I.S.T. Molchtechnik GmbH The address for pigging technology · Pigging technology is the most cost...

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

Experience in pigging technology for more than 35 years

T h e O r i g i n a l

detailed system design and planning we recommend that you seek further advicefrom I.S.T.'s qualified project engineers andbenefit from their many years experience inthis specialised field.

We endeavour to provide a very high levelof customer care and after sales service toall our clients. With this in mind we recommend that I.S.T. service engineersare utilised for start-up, commissioning andtraining works. This will ensure that the pigging system is installed correctly andoperates to your entire satisfaction.

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

The pipeline contents is recovered by a special contoured plug, the "pig", which isdriven by a propellant. This method ofbatch separation is used in many industrieson a wide variety of products. All I.S.T. pigsand stations are manufactured to the hig-hest possible standards in order to ensurethat optimum pigging results are alwaysachieved.

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

Pigging technology is the most cost effective and environmen-tally friendly method of simultaneous product handling andpipework cleaning. This technology can be applied in almostall types of industry.

The idea of pigging

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-ring val-ves, Three-way valves, Tee-pieces and Loading arms (T 91) with a piggable filling head (T 02). Indi-vidually, 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

Technical orderprocessing

Construction and Design

Pig grinding

TechnicalSupport

Production /CNC machining

Qualitymanagement

Assembly

Commercial orderprocessing

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 stations, providing a veryflexible product range.

• Welded stations can be manufactured according to individual customer require-ment.

• Cast stations are available in many different designs to suit various functions.All stations are proven designs and providereliable operation and long service life forall parts (incl. seals).

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

Technical data for standard product range:

Available diameters: DN 25 / 1" up to DN 350 / 14"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, VMQ, EPDM (other materials on request)

◗ Planning and conception of complete systems◗ Retrofitting and modification of existing systems◗ Piggable stations 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 Page

Station, T-Form 01 T-Sleeve valve AT 1Station, T-Form 09 T-Ring valve AT 1Station, T-Form 10 T-piece AT 2Station, T-Form 10.3/4 T-piece as pig launching and receiving station AT 2Station, T-Form 26 Filter with pig launching and receiving station AT 2Station, T-Form 35 Pig launching and receiving station with 90° branch AT 3Station, T-Form 40 T-Port valve AT 3Station, T-Form 40.29 T-Port valve as pig launching and receiving station AT 4Station, T-Form 43 Inline valve AT 4

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

Station, straight form 14 Pig receiving station with pig catcher ring AG 1Station, straight form 16 Pig launching and receiving station AG 1Station, straight form 17 Pig trap AG 1Station, straight form 29 Pig loading and unloading station AG 2Station, straight form 39 Pig loading and unloading station, swivel type 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 - 2 to 12 VT 1Manifold 06 Plug in manifolds VT 1Manifold 08 2/2 way manifolds VT 2Manifold 51 1 to 4 manifold VT 2Manifold 57 Full system manifold VT 3

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

Components 45 Inline Blender C 1Components 45 SMB Simultaneous Metering Blender C 2Components 65 DDU Drum Decanting Unit C 3

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 3 Accessories 48 Control units Z 4Accessories 59 Pipeline and pipe bends Z 4Accessories 92 Measuring instruments Z 5Accessories 97 Air pressure booster Z 5

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

Subject to alteration

T-sleeve valve T 01

S T A T I O N S

The T-sleeve valve is a highly versatile station. 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 slee-ve and the straight passage can be pigged pok-ket-free. The sliding sleeve is simple in opera-tion because it is 100% relieved from pressure.Moreover, its sealings have a long service life.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: PiggableTee piece, product isolation valve and pig stop.It is possible to use it as a single station or as apart of a manifold assembly. The T-ring valve isoperated automatically. Its straight passage canbe pigged pocket free when the valve is closed.The T-branch is opened by the sliding ring thatalso serves as pig catcher. Moreover, contami-nation is avoided by a spring-balanced seal de-sign.


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

AT 1

T-piece T 10

S T A T I O N 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. Thestation can also be equipped with a pig stop thatserves as a buffer for one and two pig systems.The T-piece is a welded station, especially suita-ble for non standard designs, inner diameters,heating jackets etc.

Available diameters: DN 25 - DN 350 (1" - 14 ")

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 productturbulences a pig retainer can be mounted.

Available diameters: DN 25 - DN 350 (1"-14")


AT 2

Filter with pig launching and receiving station T 26

This station combines the functions of a filter, apiggable T-piece and a pig launching and recei-ving station. Pigging is possible up to the filterinsert. The filter is a reversible-flow filter thatcan be changed quickly. Moreover, it is availablein various mesh sizes.


S T A T I O N S

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 effectthat pockets for contaminate and bacteria arereduced and the station has a relatively lowweight. This station is often used for hose con-nections where an unloading of the pig is notnecessary.

Available diameters: DN 25 - DN 350 (1"- 14")


AT 3

T-Port Valve T 40

The T-Port valve is particularly suitable for sin-gle direction pigging systems. For such applica-tions the T-Port valve provides safe and cleanpigging results comparable with two pig systems,but with reduced control system expenditure:with only two positions it is possible to open theT-Branch and transfer the product with minimalpressure drop and also stop the pig. In this po-sition the pipe behind the T-Port valve is isola-ted. In the second position the pig passage isopened and the T-Branch is isolated.

The sealing principle utilised in the T-Port val-ve is the same as our proven T 41 Three way val-ve. The main seal is manufactured from PTFEand covers the valve drum completely. Hence,no product residue remains in the piggable pas-sage.


S T A T I O N S


Inline valve T 43

The Inline valve T 43 can dose single productcomponents into the piggable line. The flow inthe branch is controlled by a piston. In the clo-sed position the piston closes exactly with the pi-pe's inner wall and thus grants a pocket free pas-sage for the pig. The inline valve has a doubleacting pneumatic actuator with spring return sothat in case of emergency an immediate closingof the station is made sure. The non-piggablebranch can easily be cleaned by special rinsingconnections.


T-Port valve as pig launching and receiving station T 40.29

T-Port valve as launching station: New safetystandards for pig changing procedure incorpo-rating the many advantages of the multifunctio-nal T-Port valve, together with a unique and in-novative safe method for loading and unloadingpigs. This version is also equipped with an inte-grated pig changing chamber and pig propel-lant connections. In addition to the standardtwo automated valve positions there is also athird manual valve position for changing pigs.The pig changing procedure requires no exter-nal utility services, or control system action. Theorientation of the pig changing chamber ensu-res that the pigging line is isolated whenchanging pigs, providing the highest levels ofoperator safety.


AT 4

Loading lance T 02

S T A T I O N 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 directly in-to the filling station. Thus the contents of thenon-piggable area is fully drained. The loadingvalve can handle various filling operations suchas top level, bottom level and bottom bungholefilling. This valve design allows a fully automa-ted piggable filling plant to be realised.


AB 1

The loading lance is designed for application inpiggable filling plants. It is mounted at the endof a 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 loading lance is equipped with a level con-trol switch.Thus the product is 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 pos-sible to fill several different products throughthe same loading arm. Product flow is control-led by a sliding sleeve installed in the loadinglance. This sleeve is operated by instrument air(positions open/closed/throttle). In case ofemergency air failure, the loading lance is clo-sed automatically by spring.


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 in-dividually. Special constructions for top leveland bottom level filling are possible, as well as asuction device for the filling process. The loa-ding arms are available with mechanical orpneumatic level compensation.


Pig launching and receiving station T 16

S T A T I O N S

This station can also be applied to both one andtwo pig systems. It is equipped with a pig stop in-sert and facilitates rinsing and drying of the pigsafter the pigging process by installation of inter-nal and external by-passes. With help of theI.S.T. sliding coupling it is easy to connect the T16 to the pig loading and unloading station T29.


Pig trap T 17

The pig trap facilitates the catching of the pigwithin the pipeline. With this simple station thepig can be stopped at any desired position.Thus, it is also possible to pig only parts of thepipeline. It can be applied to both one and twopig systems. It can be operated manually (hadlever), or automatically.


Straight shape

Pig launching and receiving station T 14

The product can flow straight through this sta-tion whilst the pig is held 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

S T A T I O N S

With this station pigs can be safely be removedfrom or loaded into the system. On the loa-ding/unloading side it is equipped with I.S.T.sliding couplings (male and female part) whichfacilitates a quick and safe unloading. After ope-ning, the pig can easily be removed from theoversize section of the station. In order to avoidan unauthorised opening of the station it canbe locked mechanically or pneumatically. Thepipeline side can be equipped either with a flan-ge or a female sliding coupling. Due to safety re-asons 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 secured. So the processof pig exchange is made easier and operationalerrors are avoided.

The pipeline side can be equipped either witha flange or a female sliding coupling. Due to sa-fety reasons I.S.T. recommends the use of thisstation.


Pig loading and unloading stations

AG 2

Three way valve T 41 (cylinder)

S T A T I O N 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 pocketfree and is therefore successfully used in thechemical and in the paint industry. The T 41can be operated manually (hand lever) or auto-matically. In combination with a pig stop insertand a pig sensor the T 41 can also be used forlaunching and receiving of a pig. Thus the pigcan be deviated into another pipeline or drivenback into its home station.


Three way valve T 42

The three way valve T 42 has the same switchingfunctions as the T 41. Optimum pigging resultsare provided thanks to the big radius in the pas-sage. Due to the small torque switching of thevalve is made easier. The T 42 can be operatedwith a lever or by a pneumatic actuator for twoor three positions. In combination with a pigstop insert and a pig sensor the T 42 can also beused for launching and receiving of a pig. Thus,the pig can be reversed into another pipeline ordriven back into its home station.

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

AW 1

Three way valves

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, tankgroups, mixers etc, can be interconnected to 1 or2 filling devices. The fully piggable version of theT 06 allows for a pigging process from the tankup to the filling device. The manifold is also avai-lable with dry break couplings. These couplingsshut both sides of the line after disconnection ofthe 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. The connections are madeby the patented I.S.T. sliding coupling - unique-ly safe and comfortable to operate


Connection Version1 to 6 manual1 or 2 to 12, 1 to 18 manual / automatic

VT 1

Two / two way valve T 08

M A N I F O L D S

This valve facilitates the simultaneous diversionof product flows in two directions. Thus, diffe-rent pipelines can be switched and pigged. Themanifold can also be used as a piggable pumpbypass. In this case the product flow is connec-ted to the pump. After conveying the piggablepump bypass is switched on. Its integrated cy-linder is pocket free due to its optimum sealingand therefore it can especially be used for pro-ducts that allow no or only minimum contami-nation. The valve can be switched either manu-ally or automatically. There is no overlappingwhile switching since all outlets are blocked. Incombination with a pig stop insert and a pigsensor the T 08 can also be used for launchingand receiving of a pig. Thus, the pig can be re-versed 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 pigga-ble and pocket free design the possibility of con-tamination is almost deleted. A pneumatic fourposition actuator rotates the valve to any of thedesired connections.



VT 2

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). The sy-stem 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 and simultane-ously acts as a pig receiving station. The respec-tive ring valves are opened by a manual or pneu-matic actuating unit. This actuating unit movesin parallel direction over the piggable pipelineto the required product feed full system section.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 parallely. The manifoldcan open and close the connections independ-ently. Transfer pumping from tank to tank or ofpigging line into pigging line is also possiblewith the corresponding switch processes. Thisunique manifold design provides a very com-pact and low cost solution with minimal main-tenance.

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


VT 3

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.). Itis robust and simple to handle. Without havingto take it out of the pipeline it can be rinsed inthe pigging stations. The pig can be detected inthe stations or in the pipeline due to its inte-grated magnet. For manual systems the Duo-pigcan also be supplied without magnet. In this ca-se it would be detected with manual pig loca-tors.

Available diameters: DN 25 - DN 150 (2" - 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 facilitates an optimum sealing. Even with in-ferior quality pipelines it provides excellent ope-ration 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 35 years experience in de-sign and development of pigs for pipeline clea-ning. I.S.T. pigs are manufactured in various de-signs and materials to suit individual customerrequirements. In principle, if a product can bepumped then it can also be pigged: Lube oils,aggressive chemicals, toiletries, cosmetics, pastesand foodstuffs. In special cases even granulates,powders etc., can also be pigged. We have outli-ned below the various pig designs available fromI.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 was designedespecially for handling aggressive media. Theadvantage of this pig is that the seal lips can bereplaced separately. The body of this pig is ma-nufactured from a chemical resistant thermo-plast such as PA 6 or PVDF. The replaceable se-aling lips are typically manufactured from non-abrasive polyurethane or FKM (Viton). In mostcases the Duo lip pig with exchangeable lips isapplied 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. It can be manufac-tured in various elastomers such as: AU, FKM,EPDM, NBR etc. and can therefore be used uni-versally. The jet pig is available with or withoutintegrated magnet.

Available diameters: DN 25 - DN 150 (2" - 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. These special types(e. g. brush pigs, pigs with more sealing lips orpig forms designed for systems that outside ourstandard product range)

Available diameters: on request

I.S.T. pigs are sold together with our pigging sy-stems, only.

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 lube oils, chemicals,food etc. The professional mounting of thesteel/stainless steel parts as coupling flanges orswivel joints grant highest flexibility and safety.Examples for the use of piggable hoses are di-stributions with different connecting points andchanging distances as well as the flexible fillinginto tank trucks etc.


Swivel arm T 04

With the I.S.T. swivel arm variable piggable con-nections can be produced. With the correspon-ding coupling connections between pipelineconnections and tank trucks or movable tanksetc. are possible.


Connecting elements

VE 1

Inline Blender T 45


This continuous, dynamic multicomponentblender was designed for the continuous flow of2-9 components. In the standard version it ispossible to achieve a flow rate of 60 m3/h with ablending chamber volume of 60 l. Its specialconstruction allows the direct mounting of re-gular stations. So a simultaneous supply of allcomponents is possible. The locking cones ofthe regular stations open into the interior of theblending chamber and terminate with the inte-rior side of the mixer. Control of the volume ofthe various mixing products is usually donethrough flow meters with pulse transmitters inconnection with pneumatically operated con-trol valves. . The blending proportions are donethrough the control unit. The combination ofI.S.T. Inline Blender and automatic control gua-rantees an accurate and consistent mixing re-sult. Despite the varied flowpath of the compo-nents in the blending chamber the quality ofthe final blend is unaffected. Even productswith very high and very low viscosity can be mi-xed together to a homogeneous product. Alt-hough the mixing time in the blender is relati-vely short, the mixed product is to exact specifi-cation from beginning to end of the operation.The liquid/liquid blending operation of theI.S.T. Inline Blender is an answer to the requi-rement of continuous process operation whichis easier controlled and automated than con-ventional batch blending operation.

The excellent blending results show the effectof this unique technique.

Components

C 1


C 2

SMB Simultaneous Metering Blender T 45

All raw material components (base oils and add-ditives) are pumped to the SMB from dedicatedtanks, where a series of metering channelsequipped with mass flow meter, control valveand non-return valve allow very accurate and si-multaneous dosing of all blend recipe compo-nents. The SMB design incorporates a fully pig-gable distribution header pipe in order to avoidcross-contamination between blend recipes andto maximise product recovery. This unique pig-gable SMB concept even allows for the differentfamily groups of lubricating oils to be blendedin the SMB and hence maximises plant equip-ment utilisation.

The general principle of operation for the SMBis as follows: Operator provides production da-ta (such as: product name / code, type, blend si-ze, and tank destination etc) to SMB control sys-tem.

The SMB control system will then automaticallydose all required raw material components ac-cording to the customers specific blend formu-lation (recipe), in following three stages: Firststage is an initial dosing and transfer of base oil,followed by dosing and transfer of the mainblend components base oils and additives, fol-lowed by a final dosing and transfer of the re-maining base oil. This dosing sequence ensuresoptimum pigging results are achieved, with re-spect to cross-contamination between subse-quent SMB blends.

The pigging system is directly integrated in theSMB. Thus the connecting pipelines and the ba-sic isolation valves can be emptied without resi-dues.

The non piggable areas such as flow meters /counters are emptied according to a program-med procedure and rinsed with base product.Now the system is completely emptied and thenext process can be prepared.

Components


Components

DDU Drum Decanting Unit T 65

A perfect supplement in pigging technology inorder to provide safety and functionality whenemptying drums and containers (IBC). Here,the pumped products are often used as additi-ves for blending processes. The decanting pro-cess is semi automated. With a pre-heated baseproduct the drums will be emptied almost com-pletely. The product is decanted with a pneu-matically driven lance which transports the pro-duct directly into the piggable transport line.The product will be conveyed directly to the sto-rage tanks or into the subsequent blenders. Theexact dosing of the product is effected by aweighing system that is connected to the centralcontrol unit of the DDU. A quick change-overfrom drum decanting to container decantingcan be done with help of the flexibly designedroller conveyor. The system can be retooled forthe decanting of a completely different kind ofpackaging within seconds.

The advantages:• Complete discharge of high quality additives • No product losses thanks to pigging

technology• No cross-contamination between drummed

additives • Local control system for automated filling

processes• Unique combination with pigging technology • Products are transported directly into a

piggable station.• Traversable and piggable pipe connections

to the pump.• Minimised, non-piggable pump areas• Piggable connection direct to blender or

storage tank

C 3


I.S.T. Sliding coupling T 27

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

The coupling system can be completed with acoding system. Thus each coupled connectioncan be monitored by a control unit so that ope-rational 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 resi-dual contaminate. The T20 is equipped with ademister 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 off as required.

The pressure relief vessel is available with a vo-lume of 60, 100 and 300 litres as well as with orwithout heating.

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 mag-netic 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 stations other sensors are screwedinto a housing. I.S.T. also offers electro mecha-nic devices 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, in orderto check for the presence of the pig. The tappetis then automatically removed from the pipeli-ne by a spring.

I.S.T. also offers a portable pig sensor pen withwhich the pig can be detected throughout thepipeline. This method is only applicable forstainless steel pipelines.

Accessories

mechanic

electromagnetic

electromechanic

electromagnetic

Z 2

portable pig sensor pen

Pig stop and pig retainer T 32


The pig stop catches the pig in the T-stations. Sothe pig can be used as a closure device.

The pig retainer is holding the pig in the laun-ching or receiving station. It prevents the pigfrom being pulled out of its home position intothe pipeline through high flow speed of theproduct.

The operation of the pig stop and the pig retai-ner can be done manually (with hand lever upto DN 100 / 4") or automatically (with actua-tor).

Available for diameters: DN 25 - DN 300 (2" -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 better flexibility. Swivel joints can make the handling of piggable hoseseasier.


Welding ring T 34

Piggable pipelines have to be installed withoutany misalignment. A simple aid to assure cor-rect alignment of a pipeline are welding rings.These rings provide an externally welded sleevejoint which prevents weld seams sagging intothe piggable pipeline.


Z 3

Control system T 48


Automated pigging systems need a control sy-stem for the control of the various steps of thepigging operation. This is effected by a "SPS"(stored program system). So the switch positionof all stations and the position of the pigs can becontrolled at any time. The elements of the pig-ging system can be connected to the controlunit either conventionally or via a bus system.When programming the control system theknowledge of the programmers is most impor-tant in order to grant a smooth pigging process.I.S.T. has more than 35 years experience in de-velopment of automated process control.

Piggable pipes and elbows T 59

I.S.T. applies strict standards in view to the pro-duction of piggable pipes and elbows since thequality of these parts has a high influence onthe pigging result. Pipe tolerances, ovality, sur-face quality, material thickness and the qualityof the welded seams are the most important pa-rameters. Piggable elbows are produced in 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. Of course all parts are alsoavailable for the application in the chemical in-dustry according to DIN 2430.

Available diameters: DN 25 - 300 (2" - 12")

Accessories

Z 4


Measuring instruments T 92

For the control of pressure, filling level of li-quids, volume flow etc. I.S.T. offers a wide ran-ge of various measuring instruments.

Accessories

Air pressure booster T 97

For all pneumatically actuated piggable stationsa 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 5

Engineering

In the planning phase for a pigging system ex-perience, co-operation and innovation are high-ly important factors for a successful end result.I.S.T. offers a complete planning and projectengineering service for pigging systems fromconception to final design, completion.

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 the I.S.T. service staff provi-des.

Site supervision service

Experienced engineering support during in-stallation, commissioning and final hand-over isa critical factor. We provide complete site super-vision together with experienced partners.

Test pigging

With test pigging new and existing lines are te-sted to confirm suitability for pigging. All pipejoints, elbows, welded seams are tested to iden-tify any problem areas.

I.S.T. Service

S 1

Training

For the daily work with a pigging system detai-led training of the operational staff is impor-tant. This kind of training is offered by I.S.T.

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 further elements the ex-perienced technicians are at your disposal; eit-her for an exchange at I.S.T. in Hamburg or atyour premises. Regular maintenance by I.S.T.personnel will ensure a continuous operationand avoids non-productive times. Should there,however, be any "emergency" the flexible I.S.T.team will always be at your disposal to solve anyproblems at site.

Technical support

For any questions regarding pigging systems youcan benefit from our technical support - by pho-ne or personally. Be it for a planned or an exi-sting pigging system, our experts will supportyou in word and deed.

I.S.T. Service

S 2

Internationalrepresentatives for I.S.T. pigging technologycan be found in:Europe, USA and Asia

If you are interested in a non-bindingquotation, and would like further informationabout the benefits of this kind of system,perhaps including detailed comparisons withother systems, please do not hesitate to contactus. We will be pleased to send you more detailedinformation, or to give you advice at a more personel level:

Wether 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 piggingInstallationMaintenanceInspectionTraining… all from one supplier.

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■ = I.S.T.-Sales offices

• = I.S.T.-Reprentatives

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Spain / South EuropeXavier de BARBERÀ VAN HACHTC/ Fra Antoni Cardona i Grau7A Edif A2 6è-4aE – 43002-TarragonaPhone: + 34 - 9 77 22 87 65Gsm: + 34 - 6 99 43 89 23e-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.ist-molchtechnik.de

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]

U.K. / IrlandI.S.T. Molchtechnik GmbHPO Box 172GB – Deeside, CH5 9ANPhone: +44 - 12 44 53 95 39Fax: +44 - 12 44 53 97 80e-mail: [email protected]

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