Welcome to part four of our series on how to keep your pigging systems up to date! Previously, we’ve covered software updates, employee training, and system upgrades.

In this article we’ll look at pigging system servicing, what it covers, how often it should be performed, and the benefits of servicing.

HPS pigging systems are used by manufacturers of liquid products, ranging from food and drink to chemicals and adhesives, to recover residual products from pipelines. The process typically takes place at the beginning of changeover sequences and before CIP procedures (if applicable).

To perform a pigging sequence, a specialist projectile, known as a “pig”, is automatically introduced into the line and propelled using a suitable propellant. The pig pushes the residual product, which would normally be flushed to waste or downgraded, to its destination, increasing yields and reducing waste.

Why Service HPS Pigging Systems?

Regular maintenance of all equipment within a production facility is important for efficiency and effectiveness.

Pigging system servicing ensures that your equipment and components remain in peak condition and deliver optimal performance. Through regular maintenance, manufacturers will continue to see the benefits of pigging, including high product recovery rates, reduced resource consumption, decreased production downtime, and more.

HPS service plans provide comprehensive coverage, making sure that your equipment remains in full working order and employees are fully trained.

Why Invest in an HPS Service Plan?

HPS service plans are bespoke and designed to make your life easier. Whilst each plan is unique, they all aim to provide:

Prolonged operational equipment lifespan.

Pigging systems require an upfront investment and, prior to placing an order, HPS will help you determine the business case and provide you with an estimated return on investment (ROI).

With the correct maintenance and operator training, your pigging systems can be used for decades without depreciating in value. For many HPS customers, the initial investment is paid off within 6 to 12 months and from that point onwards, the pigging systems simply increase company profit.

Ensured system reliability.

Without maintenance and correct operation, your pigging systems will prove to be less effective over time. The timescale for diminished performance varies based on product, length, frequency of use, and other factors, but is easily preventable.

Knowing when to replace parts and pigs is easy to identify with the proper training and software, and we encourage your team to attend a refresher training course once every two years at a minimum.

Reduced production downtime.

Pigging systems are effective at reducing production downtime by speeding up the changeover and CIP processes. For many manufacturers, these processes are time consuming and require extensive flushing or pipework dismantling to remove the product.

HPS pigging technology has a product recovery rate of up to 99.5% and a fast operation time. Maintaining the pigging systems decreases the amount of time spent by operators cleaning lines in preparation for the next transfer sequence.

Increased productivity and yields.

Following on from how maintenance reduces production downtime, fully maintained pigging systems increase productivity and yields. Operators can focus more on production, improving labour cost efficiency. This leads to higher output and greater flexibility in product scheduling.

Thorough operator training.

Mistakes are more likely to occur when operators aren’t using equipment properly. For this reason, we encourage our clients to include training sessions in their service plans. All operators will receive training during the commissioning of the pigging systems, however the difficulty that comes with retaining labour means that there are high employee turnover rates within the manufacturing industry.

As such, having yearly or two-yearly training sessions will keep all your staff up to date on how to use the system safely, how to identify maintenance needs, and basic troubleshooting skills.

Investing in an HPS service plan will, above all else, give you peace of mind that your pigging systems will operate at peak efficiency, minimise unexpected downtime, and continue to deliver optimal performance for years to come.

What’s Included in an HPS Service Plan?

HPS service plans are customisable in many aspects, including length, consumables provision, training days, and site visits.

Pigging System Maintenance

HPS service plans are typically acquired by customers looking to keep on top of their maintenance requirements.

As part of the service plan, HPS can:

  • Check components such as filters, seals, and pigs, and replace them if necessary.
  • Check valves and realign if necessary.
  • Perform an AccuTect performance assessment and recalibrate if necessary.
  • Check for unusual wear on existing pigs and replace them if required.
  • Check process air supply and pigging pressures.
  • Perform a system operational check.
  • Discuss and supply HPS Pig Health Software.
  • Discuss any proposed site, line, or product changes that could impact pigging operations.
  • Advise on any beneficial system improvements or upgrades.

The scope of maintenance is customisable to your needs and requirements. We recommend having an HPS engineer on site to check your equipment once a year. As part of the maintenance plan, site visits are included and can be scheduled at your convenience.

Pigging System Training

You may elect to have training days included in your service plan that will enable you to keep your employees knowledgeable in how to operate, troubleshoot, and maintain your pigging systems.

Training sessions with HPS can include:

  • Understanding Liquid Product Recovery (Pigging) Technology.
  • A mechanical overview of HPS pigging systems.
  • New operator training.
  • On-site trainer training.
  • Operator refresher training.
  • Maintenance Operative training.

Regular training sessions ensure that you always have someone on your team who is HPS certified to operate your pigging systems.

Find out more about how operator training helps keep your pigging systems up to date.

pigging system Consumables Package

Component replacement is a crucial part of pigging system maintenance. Components that may need to be replaced during a maintenance visit include pigs, filter elements, and valve seals.

As part of the service plan, you’ll receive a list of items that HPS recommends you keep in your inventory for use during site visits. These items can be purchased as part of the service plan and kept on site in preparation for replacement.

In addition to pre-purchasing, any non-standard items that need to be replaced can be bought at a discounted price.

How Do We Get an HPS Service Plan?

Once your pigging system is commissioned, you’ll be introduced to our dedicated customer support team.

The customer support team will ask about any needs or requirements that you have for planned preventative maintenance and create a bespoke service plan for you. Your first service plan can provide coverage for any length of time that you determine and then periodically renew. Renewals will be discussed with you after your last site visit covered by the existing plan.

HPS service plans are available for purchase at any time, however we recommend purchasing them with the project or at project sign off. This way, they can be considered part of the CapEx investment.

Alternatively, you can approach the customer support team at any point after your pigging systems are commissioned to discuss setting up a service plan. Here’s more information on how HPS supports you after pigging system commissioning.

About HPS

HPS Product Recovery Solutions is the leading provider of Advanced Liquid Product Recovery (Pigging) Technology for manufacturers around the world. We’ve been providing and supporting clients with pigging technology and liquid transfer solutions since 1995, making us the experts in product recovery.

For support in starting your pigging journey, upgrading your systems, or anything else, please contact us today. Alternatively, find out more about how HPS supports pigging system operators.

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