How Pig Tracking Has Evolved: From Manual Coordination to Real-Time Remote Tracking

Pipeline pig tracking has not always looked the way it does today.

What was once a fully manual, field-driven process has gradually evolved into a connected, data-driven system. From paper maps and radios to real-time data and remote tracking, the way operators track tools through pipelines has changed significantly over the decades.

To put that into perspective, we looked back at how pig tracking was done in the early days through the experience of the founder of In-Line Pigging Solutions, Richard Thul, and compared it to how modern tracking systems are used today.

Pig Tracking Then: Before Real-Time Systems

Before digital systems and remote tracking, pig tracking was built on coordination, manual planning, and experience in the field.

Planning a run started long before anyone stepped onto site. Locations were determined using pipeline chainage provided by the operator, often in formats like 35 + 1200, meaning 35 kilometers down the line plus another 1,200 meters. Crews relied on grid road maps or hand-drawn directions to find their way, sometimes mapping out every turn just to reach a single tracking location. If a road followed the pipeline, there might be markers or access points, but more often it meant navigating with limited guidance.

There was no GPS. Distances from the road to the AGM were measured manually, typically placing them in farmers’ fields about 30 meters off the road. Each location had to be probed to confirm depth, and access often required coordination with landowners before crews could even enter the property.

Getting to site was often the hardest part. Long drives through rural areas, sometimes late at night, with little to no visibility. In places like Saskatchewan, it could mean driving in complete darkness, relying on instinct and memory just to find the right location.

"You didn’t have a screen to look at. You had to trust what you heard and be confident you caught the pig." - Richard Thul, Founder of ILPS

Once the run was underway, the scale of the operation became clear. A single project could involve more than 30 personnel, with technicians positioned along the pipeline at key locations and mainline valves. Every valve might have one or two people assigned, all working together to ensure the tool passed through as expected. Before the run, teams would review as-builts in detail to understand the line, a time-consuming but necessary step.

Tracking followed a coordinated leapfrogging approach. After confirming passage at one location, a technician would move ahead to the next site, staying in sync with the rest of the crew. It was a system that worked, but it depended heavily on timing, communication, and trust.

The tools themselves were simple and often improvised. Technicians relied on geophones connected to basic amplifiers, sometimes sourced from Radio Shack, along with compasses for certain tool types. In some cases, rattler wheels were installed on pigs just to make them easier to hear. Transmitters were limited, and some tools only had audible beepers to indicate they were active.

If a pig got stuck, crews relied on additional tools like gauss meters to help locate it. At one point, teams were even using large electromagnetic coils, some over 6 feet in diameter and weighing more than 80 pounds, powered by portable generators. These had to be carried out, set directly on the pipeline, and activated at the right moment to detect the passing tool. In difficult conditions like rain or mud, this added another layer of complexity to an already demanding process.

Communication between crews was handled over VHF radio, with each passage called in and relayed down the line. Times were recorded manually, often written in notebooks before being transferred into spreadsheets later. Tool speed was calculated after the run, meaning there was no real-time visibility into how the tool was performing while it was in the line.

Out in the field, everything came down to awareness and experience. If you missed the signal, you missed the pig.

Field conditions only added to the challenge. Equipment breakdowns, limited communication, and the risk of getting stuck or isolated between locations were all part of the job. In some cases, crews had to wait until the run was complete before help could reach them.

At the end of the day, pig tracking was not just about the tools. It was about instinct, coordination, and the ability to make the right call in the moment.

Pig Tracking Now: Remote and Permanent Tracking for Real-Time Visibility and Efficient Pig Tracking Programs

Today, pig tracking looks very different.

What was once a manual process has shifted into a more streamlined, data-driven approach supported by modern technology and innovative tracking systems.

Planning and deployment are now guided by GPS and digital mapping tools, allowing teams to position tracking equipment with far greater accuracy. Remote tracking units can be installed along the pipeline, including permanent, solar-powered systems that provide continuous monitoring without the need for repeated mobilization.

The scale of manpower has changed significantly. Instead of deploying large field crews, operators can now monitor tracking data remotely. Centralized systems have replaced much of the manual coordination, allowing teams to stay aligned without relying on leapfrogging between locations.

The technology itself has evolved to support more precise and reliable tracking. Modern systems integrate multiple detection methods, including geophone, ELF, and magnetic sensors, along with remote units that transmit data through cellular or satellite networks. This allows for continuous data capture and a level of consistency that was not possible before.

The biggest shift is in visibility. Tracking data is now available in real time through centralized platforms like the Element System, giving teams immediate access to pig location, tool speed, and passage events. Decisions that once relied on delayed information can now be made instantly.

This shift has also improved safety and reliability. With fewer personnel required in the field and less travel to remote locations, overall exposure is reduced. At the same time, more consistent and auditable data improves confidence in both the tracking process and the results.

How Pipeline Pig Tracking Has Changed, and Why It Matters

The evolution of pig tracking reflects a broader shift in how pipeline operations are managed.

What was once dependent on manual coordination and field experience is now supported by real-time data and integrated systems. Operators are able to improve accuracy, reduce labor and mobilization costs, and maintain better alignment across teams.

Remote tracking is not just a technological upgrade. It represents a more efficient and reliable way to plan and execute pigging operations.

Connecting the Past to Modern Remote Pig Tracking

Looking back at how pig tracking was done makes the value of modern systems clear.

Today, remote tracking allows operators to maintain real-time visibility, reduce field personnel, minimize delays, and improve overall operational performance. Permanent tracking systems take this even further by enabling continuous monitoring across multiple runs without redeployment.

For a deeper look at how these systems reduce costs in practice, read our article:
5 Ways Remote Pig Tracking Reduces Costs in Pipeline Pigging Operations


Final Thoughts

Pig tracking has come a long way.

What once relied on coordination, experience, and limited tools is now supported by advanced technology, centralized data, and real-time visibility. This shift has not only improved efficiency, but also changed how operators approach safety, planning, and execution.

With solutions from In-Line Pigging Solutions, operators can apply these advancements to improve performance, reduce costs, and execute projects with greater confidence.

Contact our team to learn more about remote pig tracking systems and how they reduce costs in pipeline pigging operations. 

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