This paper discusses issues such as: removal of the locking devices (valves, not participating in the process and in dead zones) after any manufacturing operations on the pipeline or after using the hot tap device, reducing the cost of pipeline repair, dismantling locking devices, excluding the possibility of unauthorized siphoning of fluid from the pipeline, facilitating labor working staff, reducing risks and hazards, universality of the equipment during introduction of new technologies for pipeline repair without stopping the pump.

The main purpose of research is to reduce costs for operation of pipelines and uninterrupted transfer of petroleum products. The main tasks that authors of the project set:

  • Analyze of existing sealing methods available for working holes on pipelines that are already used in large companies;

  • After thorough analysis suggest to introduce an innovative method of technological holes sealing without stopping the pumping of fluid through the pipe, surpassing foreign analogues;

  • To prevent theft of well site output and reduce environmental risks in possible pipeline emergencies.

As a result of this work has been developed and proposed to introduce a set of equipment for the installation of shutoff gate valve into technological holes without stopping the pipeline.

This set of equipment will help to avoid dumping pipeline valves under the ground, to avoid unauthorized siphoning liquid and allow producing tie of newly built pipeline sections to the existing communications without stopping the pumping of fluids.

Example of shutoff gate valve installation technology.

For carrying out production operations of installing the valves and shut-off devices on pipelines used a set of equipment and devices in the following order:

  • Spool with pre-welded flange with conical internal thread is welded to the pipeline;

  • Full bore valve mounted on the flange;

  • Hot tap device mounted on the valve for hot tapping operation, a milling tool cut a technological hole, then the milling tool rises on the stock, then valve blocks orifice and then hot tap device will be dismantled;

  • To remove the installed valve device we developed is installed on valve to tighten the plug. Plug through adapter is attached to the stock using a powerful magnet. The principle of fixing the stock to the plug based on magnetic pull. Connection "tongue and groove" is provided to ensure the tightening;

  • Further the stock with installed plug get down to the flange and then plug screwed into a tapered thread flange;

  • To check the tightness of the installed plug need to open the pressure relief valve. Clear the residual pressure. If the pressure is offline in the device the sealing has successfully completed.

Utility model patent of the Russian Federation № 130032 «The device for repairing existing pipelines without shutoff» confirms the uniqueness of the technology. The proposed device is a separate hub of patent technology № 130032 where we are the authors, and formalized as the rationalization proposal № 161 «Device for the installation of shutoff plug for technological holes in the pipeline». Rationalization proposals were approved and adopted for implementation.

After registration of the rationalization proposal entitled «The device for screwing the plug into the technological holes of pipelines» and testing of the first prototype at the test stand, we have developed activities for the implementation of complex equipment and obtain permits.

Presently equipment we have proposed is in the process of design and technical documentation development, production and testing of the new modified prototype device to screwing the plug in accordance with all regulations.

Implementation of the proposed technology will allow:

  • Make the hole sealing process without stopping the pipeline;

  • Use a shut-off device again;

  • Optimize the repair process on the pipeline,

  • Reduce environmental risks;

  • Prevent the risk of well site output theft;

  • Make changes to improve the technology by the rights holder.

The cost-effectiveness of the proposed equipment implementation was also calculated in our work, confirming the need for its implementation to enhance the safe operation of pipelines and fluid transport in oil-producing and oil transportation companies.

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