Project Snapshot
| Element | Details |
|---|---|
| Client | PipeChina Shandong Operation & Maintenance Center, Jining Operation Area |
| Location | Weishan County, Zaozhuang City, Shandong Province, China |
| Core Challenge | Execute a high-risk pipeline hazard management project on an operational D711mm crude oil pipeline. This involved the safe abandoned pipeline disposal of 5.8km of old pipeline and the construction of 5.5km of new line, including critical crossings of three major canals (Lianyun, Zhongyun, Yijia). The primary objectives were to eliminate geohazards, ensure 100% operational safety, and minimize production disruption. |
| JSW Solution | Provided turnkey pipeline services, including integrated project management, a customized hot tapping and plugging plan, a standardized old pipeline abandonment procedure, and technical support for river crossings. Our “build-before-break” methodology ensured continuous crude oil throughput. |
| Key Results | Completed all critical work within the 14-day planned window. Achieved a perfect record of zero safety incidents and zero environmental releases. Our efficient execution helped the client avoid significant potential production losses. The retired pipeline was processed according to the highest environmental and long-term safety standards. |
The Challenge: Performing High-Risk Surgery on a Critical Artery
PipeChina’s Luning Line is a vital crude oil transmission artery. A section in Weishan County, Shandong, presented growing pipeline hazard management concerns due to geographical shifts and proximity to key waterways. The client faced a multifaceted engineering challenge:
- The Need for Continuous Operation: As a critical infrastructure company, PipeChina could not afford extended, unscheduled shutdowns. Any prolonged stoppage would disrupt downstream refinery operations, risking millions in daily production losses.
- Complex Environmental Crossings: The pipeline relocation project required successive underwater crossings of the Lianyun, Zhongyun, and Yijia Canals. This demanded precision engineering to mitigate environmental impact and construction risk.
- Legacy Pipeline Liability: The 5.8km section of old, asphalt-coated φ720×8.7mm pipe required proper oil pipeline decommissioning. This was not mere removal; it demanded a compliant old pipeline abandonment procedure to prevent future corrosion leaks, third-party damage, and environmental liability.
- Aggressive Timeline: The entire operation had to align with strict agricultural and navigational windows, placing immense pressure on project scheduling and execution efficiency.
PipeChina needed more than a standard contractor; they needed a pipeline services company with deep expertise in risk assessment, complex engineering, and flawless execution.
The Solution: Integrated Engineering & Specialized Technology
As an experienced service provider in pipeline hazard management, JSW deployed a dedicated team of senior engineers and field specialists. Our core strategy integrated advanced hot tapping and plugging technology with a systematic abandoned pipeline disposal protocol.
1. Customized Hot Tapping & Plugging Plan:
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Engineering Principle: Utilizing proprietary hot tapping and plugging equipment, we established temporary isolation points upstream and downstream of the planned cut-out section on the live pipeline. This created a secure “work zone,” allowing us to sever the old section and tie-in the new line without ever halting the mainline flow.
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Technical Advantage: As both a service company and equipment manufacturer, JSW employed custom-fitted hydraulic sandwich valves and composite sealing plugs. This equipment, engineered specifically for D711mm pipelines at 2.5MPa, guaranteed absolute seal integrity against pressure fluctuations.
2. Systematic Pipeline Abandonment Procedure:
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Cleaning & Inerting: The isolated pipeline segment was meticulously cleaned of residual crude and purged with nitrogen to eliminate all combustible gases, ensuring a safe cutting environment.
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Segmentation & Processing: The old pipeline was strategically cut into manageable sections. We evaluated multiple abandoned pipeline disposal options, ultimately implementing a cost-effective and environmentally sound plan: suitable sections were recycled, while others were processed and disposed of in accordance with stringent regulations.
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Documentation & Handover: Every step of the decommissioning process was documented in a comprehensive “pipeline passport,” detailing locations, depths, and methods used. This final report provides the client with permanent records for future land use and regulatory compliance.
Execution: Precision Project Management in Action
The field implementation highlighted JSW’s rigorous approach as a premier pipeline contractor:
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Pre-Simulation & Planning: We used GIS data and field surveys to digitally simulate every hot tap location and canal crossing, conducting virtual walkthroughs of all critical steps.
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Prefabrication & Modularization: Key components, including pre-welded river crossing sections, were manufactured off-site. This minimized field welding time and significantly reduced environmental risk during the sensitive canal crossing phases.
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24/7 HSE Monitoring: Our dedicated Health, Safety, and Environment team maintained round-the-clock surveillance. Real-time data on pressure, gas levels, and site conditions was fed back to the command center.
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Stakeholder Coordination: The JSW team maintained seamless communication with the client (PipeChina), local authorities, and canal management bodies, ensuring every phase met all specifications and permitting requirements.
Results & Benefits: Delivering Tangible Value Beyond Scope
The project successfully mitigated the primary hazard and delivered exceptional operational and financial benefits:
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Flawless Safety Performance: Achieved a perfect record of zero recordable incidents and zero leaks throughout the complex, pressure-containing pipeline relocation work. This is the ultimate validation of our pipeline hazard management capabilities.
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Optimized Schedule & Cost-Efficiency: All critical work was completed within the 14-day operational window. Our hot tapping and plugging approach prevented a mainline shutdown, preserving continuous revenue flow for the client and safeguarding against an estimated multi-million dollar potential loss.
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Elimination of Long-Term Liability: The 5.8km of retired pipeline was decommissioned following industry best practices, permanently eliminating future leak risks and third-party damage exposure for this segment.
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Environmental Stewardship: Stringent soil and water protection measures were implemented during canal crossings and pipeline disposal. The site was fully restored upon project completion.
Client Testimonial:
“Partnering with JSW was a demonstration of high-level professionalism. They acted not just as a contractor, but as a true engineering partner. Their understanding of the complexities involved in oil pipeline decommissioning, combined with their unwavering reliability during live pipeline interventions, gave us complete confidence. This project is a benchmark for how to execute a safe and efficient pipeline relocation in a high-consequence environment.” — Project Manager, PipeChina Shandong Operation & Maintenance Center.
About JSW Pipeline Services: Your Total Pipeline Solution Partner
JSW is a unique pipeline services company, integrating the manufacturing of advanced pipeline intervention equipment with specialized field engineering services. Our core services include:
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Pipeline Hot Tapping & Plugging Services
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Pipeline Relocation, Replacement & New Installations
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Pipeline Integrity Management & Hazard Mitigation
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Pipeline Emergency Response & Maintenance
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Pipeline Decommissioning & Abandonment Consulting
From building the industry’s most reliable equipment to executing its most challenging field operations, JSW delivers a “single-source” solution across the pipeline lifecycle. We transform advanced engineering into tangible benefits for our clients: enhanced safety, operational certainty, and asset longevity.
Are you planning a pipeline modification, facing an integrity challenge, or require expert decommissioning services? The specialized team at JSW is ready to consult and deliver a tailored solution for your project.
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