Project Overview
| Project Name | WenChao River Pipeline Relocation – Section 1 |
|---|---|
| Client | Beijing Water Construction and Management Center |
| Location | Beijing, China |
| Challenge | Relocate 750m of active high-pressure (10 MPa) oil and aviation fuel pipelines to accommodate new river construction without service interruption. |
| Solution | Custom Hot Tapping and Line Stopping Project with a temporary bypass installation to isolate the section and maintain flow. |
| Key Results | Zero downtime, 100% safety record, on-time project completion. |
In the realm of infrastructure development, the most successful projects are often those that go unnoticed. When the Beijing Water Construction and Management Center initiated the WenChao River Diversion Project, a critical challenge emerged: the proposed river path intersected with two active, high-pressure energy arteries vital to the capital’s operations. This onshore pipeline hot tapping service for railway construction (and in this case, river construction) showcases the precision and reliability required to execute a complex pipeline relocation without interrupting the flow of energy.
The Challenge: A High-Pressure Conflict
The core challenge was a physical conflict between the new river course and the existing pipelines. These were no ordinary lines. The project involved the relocation of a Sinopec refined oil pipeline and an aviation fuel pipeline—a combined 750 meters of infrastructure operating under extreme conditions.
- Pipeline 1 (Sinopec): Transporting refined oil at a design pressure of 10 MPa, with a diameter of D323.9×7.1mm.
- Pipeline 2 (Sinopec): Transporting aviation fuel (jet fuel) at a design pressure of 6.4 MPa, with a diameter of D273.1×6.4mm.
For the client, Beijing Water Construction and Management Center, a traditional shutdown was not a viable option. A shutdown would have meant:
- Massive Financial Loss: Halting the flow of fuel to Beijing would have incurred penalties and lost revenue.
- Supply Chain Disruption: Jet fuel supply to the airport and refined oil to the city would be at risk.
- Safety Hazards: The process of de-pressurizing, purging, and later re-pressurizing such high-pressure lines introduces its own set of significant risks.
They needed a high-pressure natural gas pipeline isolation procedure, adapted for liquid hydrocarbons, that would allow them to “cut” a section of the live pipeline out and connect the new section seamlessly. This is where our expertise as a specialized pipeline contractor came into play.
The Solution: A Customized Pipeline Bypass Installation and Plugging Method
Our team at JSW proposed a turnkey solution centered around a pipeline bypass installation and plugging method. This approach allows the mainline to remain operational while a section is isolated and removed.
Instead of a shutdown, we implemented a live hot tapping and line stopping project case study in action. The strategy involved three key phases, utilizing our proprietary equipment designed and manufactured in-house.
- Bypass Installation: We performed two hot taps on the upstream and downstream sides of the section to be relocated. A temporary bypass line was then installed, creating an alternate flow path. This allowed us to redirect the entire flow of refined oil and aviation fuel through the bypass, ensuring uninterrupted service to the end-users.
- Line Stopping (Isolation): With the flow safely diverted, we inserted line-stopping plugs into the original mainline. This effectively isolated the 750-meter section, creating a safe, depressurized work zone.
- Relocation and Tie-In: The isolated section was cut out, and the new pre-fabricated pipeline section was connected. The primary technologies used were L360M steel gas pipeline maintenance construction techniques, chosen for their compatibility with the high-strength steel of the existing lines.
Our ability to provide both the services as a contractor and the equipment as a manufacturer gave us an unparalleled advantage. We didn’t just plan the procedure; we engineered and supplied the specialized hot tapping machines, line stopping actuators, and bypass fittings, ensuring complete quality control.
The Implementation Process: Precision Under Pressure
Executing a project of this magnitude requires more than just technical know-how; it demands meticulous planning and project management. Our company’s approach was methodical:
- Phase 1: Engineering & Simulation: We began with a detailed engineering review of the site. We used 3D modeling to simulate the bypass installation and plugging method, identifying potential interferences with the L360M steel before a single weld was made.
- Phase 2: Site Preparation & Safety Protocols: The construction site was prepared with reinforced excavation and shoring. A 24/7 gas monitoring system was deployed to ensure absolute safety.
- Phase 3: Live Hot Tap Operations: The critical moment. Under the supervision of our senior engineers, two simultaneous hot taps were performed on the high-pressure lines. The precision was paramount—any deviation could have compromised the integrity of the 10 MPa pipeline.
- Phase 4: Bypass Activation & Line Stopping: With the hot taps completed and the bypass valves opened, we activated the line stops. The seamless transition of flow was confirmed by monitoring pressure gauges on both the mainline and the bypass.
- Phase 5: Relocation, Tie-in & Restoration: The 750-meter segment was removed, the new section welded in, and all connections were 100% non-destructively tested (NDT). The line stops were then retracted, and the flow was gradually transitioned back to the newly installed permanent pipeline.
The Results & Client Endorsement
The project was completed on schedule, achieving a 100% safety record with zero incidents. The client’s core objectives were not only met but exceeded.
- Uninterrupted Operations: The pipeline bypass installation and plugging method allowed for zero disruption to the flow of refined oil and aviation fuel throughout the project duration.
- On-Time Delivery: The project timeline of April 2024 was achieved, meeting the critical path requirements of the larger WenChao River Diversion project.
- Enhanced Safety: The customized onshore pipeline hot tapping service for railway construction (adapted for waterway construction) eliminated the risks associated with a full system shutdown and re-start.
“The WenChao River relocation was a high-consequence project. JSW’s ability to provide a complete solution—from engineering a complex bypass installation and plugging method to deploying their own hot tapping equipment—was instrumental to our success. Their team acted not just as a contractor, but as a true partner, managing the high-pressure natural gas pipeline isolation procedure (adapted for our liquid lines) with exceptional technical skill and safety discipline. They delivered peace of mind.”
— Project Manager, Beijing Water Construction and Management Center
About JSW Pipeline Services
JSW stands as a premier integrated pipeline services company, uniquely positioned as both a specialized pipeline contractor and an innovative equipment manufacturer. We provide end-to-end services including oil and gas pipeline relocation, new installation, emergency repair, hot tapping, line stopping, and maintenance.
Our dual identity means we don’t just rely on third-party tools; we engineer and build the equipment that drives our solutions. This synergy ensures unparalleled reliability, efficiency, and cost-effectiveness for complex onshore projects. When you choose JSW, you partner with a team that combines the ingenuity of a manufacturer with the field-tested experience of a leading contractor.
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