What is Pipeline Pigging and Why It's Important
Pipelines transport various materials including oil, gas, water, and chemicals over long distances. Over time, pipelines accumulate deposits of sediment, scale, and other contaminants. The buildup of these deposits reduces a pipeline’s efficiency and increases its risk of corrosion and failure.
The term, “pipeline pigging,” derives directly from the pig-shaped devices designed to move through the pipeline as they clean and inspect the interior walls. “Pigs” are inserted into a pipeline through existing openings. They are propelled by the flow of the material carried by the pipeline or, in some cases, by an external energy source.
Pigs
Can be made of various materials and different designs, all based on the task they are performing.
The history of this technology dates to the early 20th century when pigs were first used to clean sections of natural gas pipelines in the United States. Through the years, smart pigging has advanced to include various types of pigs for an assortment of specific purposes. In recent years tracking and data collection systems used to monitor pipeline conditions have exponentially improved.
The following information offers an explanation of pipeline pigging and its relevance to efficient pipeline maintenance.
What Is Pigging?
Pigging is a maintenance technique where a projectile-like device called a pig is inserted into a pipeline to perform tasks such as cleaning, separating products, or inspecting the pipe's internal condition. The pig is typically made of foam, rubber, or urethane and may contain brushes, discs, or advanced sensors.
Originally developed for cleaning oil and gas pipelines, pigging has evolved into an advanced technology used across various industries, including food and beverage, pharmaceuticals, chemicals, and personal care. Pigging is also referred to as line pigging, pipeline pigging, or product recovery pigging, depending on the industry and purpose.
What is Pipeline Pigging?
The process of pipeline pigging involves inserting a “pig” into a pipeline for cleaning and inspection. The “pig” is a cylindrical or spherical-shaped tool made from a variety of materials such as rubber, polyurethane, steel, or even ice!
Several types of pigs are used in this process.
Cleaning pigs are designed to remove debris, scale, and other deposits that can accumulate in a pipeline. They typically are equipped with brushes or other scraping devices to clean the interior of the pipeline as they move.
Inspection pigs do exactly what the name implies. They inspect the pipeline interior for defects such as cracks, corrosion, or other damage. Sensors within the pig collect data and images used to assess the condition of the pipeline.
Batching pigs separate different types of materials in a pipeline. For example, in a pipeline carrying oil, batching pigs can be used to separate the grades thus preventing contamination.
Gauging pigs measure the diameter and thickness of a pipeline. They often contain magnetic or ultrasonic sensors that detect changes in wall thickness. Such changes can indicate areas of corrosion or damage.
Regardless of type, pigs are propelled through the pipeline either by the flow of the material being carried or by an external energy source such as compressed air or water. As they move through the pipeline, the pigs clean or inspect the interior while collecting and transmitting data to monitoring systems for analysis.
Pipeline Experts: Inspection, Cleaning, Coating & More
Certified solutions for inspection, pre-commissioning, cleaning, internal coating, ice pigging™, mapping, and turnkey pipeline projects—maximizing safety and reliability at every stage.
How Does Pipeline Pigging Work?
The pig is launched into the pipeline through a pig launcher and is pushed along the line by the pressure of the fluid, compressed air, nitrogen, or even the next batch of product. As the pig travels through the line, it performs its designated function—whether it’s cleaning, gauging, or inspecting the pipe. Once it reaches the end of the line, it is collected in a pig receiver.
To ensure full coverage and effectiveness, pigs are often tracked using transmitters (TX) and receivers (RX), geophones, or other sensor-based devices. These tracking systems confirm that the pig has passed through key pipeline segments and help detect if it becomes stuck or encounters resistance.
Why is Pipeline Pigging Important for Efficient Pipeline Maintenance?
Pigging contributes to the cost-efficiency and overall effectiveness of pipeline maintenance. By removing sediment, debris, and other contaminants from the interior of the pipeline, this process improves the flow of material and reduces the risk of costly blockages. Pigging also helps extend pipeline life by preventing corrosion and other damage.
Without regular maintenance, pipelines can become clogged or damaged, leading to costly shutdowns and repairs. Using pipeline pigging, operators can identify and address issues before major problems occur. This substantially reduces the need for unplanned downtime and expensive repairs.
Damaged pipelines can cause leaks or spills leading to environmental contamination. Pigging reduces these hazards by helping keep pipelines clean and in good working order.
Pipeline pigging is essential to effective pipeline maintenance. By using pigs to clean and inspect pipelines, operators can reduce the risk of downtime, extend the life of pipelines, and prevent environmental damage.
Types of Pipeline Pigs
As a pigging service provider, we utilize a range of specialized pigs—each selected for your pipeline’s specific needs. Our team determines the right type of pig for each project, whether the goal is cleaning, inspection, or product recovery. Common pig types we deploy include:
1. Cleaning Pigs
These pigs are designed to remove dirt, wax, scale, and biofilm. They may include brushes, discs, or blades to scrape and push debris forward.
2. Inspection Pigs (Smart Pigs)
These high-tech pigs are equipped with sensors to detect corrosion, cracks, dents, or changes in pipe wall thickness. They use technologies such as Magnetic Flux Leakage (MFL) or Ultrasonic Testing (UT).
3. Batching Pigs
Used to separate different products in a pipeline (e.g., between two grades of oil or chemicals) to prevent contamination.
4. Gauging Pigs
Often used before the first run of a smart pig, gauges pigs check for pipe bore obstructions and deformation.
5. Product Recovery Pigs
Common in food and sanitary industries, these pigs reclaim residual product left in the pipe, helping companies improve yield and reduce waste.
Why Is Pigging Important?
Regular pigging helps:
Maintain Optimal Flow Rates: By clearing debris and buildup.
Prevent Corrosion: By removing moisture and contaminants.
Detect Early Defects: Reducing the risk of costly failures.
Extend Pipeline Lifespan: By supporting preventive maintenance.
Enhance Environmental Safety: By reducing leaks and product waste.
Pigging is essential not just for oil and gas pipelines but also for hygienic and sanitary applications. For example, food-grade systems use pigs to recover product left in the line and reduce water and cleaning agent usage.
Components of a Pigging System
Every pipeline presents unique challenges. When you engage our pigging services, we bring and operate all required equipment—pig launchers, receivers, pigs tailored for your line, and advanced tracking systems. Our technicians handle setup, operation, and data analysis, ensuring you don’t have to worry about system components or technology.
Pigging systems can be fully automated or manual, depending on pipeline size, frequency, and industry application.
The Pipeline Pigging Process
The pigging process involves several steps to ensure proper cleaning and inspection of the pipeline.
First, the pipeline must be prepared for pigging. To prevent damage to the pig and promote its movement, the pipeline must be isolated with all appropriate valves shut or opened accordingly. Next, the pig is inserted into the pipeline using a launching station. Once installed, the pig is propelled forward by the flow of material in the pipeline or by an external energy source. During this process the pig cleans or inspects the interior of the pipeline. Special sensors and monitoring equipment track the pig’s movement. A receiving station, located at the end of the pipeline, collects the pig and any debris removed from the pipeline.
After the pig has been removed, the pipeline must be inspected to ensure it has been properly cleaned or inspected. This is accomplished by visual inspection, ultrasonic testing, or other techniques. If any issues are detected during this post-pigging inspection, further maintenance or repairs may be required before the pipeline can be put back into service.
The pigging process is designed to properly clean or inspect pipelines in order to reduce the risk of downtime, prevent leaks and spills, and extend the life of the pipeline. By following a rigorous
pigging process, pipeline operators can ensure their pipelines are operating at peak efficiency and meeting regulatory requirements.
The pigging process involves the following steps:
Step 1: Preparation
The pipeline is isolated and set up for pigging. Valves are adjusted, and launch/receive equipment is secured.
Step 2: Launching the Pig
A pig is inserted into the launcher and pushed through the pipe using fluid pressure, compressed air, or gas.
Step 3: Cleaning or Inspecting
The pig performs its task as it travels, scraping residue, separating products, or scanning pipe walls.
Step 4: Monitoring the Pig
Its location is tracked to ensure it completes the run. If it encounters issues, tracking equipment helps pinpoint its position.
Step 5: Receiving the Pig
It exists at the receiving station where the debris or data it is collected.
Step 6: Post-Run Analysis
The pipeline is inspected visually or digitally to assess cleaning effectiveness or evaluate inspection data.
This method allows pipelines to remain operational (in some cases) or be quickly returned to service after cleaning or inspection.
Industries That Use Pipeline Pigging
Pigging is not limited to oil and gas. It’s used in diverse industries:
Oil & Gas: For pipeline integrity, separation, and flow assurance.
Food and Beverage: Chocolate, dairy, sauces, beer, and juices
Personal Care: Shampoo, toothpaste, cosmetics
Household Products: Detergents, cleaning liquids
Chemical Manufacturing: Paints, resins, coatings
Pharmaceuticals: Liquid medications and sterile compounds
These industries rely on pigging to reclaim valuable products, prevent contamination, and minimize downtime between batch changes.
We serve a broad range of industries with our pigging services, customizing solutions for oil & gas, food and beverage, chemical manufacturing, pharmaceuticals, and more.
Challenges and Limitations of Pipeline Pigging
While pipeline pigging is an effective maintenance method, several challenges and limitations are associated with the process.
Pipeline design can impact the effectiveness of pigging. For example, pipelines with sharp bends or changes in diameter may require special pigs to navigate these obstacles. A limited array of pigs may be available for use in smaller-diameter pipelines. When planning to use the pigging process, operators must carefully consider the design of their pipelines. Pipelines not well suited for pigging may require modifications or the use of special equipment.
Operators must also consider the frequency of pigging. If done too infrequently, debris and contaminants can build up inside the pipeline, making cleaning more difficult. Conversely, if pigging is performed too frequently, the pipeline may be at risk for unnecessary wear and tear thereby increasing the risk of damage. To best address these challenges, operators should develop a pigging schedule adapted to the specific needs of their pipeline. The material being transported, the age of the pipeline, and the environmental conditions under which the pipeline operates, must all be considered when creating this schedule.
Challenges and limitations of pipeline pigging can be addressed through careful planning, design, and equipment selection. By working closely with experienced pigging professionals and following best practices, pipeline operators can ensure their operations are effective, efficient, and safe.
Pipeline Experts: Inspection, Cleaning, Coating & More
Certified solutions for inspection, pre-commissioning, cleaning, internal coating, ice pigging™, mapping, and turnkey pipeline projects—maximizing safety and reliability at every stage.
Conclusion
Pipeline pigging is crucial to maintaining efficient and safe pipeline operations. Regular pigging removes debris and contaminants, prevents corrosion, and detects potential issues before they become major problems. These actions help reduce the need for costly shutdowns and repairs, increase the lifespan of the pipeline, and minimize negative environmental impact.
To implement a successful pigging program, pipeline operators should work closely with experienced professionals who can provide guidance on pig selection, pigging frequency, and other best practices. Well developed pigging programs help operators ensure their pipelines are working at peak performance and are complying with regulatory requirements.
At American Pipeline Solutions, we provide end-to-end pigging services—from cleaning and inspection to internal coating, 3D mapping, and turnkey project execution.
Looking to reduce downtime, boost throughput, or improve pipeline integrity?
Contact us today to discuss how a custom pigging solution can support your operations.
