Executing critical valve replacement without halting production

STATS Group has successfully completed a 56-inch inline isolation of a crude oil pipeline in Saudi Arabia to enable a scraper trap valve replacement without halting production.

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A major client in Saudi Arabia required the replacement of a 56-inch scraper trap valve, with the critical condition that the work be completed without shutting down, purging, or flushing the entire pipeline.

STATS was approached to engineer a solution whereby an isolation tool could be deployed to allow the safe replacement of the scraper trap valve.

Following a comprehensive engineering study and detailed site survey, STATS proposed a custom-designed 56-inch Tethered Tecno Plug®, tailored specifically for this application and to overcome challenges with some nonstandard scraper trap features.

Jijo George, Middle East - Manager of Projects at STATS Group, says: "This is the largest Tecno Plug in the history of STATS, highlighting a remarkable milestone in our capability to deliver safe, innovative and large-scale isolation solutions for critical pipeline infrastructure."

He adds: "This successful project provided a safe and cost-effective double block isolation, resulting in no interruption to production and preventing a costly shutdown. The safe and efficient workscope was a result of advanced planning, dedication and teamwork between STATS and client personnel."

STATS Tethered Tecno Plug isolation system featured two integrated isolation modules, engineered to deliver a safe and controlled pipeline isolation.

The first module, known as the Door Plug, replaces the scraper trap door and provides the primary isolation.

Once primary isolation is confirmed, the second module – The Tecno Plug – is advanced to its designated set location immediately downstream of the 56-inch scraper trap receiver valve.