Introduction
Insert valves provide a potent solution when the downtime of the pipeline is not an option. Insertion valves, also called insertion valves, enable the addition or replacement of valves on live pipelines without flow interruption and are therefore essential to utilities, industrial operators, and infrastructure contractors.
What Are Insert Valves?
Insert valves are gate-type split-body valves placed around an existing pressurized line. The valve body and pipeline wall are drilled through to create a hot tap through which a resilient gate (or cartridge) can be inserted, sealing off the line section. An example is the PTS Uni-Valve, which is installed in a single excavation, on lines 3″-18″ and up to 16 bar (232 psi) and provides a permanent point of flow control under full pressure.
Types of Insertion Valves
Insertion valves are available in many different designs, each with its own application:
Gate Valves:
These valves are the best to use when there is a need to shut off completely, and they are mostly applied in large pipelines in industries such as mining and power.
Butterfly Valves:
Butterfly valves are small and fast to actuate, and they are ideal where there is limited space in the pipeline, and the fluid is fast flowing.
Check Valves:
These valves are used to eliminate backflow and are necessary in water treatment plants and chemical plants.
Ball Valves:
Ball valves have tight seals and are therefore applicable in applications where high flow rates and low leakages are needed.
Needle Valves:
They are also used to control low flow rates with precision and are therefore essential in research laboratories and hydraulic systems.
How Do They Work
- A saddle or flange should be used to clamp the split valve body to the live pipe.
- Bore a hot tap hole through the pipe in the valve body.
- Place the gate or valve cartridge and fasten it.
- Turn the valve by key or gearbox–now you can regulate flow instantly, as you do with a regular valve.
All this is done without any shutdown or line drain.
Key Benefits
- Zero Downtime: No interruption of service during installation- rapid repairs, upgrades, or expansions.
- Cost-Effective: Single excavation, little labor, and no purging or refilling is necessary.
- Safety & Integrity: The less the excavation, the less the risks and the less the surroundings are affected.
- Immediate Control: The Valve is ready to work immediately after installation, which is suitable in case of an emergency.
Common Use Cases
- Emergency Repairs: Add isolation on broken mains close to sensitive installations such as hospitals.
- Upgrades & Tie-Ins: Upgrade old valves or insert new connection points without interruption of service.
- Operational Flexibility: Place valves in key positions to enhance the control and resilience of the system.
Comparison to Traditional Methods
Traditional installs involve draining, multiple excavations, purging, and re-testing of pressures. Instead, insertion valves are quick, cheap, and much less disruptive- saving time, money, and community impact.
Technical Specs & Applications
- Pipe sizes: typically 3″–18″ (DN 80–450)
- Pressure rating: up to 16 bar (232 psi)
- Material compatibility: water, wastewater, industrial fluids
- Certification: meets AWWA, ANSI, NSF standards
PTS Uni-Valve is an example of this: single excavation, minimal soil disruption, simple operation of the valve using a standard valve key, and permanent installation into the pipeline infrastructure.
Conclusion
Insert valves are the best solution when maintenance or upgrades are to be done where service continuity is essential. The Uni-Valve and associated systems offered by PTS offer live-line valve insertion that is reliable and minimally disruptive, and cost-effective.
Contact PTS to find out how insert valves can streamline your pipeline operations and make sure you are in control even on pressurized lines.
References & Further Reading
- Uni-Valve specifications: Uni‑Valve Details
- Specialized pipeline products overview: PTS Group Pipeline Solutions
