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Hot Tapping Services for CNOOC Gas Terminal: High-Temperature & High-Pressure Pipeline Solutions

Certified welder performing specialized thick-wall welding on X60 steel pipeline, a critical step in our industrial hot tapping process.

Project Overview

Category Details
Client CNOOC (China National Offshore Oil Corporation)
Location Offshore Natural Gas Terminal, China
Challenge 12 critical hot taps under extreme conditions: 300°C thermal oil, thick-walled high-grade steel (X60, L415Q), and non-standard diameters (D717, D660). Zero tolerance for leaks or downtime.
Solution Customized hot tapping services with upgraded KkJ500 machines, dynamic cooling systems, and full-weld high-temperature valves.
Results 100% weld quality, all 12 taps completed successfully, zero safety incidents, 1.5-hour average tapping time.
Our team performing critical high-temperature hot tapping services on a DN250 pipeline with 300°C thermal oil, using specially modified equipment.
Close-up of our upgraded hot tapping machine with dynamic cooling system, engineered for reliable 300°C high-temperature hot tapping procedures.

Challenge: High-Risk Hot Tapping in Critical Infrastructure

CNOOC’s gas terminal expansion demanded hot tapping services under some of the most challenging conditions in the industry:

  • 300°C Thermal Oil Taps: Six taps near the machine’s thermal limits, with orientations ranging from horizontal to inverted.

  • Thick-Walled, High-Grade Steel: Two taps on D717 (X60, 19.1mm wall) and D660 (L415Q, 30mm wall) pipelines, requiring specialized welding and sealing.

  • Zero-Downtime Requirement: Any failure risked catastrophic safety incidents, production losses, and reputational damage.

The project’s complexity placed it under intense scrutiny from CNOOC and its EPC partners, necessitating a vendor with proven expertise in high-temperature hot tapping and high-pressure pipeline interventions.

Close-up detail of the hot tapping cutter and seal during the long-stroke procedure, ensuring integrity under high pressure in thick-wall pipeline modification.
A long-stroke hot tapping machine performing a critical hot tapping service on a high-grade, thick-wall pipeline outfitted with a branch outlet.
Our team of hot tapping contractors executing a precise, long-reach hot tapping service on a Class600, high-strength pipeline, demonstrating expert execution.

Solution: Customized Engineering for Extreme Conditions

Our approach combined advanced technology, rigorous testing, and seasoned field execution:

  1. Equipment Innovation

    • Upgraded KkJ500 hot tapping machines with dynamic cooling systems and high-temperature seals.

    • Full-weld high-temperature gate valves to prevent leakage during tool extraction.

  2. Precision Welding Protocols

    • Specialized training for thick-wall (50mm) welding, including multi-pass techniques and interpass temperature control.

    • Simulated bench tests to validate weld integrity under operational stress.

  3. Process Optimization

    • Adopted short-cycle valve-inclusive hot tapping to minimize exposure to high temperatures and pressures.

    • Deployed auxiliary cooling using on-site water and ambient-temperature thermal oil.

  4. Expert-Led Execution

    • Field supervision by Senior Engineer Yang Dongsong and Engineering Manager Li Chao.

    • 24/7 technical support from the Equipment Department.

X60 and L415Q high-grade steel pipelines (D717, D660) with 19.1mm-30mm wall thickness, prepared for critical high-pressure hot tapping services.
Comprehensive overview of CNOOC gas terminal expansion project, showcasing 12 critical hot tapping service locations including high-temperature thermal oil and high-pressure gas lines.

Implementation: Precision Under Pressure

The execution phase demonstrated our capability to deliver hot tapping services under extreme constraints:

  • High-Temperature Taps: The first 300°C horizontal tap was completed in 1.5 hours with zero leaks. Machine data remained within optimal ranges, validating the cooling and sealing modifications.

  • Thick-Wall Pipeline Taps: Using long-stroke drilling systems, we achieved stable cuts on high-grade steel, with post-tap inspections confirming no deformations affecting pigging operations.

  • Real-Time Adaptability: On-site teams adjusted drilling parameters based on live hydraulic data (pressure, flow, power), ensuring consistent performance across all 12 taps.

Full-scale test rig simulating a 2-meter long-stroke hot tapping operation on a thick-wall pipeline, ensuring machine stability and seal performance.

Results & Benefits

The project achieved all its objectives, delivering measurable value to CNOOC:

  • 100% Success Rate: All hot taps completed without incident or leakage.

  • Time Efficiency: Average tap time of 1.5 hours, minimizing system exposure.

  • Safety & Compliance: Zero safety incidents; full adherence to API and class standards.

  • Client Endorsement:

    “The team’s expertise in hot tapping services for high-temperature and high-pressure applications was critical to our project’s success. Their technical rigor and innovative solutions minimized risk and ensured uninterrupted operations.”
    — CNOOC Project Manager

Why Choose Our Hot Tapping Services?

  • Expertise: Deep experience in high-temperature hot tapping, thick-wall pipelines, and offshore applications.

  • Technology: Customizable equipment for non-standard diameters and materials.

  • Reliability: Proven success in zero-failure environments like CNOOC’s terminal expansion.

Contact us today for reliable, high-stakes pipeline solutions.

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