No Interruptions, Just Precision – Hot Tapping at Its Best

Did you know?  Hot tapping is a specialized procedure that involves drilling into a live pressurized pipeline to create a new branch connection without shutting down the system. This cost-effective method minimizes operations downtime but carries high safety risks, requiring precise planning and execution to prevent hazards.

At TWD, we recently completed a challenging stopple operation at a major refinery requiring hot tapping a 12" nozzle to a 20" live pipe, helping our client achieve compliance with SO2 regulation.

The project involved isolating the 20" ZTOF flare line to install a new isolation valve and a flow meter. This complex operation required a high level of expertise, meticulous planning, and specialized techniques to ensure success.

TWD successfully delivered full engineering packages, working hand-in-hand with the hot tapping contractor to ensure seamless coordination. We secured all necessary TSSA approvals, completed all paperwork, and provided dedicated on-site supervision to oversee the entire construction process.

Key aspects of the operation which was executed in a safe manner with no incidents, included:

• Performing non-destructive testing (NDT) to assess pipe integrity and ensure the selected location met all safety conditions.
• Conducting a full review to mitigate risks like coupon loss and burnout during welding.
• Welding a 12" flange on the live 20" pipe and installing a supporting sleeve around the flange and the pipe.
• Performing leak test with nitrogen to verify the weld’s sealing effectiveness before proceeding with the stopple machine installation.
• Executing the hot tap to safely open the live 20" pipe.
• Installing stopple machine on the 12" flange and provide an isolation to the 20" pipe to allow chemical cleaning and replacing the existing isolation valve, then install the 20" flowmeter to monitor SO2 levels in the flare

This successful operation showcased TWD’s technical precision and commitment to safety in executing high-stakes refinery projects.

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#TogetherWeDeliver #HotTapping #Refining #Oil&Gas #Safety #Engineering #Construction #Pipeline

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