Emergency Pipeline Repair
A corroded section of 20-inch high-pressure natural gas pipeline in Virginia was replaced within two weeks without interrupting gas service.
20-inch TDW double STOPPLE® in action
After a smart pig in-line inspection identified severe corrosion on a 20-inch high-pressure natural gas pipeline, immediate action was needed. The Virginia utility turned to Daryl Smith, Sr. Application Specialist from Kerr Engineered Sales to set into motion an emergency project. The corroded section had to be replaced in two weeks without interrupting gas service.
Equipment and technical support for the double STOPPLE® train with full bypass was fast tracked. Daryl worked with T.D. Williamson to rapidly secure STOPPLE® isolation equipment, fittings, and completion plugs. Schedules were rearranged so that a TDW Technician could be on site within days.
On site, crews installed fittings and valves on the live pipeline and performed hot taps at multiple sites. The emergency project used 20” double STOPPLE® plugging equipment that isolated each section and controlled the flow of gas.
Complicated Bend
A bend in the pipeline was an added challenge
A temporary bypass maintained gas flow while the damaged pipe and bends were removed and replaced. One section of approximately 30-feet included a bend, complicating the project.
Once the corroded section was replaced, the isolation equipment was removed and the pipeline was safely restored to normal operation.
Risks & Fines Averted
The emergency repair was completed within two weeks, restoring the integrity of the pipeline without interrupting gas service.
Due to highly skilled crews and fast acting support, the risks and costly fines associated with a severely corroded pipeline were averted without interrupting gas service.
The pipe being prepared for the double STOPPLE® Train
Application specialists at Kerr Engineered Sales Company are available for demonstrations, team presentations, lunch and learns and site visits. We are here to help you optimize your gas utility operations and ensure the safety and efficiency of your assets.
Kerr Engineered Sales Company has been representing leading pipeline repair and performance companies in Eastern US since the company was founded in 1952. Seventy four years later, KERR remains a family business delivering the highest quality service and expertise.
Converting a Pipeline to a Piggable Asset
A multi-phased operation transformed a ten mile segment of a 12-inch transmission line into a piggable asset. The project was completed without interrupting gas service to customers.
An eastern utility had a critical transmission line that wasn’t piggable. When pigging, a device is run through a pipeline for cleaning, inspection, and maintenance. It’s an essential tool for an operator to perform in-line inspections and compliance with evolving regulatory requirements
Success wasn’t by chance. Nearly three years of planning and coordination between the utility, construction crews and technicians laid the groundwork for a disciplined, methodical execution. Over the course of six months, the ten-mile segment of a 12-inch bare steel pipeline was successfully transformed.
12-inch TDW Double STOPPLE® in action
Each phase was carefully sequenced to maintain system integrity while advancing the line toward full piggability. Today, the modernized asset supports in-line inspection, proactive maintenance, and long-term operational reliability.
Phases & Challenge
Converting the line was a multi-phase operation that required modifying a live pipeline under pressure. Dozens of precision isolation and tie-in activities were coordinated before the final commissioning.
Each step was executed while the line remained in service, maintaining continuous gas delivery across rural, suburban, and urban areas. The high-pressure transmission line traversed varied terrain and fed into multiple regulator stations with stops supplying gas to communities, schools, and businesses.
Equipment and services from KERR principals T.D. Williamson, CECO Peerless and ZEVAC® were deployed at different stages. Technologies included double STOPPLE® operations, hot taps, bypass, cross compression, separation and ultimately, pigging.
Pipeline Modifications
Multiple bends and fittings throughout the system that prevented pig passage had to be systematically cut out and replaced. One by one, these components were removed and replaced with configurations suitable for pig passage.
Each modification required isolating a section of the live pipeline. This was accomplished using double STOPPLE® operations with bypass.
At each location:
Fittings and valves were installed on the live line
Hot tapping services created access points
TDW STOPPLE® heads were inserted to isolate the section
Temporary bypass lines maintained flow around the work area
There were multiple 12-inch STOPPLE® operations, with additional 4-inch double TDW STOPPLE® bypasses. STOPPLE® train?
The approach allowed crews to cut out bends, install new sections including TDW 3-WAY™ tees. Then, the pipeline configuration was restored in stages, while gas continued to flow.
Emissions Reduction Through Cross Compression
Managing trapped gas between isolated sections was a critical project component. Rather than venting methane to the atmosphere, cross compression technology was used.
ZEVAC® cross compression was used to capture gas from isolated sections.
TDW crews were trained to operate a ZEVAC® system, allowing gas to be extracted from isolated sections and redirected back into the pipeline.
This approach:
Eliminated unnecessary methane emissions
Avoided costly third-party service dependencies
Maintained operational efficiency throughout the project
Additional System Upgrades
During the project, the utility used the opportunity to complete additional operational improvements, including:
Replacing and upgrading sections of pipe
Relocating pipeline components for improved performance
Testing of a new advanced isolation technology, TDW SHiiELD® double block and bleed system with dual independent barriers during live pipeline isolation.
Preparing for Pigging
TDW D2000 Proseries closure on the pipeline.
Once the pipeline was fully modified, pigging operations were introduced using TDW pipeline pigs and D2000® closures.
A CECO Peerless filter separator was installed at the end of the line. During pigging, accumulated debris such as rust and sediment carried through the pipeline had to be removed from the gas stream. The filter separator ensured effective removal of these materials before gas re-entered the system.
Peerless Filter Separator removed sediment and debris from the gas stream
Results
The project was completed within six months without service interruptions or safety incidents.
[Need #] STOPPLE® operations completed successfully
Continuous gas service maintained throughout the project
Significant cost savings achieved by avoiding shutdowns
Methane emissions reduced through cross compression
Today, the transmission line is a modern, fully piggable asset compliant for ongoing inspections, maintenance, and long-term integrity management.
A winning formula for complex operations like these consists of meticulous coordination, proven technology and highly skilled teams.
Application specialists at Kerr Engineered Sales Company are available for demonstrations, team presentations, lunch and learns and site visits. We are here to help you optimize your gas utility operations and ensure the safety and efficiency of your assets.
Kerr Engineered Sales Company has been representing leading pipeline repair and performance companies in Eastern US since the company was founded in 1952. Seventy four years later, KERR remains a family business delivering the highest quality service and expertise.
V-Jet Pig: Combatting Corrosion
TDW V-Jet® Corrosion Inhibitor Pig was engineered to address the challenge of Top of Line Corrosion. the V-Jet® pig takes a direct and efficient approach of redistributing inhibitor fluid where it’s needed most.
TDW PIGGING INSIGHTS - Episode 7
Top-of-line corrosion (TLC) remains a persistent issue in natural gas pipelines. By its nature, TLC is difficult to control because corrosion inhibitors tend to settle along the bottom of the pipe, leaving the uppermost portion of the pipe wall exposed and vulnerable. Over time, this uneven protection can lead to accelerated internal corrosion, integrity concerns, and increased maintenance costs.
How it Works: The TDW V-Jet® Pig
The TDW V-Jet® Corrosion Inhibitor Pig was engineered to address the challenge of TLC. Instead of relying on traditional methods that struggle to reach the top of the pipe, the V-Jet® pig takes a more direct and efficient approach by redistributing inhibitor fluid where it’s needed most.
The V-Jet® design is a series of strategically placed spray nozzles integrated into the scraper body. As the pig travels through the pipeline:
Corrosion inhibitor that has pooled at the bottom of the pipe is drawn into the pig through inlet ports
The system uses differential pressure to propel the pig forward
That same pressure is leveraged to redirect inhibitor fluid through the internal spray system
The inhibitor is then projected upward, coating the top of the pipe wall
This process is enhanced by a venturi effect created by the pig’s bypass design. The bypass flow acts as an accelerant, helping atomize and distribute the inhibitor more effectively across the upper internal surface.
Engineered for Simplicity and Reliability
TDW V-Jet® Corrosion Inhibitor Pig
One of the strengths of the V-Jet® pig is its straightforward, field-proven design:
No moving parts
No onboard pressure vessels
No need for pre-charging or complex setup
That simplicity translates to reliability in the field and reduces operational complications during pigging runs.
The ability to consistently deliver corrosion inhibitors to the top of the line is a significant step forward in managing internal corrosion. The V-Jet® pig provides a practical, cost-effective way to improve inhibitor distribution without adding unnecessary complexity to operations.
Bottom Line
With the right tools, TLC can be managed effectively. The TDW V-Jet® Corrosion Inhibitor Pig offers a proven method to enhance protection where traditional approaches fall short.
To learn more about the TDW V-Jet® Corrosion Inhibitor Pig or to discuss your application, contact the KERR team.
The team of Application Specialists at Kerr Engineered Sales Company is available for presentations, product demonstrations, lunch and learns and customer visits.
TIPS TO CONSIDER WHEN PURCHASING CLOSURES
When selecting Closures, pipeline operators should consider safety and performance factors. The TDW D2000 Closures with the ProSeries™ Advantage is the safest, most trusted closure on the market.
“Imitation is the sincerest form of flattery that mediocrity can pay to greatness.”
Don’t compromise safety and performance by settling for imitations. When it comes to closures, cutting corners isn’t an option. The safety of your crews, the integrity of your pipeline, and the efficiency of your operation all hinge on choosing the right product.
TDW’s D2000 ProSeries closures are backed by more than 100 years of engineering expertise, field experience, and continuous innovation.
When you invest in the D2000 ProSeries, you’re not just buying a closure—you’re choosing the best-in-class solution backed by a manufacturer who will be here for the lifetime of your pipeline.
the manufacturer
Proven track record – Does the manufacturer have decades of field-proven reliability, or are they new to the market? TDW closures have been rigorously tested and trusted by operators worldwide for generations.
Life cycle support – A closure is only as good as its support. Look at availability of parts, repair services, and consumables like O-rings and Pressure Warning Locks (PWLs). TDW ensures long-term support for every component.
See the D2000 Closure in action
SAFETY FIRST
The primary question: Does the design keep the operator out of the danger zone?
Operator positioning – With the D2000, operators can safely open the closure from outside the direct line of danger.
Pressure Warning Locks – Placement matters. PWLs located in the 12 o’clock position are less likely to collect debris than those on the door face. The D2000 design directs any retained pressure safely away from the operator.
Durability and spares – Unlike metal-to-metal seals that wear out quickly, TDW’s PWLs are supported with readily available O-rings and replacement parts, ensuring reliability and uptime.
Design AND FEATURES that matter
Simplicity of operation – Fewer moving parts mean fewer failure points and easier maintenance.
Ease of alignment – A single pivot point makes aligning the door with the collar straightforward and efficient.
Clamping surface design – Closures with parallel, non-wedging clamp-rings eliminate force transfer to holding components, reducing wear compared to tapered, wedging surfaces.
O-Ring LOCATION and performance
Sealing performance is critical, and O-ring placement makes a big difference.
Protected placement – O-rings positioned on the external outer edge of the collar are less likely to be damaged during pig loading or removal, and they’re better protected from debris.
Leak prevention – Properly compressed O-rings perform even at low pressure, reducing leak risks.
Material options – TDW offers multiple O-ring materials to suit varying operating conditions, giving operators flexibility and reliability.
TDW closures are there for the lifetime of your pipeline.
DOWNLOAD CLOSURE BROCHURE
At Kerr Engineered Sales Company, we know closures inside and out. For over 73 years, we’ve been helping operators make the right decisions for pipeline safety and efficiency. As TDW’s representative since 1952, we stand firmly behind their products and their commitment to excellence.