Project Overview
- Client: Shanxi Tongyu Coalbed Methane Pipeline Distribution Co., Ltd.
- Location: Bo’ai County, Jiaozuo City, Henan Province, China
- Challenge: To reroute a critical section of a high-pressure (6.3 MPa) natural gas pipeline without interrupting the supply, thereby avoiding massive economic losses and supply disruptions.
- Solution: Executed a live-line pipeline installation and tie-in using advanced Hot Tapping and Double Block and Bleed (DBB) technology.
- Results:
- Zero Interruption: Mainline gas supply was maintained throughout the project.
- 100% Safety: Achieved a perfect zero-accident safety record.
- On-Schedule Execution: Completed the critical tapping and tie-in operations within the planned window.
- Quality Assurance: All welds, hydrostatic, and pneumatic tests passed on the first attempt.
The Challenge: Relocating a Critical Artery Without Stopping the Heartbeat
Imagine being asked to perform open-heart surgery on a patient while they are still running a marathon. This was the scale of the challenge presented to us by Shanxi Tongyu Coalbed Methane Pipeline Distribution Co., Ltd.
The construction of the new North Henan LNG Emergency Reserve Center necessitated the relocation of a section of the vital Duanbo Line. This was not just any pipeline installation job. This was a high-pressure natural gas pipeline (6.3 MPa), a crucial energy artery, where any planned shutdown for pipeline maintenance or replacement would result in massive economic losses and disrupt supply to countless end-users.
The client’s core requirements were non-negotiable:
- Zero Interruption: The main pipeline’s gas supply must not be halted.
- Absolute Safety: Working on a live, high-pressure gas line demanded a flawless safety record.
- Minimal Environmental Impact: The project involved road crossings and required meticulous site restoration.
The question was: How do you replace a section of a live, high-pressure pipeline without depressurizing it? The answer lay in our core expertise.
The Solution: A Customized Engineering Plan Centered on Hot Tapping & Double Block and Bleed
As a leading pipeline contractor in China, Beijing Jinshiwan designed a sophisticated pipeline engineering services plan centered on the precise application of Hot Tapping and Stoppling technology.
Our solution was a textbook example of the Double Block and Bleed (DBB) procedure, which provides the highest level of safety for live-line interventions.
Our Customized Technical Approach:
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Pre-Construction & New Pipeline Installation:
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We managed the entire scope of the new 920-meter DN550 pipeline construction, including surveying, stringing, welding, bending, lowering-in, and backfilling.
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All welds underwent rigorous Non-Destructive Testing (NDT). The new section was hydrostatically tested to 9.45 MPa (1.5x design pressure) and passed pneumatic tests to ensure ultimate integrity before being tied into the live system.
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The Critical Live-Line Intervention – A Two-Step Process:
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Step 1: Hot Tapping. We used a specialized drilling machine to safely create an opening into the live, pressurized pipeline. This allowed us to install the temporary bypass and later, the stoppling equipment, without any gas escape.
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Step 2: Stoppling (Double Block and Bleed). This is where our expertise shone. At the designated upstream location, we installed two sequential stopples (primary plugs). The cavity between them was safely bled down, creating an isolated, gas-free work zone for the final tie-in. This complex pipeline maintenance procedure completely eliminated the need for a system-wide shutdown.
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Technology & Equipment: The success of this operation hinged on our use of state-of-the-art, certified hot tapping and stoppling machines from industry leaders, operated by our extensively trained and certified engineers.
The Implementation: Precision Engineering and Meticulous Execution
Our project management and technical prowess were put to the test during the execution phase. The key steps unfolded with clockwork precision:
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Phase 1: Preparation. The new pipeline section was constructed and tested independently. Temporary bypass lines were fabricated and all equipment was pressure-tested and calibrated.
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Phase 2: The Main Event – Hot Tapping & Stoppling. Over a concentrated 48-hour window, our crew executed the planned hot tapping and stoppling sequence. Under the constant monitoring of gas detection systems, the double block and bleed isolation was successfully achieved.
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Phase 3: Tie-In and Commissioning. With the section safely isolated, our welders performed the final two tie-in welds. Following rigorous inspection, the stopples were retracted, the line was recommissioned, and the temporary bypass was removed. The entire process was completed without a single safety incident, underscoring our commitment to risk-free pipeline installation.
The Results & Quantifiable Benefits: Zero Downtime, 100% Success
The collaboration between Shanxi Tongyu and Beijing Jinshiwan delivered outcomes that exceeded expectations.
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Financial Impact: We saved the client from an estimated multi-million RMB loss that would have resulted from a traditional shutdown method.
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Safety Performance: Achieved a perfect zero-accident record during the entire high-risk pipeline construction and live-line operation.
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Operational Integrity: Guaranteed uninterrupted natural gas supply to downstream customers, reinforcing the client’s reputation for reliability.
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Project Quality: All welds, the hydrostatic test, and the final pneumatic test were passed on the first attempt, a testament to our quality control in pipeline engineering services.
Client Testimonial:
“The Beijing JSW team demonstrated why they are a top-tier pipeline company in China. Their mastery of hot tapping and stoppling technology gave us the confidence to proceed with this complex relocation without fear of supply disruption. Their ‘safety-first’ culture and precise execution were evident throughout the project. They turned a high-stakes challenge into a seamless success.”
— Project Manager, Shanxi Tongyu Coalbed Methane Pipeline Distribution Co., Ltd.
Is Your Pipeline Project Demanding a Zero-Interruption Solution?
If you are facing a complex pipeline maintenance, relocation, or repair challenge on a high-pressure line, the proven methodology showcased in this case study can be your solution.
Don’t let the risk of downtime dictate your project timeline. Contact Beijing Jinshiwan today for a confidential consultation. Let our expertise in live-line pipeline engineering services secure your operations and your bottom line.
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