High Pressure Hydraulic Hot Tapping Machine – Safe, Reliable Pipeline Connections & Repairs Without Service Interruption

The High Pressure Hydraulic Hot Tapping Machine is a specialized pipeline maintenance solution designed for oil & gas operators, pipeline contractors, and maintenance companies to perform branch connections, emergency repairs, and line stopping operations on live pipelines without shutdown, eliminating production losses and safety risks.

Core Advantages:

Detailed Product Description & Technical Specifications

How It Works – The Hot Tapping & Line Stopping Process

The High Pressure Hydraulic Hot Tapping Machine operates on a proven mechanical principle that enables safe pipeline intervention without depressurization or product loss:

Step 1: Installation → Step 2: Hot Tapping → Step 3: Line Stopping → Step 4: Completion

1. Installation: The machine is mounted onto the pipeline via a tapping fitting and isolation valve

2. Hot Tapping: The boring bar advances through the valve, cutting a coupon from the pipe wall while pressurized product is contained

3. Line Stopping: For bypass or isolation applications, a plugging head is inserted to block flow

4. Completion: Equipment is retracted, valve is closed, and the machine is removed—pipeline integrity maintained throughout

Technical Specifications

Core Components

Solved Core Pain Points & Application Scenarios

Customer Pain Points We Address

Application Scenarios

Scenario 1: Emergency Pipeline Repair
Location: Remote crude oil transmission line, environmental sensitive area
A pipeline contractor discovered a corrosion leak on a 24″ crude oil pipeline. Using the High Pressure Hydraulic Hot Tapping Machine, they isolated the damaged section, installed a bypass, and completed repairs—all without spillage or shutdown.

Scenario 2: Branch Connection for City Gas Network
Location: Urban natural gas distribution, residential area
A gas utility company needed to connect a new residential development to an existing 12″ high-pressure gas main. Traditional methods would require weeks of permitting for hot work. Our hydraulic hot tapping machine completed the connection in 4 hours with zero service interruption.

Scenario 3: Preventive Pipeline Maintenance
Location: Refinery piping system
A petrochemical plant scheduled maintenance required installing isolation points for future work. Line stopping operations were performed on multiple lines simultaneously, allowing the plant to continue operations while preparing for turnaround.

Scenario 4: Offshore Platform Modification
Location: Offshore production platform
Space constraints and safety requirements demanded compact, explosion-proof equipment. The AHT0616 model was helicopter-lifted to the platform for hot tapping operations on produced water lines.

Comparative Advantage – Why Choose Our Hot Tapping Systems?

Traditional Methods vs. Hydraulic Hot Tapping Machine

Competitive Differentiators

Certifications, Safety & Quality Standards

Industry Certifications

Safety Features

• Explosion-proof hydraulic system – No electrical sparks in hazardous areas

• Mechanical over-travel protection – Prevents boring bar damage

• Pressure-containing seal design – Multiple redundant seals for absolute containment

• Emergency manual retraction – Allows tool removal even if hydraulic power fails

• Torque limiting control – Prevents cutter stall and pipe damage

Testing & Validation

Every High Pressure Hydraulic Hot Tapping Machine undergoes:

• Hydrostatic pressure testing at 1.5× rated working pressure

• Functional testing of feed mechanisms and controls

• Seal integrity verification

• Torque calibration certification

• Third-party witness testing available upon request

Customer Testimonials & Success Cases

Trusted By Industry Leaders

Case Study 1: Major Asian Oil & Gas Company

Case Study 2: European Gas Transmission Operator

“We’ve used various hot tapping equipment from different manufacturers over 20 years. The precision of the automatic feed system and the reliability of the hydraulic drive make this machine our preferred choice for critical operations.”
— Pipeline Maintenance Manager, International Oil Company

Service & Support Systems

Complete Support Lifecycle

Service Commitment

Flexible Business Models

FAQ (Frequently Asked Questions)

Q1: Can this hot tapping machine operate on live pipelines without shutdown?

A: Yes, absolutely. The High Pressure Hydraulic Hot Tapping Machine is specifically designed for no-shutdown operation. The machine installs onto the pipeline through an isolation valve, then performs cutting and plugging operations while the line remains under full operating pressure and flow. This is the fundamental advantage of hot tapping technology—maintaining pipeline service throughout the maintenance activity.

Q2: What is the maximum pipe wall thickness this equipment can handle?

A: The machine’s cutting capability depends on pipe material and diameter, but generally:

• For carbon steel pipelines (API 5L Grade B through X80): Up to 1.5″ (38mm) wall thickness with standard cutters

• For higher alloy materials or thicker walls: Special cutter geometries are available

• The automatic feed mode (0.096mm/r) provides precise control for tough cutting applications, preventing cutter damage and ensuring clean cuts

Contact our engineering team with your specific pipe specifications for exact capability confirmation.

Q3: What training and support do you provide for new equipment owners?

A: We offer comprehensive training programs:

• Operator Training: 3-5 day course covering equipment setup, operation, safety procedures, and troubleshooting

• Maintenance Training: Advanced course for in-house service teams

• On-Site Support: Our technicians can accompany your first 1-2 field operations

• Certification: Trained operators receive documented certification recognized by major pipeline operators

Training is available at our facility or on your site, and we maintain a 24/7 technical support hotline for ongoing assistance.

Q4: Is this equipment suitable for offshore platform use?

A: Yes. The High Pressure Hydraulic Hot Tapping Machine is widely used in offshore applications including:

• Platform piping modifications

• Subsea pipeline hot tapping (with appropriate deployment frames)

• FPSO vessel connections

Key offshore features include:

• Compact footprint (smaller models suitable for helicopter transport)

• Corrosion-resistant coatings

• Explosion-proof certification for hazardous Zone 1/2 areas

• Hydraulic power units compatible with offshore power systems

Q5: What is the typical lead time and pricing?

A: Lead times and pricing vary based on configuration:

• Standard configurations: 8-12 weeks from order

• Custom-engineered solutions: 14-20 weeks depending on complexity

• Rental equipment: Available from stock in multiple regions

Price range: $45,000–$120,000 USD depending on model, accessories, and pressure rating. Contact our sales team for a firm quotation based on your specific requirements. We offer volume discounts for multiple units and package deals with complementary equipment.

About JSW Pipeline Services

JSW Pipeline Services is a premier pipeline equipment manufacturer and service provider specializing in hot tapping, line stopping, and pipeline isolation solutions. With over two decades of engineering excellence, we serve:

• Pipeline operating companies seeking reliable maintenance equipment

• Pipeline contractors and engineering firms requiring specialized tools and systems

• Emergency response teams needing rapid-deployment solutions

• Municipal utilities maintaining critical water and gas infrastructure

As a trusted manufacturer and supplier to major oil & gas companies worldwide, we combine engineering expertise with practical field experience. Our factory-trained service teams support every machine we deliver, ensuring our customers achieve safe, successful operations every time.

Why Partner With JSW?

Ready to Eliminate Pipeline Shutdowns?

Contact our engineering team today for:

• Free application assessment

• Equipment quotation with price and delivery

• Rental availability inquiry

• Technical specifications for your specific pipeline size and pressure

JSW Pipeline Services – Keeping The World’s Pipelines Flowing, Safely and Continuously