365 km Long-Distance Dual-Diameter Pipeline Pigging Success in a 24”–28” High-Pressure Gas Pipeline

EUREKA EFEKTIF successfully engineered and executed a 365 km continuous pigging operation in a 24”–28” dual-diameter high-pressure gas pipeline using a pig fully designed, engineered, and manufactured in-house. The pipeline consisted of a 24-inch offshore section transitioning through a wye-piece into a 28-inch onshore section, requiring the pig to adapt to varying diameters and complex geometry while maintaining sealing and propulsion throughout the run.

Dual-diameter pipeline pigging presents significant technical challenges, including maintaining sealing performance and differential pressure across different pipe sizes. The presence of a wye-piece transition and the long run distance of 365 km increased the risk of pig instability, disc damage, and operational failure.

EUREKA EFEKTIF developed a custom dual-module pig connected by a universal coupling, enabling articulation through pipeline transitions. The pig was designed to contract in the 24” section and expand again in the 28” pipeline utilising multiple discs configuration. The configuration was validated through engineering simulations, and a launching cassette was developed to protect the discs during offshore launch.

The pig was successfully launched on 3 January 2026 and completed the 365 km run in approximately 56 hours. Post-run inspection confirmed the pig was retrieved intact, with disc wear within expected limits, validating EUREKA EFEKTIF’s polyurethane disc technology for long-distance dual-diameter pipeline pigging.
 

Planning a pipeline pigging campaign, dual-diameter pipeline operation, or custom pig design?
Contact EUREKA EFEKTIF today to discuss your pipeline engineering requirements.