As pipeline infrastructure grows more complex, so does the need for pigging solutions that can handle the challenges of variable diameters, high operational demands, and harsh conditions. At Apache Pipeline Products, dual diameter pigging isn’t just a capability—it’s a core strength backed by engineering excellence, real-world testing, and a commitment to continuous innovation.
With over 40 years in the pipeline maintenance industry, Apache has become a trusted name in pigging solutions across North America. Our recent advancements in dual and multi-diameter pigging reflect our dedication to solving real-world challenges with precision, reliability, and purpose-built technology.
Why Dual Diameter Pigging Is Essential for Modern Pipelines
Modern transmission and gathering systems often include pipelines of varying diameters, due to infrastructure changes, retrofits, or design decisionsmade to meet flow or environmental requirements. This creates a significant challenge: how do you move a pig smoothly and efficiently through these transitions without compromising cleaning effectiveness, tracking accuracy, or the structural integrity of the pig?
That’s where Apache comes in.
Dual diameter pigs are designed to navigate transitions—like a 36” line reducing to 30”, or even a 42” launcher leading into a 36” and then expanding to 48”. But designing pigs that can adapt to those variations while maintaining pressure integrity and consistent performance requires testing, data, and precise engineering.
Field-Tested. Operator-Approved.
At our 55,000 sq. ft. manufacturing and testing facility in Edmonton, Alberta, Apache engineers put our pigs through real-world scenarios to ensure every product we release is ready for the field. This quarter, we conducted two key dual diameter pull tests that are helping shape the next generation of pipeline pigging products.
36” x 30” Reducer Pull Test
In this scenario, a dual diameter pig was pulled through a specially built test fixture simulating a 36-inch line reducing to 30 inches. The setup involved a welded 36” x 30” reducer connected to a short section of 30” standard wall pipe. Using a winch truck, the pig was pulled through the dry pipe with a peak force load of 9,500 lbs.
This test yielded critical data that allowed our engineering team to refine the pig’s geometry and materials, improving its flexibility and reducing resistance during field deployment. These insights help mitigate risk for pipeline operators and ensure smoother transitions across diameter changes.
42” x 36” x 48” Multi-Diameter Pull Test
In a more complex test environment, we evaluated a pig’s performance across multiple transitions. The test fixture simulated a 42-inch launcher, reducing to 36 inches before expanding to 48 inches. The pig was pulled through lubricated pipe segments, recording:
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4,200 lbs of force in the 42” section
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7,200 lbs in the 36” section
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3,600 lbs in the 48” section
These findings confirm that Apache pigs are not only adaptable but excel in demanding, multi-diameter environments. They maintain structural integrity, consistent velocity, and precise tracking—critical for both cleaning and inline inspection runs.
End-to-End Engineering That Sets Apache Apart
What sets Apache apart in the pipeline pigging industry is our vertically integrated process. From concept and design to fabrication and final testing, every pig we produce is engineered in-house. This allows us to maintain full quality control, rapidly iterate based on field data, and provide customers with customized pigging solutions that solve their unique challenges.
Our team includes engineers, fabricators, and field testing specialists who work closely to ensure every product that leaves our facility is built to perform—and built to last.
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Custom Pig Design – Tailored for specific line conditions, bends, reducers, and flow characteristics
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Robust Materials – High-performance polyurethane and elastomers for durability
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Real-World Testing – Pull tests, load analysis, and transition simulations under dry and lubricated conditions
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North American Manufacturing – Built in Canada, trusted across the globe
Meeting the Industry’s Most Complex Pigging Needs
Apache is a trusted partner for midstream operators, transmission companies, and pipeline contractors who need pigs that work—n
o matter the condition of the line. Whether you’re dealing with high-differential pressures, unknown debris loads, or dual diameter transitions, Apache’s pigs are engineered to get the job done safely and efficiently.
Our dual diameter pigs are ideal for:
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Cleaning lines with varying diameters
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Decommissioning and abandonment preparation
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New construction lines with non-standard geometry
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Temporary setups requiring bidirectional travel
Driving the Future of Pigging Technology
Every test we conduct at Apache is more than a checkmark—it’s a building block toward better performance, smarter design, and safer pipeline operations. Our testing protocols not only validate our pigs in controlled environments but also provide real-time feedback that drives future innovations in our product line.
We’re proud to serve as both a manufacturer and an industry thought leader—sharing insights, data, and experience that help move the entire field forward.
Ready to Solve Your Pipeline Challenges?
If you’re operating dual diameter pipelines or facing tough pigging scenarios, Apache Pipeline Products is here to help. Our team will work with you to assess your line’s geometry, recommend the right pigging solution, and support you through testing and deployment.
Let’s talk about your pipeline.
Contact us today or learn more about our dual diameter pigging products.
About Apache Pipeline Products
Founded in 1986, Apache Pipeline Products is a leading manufacturer of pipeline cleaning and maintenance products, including pipeline pigs, pig detectors, closures, and custom solutions. Based in Edmonton, Alberta, Apache serves pipeline operators and contractors across North America with an emphasis on innovation, reliability, and end-to-end quality control.