Project Snapshot
- Client: National Pipeline Network Group (South China Company)
- Location: Meizhou, Guangdong, China
- The Challenge: Relocate 5 sections of a high-pressure (9.5MPa) petroleum products pipeline conflicting with a major highway expansion, without shutdown or leakage.
- The Solution: A customized pipeline relocation plan using advanced Hot Tapping and Stoppling technology with a Double Block and Bleed with Isolation Bag method.
- The Result: Successful relocation of 1058m of pipeline with 4 stoppling points completed under live conditions, achieving zero leakage, zero accidents, and enabling uninterrupted highway construction.
The Challenge: A Critical Conflict Between Energy and Transportation Infrastructure
The expansion of the Shantou-Meizhou Highway was a vital project for regional economic development. However, its planned route directly encroached upon five separate sections of the Pearl River Delta Phase II Products Pipeline (Quxi-Meizhou Section).
This was not a simple crossing. The pipeline is a critical energy artery, transporting essential fuels with a high-stakes operational profile:
- Product: Petroleum Products
- Diameter: 273.1 mm
- Design Pressure: 9.5 MPa (a very high pressure requiring extreme precision)
- Pipeline Length Involved: 1058 meters
A conventional shutdown-and-replace approach was not a viable pipeline maintenance strategy. It would have caused widespread disruption to the fuel supply chain, resulting in significant economic losses for the client. The challenge was clear: execute a complex pipeline relocation under live, high-pressure conditions.
Adding to the complexity, the onshore pipeline construction site was in a mountainous region with difficult terrain, making equipment access a logistical puzzle. Unstable soil conditions also raised the constant risk of excavation collapse, posing a serious safety threat.
Our Solution: Engineering Safety with Double Block and Bleed Technology
Our expertise in high-pressure pipeline repair was put to the test. We designed a solution that prioritized absolute safety and operational integrity. The core of our strategy was a sophisticated Hot Tapping and Stoppling operation.
Here’s how we translated technical capability into a guaranteed safe outcome:
- Comprehensive Pipeline Relocation Services: We engineered a new pipeline route totaling 771 meters, designed to permanently resolve the conflict with the highway. This demonstrated our full-service capability from planning to execution.
- Advanced Pipeline Plugging Services: To isolate the work sections without shutting down the entire line, we employed a Double Block and Bleed (DBB) with an Isolation Bag.
- High-Pressure Disk Stoppling: Provided the primary mechanical seal against the extreme 9.5 MPa pressure.
- Bag Stoppling: Inflated an isolation bag inside the pipeline, creating a secondary, flexible seal for an added layer of protection.
- This dual-seal system effectively created a safe “work zone” between the two stopples, completely mitigating the risk of media leakage or (oil and gas leakage), and making the subsequent pipeline tie-in work safe for our crew.
This method is the gold standard for pipeline isolation services on live lines, and our team is expertly trained in its execution.
The Implementation: Precision Execution in Adverse Conditions
Despite the complex pipeline construction environment, our field team’s proficiency ensured a flawless operation. The process involved:
- Precise Hot Tapping: Creating entry and exit points on the live pipeline under full pressure.
- Stoppling Head Insertion: Installing the disk and bag stopples to isolate the section.
- Bypass Operation (if applicable): Maintaining product flow through a temporary bypass line.
- Pipeline Tie-In and Welding: Completing the final welds on the isolated and safely depressurized section.
- Stopple Removal and Commissioning: Restoring the pipeline to its full operational status.
Throughout the project, we maintained the highest safety standards. The leadership from National Pipeline Network Group conducted site inspections, observing our rigorous procedures firsthand. The successful installation of the final blind flange marked the completion of all four stoppling points without a single safety incident.
Results and Client Benefits: Quantifiable Success and Strengthened Trust
The project was not just a completion; it was a demonstration of excellence with measurable outcomes.
- 100% Safety Record: Achieved zero accidents and, most critically, zero leakage throughout the entire hot tapping and stoppling process, even under high-temperature working conditions.
- Uninterrupted Energy Supply: Enabled the client to avoid costly shutdowns, ensuring a stable supply of petroleum products to the region.
- Enabled Critical Infrastructure: The highway expansion project proceeded on schedule, thanks to the timely resolution of the pipeline encroachment issue.
- Client Endorsement: The on-site project manager from the client team was quoted as saying:
JSW’s team handled a highly complex situation with exceptional professionalism. Their dual-seal plugging services gave us absolute confidence in the safety of the operation. This project sets a new benchmark for collaboration between energy and transportation infrastructure projects.”
Your Partner for Complex Pipeline Challenges
The successful relocation of the Shantou-Meizhou highway pipeline is a testament to our commitment to solving the most demanding pipeline maintenance and construction challenges. We don’t just perform tasks; we deliver engineered solutions that safeguard your assets, your schedule, and your reputation.
Are you facing a pipeline encroachment, required relocation, or need live maintenance on a high-pressure line?
Let JSW’s expertise in hot tapping and stoppling become your competitive advantage.
Contact Us Today for a Free Project Consultation
Our engineering team is ready to analyze your specific challenge and develop a safe, efficient, and cost-effective solution for you.
