Solutions Engine

Valve Replacement

Even under ideal operating conditions and comprehensive maintenance regimens, valves are subjected to significant wear and tear that can cause them to leak, resulting in a cascade of problems. For example, when launcher or receiver valves won’t isolate because they’re leaking, it prevents safe access to pig loading or retrieval and can halt pigging programs. When offshore platform emergency shutdown valves (ESDV) leak, it can create a hazard for the entire pipeline and platform. 

TDW helps operators repair and replace leaking valves, mitigating the risks that accompany them. Depending on the industry, services can include:

  • Pigging to displace pipeline products so valve repair and replacement can proceed safely and with minimal downtime.
  • Non-intrusive inline isolation for that enables repair and replacement of pipeline sections while the system remains in service.
  • Hot tapping and plugging services that allow work to proceed at operating pressure.



When pipeline contents must be removed before valve replacement, TDW offers Offshore Pipeline operators a full suite of pigging tools to effectively and efficiently displace liquids and natural gas, including:

  • UNISPHERE™ pig – Heavy-duty inflatable sphere that removes liquid hydrocarbons and water from pipelines and piping systems.
  • REDSKIN™ foam pig – Tough and abrasion-resistant, used for dewatering, air removal prior to hydrostatic testing, and drying after hydrostatic testing.
  • OptionALL™ batching pig – Designed for light cleaning, line filling and dewatering, batch separation, and liquid removal.
  • VANTAGE® V batching pig – Used for batching, displacing, and light cleaning.
  • ULTRA™ pig – All-urethane pig that is batching- and displacement-capable.    
  • X-Pig® multi-purpose utility tool – Flexible and versatile all-urethane pig that can negotiate tight pipeline turns and is appropriate for cleaning, batching, and displacement operations.
  • VANTAGE® + pig – Can be used for batching and displacement. Flexible in tight bend pipelines and can traverse a 20 percent reduction in interior pipe diameter.   


In the Offshore Pipeline market, risk reduction is of utmost importance. TDW offers safe, proven hot tapping and plugging (HT&P) solutions for a wide array of pipeline defects and maintenance challenges from dents to corrosion to valve failure.

TDW technicians, who have a long track record of successful offshore projects around the globe, ensure that the work entrusted to the company is done efficiently with minimal interruption to product flow.

Whether operators need an emergency pipeline intervention or topside maintenance during a planned shutdown, HT&P offers safe and proven solutions for getting the project completed. The process incorporates a high pressure pipeline fitting, valve, tapping machine, and isolation equipment – all working together to provide a safe and proven isolation solution. Once the area of pipeline that needs work has been safely isolated and evacuated, the line modification can be performed.

TDW isolation technology plays a critical role in this process and, when combined with a temporary bypass, allows repairs to be performed without the need to stop product flow. The STOPPLE® Train Plugging System, for example, uses double block and bleed technology to help increase efficiency and safety during pipeline maintenance and repair. The system is able to create a double block and bleed seal through a single fitting – reducing costs associated with fittings, valves, welding, and inspection services. The bleed port affixed on the line ensures that any product that bypasses the first seal is contained and evacuated through the bleed port, which creates a safe zone in high-consequence areas.

Whether operators are purchasing equipment to perform their own HT&P jobs or turning to TDW to execute the service, they can rely on the TDW line of equipment and consumables. The Subsea 1200RC tapping machine, for example, is a topside-driven hot tap machine that can be safely operated down to a depth of 3,000 meters (9842.5 feet). The machine has proven to be a highly reliable shallow and deep-water solution.


When the damaged valve can be pigged through and flow is not restricted or stopped, TDW can isolate the pipeline in a pre-determined position at full line pressure. In fact, TDW has performed hundreds of isolations related to valve replacement or remediation with its industry-standard technology.

  • SmartPlug® isolation technology – The TDW SmartPlug inline isolation tool is a remotely controlled and operated, non-tethered, double block and monitor pipeline isolation system for oil and gas pipelines. It helps protect people, assets, and the environment while saving time and money compared to the temporary decommissioning of the entire pipeline. In addition, SmartPlug technology enables local hydrotesting of the replaced/repaired area without affecting the integrity of the initial isolation, which can be held in place. The SmartPlug tool also allows production and flow of other lines tied in to the downstream section of the isolated pipeline to continue uninterrupted.

    SmartPlug isolation tools can be tracked and identified by the SmartTrack™ two-way communication system. The SmartTrack system is capable of through-wall communication in any pipeline medium and can operate in pipelines up to 50 millimeters (approximately 2 inches) thick. The system also allows for extremely precise tool positioning, with accuracy of +/- 25 millimeters (approximately 1 inch), depending upon the environment.