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. |
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:
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300°C Thermal Oil Taps: Six taps near the machine’s thermal limits, with orientations ranging from horizontal to inverted.
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Thick-Walled, High-Grade Steel: Two taps on D717 (X60, 19.1mm wall) and D660 (L415Q, 30mm wall) pipelines, requiring specialized welding and sealing.
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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.
Solution: Customized Engineering for Extreme Conditions
Our approach combined advanced technology, rigorous testing, and seasoned field execution:
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Equipment Innovation
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Upgraded KkJ500 hot tapping machines with dynamic cooling systems and high-temperature seals.
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Full-weld high-temperature gate valves to prevent leakage during tool extraction.
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Precision Welding Protocols
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Specialized training for thick-wall (50mm) welding, including multi-pass techniques and interpass temperature control.
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Simulated bench tests to validate weld integrity under operational stress.
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Process Optimization
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Adopted short-cycle valve-inclusive hot tapping to minimize exposure to high temperatures and pressures.
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Deployed auxiliary cooling using on-site water and ambient-temperature thermal oil.
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Expert-Led Execution
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Field supervision by Senior Engineer Yang Dongsong and Engineering Manager Li Chao.
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24/7 technical support from the Equipment Department.
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Implementation: Precision Under Pressure
The execution phase demonstrated our capability to deliver hot tapping services under extreme constraints:
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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.
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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.
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Real-Time Adaptability: On-site teams adjusted drilling parameters based on live hydraulic data (pressure, flow, power), ensuring consistent performance across all 12 taps.
Results & Benefits
The project achieved all its objectives, delivering measurable value to CNOOC:
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100% Success Rate: All hot taps completed without incident or leakage.
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Time Efficiency: Average tap time of 1.5 hours, minimizing system exposure.
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Safety & Compliance: Zero safety incidents; full adherence to API and class standards.
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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?
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Expertise: Deep experience in high-temperature hot tapping, thick-wall pipelines, and offshore applications.
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Technology: Customizable equipment for non-standard diameters and materials.
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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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