Tecno Plug Non-Intrusive Inline Isolation

STATS DNV GL type approved Tecno Plug® provides fail-safe double block and bleed isolation of pressurised pipelines while the system remains live and at operating pressure. Dual seals provide a zero-energy zone to enable maintenance work on pressurised systems to be carried out safely and efficiently. The dual seal configuration of the Tecno Plug provides an annulus void which can be pressure tested to verify both seals are leak-tight before maintenance work is carried out. Both seals are leak tested with full pipeline pressure. Once the seal integrity has been proved the annulus is then vented to ambient to create a zero-energy zone, providing effective double block and bleed isolation. The large section elastomer seals are highly compatible with poor pipe surfaces and are engineered to suit corrosion or ovality issues ensuring a leak-tight seal even in ageing assets. The Tecno Plug has the ability to monitor the isolated pipeline pressure, this is done via a dual sealed pressure impulse line, this ensures there is no leak path through the tool. If required, pressure application though the tool is done by adding an additional control module containing a second equalisation valve. Isolation safety is ensured as two separately controlled valves need to be functioned to allow pressure communication through the Tecno Plug.

The Tecno Plug fail-safe design uses differential pressure acting on the tool to energise the locks and seals, this is referred to as self-energisation. When the isolation plug is self-energised the isolation is maintained independent of the control system, it is however backed up by the hydraulic control system which maintains the isolation when the differential pressure is below the self-energisation threshold. Once the Tecno Plug is activated the hydraulic circuits are locked in by pilot operated check valves and manual isolation valves (tether controlled) or fail-safe solenoid valves (remote controlled). The check valve pilot lines can be separate lines controlled independently if required. The Taper lock-ring provides twice the required lock contact area giving 100% contingency. In the event that the control system is compromised, the tool actuation mechanism will unset when differential pressure is equalised. This feature ensures pipeline integrity is maintained and the Tecno Plug is always recoverable upon job completion. The remotely operated Tecno Plug system is a piggable, remote controlled, tetherless isolation tool.

The remote control system provides a high degree of flexibility and eliminates the need for tethers or specially modified pig-trap doors. Through-wall communication is achieved using an extremely low frequency (ELF) inductive system for reliable tracking and accurate positioning of the Tecno Plug. An onboard hydraulic power pack provides the necessary actuation and control functions for the tool. The remote control module provides a robust system for safety critical activities. The remote control module has been assessed for use in an explosive atmosphere (EN60079-0:2004 and EN60079-2:2004) against rating Ex pz II T3. The external communication system is housed in an ATEX rated enclosure Exe IIC T6 GB.

DNV GL Type Approval

STATS Tecno Plug is fully certified by DNV GL to verify that the design criteria satisfies the requirements for Pipeline Isolation Plugs to provide dual seal and isolation in accordance with Offshore Standards; DNV-OS-F101 (Submarine Pipeline Systems) and recommended Practices; DNV-RP-F113 (Subsea Pipeline Repair) and in compliance with the following code; ASME BPVC Section VIII, Division 2.

Pigging Bypass Technology – Unpiggable Pipelines

STATS have developed a patented pigging bypass system for our isolation plugs which allows two Tecno Plugs to be pigged towards a blind centre. The technology was developed to facilitate the pipeline repair of unpiggable defects. This system allows a section of pipeline to be isolated where full bore pipeline access is unavailable due to a defect such as a pipeline buckle or dent. Each Tecno Plug is pigged from either end of the pipeline towards the defect to isolate the section and allow repair or replacement.

Applications

  • Pipeline valve replacement / repair
  • Riser replacement / repair
  • Pressure testing i.e. leak detection of risers or repaired pipelines
  • Mid-line pipeline repair / tie-in
  • Platform abandonment and bypass
  • Pipeline diversion

Videos

Tecno Plug™ | Vertical Riser Isolation

Piggable Pipeline Isolation Plug, Valve Replacement

Webinars

Unconventional Applications of Pipeline Isolation Plugs

Unconventional Applications of Pipeline Isolation Plugs

This webinar will give an increased awareness of how isolation plugs can be used in a variety of ways, during different phases of a pipelines lifecycle, leading to substantial risk reduction and cost benefits.

Watch Now

Operator Benefits

  • Safe breaking of containment on pressurised pipelines, providing a fully proved double block and bleed isolation, with a zero-energy zone maintained between the two barrier seals – in accordance with topside and subsea isolation guidelines
  • Piggable isolation tools require no welding or cutting into live lines, leaving no residual fittings or hardware on the pipeline
  • De-commissioning (bleeding down) and re-commissioning (refilling and re-pressurising) of pipelines minimised or eliminated, saving time and reducing costs
  • Production continued during pipeline maintenance or modifications
  • No flaring of gas or displacement of pipeline inventory
  • No emissions of gas or hydrocarbon vapour to the atmosphere during blow down
  • No danger of accidentally flooding offshore pipelines during construction
  • No need to dispose of hydrates, chemicals and contaminated water
  • Isolates short sections of pipeline anywhere in the pipeline system
  • Emergency preparedness and operational readiness

Key Features Tecno Plug

  • Size range: 3” – 54”
  • Pressure range: standard Tecno Plug up to 230 bar / 3336 psi with bespoke solutions up to 600 bar / 8702 psi available upon request
  • DNV GL Type Approval in accordance with; DNV-OS-F101 (Submarine Pipeline Systems) and recommended Practices; DNV-RP-F113 (Subsea Pipeline Repair)
  • Available as 3D bend compliant as standard with 1.5D on request
  • Robust compact design, enables Tecno Plug to be set in short sections of pipeline. In many instances production can be continued during pipeline maintenance or modifications activities
  • Twin compression elastomer seals are highly effective even in pipelines with corrosion and ovality issues
  • High integrity isolation, taper lock grips provides twice the required lock contact area i.e. 100% contingency
  • Annulus bleed between seals allows pressure to be vented to ambient creating a zero-energy zone providing true double block and bleed isolation
  • Fail-safe design feature; taper lock grips and seals energised by differential pressure; referred to as self-energisation
  • Self-energisation feature maintains safe isolation while differential pressure exists across the plug
  • Hydraulic system override releases the plug setting mechanism when pressure is equalised (Fail-safe passive unset feature) ensuring in any circumstances the tool can be unset and recovered.
  • Both seals fully energised by pressure – rubber pressure 1.1 – 1.4 times greater than pipeline pressure
  • Reverse pressure can be applied across the Tecno Plug to facilitate system leak testing
  • Outboard pressure monitoring options

Key Features Remote Tecno Plug

  • Size range: 10” – 54”
  • Pressure range: standard remote control module housing is rated for 200 bar /2900 psi external pressure
  • DNV GL Type Approval in accordance with; DNV-OS-F101 (Submarine Pipeline Systems) and recommended Practices; DNV-RP-F113 (Subsea Pipeline Repair)
  • The remote control module provides a robust system for safety critical activities. The remote
    control module has been assessed for use in an explosive atmosphere (EN60079-0:2004 and EN60079-2:2004) against rating Ex pz II T3
  • The external communication system is housed in an ATEX rated enclosure Exe IIC T6 GB
  • Through-wall communication is achieved using an extremely low frequency (ELF) inductive system for reliable tracking and accurate positioning
  • Subsea communication via acoustic link (3000m depth rating)
  • Remote Tecno Plug does not use lithium batteries negating the need for Emergency Response Procedures for the transportation / use of extremely hazardous materials