Industrial Pigging Technology

Transcription

1 Gerhard Hiltscher, Wolfgang Mühlthaler, Jörg Smits Industrial Pigging Technology Fundamentals, Components, Applications

2

3 G. Hiltscher, W. Mühlthaler, J. Smits Industrial Pigging Technology

4

5 Gerhard Hiltscher, Wolfgang Mühlthaler, Jörg Smits Industrial Pigging Technology Fundamentals, Components, Applications

6 Editor Prof. Dr.-Ing. Gerhard Hiltscher University of Applied Sciences Mechanical Engineering Department Mannheim Germany Dipl.-Ing. Wolfgang Mühlthaler K. Mühlthaler Industrieberatungsservice Molchtechnik und Tanklagerbau Regerstr Hemsbach Germany Dipl.-Ing. Jörg Smits BASF Aktiengesellschaft WLF/EA-L Ludwigshafen Germany & This book was carefully produced. Nevertheless, authors and publisher do not warrant the information contained therein to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate. Library of Congress Card No. applied for British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. Bibliographic information published by Die Deutsche Bibliothek Die Deutsche Bibliothek lists this publication in the Deutsche Nationalbibliografie, detailed bibliographic data is available in the Internet at < WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim Printed on acid-free paper. All rights reserved (including those of translation in other languages). No part of this book may be reproduced in any form by photoprinting, microfilm, or any other means nor transmitted or translated into a machine language without written permission from the publisher. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law. Printed in the Federal Republic of Germany Composition Kühn & Weyh, Freiburg Printing Strauss Offsetdruck, Mörlenbach Bookbinding Großbuchbinderei J. Schäffer GmbH & Co. KG, Grünstadt ISBN

7 V List of Contents I Fundamental Principles of Pigging Technology 1 1 Introduction to Pigging Technology Historical Development and Definition Fields of Application of Pigging Technology 6 2 Pigging Units and Pigging Systems Definitions Selection and Design Criteria Pigging Units Pigging Units without Branches Pigging Units with Branches Pigging Units with Switches Pigging Systems Sequence Tables One-Pig Systems Two-Pig Systems 18 II Components 21 3 Pigs Pigs for Industrial Pigging Units Function Fields of Application Materials Selection Pig Materials Tests for the Selection of Pig Materials Shear Strength of the Pig Material Deformation of a Solid Cast Pig under Pressure Pig Designs One-Piece Pigs Multicomponent Pigs Special Pigs 43

8 VI List of Contents 3.4 Fabrication of Pigs Quality Assurance 45 4 Valves Function of Piggable Valves Classification of Piggable Valves Examples of Standard Valves Stations Branches Pig Traps Switches Examples of Commercially Available Special Valves Crossing of Two Piggable Pipes Manifolds Piggable Loading Facilities Drum-loading Valves Pressure Drop in Piggable Valves Stress on Pig Traps 71 5 Pipework Requirements for Piggable Pipes Materials for Piggable Pipes Piping Elements Pipes Pipe Bends Tees Pipe Joints Flange Connections Welded Pipe Joints Example of a Pipe Specification Construction of Piggable Pipes Piggable Hoses 96 6 Additional Equipment Pressure-Relief Vessel Propellant Tank Filters Pumps Propellants Gaseous Propellants Speed Behavior of Gas-Driven Pigs Remedial Actions Liquid Propellants 110

9 List of Contents VII Properties of Liquid Propellants Dimensioning of Liquid-Propelled Pigging Units Control System Components of the Control System Sensors Permanent Magnets and Magnet Sensors Actuators Operating Modes of the Sequence Control Manual Operation Enhanced Manual Operation Touch-Controlled Operation Automatic Operation Examples of Sequence Control Sequence Control of a One-Pig System Sequence Control of a Two-Pig-System Sequence Control of a Cleaning Procedure 134 III Applications Decision Criteria for Pigging General Criteria Product Infrastructure Technology Physical and Chemical Properties of the Products Economic Criteria Long Pipeline without Cleaning Procedures Omission of Tracing Multiproduct Pipe Evaluation of the Examples Quality Criteria Environmental Criteria Cleaning Degree after Pigging Qualitative Classification Precalculation for the Cleaning Degree Concept Inner Surface Roughness of Pipes and Valves Welding Seams Flange Connections Dead Spaces Residual Film of the Pigged Pipe Exemplary Calculation for Residual Concentration in a Plant Errors 169

10 VIII List of Contents 11 Pig Wear Fundamentals Wear Characteristics and Service Life of Pigs Minimum Permissible Pig Diameter Wear Inspection Operating Mode Medium-Specific Characteristics Introduction to Fluid Dynamics Classification of Fluids with Examples Viscosity Curves Principles of Calculation Examples and Applications Newtonian Behavior Non-Newtonian Behavior Checks before Start-up Checking Equipment Piggable Pipes Pigs Additional Equipment Function Checks Test Pigging Concentration Measurement Test Pigging: a Practical Example Experiences with Pigging Units Experiences before Start-up Decision-Making Planning Procurement Installation Experiences after Start-up Equipment Defects Malfunctions during Operation Documentation of Rare Events Applications in the Chemical Industry Polymer Dispersions Production Plant Product Properties Purpose of the Pigging Unit Technical Data of the Pigging Lines Description of the Function Urea Formaldehyde Resins 209

11 List of Contents IX Production Plant Product Properties Purpose of Pigging Technical Data of the Pigging Lines Description of the Function Dispersion Adhesives Production Plant Product Properties Purpose of Pigging Technical Data of the Pigging Lines Description of the Function Fragrances Production Plant Product Properties Purpose of Pigging Technical Data of the Pigging Line Description of the Function Raw Materials Production Plant Product Properties Purpose of Pigging Technical Data of the Pigging Line Description of the Function Pigging Units for Sterile Technology Characteristics of Sterile Technology Terms in Hygienic Design Materials for Sterile Technology Elements of Sterile Pigging Technology Pigs Pig Cleaning Stations Pipelines Pipe Joints Example Pipeline Pigging Distinction from Industrial Pigging Units Pipes and Fittings Pipes Tolerances Fittings Function of Pigs in Pipelines Pigs for Pipelines Mechanical Pigs Smart Pigs 249

12 X List of Contents Gel Pigs Pig Launchers and Receivers Pigging of Pneumatic Conveying Lines for Bulk Materials Pneumatic Conveying of Bulk Materials Structure of Pneumatic Conveying Systems Basic Structure of Pneumatic Conveying Systems Structure of a Pigging System for Bulk Conveying Lines Cleaning of Pneumatic Conveying Lines Purging Cleaning Pellets Wet Cleaning Pigs for Pneumatic Conveying Lines Soft Pigs Turbo Pig Notch Pigs Jet Pigs 271 IV Law and Regulation Legal Requirements Laws, Regulations, and Guidelines Required Permissions and Examinations Pressure Hazard Ground Water Contamination Explosion-Hazard Areas Safety and Occupation Health Kinetic Energy of the Pig Energy of the Propellant Definition of Explosion Hazard Terms Ignitibility and Ignition Temperature Explosion Protection of Environment and Off-Gas Protection against Electrostatic Charging Accident Prevention in Explosion-Hazard Plants Ignition Hazard with Compressed Air as Propellant Explosive Mixture Properties Calculation of the Explosive Composition and Volumetric Concentration in a Pipeline Electrostatic Charge Accident Prevention for Equipment Remedial Measures for Hazardous Operating Conditions Evaluation of Operation Safety and Explosion Hazard Classification 293

13 List of Contents XI V Appendix 295 References 297 List of Chemical Resistances 301 Description of Material Codes 302 Properties of Solvents 324 Buyer s Guide 325 Suppliers Names and Adresses 327 Index 329

14

15 XIII Notation Symbol Designation Unit A area, cross-sectional area m 2 a distance m a sound velocity m/s B magnetic induction T = Wb/m 2 b width m, mm c velocity m/s C concentration %, ppm C R residual conc. in the following product %, ppm C v volume concentration %, ppm C m molar concentration %, ppm D shear rate, velocity gradient s 1 D, d diameter m, mm E modulus of elasticity in tension N/mm 2 E kinetic energy J F force N f frequency Hz f deflection mm G modulus of elasticity in shear N/mm 2 h height mm H magnetic field intensity A/m I moment of inertia mm 4 K constant K modulus of elasticity in compression N/mm 2 L*/d pig: sealing length/diameter ratio L, l length m, mm L/d pig: total length/diameter ratio M molar mass kg/kmol m mass kg M b bending moment Nm n number O l largest possible oversize mm