Project Overview at a Glance
- Client: Sichuan Renshengxin Construction Co., Ltd. (on behalf of the asset owner, Huabei Oilfield)
- Location: Shenzhou, Hebei Province, China
- Challenge: Relocate a high-pressure crude oil pipeline obstructing a critical high-speed rail foundation without stopping production, avoiding massive financial loss and safety risks.
- Solution: A meticulously planned in-service pipeline modification using hot tapping and stoppling technology to bypass the section, followed by a safe pipeline tie-in.
- Results: Successfully completed with zero safety incidents, zero production interruption, and ahead of the tight construction schedule.
The Critical Challenge: A High-Stakes Intersection of Energy and Infrastructure
The monumental Xiongshang High-Speed Rail project, a vital artery in China’s transport network, faced a significant obstacle in its Shenzhou section. The proposed foundation (Pile Cap 65) for the rail line was in direct conflict with an active, high-pressure crude oil pipeline—the Shen-Chu transmission line.
For pipeline construction companies and infrastructure developers, this scenario represents a classic but high-risk problem:
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Immense Financial Pressure: A shutdown of the pipeline for traditional relocation was not an option. The cost of halting crude oil flow—in terms of lost production, supply chain disruption, and contractual penalties—would have been astronomical for the owner, Huabei Oilfield.
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Significant Safety Risks: The pipeline operated at a high design pressure of 6.3MPa. Any work involving “live” crude oil pipelines carries inherent risks of leaks, fires, or explosions, especially during cutting and welding phases. The proximity to ongoing high-speed rail construction activities amplified these risks.
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Engineering Precision: The new 227-meter section of Φ219*7.1mm pipeline had to be installed with perfect alignment and integrity to ensure long-term operational safety and efficiency, matching the exact specifications of the existing line.
The client, Sichuan Renshengxin Construction, needed a pipeline engineering contractor with proven expertise in handling such sensitive, high-stakes operations. They turned to Beijing Jinshiwan Pipeline Technology for a solution.
Our Tailored Solution: Engineering a Safer, Smarter Bypass
Our approach was rooted in a fundamental principle: eliminate the risk by never exposing the live pipeline. We designed and executed a custom in-service pipeline modification plan centered on hot tapping and stoppling.
Here’s a breakdown of our technical solution:
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Comprehensive Pre-Construction Survey: Before fabrication, our team conducted an on-site verification of pipe material, exact length, and surrounding environment. This crucial step, as stipulated in our contract, ensured all materials and plans were perfectly tailored to real-world conditions, preventing costly delays.
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The Bypass Installation: We first installed the new 227-meter bypass section, meticulously welding and testing it according to the strictest quality standards, while the original pipeline remained fully operational.
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Hot Tapping & Stoppling – The Core of Zero Downtime:
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Hot Tapping: Using specialized equipment, we safely drilled into the live pipeline at two designated points to create connections for the bypass. This process is done without leaking a single drop of oil, thanks to pressure-sealing technology.
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Stoppling: Following the taps, we inserted sealing heads (stopples) into the pipeline. These devices temporarily blocked the flow of oil through the old section, diverting it seamlessly through the new bypass line we had just installed.
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Safe Tie-In and Commissioning: With the flow safely diverted, the isolated section obstructing the rail construction was removed. The final, critical phase was the pipeline tie-in—the permanent welding of the new section into the main line. This was conducted under strictly controlled conditions, with comprehensive safety measures in place. Once tested and verified, the stopples were removed, and the pipeline was returned to its normal flow path through the new route, ready for operation.
The Execution: Meticulous Planning Meets Flawless Implementation
Our reputation as a leading provider of oil and gas pipeline services is built on our methodical project management. For this project, execution was key:
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Phased Workflow: The project followed a strict sequence: Bypass Installation → Hot Tapping → Flow Diversion (Stoppling) → Old Section Removal → Final Tie-In → System Commissioning.
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Safety-First Protocol: Every team member was drilled in emergency procedures. The worksite was secured, and all hot work was conducted under permits and continuous atmospheric monitoring.
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Seamless Collaboration: We worked in close coordination with Sichuan Renshengxin Construction and the asset owner, ensuring our work integrated perfectly with the overall high-speed rail construction timeline.
Quantifiable Results & Lasting Benefits
The success of this project is measured in hard data and client satisfaction.
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100% Uptime Maintained: Achieved the primary goal of zero interruption to the crude oil transmission, safeguarding the client’s revenue and operational continuity.
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Flawless Safety Record: Completed the complex pipeline relocation and hot tapping operations with zero accidents or environmental incidents.
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On-Time Delivery: All work was completed efficiently, ensuring no delays to the critical path of the high-speed rail project.
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Long-Term Infrastructure Integrity: The newly installed section ensures the safe, reliable operation of the oil pipeline for decades to come, coexisting securely with the new rail infrastructure.
Client Testimonial:
“The complexity of working on a live high-pressure pipeline next to a national-level infrastructure project cannot be overstated. Beijing Jinshiwan’s expertise was the differentiator. Their methodical approach and mastery of hot tapping and stoppling technology gave us absolute confidence. They delivered a perfect safety and operational record, turning a major project risk into a resounding success.”
— Project Manager, Sichuan Renshengxin Construction Co., Ltd.
This project for the Xiongshang High-Speed Rail is a testament to how technical expertise can solve complex industrial challenges. For pipeline construction companies and asset owners facing the dilemma of maintaining flow while modifying infrastructure, in-service pipeline modification is not just an option—it’s the most reliable and economical solution.
Is your next project facing a similar challenge with a critical pipeline?
Contact Beijing Jinshiwan Pipeline Technology today. Let our experience become your advantage.
