Project Overview: High-Pressure Pipeline Relocation with Zero Supply Interruption
| Aspect | Details |
|---|---|
| Client | Hunan Zhongyou Gas Co., Ltd. |
| Location | Liling City, Hunan Province, China |
| Project Name | Xiangli Branch Line (Yuci Road to Gas Company Section) High-Pressure Gas Pipeline Relocation |
| Core Challenge | Relocating a critical 6.3MPa gas supply line without interrupting the 2.2MPa operational flow to downstream users, amidst complex urban terrain. |
| Key Solution | Advanced hot tapping and plugging techniques to create a new pipeline section tie-in, eliminating the need for a costly and disruptive full system shutdown. |
| Key Results | 100% success with zero safety incidents, zero gas supply interruption, and project completion within a strict 5-day timeline. |
The Challenge: Relocating a Critical Artery Without Stopping the Heart
For natural gas pipeline construction companies, the most demanding projects are those where the pipeline cannot be shut down. Our client, Hunan Zhongyou Gas, faced precisely this dilemma.
The existing high-pressure natural gas pipeline, operating at 2.2MPa, was in the path of new urban development in Liling City. Relocating this section was essential, but a traditional shutdown for a cut-and-weld operation was not an option. The financial and reputational cost of interrupting gas supply to residential and commercial users would be immense.
The technical specifications added layers of complexity:
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High Design Pressure: The pipeline is classified as a GA1-class pressure pipeline, the highest risk category, with a design pressure of 6.3MPa.
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Live Operation: All work had to be performed on the high pressure gas pipeline while it remained in service.
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Complex Urban Setting: The new route wove through green belts, sidewalks, and under roads, requiring precision and minimal surface disruption.
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Aggressive Timeline: The client required the entire relocation, including the abandonment of the old section, to be completed within a 5-day window.
This project was a test of true expertise, where failure was not an option.
The Solution: A Precision Engineered Live Tapping and Plugging Plan
As a specialist in live pipeline modification, Beijing Jinshiwan Pipeline Technology designed a bespoke solution centered on hot tapping services and pipeline plugging services. Our approach ensured a seamless transition from the old line to the new one with zero downtime.
Our pipeline relocation services included:
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Precision Planning & Tie-In Design: Before a single piece of equipment was mobilized, our engineers developed a meticulous procedure. This included designing the exact points for the two hot taps and four non-fire cuts, ensuring the new 551-meter section of L360M pipe would integrate perfectly.
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Advanced Hot Tapping & Plugging: The core of the operation. We performed two separate hot tapping procedures on the live, pressurized DN350 pipeline. This allowed us to install temporary plugging devices, isolating the section to be decommissioned and directing the gas flow through the newly laid parallel pipeline. This is the hallmark of a top-tier pipeline construction company, enabling work on active lines without pressure reduction or flow stoppage.
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Safe Decommissioning of the Old Line: Once the flow was diverted, the abandoned section was made safe through a nitrogen purge and grouting procedure, a critical step in the pipeline abandonment process that prevents future corrosion and ensures long-term integrity.
The Implementation: Flawless Execution Under Pressure
Our reputation as a reliable pipeline contractor in China is built on our ability to execute complex plans with military precision. The 5-day timeline was a testament to our project management and technical skill.
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Day 1-2: Preparation & Excavation. Site setup, excavation of operational pits for the hot tapping machines, and final alignment checks of the new pipeline.
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Day 3: Critical Tapping Operations. The two hot taps were successfully executed on the live mainline. This phase required the highest level of safety protocols and expert machine operation.
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Day 4: Flow Diversion & Tie-In. The plugging heads were set, diverting the gas flow to the new pipeline. The old section was then isolated, and the final connections were made.
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Day 5: Testing, Reinstatement, & Commissioning. The new section underwent rigorous pressure testing and purging before being brought fully online. The operation pits were backfilled, and the site was restored to its original condition.
Throughout the process, our expertise in L360M pipe welding and 3PE anti-corrosion coating ensured the new pipeline section met all GA1 class pipeline construction standards for safety and longevity.
Results & Benefits: Quantifiable Success for the Client
The successful completion of this project delivered immediate and long-term value, solidifying the trust clients place in expert natural gas pipeline construction companies.
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Zero Supply Interruption: Gas continued to flow to all end-users at the required 2.2MPa pressure throughout the entire project. The client avoided significant revenue loss and customer dissatisfaction.
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100% Safety Record: The project was completed with zero accidents or safety incidents, a non-negotiable standard for high-risk high pressure gas pipeline work.
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On-Time Delivery: All work was completed within the aggressive 5-day contractual deadline, minimizing community impact and project overhead.
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Long-Term Infrastructure Integrity: The new pipeline section, built to the highest standards, ensures reliable energy supply for the region’s future growth.
Client Testimonial:
“The Beijing JSW team demonstrated why they are considered leaders among natural gas pipeline construction companies. Their ability to execute a complex live pipeline modification under such a tight deadline and without any disruption to our service was impressive. Their hot tapping services were flawlessly managed, and their communication was clear throughout. They turned a high-risk challenge into a seamless operation.”
— Project Manager, Hunan Zhongyou Gas Co., Ltd.
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