Project Snapshot:
| Category | Details |
|---|---|
| Client | International Energy Major (EPC Project) |
| Location | Ningbo, China |
| Core Challenge | Execute 12 hot taps on live, high-pressure (7.0 MPa) natural gas and high-temperature (300°C) thermal oil pipelines made of high-grade steel (X60/L415Q) with thick, non-standard walls, without shutdown. |
| JSW Solution | Custom-engineered hot tapping services, including design/fabrication of heavy-duty fittings, stringent welding procedures, and deployment of proprietary high-capacity drilling equipment. A full-scope EPC support service. |
| Key Results | Zero shutdowns achieved. 100% success rate on all connections. Flawless safety record. Client’s expansion timeline and continuous production guaranteed. |
Project Challenge: Performing “Heart Bypass Surgery” on a Live “Energy Artery”
For any major LNG receiving terminal, its internal pipeline system is a vital “energy artery” where failure is not an option. When our client — a leading international energy company — advanced the third-phase expansion and modification EPC project at its Ningbo Terminal, they faced a critical pipeline modification challenge: adding new connections to live pipelines carrying 300°C thermal oil and high-pressure natural gas (up to 7.0 MPa) without a single shutdown.
A full shutdown would have meant staggering production losses, measured in millions per day. The technical hurdles were formidable:
- Extreme Parameters: Simultaneous high-temperature (300°C) hot tapping on thermal oil lines and high-pressure (7.0 MPa) hot tapping on gas lines.
- Demanding Materials: Working on high-grade steel (X60, L415Q) pipelines with non-standard diameters (D717, D660) and extra-thick walls (up to 30mm pipe, 50mm fitting reinforcement).
- Zero-Margin for Error: Operations were on critical infrastructure where safety and integrity were paramount. Any flaw in welding or the under-pressure drilling process could lead to catastrophic failure.
They needed more than just a contractor; they needed a partner with proven expertise in specialized pipeline hot tapping services capable of handling such a complex EPC scope. That’s where JSW Pipeline Services was engaged.
Our Solution: A Tailored Engineering Protocol for Precision Live Intervention
As a company that is both a specialized pipeline services contractor and a manufacturer of related equipment, JSW approached this not as a standard job, but as an engineered project. Our solution was a multi-layered, custom-designed protocol:
1. Engineered Fitting & Advanced Welding:
We designed and fabricated full-encirclement split tees with 50mm-thick reinforcing pads to manage stress. Our certified welders executed stringent Welding Procedure Specifications (WPS) for X60 and L415Q materials, involving pre-heat, controlled interpass temperature, and Post Weld Heat Treatment (PWHT) where necessary, all monitored and documented to ensure integrity equal to the parent pipe.
2. Proprietary Hot Tapping Equipment:
We deployed our own large-stroke, high-torque hot tapping machines (JSW-HT Series), specifically designed for thick-wall pipeline drilling. These machines feature enhanced stability and cutting tool technology to handle the high-grade steel efficiently and safely under full pressure.
3. Rigorous Risk-Mitigated Execution Plan:
Every hot tap service was preceded by a Job Safety Analysis (JSA) and a detailed “hold point” procedure. Our methodology for under pressure drilling included dual-valve isolation, pilot hole verification, and continuous pressure monitoring throughout the cutting process.
Implementation: Flawless Execution Through Military-Grade Precision
Our role as the specialist EPC pipeline services partner involved seamless integration with the main contractor’s schedule. The key phases were:
- Phase 1: Fit-for-Purpose Preparation. Site surveys, procedure qualification, and fit-up of custom fittings using laser alignment for perfect orientation.
- Phase 2: Critical Welding Campaign. Execution of thick-wall welds under controlled conditions, followed by 100% Non-Destructive Testing (NDT) via Ultrasonic Testing (UT) and Radiographic Testing (RT).
- Phase 3: The Live Tap. Mounting the tapping machine, pressure testing the assembly, and performing the pipeline hot tapping. The drilling of the D717 high-pressure gas line was a pinnacle moment, requiring meticulous control as the cutter penetrated the 19.1mm thick X60 steel under 7.0 MPa.
- Phase 4: Completion & Handover. Machine retrieval, installation of the completion plug, final testing, and corrosion coating application. All waste (coupons) was safely contained and removed.
Results & Benefits: Delivering Quantifiable Value Beyond the Task
The success of this pipeline modification service was measured in safety, reliability, and economics.
Quantifiable Outcomes:
- Zero Safety or Environmental Incidents: Perfect HSE record throughout the project.
- 100% Operational Continuity: All 12 hot taps were completed without requiring a shutdown, saving the client an estimated multi-million-dollar loss in potential production downtime.
- 100% Success Rate: All connections were completed on schedule, passed all integrity tests, and are fully operational.
- Future-Proof Design: The installed tee fittings with internal debris filters ensure no interference with future pipeline inspection gauges (PIGs).
Client Feedback:
“The JSW team managed our most critical pipeline intervention with outstanding professionalism. Their dual capability as equipment makers and field specialists was evident. They engineered solutions for our unique thick-wall, high-pressure taps, not just applied standard tools. Their work ensured our expansion stayed on track without disrupting terminal operations for even a minute.”
— Project Manager, Client EPC Team
Why JSW Pipeline Services is Your Trusted Partner
This Ningbo Terminal project exemplifies the core of JSW. We are not just a service company; we are a technology-integrated contractor. As both manufacturers and practitioners, we control the entire value chain—from designing the right equipment for the job to executing the field work with unparalleled know-how.
Our service portfolio includes:
- Hot Tapping & Plugging Services: For all diameters, pressures, and media.
- Pipeline Emergency Response & Repair: 24/7 readiness for urgent interventions.
- Pipeline Commissioning & Modifications: Supporting EPC projects globally.
- Preventive Maintenance & Integrity Solutions: Extending asset lifecycles.
We combine engineering excellence with field-proven experience to deliver pipeline solutions that are safe, efficient, and economically superior.
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