Project Overview Summary
Client: Taixing Xin’ao Gas Co., Ltd.
Location: Taixing City, Jiangsu Province, China
Contractor: Beijing Jinshiwan Pipeline Technology Co., Ltd.
Project Challenge: Relocating 156 meters of critical DN400 high-pressure natural gas pipeline (4.0MPa) serving an industrial park without interrupting gas supply
Solution: Comprehensive hot tapping and line plugging services with temporary bypass system
Key Results: Completed within 30-day timeline with zero safety incidents and continuous gas supply throughout the project
The Critical Challenge: Maintaining Industrial Gas Supply During Essential Pipeline Relocation
When Taixing Xin’ao Gas Company faced the necessity of relocating 156 meters of critical DN400 high-pressure natural gas pipeline in the bustling Chengdong Industrial Park, they confronted a seemingly impossible dilemma. This high-pressure gas pipeline maintenance operation served numerous manufacturing facilities that depended on uninterrupted natural gas supply for their operations. A traditional shutdown would have caused:
- Production stoppages across multiple industrial plants
- Estimated economic losses exceeding millions of yuan daily
- Potential safety risks associated with complete depressurization and repressurization
- Extended downtime affecting regional economic activity
The technical specifications added further complexity: the 4.0MPa design pressure and DN400 pipeline diameter represented significant engineering challenges for any non-stop pipeline repair operation. The client needed a solution that would allow the pipeline relocation while maintaining continuous gas flow to downstream consumers.
Our Customized Solution: Advanced Hot Tapping and Line Plugging Technology
Beijing Jinshiwan Pipeline Technology developed a comprehensive pipeline relocation services package centered around advanced hot tapping and line plugging services. Our solution combined decades of experience in high-pressure pipeline engineering with state-of-the-art equipment and methodology.
Technical Approach Overview:
Our engineered solution involved a multi-phase approach to ensure safety and continuity:
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Temporary Bypass System Installation: Designing and implementing a DN300 temporary bypass line to maintain gas flow during the critical cutting and connection phases
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Four-Point Isolation Strategy: Executing simultaneous hot tapping and line plugging at four separate locations to create isolated sections for safe modification
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Pressure Equalization Technology: Implementing DN50 pressure balance connections to ensure safe plugging head operation under 4.0MPa pressure conditions
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Butterwall Construction: Building two specialized butterwall barriers as additional safety measures at critical connection points
Our pipeline plugging services utilized equipment specifically rated for the 4.0MPa operating pressure, with all DN400 pipeline fittings undergoing rigorous testing and certification before deployment. The technical implementation represented some of the most challenging pipeline maintenance solutions in the industry due to the combination of diameter, pressure, and operational criticality.
Implementation Excellence: Precision Execution Under Pressure
The successful implementation of these hot tapping and line plugging services required meticulous planning and flawless execution. Our certified pipeline technicians followed a rigorously tested procedure:
Phase 1: Preparatory Work and Bypass Installation
- Site preparation and safety perimeter establishment
- Installation of temporary DN300 bypass piping with full pressure testing
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Welding of hot tapping fittings and pipeline plugging fittings at all four locations
Phase 2: Hot Tapping Operations
- Execution of 8 separate hot tapping operations (4×DN50 and 4×DN400)
- Installation of pipeline plugging equipment and pressure testing of all connections
- Comprehensive leak testing of all mechanical connections
Phase 3: Line Stopping and Pipeline Modification
- Activation of pipeline plugging heads to isolate sections for modification
- Verification of plugging head seal integrity under full operating pressure
- Execution of non-stop pipeline cutting and connection of new pipeline sections
- Construction of butterwall barriers at critical junctions
Phase 4: System Restoration and Testing
- Deactivation of plugging equipment and restoration of flow through main pipeline
- Disconnection and removal of temporary bypass system
- Hydrostatic testing and pipeline commissioning
- Comprehensive documentation and client handover
Throughout the 30-day project timeline, our team maintained strict adherence to industrial safety standards while implementing these complex pipeline intervention services.
Quantifiable Results and Client Benefits
The successful completion of this challenging pipeline relocation project delivered significant measurable benefits to Taixing Xin’ao Gas Company:
Operational and Safety Outcomes:
- Zero supply interruptions to downstream industrial customers throughout the project
- 100% safety record with no incidents or environmental releases
- Completion within the 30-day project timeline despite technical complexities
- All pipeline connection points tested to exceed original design specifications
Economic Impact:
- Eliminated production losses for industrial customers estimated at over 20 million yuan
- Avoided emergency response costs associated with traditional shutdown methods
- Extended pipeline service life with new sections featuring enhanced corrosion protection
Client Testimonial:
“Beijing JSW’s expertise in hot tapping and line plugging services was instrumental to our project’s success. Their ability to maintain gas flow while relocating a critical high-pressure pipeline prevented massive economic disruption to our industrial customers. Their technical team demonstrated exceptional professionalism and problem-solving capabilities throughout the project.”
— Project Manager, Taixing Xin’ao Gas Co., Ltd.
Why Choose Beijing Jinshiwan for Your Pipeline Challenges?
This Taixing Industrial Park project exemplifies our core capabilities in delivering complex pipeline engineering solutions under challenging conditions. Our hot tapping and line plugging services division specializes in:
- High-pressure pipeline interventions up to 10MPa operating pressure
- Large-diameter pipeline plugging services for DN50 to DN1000 pipelines
- Emergency pipeline repair capabilities with rapid response teams
- Non-stop pipeline modification services for various industries including oil, gas, and chemical sectors
- Comprehensive pipeline maintenance solutions from planning through execution
Contact Our Pipeline Solutions Team
Facing similar challenges with your pipeline infrastructure? Our team of certified pipeline engineers is ready to develop customized hot tapping and line plugging services for your specific requirements.
Contact Beijing JSW Pipeline Technology today to schedule a consultation and discover how our non-stop pipeline maintenance solutions can protect your operations while enabling essential infrastructure modifications.
