Product Overview

Sandwich Valve – The Critical Safety Equipment for Non-Stop Pipeline Hot-Tapping & Plugging

The Sandwich Valve is an essential piece of equipment for pipeline contractors and companies, enabling safe, reliable isolation during critical hot-tapping and plugging operations on live oil, gas, and utility pipelines, minimizing downtime and eliminating shutdown risks.

Core Advantages:

• ✔ Superior Safety for Live Lines: Engineered for sandwich valve hot-tapping in flammable and explosive environments. Enables zero-downtime work on operational pipelines.

• ✔ Compact, Low-Profile Design: Features a lower height than traditional valves, significantly reducing equipment travel and simplifying installation in confined spaces.

• ✔ Full-Bore, High-Flow Capacity: Offers an internal diameter larger than conventional valves, minimizing pressure drop and allowing easy passage of tools and pigs.

• ✔ Manual & Hydraulic Flexibility: Available in both manual and hydraulic (sandwich valve in hydraulic) actuation types to suit project scale and contractor preference.

• ✔ Robust Pressure & Size Range: Manufactured to withstand high pressures (Class 150 to 10.0MPa) and available in sizes from NPS 2″ to 40″ (DN 50 to DN 1000), with custom sizes available.

Detailed Product Description

The Sandwich Valve functions as a specialized, temporary isolation machine installed between pipeline fittings (like a tapping tee) and plugging systems. Its sliding gate, operated manually or hydraulically, provides a positive seal, allowing contractors to safely create branch connections or isolate sections of pipe without interrupting flow.

Visual Guide:

1. Preparation: The valve is mounted onto the pipeline fitting.

2. Hot-Tapping: The tapping machine drills through the pipe wall through the valve while it is in the open position.

3. Isolation: The valve gate is closed, creating a sealed barrier.

4. Downstream Work: Safe work (plugging, modification, repair) can be performed downstream of the valve.

5. Restoration: The valve is reopened, and the temporary fitting is removed or capped.

Technical Specification Tables

Pressure Ratings & Model Numbers

Key Design & Operational Parameters

• Actuation: Manual (typically for DN500 and below) or Hydraulic (for DN500+; model suffix ‘Y’).

• Construction: High-grade carbon or stainless steel body, durable sealing components.

• Standards: Designed to meet rigorous industry specifications for pressure containment.

• Connection: Custom flanged ends to match client specifications.

Core Components

• Valve Body & Gate: Precision-machined for a perfect seal and smooth operation.

• Seal Stack: Multi-layered, resilient seals designed for specific media (oil, gas, chemicals).

• Actuation System: Robust manual handwheel or integrated hydraulic cylinder (Parker sandwich valves or Rexroth sandwich valves compatible systems available).

• Bleed/Vent Ports: Standard for pressure equalization and testing.

Solving Core Pain Points

Client Pain Analysis:

• “Facing catastrophic revenue loss from a pipeline shutdown for repairs?” Our Sandwich Valve enables true non-stop operations.

• “Worried about the safety risks of live pipeline intervention?” This valve is purpose-built for safe hot-tapping and plugging in hazardous conditions.

• “Struggling with bulky equipment in tight spaces?” The low-profile design solves spatial constraint challenges.

• “Need a reliable solution for diverse pipeline sizes and pressures?” We offer one of the industry’s widest ranges, from 80mm sandwich valve to 1000mm.

Application Scenarios:

• Scenario 1: Emergency Pipeline Repair – Isolating a damaged section for replacement without shutting down the entire line.

• Scenario 2: New Connection (Hot-Tap) – Safely adding a new branch line to an active gas or crude oil pipeline.

• Scenario 3: Planned Maintenance (Stopple Plugging) – Using the valve with stopple sandwich valve systems to bypass a section for valve replacement or inspection.

• Scenario 4: City Gas/Water Network Upgrades – Performing work on urban distribution networks with zero service interruption to customers.

Comparative Advantage (Why Choose Our Sandwich Valve?)

We are not just a supplier; we are a manufacturer and solution provider. Our valves integrate seamlessly with leading hydraulic systems (D03 sandwich valves standards) and are backed by direct engineering support.

Certifications, Safety & Quality Standards

• Quality Manufacturing: Our factory operates under strict ISO 9001-certified quality management systems.

• Material & Testing: All valves undergo rigorous hydrostatic and functional testing. Materials are traceable and certified.

• Safety by Design: The design prioritizes fail-safe operation, with clear open/close indicators and robust pressure containment.

Client Testimonials & Success Cases

Case Study:

• Client: A leading European gas transmission company.

• Challenge: Install a new metering station on a high-pressure gas line without interrupting supply to downstream industrial customers.

• Solution: Utilized our Sandwich Valve (Model SV300-63Y) in a hot-tap and stopple plugging operation.

• Result: The connection was completed successfully over 48 hours with zero gas supply interruption, saving the client an estimated €2M in potential shutdown losses.

Service & Support Ecosystem

1. Pre-Sales Consulting: Our experts help select the correct sandwich valve dimensions and model for your specific job.

2. Training: Comprehensive operation and safety training for your crew.

3. After-Sales Support:

   • Standard warranty on all valves.

   • Global spare parts availability for critical components.

   • Emergency technical support hotline.

4. Flexible Commerce: Available for direct purchase (sandwich valve for sale), project rental, or as part of a complete service package.

Frequently Asked Questions (FAQ)

Q1: Can your Sandwich Valve be used for both hot-tapping and plugging?

A: Absolutely. The Sandwich Valve is the fundamental isolation device in both hot-tapping (to create an opening) and subsequent plugging (to isolate a section) procedures. It is designed to work in tandem with tapping and plugging machines.

Q2: What is the difference between a Sandwich Valve and a sandwich check valve?

A: They are different. Our Sandwich Valve is an isolation valve with a sliding gate for positive shut-off. A sandwich type check valve is a non-return valve typically installed between a directional control valve and a subplate to prevent reverse flow. Both are “sandwich” style but serve distinct purposes.

Q3: Do you offer custom sandwich valve dimensions and pressure ratings outside your standard chart?

A: Yes. As a premier manufacturer, we specialize in custom-engineered solutions. We can design and fabricate valves for sizes above DN1000 and for unique pressure ratings to meet your exact project specifications.

JSW Pipeline Services

About JSW Pipeline Services:
JSW is a global leader as both a pipeline service contractor and a specialized equipment manufacturer. We don’t just sell tools; we provide the complete solution backed by decades of field experience. Our dual role means every Sandwich Valve we design is proven in real-world, high-stakes environments.

Why Partner with JSW?

• End-to-End Expertise: From equipment manufacturer to field service execution.

• Guaranteed Compatibility: Our valves are engineered to work flawlessly with all major hot-tapping and plugging systems.

• Total Cost Solution: Optimize your project’s safety, timeline, and budget.

Ready to Isolate Risk and Maximize Uptime?
Contact our engineering team today for a detailed quote, technical specifications, or to discuss your upcoming project. Let us provide the right Sandwich Valve solution for your critical pipeline work.