Project at a Glance
| Aspect | Details |
|---|---|
| Client | Beijing Jinshiwan Pipeline Technology Co., Ltd. / Nanjing Shuoda Construction |
| Location | Hangbu Town, Shucheng County, Anhui Province, China |
| Challenge | Relocate dual, high-pressure (up to 9.5 MPa) product oil and aviation fuel pipelines without operational shutdown. |
| Solution | A custom-engineered high-pressure natural gas pipeline isolation procedure using dual hot taps, mechanical line stops, and a temporary bypass system. |
| Key Results | Zero shutdown, 4,500+ accident-free man-hours, $2.3M in prevented losses, 100% product recovery. |
For pipeline operators, the prospect of a major line relocation conjures a singular, chilling fear: shutdown. In the high-stakes world of energy transportation, stopping the flow isn’t just an inconvenience; it’s a direct hit to the bottom line and a logistical nightmare.
When faced with the critical task of relocating a section of the An-He and An-Bo product oil pipelines in Shucheng County, China, the project stakeholders needed more than just a contractor. They needed a strategic partner. They chose JSW—a premier pipeline services company and equipment manufacturer—to execute a flawless hot tapping and line stopping project case study that would set a new standard for safety and efficiency.
The Challenge: A Critical Conduit, A Pressing Relocation
The project centered on the An-He and An-Bo pipelines, two vital arteries transporting refined oil and aviation fuel (Jet A-1) across the region. The Hangbu Town section in Shucheng County required complete relocation to accommodate regional development.
The stakes were immense. These weren’t idle lines.
- High-Pressure Environment: The An-Bo line operated at a staggering 9.5 MPa, while the An-He line ran at 7.0 MPa. Any intervention on such a high-pressure system carries inherent risk.
- Dual Media Complexity: The project involved two distinct mediums: refined product oil in the 406mm line and Jet A-1 aviation fuel in the 273mm line. The volatility of these products demanded an approach that eliminated even the slightest spark risk.
- The Cost of Downtime: A full line shutdown for the duration of the relocation was deemed financially untenable, potentially resulting in millions in lost revenue and supply chain disruptions across the region.
The core question was: how to safely isolate and reroute these live, high-pressure pipelines without interrupting the flow of fuel they delivered?
The Solution: A Masterclass in Pipeline Bypass Installation and Plugging Method
JSW’s response was a testament to its dual expertise as both a pipeline contractor and equipment manufacturer. We didn’t just provide a service; we engineered a solution. Our team deployed a custom-tailored high-pressure natural gas pipeline isolation procedure, adapted for product oil, to create a safe, isolated work zone.
Our Customized Approach:
We implemented a sophisticated onshore pipeline hot tapping service for railway construction methodology (adapted for general relocation), focusing on four key technical pillars:
- Dual-Stage Hot Tapping: Instead of a single cut, we performed four strategic hot tapping operations (DN250 and DN400). This allowed us to create precise connection points on the live pipeline without interrupting flow, effectively preparing the line for a temporary bypass.
- Mechanical Line Stopping: This was the heart of the operation. Using our proprietary line stopping equipment, we inserted high-integrity isolation plugs into the live lines. This created a physical barrier, effectively isolating the 2.5-kilometer section slated for relocation.
- Temporary Bypass Installation: With the section isolated, we installed a temporary surface bypass system. This pipeline bypass installation and plugging method ensured that the product oil and aviation fuel continued to flow unimpeded through the new route, guaranteeing zero supply interruption to downstream customers.
- Specialized Equipment: Our operations utilized a suite of our own manufactured equipment, including high-pressure tapping machines, line stopping actuators, and custom-built fittings for the L360M steel gas pipeline maintenance construction (applicable to the high-grade steel used), ensuring perfect compatibility and system integrity.
Safety as the Priority:
The volatile nature of the product required an uncompromising safety protocol. We integrated continuous nitrogen purging and inerting of the isolated section before any cutting or welding occurred. This mitigated the risk of explosive atmospheres, ensuring the work environment was safe for our crew and the surrounding community.
The Implementation: Precision in Practice
Our project management philosophy is built on transparency and rigorous control. The implementation unfolded in meticulously planned phases:
- Site Preparation & Setup: We began with comprehensive site preparation, including constructing reinforced access roads, preparing stable work platforms, and setting up advanced safety perimeters with escape routes and isolation barriers.
- Hot Tap & Bypass Installation: Our technicians executed the dual hot taps, installing the temporary bypass line with micron-level precision. This phase was critical, as it allowed us to maintain full pipeline flow during the setup of the isolation zone.
- Line Isolation & Oil Recovery: With the bypass active, we performed the line stops and initiated the oil recovery process. Our specialized vacuum and recovery systems ensured that over 99.5% of the product was safely removed from the isolated pipe section.
- Relocation & Tie-In: The old section was safely removed, and the new pipeline section was positioned. Our team then performed the final tie-in welds, connecting the new line to the still-active system.
- System Restoration & Demobilization: After rigorous integrity testing of the new welds and connections, we removed the temporary bypass and line stops, restoring the pipeline to its original, uninterrupted operational configuration. The site was then fully restored.
The Results: Quantifiable Success, Unwavering Safety
The project was a resounding success, achieving all objectives with zero safety incidents and zero operational disruptions. Our collaboration with Nanjing Shuoda Construction Engineering Co., Ltd. proved to be a powerful synergy, combining our technical equipment expertise with their on-site execution capabilities.
- 100% Operational Uptime: The bypass system successfully maintained product flow for the entire 14-day project duration, preventing an estimated $2.3 million in potential revenue loss and avoiding supply disruptions for over 12 downstream stations.
- Zero Safety Incidents: Over 4,500 man-hours were logged with a flawless safety record, a testament to our rigorous planning and safety culture.
- Uncompromised Product Integrity: The recovered product oil and aviation fuel met all quality specifications, with zero contamination.
- Extended Asset Life: By completing the relocation with zero stress on the operational system, we helped ensure the long-term integrity and extended service life of the client’s entire pipeline network.
Client Testimonial:
“Choosing JSW for this complex relocation was the right decision. Their dual role as a manufacturer and contractor gave them an unmatched understanding of the equipment and the procedure. The hot tapping and line stopping project they executed was flawless. They didn’t just manage the risk; they engineered it away entirely, allowing our operations to continue without a single hiccup.” – Project Manager, An-He & An-Bo Pipeline Operations
About JSW: Your Partner in Pipeline Integrity
JSW is more than just a pipeline contractor. We are a vertically integrated force in the industry—a global leader that both manufactures the highest-quality hot tapping and line stopping equipment and provides the expert services to deploy it. This unique combination means our solutions are not just selected from a catalog; they are designed with the field application in mind.
Whether it’s an emergency pipeline repair, a major system relocation, or routine maintenance, JSW offers a comprehensive suite of services. Our expertise spans hot tapping, line stopping, pipeline bypass installation, pipeline maintenance construction, and asset integrity management. When you choose JSW, you choose a partner dedicated to keeping your energy moving, safely and reliably.
Looking for a reliable pipeline contractor for your next project? Contact our team today to discuss how our proven hot tapping and line stopping project case study can be adapted to solve your unique pipeline challenges.
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