Smart Pigging Services
Precision Pipeline Inspection and Integrity Testing
Modern pipelines demand precision, reliability, and real-time insights. Smart pigging—also known as inline inspection (ILI)—is the most advanced method available for evaluating a pipeline’s internal condition without interrupting operations. Using instrumented inspection tools called smart pigs, American Pipeline Solutions (APS) provides accurate, data-driven assessments of your pipeline’s integrity, helping operators make informed maintenance and safety decisions.
At APS, smart pigging isn’t just a service—it’s a cornerstone of proactive pipeline management. Our experienced technicians combine decades of field expertise with the latest inspection technology to ensure your system operates safely, efficiently, and in full compliance with industry regulations.
What Is Smart Pigging?
Smart pigging is a non-invasive inspection process that uses instrumented devices—known as pigs—to gather precise data about the inside of a pipeline. Unlike traditional cleaning pigs, which focus on removing debris or separating product batches, smart pigs collect engineering-grade data on wall thickness, corrosion, cracking, and geometry.
As the tool moves through the pipeline, it records high-resolution data onboard, which is downloaded and analyzed after retrieval. This information reveals the exact condition of the pipe wall, welds, and fittings, enabling operators to identify corrosion, deformation, or mechanical damage before they pose safety risks or cause costly downtime.
How APS Smart Pigging Works?
APS follows a systematic process that combines field experience, advanced instrumentation, and strict quality control.
Pipeline Preparation
Each project begins with a detailed review of the pipeline’s configuration and operating conditions. APS ensures the line is clean and obstruction-free using conventional pigging or Ice Pigging™ technology. This step provides a smooth pathway for the smart pig and guarantees consistent sensor coupling and accurate readings.
Launch and Tracking
Once prepared, the smart pig is inserted into the line using a launch trap. The pig is propelled by controlled line flow or pressure. APS technicians monitor its progress using tracking systems, ensuring the tool maintains proper velocity and collects data continuously throughout its run.
Data Collection and Retrieval
During travel, the smart pig’s onboard sensors—such as Magnetic Flux Leakage (MFL) and Ultrasonic Testing (UT) units—measure wall thickness, detect corrosion, and map pipeline geometry. The data is recorded internally and stored until the pig is received at the end of the line, ensuring complete data integrity.
Data Interpretation and Reporting
Once retrieved, APS engineers process the recorded data, identify anomalies, and classify features by severity and location. These insights are compiled into a comprehensive integrity report that supports maintenance planning, integrity management, and regulatory compliance programs.
Advanced Smart Pigging Technology
APS employs inspection tools that combine the latest MFL and UT technologies to deliver precise, high-resolution data. MFL sensors identify corrosion and metal loss by detecting variations in magnetic flux caused by thinning of the pipe wall. Ultrasonic sensors measure wall thickness and detect cracking or laminations with remarkable accuracy.
In gas systems where liquid coupling for UT is not possible, APS can deploy Electromagnetic Acoustic Transducer (EMAT) or geometry/caliper pigs to capture comparable defect information. All data are validated against industry standards and correlated with field conditions to ensure accuracy and reliability.
Why Smart Pigging Matters?
Regular inline inspection is essential for maintaining pipeline integrity and ensuring continued safe operation. Smart pigging provides early detection of corrosion, fatigue, and mechanical deformation—conditions that, if left unaddressed, can lead to leaks, ruptures, or environmental harm.
By integrating smart pigging into their maintenance programs, operators can perform targeted repairs instead of large-scale replacements. The process also supports compliance with PHMSA, ASME B31.1/B31.3, and DOT integrity management requirements. The result is improved safety, extended asset life, and reduced lifecycle costs.
APS Expertise and Experience
With more than a century of combined industry experience, American Pipeline Solutions has earned its reputation as a trusted provider of precision pigging and inspection services. Our team includes specialists in mechanical pigging, integrity assessment, and advanced ILI data analysis.
APS maintains partnerships with leading technology providers to offer clients access to the latest inspection platforms—capable of handling high-pressure, multi-diameter, and long-distance pipeline systems. Whether inspecting crude oil, natural gas, water, or industrial lines, APS delivers actionable insights that protect assets and optimize performance.
Integrating Smart Pigging with Pipeline Maintenance
Smart pigging achieves its greatest impact when integrated with a complete pipeline maintenance strategy. APS combines intelligent inspection with cleaning, hydrostatic testing, internal coating, and pipeline mapping to deliver a full lifecycle solution.
ILI results are often paired with hydrotest data and coating condition assessments to verify both structural integrity and pressure performance. This integrated approach helps operators identify corrosion trends, monitor degradation over time, and schedule maintenance with precision—minimizing downtime and maximizing operational efficiency.
Safety, Quality, and Regulatory Compliance
Every APS smart pigging project is governed by strict quality assurance and safety standards. Our technicians are trained in high-pressure operations and confined-space procedures, and all inspection devices are calibrated and certified to meet PHMSA, ASME, and DOT requirements.
We tailor each inspection to site-specific conditions, selecting the correct pig type and technology for the pipeline’s pressure, diameter, and flow medium. From pre-launch safety checks to post-run validation, APS ensures that each project is executed safely, efficiently, and in full compliance with applicable regulations.
Understanding the Limitations of Smart Pigging
While smart pigging delivers unmatched insight into a pipeline’s internal condition, certain limitations must be considered. Pipeline geometry—such as tight bends, diameter changes, or branch connections—can affect tool movement and data resolution. Heavy internal scale or debris may also limit sensor performance if not properly cleaned beforehand.
Ultrasonic inspection tools require liquid coupling for accurate readings, so they are best suited to liquid or water-filled lines. For gas systems or pipelines with internal restrictions, APS may recommend MFL, EMAT, or caliper-based inspections to ensure complete coverage.
Operating conditions such as temperature, flow rate, and medium viscosity are factored into every tool selection to ensure precise, reliable results.
Smart Pigging Across Industries
Smart pigging is a critical part of pipeline integrity management across industries including oil and gas transmission, municipal water systems, industrial processing, and chemical manufacturing.
In oil and gas, it identifies early corrosion, metal loss, and weld fatigue before leaks occur.
In water and wastewater, it detects sediment buildup and deformation without disrupting service.
In chemical and energy pipelines, it ensures product purity and verifies containment integrity under demanding operating conditions.
Whatever the application, APS tailors smart pigging programs to fit the operational realities of each industry—delivering measurable improvements in reliability, compliance, and safety.
Choosing the Right Smart Pigging Solution
Selecting the right pigging approach requires understanding pipeline configuration, flow medium, and inspection objectives. APS evaluates every parameter—including diameter, length, temperature, and operating pressure—to determine the most effective inspection plan.
Our specialists handle everything from preparatory cleaning to data analysis and reporting, providing clients with a single point of contact for complete inspection management. When necessary, APS also coordinates follow-up maintenance or rehabilitation based on inspection results.
Contact APS for Smart Pigging Services
As pipelines age and regulatory requirements grow stricter, intelligent inspection is more important than ever. American Pipeline Solutions delivers advanced smart pigging services that combine cutting-edge technology, proven methodology, and decades of experience to ensure your pipelines remain safe, efficient, and compliant.
Call (201) 525-0088 today to discuss your project or schedule a consultation with our team. APS is committed to safeguarding your pipeline performance—one intelligent inspection at a time.
