The shutdown of pipelines is expensive, hazardous, and inconvenient, especially when it comes to critical infrastructure and utility services. It is where it comes in. This new method allows engineers and contractors to live connect to pressurized pipelines without interruption of service.
PTS Group is a world-leading pipeline solutions provider that provides state-of-the-art hot tapping equipment and services that keep your system operating and allow you to get the upgrades you require. This blog post will examine the basics of hot tapping and how PTS makes it safe, efficient and reliable.
What Is Hot Tapping?
Hot tapping, or live tapping, is the method of connecting to a live pipeline without depressurizing or shutting it down. It enables the operators to install branches, valves, meters or sampling ports without shutting down the system.
It is a pressurized non-invasive solution, unlike traditional tie-ins, which necessitate the pipeline to be drained. Technicians drill a hole in a pipeline wall through a welded fitting and full-bore valve using a special hot tapping machine-then safely capture the section of the pipe (known as a coupon) as the flow proceeds uninterrupted.
How Hot Tapping Works
The process involves a number of important steps:
Fit and weld the branch fitting- A full-encirclement hot tap tee is welded on the live pipe.
Bolt on the full-port valve- A valve is attached to the fitting to create a sealed chamber.
Install the hot tapping machine- The hot tapping equipment is installed on the valve outlet.
Hot tap drilling -The cutter drills into the pipe under pressure and brings back the coupon.
Connecting the gap – The machine is taken out and now the valve can be used to reach or isolate the line.
The flow and pressure in the pipeline are constant during the process- this allows the modification to be done smoothly without any disruption of service.
Key Benefits
- Zero Downtime: Perform tie-ins, upgrades, and repairs while the pipeline remains active.
- Cost-Effective: Avoids draining, purging, refilling, and production losses.
- Safe & Controlled: Performed using pressure-rated equipment and certified operators.
- Environmental Advantage: No venting or product loss during installation.
- Versatile Application: Suitable for gas, water, oil, chemical, and industrial lines.
Safety & Compliance Considerations
Hot tapping is a work on pressurized systems, and therefore, safety is the key. PTS is compliant and secure as it:
- Pressure-balanced machines up to 150 bars are used.
- Using certified and trained technicians.
- Complying with international standards (e.g., ANSI, API) and ISO quality standards.
- Carrying out pressure equalization and environmental protection operations.
- The provision of fittings that can fit in different types of pipes (steel, ductile iron, etc.).
PTS has decades of experience in adhering to strict safety measures during the hot tapping services they provide.
Common Use Cases
Hot tapping is applicable in various industries such as oil and gas, water utilities, chemicals and power generation. Typical uses are:
- Emergency Repairs: Insert isolation points without service cut.
- Pipeline Expansions: Tie-in new branches when upgrading a plant or system.
- Flow Meter Installations: Instrumentation ports should be added to monitor and sample.
- Bypass Lines: Install loop systems to enable the work in other sections.
- Drainage & Venting: Insert taps to safely remove liquids or gases.
PTS Group’s Hot Tapping Solutions
PTS Group provides a turnkey package of hot tapping products and services, which include:
- Hot Tap Machines: Hydraulic and pneumatic tapping machines on 1/2 to 60 inch pipelines.
- Split Tees & Fittings: Full-encirclement fittings and three-way tees ANSI 150 600 class.
- Valves & Accessories: Full-port valves and coupon retainers are compatible.
- Hydraulic Power Units: Remote HPUs, diesel, petrol or electric.
- Certified Field Services: Experienced crews take care of everything including welding to final tie-in.
- Emergency Services:Hot tapping services with rapid response to avoid downtime of critical infrastructure.
PTS has been a reliable subcontractor to utility companies, industrial clients, and infrastructure contractors around the globe.
Comparison to Traditional Methods
Conventional tie-ins involve complete shutdown, depressurization, excavation and re-testing- time consuming, labor intensive and operationally disruptive.
In comparison, hot tapping will enable you to:
- Avoid line draining and purging
- Avoid service interruptions
- Restrict digging and environmental degradation
- Complete the work quicker and cheaper
PTS equipment and techniques are designed to provide safe, low impact pipeline alterations, even in high pressure.
When to Use Hot Tapping vs. Line Stopping
Hot tapping and line stopping are meant to be used in different aspects of pipeline maintenance and the appropriate one to use should depend on the objectives of your project. Hot tapping is the process to use when you want to install a new branch or connection on a live pipeline without shutting down the flow, ideal in system expansions or upgrades. Use line stopping when you require an isolation of part of the pipeline to repair or modify it whilst continuing to operate the rest of the system. The consideration of such factors as pressure, type of fluid, and shutdown tolerance will allow defining the method that will be the safest and most efficient.
Learn more in our full guide: Hot Tapping vs. Line Stopping: Which Pipeline Shutoff Method Works Best for Your Project?
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Technical Specs & Applications
- Pipe Sizes: 1/2 inch to 60 inch
- Pressure rating: 150 bar (2,175 psi)
- Materials: Steel compatible, ductile iron, cast iron, PE-lined steel, etc.
- Certifications: ISO, ANSI, API, AWWA, NSF (where applicable)
Conclusion
Hot tapping is the best option when there is a need to maintain continuous service. PTS Group offers industry-leading hot tapping machines and hot tapping services, whether you are working in utility infrastructure, industrial systems or emergency repair projects.
Are you ready to make safe, live pipeline connections without any downtime?
Contact PTS to speak with an expert.
