Pigging Municipal Water Mains: Process & Benefits

It’s essential for municipal pipelines to be cleaned routinely to ensure the quality of water people receive meets health and safety standards. Yet, even though many realize the importance of pipeline cleaning, not many know how pipelines and municipal water mains are cleaned. 

One of the most reliable and popular methods of cleaning municipal pipelines involves a process called pigging. Many municipalities use this technique because it removes tuberculation, biofilm and other sediment very effectively; much more so than flushing. 

There are numerous benefits involved with pigging water lines, and luckily at American Pipeline Solutions, we understand this process. In this article, we will discuss these benefits alongside the process involved with pigging water mains for municipalities. This article will also look at the latest development in pigging technology, Ice Pigging™.

What Is the Process of Pigging Water Mains?

The exact process of pigging water mains will depend on the type of pigging chosen, yet there is a generalized process that many pigging procedures use. Initially, a “prover pig,” which can be equipped with a location device, will be deployed into the water pipeline to determine if there is an obstruction. The material of this pig is very light in density, so if it does encounter a solid obstacle, it will break apart and not become lodged inside the pipe.

After this has been done, and based on the condition of the prover pig, a specialized cleaning pig will be inserted, where it will travel to remove sediment while being propelled by pressure to the exit access endpoint. The sediment and pigging material will be removed and safely discarded at the endpoint. 

Below we have given a detailed step-by-step look into how pigging a municipal water main (above was a summary) is done so that you can understand the process better. 

1. A thorough municipal pipeline system evaluation and performance baseline will be completed.

2. A team of experts will work together using their evaluation and performance baseline to develop a work and contingency plan.

3. After the work and contingency plan have been done, the next step will be to isolate the municipal water line to be cleaned.

4. Once the pipeline has been isolated, a “prover pig” will be inserted and run through the water line to prove flow.

5. When the “prover pig” has been run through the waterline, a team will examine it and decide the size and type of cleaning pigs based on the “prover pig’s” condition. They will also take into account the conditions of the pipeline.

6. After the pig type has been chosen, it will be run through the municipal water pipeline. After each subsequent run, the condition of the cleaning pig will be visually analyzed. Based on the condition of the pig, a similar one may be run, or the next size/material type of pig will be run; this is known as the progressive pigging method.

7. Once our team has determined that a pipeline is clean based on the condition of the most recent pig or the amount of dirty water accompanying the pig, the water line will be flushed so that any loose debris is removed.

8. If the water supply needed to be cut, it would be restored after the line had been flushed. The team will ensure the system is fully operational after the restored water flow.

9. Usually, the last step in confirming a municipal water main has been cleaned successfully is to document the results and compare them to the baseline performance results. Depending on the comparison of the results, it might be necessary to run a secondary pigging operation.

Factors To Consider Before Pigging Water Mains

Although, for the most part, the pigging process is straightforward, several factors need to be considered before pigging can commence. Below we have briefly discussed these factors to further help you understand the process of pigging water lines. We have briefly touched on some of what we mentioned below in the above section. 

1. Planning

Planning is the most important part of the pigging process. Before a municipal pipeline can be pigged, workers must determine the fittings and pipe design. The workers at American Pipeline Solutions know that the overall design of the water main will affect the insertion and retrieval points. For many water mains, pigs can be launched and retrieved through fire hydrants, limiting the need for holes to be dug.

Additionally, securing data on the water main will help workers learn if there are any obstructions that might block the pig from completing its task, such as a half-opened valve. 

2. Pig Selection

Besides planning, it’s crucial to determine the type of pig needed and the required length (usually 1.5 times the length of the pipe section being cleaned). The types of pigs used will be based on the type and age of the pipe, current flow rates, type of debris in pipe (biofilm, tuberculation, etc), and many other variables.

3. Type of Pigs Needed

There are many different types of pigs that can be used to clean municipal water mains and pipelines. Below we have briefly listed the types of pigs that could be needed when cleaning a municipal water main. 

• A prover pig: Light in density, these are used due to their ability to break apart when met with an immovable obstacle

• Durafoam pig: Medium density and usually coated, these pigs are used in majority of cleaning and are effective at removing most types of debris

• Wire brush pig: Heavier density pig wrapped in wire brushes used to remove heavier debris such as tuberculation

• Ice pigs: See Ice Pigging™ service page

What Are the Benefits of Pigging Water Lines?

There are several benefits of pigging municipal water mains. For example, when a municipal water main line is pigged, mud, sediment, calcium carbonate, scale, manganese iron, bacteria, biofilms, and other contaminants are removed. 

In addition to this, traditional pigging can navigate a short radius, most valve types, and tees to ensure every inch of a pipe is cleaned to restore pressure and optimal water flow and ensure better water quality. 

The pigging process is also incredibly effective at restoring a water main to almost its original conditions. Furthermore, traditional hydraulic pigging is still often preferred because one of its most significant benefits is that it can clean a wide range of pipeline diameters of up to 95 inches. 

Notable Mention: Ice Pigging™ Benefits

Although traditional pigging processes are useful for cleaning municipal water mains, Ice Pigging™ has become a popular choice in recent years. This is because Ice Pigging™ is incredibly cost-effective and uses up to 50% less water. 

Additionally, Ice Pigging™ has the added benefit of never getting stuck in a pipeline during cleaning. If it encounters an obstacle, it will simply melt. This is why Ice Pigging™ also causes no infrastructure damage. 

Moreover, Ice Pigging™ has numerous applications. This pigging process also has an impressive three-mile daily coverage limit, has a short water interruption timeframe (1-4 hours), and is highly effective at removing sediment.

Get In Touch With American Pipeline Solutions To Discuss Your Pigging Needs

The pigging process is somewhat involved but is not challenging to complete if a professional team manages the pipeline cleaning project. Should you want to learn more about the pigging solutions available for municipal water mains, don’t hesitate to speak with the professionals at American Pipeline Solutions. We know the benefits and pigging processes and can advise you accordingly on the best pigging process for your needs. To speak with us, you can contact us here.

Pipeline Pigging Problems & How to Address Them

There are many advantages associated with pipeline pigging. Additionally, in many instances, pipeline pigging is utilized when pre-commissioning or decommissioning a pipeline is needed. Companies like American Pipeline Solutions use pigs to clean out debris, water, or oil and execute corrective or preventive maintenance. 

Without pigging, many pipelines would degrade, environmental issues would arise, and water quality would be affected (municipal water lines), thus endangering the lives of many. However, there are pigging limitations and problems can occur with pipeline pigging. 

Many challenges are associated with foam pigs, ice pigs, mechanical pigs, and the other commonly used pigging types. These challenges could result in expensive problems or prevent a pigging procedure from getting underway. 

Since pigging is crucial to pipeline maintenance and repair, it’s important that pigging pipeline problems are addressed. In our article, we will examine the question, “Why do pigs get stuck in the pipeline?” and discuss the possible solutions to common pipeline problems. 

What Are the Three Common Pipeline Pigging Problems?

There are other pigging issues besides pigs getting stuck in a pipeline. Below, we will discuss this common problem and two others you need to be aware of if you’re considering using a pigging method. 

1. Pigs Getting Stuck In a Pipeline

Although pigs getting stuck in a pipeline is rare in this modern day and age, it does happen often enough with certain pig types to be a common problem. If a pig has failed to reach its destination and complete its job, there is often a logical reason for it. 

For example, some of the reasons for a pig getting stuck include faults with the pipeline, lack of propellant pressure, an obstruction like a closed valve in front of a pig, and leakage from a faulty pipe connection. 

Additionally, a pig could also get stuck if worn or damaged, or the incorrect pig for the type of pipeline being serviced. 

How Is This Pigging Problem Addressed? 

To address a pigging problem like this, it’s best to consider preventative measures like choosing an experienced pigging company like American Pipeline Solutions for your pipeline pigging needs. An experienced and professional pigging company has the skills and knowledge to complete a pipeline pigging project. 

In addition, the issue of pigs getting stuck in a pipeline can be avoided if routine maintenance is completed and if a worn or damaged pig is never used.

2. Pigs That Cannot Travel Both Directions or Navigate Sharp Bends

Many pigs cannot travel in both directions or navigate sharp bends. This is a problem for pipeline cleaning projects with sharp bends as effective product recovery rates cannot be achieved, meaning a pipeline cannot be cleaned properly. 

One directional pigs are not efficient. This is because they can involve complex return loops that require operators to manually remove the pig and return it to its proper housing after completing a project. This is often incredibly time-consuming, but it also poses a significant risk to operator safety. One directional pigs are also not sanitary, which poses risks of its own.

Additionally, problems can occur when a pig is unable to navigate a bend. This is especially true when pipeline maintenance or repair needs to be done on complex piping at industrial sites that have bends. Pigs that are unable to navigate bends cannot achieve a good recovery rate, which makes the pigging solution less effective overall. 

How Is This Pigging Problem Addressed? 

Generally, this pigging problem can be addressed by utilizing pipeline pigging products and equipment that is suitable for bends and complex pipeline systems. 

For example, Ice Pigging™ could be utilized instead of less effective traditional pigging methods. At American Pipeline Solutions, we have an array of pigging options available that are ideal for pipelines with bends while ensuring excellent recovery rates. 

3. Pig Product Bypass Issues

Another common problem is product bypass problems that occur from utilizing pigs that feature assembled pieces like caps and fins. Often when pigs with caps, fins, or other assembled pieces are used, it is almost impossible to guarantee effective cleaning between these assembled pieces in a pipeline. 

Assembled pieces like fins on pigs will allow a small amount of product to get past, and throughout the project, this could cause a build-up. When significant build-up occurs, it causes a significant problem because it can considerably hamper product recovery rates. 

In addition, another issue with using pigs with fins or other assembled parts is that they are usually far more likely to have parts break or rip off. When this occurs, contamination issues could arise. 

Moreover, pigs with assembled parts are often not as robust as other pigging types, which means they might need to be replaced more often, and this could drive up costs on maintenance or repair pipeline pigging projects. 

How Is This Pigging Problem Addressed? 

Generally, these issues can be addressed by ensuring the pigging on your pipelines is not completed with pigs with assembled parts like fins and caps. Instead, a pipeline pigging company should opt to use one-piece pigs with a full-contact design that are more versatile and robust. 

Speak With a Professional from American Pipeline Solutions Today

Now you know the common pipeline pigging problems and how they can be addressed. If you want your pipeline maintained or repaired, you should consider pipeline pigging to prevent or counteract these issues. At American Pipeline Solutions, we can help you with your pipeline pigging needs. To speak to one of our pigging professionals, you can contact us here.

3 Most Common Issues in Force Main Sewer Lines

A functional sewer system plays an integral part in a city’s waste management processes. As a sewer system ages, its pipes begin to show signs of wear. Without proper maintenance, a pipe can become severely damaged to the point where it must be replaced.

The first step in your wastewater pipeline maintenance strategy is assessing the conditions of the sewer system. Typically, the processes differ depending on the type of sewer pipeline examined. In the end, these processes will determine what cleaning and maintenance method is most effective for your pipelines. One important area to cover in your maintenance is your sewer system’s force mains. 

At American Pipeline Solutions, our goal is to help you understand the issues your pipeline faces and how to properly address it. This article outlines some common force main problems to help you identify these issues in your systems. 

3 Common Force Main Problems 

1. Buildup in the Pipeline

Even if you don’t see any telltale signs of pipeline blockage, buildup in your force main can still cause issues. An example of this is the accumulation of solid deposits along the bottom of your pipeline. 

As wastewater flows through your pipes, heavier particles can accumulate in a solid deposit. Depending on the type of particles, this results in a flow regime with a sliding bed or a stationary bed. A sliding bed can cause abrasion of the pipe’s interior, which wears away at the pipe’s interior wall. Conversely, a stationary bed reduces the cross-sectional area available in the pipe. By and large, both types of solid deposits can cause long-term force main problems to occur if left unaddressed.

2. Corrosion of Pipeline’s Interior

Corrosion force main problems are unique due to the presence of hydrogen sulfide in the pipeline. Hydrogen sulfide is a naturally occurring gas in low-lying, enclosed spaces such as the sewer. Not only is this gas dangerous to inhale, but it can also cause damage to a sewer’s pipelines. 

Internal corrosion caused by hydrogen sulfide occurs in two ways. The primary cause of internal corrosion is known as an acid attack. An acid attack occurs when hydrogen sulfide gas converts to sulphuric acid when the gas is in the presence of moisture. Another internal corrosion mechanism is hydrogen sulfide having a direct chemical reaction to the metal in a pipe’s interior, such as iron. 

3. Loss of Structural Integrity in the Force Main 

Damage caused by force main problems like buildup or corrosion can lead to the loss of a pipe’s structural integrity. For example, abrasion caused by buildup in a pipeline can grind away at a pipe’s interior surface. This weakens the pipeline and, thus, shortens the pipeline’s longevity. 

Corrosion causes a more immediate concern due to the increased likelihood of a leak occurring. A localized acid attack in a pipe can result in a hole appearing in the pipe’s wall. This hole leads to leakage of the pipe’s sewage, which then causes environmental damage. 

Protect and Prevent Damage to Your Force Mains

This is by no means an exhaustive list of every issue that might occur in your force mains. Nevertheless, these issues clearly show why routine force main maintenance is necessary.

One way to achieve this is by contacting experts like American Pipeline Solutions to perform force main inspections. Visual inspection of your pipeline by American Pipeline Solutions can quickly identify issues such as pipeline blockage. 

All in all, American Pipeline Solutions combines quality inspection equipment with years of industry experience to identify and address a client’s needs.

Are you looking to improve your wastewater pipeline maintenance strategy?

Contact American Pipeline Solutions today to partner with a team that has 100 years of combined experience in the pipeline industry. 

Force Main Inspections: How They Work & When to Do Them

A functioning sewer system is necessary and vital to proper sanitation and disease prevention. The longer a sewer system is in use, the more its pipelines face issues such as blockages and deterioration. A city needs to create a wastewater pipeline maintenance strategy to prevent devastating expenses and public safety problems.

The first step in maintaining wastewater pipelines is to assess the condition of the sewer system. This examination varies depending on the sewer system pipelines. The primary purpose of these examinations is to determine the best pipeline cleaning and maintenance method for a sewer system.

In this article, we focus on a particular type of sewer system pipeline: the force main. Keep reading to learn what a force main sewer pipe is and what to expect from force main inspection.

Force Main Pipe Inspections: What to Know

What is a Force Main Pipe?

A sewer system consists of pipes that run from a city’s buildings. These pipes typically lead to other sections of the sewer system for wastewater processing. 

A common pipe used in these systems is one that uses gravity to transport wastewater. However, the topography of a city can create obstacles. Some scenarios exist where a sewer system must transport wastewater from a lower elevation to a higher elevation. A gravity pipeline would be inefficient here, as it would be unable to move wastewater against gravity.

As a result, many sewer systems use a force main sewer pipe, which uses a lift station to pump wastewater from a low elevation to a higher elevation. 

When a city examines its sewer system to determine pipeline conditions, these examinations will likely include force main inspections. 

Force Main Pipe Inspection Processes

Like other types of pipelines, a force main sewer pipe wears as it’s used.

A city can proactively evaluate its force main pipeline infrastructure by partnering with companies like American Pipeline Solutions. The team at American Pipeline Solutions has 100 years of combined experience in pipeline testing and pigging. 

One type of pipeline testing that American Pipeline Solutions uses when evaluating force mains is a pipeline integrity test. 

Pipeline integrity testing is a universal testing method that applies to all pipelines. This form of testing examines the structural integrity of a pipe using specialized pigging tools.

Common Pipeline Issues to Assess With Pipeline Inspections

Force main inspection encompasses two types of processes: pipeline integrity testing and visual inspection of a pipeline. 

Let’s say a city noticed their force main sewer pipes were performing below industry standards. Potential pipeline issues can include low pipeline flow, blockage in the pipe, or low pump speed. 

In this scenario, American Pipeline Solutions would visually inspect the pipeline using a camera pig and closed-circuit television system or CCTV. The pig is run through the pipe so that the American Pipeline Solutions team can obtain visual records on the pipe’s interior. After, the team can assess the footage to determine if there are blockages and the most efficient solution. 

A visual inspection is not the most effective way to inspect pipeline leakage or internal corrosion. Instead, American Pipeline Solutions uses an i2i smart tool to conduct an integrity test. 

An i2i smart tool is beneficial for proactive force main inspections. This tool is sensitive to internal issues like pits, metal loss, and circumferential cracking in pipelines. So, American Pipeline Solutions can better detect integrity issues before they cause any further damage to the pipe.

Maintain Your Sewer System Pipelines With Routine Inspections

A common question about force main inspections is this: How often should I inspect my force main sewer pipes? 

The simple answer is it depends. 

American Pipeline Solutions recommends that you inspect your newer force main pipes every five years. However, for a sewer system with older pipes, inspection frequency must be determined on a case-by-case basis. 

Because pipeline inspections are integral to regular maintenance, you should ensure it occurs when necessary. Thankfully, partnering with the pipeline pigging experts at American Pipeline Solutions helps ensure the longevity of your pipes.

By combining quality inspection equipment with decades of industry experience, American Pipeline Solutions provides unparalleled pipeline maintenance services. 

Are you looking for an expert to help you inspect the integrity of your force main pipes?

Contact American Pipeline Solutions by calling (201) 525-0088 or online to find the best pipeline solution.

How Zebra & Quagga Mussel Removal Works with Pigging

Ensuring that a city’s water pipelines operate at top system performance levels is critical. Without the proper cleaning method, a pipeline’s performance can decrease.

A unique factor that some cities and towns face is the presence of invasive species, such as the quagga and zebra mussels. While native parts of Eastern Europe such as Ukraine, these aquatic hitchhikers made their way into Toronto’s Great Lakes. 

The damage that these invasive species cause is without question. Tom Nalepa, an emeritus research biologist and recognized expert on the species, stated that “the quagga mussel represents the greatest threat to the Great Lakes of any invasive species.”

Past quagga and zebra mussel removal methods have used various chemicals, such as chlorine. However, these methods have failed to present effective solutions to control increasing biofouling growth. 

An interesting alternative to dealing with the presence of these two mollusk species is hydraulic pigging. 

This article illustrates how pigging works to remove quagga and zebra mussels. Below, examine a project completed by American Pipeline Solutions in Toronto to address quagga mussel build-up. 

Quagga & Zebra Mussel Removal: City of Toronto, 2018

The Issue Caused by Quagga & Zebra Mussels in Toronto’s Water Intakes 

In the fall of 2018, Toronto found that the hydraulic capacity of its three water intakes at the Island Water Treatment Plant had reduced after 14 years of use. 

Quagga mussel build-up inside the deep-water pipelines caused the reduced hydraulic capacity. Quagga mussels adhere to submerged surfaces, such as pipes, and subsist on plankton in the nearby water. 

The accumulation of quagga mussels within Toronto’s intakes is known as biofouling or aquatic fouling. When an organism like the quagga mussel accumulates within water intakes, it can lead to structural or functional defects. 

This organism also has a major impact on the surrounding ecosystem. 

In addition, quagga mussels and their cousin, the zebra mussel, propagate quickly. Quagga mussels displace existing native species and alter the food chain, resulting in less game and commercial fish. 

American Pipeline Solutions’ Scope of Work

American Pipeline Solutions was contacted because the team had successfully pigged Cornell University’s 60-inch HDPE deep water intake in Lake Cayuga. 

After examining the Cornell project results, the City of Toronto engineers assessed the criteria, specifications, and required budget for hydraulic pigging to restore flow capacity at the Toronto Island WTP.

In preparation for the project, American Pipeline Solutions partnered with Galcon Marine Ltd., a local contractor with local offshore expertise. Galcon provided support with island transport, barge delivery, ROV (remote operated vehicle) operation, and other marine operations. 

Project preparation also included the specification of the scope-of-work, which was defined as the following:

• Design and manufacturing of a pig launcher and structural supports that would fit the intake valve chamber and piping system at the WTP. 

• Provide documentation of the process and design for hydraulic pigging procedures. These procedures were created for quagga and zebra mussel removal in all three WTP intakes. 

• Obtain any necessary regulatory permits and approvals for work. 

• Perform an inspection via ROV (remote operated vehicle) for all three water intakes before pigging. 

• Pigging for quagga and zebra mussel removal in water intake pipes. 

• Retrieval/salvage of all used pigs. 

During the project, American Pipeline Solutions was responsible for the overall hydraulic layout, the launcher's design, and the hardware designation. Additionally, American Pipeline Solutions handled pig design, the sequence of pigs used, tracking the pigs, and pig recovery procedures. 

Hydraulic Pigging Procedures Used in Quagga & Zebra Mussel Removal Method

1. Determine Proper Pig Sequence

Before the pigging process, American Pipeline Solutions assessed the pipe to determine the pig sequence.  

This sequence matters for most pigging procedures because the process must be completed as quickly as possible. Additionally, these procedures must be performed conservatively to avoid any pressure surges or a delay caused by a “stuck pig.” 

2. Load and Launch the First Pig

While most pigs used for cleaning are larger than the internal diameter of a pipe, the first pig used in Toronto was not. The Toronto WTP pipelines had internal diameters measuring around 61 inches. The first pig that was used was only 58 inches in diameter. 

A smaller-sized pig was used first to create enough bypass flow to start the initial cleaning process. However, the pig needed to be small enough, so it wouldn’t adhere to the pipe wall or have its movement restricted. 

3. Monitor Pig Movement & Mussel Debris Build-up  

After a quagga and zebra removal project begins, it is important to monitor the building debris. As the pig moves through the pipeline, the mussel debris can accumulate ahead of the pig, slowing or stopping the pig.  

The volume of the displaced quagga mussels was monitored as the pig moved through the pipe. This was done in real-time, using submerged cameras aboard an ROV at the intake’s mouth. 

When using foam pigs, such as those used in Toronto, this debris can be controlled, depending on the pig design. Foam pigs can be designed to channel some of the water, propelling the pig towards the pig's front. When this happens, displaced mussels are suspended in the moving water flow ahead of the pig. This prevents the pig from slowing or stopping because of mussel debris.

4. Launch Second and Third Pigs

Thanks to the real-time documentation of the mussel debris and the pipe’s pressure profile, American Pipeline Solutions was able to determine the next pig’s characteristics.

Typically, the foam density and diameter of a pig will increase with each subsequent run. The last pig that is run tends to be larger than the internal diameter of the pipe itself. 

For the City of Toronto project, the last pig was a full-size pig with embedded plastic bristles. These bristles thoroughly cleaned the pipe walls of quagga mussels. 

5. Assess the Cleaning Project’s Results 

Once all three pigs were run through the water intakes, the Hazen-Williams C-Factor for all three pipes was measured. This factor determined the smoothness of the interior walls of the pipes after cleaning. In addition, the results would determine if a fourth pig run was necessary. 

The C-Factor results improved, and after the initial three pig runs, the water intake’s hydraulic condition was better than when the pipes were installed. 

A perfect C-Factor is 150+. When built in 2004, the C-Factor for these pipes was estimated to be 137 to 140. Prior to cleaning, the pipes measured a C-Factor of approximately 110. After pigging was completed, all three intakes had C-Factors ranging from 149 to 152. 

In the end, these results proved that the project’s pigging process was a complete success. 

The process was able to clear the quagga mussels from the pipes and any additional debris. The project’s success shows that hydraulic pigging as a quagga and zebra mussel removal method is reliable.  

Are you looking for a way to solve your quagga and zebra mussel removal problem?

Contact American Pipeline Solutions at (201) 525-0088 to receive a comprehensive pigging solution that is crafted around your project’s unique needs. 

2 Most Common Issues in Water Mains Pipes

Water distribution systems are the backbone of cities and towns. Without proper maintenance of the system and its components, pipeline issues can build up over long term use, a city’s residents would be left without water. 

Pipe maintenance addresses current pipe issues as well as takes preventative measures against potential issues.

At American Pipeline Solutions, it is our goal to help you maintain your water mains. Below, we’ve taken a closer look at three water mains projects to show you common pipe issues and their solutions. 

2 Common Issues in Water Mains Pipes

Clogged or Restricted Pipelines 

Can my pipelines be restricted even if there are no telltale signs of water shortages?

Pipeline issues can build up with long-term use. Due to the slow accumulation of corrosion, you may not immediately notice issues in your pipes. This was the case for a project that American Pipeline Solutions completed in Montgomery County, Maryland.

Montgomery County’s water supply lines had become clogged and restricted from years of use. After 60 years, the pipelines were heavily tuberculated. 

Tuberculation is a hard rust like deposit that accumulates predominantly in cast-iron pipe. Tuberculation can cause long-term integrity issues as well as restricted flow and discolored water.

A tuberculated pipe can increase water pumping costs. Additionally, it may increase the distribution system’s pressure while decreasing efficiency.

In this project, tuberculation within the water distribution system’s mains pipes caused a decrease in gallons' flow rate per minute. Generally, a clean six-inch pipe has a flow rate of 800 gallons per minute. However, these pipes could only achieve 130 gallons per minute. 

To address the tuberculation, we used a combination of high pressure jetting–8,000 PSI–and foam pigs, and were able to return the system to normal flow coefficients.

Not only does this solution address the issue, but saved the county money because it didn’t have to replace the pipes.

Pipeline Has Dirty Water

If your pipeline is running dirty water, there is likely an issue that needs to be addressed.

The cause of dirty water in your mains pipes can vary.

For example, some causes can be traced back to construction activities for new buildings. When a new building is constructed, it must be connected to the water mains system, which can result in temporary dirty water. 

However, there are instances where a dirty water issue is not temporary.

Over time, a pipeline will accumulate sediment and debris and can lead to water discoloration. The American Pipeline Solutions team encountered this issue in South Carolina. 

We used a traditional foam pig to clean the pipeline. Below is a video of part of this project’s pigging process. You may be surprised at just how much debris could be in your pipes!

Looking for the right main water pipeline management solution?

Contact American Pipeline Solutions and partner with a team with over 100 years of combined experience in pipeline pigging integrity testing.

How to Choose an Industrial Pipeline Cleaning Method

When a city is tasked with the maintenance of its water pipelines, ensuring top system performance is crucial. Naturally, there are various factors that can impact the performance of municipal water pipelines throughout their use.

Factors, such as the cleanliness of the pipeline, can result in changes in the overall system performance of water and force mains. In other words, you might experience low flow or changes in water quality when your pipelines begin to build up debris. 

When dealing with issues such as these, you want to find the right pipeline cleaning methods that are effective and reasonably priced. In this case, you want to learn if pigging, for example, is the right solution that fits your needs and your budget. 

By and large, knowing how to choose a cleaning method can seem daunting due to the many solution options available. 

To help you get started, we’ve put together key information on how to choose an industrial pipe cleaning method that’s right for you.

How to Choose a Pipeline Cleaning Method

Identify Your Problem

It may seem simple, but your first step needs to be identifying your problem. This doesn’t necessarily mean you need all the finer details of your problem at this point.

Let’s use one of our previous scenarios of a pipe that has low flow as an example. Originally, the flow of your pipeline was at a certain level. Now, the flow is much lower than normal. 

In this scenario, the issue of low flow is likely being caused by something obstructing the flow in your pipelines. 

Now that you know your pipelines are dirty, which is likely causing your low flow, you want to get that flow back up.

Analyze Different Pigging & Pipeline Cleaning Methodologies

As we shared before, there are a plethora of different pipeline cleaning methods. While there is only one way to pig, there are other cleaning methods that aren’t pigging but use the term. 

Each method for industrial pipe cleaning has different pros and cons to consider. 

However, to illustrate how to choose a cleaning method, we will cover the three main approaches you’ll likely see. 

1. Flushing

This methodology is one of the more basic ways of cleaning your pipelines. In fact, this is a method you can do on your own. 

As the name suggests, flushing your pipes is when you turn your water pumps up, pumping out the maximum amount of water.

This method is used to knock loose general debris that might be in a pipe. 

While this method can help with less difficult debris, it can’t tackle solidified dirt and debris, which can be the case. 

So, if you’ve tried flushing out your pipes and it didn’t solve your issue, you’re next option is likely pigging. 

2. Ice Pigging™

This type of cleaning is a newer form of technology that has become more common. 

Instead of the typical solid foam pig, this pigging method uses an ice slurry. As this slurry goes through your pipes, it tackles lighter debris. 

Ice Pigging™ is appropriate for cleaning out debris, like built-up biofilm, that doesn’t need a tougher cleaning method.  

While Ice Pigging™ is faster than traditional pigging, it is not the ideal solution for most major issues in your pipeline. Thus, if you use Ice Pigging™, you’ll likely end up using it more often, which will cost you more in the long run. 

3. Traditional Pigging and Swabbing

The traditional pigging and swabbing method, unlike the previously described pipeline cleaning methods, uses a solid foam pig. 

By and large, traditional pigging is the most comprehensive methodology when it comes to tackling tough pipeline debris. 

Why?

First, your pipelines are swabbed. Swabbing is an important initial step in pigging because it helps determine the degree of debris in the pipeline. 

The initial swabbing pig is a soft, sponge-like foam pig that is extremely malleable. This malleability is beneficial for the pig as it makes its way through your pipes. Not only can the pig bend as needed through your pipes, but it also helps prevent the pig from becoming lodged. 

As this initial pig encounters the debris in your pipe, it’ll either bend around the debris or break apart in more difficult cases.

When the initial pig comes out of the pipeline, it is known as a “prover pig.” Essentially, this prover pig lets your pigging experts know how tough the debris in the pipeline is. 

Next, the pigs that go into your pipeline slowly progress towards denser foam pigs. As the pig gets denser, it is better able to tackle debris that has solidified or adhered to your pipeline.

This process is continued until your pipelines are free from debris.

Consult With Top Industry Experts at American Pipeline Solutions

With over 100 years of combined experience, American Pipeline Solutions is North America’s oldest continuous pigging company. 

In those 100 years, American Pipeline Solutions has provided clients with comprehensive services for their water mains, wastewater, and overall pipeline integrity needs. 

In addition to these services, we at American Pipeline Solutions offer consulting services to clients in need. When called in, we assess the client’s problems and use our expertise to recommend the best pigging solution. 

Contact American Pipeline Solutions today to request a quote and learn more about the pigging services we can provide. 

Ice Pigging™ vs Traditional Pigging: Pros and Cons

Municipal water pipelines face several issues throughout their lifespan. Compounding issues can impact the water taste and odor, affect capacity negatively, increase pumping costs, and cause biofilm complications. Several types of pipeline cleaning methods exist to address these issues, clear debris and improve the system performance of water and force mains.

Perhaps two of the most well-known cleaning technologies are hydraulic pigging with foam pigs and Ice Pigging™. Each method has its own strengths and challenges that will influence which is best for a pipeline cleaning project.

Traditional Pigging Pros and Cons

Traditional hydraulic pigging initially uses a “prover pig” equipped with a location device to check for obstruction. Then a series of specialized cleaning pigs navigate the pipe to remove sediment and scale propelled by system pressure. 

Advantages

Beneficial for long miles and piping of all diameters

Using various sized pigs, traditional hydraulic pigging can clean a broad range of pipeline diameters up to 96 inches. Pigging can (generally), also clean longer segments without stopping when compared to Ice Pigging™, although Ice Pigging™ is certainly capable of pigging 2-3 miles of smaller pipe diameters.

Pigs rarely get stuck

Although a large concern of using foam pigs is that they may get lodged somewhere along the line, this rarely happens. In its over 100 years of combined experience in pipeline pigging, American Pipeline Solutions has only had a problem with a lodged pig when severe line obstructions are present. The identification and location (pigs can be tracked) of these obstructions and subsequent removal are essential to returning flows to original/near original rates. An ice pig will never become permanently stuck, because it will just melt.

Navigates short radius elbows, tees, and most types of valves

When materials and pig types are used correctly, pigs have no issue traveling through short radius elbows, Ts, and several valve types.

Restores pipelines to near original conditions or close to it

Hydraulic pigging will return a pipe to almost original conditions.

Smart Pigs detect potential integrity issues in the pipeline before they arise

For cast iron, ductile, and steel mains, SmartFoam Tools are both cost-effective and successful in evaluating pipeline integrity. This technology can identify cracks, wall anomalies, and internal corrosion in a less disruptive manner than conventional in-line inspections.

Disadvantages

Requires involved set-up processes

Traditional pigging requires the installation of a launcher and receiver through which to run pigs. This installation process can add time to an overall pigging operation, especially when excavations are involved.

Consumes more water

Compared to Ice Pigging™, traditional pigging techniques can use up to 50% more water for a typical operation. Uni-directional flushing will likely use 5 times more water.

Ice Pigging™ Pros and Cons

Ice Pigging™ is a newer technology that uses an ice slurry instead of solid pigs to clean common pipeline issues, such as sediment, deposits, and biofilms. Ice is 1,000 times more effective than flushing with water alone.

Advantages

Flexible to the varied topography of pipes

Due to its almost liquid form, (a liquid that behaves as a solid) Ice Pigging™ is malleable to a range of changing pipe sizes and obstacles such as pipe bends, and butterfly valves pose no problem to an ice pig

Exceptional low risk will never get stuck permanently

As its name suggests, Ice Pigging™ depends mainly on ice as its main material, meaning that the “pig” will melt away even if the slurry gets blocked. 

Faster than traditional pigging for underground pipes

Ice Pigging™ requires less of a physical set-up than traditional pigging, as it doesn’t need a launcher and catcher installed at both ends of the pipeline. In most cases, the ice is introduced via existing fittings, such as fire hydrants, air release values, or even manual air bleeds and washouts. As long as the opening is two inches or greater, the ice can be injected into the pipe in twenty minutes or less.

Disadvantages

Not as aggressive as a traditional hard pig

The ice pig is not as aggressive as a hard pig and is unlikely to remove hard tuberculation or calcified fats, oils and grease (FOG).

Not very successful for large diameter piping

Ice Pigging™ is best suited for diameters ranging from 1.5” 3 inches to 24 inches. For larger diameters, traditional pigging is usually a better option assuming there are not too many bends or obstacles that a hard pig will not pass.

Not likely to discover obstructions

Because the ice slurry is less likely to get stuck and cannot be tracked, there is less chance of detecting obstructions that may hint at a larger issue. An unknown closed valve on the system or full blockage will quickly be discovered in the ice insertion process, however.

Learn more about the best solution to solve your pipeline flow issues

American Pipeline Solutions is North America’s oldest continuous pigging company with over 100 years of combined experience. We have pigged and restored over two million feet of pipeline to near original conditions.

Contact American Pipeline Solutions to learn more about our institutional expertise and to request a quote.

When Are Pipelines Unpiggable? Possible Solutions

Pipeline maintenance and integrity testing are checks that should be performed regularly to ensure the optimal functioning of your pipeline system. Although pipelines are made of heavy-duty metal or plastic materials, they are still prone to wear and tear from years of use. At some point in your pipeline's operation, when it experiences low flow or stops functioning completely, you will have to apply various pigging solutions to clear out debris that might have accumulated.

However, simply cleaning out your pipelines doesn't always work out seamlessly. When a pipeline becomes ridden with tuberculation or the blockage is too huge, it becomes unpiggable, requiring more complex solutions.

In this article, we discuss the different scenarios that make a pipeline unpiggable and how they can be addressed.

When Are Pipelines Unpiggable?

If there is too much tuberculation or a total blockage in the line, it can become unpiggable. Most line issues can be pigged, but sometimes, steps need to be taken first to make pigging feasible. One such approach is jetting the pipeline first, which involves using high-pressure water jets to remove clogs, buildup, and debris. Hydro jetting is an eco-friendly way of clearing your pipes or preparing them prior to pigging.

If it has been a while since your pipeline was last maintenanced, total blockage and tuberculation can be expected. In this instance, your pipeline could be rendered unpiggable, even with pre-jetting. Below are some scenarios when pigging might not be possible.

Tuberculation in the Pipeline

Tuberculation happens when mounds of rust accumulate on the inside of your metal pipe, thus making it resistant to the flow of water. It is caused by the combination of bacteria and oxygen and can become so large and hardened that it obstructs water movement, rendering your pipeline eventually useless.

There are many ways to address tuberculation, but one of the most effective is the Picote cleaning process. In this procedure, a camera is used to inspect the pipeline and determine its readiness for a cleanout. When the extent of the debris is identified, a section of the pipeline is removed, usually along the 90-degree bend, and the Picote machine is attached to begin the process.

However, not all tuberculated pipelines are piggable; those built in the 70s, and earlier, usually need to be replaced completely. Minor tuberculation issues can still be addressed through pipe descaling, but when the problem has become so large on a pipe that's well past its lifespan, it's more practical to declare it unpiggable.

Pig is Blocked From Passing Through the Pipeline

If a pipeline is completely blocked, it becomes unpiggable. In order to travel through a line, the flow should be present by at least 30% to facilitate movement. In this scenario, the best alternative to pigging pipelines would be to remove the section that contains the blockage and clear it externally or replace the entire area.

Unconventional Valve Structures

Another reason why a pipeline could become unpiggable is the structure of the valves themselves. Eccentric plug valves and butterfly valves are uniquely designed that pigging equipment isn’t able to pass through. To clean this area, specialists would have to pig between the valves or take them out and replace them with full port units to allow for pig passage; however, Ice Pigging™ (another APS service offering) is another viable alternative to this specific problem.

Short Diameter Pipes

When your pipes are small and short, measuring 10 inches or less, pigging might not be a practical cleanout option. To pig effectively, you need a good launch location and a retrieval location, which isn't possible with a short pipe. Although unpiggable, the site can still be cleaned out using the Picote process.

Next Steps for Unpiggable Pipelines

With the advancements in pipeline cleaning and maintenance technology, the term "unpiggable" has started to lose its finality. Pipeline experts argue that there's no such thing as unpiggable pipelines, only those that are tricky to manage and will require unique interventions.

APS provides pigging solutions for pipelines of any size, structure, and issue. We have several options based on the problem and why the pipe needs to be pigged (or cleaned out using alternative techniques). Using our smart solutions, let us help you track the problem at the source and find the most efficient and safe cleanout strategies that will keep your pipelines in top condition for many years to come.

Contact American Pipeline Solutions and learn more about our unique pipeline pigging and cleanout solutions.

Reasons for a Failed Fire Pump Test & Next Steps

Each year, it is required that fire suppression systems undergo a flow test. This test assesses the flow rate of the fire line being tested to determine if it complies with industry standards. When a fire line has a low flow rate, it is more likely to result in a failed flow test.

Numerous factors can cause a pipeline’s low flow, including the type of pipeline system, the pipeline material, and the product it transports. Typically, fire line systems are comprised of metallic pipelines, with the most common material being cast iron. And the main cause for low flow in cast iron pipes is tuberculation.

Keep reading to learn about tuberculation in fire line systems and how American Pipeline Solutions can help clean and prevent tuberculation.

Causes For Failed Fire Line Flow Tests and Next Steps

What Causes Tuberculation in Fire Lines?

The main cause for low flow in a fire line is tuberculation. Tuberculation is commonly found in metallic pipes, such as cast iron or ductile iron pipes. The reason that tuberculation is unique to metallic pipes is due to the way it forms.

Tuberculation is the result of chemical reactions in your fire line system. Specifically, tuberculation is caused by the chemical reaction between bacteria in the fire line’s water and the iron found in the pipe’s interior. This reaction creates a build-up inside of the pipeline known as pipe scale or tuberculation. As the pipeline is used, this build-up increases and eventually begins to disrupt the pipeline’s flow.

How to Detect Tuberculation

The signs of tuberculation in a pipeline can manifest in numerous ways. The most telling sign of a tuberculated fire line is low flow.

When addressing the low flow rate of a fire line, American Pipeline Solutions first performs a visual inspection of the pipeline. This visual inspection is necessary to detemine the cause of the low flow rate. With tuberculated pipes, this visual inspection also helps the APS team determine the thickness of the tuberculation in the pipeline.

Once APS has determined the cause of your fire line’s low flow, our next steps address this cause.

Determining the Best Cleaning Approach

While replacing your fire line is a surefire way to address tuberculation, it is not necessarily cost-effective. In addition, you will likely face the same tuberculation issue without the proper prevention protocols in place.

Rather than replacing your firelines, American Pipeline Solutions can clean out the tuberculation in your existing line.

First, APS examines the drawings and as-builts of a fire line to determine what cleaning approach would work best for a client. After performing a site visit, APS creates a comprehensive proposal that illustrates our recommended solution in descaling their fire line.

Descaling Your Fire Line

APS addresses tuberculation in firelines with pigging, rotary head technology, and Picote mechanical equipment. The cleaning method that is used will depend on the characteristics of a particular fire line.

Typically, pigging is not the first method used when descaling a fire line. Due to the build-up’s toughness, most foam pigs will come apart instead of removing the pipe scale.

APS uses unique Picote mechanical equipment to apply a stronger force to remove pipe scale successfully. This process also uses less water to remove scale build-up than pigging or rotary head technology.

Preventing Scale Build-Up and Low Flow

Once the tuberculation restricting your fire line’s flow is removed, the line’s flow rate will return to normal. It is necessary to clean your line every five years to maintain your fire line’s flow rate. Without this routine maintenance, you will face a similar issue in the future as tuberculation builds back up in your line.

Thankfully, there are preventative measures you can take to stop tuberculation build-up from reoccurring in your line. The most cost-effective method to prevent tuberculation is epoxy coating.

One reason that epoxy coating is more cost-effective than repiping your fire line is due to each method’s completion time.

Repiping your fire line can take several weeks to complete as you remove and replace your line. During that time, your fire lines will be out of operation. Rather than undergoing the time-consuming process of repiping, you can coat your newly cleaned pipelines. By coating your pipelines, you can address and prevent future signs of tuberculation for up to 50 years.

Looking to improve the low flow of your fire line?

Contact American Pipeline Solutions today to learn about our fire line tuberculation cleaning and prevention solutions.

What is Epoxy Pipe Lining & When to Use It

When it comes to pipeline maintenance, your top priority is ensuring your pipeline system operates efficiently. There are several factors that can impact the efficiency of that pipeline, from tuberculation to pipeline corrosion.

It may seem like the only solution to address issues like these is to replace your pipeline. However, replacing your pipeline can be costly and time-consuming. Thankfully, there are preventative measures you can take instead by utilizing epoxy pipe lining. With epoxy lining, you can avoid costly emergency repairs that can take weeks to complete.

Keep reading to learn about internal pipe coating, when it use it and the pros and cons of epoxy pipe lining.

What is Epoxy Pipe Coating: What to Know

When Do I Need Epoxy Pipe Coating?

The signs of when your pipe needs pipe coating vary depending on how the pipe is used. In other words, does the pipe transport gas, water, wastewater or other substances? Another factor that influences what issues are present in a pipeline is the pipeline material.

Let’s say you discovered that your fire suppression system has a restricted flow when performing an annual test. This low flow can indicate an issue present in the fireline. Because most firelines consist of metallic pipelines, such as cast-iron, the cause of this low flow can be tuberculation. Other issues that you may experience in your pipelines can include corrosion, leaks and other structural integrity issues.

When you use epoxy lining in your pipeline will depend on the issue you’re addressing. For tuberculated cast iron pipes, epoxy lining repair becomes necessary after the tuberculation is cleaned out. The reason behind this is that lining your pipeline prevents it from showing future signs of tuberculation for up to 50 years. Epoxy pipe lining can address other problems such as corrosion by targeting the leaks and breaks corrosion can cause.

What Pipes Can Be Lined?

To ensure that a pipeline receives the proper solution, the pipeline must be evaluated. At American Pipeline Solutions, we perform a visual inspection of a pipeline to determine the pipeline issue. This inspection is necessary to determine the appropriate cleaning solution for the pipeline, which must be done before lining the pipeline.

There are numerous types of pipelines that can receive internal pipe coating. The types of pipelines and pipeline systems that American Pipeline Solution can coat include:

Pipeline materials:

• Cast iron

• Ductile iron

• Copper

• Steel

• HDPE

• PVC*

*For certain pipeline materials like PVC, the pipeline must first be sanded before it can be lined. This is done to ensure that the epoxy coating sticks to the pipeline’s internal walls.

Pipeline systems:

• Water lines

• Fire lines

• Wastewater and sewerlines

• Clarifier drains

• Feed pipes

• Drain lines

This is by no means an exhaustive list of the types of pipes that can receive internal epoxy pipe coating. If you have a pipeline that you’d like to coat, contact American Pipeline Solutions to determine if your pipe can be coated.

Epoxy Pipe Lining vs. Repiping Pros and Cons

When comparing epoxy pipe lining vs. repiping, there are various pros and cons to consider. The first factor to examine is the cost of repiping and pipe coating.

Typically, repiping will cost more than internally coating your pipelines. In addition to the cost of replacing the pipes, there are also the costs associated with taking your pipelines out of operation. Due to the length of time necessary during the repiping process, resulting in a loss of revenue. The amount of time needed to internally coat your pipes is much shorter than repiping.

A disadvantage of epoxy pipe lining vs. repiping is in the prevention of certain pipeline issues. For example, replacing a tuberculated pipe does remove the issue of tuberculation but doesn’t prevent it. The newly installed pipe can still show signs of tuberculation as it ages. This is also true of a pipeline once tuberculation has been cleaned out of it. If the pipeline is not lined, it will need tuberculation In the end, epoxy pipe coating is advantageous because it aids in addressing and preventing additional pipeline cleaning for up to 50 years.

Looking to protect your pipeline systems?

Contact American Pipeline Solutions to learn how epoxy pipe lining can help.

How to Clean and Prevent Tuberculation in Cast Iron Pipes

There’s no question that cast iron pipes are known for their longevity and durability. Because of this, the water lines in buildings, like condos, apartments and office buildings, consist of cast iron pipes. 

While the benefits of these long-lasting systems are clear, some issues can appear later on. As systems begin to age, property managers will see signs of pipe tuberculation. 

If you think you have a tuberculated pipe problem, you may think your only solution is to replace your pipes. Thankfully, there are other options available for you to consider. 

Keep reading to learn more about tuberculation in cast iron pipes and how American Pipeline Solutions cleans and prevents tuberculation. 

How to Clean & Prevent Tuberculation in Cast Iron Pipes

What Causes a Tuberculated Pipe?

Chemical reactions cause tuberculation in cast iron pipes and other metallic pipes, such as ductile iron.

Bacteria in a pipeline’s water reacts to the iron found in the pipe’s interior. The result of this reaction is a buildup inside the pipeline. Over time, this buildup grows thicker and disrupts the pipe's flow.

Tuberculation tends to occur in older pipelines. Many pipelines built in the 50s-70s are more likely to start showing signs of pipe tuberculation today. 

The Signs of Pipe Tuberculation 

Several tuberculation warning signs are dependent on the pipe's use.

If your pipelines provide water to your building’s plumbing fixtures, you might notice tuberculation signs such as water discoloration or reddish-brown staining. 

Another common sign of tuberculation in your building’s pipelines is restricted water flow. This can appear as low water pressure from a building’s fixtures. 

Restricted flow can also appear in your fire suppression systems. When testing these systems each year, you might discover that you aren’t getting the standard gallons per minute. This lowered flow indicates a larger problem in the fireline, which may be restricted due to tuberculation. 

Cleaning and Prevention Solutions for a Tuberculated Pipe

Replacing your pipes is a surefire solution; however, it is not the most cost effective. And, you may face the same problem if a prevention protocol is not implemented. 

Instead of replacing your pipelines, there are alternative options for you to consider with American Pipeline Solutions. 

If your pipes are restricted because they’re tuberculated, your first goal will be to clean out this tuberculation. APS addresses pipeline tuberculation in fire lines with pigging, rotary head technology and Picote mechanical equipment.

Typically, pigging is not the first method used because of the buildup's toughness—most foam pigs will simply come apart rather than removing the buildup. 

This is where the Picote mechanical equipment comes into play. This method can apply a stronger force to the tuberculation buildup to remove it successfully. Plus, this method also uses less water than pigging or rotary head technology. 

Once your pipeline has been cleaned, your next step should be prevention. Without this prevention step, you’ll need to clean your tuberculated pipes every five years. 

When the pipeline is newly cleaned, APS can add a thin epoxy coating to your pipe’s interior. This epoxy coating is safe and is even used by experts at NASA. With this epoxy lining, you can operate your pipeline without worrying about tuberculation build-up for up to 50 years! 

Are you looking for an efficient solution to your tuberculated pipe?

Contact American Pipeline Solutions and learn about our unique pipeline tuberculation solutions.

Common Pipeline Pigging Terminology to Know

The pigging pipeline process is a unique one. If you’ve ever found yourself curious about various pigging and pipeline terminology, you aren’t alone. When looking to maintain your pipelines, obtaining key information about various pigging terms can provide beneficial insights. 

What types of pipeline corrosion should I know about? What’s the difference between a caliper pig and a configuration pig? What do dents in my pipeline look like, exactly? 

By and large, the art of pigging can best be understood by examining various pigging and pipeline terminology. 

To give you an idea of what pigging is all about, we’ve defined the following pigging and pipeline terminology. 

Pigging and Pipeline Terminology to Know

Camera pig: A camera pig is a configuration pig. The configuration pig uses a camera and light sources inside a pipe to photograph the pipe’s inner surface.

Caliper pig: A caliper pig is similar to a gauging pig. A caliper pig tool is a pig designed with mechanical sensors or arms on the pig’s body. These mechanical sensors record the internal structure of the pipeline. 

Cleaning Pig: The purpose of running a cleaning pig is to remove debris or build-up inside a pipeline. Running a cleaning pig increases cleaning efficiency. 

Configuration Pig: A configuration pig is a pig that is used to gather data about the internal pipeline wall. There are several types of configuration pigs, such as a camera pig. 

Corrosion: There are several types of pipeline corrosion, which are defined as the following:

External: External corrosion of a pipeline is a chemical or electrochemical reaction of a pipeline’s metal to the surrounding environment. When corrosion of a pipeline occurs on the pipe’s external surface, it is external corrosion. Rust, or the formation of iron oxides, is a common electrochemical corrosion process. 

Internal: Similar to external corrosion, internal corrosion differs due to the location of the corrosion. 

Pit, or Pitting Corrosion: A pit in a pipeline is caused by a process known as pitting corrosion. This is a localized form of corrosion that can occur on the internal or external surface of a pipeline. A pit, also referred to as a cavity, is the result of localized corrosion process.   

Selective Seam Weld Corrosion: Another form of localized corrosion is selective seam weld corrosion. This type of corrosion is selective because it affects the weld metal instead of the pipe’s base metal.  

Stress Corrosion Cracking: Within a corrosive environment, cracks can occur. This is referred to as stress corrosion cracking. These cracks can be the cause of a pipe’s sudden failure due to pressure on the pipe. 

Cracks: In pipeline terminology, there are three types of cracks: 

Fatigue: Fatigue of a pipeline occurs when the pipeline’s material is weakened. The weakening of a pipeline’s material is the result of regular use. Accordingly, the pipeline experiences localized structural damage, and cracks begin to grow in the pipe. 

Girth Weld Crack: A girth weld is a type of arc welding that joins together a pipeline. When a pipeline has cracks along its girth weld, it is known as girth weld cracks.  

Seam Weld Crack: A seam weld is another type of arc welding that joins together a pipeline. Similar to girth weld cracks, when a pipe has cracks along its seam weld, it is seam weld cracks.  

Dent: When a pipeline’s surface has a depression, typically the result of mechanical damage, it is known as a dent. A dent is identified partly by the fact that it does not reduce the wall thickness of the pipeline. 

Fill Pig: A fill pig is a type of pig run through a pipeline during various testing processes. Specifically, the fill pig is used during a pipeline filling procedure. The pig is propelled by a column of test water, ensuring that air in the pipeline is eliminated.

In-Line Inspection (ILI): In-line inspection is when a pipeline is inspected through processes that examine the interior of a pipeline. 

In-Line Inspection Tool: The tool used in in-line inspections is known as an in-line inspection tool. This device is also referred to as a “smart” pig or an “intelligent” pig. The focus of this tool is the inspection of a pipeline’s walls. 

Instrumented Pig: An instrumented pig is a tool equipped with instruments such as sensors or records, to examine a pipe’s interior. There are two main types of instrumented pigs: configuration pigs and in-line inspection tools. 

Mapping Pig: One type of configuration pig is a mapping pig. A mapping pig uses technology, often inertia sensing, to produce a plan view of a pipeline’s route. 

Metal Loss: Metal loss refers to numerous types of pipeline anomalies. These anomalies are identified by the loss of metal in a pipeline’s surface. This metal loss can be the result of pipeline corrosion or gouging. 

Obstructions: Any foreign objects or general restriction that reduces a pipe’s flow is an obstruction. Obstructions can be identified through the visual inspection of a pipeline’s interior. 

Pig: A pig is a universal term referring to a device used in pipeline pigging procedures. A pig tends to be self-contained, such as an instrumented pig like a configuration pig. The general purpose of using a pig is to clean, inspect, or measure a pipeline. 

Swab: The first pig used in a pigging process is often referred to as a swab. A swab tends to be made of soft foam and is meant to be malleable, as it must navigate potential pipeline obstructions. Once a swab arrives at a pipeline receiver, it is known as a “prover pig.” The condition in which this pig emerges indicates the internal condition of a pipeline. 

Trap: A pipeline trap is used for either a pig launcher or a pig receiver. The use of these devices is integral to pigging procedures. 

Launcher: A launcher, or pig launcher, is part of a pig trap used to introduce a pig into a pipeline. A pig is forced into a pipeline without interrupting the pipeline’s flow with a launcher. A pig can also be inserted from a launcher into a pipeline by towing it with a device or cable. 

Receiver: A pipeline receiver is used alongside a pig launcher. The receiver is used to remove a pig from a pipeline. The receiver is important because examining the pig, such as a prover pig, can help identify the next steps of the pigging process. 

Are you wondering how pipeline services can be implemented within your industry?

Contact the team of experts at American Pipeline Solutions to discover a personalized pipeline and pigging solution today.

Checklist for Pipeline Pre-Commissioning Procedures

Once you have completed the construction process on a new pipeline, your next step is to start pre-commissioning procedures. These procedures are an important part of the transition process from pipeline construction to operation. 

To ensure that your pipeline operates correctly, the pre-commissioning process must be completed properly. To do so, the process must be done in the proper order with each step using the appropriate tools. 

Below, we’ve outlined the pre-commissioning procedures we use at American Pipeline Solutions. Keep reading to learn what each of these steps is used for, the tools it might require, and more. 

Checklist for Pipeline Pre-Commissioning Procedures 

Pig the Line

The first phase to undertake in pre-commissioning procedures is cleaning out the pipeline. This is typically done by pigging the pipeline. 

A pipeline must be pigged before any other step to ensure all construction debris has been removed. 

Doing so will also improve the accuracy of any tests run in the pipeline. 

Gauge the Internal Diameter With a Caliper Tool 

Once the pipeline is clear of any debris or buildup, the internal diameter is recorded. 

Measurements from this step can be used to compare the constructed pipe to the piping and instrumentation diagram. 

APS uses a caliper tool, or caliper pig tool, for this step of the pre-commissioning process. 

A caliper pig tool is a unique pig that is designed with mechanical sensors or arms on the pig’s body. When run through the pipe, these mechanical fingers or arms help record the internal structure of the pipeline. 

Once this is complete, the pipe is ready for testing preparations.

Perform Pipeline Integrity Tests

Pipeline integrity testing is a proactive process used to detect any leaks or pipeline anomalies before they get worse. By testing your pipeline before putting it into operation, you can address any potential issues without the worry of downtime.

It is also important to note that the PHMSA requires testing for newly constructed pipelines. 

One type of test that is used for newly constructed pipelines is hydrostatic testing. This specific type of test verifies the pipeline can maintain a certain level of pressure over a specified amount of time. Additionally, hydrostatic testing can help locate any possible leaks in the pipeline. 

During the testing process, APS uses various monitoring equipment to determine your pipeline’s pressure levels. APS's equipment to monitor pipeline pressure consists of digital gauges, certified and calibrated deadweights, and recorders.  

Various other tests can also be beneficial for testing your pipeline. For example, nitrogen pressure testing is useful for smaller pipelines, or in cases where weather adversely impacts a test using water. 

While nitrogen testing might eliminate the need for pipeline drying, most other integrity tests still require this important next step.

Fill and Stabilize the Line

The next phase of pre-commissioning procedures begins with preparing the pipeline for testing. 

To fill a pipeline, APS uses a specialty tool called a “fill pig.” A column of test water propels the fill pig through the pipeline.  

As the pig runs through the pipe, it eliminates any air that is in the pipeline. The removal of this air is important because it can result in a failed pipeline integrity test later on. 

Once the pipeline is filled, the next step is to stabilize the pipeline. First, a pipeline is pressured slightly—around 200psi—and then left for a set number of hours. 

A pipeline is considered stable and ready for testing when the pipeline’s temperature and pressure have equalized. 

Dewater and Dry the Line

After you’ve completed your pipeline testing, the final steps in the pre-commissioning process if you do a hydrostatic test are dewatering and drying your pipeline. This step is not applicable if you conduct a nitrogen test.

The same pig used to fill the pipeline prior to hydrostatic testing is run back through the pipeline. This time, though, the pig is run back to the launch site using compressed air. 

Because the dewatering process can prove dangerous due to developing air pockets, APS technicians carefully monitor the pig as it dewaters the pipe. 

After the dewatering process is complete, the drying process can commence. Another series of cleaning pigs and soft foam swabs are sent through the pipeline. This is done until all standing water is removed from the pipeline. 

Finally, the pipeline is dried to the required dew point using oil-free compressors and desiccant dryers. Typically, pipeline drying specifies a -40° dew point.

Looking for an expert in pipeline pre-commissioning services? 

Contact American Pipeline Solutions and receive a timely and affordable solution today.

Guide to Pipeline Hydrostatic Testing

In the United States, there are more than 2.6 million miles of pipelines. These pipelines deliver natural gas and liquid petroleum products every year. 

When transporting these important fuel resources, pipeline systems are one of the safest modes of transportation. Ensuring that these systems operate correctly is crucial. 

Organizations like the Pipeline and Hazardous Materials Safety Administration (PHMSA) are dedicated to advancing pipeline transportation while prioritizing the safety of people and the environment. 

One important procedure that state and federal regulations require is the hydrostatic testing of pipelines. 

So, if you are part of a pipeline construction project or even a repair project, you may wonder: what is hydrostatic testing? Why is it important, and what does it tell us about our pipelines?

Keep reading to learn more about hydrostatic testing in pipelines as well as recommended procedures. 

Guide to Pipeline Hydrostatic Testing 

What is Hydrostatic Testing? 

Even if you’ve heard the term before, you may be unsure what hydrostatic testing means. 

Generally, hydrostatic testing refers to the process of testing specific pressure vessels, such as tanks, plumbing systems, and pipelines. 

This testing examines the strength of these vessels’ pressurization. Additionally, hydrostatic testing also allows you to identify and locate leaks in these vessels, which can weaken the vessel’s strength. 

While the goal of testing a vessel’s strength and locating any leaks remains the same, the procedure will differ depending on the type of vessel. 

Hydrostatic Testing Pipelines & Pipeline Systems 

Overall, hydrostatic testing pipelines is a popular procedure. 

In pipelines, this testing is usually required when a new pipeline has been constructed. The PHMSA also allows this same testing procedure on existing pipelines. 

Hydrostatic testing pipelines is a procedure used to ensure the pipeline’s operational fitness as well as it’s MAOP or maximum allowable operating pressure. 

It is also important to know that there are various factors that can change the pressure within a pipeline during testing. 

Some of these variables include temperature, elevation, water source, air pockets, and inadequate stabilization. 

So, factors like changes in temperature or air pockets in your pipeline can affect the pressure and overall test outcome. 

American Pipeline Solutions’ Hydrostatic Testing Procedure 

To give you a better idea of what to expect when testing your pipelines, we’ve broken down our testing process at American Pipeline Solutions below. 

FILLING THE PIPELINE

Hydrostatic testing starts with filling your pipeline. APS has high flow pumps that are used when filling a pipe for testing. 

Next, the pipeline’s pressure is brought to the proper test pressure. This is done using a “squeeze” pump that is equipped with a stroke counter, depending on the required specified minimum yield strength or SMYS. 

MONITORING PIPELINE PRESSURE

Once your pipeline has a good line fill, our technicians at APS use monitoring equipment to determine your pipeline’s pressure. 

This equipment includes certified and calibrated deadweights, recorders, and digital gauges. Using these devices, APS is able to monitor and record your pipeline pressure during the hydrostatic testing process. 

AFTER TESTING IS COMPLETE

When APS technicians have confirmed that testing is complete to industry standards and the client’s satisfaction, they begin to depressurize the pipeline. 

This depressurizing process is done carefully to ensure that the line’s pressure complies with industry code and standards. 

Maintain Your Pipeline With Unmatched Testing Services 

By and large, the fitness of your pipelines is crucial to your business and safety. So, utilizing the best possible hydrostatic testing services is vital to the success of your pipelines and your business. 

At American Pipeline Solutions, we are dedicated to helping clients with timely and affordable services for their pipeline needs. 

With 100 years of combined experience, APS is able to provide comprehensive hydrostatic testing services for pressure pipelines. The team at APS is able to clean and hydrostatically test pipelines with a diameter of up to 48 inches. Additionally, APS can pressure test pipelines up to 10,000 pounds per square inch (PSI). 

In addition to hydrostatic testing for pipelines, other services that APS offers include pigging, testing and drying services. 

Wondering what the right hydrostatic testing option is for your needs?

Contact American Pipeline Solutions today at (201) 525-0088 to find the right hydrostatic testing solution for your pipelines.

How Gas Pipeline Leak Detection Has Changed Through Time

The history of the modern pipeline system is an interesting one. In America, oil and gas pipeline systems can be sourced back to the efforts of Edwin Drake. 

In 1859, Drake used his unique drilling technique to drive pipe sections into the ground in an attempt to reach oil deposits. In August of 1859, he succeeded—at 69 feet, he hit oil and natural gas deposits. 

Other notable examples of pipelines can be found in the implementation of natural gas streetlights in London. In fact, archaeologists in 1994 uncovered the remains of what once was a copper plumbing system in Ancient Egypt. 

Suffice it to say, civilizations throughout history have benefited from the innovative pipeline system. 

As the technology to create pipeline systems has evolved, so has the technology we use to maintain them. 

Pipeline leak detection systems have evolved alongside our understanding of safety measures around natural gas.

How?

If a natural gas pipeline leaks, it can be dangerous to the workers or citizens nearby. Having safe and comprehensive detection tools has been a must for many years. 

How Gas Pipeline Leak Detection Has Changed Over Time

Coal Miners & Early Gas Detection Methods 

The most memorable method for detecting natural gas can be traced back to the Industrial Revolution. Thanks to his research on carbon monoxide, John Scott Haldane, the father of oxygen therapy, recommended using canaries to detect methane in coal mines, which eventually came to an end in 1986.

A second renowned portable gas detection method was the safety lamp developed by Humphry Davy in 1815. Davy was asked to create a safer way to illuminate the miner’s environment after a series of fatal explosions in coal mines. The result was the safety lamp, which worked as a source of light and a natural gas detector. 

The Birth of the Catalytic Sensor

In 1926, Dr. Oliver Johnson invented a catalytic sensor meant to detect combustible natural gases in the atmosphere around it. This sensor is the first modern portable gas detection device. 

As more research on the use of natural gas took place, the uses for this resource expanded. By the 20th century, more effective pipelines were being manufactured, which allowed natural gas to heat homes and even generate electricity. 

Today’s Natural Gas Pipeline Leak Detection Systems

Over half of the energy that residential and commercial customers use today comes from natural gas.

And, as the use of natural gas became more prominent, so do natural gas pipeline regulations. 

Monitored by both federal and state agencies, these regulations are used to ensure newly built, and existing pipelines are safe to operate.  

While there are numerous methods of pipeline leak detection companies use to inspect pipelines, there are two main categories these methods fall under: continuous and non-continuous methods. 

Companies tend to use both continuous and non-continuous methods, including hydrostatic pressure testing and even smart pigging tools. 

The Future of Pipeline Leak Detection: The i2i Smart Pigging Device 

A pipeline pig is used for a variety of reasons. It is used to inspect the pipeline’s condition, but it is also used for cleaning the pipeline. 

The smart pig gathers data as it moves through your pipeline. Once it reaches the receiver, technicians use the collected data to identify any problems.

An example of an innovative smart pig is the i2i smart pig tool. This pig was created to make the pipeline inspection process easier. The i2i smart pig offers a low risk, low cost, and non-disruptive method for gathering data on pipeline conditions. 

By combining the technology of typical cleaning pigs and conventional ILI, you can inspect your pipelines without disrupting your daily operations. 

Additionally, the i2i smart pig comes at a fraction of conventional ILI tools without sacrificing the beneficial data the tool gathers.  

Other benefits of this smart pig device include its sensitivity. The i2i smart pig is sensitive to pits, internal metal loss, and circumferential cracking in your pipes. Thus, you can easily detect these factors and fix them before they end up creating a bigger issue in your pipes. 

To find the best solution for your pipeline, contact American Pipeline Solutions today to learn more about testing services and the i2i smart pig!