Newsletter
February 2025
Quarterly Review
Enabling Critical Repairs Without Shutdowns
Hi there.
Across the world’s energy networks, the integrity of operating pipelines underpins safety, environmental protection, and reliable hydrocarbon delivery. Yet these critical assets face constant threats - corrosion, mechanical damage, ageing infrastructure, and evolving operational demands. When intervention is required, traditional approaches often mean shutting down production, depressurising long pipeline sections, and absorbing significant costs, delays, and supply disruption. That’s a compromise operators can no longer afford.
STATS’ tethered Tecno Plug® technology is transforming how pipeline repair and maintenance is carried out. Designed to deliver leak-tight, double block and bleed isolation, Tecno Plugs enable operators to safely isolate live, pressurised pipelines. But the real benefit of the tethered plug is its short design, allowing it to be set before the production tee so avoiding a shutdown.
By enabling localised isolation rather than complete depressurisation, planned activities can be completed safely, efficiently, and cost-effectively. Whether it’s valve replacements, trunkline repairs, or complex maintenance campaigns.
As the industry drives towards safer operations and a lower-carbon future, independently verified, high-performance isolation technology isn’t optional - it’s essential. Read on to see how tethered Tecno Plugs are helping operators protect their assets, maintain supply, and keep production flowing during the most critical interventions.
Featured Case Study
Keeping Production Flowing During Critical Valve Replacement
When a pig trap valve on a 56” receiver required replacement, a conventional shutdown would have halted a major production system. STATS deployed a tethered Tecno Plug to create a secure isolation on the live pipeline, allowing the operator to complete the valve changeout safely while maintaining uninterrupted flow, preventing a costly shutdown. Here's how we did it.
Tethered Tecno Plug in Action
42" Pipeline Isolation Using Stats Tethered Tecno Plug and 46" Door Plug
STATS' DNV Type-approved Tecno Plug delivers fail-safe double block and bleed isolation for live, pressurised pipelines. Dual seals create a zero-energy zone enabling safe maintenance. Both seals are tested at full pipeline pressure before the annulus is vented. Engineered for ageing assets with large elastomer seals that handle poor surfaces, the same solution has been applied successfully by STATS teams at a number of sites and for varying pipeline sizes. This animation shows a 42" pipeline being isolated.
How It's Done
Meeting the Isolation Challenge: Tethered Tecno Plug in Action
If you're pushed for time, we've pulled out a few examples that demonstrate real-world examples of the Tecno Plug tool in use – geared towards the completion of safe and effective projects that saved our clients time and money.
Case Study
Compact Design Key to Isolation Success
STATS installed a tethered Tecno Plug to provide robust double block and bleed isolation on the critical Brent 36” oil export pipeline. The plug’s compact design allowed it to be set in the short section of pipework upstream of the production tee and receiver valve, enabling export to continue throughout the valve replacement.
The solution delivered safe, precision isolation on a pressurised system while keeping production online - highlighting how advanced isolation technology supports operational continuity where reliability is paramount.
Challenging Bend Removal on Flowing Oil Export Pipeline
Location: Oman
Petroleum Development Oman (PDO) needed to remove and replace 14 pipe bends at block valve stations across seven sites on a critical 20” main oil line. This was all completed while the pipeline remained live and flowing at 55 bar. Rather than accept a lengthy shutdown, PDO turned to STATS’ tethered Tecno Plug technology to deliver safe, high-integrity double block and bleed isolation and keep oil flowing throughout the campaign. The multi-site project was completed safely, three weeks ahead of schedule, with zero production loss.
Pushing the Boundaries of Pipeline Isolation: Real World Examples
Pipeline owners and operators regularly face asset integrity challenges that demand innovative technology to ensure maintenance is completed safely, on time, and within budget. Unlike traditional methods, STATS' type-approved technology requires no welding or cutting into live lines, covering 3" to 56" pipelines without leaving residual hardware. Here we explore real-world examples highlighting the benefits of temporary double block and bleed isolation for maintenance on pressurised systems - without shutting down.
What's next?
Innovative Isolation Technology to Eliminate Shutdowns
STATS’ tethered Tecno Plug offers operators a smarter approach to pipeline repair, maintenance, and modification - keeping production online throughout. Not only this, the design ensures secure deployment and retrieval, while robust sealing capability delivers reliable isolation even in high-pressure, high-consequence applications.
Delivering high-integrity, leak-tight double block and bleed isolation, the system enables safe, controlled intervention on pressurised pipelines. Covering diameters from 3” to 56” and pressures up to 230 bar, the Tecno Plug deploys across a wide range of pipeline configurations, from complex valve stations to major trunklines.
By facilitating localised isolation rather than widespread depressurisation, Tecno Plugs significantly reduce downtime and minimise overall project costs and schedules. That capability is particularly valuable where production continuity, safety performance, and environmental protection are critical priorities.
Until next time,
Vikas Shangari
Global Sales Director
STATS Group