Pipeline Technology Conference, Ostend, 12-14 October 2009

Paper no: Ostend2009-011

Innovative plugging head

solution
by A Lounis
TD Williamson SA, Nivelles, Belgium

This paper is © copyright of the organizers of the Pipeline Technology Conference held in Ostend, Belgium, on 12-14 October, 2009, and of
the author(s). No copying (either electronic or otherwise), transmission electronically, or reproduction in any way is permitted without the
specific permission of the copyright holders.
 Innovative Plugging Head
solution
Pipeline Technology 2009 - Belgium

Presented by: Azibi Lounis

Date: October 2009

Innovative Plugging Head solution

Table of contents
• Introduction

– Objective and jobsite description

– Customer requirements
– Job and equipment specifications

• Urethane Plugging Head

– Testing and job performance

• Conclusion

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 Innovative Plugging Head solution

INTRODUCTION

Innovative Plugging Head solution

Introduction

Objective and jobsite description

• Customer: Major nitrogen gas provider in Latin America

• Pipe dimension: 8IN

• Pipe class: ANSI 300lbs

• Initial job: 6IN line Tie-in  Plant expansion project

• Initial contract to local Hot Tap contractor

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 Innovative Plugging Head solution

Introduction

Objective and jobsite description

• Situation:
– Tapping Machine got stuck on the line
– Gas leak
– Impossible to close the valve

Client called for TDW

expertise:
 Needed to remove the
stuck TM
 Finalize the job (Tie-
in)
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Innovative Plugging Head solution

Introduction

Customer requirements
 100% SAFETY
TDW had to comply with customer procedures

 100% RELIABILITY
Cost of failure could NOT be repeated

 The leak had to be plugged

 TDW had to propose reliable method

 Daily operations were to continue

 NO shutdown or flow reduction

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 Innovative Plugging Head solution

Introduction

Job & equipment specifications

• Working space short  Double Stopple® impossible
• After analyze: Seal the leak in the pipeline first

 Identical Hot Tap on the direct opposite side of the leak.

 Specially designed urethane Plugging Head
 TM 760 with special plug holder will be used

TM760 with special urethane Stuck TM during failed

Plugging Head Hot Tap
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Innovative Plugging Head solution

URETHANE PLUGGING HEAD

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 Innovative Plugging Head solution

Urethane Plugging Head

Testing and job performance

• Urethane Plugging Head:
– Totally seal the leak
caused by the failed Hot
Tap

– Careful measures were

taken
precision around the
cavity.
Urethane shape = inside
of pipe shape
TM760
TM760boring
plug bar
holder
Urethane Plugging Head
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Innovative Plugging Head solution

Urethane Plugging Head

Testing and job performance

• Factory Acceptance Testing
(FAT):

– Metal hardness
– T° and Pressure
Affect machine stability,
torque and cutting rate.

– Hot Tapping equipment:

std FAT + pressure test

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 Innovative Plugging Head solution

Urethane Plugging Head

Testing and job performance

• TDW makes a correctional Hot Tap directly opposite the
failed one by a local contractor:

TDW Stuck machine

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Innovative Plugging Head solution

Urethane Plugging Head

Testing and job performance

• A 760 Tapping Machine is used to mount the urethane
Plugging Head to seal the leak:

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 Innovative Plugging Head solution

Urethane Plugging Head

Testing and job performance

• Stuck TM was retrieved and valve was closed:

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Innovative Plugging Head solution

CONCLUSION
 New Tie-in was installed properly by TDW

 1st call to TDW to project finalization  within 1 week

By experienced TDW engineers and technicians.

 ALL safety procedures were followed

 NO Shutdown or flow reduction

 NO UNNECESSARY PENALTIES

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 Innovative Plugging Head solution

Thank you for your attention.

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