Foam Projectiles: A Versatile Pipeline Maintenance Device

Foam projectiles are commonly used in pigging for the purpose of cleaning, drying, batching, and dewatering, and are used across many industries. Generally, these projectiles are pushed through pipes, hoses, tubes, and assemblies using compressed air.

When it comes to cleaning pipelines, the primary goal is often to remove fine particles of loose dirt and other contaminants to ultimately improve product flow. Many companies are accustomed to cleaning pipes or tubes using traditional methods, which usually leaves leftover water and even a small amount of surface deposit inside the pipe; so the goal of cleaning is not properly met. With the wide variety of options and customization available, foam projectiles are essentially specially designed, oversized devices that are shot inside the tube to instantly remove this leftover water and surface deposit.

They also have an added benefit: Traditional cleaning methods take a lot of time for the whole process. This time can be significantly reduced by sending through these universal foam projectiles.

As an example for a more specific application, foam projectiles can also be used for purposes such as improving and accelerating the drying process of a heat exchanger. The applications and possibilities truly are endless, especially when you're working with high quality foam projectile products that are tailored to your purposes, application, and industry.

How Does a Foam Projectile Work?

The projectile applies high outward pressure against the internal surface of the hose, tube, or pipe for a superior outcome. This compression is made possible because the projectile is approx. 20% to 30% larger than the hose ID. For example, an expert might recommend using a 50 mm projectile for a 38 mm hose. In addition to the importance of sizing, foam projectiles have additional optional features when it comes to their material and design to get the job done effectively.

Foam Projectile Material, Design, And Size

Choosing the right-size projectile is extremely important. Depending on your particular case, you may need a smaller or a larger projectile. For instance, if you purchase a larger projectile than what is required, it won't leave the nozzle. On the other hand, if the projectile is too small, the hose won't be cleaned properly. If you're dealing with the most commonly used diameters/coupling sizes, a reduction in projectile size may still work. But the situation can get more complex if you consider the vast variety and sizes of couplings available in the market. And depending on your specific goal, in some cases, that means the typical standard sizing is not suitable for your needs, so an expert opinion is recommended for these types of cases.

Also called cleaning projectiles or clean foam projectiles, foam projectiles are made from virgin dense foam. The foam has a unique cell structure and density. This allows the projectile to work with both coupling and plain-end applications. This also ensures that they meet different ISO cleanliness levels when proper assembly guidelines are followed.

When it comes to design and material, some experts recommend avoiding projectiles made from re-bonded, scrap, or recycled materials.

As discussed earlier, foam projectiles clean by using compressed air to launch through the pipeline or tube, thereby loosening and propelling dirt and deposits through the path. Some manufacturers might encourage using products that are only about 15% larger than the actual internal diameter of the line to be cleaned. But depending on your particular application and for maximum cleaning action, pipe projectiles are more often sized 20% to 30% larger than the tube or hose to be cleaned. These oversized projectiles ensure proper compression, friction, and cleaning. The size of these projectiles can vary from ½ inch to several inches. Match the projectile size to your hose/tube I.D. for proper sizing. If nothing works, go for custom sizing.

It's also good practice to buy foam projectiles that are specific to the type of dirt you're working with: loose dirt, light to strong rust, hardened materials, and other residues.

Industries that commonly use versatile recovery projectiles

•    • Oil and gas
•    • Municipality
•    • Food and beverage
•    • Mining
•    • Chemical and petrochemical
•    • Cosmetic
•    • Pharmaceuticals

Foam projectiles are generally lightweight and flexible so they can work with uncommon piping, fittings, and valves. They come in various designs, lengths, and diameters.

If the available configurations are not working for your unique pigging application, manufacturers can design special configurations for you. You may also want to take a deep dive into the specification sheets of each product for more technical data.

Types of Projectiles

Bare Foam Pig Projectiles

These projectiles are made of open-cell polyurethane foam with a durable polyurethane elastomer coating on the base. Mostly used for drying and sweeping loose debris, these tube projectiles can also be used under different circumstances.

Abrasive Projectiles

These foam projectiles have a rough fibrous material on the outer side. They are often used in application where removing stubborn deposits and coarse contamination are issues. If you're dealing with tube bundle heat exchangers, get these scrub projectiles.

These are several different options for this type of projectile:

•    • Silicone Carbide Foam Pig Projectiles
•    • Stud Pig Projectiles
•    • Brush Foam Pig Projectiles
•    • Plastic Bristle Foam Pig Projectiles

Foam Disc Pig Projectiles

Foam disc projectiles are made of polyurethane foam and have a design that features a series of wiping edges. Use these dense foam projectiles if you're looking for efficient liquid removal and/or wax removal pigs.

Coated Criss Cross Pig Projectiles

The polyurethane foam body is coated with polyurethane elastomer in a criss-cross pattern – thus the name Criss Cross pigs! These pipe cleaning foam projectiles are well-suited for regular-duty wiping, batching, and product removal applications.

Pigs Unlimited International LLC is a leader in pipeline cleaning and carries a wide range of in-stock foam projectiles and other pigging supplies and equipment. This includes foam pigs, steel mandrel pigs, other types pipeline cleaning pigs, related components such as brushes, cups, discs, blades, and more. Their expert and experienced team can also advise and assist you in selecting the right foam projectile for your specific application.