【Haichuan’s Insights from Other Sources】Zongzi-style plugging to solve pipeline repair challenges

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The zongzi-style sealing method solves the challenges associated with pipeline repair; Liu Wenpei (left), a technician from the Jianghan Oilfield, is wrapping up a leak in a pipeline to seal it. Photo by Li Dongyong. Small innovations to solve big problems. Problem: In the daily operation of oil fields, pipe bends are prone to leakage or even perforation due to prolonged exposure to the flow of fluids. Sealing leaks is often done by welding, using clamps, or applying steel strips. However, traditional welding methods pose safety risks in flammable and explosive environments, while clamps and steel strips have the problem of insufficient pressure resistance and a high likelihood of further leakage. What’s more troublesome is that the repair processes using these traditional methods are cumbersome; they often require a production halt for over 4 hours, thereby affecting the production schedule. Innovation: Liu Wenpei, a technician from the Jianghan Oilfield, drew inspiration from the structure of zongzi wrapping and developed a flame-free leak repair technique based on \"elastic wrapping + high-strength binding\". Elastic rubber is used to mimic the sealing effect of zongzi leaves, while composite leak-sealing materials serve as a \"sticky rice layer\" to fill gaps. Nylon ropes are used in place of cotton threads, and a cross-wrapping method is employed to create a network-like structural support, thereby enhancing pressure resistance and enabling immediate repair once a leak is detected. Effect: This technology raises the pressure resistance value against leaks from 3 MPa to 10 MPa, meeting the standards for high-pressure pipelines in oil fields. Compared to traditional methods, this approach eliminates the risks associated with hot work and removes potential safety hazards caused by sparks. Additionally, the cost per repair is reduced by over 10,000 yuan, while the required working time is cut from 4 hours to just 20 minutes. To date, this technology has been successfully applied at high-field stations in oil fields, as well as at sites such as Wangchang Joint Station, resulting in cumulative cost savings of 100,000 yuan. On June 24th, at Haokou Station of Jianghan Oil Production Plant in Jianghan Oilfield, oilfield technician Liu Wenpei applied a special wrapping to fix a leak in a pipeline. He skillfully used elastic rubber to tightly seal the leak, then wrapped it up with nylon rope in several layers; in less than 20 minutes, the leak was turned into a tightly sealed \"zongzi\". This seemingly simple procedure solved the problem of pipeline blockages that had plagued oil fields for many years. During oil field production, oil and water pipelines are prone to corrosion and subsequent perforation and leakage due to prolonged exposure to the flow of fluids. To address this, oil fields have previously used three methods for sealing leaks: welding, packing, and steel strip application. However, each of these methods has its limitations. Welding requires working with fire, posing safety risks, while packing and steel strip application lack sufficient pressure resistance and are prone to secondary leaks. “The biggest headache is that before each welding operation, the pipes must be emptied and a hot work permit obtained. The preparatory work alone takes several days. Additionally, the cost of a single repair can reach tens of thousands of yuan. The complicated and time-consuming procedures significantly hinder production efficiency. ”Lu Qijun, the safety officer at Haokou Station, said, “Moreover, sparks are generated during welding, and if those sparks ignite the leaked oil and gas, the consequences could be disastrous.” ” The turning point came from an inspiration from a real-life scenario. “One morning, I saw a breakfast shop wrapping zongzi. The glutinous rice was wrapped in bamboo leaves and tied up with cotton thread, resulting in a completely leak-proof package. Isn’t this a natural sealing mechanism? Could we apply the same principle to fixing leaks in pipes? ”Liu Wenpei recalled. The technical expert from the Jianghan Oilfield Innovation and Efficiency Alliance immediately began conducting experiments: elastic rubber was used to simulate the wrapping effect of zongzi leaves, composite sealing materials served as the \"sticky rice\" to fill the gaps, and high-strength nylon ropes were used for professional tying. After repeated tests, this zongzi-style wrapping method has yielded astonishing results: it not only increased the pressure resistance from 3 MPa to 10 MPa, fully meeting the requirements for high-pressure pipelines, but also eliminated the safety risks associated with hot work. What’s even more remarkable is that the cost of a single repair has dropped by over 10,000 yuan. In the demonstration at Haokou Station, Liu Wenpei managed to seal a leak in just 20 minutes. “It’s now as simple and efficient as wrapping zongzi! ”He said with a smile. Since its introduction, this innovative technology has been successfully applied at various sites in the oil fields, including the Gaochang Station and Wangchang Joint Station of the Jianghan Oil Production Plant, resulting in savings of over 100,000 yuan in maintenance costs. Currently, Jianghan Oilfield has developed standardized rapid leak-plugging toolkits based on this technology, which are being deployed throughout the oilfield. From breakfast zongzi to unclogging pipes, this innovation born out of practical wisdom not only solved production problems, but also demonstrated the boundless creativity of frontline technical workers.