Case Study
SureLaunch Pig Helps Colorado Operator Cut Costs
A Colorado-based midstream operator was experiencing higher-than-expected operations costs associated with one of their pipelines that required regular pigging. Their automated launcher, while efficient, required each pig to have extra hardware bolted on before loading to prevent sticking or binding during launches. This design limitation drove up material costs as each pipeline pig had to be customized before use. This additional hardware also posed a risk to the operator if it were to become detached from the pig while in the pipeline. The customer needed a more cost-effective solution that could handle their tough pipeline conditions — including weld deformities and tight bends — without compromising performance or automation efficiency.
WeldFit introduced the SureLaunch® pig (SLp), purpose-built for automated launching applications. Its innovative one-piece, three-cup design eliminates the need for bolt-ons entirely, allowing multiple pigs to be stacked safely in the launcher without risk of sticking or double launches.
During launch testing, the SLp was evaluated at five separate intervals to confirm consistent performance. It maintained its shape and sealing integrity across all test runs, demonstrating that the design supports repeated automated launches without requiring assembly or adjustment between cycles.
With advanced urethane composition, 80A durometer, the SLp is high strength while also displaying the flexibility needed to navigate the customer’s challenging pipeline geometry. The pigs successfully traveled over 189 miles without requiring replacement, confirming longevity and sealing performance under demanding operating conditions.
The SLp delivered immediate and measurable value:
- Improved automation efficiency – By removing barriers to reliable automated stacking and launching, the SLp helps operators get more out of their existing equipment.
- Lower total cost per pig – By removing the need for bolt-ons, the one-piece design significantly reduces additional component costs and time.
- Extended service life – The long run performance minimizes reorder frequency, saving both time and procurement costs.
- Fleet standardization – The versatile design performs reliably across the company’s entire pipeline system, including sections with bends, enabling a simplified and streamlined ordering process.
With the SLp, the Colorado operator reduced maintenance complexity, cut operating costs, and improved pipeline efficiency — all while maintaining the reliability and safety of their automated pigging operations.
