Project Summary
PTS was able to carry out a shutdown-free re-route of a dangerous liquid ammonia pipeline at one of the key government fertilizer plants. This became the challenge of handling -20 °C temperature and 25 Bar pressure without interruptions via Line stopping services. The solution? The first-ever double tandem line stop in India on such a line is a milestone in live pipeline interventions. The project illustrated high containment, zero-leakage guarantee, as well as technical expertise in engineering, and upholding the continuity of plants.
Industry Background
Liquid ammonia is crucial to the fertilizer and chemical industries. 70%of liquid ammonia is used in crop nutrient production, such as urea and DAP. Nonetheless, it is extremely dangerous, pressurized, and cryogenic, which is why it is quite dangerous to handle via the pipeline. Small mistakes made in the process of change can result in major dangers. This requires sophisticated intervention procedures that do not cause significant disruption of the operation but ensure that safety is a priority. The extreme environmental conditions, process sensitivity, and adherence should also be considered in any ammonia handling project, particularly the live lines in full operation, as was done in this project.
Project Requirements
The client was a Government of India fertilizer plant that had to redirect ~60 meters of a live liquid ammonia line. They were -20 degrees Celsius temperature, 25 Bar pressure, and the no-shutdown rule. The work had to be done in full flow without any leakage or compromise in safety. PTS offered a tandem double line stop with bypass to isolate the section and to reroute the pipeline under live conditions. This was a safe in-service modification method that ensured uninterrupted transfer of the product. The main goal was to redirect without stopping the production and without putting the environment or the personnel at risk.
Challenges Faced
The location posed several dangers: low temperatures, high pressure, and the high toxicity and volatility of ammonia. There was no tolerance for leakage or downtime in the operation. There was no shutdown window, so everything was to be performed live-with all safety precautions followed in an active plant. Moreover, there was the limitation of space and the rigid regulatory process. Every move had to be carefully planned, coordinated in real time, and contingency prepared. PTS needed to guarantee the strong sealing, surveillance, and professional implementation at every stage of the intervention without any room for error.
PTS Solution
a. Tandem Double Line Stop
Tandem double line stop was selected due to its dual seal safety feature and the capability to keep the flow with a bypass via line stopping services. The flow was isolated by the first seal to be rerouted, and the second seal acted as a fail-safe. The bypass line made sure that the system remained functional all the time. This approach offered redundancy, safety, and zero disruption, which was essential in such a high-risk pressurized line. Since there was no other solution that would have worked within the constraints, the tandem arrangement was the only way that would have satisfied safety, containment, and operational needs. Learn more about our Line Stopping Services
b. Hot Tapping & Execution
PTS technicians adhered to the safety measures and were fully dressed in chemical protective suits. First, post heat treatment was done on split tees (8,600). Sandwich valves were installed next. Hot tapping services were employed using hot tapping machines, and then 4 and 6-inch live hot taps were performed. The tandem seals were enabled through the use of gas bag fittings (4 600). Everything was done on a live line, and the ammonia was running at full pressure. The whole process was done in real time, and therefore it was precise, compliant, and the crew was safe.
Safety & Compliance
Safety was part of the planning to implementation. PTS adhered to all the rules and regulations regarding pipeline and chemical handling, and there were PPE requirements, trained personnel, and supervision. Containment measures were in standby. The crew was able to guarantee zero leaks, zero emissions, and zero safety violations. The planning was based on pre-job risk assessment, preparedness of response, and multi-level monitoring. There were no exceptions in meeting the pressure containment standards and the best practices in live-welding. The project is an example of operational safety in hazardous pipeline operations in extreme and limited conditions.
Outcomes & Effect
The project was successfully rerouted with no downtime and no safety incidents. There was no leakage of any products, and all operations were not affected. The client enjoyed complete continuity of operations, low exposure to risk, and low cost as compared to shutdown. This was the initial successful tandem double line stop on an operating ammonia pipeline in India–a pioneer in the safe, shutdown-free chemical line intervention. The result affirmed PTS as a reliable source of mission-critical work and demonstrated that it is possible to perform complex pressurized rerouting safely and efficiently.
Project Significance
The project was the first of its kind in the chemical and fertilizer industry in India to be shutdown-free. It demonstrated how engineering innovation could meet vital safety, operational, and compliance requirements, without stopping production. It also increased the leadership of PTS in high-risk, live pipeline interventions. The success gives confidence in the application of tandem line stops to future liquid ammonia or hazardous chemical lines, and they are safer and smarter as compared to shutdowns. It is not only the milestone of PTS but also a step in the right direction for the industry.
About PTS
Plant Technology Services (PTS) is a reliable pioneer in live pipeline intervention, offering shutdown-free, high-precision solutions in key industries. Our hot tapping, line stopping (single, tandem, and bypass), in-service welding, and emergency modifications expertise allows us to assist clients in ensuring continuity in their oil, gas, chemical, and fertilizer operations. Our workforce is conditioned to perform in high-pressure, high-temperature, and risky environments without compromising safety or performance. Whether it is government infrastructure or a privately owned industrial plant, PTS group has a reputation for taking on complicated, high-risk work where there is no time to stop working. We integrate innovation, compliance, and engineering excellence to bring reliable pipeline solutions each time.