three way valve allows either two or threepipeline routes to be connected. The internalcylinder rotates and locks the desired connec-tion. Due to its shape the valve is almost pocket-free and is therefore successfully used in thechemical and in the paint industry. The T 41can be operated manually (hand lever), or au-tomatically. In combination with a pig stop in-sert and a pig sensor the T 41 can also be usedfor launching and receiving of a pig. Thus thepig can be reversed into another pipeline ordriven back into its home station.


Three way valve T 42

The three way valve T 42 has the same switchingfunctions as the T 41. The large bend radiusthrough the ball provides an optimum sealingwith a small torque for switching. The T 42 canbe operated with a lever or by a pneumaticactuator for two or three positions. In combina-tion with a pig stop insert and a pig sensor theT 42 can also be used for launching and receiv-ing of a pig. Thus, the pig can be reversed intoanother pipeline or driven back into its homestation.


Three way valves

AW 1

Rotary manifold T 06

M A N I F O L D S

The I.S.T. rotary manifold T 06 connects one ortwo supplies with up to 18 outlets. Thus, for ex-ample tank groups, mixers etc, can be inter-connected to 1 or 2 filling devices. The fully pig-gable version of the T 06 allows a pigging pro-cess from the tank up to the filling device. Themanifold is also available with dry break coupl-ings. These couplings shut both sides of the lineafter disconnection of the couplings.The I.S.T. rotary manifolds are available in thefollowing designs:


Distribution / Manifolds

I.S.T. plug-in manifolds

Plug-in manifold concept, using piggable elbowsto connect pipelines together. The connectionsare made by the patented I.S.T. sliding coupling– uniquely safe and easy to operate.


Connection Version1 to 6 manual1 to 12 or 18 manual / automatic2 to 12 or 18 automatic

VT 1

Two / two way valve T 08

M A N I F O L D S

This valve facilitates the diversion of productflows in two directions simultaneously. Thus, dif-ferent pipelines can be switched and pigged.This fitting can also be used as a piggable pumpbypass. In this case the product flow is connec-ted with the pump. After conveying the pig-gable pump bypass is switched on. Its integratedcylinder is pocket free due to the optimum seal-ing design. Therefore it can especially be usedfor products that allow no or only minimumcontamination. The valve can be switchedeither manually (with hand lever) or automati-cally (with actuator). There is no overlapping of ports while switching since all outlets areblocked. In combination with a pig stop insertand a pig sensor the T 08 can also be used forlaunching and receiving of a pig. Thus, the pigcan be reversed into another pipeline.


1 to 4 manifold T 51

This manifold is suitable for smaller distribu-tions. 4 supplies which are arranged radially canbe connected to a central outlet. Thus an easyand cost effective distribution is facilitated. Thismanifold is based on the sealing principle of theT 41 (cylindrical form). Due to the fully pig-gable and pocket free design the possibility ofcontamination is virtually eliminated. A pneu-matic four position actuator rotates the valve toany of the desired connections.



VT 2

Modular multi direction manifold T 54

M A N I F O L D S

This piggable pipeline manifold connects 12 in-lets to max. 4 outlets. 4 products can be con-veyed simultaneously and completely throughthe manifold. All coupled connections areequipped with safety devices. The distributionis done with 4 movable joint arms that areconnected to 12 fixed pipeline connections.The jointed arm is picked up by a slide and isthen driven to the desired position. Integrity ofcoupling and uncoupling is ensured by the useof pneumatic cylinders. All connections arecoup-led in parallel and are equipped withsafety devices. The manifold is of modular con-struction and thus facilitates various options ofinstallation. For safety reasons unused pipelineinlets are locked with a blind coupling. Thus, anunwanted product or pig escape is avoided. Themanifold is designed for automatic operationand the control system is an integral part of oursupply. With a special coding system the posi-tion of the jointed arms is continually moni-tored by the control system. The operation ofthe manifold is done via keyboard and monitor.This programme can control the manifold aswell as the fully automated pigging system. Astructured menu facilitates an easy operation. Itis also possible to integrate a local hand controlfor start up and maintenance purposes.

Available diameters : DN 50 - DN 100 (2" - 4")


VT 3

M A N I F O L D S

I.S.T. Full system manifold T 57

This is the first manifold which allows pipelinesof different nominal diameters to be combinedin a single design (DN 50, 80 and 100). Thesystem is closed and piggable on one side. Thefull system section consists of non-piggable rect-angular ducts for product feed. At right anglesto these ducts are the piggable pipelines whichare connected at the intersection by means of aring valve principle. This ring valve opens theconnection from the product feed duct to thepiggable part of the manifold. The valve alsoacts as a pig receiving station. The respectivering valves are opened by a manual or pneuma-tic actuating unit. The actuating unit moves ina direction parallel to the piggable pipeline,and is stopped at the ring valve to be opened.This means that only one actuating unit per pig-gable pipeline is required. Cost effective soft-ware and interlocking devices are thus reducedto a minimum. The small shut-off unit makesthe manifold very compact. All dynamic sealsare exchangeable within minutes. The T 57 ma-kes it possible to connect and distribute up to50 feed pipelines to as many as 20 pigging pipe-lines in a single module. All filling and piggingprocesses are effected in parallel. The manifoldcan open and close the connections independ-ently of each other. Transfer pumping fromtank to tank or from pigging line into piggingline is also possible with the correspondingswitch processes. This unique manifold designprovides a very compact and low cost solutionwith minimal maintenance.

Available diameters: DN 50 - DN 100 (2" - 4")(others on request)


VT 4

I.S.T. Duo-pig

P I G S

The I.S.T. Duo-pig is used universally due to itsform and the wide variety of elastomers. It canbe made from AU, FKM, EPDM, NBR etc. It isrobust and simple to handle. With the design ofcertain pig launch/receive stations, the pig itselfcan be rinsed in place. Pig removal is not re-quired for this cleaning function. The pig canbe detected in the stations or in the pipelinedue to its integrated magnet. For manualsystems the Duo-pig can also be suppliedwithout a magnet. In this case it would be de-tected with manual pig locators.

Available diameters: DN 25 - DN 150 (1" - 6")On request also up to DN 300 (12")

I.S.T. Duo lip pig

Due to its flexible sealing lips the I.S.T. Duo lippig ensures optimum sealing. Even with inferiorquality pipelines it provides excellent operatio-nal characteristics. It is also available with orwithout magnet. The body of this pig is manu-factured from polyurethane (AU) - foamed orsolid and the seal lips are non-abrasive solidpolyurethane.


Pigs

I.S.T. has more than 25 years experience in thedesign and development of pigs for pipelinecleaning. I.S.T. pigs are manufactured in variousdesigns and materials to suit individual custo-mer requirements. In principle, if a product canbe pumped then it can also be pigged: Lubeoils, aggressive chemicals, toiletries, cosmetics,pastes and foodstuffs. In special cases even gra-nulates, powders etc., can also be pigged. Out-lined below are the various pig designs availablefrom I.S.T.

M 1

I.S.T. Duo lip pig with replaceable lips

P I G S

The I.S.T. Duo lip pig with replaceable lips is aspecial type of Duo lip pig that has been de-signed especially for handling aggressive media.The advantage of this pig is that the seal lips canbe replaced separately. The body of this pig ismanufactured from a chemical resistant ther-moplast such as PA 6 or PVDF. The replaceablesealing lips are typically manufactured fromnon-abrasive polyurethane or FKM (Viton). Inmost cases the Duo lip pig with replaceable lipsis supplied with integrated magnet.


I.S.T. jet pig

The I.S.T. jet pig is used for pigging granulatesand powders. Used regularly it prevents the for-mation of residual material. The body of thispig is manufactured from polyurethane (AU) -foamed or solid and the seal lips are non-abra-sive solid polyurethane. The jet pig is availablewith or without integrated magnet.

Available diameters: DN 25 - DN 150 (1" - 6")On request also up to DN 300 (12")

I.S.T. special pigs

In addition to the above pigs I.S.T. also designspigs for special applications (e. g. brush pigs,pigs with more sealing lips or pig forms de-signed for systems outside our standard productrange).

Available diameters: on request

I.S.T. pigs are only sold together with our pig-ging systems

Pigs

M 2

Piggable hoses T 99

F U R T H E R C O M P O N E N T S

Piggable hoses are available in different materi-als for different products as lubeoils, chemicals,food etc. The professional mounting of thesteel/stainless steel coupling flanges or swiveljoints ensures the highest flexibility and safety.Examples of the use of piggable hoses aredistribution to different connecting points andchanging distances and flexible connections in-to tank trucks etc.


Swivel arm T 04

With the I.S.T. swivel arm variable piggableconnections can be produced. With matchingcouplings, connections between pipeline con-nections and tank trucks or movable tanks etc.are possible.


Connection elements

VE 1


I.S.T. Sliding coupling T 27

With the piggable I.S.T. sliding coupling thecoupling of hoses or pipeline connections ismade easier. Two coupling halves slide on eachother until they are locked. Both coupling partsare sealed by an O-ring that lies in a specialgroove. The protected locking device ensures asafe closure of the coupled halves.

The coupling system can be built with an inte-gral coding system. Thus each coupled connec-tion can be monitored by a control unit so thatoperational errors are avoided.


Pressure relief vessel T 20

The pressure relief vessel is used for the safeventing and filtering of pig propellant (com-pressed air, nitrogen etc.) and collection of re-sidual contaminate. The T 20 is equipped witha demister that separates contaminates and pigpropellant. The volume of the residual conta-minate is monitored by a level control switch al-lowing it to be disposed of as required.

The pressure relief vessel is available with a vo-lume of 60 and 100 litres with optional heating-jacket.

Accessories

Z 1

Pig sensor, manual pig locator T 31


In order to locate the pigs in the pipeline or inthe pigging stations I.S.T. has developed variousspecial pig sensors. In automated systems thepig is equipped with an integrated magnet. Thefield of this magnet is sensed by a special ma-gnetic field switch. For welded stainless steel sta-tions these sensors are fixed to an externallymounted rod with a special clamp. This allowsthe sensor to detect the pig through the pipewall. In cast fittings other sensors are screwed in-to a housing. I.S.T. also offers electromechanicdevices for location of pigs without magnet.

For high temperature areas special sensors arealso available.

All pig sensors are available for EX and NON-EX areas.

Pigging stations can also be equipped with ma-nual pig locators. With this type of device a tap-pet is manually pressed into the station to checkfor the presence of the pig. A spring ensures thelocator returns and does not protrude into thepipe when it is released.

I.S.T. also offers a mobile pen shaped magneticfield detector which allows the pig to be detec-ted throughout the pipeline. This method isonly applicable for stainless steel pipelines.

Accessories

mechanic

electromagnetic

electromechanic

electromagnetic

Z 2

mobile pig sensor

Pig stop and pig retainer T 32


The pig stop catches the pig in the T-stations.This allows the pig to be used as a closure device.

The pig retainer is designed to hold the pig inthe launching or receiving station. It preventsthe pig from being pulled out of its home posi-tion and into the pipeline.

The operation of the pig stop and the pig re-tainer can be done manually (with hand leverup to DN 100 / 4") or automatically (with actu-ator).

Available for diameters: DN 25 - DN 300 (1" - 12")

Accessories

Swivel joint T 33

The piggable swivel joint T 33 is a componentthat allows axial rotations into a piping systemand thus facilitates a greater flexibility. Swivel joints can make the handling of piggable hoseseasier.


Welding ring T 34

Piggable pipelines have to be installed withoutany misalignment. To ensure correct alignmentof a pipeline, I.S.T. recommend the use of weld-ing rings. These rings provide an externallywelded sleeve joint which eleminates the needfor a full penetration weld and keeps the inter-nal surface of the pipeline weld free.


Z 3

Inline Blender T45


This dynamic multicomponent blender hasbeen designed for the continuous mixing of 2-9components. In the standard version it is pos-sible to achieve a flow rate of 60 m3/h with ablending chamber volume of 60 l. Its specialconstruction allows the direct mounting ofstandard dosing valves to ensure a simultaneoussupply of all components. The locking cones ofthe dosing valves open into the interior of theblending chamber, and when closed are a flushfit with the inside surface of the blender. Con-trol of the volume of the various mixing pro-ducts is usually done through flow meters withpulse transmitters in connection with pneuma-tically operated control valves. . The blendingproportions are done through the control unit.The combination of I.S.T. Inline Blender andautomatic control guarantees an accurate andconsistent mixing result. Despite the variedflowpath of the components in the blendingchamber the quality of the final blend is unaf-fected. Even products with very high and verylow viscosity can be mixed together into a ho-mogeneous product. Although the mixing timein the blender is relatively short, the mixed pro-duct is to exact specification from beginning toend of the operation. The liquid/liquid blen-ding operation of the I.S.T. Inline Blender is ananswer to the requirement of a continuous pro-cess operation which is easier controlled andautomated than conventional batch blendingoperation. The excellent blending results show the effectof this unique technology.

Accessories

Z 4

Control system T 48


Automated pigging systems need a controlsystem for the control of the various steps of thepigging operation. This is effected by an "SPS"(stored programme system), which is oftenknown to as a PLC controlled system. The statusof all stations and the position of the pigs can becontrolled throughout the whole plant opera-tional process/procedure. The single elementsof the pigging system can be connected to thecontrol unit either conventionally or via a bussystem. When programming the control systemthe knowledge of the programmers is most im-portant in order to ensures a smooth piggingprocess. I.S.T. has more than 25 years experien-ce in the development of automated processcontrol.

Piggable pipes and elbows

I.S.T. applies strict standards with regard to theproduction of piggable pipes and elbows sincethe quality of these parts has a high influenceon the pigging result. Pipe tolerances, ovality,surface quality, material thickness and the qua-lity of the welded seams are the most importantparameters. Piggable elbows are produced by aspecial method so that the roundness discre-pancies are kept within small tolerances. For thedifferent applications I.S.T. offers a wide rangeof pipes and elbows. All parts are available forthe application in the chemical industry accord-ing to DIN 2430.

Available diameters: DN 25 - 300 (1" - 12")

Accessories

Z 5


Measuring instruments T 92

For the control of pressure, filling level ofliquids, volume flow etc. I.S.T. offers a widerange of special measuring instruments for pig-ging systems

Accessories

Air pressure booster T 97

For all pneumatically actuated piggable fittingsa certain compressed air supply is necessary. Ifthis pressure is not available the air pressurebooster can be used. This pump works with apressure multiplication of 1 : 2 and is suppliedcompletely with a pressure tank.

Z 6

Engineering

In the planning phase for a pigging systemexperience, co-operation and innovation arehighly important factors for a successful end re-sult. I.S.T. offers a complete planning and pro-ject engineering service for pigging systemsfrom conception to final design.

The supply of individual components alone willnot guarantee the correct function of a piggingsystem. For optimum results it is very importantto utilise the experienced engineering supportand services which I.S.T. staff can provide.

Site supervision service

Experienced engineering support duringinstallation, commissioning and final hand-overis a critical factor. I.S.T. offers multi-disciplinedengineering services to cover all aspects of aproject.

Test pigging

Test pigging allows new and existing lines to betested to confirm suitability for pigging. All pipejoints, elbows, welded seams are tested to iden-tify any problem areas.

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Training

To ensure optimal understanding of design con-cepts, operational requirements, maintenanceand safety issues, I.S.T. recommend that all per-sonnel are trained accordingly. Centres are offered by I.S.T. for this purposeeither at customer’s premises or at HamburgHead Office.

Repair and maintenance

All I.S.T. pigging components are made fromlong wearing materials. However, certain main-tenance work will obviously be necessary. Forexchange of seals and any other elements ourexperienced technicians are at your disposal;either for an exchange at I.S.T. in Hamburg orat your premises. Regular maintenance by I.S.T.personnel will ensure a continuous operationand avoids downtimes. Should there, however,be any "emergency" the flexible I.S.T. team willalways be at your disposal to solve any problemsat site.

Technical support

For any questions regarding pigging systems youcan benefit from our technical support – byphone or personally. Be it for a planned or anexisting pigging system, our experts will supportyou in word and deed.

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Documents

The address for pigging technologyI.S.T. Molchtechnik … · fittings and test pigging Installation Maintenance ... an interlock device and as a pig launching and receiving station