When a major infrastructure project like a high-speed railway intersects with an active high-pressure energy pipeline, the stakes are incredibly high. The pipeline operator faces a critical challenge: how to safely relocate a section of the line without disrupting the flow of vital energy resources. This onshore pipeline hot tapping service for railway construction case study details how our team, acting as a specialized contractor, successfully navigated this complex scenario.
We executed a turnkey solution for Nanjing Shuoda Engineering Co., Ltd., combining advanced pipeline bypass installation and plugging methods with precision L360M steel gas pipeline maintenance construction techniques. The result was a seamless pipeline relocation that eliminated safety risks and avoided any operational downtime.
Project Overview
| Item | Detalles |
|---|---|
| Client | Nanjing Shuoda Engineering Co., Ltd. |
| Location | Anhui Province, China |
| Project | Anhe & Anhao Pipelines Relocation for Anjiu High-Speed Railway |
| Challenge | Safely relocate two active, high-pressure pipelines crossing a new railway construction site. |
| Solution | Custom-engineered hot tapping and line stopping with B-Type sleeve repairs and oil recovery. |
The Challenge: When Infrastructure Clashes
The Anjiu High-Speed Railway project necessitated the relocation of two critical pipelines: the Anhao (成品油) and Anhe (aviation fuel) lines. The pipelines, operating at pressures of 9.5 MPa and 7.0 MPa respectively, were located directly in the railway’s path.
For the pipeline operator, a traditional shutdown was not an option. Any interruption to the flow of refined products and jet fuel would have resulted in:
- Massive Financial Losses: Millions in lost product revenue and demurrage costs.
- Supply Chain Disruption: Critical fuel shortages for regional airports and markets.
- Significant Safety Risks: Purging, cutting, and reconnecting a live, high-pressure pipeline presents extreme hazards.
Our client, Nanjing Shuoda, needed a contractor with proven expertise in high-stakes pipeline isolation. They required a partner who could execute a high-pressure natural gas pipeline isolation procedure (adapted for refined products) that was not only safe but also guaranteed zero production loss.
The Solution: A Customized Pipeline Isolation and Relocation Plan
We deployed a comprehensive solution centered on a double block and bleed hot tapping and line stopping strategy. This approach allowed us to isolate the section to be relocated while maintaining full flow through a temporary bypass.
Our work scope was divided into three critical phases:
1. High-Pressure Hot Tapping & Line Stopping
The core of our onshore pipeline hot tapping service was to create safe, temporary isolation points. We executed a “double-sided, double-seal” operation on both pipelines. This involved:
- Precision Welding: We performed 4 welding procedures on the Anhao (DN400) pipeline and 6 on the Anhe (DN250) pipeline for various fittings (extraction, equalization, and isolation points).
- Hot Tapping: Using our in-house designed tapping machines, we performed hot taps on the live, pressurized lines to install the isolation fittings.
- Line Stopping: High-pressure, disk-type plugging heads were deployed to stop the flow within the designated work section. For the Anhe line, we also deployed inflatable bags to provide an additional barrier, ensuring a 100% safe work zone.
This pipeline bypass installation and plugging method created a closed loop, diverting the product flow around the work area. It allowed the client’s operations to continue uninterrupted.
2. Advanced Pipeline Maintenance: B-Type Sleeve Repairs
During the inspection phase, we identified areas on the Hefei-Lu’an成品油pipeline requiring reinforcement. As part of our L360M steel gas pipeline maintenance construction scope, we engineered and installed four custom-fabricated B-Type sleeves. These sleeves (one 2.5m and three 1.0m units) provide a permanent, high-integrity reinforcement solution, extending the pipeline’s operational life and preventing future failures. The process included the sleeve fabrication, precise welding, and final corrosion protection coating.
3. Safe Decommissioning and Oil Recovery
Safety extends beyond the live pipeline. Before the final cut and tie-in, we performed a controlled extraction of the product from the isolated section. Our team executed a meticulous procedure involving:
- Pumping the remaining oil to tankers for recovery.
- Performing a controlled cut and removal of the isolated pipe section.
- Installing “butterfly walls” as a secondary safety barrier.
- Installing final plugging heads to permanently seal the ends.
The Execution: A Symphony of Precision and Safety
Our project management approach was built on real-time coordination and rigorous safety protocols.
- Pre-Work Engineering: We conducted a comprehensive engineering review, mapping every weld, tap point, and pressure calculation. This pre-planning was crucial for mitigating risks associated with the high operating pressures.
- On-Site Mobilization: Our crew deployed a full suite of specialized equipment, including our patented hot tapping machines, line stopping actuators, and B-Type sleeve welding gear.
- Phased Operations: We executed the work in a strict sequence: first, the hot tapping and line stopping on the Anhao line, followed by the Anhe line, and finally, the B-Type sleeve repairs. This parallel workflow optimized time on site.
- Real-Time Monitoring: Throughout the operation, we maintained continuous pressure monitoring. Any deviation would have triggered an immediate emergency response, ensuring a zero-incident outcome.
“The complexity of this project—with its dual pipelines, high pressures, and coordination with railway construction—demanded a partner with deep technical expertise. JSW’s ability to seamlessly execute the hot tapping, line stopping, and B-type sleeve repairs under tight deadlines was exceptional. Their team didn’t just perform a service; they provided a complete solution that kept our project on track and, most importantly, safe.”
— Project Manager, Nanjing Shuoda Engineering Co., Ltd.
Results & Benefits: Delivering Tangible Value
Our goal was to provide more than just services; we aimed to deliver a risk-free outcome that protected our client’s bottom line. The project’s success is measured in the critical results we achieved:
- Zero Operational Shutdown: By utilizing our pipeline bypass installation and plugging method, we maintained 100% flow through both pipelines for the duration of the project, preventing an estimated $500,000+ in potential lost revenue and demurrage costs.
- Zero Safety Incidents: We completed over 1,500 man-hours on a live, high-pressure site with a flawless safety record, demonstrating the reliability of our high-pressure natural gas pipeline isolation procedure.
- Enhanced Asset Longevity: The installation of four high-quality B-Type sleeves not only resolved the immediate safety concern but also extended the operational life of the Hefei-Lu’an pipeline by an estimated 20+ years.
- Seamless Infrastructure Coordination: We successfully completed the complex pipeline relocation within the railway’s construction window, preventing delays to the critical national infrastructure project.
About JSW: Your Partner in Pipeline Integrity
At JSW, we are more than just a pipeline services company; we are a manufacturer and a contractor offering a unique, integrated solution. Our dual identity as both a manufacturer of pipeline equipment and a provider of field services gives us an unparalleled advantage. We don’t just use tools—we design and build them, ensuring we have the right solution for the most complex challenges.
Our expertise spans:
- Pipeline relocation and installation
- Hot tapping and line stopping (onshore)
- Emergency pipeline repair and maintenance
- B-Type sleeve and composite repair installation
We combine engineering precision with field-proven execution to deliver safety, reliability, and certainty.
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