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Project Introduction

Pipeline integrity remains a critical component of safe and reliable hydrocarbon transportation. During routine surveillance and Joint Investigation Visit (JIV) activities along the 24-inch Nkpoku-to-Bomu Trunkline (TNP) at Baralue Community, an illegal connection was discovered on the pipeline at the 12 o'clock position.

Following the confirmation of the illegal connection by the Pipeline Maintenance Department of SPDC, Greenspan Concepts Limited was engaged to execute the repair work using an in-service welding technique involving the installation of a Split Tee. The objective of the intervention was to safely eliminate the illegal connection, restore the structural integrity of the pipeline, and ensure continued operational reliability while maintaining the highest safety standards throughout execution.

Engineering Insight
Pipeline integrity is not only about repairing defects; it is about preserving the safety, reliability, and sustainability of critical energy infrastructure through disciplined engineering execution.

— Greenspan Engineering Project Team

Scope of Work

The project involved the execution of specialized pipeline repair activities designed to safely remove the illegal connection and restore the pipeline's integrity without disrupting operations.

Mobilization of certified personnel, equipment, and materials to site.
Site preparation and work area layout.
Mechanical excavation and ditch preparation.
Pipe exposure and de-coating activities.
Preliminary Non-Destructive Testing (NDT) including Visual Inspection (VI),
Magnetic Particle Inspection (MPI), and Ultrasonic Testing (UT).
Blind flanging and sealing of the illegal connection.
Cement grouting of the illegal connection point.
Split Tee fit-up and alignment.
Controlled preheating operations.
Longitudinal groove welding.
Circumferential buttering weld installation.
Circumferential fillet welding.
Intermediate and final NDT inspections.
Field joint coating using Heat Shrinkable Sleeves.
Holiday detection and coating integrity verification.
Ditch backfilling and complete site restoration.
welding
split tee

Working Process

The repair operation was executed through a carefully planned and controlled sequence of activities to ensure safety, quality, and operational excellence.

01
Step

Site Investigation and Defect Confirmation

The project commenced with personnel mobilization, site preparation, and mechanical excavation to expose the affected section of the 24-inch TNP pipeline. A Joint Investigation Visit (JIV) was conducted, during which a 2-inch screw valve illegal connection was identified and assessed. Following documentation and verification, the excavation was temporarily backfilled pending repair mobilization.
02
Step

Pipeline Exposure and Integrity Assessment

The repair phase began with re-excavation and exposure of the pipeline section. The pipe coating was removed, and detailed integrity assessments were performed using Ultrasonic Testing (UT), Magnetic Particle Inspection (MPI), and flow-rate evaluations. The illegal connection was blind-flanged and permanently secured through cement grouting to eliminate the unauthorized tapping point.
03
Step

Split Tee Installation and Welding Operations

A specially designed 24-inch Split Tee was fitted around the affected pipeline section. Welding activities were carried out in stages, including root pass welding, hot pass welding, longitudinal seam welding, and circumferential buttering welds. Continuous quality control inspections, including Dry MPI examinations, were conducted throughout the process to verify weld integrity and compliance with engineering standards.
04
Step

Final Inspection, Coating, and Site Restoration

Following successful completion of welding activities, final wet MPI inspections were performed on all welded joints. The repaired section was then protected using Heat Shrinkable Sleeve (HSS) coating systems. After coating verification and holiday detection, the ditch was backfilled, the worksite restored to its original condition, and all personnel and equipment demobilized from site.

Project Outcome

The repair of the illegal connection on the 24-inch TNP pipeline at Baralue was completed successfully and safely using the Split Tee in-service welding method. The project achieved its primary objective of eliminating the unauthorized connection while restoring the pipeline's integrity without operational disruption.

The work was executed with zero recorded incidents, adherence to approved procedures, successful completion of all quality inspections, and full compliance with SPDC safety and engineering requirements.

HSE Performance Highlights

  • Zero Fatalities
  • Zero Lost Time Injuries (LTI)
  • Zero Total Recordable Cases (TRC)
  • Zero Road Traffic Accidents (RTA)
  • Zero Security Incidents
  • 100% Compliance with Job Hazard Analysis (JHA)
  • 100% Personnel Medical Fitness Compliance

Conclusion

The successful completion of the JIV/Non-Leak Illegal Connection Repair Project at Baralue demonstrates the effectiveness of in-service welding and Split Tee technology in maintaining pipeline integrity while minimizing operational downtime. Through proper planning, skilled execution, stringent quality assurance, and unwavering commitment to safety, Greenspan Concepts Limited delivered a durable and compliant repair solution that supports the continued safe operation of the 24-inch TNP pipeline.

 

This project stands as another example of engineering excellence in protecting critical pipeline infrastructure and ensuring uninterrupted energy transportation across the region.

Project Information

Key Project Information at a Glance

Project Title

JIV / Non-Leak IC Repair by In-Service Welding Using Split Tee on the 24" TNP

Location

Baralue Community

Pipeline Size

24-inch TNP Pipeline

Terrain

Land

Execution Period

16 June 2023 – 29 June 2023

Client

Renaissance Africa Energy Company Limited

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