At PTS Group, we acknowledge that downtime directly translates to lost revenue for pipeline operators. This is particularly true in industries like oil and gas, where production losses and missed deadlines can have significant financial impacts.. That is the reason we rely on two of the most effective methods in the industry — Hot tapping and Line stopping — to reduce downtime, enhance safety, and protect pipeline integrity.
In this blog, we’ll walk you through everything you need to know about hot tapping vs. line stopping, including the main differences between them, typical uses, safety precautions, and how to determine which operation is suitable for your pipeline.
Understanding the Need for Pipeline Shutoff Methods
It is common that most hydrocarbon products, such as oil, gas, chemicals, fertilisers, including water, are transported over long distances through pipelines at high pressure and with continuous flow. A pause in these flows for any reason can result in major interruptions, impact customers, and cause major concerns.
Traditionally, shutting down a pipeline means depressurising a lot of it, draining the systems, and setting aside a lot of time for repair. This approach creates a lot of inconvenience and adds to the budget.
That’s why we provide pipeline intervention services without shutdowns, such as hot tapping and line stopping services, to keep your pipeline online safely during upgrades or repairs. Choosing between hot tapping vs line stopping depends heavily on your project’s constraints, flow needs, and system design.
What is Hot Tapping?
With our hot tapping technique, we can take out a branch connection on a pressurised, active pipeline — all without disrupting flow. We have the capability of carrying out hot tapping operations from ½” to 96” on oil, gas, water, etc, product lines.
How Hot Tapping Works
- The Hot tap split tee fitting of appropriate dimensions is welded onto the pipeline using qualified in-service welders.
- Then the sandwich valve is mounted onto the fitting
- Next, the machine is installed on the sandwich valve
- All safety checks are performed, and then the Hot Tapping operation begins
- The Hot tapping machine will drill into the pipe
- And the cut section of the pipe, which is called the coupon, will be retained by the hot tapping machine with the U-wires on the pilot drill
Advantages of Hot Tapping
- Allows you to do modifications on your pipeline without changing the pipeline parameters, and no expensive shutdown is required.
- Extensive pipeline shutdowns reduce emissions and waste associated with production halts.
- Cuts environmental dangers by not having to depressurise the system.
- It is flexible and can be performed for various industries such as oil, gas, fertilisers, chemicals, steel plants, water, a nd utility sectors
What is Line Stopping?
When a section of a live pipeline needs to be replaced or some modifications, such as Installation/replacement of a valve or return of a pipeline, require a line stopping operation.
We provide line-stopping operations from 2” to 66” on different product lines. Up to 80 bar pressure and temperature as low as -10 Deg C and High up to 150+ Deg C
How Line Stopping Works
- First, the Line Stop Tee is welded or bolted onto the line
- The Sandwich valves is installed onto the Line Stop Tee.
- Next the Hot tapping machine is Mounted
- The Hot Tapping operation is carried out , the coupon is retained
- The Hot tapping machine is uninstalled and the Linestop equipment is Installed which comprises of Line stop actuator , housing & Head
- The Line stop head is inserted to stop the flow of the product in the pipeline this we are capable doing line stop operation from 2” to 66” for ANSI 150# , 300# , 600# and higher – with Articulating & Folding Heads .
- During the line stop operation , the vales can be replaced/ Installed or line modification such as rerouting the line or replacing the damaged section of the pipeline could be done while the flow is shut off.
- Once the desired work is completed , the line stop head is retracted and the fitting is Closed off using the Clouser Plug and the product flow continues.
Advantages of Line Stopping
- No shutdown time is required for carrying out maintenance work on pipelines.
- Saves a lot of time and avoids expensive shutdown.
Hot Tapping vs Line Stopping: When to Choose Which?
| Use Case | Choose Hot Tapping | Choose Line Stopping |
|---|---|---|
| Adding a new branch connection | ✅ | ❌ |
| Replacing damaged pipeline section | ❌ | ✅ |
| Valve installation or replacement | ❌ | ✅ |
| Rerouting lines | ❌ | ✅ |
| Minimal equipment, faster completion | ✅ | ❌ |
| Flow isolation needed | ❌ | ✅ |
Real-World Example:
When a new Pipeline connection for oil, gas or water needs to be connected to a main line without interrupting the flow, we provide hot tapping services to make the connection seamlessly, keeping operations running smoothly and without service loss.
Important factors to consider for safety and technical issues.
Because both hot tapping and line stopping are conducted in pressurised systems, they carry a high level of risk and require certain precautions.
- In-depth risk reviews and safety standards
- Workers who know the equipment and the materials used in the pipeline
- Regularly watching pressure, flow, and conditions of the environment
- Following the standard Safety rules set by the clients and industries
At PTS Group, we treat safety as a non-negotiable. Every project involving hot tapping vs line stopping is approached with updated tools and a strict safety protocol.
Compatibility with Pipeline Materials and Sizes
The techniques apply to pipelines constructed from a range of materials:
- Carbon steel
- Stainless steel
- Alloy Steel
- Cast and ductile iron
- PVC and HDPE
Selection is based on several things:
- Pipeline diameter
- Pressure class and pressure rating
- Fluid type, as well as temperature
- Site conditions and their access
Our team of Engineers at PTS Group evaluates all factors when deciding which pipeline shutoff method to implement for your project..
Our in-depth knowledge makes us the right partner for your pipeline needs:
- Choosing between hot tapping and line stopping doesn’t have to be complicated — we’re here to guide you through it.
With years of hands-on experience, cutting-edge equipment, and a strong commitment to client success, we’re ready to tackle any pipeline challenge alongside you. - Hot tapping machines have been developed for the safest and most efficient performance
- Line stopper tools capable of precise flow prevention and pipeline sealing
- Skilled tEngineers to help you move your project forward from the beginning to the finish
- Adaptable leasing, sales, and healthcare are available at the event
Final Thoughts: Smart Decisions Lead to Safer, More Efficient Pipelines
When you know the pros and cons of hot tapping vs line stopping, you are better able to choose what’s best for your assets, your personnel, and your budget.
How you apply these pipeline shutoff methods is what makes them successful, so look at your project’s details, safety needs, and goals before deciding.
Let’s Make Your Pipeline Work Smarter in Addition to Being Safe.
No matter if you need to connect new pipes or stop a line to make critical repairs, PTS Group has hot tapping and line stopping tools to help you minimise downtime and maximise your safety.
Let’s talk about how we can support your next project. Reach out to our team today to explore our latest hot tapping and line stopping solutions.
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