Project Overview
| Aspect | Details |
|---|---|
| Client | A Major Pipeline Operator in China |
| Location | Yueyang County, Hunan Province, China |
| Core Challenge | A critical high pressure pipeline segment was in dangerously close proximity to residential buildings, posing a significant public safety risk. Traditional repair methods would require a prolonged, costly full-line shutdown. |
| Our Solution | A planned shutdown operation utilizing double block and bleed plugging technology. This allowed for the safe repair and replacement of the compromised section without interrupting the flow in the main pipeline. |
| Key Results | • 100% Safety Record: Zero incidents, zero injuries, zero environmental releases. • Minimal Disruption: Critical pipeline flow was maintained for 95% of the project duration. • On-Time Completion: All pipeline plugging services and the tie-in were completed within the critical 5-day window. • Risk Eliminated: The structural and safety threat to the nearby community was permanently removed. |
The Critical Challenge: An Unacceptable Risk in a Sensitive Location
Our client, a national energy infrastructure operator, faced a severe pipeline integrity emergency. A section of their vital Changsha-Chenzhou (Chang-Chen) petroleum pipeline, located in Yueyang County, Hunan, passed alarmingly close to a residential area in Wuyuan Township.
-
The Asset: The line was a DN406.4mm (16-inch) high-pressure trunk line, transporting refined products at a design pressure of 10MPa.
-
The Risk: The proximity to occupied dwellings created an intolerable public safety hazard. Any potential leak or failure could have catastrophic consequences. This was a classic “encroachment” hazard that demanded immediate resolution.
-
The Client’s Pain Point: A conventional pipeline repair and replacement would necessitate a complete and extended pipeline shutdown operation. For our client, this meant:
-
Massive revenue loss from interrupted product delivery.
-
Complex logistics and potential supply chain disruptions for downstream customers.
-
An extended period of elevated risk until the repair was complete.
-
The question was clear: How do you completely replace a section of a live, high-pressure fuel pipeline, in a high-risk location, without causing a prolonged shutdown? This is where our expertise as a specialized pipeline repair contractor provided the answer.
Our Engineered Solution: Precision, Safety, and Zero Interruption
We proposed and executed a double block and bleed plugging plan—the industry gold standard for safe, non-disruptive modifications to live lines. This hot tapping and plugging procedure is not just a service we offer; it’s a core competency that defines our company’s commitment to innovation and safety.
The Technical Strategy:
-
Isolate the Segment: We engineered a plan to install two DN400 plugging heads upstream and downstream of the compromised section. Between them, a bleed (vent and balance) line would ensure the isolated segment was completely depressurized and safe for cutting.
-
Maintain Flow: Critically, the main pipeline would remain in service throughout the hot tapping (the process of safely drilling into the live pipe) and plugging head installation phases.
-
Execute the Replacement: Only after the dual isolation was verified would we perform cold cutting, remove the old pipe section, weld in the new L415M steel replacement spool, and perform non-destructive testing.
Why This Solution Was Superior:
-
Eliminated Shutdown Losses: The client avoided millions in potential lost revenue.
-
Maximized Safety: The double block and bleed method provided two independent mechanical barriers, ensuring the work area was completely isolated from product and pressure.
-
Proven Technology: As an experienced contractor, we utilize only certified equipment (like hydraulic hot tapping machines and plugging heads) and procedures, ensuring reliability.
The Execution: A Symphony of Specialized Services
As the lead pipeline plugging services contractor, our role encompassed end-to-end project management and execution of the critical isolation phases:
-
Preparation & Engineering: Our team conducted detailed site surveys and engineered the specific fitting assemblies. We provided all specialized equipment, including DN400 and DN50 hot tap machines, plugging heads, temporary block valves, and bypass systems.
-
Hot Tapping: Under strict high pressure pipeline maintenance protocols, we expertly performed four hot taps—two for the main DN400 plugging points and two for the DN50 balance lines.
-
Plugging & Isolation: We successfully set the two primary pipeline plugs, creating a secure, product-free work zone. The isolated section was then purged, making it safe for the client’s welding crews to perform the pipeline replacement.
-
Quality & Safety Controls: Every step was governed by a Special Class Hot Work Permit. We implemented rigorous electrostatic discharge grounding after cutting and maintained continuous atmospheric monitoring.
Measurable Results and Lasting Value
The success of this DN400 pipeline plugging project is defined by hard data and client satisfaction:
-
Zero Incidents: The project was completed with a perfect safety and environmental record, paramount for an operation near a community.
-
Schedule Adherence: All hot tapping and plugging operations were completed within the tight 72-hour critical path window, enabling the overall project to finish on schedule by May 27, 2024.
-
Operational Integrity: Post-replacement pressure testing and inline inspection runs confirmed the integrity of the new section and the success of the isolation procedure. The pipeline was returned to full 10MPa service with enhanced safety margins.
-
Client Testimonial: “Facing a high-stakes repair in a sensitive location, we needed a contractor with impeccable technical skill and safety discipline. Their team’s command of the double block and bleed procedure turned a potential crisis into a seamlessly executed project. They weren’t just a vendor; they were true partners in risk management.” — Project Manager, Client Company.
English