Hot tapping is one of the smartest ways to connect to a live pipeline without stopping the flow. It lets you add new connections, install equipment, or take samples whilst your pipeline keeps running normally. This means no lost production time and no costly shutdowns.
Think of it like adding a new tap to your water pipes at home, except you’re doing it whilst water is still flowing through them. That’s essentially what hot tapping does for industrial pipelines.
What Is Hot Tapping?
Hot tapping involves cutting into a pressurised pipeline and installing a new connection whilst the system stays operational. The process uses special equipment that creates a seal around the work area, then cuts through the pipe wall without letting any product escape.
The name “hot tapping” comes from the fact that you’re working on a “hot” or live system. It doesn’t necessarily mean the pipeline is physically hot, just that it’s active and under pressure.
Keep Your Operations Running
The biggest benefit of hot tapping is that you don’t have to shut down your pipeline. This is huge for businesses that can’t afford downtime. Every hour a pipeline sits idle costs money in lost production.
With hot tapping, you can add new connections for meters, valves, or branch lines without stopping flow. Your main operations keep running whilst you make the improvements you need.
This is especially valuable for critical systems like water supplies, gas networks, or chemical processing plants. These systems often run 24/7, and shutdowns can affect thousands of people or entire production processes.
Save Money on Shutdowns
Shutting down a pipeline costs more than just lost production time. You often need to drain the system, purge it with nitrogen or other gases, and then refill and restart everything. All of this takes time and resources.
Hot tapping eliminates most of these costs. You’re working with the system as it is, so there’s no need for expensive shutdown procedures. The only cost is the hot tapping work itself.
For large pipelines, the savings can be enormous. A single day of shutdown might cost tens of thousands of pounds in lost production. Hot tapping typically costs a fraction of that amount.
Maintain Product Quality
When you shut down and restart a pipeline, you often have to deal with contamination issues. Air can get into the system, or you might need to flush out cleaning fluids before returning to normal operation.
Hot tapping avoids these problems because the product never stops flowing. There’s no air introduction, no contamination risk, and no need for extensive flushing. Your product quality stays consistent throughout the process.
This is particularly important for food-grade systems, pharmaceuticals, or other products where contamination could ruin entire batches.
Work Safely Under Pressure
Modern hot tapping equipment is designed to work safely on pressurised systems. The tools create multiple barriers between the work area and the flowing product. Even if something goes wrong, these safety systems prevent dangerous releases.
The process typically involves installing a fitting around the pipe, then using specialised cutting tools that can seal themselves if needed. Everything happens in a controlled environment with proper safety protocols.
Experienced hot tapping teams know how to handle different pressures and products safely. They bring the right equipment for your specific conditions and follow strict safety procedures.
Add Connections Exactly Where You Need Them
Hot tapping gives you flexibility in where you add new connections. You don’t have to work around existing valves or fittings. You can put the new connection exactly where it makes the most sense for your system.
This is especially useful for retrofitting older pipelines that weren’t designed with future expansion in mind. You can add monitoring points, sample ports, or branch connections wherever they’re needed most.
Quick Installation Process
A typical hot tapping job can be completed in a few hours or a day, depending on the size and complexity. Compare this to a full shutdown, which might take days or even weeks for large systems.
The process starts with installing a special fitting around the pipe. This fitting includes the cutting mechanism and all the safety systems. Once everything is in place and tested, the actual cutting happens quickly.
After cutting, you can install whatever equipment you need – valves, meters, or connecting pipes. The whole job is finished without ever stopping your main flow.
Perfect for Emergency Repairs
Sometimes you need to make emergency connections or repairs that can’t wait for a scheduled shutdown. Hot tapping is ideal for these situations because it works immediately on live systems.
You might need to install a bypass around a damaged section, add a pressure relief valve, or create an emergency drain point. Hot tapping lets you do this work right away, without waiting for the next planned maintenance window.
Reduce Environmental Impact
Pipeline shutdowns often involve venting gases or draining liquids that might not be environmentally friendly. Hot tapping eliminates most of these releases because the system stays sealed throughout the process.
This is particularly important for gas pipelines, where venting can release significant amounts of methane or other greenhouse gases. Hot tapping keeps these gases contained in the system where they belong.
Work in Difficult Locations
Some pipelines run through areas where shutdowns are particularly difficult or expensive. They might cross under roads, railways, or waterways where disruption causes major problems.
Hot tapping lets you work on these difficult sections without the complications of a full shutdown. You don’t need to worry about traffic diversions, railway closures, or environmental permits for drainage.
Maintain System Pressure
Many pipeline systems rely on maintaining specific pressures for proper operation. Shutdowns can disrupt these pressures and affect equipment throughout the network.
Hot tapping preserves system pressure because flow never stops. Pumps keep running, pressure vessels stay pressurised, and all your downstream equipment operates normally.
When Hot Tapping Makes Sense
Hot tapping works best when you need to add connections to existing pipelines. This includes installing new meters, adding branch lines, or creating sample points.
It’s particularly valuable for high-pressure systems, expensive products, or critical infrastructure that can’t afford downtime. The technique works on most types of pipes and products, though some situations require special considerations.
Getting Professional Results
Hot tapping requires specialised equipment and expertise. The cutting tools, safety systems, and installation procedures all need to work perfectly together. This isn’t typically a job for general maintenance teams.
At RDS Pipeline, we have the equipment and experience to handle hot tapping jobs safely and efficiently. We understand the technical requirements and safety procedures that make the difference between a successful job and a dangerous situation.
The Smart Choice for Live Connections
Hot tapping offers clear benefits for most pipeline connection projects. It saves money, reduces downtime, maintains safety, and gets you the connections you need quickly and efficiently.
When you need to add connections to a live pipeline, hot tapping is often the smartest approach. It keeps your operations running whilst giving you the flexibility to improve your system exactly how you need it.
