*In June 2023, a high-risk section of the East China Crude Oil Pipeline was successfully replaced without a single minute of shutdown, thanks to precision hot tapping and plugging technology. The 9-day operation eliminated critical encroachment risks, ensuring continuous energy supply and long-term pipeline integrity for the National Pipeline Network.*
Facing a critical safety hazard where above-ground structures encroached upon a major crude oil pipeline in Jiaxing, the client, National Pipeline Network Eastern Crude Oil Storage and Transportation Co., Ltd. Ningbo Oil Transportation Department (NPN Ningbo), needed an urgent solution. The conventional method of shutting down the pipeline for repair was not an option due to the massive economic and operational disruptions it would cause.
This case study details how JSW Pipeline Solutions, a leading integrated pipeline services contractor and equipment manufacturer, executed a complex pipeline relocation project using advanced hot tapping and plugging technology. Our mission was clear: perform a “bypass surgery” on this critical energy artery while it remained fully operational.
Project Snapshot
| Project Element | Details |
|---|---|
| Client | National Pipeline Network Eastern Crude Oil Storage and Transportation Co., Ltd. (Ningbo Department) |
| Location | Nanhu District, Jiaxing, Zhejiang Province, China |
| Core Challenge | Eliminate severe building encroachment on a live, large-diameter (762mm) high-pressure crude oil pipeline without shutdown. |
| JSW Solution | Custom-engineered Double Block and Bleed (DBB) procedure using hot tapping and plugging to isolate and replace a 1.04km pipeline section while maintaining flow through a temporary bypass. |
| Key Results | 1. 100% Safety Record: Zero leaks, zero spills, zero safety incidents. 2. Zero Operational Impact: Continuous crude oil supply throughout the project. 3. Project Success: Hazard permanently eliminated on schedule, restoring full pipeline integrity. |
The Critical Challenge: Performing Major Surgery on a Live Energy Artery
The section of the Ningbo-Shanghai-Nanjing pipeline near stake 181# in Jiaxing’s Nanhu District presented a severe and urgent threat. The pipeline integrity was compromised by long-term building encroachment, creating a significant risk of rupture or leak.
- The Imperative of Zero Interruption: As a vital artery in China’s national energy grid, any shutdown of this crude oil pipeline would result in staggering financial losses for the client and disrupt downstream refinery operations across the region. An on-line pipeline repair was the only viable path forward.
- Operating Under Extreme Conditions: The technical demands were immense. The work had to be performed on a large-diameter (762mm), thick-walled (10.3mm) pipeline carrying live crude oil under pressure (1.0 MPa operating, 8.5 MPa design). The margin for error was zero.
- Navigating a Constrained Environment: The project site in an urban fringe area of Jiaxing demanded strict adherence to environmental, safety, and scheduling protocols. Every step had to be meticulously planned and executed without incident.
Our Engineered Solution: Custom Double Block and Bleed Hot Tapping & Plugging
JSW deployed its proprietary Double Block and Bleed (DBB) with Temporary Bypass methodology, the industry’s gold standard for safe, on-line pipeline repair and modification.
This procedure allows a section of pipeline to be completely isolated and worked on while product flow is maintained through a temporary bypass line.
The Technical Workflow: A Four-Act Operation
- Precision Hot Tapping: Specialized split tees were welded onto the pipeline at calculated upstream and downstream locations. Using hot tapping machines, precise openings were cut into the live pipe, all without any product release.
- Establishing the Bypass: Temporary piping was connected to the newly installed taps, creating a parallel flow path for the crude oil. Flow was then seamlessly diverted, maintaining 100% throughput.
- Absolute Isolation via Plugging: Once the bypass was confirmed operational, plugging heads were inserted through the tap fittings. These heads were expanded to form a perfect mechanical seal inside the pipeline, creating a double-isolated “work zone” on the 1.04km section slated for replacement.
- Safe Section Replacement: The isolated segment was depressurized, purged, and made safe for cutting. Using cold-cutting (no-spark) technology, the old pipe was removed. The new, pre-tested pipeline section was aligned, welded, inspected, and the system was restored by reversing the plugging and bypass process.
The JSW Advantage: Integration of Manufacturing and Service
As both the equipment manufacturer and the field contractor, JSW controlled the entire quality chain. The custom-built DBB equipment used on this project offered unparalleled reliability:
- Dual-Seal Security: Redundant sealing mechanisms provided a fail-safe isolation barrier, mitigating the primary risk of hydrocarbon release.
- Real-Time Monitoring Hub: Continuous monitoring of plug cavity pressure and bypass flow rates allowed for instant intervention if any parameter drifted.
- Purpose-Built for Large Diameters: Our equipment is engineered specifically for the challenges of large-diameter, high-pressure pipelines, ensuring smooth operation under the demanding conditions of this crude oil pipeline repair.
Execution: Nine Days of Flawless Precision
From June 19 to June 27, 2023, the JSW team executed the plan with military precision.
- Days 1-3 (Mobilization & Prep): Site establishment, excavation, bypass prefabrication, and rigorous equipment checks. All procedures were reviewed under a strict Permit-to-Work system.
- Days 4-5 (Critical Hot Taps): Successfully performing the four main hot taps was the project’s first major milestone. Each operation was completed without incident, a testament to the skill of our certified technicians.
- Days 6-7 (Isolation & Removal): Plugging heads were set, and isolation was verified. The old pipeline section was safely decommissioned, cut, and removed. The site remained fully compliant with all environmental controls.
- Days 8-9 (Tie-In & Restoration): The new pipeline section was welded in place. Every weld underwent 100% radiographic (RT) and ultrasonic (UT) inspection. Finally, the plugs were retrieved, the bypass was disconnected, permanent blinds were installed, and all fittings received new 3PE corrosion coating.
Measurable Results & Client Benefits
The success of this pipeline relocation construction project delivered immediate and lasting value.
Quantifiable Outcomes:
- Risk Eliminated: The critical encroachment hazard was permanently removed, safeguarding the community, environment, and the client’s asset.
- Zero Supply Disruption: The client’s operations continued uninterrupted. Not a single barrel of throughput was lost during the entire construction window, preserving millions in potential revenue.
- On-Time, On-Budget Delivery: All high-risk activities were completed within the tight 9-day schedule, demonstrating superior project management and technical execution.
Client Testimonial:
“The encroachment issue at our Jiaxing section was a top-level safety concern. JSW’s proposal for a non-stop repair using their advanced hot tapping and plugging technology was the optimal solution. Their team’s professionalism, from engineering to field execution, was exceptional. They turned a high-risk challenge into a textbook example of safe and efficient pipeline integrity management.”
— Project Manager, National Pipeline Network Ningbo Oil Transportation Department
About JSW: Your Partner for Pipeline Integrity
JSW is not just a services company or an equipment vendor. We are a solutions provider that integrates manufacturing with field contracting.
This unique model means we take full responsibility for project outcomes. We deploy our own engineered equipment, operated by our own certified experts, ensuring unmatched reliability and accountability for clients like National Pipeline Network, Sinopec, and PetroChina.
Our core services encompass the full lifecycle of pipeline assets:
- Pipeline Engineering & Relocation Construction
- Hot Tapping and Plugging Services
- Pipeline Integrity Maintenance Programs
- Emergency Pipeline Repair & On-Site Machining
- Pipeline Commissioning & Decommissioning
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