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sectional replacement

Project Introduction

Following the confirmation of internal pipeline defects on the 20-inch Kolo Creek Trunk Line (KCTL) at Ozorchi, the Pipeline Maintenance Department of SPDC initiated a Post Intelligent Pigging (IP) Defect Verification exercise to assess the integrity of the affected section.

Greenspan Concepts Limited was engaged to execute the repair through sectional replacement of the defective pipeline segment. The project was undertaken to eliminate integrity threats, restore pipeline reliability, and ensure uninterrupted and safe hydrocarbon transportation.

 

The repair activities were executed in accordance with approved engineering procedures, industry standards, and strict HSE requirements to achieve a successful repair with zero incidents.

Engineering Insight
Pipeline integrity is not measured by the absence of failure, but by the proactive identification and elimination of defects before they become failures. Every successful repair strengthens the reliability, safety, and longevity of critical energy infrastructure.

— Project Engineering Team

Scope of Work

The project involved the verification, excavation, removal, and replacement of a defective section of the 20-inch KCTL pipeline. Activities included inspection, welding, non-destructive testing, coating, and restoration works necessary to safely return the pipeline section to operational service.

Mobilization of personnel, equipment, and materials to site
Site preparation and work area setup
Mechanical and manual excavation of defect location
Pipeline exposure and defect verification
De-coating and pipe surface preparation
Cold cutting of defective pipeline section
Dewatering and ditch preparation
Joint preparation and fit-up activities
Welding of replacement spool
Non-Destructive Testing (UT, MPI, and Radiography)
Field Joint Coating using Heat Shrink Sleeves (HSS)
Holiday detection and coating inspection
Backfilling and site reinstatement
Demobilization of personnel and equipment
sectional replacement2
sectional replacement2

Working Process

The project was executed through a structured engineering methodology designed to ensure quality, safety, and operational efficiency.

01
Step

Defect Verification and Excavation

The project commenced with mobilization to the site and identification of reference points using survey measurements. Mechanical excavation was carried out to expose the pipeline and verify the exact location and extent of the defect. Detailed inspections and phased array testing were conducted to confirm repair requirements.
02
Step

Pipeline Preparation and Section Removal

Following verification, the defective section was de-coated and prepared for replacement. The repair team established tie-in points, performed cold cutting operations, and safely removed the affected pipeline segment. Pipe ends were prepared through beveling and surface conditioning to ensure weld quality.
03
Step

Sectional Replacement and Welding

A new 49.3-meter replacement spool was installed and aligned with the existing pipeline. Qualified welders carried out fit-up, root pass, hot pass, filling, and capping operations in accordance with approved welding procedures. Continuous inspection and quality control activities ensured compliance with engineering standards.
04
Step

Inspection, Coating, and Restoration

Upon completion of welding, extensive Non-Destructive Testing (NDT) including Ultrasonic Testing (UT), Magnetic Particle Inspection (MPI), and Radiographic Testing (RT) was performed to validate weld integrity. The repaired joints were coated using Heat Shrink Sleeves (HSS), followed by backfilling, site restoration, and final close-out activities.

Conclusion

The Post IP Defect Verification and Repair by Sectional Replacement on the 20-inch KCTL at Ozorchi was successfully completed within the planned execution period. The project achieved its primary objective of removing a defective pipeline section and restoring the structural integrity of the line.

 

Through effective planning, skilled execution, strict adherence to industry standards, and robust quality assurance processes, the repair was completed safely and efficiently. The successful replacement of the defective section has enhanced pipeline reliability, minimized operational risk, and contributed to the continued safe transportation of products through the KCTL network.

 

The project stands as a demonstration of engineering excellence, operational discipline, and commitment to pipeline integrity management.

Project Information

Key Project Information at a Glance

Project Title

Defect Verification and Repair by Sectional Replacement on the Old 20

Location

Ozorchi Community, Rivers State

Pipeline Size

20-Inch Kolo Creek Trunk Line (KCTL)

Terrain

Land

Execution Period

January 24, 2025 – February 9, 2025

Client

Renaissance Africa Energy Company Limited

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