ZEVAC VENTLESS PURGE ON NEW PIPELINE
See how ZEVAC cross compression purged a five mile section of new construction pipeline without venting. Using compressed air as a vacuum, the pipeline was cleared and feed gas was introduced into the system the next day.
ZEVAC technology purged a 12" diameter new construction pipeline.
See how ZEVAC cross compression was used to do a ventless purge on five mile segment new pipe, using compressed air as a vacuum. Pipeline feed gas was introduced into the system the next day.
Instead of releasing gas to the atmosphere, ZEVAC helps utilities safely capture and manage natural gas in pipelines. The pneumatic (air) powered and controlled technology eliminates the noise, permits, notifications, hazards, and difficulties of venting and flaring.
ABOUT ZEVAC
From mobile gas evacuation units to fully customized equipment and field services, ZEVAC enables a closed-loop system of capturing, transferring, and reusing natural gas during pipeline operations. The methane mitigation equipment reduces product loss, minimizes costly service calls, and supports safer, more efficient maintenance across the gas distribution network.
Since 1952, Kerr Engineered Sales Company has represented leading pipeline and performance equipment manufacturers across the Eastern U.S. With four generations of family leadership, Kerr continues to serve the industry with the same commitment to quality, reliability, and personal service that has defined our company for more than 74 years.
TDW FIRSTS: ISOLATION TOOLS & FITTINGS IN ACTION
To help a customer isolate a section of a gas pipeline being upgraded and replaced, TDW employed three new applications of its technology, along with the first use of ZEVAC® cross-compression equipment.
To help a customer isolate a section of a gas pipeline being upgraded and replaced, TDW employed three new applications of its technology, along with the first use of ZEVAC® cross-compression equipment.
Isolating the Lines
TDW ProStopp® DS Isolation Tool
An East Coast gas company needed to replace a section of bare steel pipe as part of their infrastructure upgrade program. They were also installing a new gas regulator station on the same project. The 3,200 foot section of 16” and 10” pipeline, needed to be replaced without shutting off service to any customers.
TDW recommended the use of Spherical 3-WAY Tees at both locations. With Stops set thru the Spherical Tees, the line could be isolated while gas was still allowed to travel thru the system thru the new permanent bypass that was welded between the outlet of the two spherical tees.
To isolate the section of pipe, TDW technicians deployed a 16” STOPPLE® Train, a patented system designed to isolate sections of pipeline for maintenance or repairs while the line remains in service. The STOPPLE® Train Isolation Machine uses double block and bleed technology, featuring two Sealing Cups with a bleed port between to ensure secure isolation.
For isolating the 10-inch line, TDW deployed the 10-inch ProStopp® DS Isolation Tool, which also uses double block and bleed technology with two hydraulically activated plugging heads.
Redirecting Gas Instead of Venting
Once the isolations were set on the 16-inch and 10-inch lines, the trapped gas between the isolated sections needed to be removed so that the line could be cut and capped. Rather than venting the gas into the atmosphere the traditional method, TDW technicians utilized a ZEVAC® (Zero Emission Vacuum and Compressor) Quad to extract the gas from the isolated section and redirect it back into the existing 16-inch line.
Gas utilities implement cross-compression technology like ZEVAC for methane emissions reduction during live gas operations.
ZEVAC® extracts gas from the isolated section and redirects it into the 16-inch line.
After depressurizing the line, the team secured the area overnight. Upon returning, they verified that the isolation seals were intact, providing a 100% shut-off. With no gas remaining, the utility safely cut out the old section and welded end caps. This permanently rerouted gas thru the spherical tees and into the new section of pipe.
Conditioning the Line
TDW TOR 3-WAY Tee Bypass
Another TDW first on this project, TDW’s new 2-inch THREAD-O-RING™ (TOR) 3-WAY™ Tee was used to build a bypass line between the new and old pipelines. The utility did this two weeks before the isolation, when they were conditioning (pickling) the line. Once the STOPPLE and the ProStopp were set, the TOR 3-WAY Tee Bypass was employed as the suction and discharge point for the ZEVAC® machine during line conditioning.
When the bypass was no longer needed, the TOR 3-Way™ Tee was isolated using TDW’s new Temporary Isolation Plug (TIP). Used for the first time on site, the TIP allowed the utility to safely decommission the outlet on the TOR 3-Way Tee. After both lines were capped off, the TOR Plugs were set in the TOR fittings, enabling the utility to complete the fittings.
Results
This complex isolation project was completed on schedule, allowing the utility to safely install the sections of pipeline without shutting off service to any customers. The new TDW technologies utilized in this project included:
TDW 10-inch ProStopp® DS Isolation Tool
TDW 2-inch THREAD-O-RING™ (TOR) 3-WAY™ Tee
TDW Temporary Isolation Plug (TIP)
Additionally, TDW technicians effectively operated a ZEVAC® Quad cross-compression unit to redirect about 25,000 scf of gas back into the 16-inch line, effectively reducing the utility’s methane emissions. The collaboration between TDW’s isolation tools and ZEVAC® marked a successful first use of these combined technologies.
Our 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 equipment.
Kerr Engineered Sales Company has been representing leading pipeline repair and performance companies in Eastern US since the company was founded in 1952. Seventy three years later, KERR remains a family business delivering the highest quality service and expertise.
GPT EVOLUTION INSTALL USES ZEVAC
A gas operator installing an 8in GPT EVOLUTION isolation gasket utilized ZEVAC to capture and recover vented gas. This made the operation emission free.
Gas operator installing 8 in GPT eVolution gasket UTILIZes ZEVAC TO MAKE THE OPERATION EMISSION free
Isolation gaskets are installed to protect lines from corrosion and unintentional leaks. Inmost cases, installing these gaskets requires sections of pipelines to be evacuated and purged, often by gas venting. The practice of venting creates intentional natural gas emissions, releasing methane into the atmosphere. It is a paradox to vent while protecting against leaks.
A gas pipeline operator in Pennsylvania needed to install an 8in GPT Evolution Isolation gasket at a well pad north of Pittsburgh. Instead of venting before installing and releasing emissions into the environment, they utilized ZEVAC services to capture and recover the vented gas. To draw down 200ft of 8in line from approximately 200 psi down to zero with ZEVAC took approximately one hour from set up to the point when the gas in the section had been re-compressed into an adjacent line.
Company personnel were then able to install the GPT EVOLUTION gasket. This gasket is fully encapsulated and just 1/8in thick for easy installation. The GPT EVOLUTION is extremely abrasion and impact resistant due to the proprietary coating. It is also fire safe and does not have lamination.
This project protected their pipeline and protected the environment.
For more information on GPT, ZEVAC or any of the manufacturers Kerr represents, please contact Kerr Engineered Sales Company.
Application specialists are available for team presentations, lunch and learns and customer visits.