What is hot tapping?
Hot tapping creates a new branch on a live pipeline — without shutdown, without draining, without interrupting the flow. A tapping fitting is attached to the line, an isolation valve is mounted, and the pressure-tight tapping machine drills through the pipe wall through the open valve. After the drill is retracted the valve is closed — the new connection has been made in service.
Line stop
Building on a hot tap, a line stop inserts a plugging head (stopple) through the fitting into the line to isolate it. With two stopples and a bypass line, a repair section can be completely separated from operation while the medium continues to flow through the bypass — valve replacement or pipe renewal without production interruption. After the work, the plug is retrieved and the fitting is closed with a blind plug/flange.
Technical data
| Parameter | Value |
|---|---|
| Tapping range | ½″ to 24″ |
| Max. operating pressure | 100 bar |
| Max. operating temperature | 300 °C |
| Fittings | in-house engineering department for fittings |
Safety & qualification
Hot taps require sound planning: wall-thickness measurement and inspection of the tapping location, qualified welding of the fitting onto the live line, pressure testing of the fitting before drilling and a documented risk assessment (TRA Hot Tapping and Line Stopping Operations is in place). The method minimises emissions — the medium is neither drained nor flared.
Typical applications
- ▸New tie-in to a product line without shutdown (e.g. for a plant extension).
- ▸Valve replacement with double stopple and bypass — production keeps running.
- ▸Isolation for repairs when pipe freezing is not possible (flowing medium, gas).
Why HSOS?
No downtime — operations and customer deliveries continue. With an in-house engineering department for fittings, documented safety planning and the combination with pipe freezing, cold cutting and heat treatment, HSOS covers the complete intervention chain from a single source.
Frequently Asked Questions
How does drilling into a live line work?
A fitting is attached to the line (usually welded) and equipped with an isolation valve; after a pressure test, the pressure-tight tapping machine drills through the pipe wall through the open valve. The coupon is retrieved with the drill, the valve is closed — at no point was the line open to the environment.
Up to which pressure and temperature is hot tapping possible?
We tap lines from ½″ to 24″ at up to 100 bar and 300 °C. Whether a specific case is feasible is assessed on the basis of medium, material, wall thickness and operating condition.
When line stop instead of pipe freezing?
A line stop works regardless of the medium — including gases and flowing media — and at large diameters; in return, a fitting remains on the line permanently. Pipe freezing requires no intervention in the pipe, but needs a stationary, freezable medium. We advise which method is safer and more economical in your specific case.