Project Snapshot

Item	Details
Client	Huasheng Huifeng Gas Transmission & Distribution Co., Ltd.
Location	Kelan County, Xinzhou, Shanxi Province, China
Pipeline	Zhonglianmei Shenmu-Anping Coalbed Methane Pipeline
Key Challenge	Repairing critical external deformations (up to 13% OD) on a high-pressure, large-diameter transmission pipeline without interrupting the gas supply.
JSW Solution	A tailored Hot Tapping and Stoppling (Pressure Isolation) plan for a live line, double-block-and-bleed replacement of three defective pipe sections.
Key Results	100% success with zero safety incidents; Zero supply interruption for downstream users; All repairs completed within schedule under 4.0MPa operating pressure.

The Challenge: Critical Deformations on a Vital Energy Artery

Imagine the pressure of managing a major energy artery—the Zhonglianmei Shenmu-Anping pipeline—only to discover critical threats hidden beneath its 3PE coating. In September 2021, inline inspection (ILI) data revealed three severe external deformations along the pipeline, with the most acute reaching 13% of the pipe’s outer diameter (OD) at the 12-kilometer mark. For an Φ813×12.5 mm pipeline carrying combustible coalbed methane at 4.0 MPa, this wasn’t just a maintenance item; it was a significant integrity threat that mandated immediate repair.

For our client, Huasheng Huifeng Gas, the stakes were immense. A conventional shutdown-and-replace approach would mean:

• Massive Financial Loss: Days or weeks of halted gas transmission, impacting downstream contracts and revenue.
• Reputational & Operational Risk: Breaking supply commitments to industrial and residential users.
• Complex Logistics: Coordinating a complete line shutdown across the network.

Their clear mandate to us, as their chosen pipeline services contractor, was: “Fix these defects without stopping the flow.” This was a classic, high-stakes scenario demanding live line pipeline repair expertise.

The JSW Solution: A Precision-Engineered Hot Tapping and Stoppling Plan

As both a specialist pipeline contractor and equipment manufacturer, JSW doesn’t just apply techniques; we engineer safe, efficient solutions. Our proposal was a comprehensive onshore pipeline rehabilitation project centered on Hot Tapping and Stoppling technology.

Our Customized Technical Approach:

1. Advanced Engineering Analysis: We modeled the stresses on the L450 steel pipeline under 4.0MPa pressure to design optimal reinforcement and calculate safe intervention windows.
2. Double Block-and-Bleed Isolation: For each defect location, we planned to install two temporary stopple heads upstream and downstream, creating a double-isolated section. The isolated segment would then be safely vented (bled), allowing for cold-cutting and replacement in a depressurized, safe environment—while the main pipeline continued operating at full pressure.
3. Specialized Equipment Deployment: We utilized JSW-manufactured hot tapping machines and stopple fittings rated for 8.0MPa (the pipeline’s design pressure), far exceeding the 4.0MPa operating pressure, ensuring a massive safety margin. Our equipment was specifically configured for the Φ813 mm diameter and 3PE coating.

Why This Was the Superior Choice:

• Zero Operational Disruption: The epitome of pipeline repair without shutdown.
• Enhanced Safety: All welding and cutting performed on isolated, gas-free sections.
• Regulatory Compliance: The method fully addressed the integrity threat in compliance with industry standards requiring repair of such deformations.

The Implementation: Expertise in Action Under Pressure

The execution phase, from April to July 2022, was a testament to meticulous planning and field expertise. Key stages included:

1. Site Preparation & Bypass Setup: At each repair location in Kelan County, we prepared the workspace and, where necessary, installed temporary bypass lines to maintain flow integrity during the final switchover.
2. Hot Tapping: Using our pipeline hot tapping machines, we safely drilled into the live, pressurized pipeline to install the temporary isolation fittings. This is the critical first step where precision is non-negotiable.
3. Stopple Insertion & Isolation: The stopple heads were inserted through the tap fittings and activated, creating the double block. Pressure between the stopples was verified as zero, confirming a perfect seal.
4. Section Replacement: With the defective segment fully isolated, it was cut out, and a new, pre-tested pipe spool was welded in place. All welding procedures were qualified for L450 material.
5. Re-commissioning & Seal Removal: The new section was tested, the stopples were retracted, the temporary fittings were removed, and the hot tap holes were permanently sealed with plugging heads. The pipeline was restored to its original, fully integrated state.

Throughout the process, our dual role as contractor and manufacturer provided seamless coordination and immediate technical support.

Results & Tangible Benefits: Safety, Continuity, and Trust Delivered

The project concluded on July 15, 2022, delivering results that directly addressed the client’s deepest concerns:

• 100% Safety Record: The entire hot tapping and stopping operation was completed with zero safety or environmental incidents.
• Zero Supply Interruption: At no point was the supply of coalbed methane to downstream users halted. The promise of a live line pipeline repair was fulfilled completely.
• Full Integrity Restoration: Three critical deformation defects (13% OD, 11.8% OD, 11.3% OD) were permanently eliminated, restoring the pipeline’s design integrity and extending its service life.
• On-Schedule Completion: All work was completed within the planned timeframe, demonstrating predictable project management.

A Word from Our Client:
“Facing these major deformations, a shutdown would have been costly and disruptive. JSW presented a clear, confident plan for a live repair. Their technical depth as both an equipment maker and a field services company was evident. They executed flawlessly under pressure, ensuring our pipeline’s safety without a single minute of supply loss. They are a true expert contractor in this field.”
— Project Manager, Huasheng Huifeng Gas Transmission & Distribution Co., Ltd.

Why Choose JSW Pipeline Services?

This project exemplifies the JSW advantage. We are not just another pipeline services company; we are end-to-end solution providers.

• Expertise Meets Manufacturing: As a manufacturer of hot tapping and stopping equipment, we possess unrivaled technical knowledge that informs our field practices. We use and trust our own tools.
• Specialized Contractor Focus: Our services are exclusively focused on complex pipeline interventions: integrity repair, emergency response, rerouting, and maintenance.
• Commitment to EEAT (Experience, Expertise, Authoritativeness, Trustworthiness): This case study, rooted in real data and results, is part of that commitment. We build trust by showcasing what we actually do.

Facing a pipeline integrity challenge that can’t wait for a shutdown?
Contact JSW today for a confidential consultation. Let our team of engineers design a live line repair solution that protects your assets and your bottom line.