Project Spotlight:

Category	Details
Client	State Reserve Pipeline (Shandong) Investment Group Co., Ltd.
Location	Linyi City, Shandong Province, China
Date	May 22-23, 2024
Core Challenge	Execute a safe, reliable hot tapping pipeline tie-in on a live natural gas pipeline operating at 3.0 MPa, with zero shutdown mandated due to critical downstream demand.
JSW Solution	Advanced hot tapping and plugging services performed by our expert contractor team using proprietary, high-pressure-rated equipment, ensuring a secure live pipeline connection.
Key Result	Successful DN500 pipeline hot tapping and interconnection completed within 48 hours under full pressure (3.0 MPa), with zero safety incidents and 100% continuous supply maintained.

The Challenge: Connecting Critical Infrastructure Without a Minute of Downtime

In the heart of Shandong’s energy network, our client, State Reserve Pipeline (Shandong) Investment Group, faced a pressing infrastructure upgrade. To enhance market supply capacity, a new Ø508mm pipeline needed to be connected to the existing operational Sinorussian East Route pipeline at the Linyi off-take station.

The dilemma was stark:

• The Pipeline: A critical artery transporting natural gas.
• The Mandate: A live pipeline connection was non-negotiable. The downstream demand was too high to permit any shutdown. Even a brief stoppage would translate to significant economic and societal impact.
• The Technical Hurdle: Performing a DN500 hot tapping and plugging operation on a live natural gas pipeline operating at a substantial 3.0 MPa (435 psi). This is a high-risk procedure demanding extreme precision, flawless equipment, and unparalleled expertise.
• The Client’s Silent Questions: “Is this pipeline services company experienced enough for such a high-stakes job?” “Can their hot tapping services guarantee absolute safety and success?” “Do they have the right equipment and contractor team for a project of this scale and pressure rating?”

The JSW Solution: Integrated Expertise as Both Manufacturer and Service Contractor

JSW Pipeline Services was entrusted with this mission because we offer a unique, integrated value proposition: we are not just a service contractor; we are also the manufacturer of the specialized equipment used in these critical operations. This allows for complete control over quality, safety, and performance.

Our engineered solution centered on a double-block-and-bleed hot tapping and plugging procedure. Here’s how we translated our technical capabilities into tangible client benefits:

• Function: Custom-designed hot tapping and plugging machines for DN500, rated for 10MPa.
• Advantage & Benefit: Our in-house manufacturing ensures equipment is perfectly matched to the task, eliminating compatibility issues and providing a fail-safe system. This translates to reduced risk and unwavering confidence for the client during the operation.
• Function: Proprietary sealing technology and rigorous procedure following ASME PCC-2 & API standards.
• Advantage & Benefit: Mitigates the extreme risks associated with high-pressure natural gas pipeline hot tapping. The client gains peace of mind knowing the procedure is backed by international best practices, protecting their asset, personnel, and the environment.
• Function: 24/7 project management and real-time engineering support from our senior team.
• Advantage & Benefit: The pipeline hot tapping services are overseen by the experts who build the tools. This seamless integration means faster on-site decision-making and problem-solving, ensuring the live pipeline connection project stayed on schedule without compromising safety.

Implementation: Precision Under Pressure

Our execution was a testament to meticulous planning and technical prowess. The key steps included:

1. Site Safety & Preparation: Establishing exclusion zones, conducting Job Safety Analysis (JSA), and securing the worksite.
2. Equipment Installation: Mounting the pre-tested hot tapping pipeline assembly (including the temporary valve and hot tap machine) onto the existing D355.6×6.3 pipe.
3. The Critical Tap: Executing the hot tapping operation to create a branch connection on the live, pressurized pipeline—a process we monitored with extreme precision.
4. Plugging & Isolation: Installing the pipeline plugging head through the newly created tap to safely isolate the section for the final tie-in.
5. Tie-in & Completion: Welding the new pipeline segment, followed by the safe retraction of the plugging head and installation of the permanent fitting.

Throughout the two-day project window, our team’s coordination was flawless. We maintained constant communication with the client’s control center, ensuring operational parameters were stable.

Results & Measurable Benefits: Delivering Beyond Expectations

The project was an unqualified success, delivering quantifiable value that directly addressed the client’s core business needs:

• 100% Uptime Maintained: The natural gas pipeline hot tapping operation was completed without a single minute of supply interruption to downstream users. This was the primary success metric.
• Flawless Safety Record: Zero accidents, zero leaks, zero environmental incidents. Safety is not just a promise; it’s a measurable outcome.
• On-Time, On-Budget Delivery: The complex interconnection was completed within the planned 48-hour schedule, demonstrating exceptional project management by our contractor team.
• Long-Term Infrastructure Integrity: The connection was executed to the highest engineering standards, ensuring the long-term reliability and safety of this expanded network node.

A Word from Our Client:
*“The pressure was immense — both figuratively and literally at 3.0 MPa. We needed a partner who understood the technical complexities of a live pipeline connection on a major artery like the Sinorussian line. JSW’s dual-role as equipment maker and field contractor gave us a distinct advantage. Their team was in complete control, from engineering to execution. They turned a high-anxiety project into a textbook success.”* — Project Manager, State Reserve Pipeline (Shandong).

Why Choose JSW Pipeline Services?

This Linyi project exemplifies the JSW difference. We are a full-spectrum pipeline services company specializing in:

• Hot Tapping & Plugging Services (DN50 – DN1200)
• Pipeline Emergency Response & Repair
• Pipeline Relocation, Installation, and Maintenance
• Technical Consulting & Engineering Support

As a manufacturer-integrated contractor, we provide a true turnkey solution: expertise you can trust, backed by equipment we build. Whether your pipeline hot tapping challenge is in Shandong or anywhere else in the world, we deliver safety, reliability, and operational continuity.

Facing a critical pipeline interconnection or repair challenge? Contact JSW Pipeline Services today for a confidential consultation with our engineering team.