WiZARTEC® Glossary

Pig (pipeline pig, scraper) A pig is a flexible “plug” that moves through a pipe and pushes the product ahead of it. A pig has a diameter slightly larger than that of the pipe. Thanks to its flexibility, it adapts to the inside of the pipe and fits tightly against the walls, scraping the product off them as it moves. The pig gives its name to the whole technology, pigging. It is also known as a pipeline pig or a

Pigging system Pigging is a method of pushing product residue out of a pipe into a tank or filling machine instead of flushing it down the drain. When product transfer is complete, some product always remains in the pipeline: on the pipe walls and in the pipe itself. In the traditional approach, it is flushed out with water, so it ends up in the wastewater. A pigging system sends a special flexible plug, called a pig, into the pipe, which

Final budget A final budget is the budget set at the procurement stage, which forms the basis of the implementation proposal and the contract. The final budget is prepared at the procurement stage, once the budget has already been approved. Even then, it is still worth analysing alternatives: alternative equipment, its suppliers or the installation methods for individual components. Pricing these alternatives makes it possible to optimise costs within the approved budget without lowering the technical specifications of the installation.

Detailed budget estimate A detailed budget estimate is a precise cost breakdown of the chosen solution, tailored to a specific plant. A detailed budget estimate is prepared once the investor has chosen a concept and it needs to be adapted to the conditions at the plant: available space, existing infrastructure, utilities, regulatory requirements and time constraints, such as maintenance windows. It is based on a defined scope of work and specific technical solutions. This type of estimate breaks costs down

Option-based budget estimate An option-based budget estimate is a separate cost estimate for each of several possible solutions, so that they can be compared. An option-based budget estimate is prepared at the concept stage. The problem has already been defined, and the investor knows what they expect from the installation, but they are considering several ways of achieving the goal. A separate cost estimate is prepared for each concept. This makes it possible to compare the options not only technically

Rough budget estimate A rough budget estimate is a preliminary cost range that shows the scale of the expenditure involved. A rough budget estimate is prepared at the very beginning, when the investor knows there is a problem in production but does not yet have an idea of how to solve it. At this point, no specific solution is priced, because there isn’t one yet. Instead, a range of amounts is given, such as “PLN 2 to 5 million”, based

Dead zones Dead zones are places in an installation where product collects and does not flow with the rest, and which water and cleaning agents do not reach during cleaning. In a well-designed installation, product flows continuously, and once production ends it can be completely removed and every part of the pipes and tanks thoroughly cleaned. A dead zone is a place that “drops out” of this flow. Product flows into it but does not flow out again, so it

Recipe A recipe is a complete set of instructions for a process line that specifies exactly what it must do to make a particular product. It defines which ingredients to add and in what quantities, in what order, to what temperature the product should be heated or cooled, at what speed it should be mixed and how long each stage lasts. Everything is expressed in numbers, leaving no room for guesswork. The recipe is stored in the line’s control system.

Maintenance windows Maintenance windows, also known as planned shutdowns or maintenance shutdowns, are predetermined periods during which a plant stops production to carry out maintenance, repairs or upgrades. These may be, for example, two weeks over the Christmas period, a few days in summer or one weekend a month. Maintenance windows are especially important when a new installation is to be built in an operating plant and needs to be connected to existing lines. Most of the work, such as

Commissioning (start-up) Commissioning, also known as start-up, is the final stage of delivering an installation. It covers switching on all the equipment for the first time, checking that everything works together as intended, and fine-tuning the parameters until the installation consistently produces a product of the required quality. Commissioning usually takes place in stages: Pre-commissioning checks: inspection of the installation work, pipe leak tightness, motor rotation directions, and the operation of safety devices and signals. Cold commissioning (water trials): the

Cable routes Cable support systems are the structures used to route cables through a plant: from control cabinets to sensors, motors, valves and operator panels. They can take the form of metal cable trays, cable ladders, trunking or conduit, fixed to walls, ceilings or dedicated support structures (steel supports and frames that carry pipes, cables and equipment). Cable support systems keep wiring organised, protect cables from damage and make servicing easier. Power and signal cables are usually routed separately, because

Control cabinets Control cabinets are metal enclosures housing the electrical and automation equipment responsible for a given part of an installation. They typically contain: PLCs (programmable logic controllers), meaning industrial computers that run the control program, input and output modules, to which cables from sensors and devices are connected, power supplies, electrical protection devices, such as circuit breakers and fuses, variable frequency drives, meaning devices that smoothly adjust motor speed by changing the frequency of the current, relays, contactors and