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Pigging Technology “Brilliantly Simple”
The idea of pigging is brilliantly simple.
The best ideas are often the most simple. This is just the case with pigging. It was expended more than 45 years ago by I.S.T. "for new branches of industry", and is based on a process which is, in principle, very simple: a shaped plug, the pig, which is driven by a propellant, is used to push out the contents of a pipe. What makes this principle so attractive is that it is suitable for use in various fields: I.S.T. pigging systems can be used to pump, fill, mix and separate large quantitites of substance and also to clean pipes, in an environmentally friendly, efficient and cost-effective way. I.S.T. has taken a brilliantly simpel idea an d developed it into perfect system solutions for all problematic tasks associated with pumping and filling systems.
The best ideas are often the most simple. This is just the case with pigging. It was expended more than 45 years ago by I.S.T. "for new branches of industry", and is based on a process which is, in principle, very simple: a shaped plug, the pig, which is driven by a propellant, is used to push out the contents of a pipe. What makes this principle so attractive is that it is suitable for use in various fields: I.S.T. pigging systems can be used to pump, fill, mix and separate large quantitites of substance and also to clean pipes, in an environmentally friendly, efficient and cost-effective way. I.S.T. has taken a brilliantly simpel idea an d developed it into perfect system solutions for all problematic tasks associated with pumping and filling systems.
Stations / Valves
Our pigging equipment was developed for an optimum application of industrial components for the production and pigging process. Flow optimisation, application-optimised design, very good piggability, compliance with standards and regulations, compatibility to your existing systems as well as a design with almost no pockets have been the standards for this proven technology.
Pipeline Manifolds
Almost any distribution can be achieved in connecting single valves to each other. The more efficient method is the use of piggable manifolds. Thus, very complex distribution networks can be realised using a combination of individual valves and modern distribution manifold systems.
Blending Equipment
Many finished products consist of several individual components which are blended during the manufacturing process. To ensure that the specified formulation is achieved and to minimise product losses, I.S.T. has developed two unique blenders, which also provide optimum connection with piggable distribution systems.
Pigs
Our many years of experience have lead to a wide range of I.S.T. pigs of highest quality and flexibility to meet almost all demands of today's process pigging technology. Basically each product can be pigged with I.S.T. pigs, be it lube oils, aggressive chemicals, granulates, powder, pastes or foodstuffs (such as chocolate, jams, meat masses etc.).
I.S.T. pigs are sold only in connection with our valves and systems.
I.S.T. pigs are sold only in connection with our valves and systems.
Special Designs
It is one of our valuable qualities to realise the individual wishes and requirements of our customers. Here our experienced engineers implement the specifications professionally and in compliance with the applicable guidelines and regulations. A successful commissioning carried out by our engineers completes the realisation of the special design.
Accessories
No complete system without accessories. Often the sensors, transmitters and couplings are vital connection elements for the complete system.
T02 - Loading Lance for Tank Trucks & Tank Wagons
The loading lance is designed for application in piggable filling plants. It is mounted at the end of a loading arm and allows pipeline pigging through the complete loading arm. The pig can transport the product into the loading lance or back into the initial source tank.
The loading lance is equipped with a level control switch. Thus the product is transported back to the tank after loading and overfilling of trucks or wagons etc. is avoided. Due to the fact that the loading arm is fully piggable, it is possible to fill several different products through the same loading arm. Product flow is controlled by a sliding sleeve installed in the loading lance. This sleeve is operated by instrument air (positions open/closed/throttle). In case of emergency air failure, the loading lance is closed automatically by spring.
Indispensable for the use of the loading lance is the piggable loading arm T91.
The loading lance is equipped with a level control switch. Thus the product is transported back to the tank after loading and overfilling of trucks or wagons etc. is avoided. Due to the fact that the loading arm is fully piggable, it is possible to fill several different products through the same loading arm. Product flow is controlled by a sliding sleeve installed in the loading lance. This sleeve is operated by instrument air (positions open/closed/throttle). In case of emergency air failure, the loading lance is closed automatically by spring.
Indispensable for the use of the loading lance is the piggable loading arm T91.
T50 - Loading Valve
The loading valve is designed for filling of drums and other containers with a bunghole > 60mm. The pig pushes the product directly into the filling station. Thus the contents of the non-piggable area is fully drained. The loading valve can handle various filling operations such as top level, bottom level and bottom bunghole filling. This valve design allows a fully automated piggable filling plant to be realised.
T91 - Loading Arm
With the loading arm T91 pigging through the arm into the filling valve is possible. It has large positioning possibilities that can be adapted individually. Special constructions for top level and bottom level filing are possible, as well as a suction device for the filling process. The loading arms are available with mechanical or pneumatic level compensation.
T06 - Rotary Manifold: Connects Piggable Pipelines
The I.S.T. rotary manifold T06 connects one or two supplies with up to 18 outlets. Thus, tank groups, mixers etc, can be interconnected to 1 or 2 filling devices. The fully piggable version of the T06 allows for a pigging process from the tank up to the filling device. The manifold is also available with dry break couplings. These couplings shut both sides of the line after disconnection of the couplings.
1 x 6 and 1 x 12: The compact solution for a filling unit. With central outlet and access port
Here's the space-saving and operationally reliable solution for distribution problems: on the I.S.T. rotary manifold 1 x 6 or 1 x 12, fixed I.S.T. sliding couplings are arranged round a central pipe nozzle, from which an 180° elbow projects. Switchovers are performed by rotating this elbow. A pneumatic cylinder activates the locking devices. Sensors ensure accurate positioning. The 1 x 12 rotary manifold operates fully automatically by pneumatic drive or manually. The smaller 1 x 6 model can only be operated manually.
2 x 12: For two filling units. Now with unrestricted rotation
On the fully automatic 2 x 12 rotary manifold, an elbow and an S-pipe rotate on the radius of the I.S.T. sliding couplings. A separate pneumatic motor moves the pipes, the positions of which are monitored by sensors. The control unit co-ordinates all paths of travel. The rotary manifold is protected by a wire mesh guard - or with shatter-proof PMMA type guards on request.
1 x 6 and 1 x 12: The compact solution for a filling unit. With central outlet and access port
Here's the space-saving and operationally reliable solution for distribution problems: on the I.S.T. rotary manifold 1 x 6 or 1 x 12, fixed I.S.T. sliding couplings are arranged round a central pipe nozzle, from which an 180° elbow projects. Switchovers are performed by rotating this elbow. A pneumatic cylinder activates the locking devices. Sensors ensure accurate positioning. The 1 x 12 rotary manifold operates fully automatically by pneumatic drive or manually. The smaller 1 x 6 model can only be operated manually.
2 x 12: For two filling units. Now with unrestricted rotation
On the fully automatic 2 x 12 rotary manifold, an elbow and an S-pipe rotate on the radius of the I.S.T. sliding couplings. A separate pneumatic motor moves the pipes, the positions of which are monitored by sensors. The control unit co-ordinates all paths of travel. The rotary manifold is protected by a wire mesh guard - or with shatter-proof PMMA type guards on request.
T08 - 2 / 2 Way Manifolds
This valve faciliates the simultaneous diversion of product flows in two directions. Thus different pipelines can be switched and pigged. The manifold can also be used as a piggable pump bypass. In this case the product flow is connected to the pump. After conveying the piggable pump bypass is switched on. Its integrated cylinder is pocket free due to its optimum sealing and therefore it can especially be used for products that allow no or only minimum contamination. The valve can be switched either manually or automatically. There is no overlapping while switching since all outlets are blocked. In combination with a pig stop insert and a pig sensor the T08 can also be used for launching and receiving of a pig. Thus, the pig can reversed into another pipeline.
T51 - 1 to 4 / 1 to 8 Manifold
This manifold is suitable for smaller distributions. 4 or 8 supplies which are arranged radially can be connected to a central outlet. Thus an easy and cost effective distribution is faciliated. This manifold is based on the sealing principle of the T41 (cylindrical form). Due to the fully piggable and pocket free design the possibility of contamination is almost deleted. A pneumatic four position actuator rotates the valve to any of the desired connections.
T56 - Piggable Manifold
The manifold consists of single T40.2 valve units. The piggable connections of the T40.2 are arranged offset by 90° in two levels. The connection of the "cross points" is achieved by turning the cylinder by 90°. The single valve units are connected to each other with sliding sleeves to the complete manifold. The valve units can easily be detached. Thus easy installation and disassembly are provided. Moreover, thermal expansions are compensated - especially in case of different product temperatures. With the flexible principle it is also possible to install or remove adjust pieces or spool pieces for easy upgrades. Moreover, with the piggable manifold T56 connections between different diameters are possible. From the upper line of the valve the product flows into the piggable lower line.
T57 - Full System Manifold
The I.S.T. full system manifold T57 sets high standards regarding reliability, efficiency and easy operation. It is a completely closed, piggable system that optimizes distribution and connection of pipelines.
The full system manifold T57 requires no hoses and reliably eliminates product losses and connection errors. It offers maximum safety and extremely straightforward operation for your staff.
This is the first manifold which allows different nominal diameters to be combined in a single design. For example, a piggable DN 50 pipeline can be filled with product next to a DN 100 pipeline and can then be pigged.
With the full system manifold T57 up to 50 transport lines can be connected to up to 20 pigging lines in one module. By attaching several manifold modules to each other, large scale distribution can be achieved.
When filling and pigging take place in parallel, the manifold can open and close the connections independently of each other.
The full system manifold T57 requires no hoses and reliably eliminates product losses and connection errors. It offers maximum safety and extremely straightforward operation for your staff.
This is the first manifold which allows different nominal diameters to be combined in a single design. For example, a piggable DN 50 pipeline can be filled with product next to a DN 100 pipeline and can then be pigged.
With the full system manifold T57 up to 50 transport lines can be connected to up to 20 pigging lines in one module. By attaching several manifold modules to each other, large scale distribution can be achieved.
When filling and pigging take place in parallel, the manifold can open and close the connections independently of each other.
T57-K - Full System Manifold
The benefits: The full system manifold T57-K has a compact design. Thus a large number of connections can be produced. Due to the closed design the risk of accidental leakages is excluded. Simple operation and minimal maintenance speak for the good suitability in daily use of this unique manifold in the area of smaller nominal sizes.
Technical description: The manifold unit T57-K consists of a matrix layout with a manifold node which is piggable to one side. The upper full system line and the lower pigging line are installed rectangular to each other. In initial state both lines are separated from each other when the manifold is switched. In the manual version the manifold is operated with a hand lever. The manifold can be applied for horizontal and vertical arrangement.
Technical description: The manifold unit T57-K consists of a matrix layout with a manifold node which is piggable to one side. The upper full system line and the lower pigging line are installed rectangular to each other. In initial state both lines are separated from each other when the manifold is switched. In the manual version the manifold is operated with a hand lever. The manifold can be applied for horizontal and vertical arrangement.
T07 - 3-Way Valve
The piggable three way valve T07 is used to bypass product streams in two or three directions. Every mounting position is possible for this compact station. The sphere is sealed at the piggable passages by PTFE-Rings; in every position one outlet is closed. It is possible to switch the three way valve under pressure.
T41 - 3-Way Valve, Cylinder
This three way valve allows either two or three pipeline routes to be connected. The internal cylinder rotates and locks the desired connection. Due to its shape the valve is almost pocket free and is therefore successfully used in the chemical and in the paint industry. The T41 can be operated manually (hand lever) or automatically. In combination with a pig stop insert and a pig sensor the T41 can also be used for launching and receiving of a pig. Thus the pig can be deviated into another pipeline or driven back into its home station.
T09 - T-Ring Valve
This I.S.T. T-ring valve takes on 3 jobs at once: it acts as a branch in pigging system pipelines, incorporates a product isolation valve and also "catches" and "launches" pigs.
It can be used either as an independent station or integrated in a distribution assembly. The horizontal plane can be pigged without pockets when the valve is closed. The vertical port can be closed with the ring-shaped seal when necessary.
Pressure balanced seal design provides effortless movement of the valve ring, using only a small pneumatic cylinder. There is only minimal pressure drop when the product flow is diverted.
It can be used either as an independent station or integrated in a distribution assembly. The horizontal plane can be pigged without pockets when the valve is closed. The vertical port can be closed with the ring-shaped seal when necessary.
Pressure balanced seal design provides effortless movement of the valve ring, using only a small pneumatic cylinder. There is only minimal pressure drop when the product flow is diverted.
T10 - T-piece
The T-piece is piggable in the straight passage. During the pigging process the special T-branch is completely sealed by the lips of the pig. The station can also be equipped with a pig stop that serves as a buffer for one and two pig systems. The T-piece is a welded station, especially suitable for non standard designs, inner diameters, heating jackets etc.
T10.3 & T10.4
This pig station is applicable for one and two pig systems. It can be operated both manually or automatically. It is equipped with a pig stop insert that catches the pig. This insert can be removed for pig change. Sockets for propellant as well as electrical and manual pig sensing can be installed individually. In order to avoid the pig being pulled out of its position due to product turbulences a pig retainer can be mounted.
T45 - Simultaneous Metering Blender
All raw material components (base oils and additives) are pumped to the SMB from dedicated tanks, where a series of metering channels equipped with mass flow meter, control valve and non-return valve allow very accurate and simultaneous dosing of all blend recipe components. The SMB design incorporates a fully piggable distribution header pipe in order to avoid cross-contamination between blend recipes and to maximise product recovery. This unique piggable SMB conecpt even allows for the different family groups of lubricating oils to be blended in the SMB and hence maximises plant equipment utilisation.
The general principle of operation for the SMB is as follows: Operator provides production data (such as: product name / code, type, blend size, and tank destination etc) to the SMB control system.
The SMB control system will then automatically dose all required raw material components according to the customer's specific blend formulation (recipe), in following three stages: First stage is an initial dosing and transfer of the main blend components base oils and additives, followed by a final dosing and transfer of the remaining base oil. This dosing sequence ensures that optimum pigging results are achieved, with respect to cross-contamination between subsequent SMB blends.
The pigging system is directly integrated in the SMB. Thus the connecting pipelines and the basic isolation valves can be emptied without residues.
The non piggable areas such as flow meters / counters are emptied according to a progammed procedure and rinsed with base product. Now the system is completely emptied and the next process can be prepared.
The general principle of operation for the SMB is as follows: Operator provides production data (such as: product name / code, type, blend size, and tank destination etc) to the SMB control system.
The SMB control system will then automatically dose all required raw material components according to the customer's specific blend formulation (recipe), in following three stages: First stage is an initial dosing and transfer of the main blend components base oils and additives, followed by a final dosing and transfer of the remaining base oil. This dosing sequence ensures that optimum pigging results are achieved, with respect to cross-contamination between subsequent SMB blends.
The pigging system is directly integrated in the SMB. Thus the connecting pipelines and the basic isolation valves can be emptied without residues.
The non piggable areas such as flow meters / counters are emptied according to a progammed procedure and rinsed with base product. Now the system is completely emptied and the next process can be prepared.
T65 - DDU: Drum Decanting Unit
A perfect supplement in pigging technology in order to provide safety and functionality when emptying drums and containers (IBC). Here the pumped products are often used as additives for blending processes. The decanting process is semi-automated. With a pre-heated base product the drums will be almost completely emptied. The product is decanted with a pneumatically driven lance which transports the product directly into the piggable transport line. The product will be conveyed directly to the storage tanks or into the subsequent blenders. The exact dosing of the product is effected by a weighing system that is connected to the central control unit of the DDU. A quick change-over from drum decanting to container decanting can be done with help of the flexibly designed roller conveyor. The system can be retooled for the decanting of a completely different kinds of packaging within seconds.
T43 - Plunger Valve
The advanced version of the proven plunger valve is designed as flow optimized inlet and outlet valve for piggable pipelines. The piggable main line is connected to the valve's housing. The vertically arranged piston is designed in a way that in the closed position a smooth, piggable passage is produced. The new protected seal concept facilitates a slim, pipeline optimized design and switching of the piston whilst the valve is pressurized. The complete valve unit with all seals can be replaced without having to dismount the valve. Thus, the plunger valve can be quickly used again.
The sealing principle utilised in the T-port valve is the same as in our proven T41 three way valve. The main seal is manufactured from PTFE and covers the valve drum completely. Hence, no product residue remains in the piggable passage.
The sealing principle utilised in the T-port valve is the same as in our proven T41 three way valve. The main seal is manufactured from PTFE and covers the valve drum completely. Hence, no product residue remains in the piggable passage.
T16 - Pig Launching & Receiving Station
This station can also be applied to both one and two pig systems. It is equipped with a pig stop insert and facilitates rinsing and drying of the pigs after the pigging process by installation of internal and external by-passes. With help of the I.S.T. sliding coupling it is easy to connect the T16 to the pig loading and unloading station T29.
About us
You can count on I.S.T. Molchtechnik GMBH as your competent partner for pigging technology!
Since 1981, we have been supplying high quality and competent pigging technology
Leader in pigging technology
Pigging applications are covered by more than 40 patents
100% customer-specific pigging technology
We are a medium-sized company characterized by quality products, innovative strength, flexibility, and service readiness. We have continuously expanded our production facility over the past few years. In the field of special valves and distribution technology, we excel at meeting individual customer needs.
The company was founded in Hamburg in the seventies by Mr. Hubert Skibowski as a planning office. Due to technical possibilities and market demands, the planning office developed and produced pigging systems as a company. There was a strong focus on the lubricating oil and chemical industries, although many systems were developed for the food and paint industries as well.
I.S.T. is one of the leading companies in industrial pigging technology today
From individual system components to innovative complete solutions, we provide a comprehensive range of services in pigging technology. The systems we develop are used in industrial plants around the world, contributing to their economic and environmentally friendly operation. A global sales and service network is also available to our customers.
Through continuous innovation of our product range, we aim to further enhance the high level of customer satisfaction.
I.S.T. Offers:
Since 1981, we have been supplying high quality and competent pigging technology
Leader in pigging technology
Pigging applications are covered by more than 40 patents
100% customer-specific pigging technology
We are a medium-sized company characterized by quality products, innovative strength, flexibility, and service readiness. We have continuously expanded our production facility over the past few years. In the field of special valves and distribution technology, we excel at meeting individual customer needs.
The company was founded in Hamburg in the seventies by Mr. Hubert Skibowski as a planning office. Due to technical possibilities and market demands, the planning office developed and produced pigging systems as a company. There was a strong focus on the lubricating oil and chemical industries, although many systems were developed for the food and paint industries as well.
I.S.T. is one of the leading companies in industrial pigging technology today
From individual system components to innovative complete solutions, we provide a comprehensive range of services in pigging technology. The systems we develop are used in industrial plants around the world, contributing to their economic and environmentally friendly operation. A global sales and service network is also available to our customers.
Through continuous innovation of our product range, we aim to further enhance the high level of customer satisfaction.
I.S.T. Offers:
- We design and manufacture pigging valves, piggable manifolds, and pigging systems
- A robust pigging system capable of withstanding pressures up to PN 40 and temperatures up to 200°C
- Quality standards according to ISO 9001 and Pressure Equipment Directive, module H
- Manifolds and valves that are easy to maintain
- ATEX-compliant pigging equipment for potentially explosive atmospheres
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