What Are the Core Components of a Pigging System?

A pigging system efficiently recovers product residue and cleans pipelines through the coordinated operation of its core components. Below are the essential parts and their functions:

1. Pig (Pigging Ball)

Function: The primary actuator that physically contacts the pipe wall to push out residual product, remove deposits, or separate media.
Types:

• Solid Spheres (Silicone/Polyurethane): Hygienic-grade, easy to clean.
• Multi-component Pigs (with scrapers/brushes): For viscous/solid residues in industrial applications.
• Smart Pigs (with sensors): Detect pipe deformations, corrosion, or temperature (advanced use).

Material Selection:

• Hygienic: FDA-grade silicone/polyurethane, high-polish, non-toxic.
• Industrial: Wear-resistant polyurethane, acid-proof rubber, or composites for high-pressure/corrosive environments.

2. Launching Station

Function: The entry point for deploying pigs, typically at the pipeline start.

Components:

• Pressure vessel (barrel)
• Quick-opening closure (Tri-Clamp for hygienic, flanged for industrial)
• Medium injection valve (gas/liquid to propel the pig)
• Pressure/position sensors

Example Models: WPE ASHLDV (hygienic), standard industrial launchers.

3. Receiving Station

Function: Captures and retrieves pigs at the pipeline end.

Design Features:

• Buffer mechanism (reduces pig impact)
• Discharge valve (removes residual media/product)
• Sight glass (hygienic-grade for easy inspection)

Example Models: WPE ASRLDV (hygienic), industrial receivers.

4. Distributed Control System

Function: Provides driving force (gas/liquid) to move pigs.

Key Elements:

• Compressed gas/liquid source (N₂, air, water, or process fluid)
• Precision control valves (regulate flow/pressure for smooth operation)
• Pressure gauges & sensors (real-time monitoring)

5. Pipeline Connections & Valves

Hygienic-Grade:

• Tri-Clamp fittings: Quick disassembly, dead-space-free, 3-A/SMS compliant.
• Sanitary valves (butterfly/ball): Polished internals, CIP/SIP compatible.

Industrial-Grade:

• Welded/flanged connections: High-pressure (>Class 600) and high-temperature (>200°C) resistant.
• Pig valves/diverters: Guide pigs to avoid branch pipelines.

6. Auxiliary Equipment

• Pig Loader/Unloader: Safely installs/removes pigs without contamination (hygienic) or high-pressure risks (industrial).
• Intermediate Station (e.g., ASILDV): Enables pigging in long/complex pipelines.
• 3-Way Diverter (e.g., 3W): Routes pigs in multi-branch pipelines.

System Integration Key Parameters

Component	Hygienic-Grade Specs	Industrial-Grade Specs
Pipe Size	1.5″ – 8″ (high precision)	2″ – 48″+ (standard)
Connection Type	Tri-Clamp	Welded/ANSI Flange
Valve Type	Sanitary Butterfly + CIP Port	Pig Valve + High-Pressure Gate
Pig Material	FDA Silicone/Polished	Abrasion-Resistant PU/NBR
Pressure Rating	Up to 10 bar	Up to 400 bar

Why Are These Components Indispensable?

• Pig: Directly affects cleaning/recovery efficiency.
• Launch/Receive Stations: Ensure safe pig entry/exit.
• Propulsion System: Provides consistent driving force.
• Valves & Piping: Maintain system integrity (leak-proof in industrial, contamination-free in hygienic).
• Auxiliary Stations: Enable complex pipeline configurations (long-distance, multi-branch).

Example Applications:

• Dairy Plant (Hygienic): A pig launches from an ASHLDV station, propelled by N₂ through Tri-Clamp piping, recovering 99.6% yogurt, and is captured in an ASRLDV station before automated CIP cleaning.
• Chemical Plant (Industrial): A multi-component pig clears resin residue at 50 bar/80°C, guided by pig valves to the receiver.

Understanding these core components and their synergy is critical for optimizing pigging system design, maximizing recovery rates, and reducing operational costs.