Tracking pigs is crucial for accurately monitoring their location and progress through the pipeline.  Any uncertainty regarding location can result in project and/or operational delays and potential additional costs due to these delays. An electromagnetic pig tracking system should be considered an insurance policy – you might not always need it, but do you want to take the risk of not having it?  As with many aspects of life, having the right insurance can prove invaluable when things go wrong.  Beyond contingency planning, these systems also play a role in confirming that operations have progressed as expected, providing reassurance and saving time.

Pig Tracking Technologies: Exploring the Options 

Pig tracking allows you to confirm a stationary pig is (or is not) at the expected location such as in the receiver.  This is when a pig tracking system’s second function may come into play – locating a stationary pig at an unknown location.  Additionally, it can track the passage of a moving pig at a specific point in the pipeline, ensuring precise monitoring throughout the process.  This is typically done by carrying a receiver from one location to the next and can often involve multiple people at different locations.  This process is commonly referred to as “leapfrogging.”  

Several technologies are available for pig tracking with acoustic pig tracking traditionally being the go-to option for subsea pipeline pre-commissioning.  Acoustic works well when tracking pigs over long distances with detection possible across several kilometres.  However, it is only suitable for a specific application: subsea pipelines that are liquid-filled and not buried or trenched.  This makes it an unsuitable choice for onshore or topside pipelines and limits its use in certain subsea pipeline scenarios.  Radio Active Isotopes (RAI) are an alternative technology that allow for more precise pig tracking and don’t rely on a power source, eliminating the risk of batteries depleting.  However, this type of equipment requires strict safety protocols and handling procedures and the need for specialised equipment and expertise, all of which can drive up operational costs. Additionally, shipping this type of equipment can be complicated due to the regulations surrounding transport of radioactive material, adding another layer of complexity and potential cost.    

What is Electromagnetic Pig Tracking? 

Electromagnetic (EM) pig tracking has emerged as the most versatile technology on the market as it allows locating and tracking in any onshore or offshore pipeline whether it is carrying gas or liquid.  It is also suitable for buried and trenched pipelines, pipeline bundles and pipe-in-pipe applications.  Some systems are certified (e.g ATEX-certified) for use in hazardous areas without the need to obtain additional permits making them the ideal choice for use on platforms and in onshore facilities such as refineries. 

EM pig tracking involves placing a transmitter inside a pig.  This transmitter emits a signal that can be detected externally using an EM Receiver which has a series of LEDs to indicate signal detection and enables precise locating of the pig within the pipeline.  Some systems offer specialised applications on handheld devices or laptops.  These offer graphical signal representation and allow users to adjust transmitter and receiver parameters as needed to ensure suitability for each individual operation.  

EM pig tracking systems allow for precise locating within a few centimetres through null spot detection.  This precision reduces guesswork and enhances efficiency by allowing issues to be dealt with swiftly, minimizing downtime and supporting decision-making during critical operations.  Although these systems come at a price, their long-term benefits make them a cost-effective solution (think back to the insurance policy analogy at the start of this article.)  The key benefits include: 

High Precision: Accurate locating within a few centimetres through null spot detection. 

Reduced Downtime: Quick identification of issues to minimize operational disruptions. 

Enhanced Efficiency: Streamlined operations by eliminating guesswork and improving tracking accuracy. 

Improved Decision-Making: Real-time data to support better decisions during critical operations. 

Cost-Effective in the Long Term: Despite initial costs, the long-term savings and operational benefits make them a valuable investment. 

Versatility Across Applications: Suitable for onshore, subsea, and complex pipeline configurations.  

For a more detailed exploration of these advantages, check out our dedicated article “Six Benefits of Electromagnetic Pig Tracking and Locating.“

While EM pig tracking offers significant advantages, it does come with certain challenges. Factors such as pipeline construction, environmental conditions, and pig design can affect tracking performance. Here are the key challenges operators may face: 

• Signal Attenuation: Buried pipelines and those with thick walls can weaken EM signals, making tracking more difficult. 

• Battery Life vs. Signal Strength: Increasing receiver sensitivity or transmitter strength can improve tracking but may reduce battery life or signal accuracy. 

• Pig Design and Materials: The design, materials and transmitter placement can affect signal strength, requiring careful consideration during system setup. 

• Small Diameter Pigs: Fitting transmitters into smaller pigs (e.g., 4”-6”) can be challenging, potentially limiting tracking capabilities. 

• Transmitter Compatibility: Collaboration with pig manufacturers is essential to ensure compatibility between the pig and transmitter. 

• Environmental Factors: Pipeline diameter, temperature, and pressure can all influence tracking performance, requiring adjustments based on specific conditions. 

To explore these challenges further and learn about solutions to overcome them check out our articles “Pipeline Pigging with Precision: The Role of Electromagnetic Technology and its Challenges” and “Key Pipeline Specifications for Optimising Electromagnetic Pig Tracking.“

Advancements in EM Pig Tracking Technology 

EM pig tracking technology has significantly evolved over the years, offering innovative features to meet the demands of pipeline operations. For instance, EM transmitters can be fitted with specialised endcaps that enable delayed activation to conserve battery life as transmitters must typically be switched on prior to pigs being loaded into the launcher.  Transmitter switch-on can be triggered by external conditions such as contact with liquid or when a pipeline reaches a specified pressure.  

Additionally, transmitters can be integrated with external equipment like Smart Gauge Plates to confirm the integrity of a pipeline.  Advancements in transmitter power and receiver sensitivity enable operators to track pigs even in challenging scenarios such as heavy walled or buried pipelines.  The introduction of multi-frequency receivers enables the simultaneous tracking of multiple frequencies, making it possible to identify individual pigs within a pig train.  

Enhancing Efficiency with Innovative Apps 

One of the more revolutionary advancements in electromagnetic pig tracking has been the introduction of specialised Apps that can streamline processes, improve data accuracy and provide operational flexibility.  

EM transmitter Apps such as IK Trax’s EMTx Config App allows operators to adjust transmitter settings such as pulse rate, frequency and power output, directly on-site.  Traditionally, these adjustments would have had to be made by the manufacturer often leading to additional transit costs and potential delays without careful forward planning.  The App also provides real-time feedback on how changes, such as increasing power or selecting a faster pulse rate, impact battery life.  This allows the operator to strike a balance between performance and longevity.   

EM Receiver Apps provide a graphical representation of the signal from the Receiver allowing you to track multiple EM frequencies as well as pigs fitted with magnets.  This visualization can simplify the tracking process leading to faster detection. With IK Trax’s EMRx Receiver App, you can also adjust the settings of the receiver e.g change the frequencies selected to be shown on each of the LED bars and pause, zoom and scroll through past data as well as export.   

To explore the full benefits of these innovative tools, check out our “Five Reasons to Use Pig Tracking Applications.”

Conclusion 

EM pig tracking offers accuracy, versatility and operational efficiency.  As technology advances, so do the capabilities of EM tracking systems, enabling precise monitoring in even the most challenging environments.  While challenges remain, ongoing developments can help address these limitations.  By integrating EM pig tracking technology, operators can enhance the reliability and effectiveness of their pipeline operations.  

When it comes to Electromagnetic(EM) Pig Tracking, knowledge of the pipeline specification is critical for selecting the right transmitter.  Typically EM transmitters operate across different pipeline types – topside, subsea, buried pipelines or bundles and in gas and liquid lines.  Several factors play a role in ensuring reliable signal detection and tracking performance.  If the appropriate transmitter is not selected, the effectiveness of the system can be severely compromised. 

One of the most important factors is pipeline diameter.  For example, the IK Trax EMTx40 is a transmitter specifically designed for pig tracking in pipelines larger than 12 inches.  Larger pipelines benefit from larger transmitters due to the increased distance between the receiver and the transmitter, making signal detection more challenging.  In short, the bigger the pipeline, the larger the transmitter required for optimal signal performance.   

Wall thickness also plays a significant role in signal transmission.  Heavy-walled pipelines, launchers, receivers and pipe-in-pipe configurations can pose challenges.  Wall thickness directly affects the EM signal’s ability to penetrate the pipeline. If the signal isn’t strong enough, it can become weakened or attenuated to the point of being undetectable.

Temperature and pressure are additional factors to consider.  For example, transmitters used in deep-water pipelines must have high-pressure ratings to ensure they can withstand the pressures encountered subsea.  Additionally, operating temperatures must be considered particularly in pipelines that transport product with extreme temperatures.  Lithium cells are often preferred for these applications due to their ability to function at a wider temperature range when compared with alkaline cells.

Testing is essential whenever there is uncertainty about whether the pig tracking system is suitable for the application.  This ensures the transmitter is configured correctly and capable of delivering reliable performance.  Testing typically involves replicating actual project conditions as closely as possible to verify signal strength and overall functionality.  By simulating operational conditions, testing minimises risk and ensures that the EM pig tracking system will perform effectively during operations.

Ultimately, selecting the right system comes down to a close collaboration between the manufacturer and the client.  By understanding every aspect of the pipeline the manufacturer can recommend a solution tailored specifically to the project’s needs.  Comprehensive testing ensures that the system will perform as expected in operational conditions, minimising the risk of signal loss and maximising operational efficiency.

Ready to optimise your pipeline pig tracking? Discover how our advanced electromagnetic transmitters can enhance your operations. Visit our Electromagnetic Transmitter Page to learn more!

Staying on schedule and within budget is crucial during pipeline pre-commissioning, as any delays can significantly increase the already high costs of vessel and equipment hire and personnel. Each stage of the pre-commissioning process must be executed efficiently. IK Trax’s cutting-edge data logging and testing equipment offers our customers assurance by recording and transmitting crucial data at every stage. This real-time monitoring allows support vessels to be utilised for other tasks, resulting in substantial cost savings.

Here are our four key strategies to ensure confidence throughout pipeline pre-commissioning.

Real-Time Pig Tracking

During the flooding and cleaning of a newly laid pipeline, it is vital that the chosen pig train can travel continuously through the pipeline and into the receiver. Pig Signallers placed at critical points and a suitable pig tracking and locating system ensure that you can quickly and confidently identify the pig’s location at each stage from launch to receipt or if the pig stalled in the pipeline.

Confirming a stationary pig’s location in the receiver is normally a routine operation but locating a pig stalled at an unknown location is more difficult and could have large cost implication. Therefore, an effective and advanced detection system, along with a clear strategy, is necessary to ensure speedy locating and recovery of the pig.

Gauge Plate Monitoring

A standard gauging pig will advise you of the presence of a pipeline intrusion. Often, this will need to be followed by a caliper pig run, an unscheduled and expensive operation, to determine the intrusion location. A more cost-effective solution is to run a gauging system with an electromagnetic transmitter. This system can monitor the condition of the gauge plate and transmit this information remotely. This data can be used to determine the approximate location of the defect without having to run a caliper.

Pressure and Temperature Monitoring

Subsea Data Loggers such as the 6001SD can monitor, display and record pressure and temperature data that can be viewed by an ROV or diver or communicated remotely. As the unit is continuously logging, the vessel or diver can use this time to perform other taks, providing more operational flexibility and resulting in work being completed on or ahead of schedule.

The unit can also examine the data received during a set period and display the time and date of the hydrotest pass. This information is readily available without needing to recover the unit, ensuring continuous monitoring efficiency.

Real-Time Dewatering Analysis

Verifying that a pipeline has been properly conditioned throughout its length can be time-consuming and costly since it is carried out so close to start-up. A system such as IK Trax’s MEG ARTS Analyser and Sampler measures the density of flowing MEG (or other chemicals) at the receipt end of the pipeline and displays and logs this data, providing a real-time account of the progress of the dewatering operation.

There may still be a requirement to provide samples for additional confirmation and/or to support the data obtained. Up to seven samples can be taken by ROV, and costs can be reduced further by taking automatic samples at pre-determined levels, eliminating the need for a vessel to transit to the receipt location.

In conclusion, effective pipeline pre-commissioning is essential to ensure the integrity and operation readiness of a new pipeline. By implementing these strategies, companies can achieve significant cost savings and operational efficiencies. These technologies not only enhance the accuracy and reliability of pre-commissioning activities but also enable better utilisation of resources, ultimately ensuring projects are completed on time and within budget.