1. Product Overview

Engineered for pipeline operators and maintenance contractors, this Hydraulic Hot Tapping Machine enables safe, high-pressure branch connections and line stops without interrupting flow, eliminating costly downtime and enhancing operational safety.

Core Advantages:

• Zero Downtime: Perform hot taps and line stops without shutting down the pipeline, saving millions in potential production losses.

• Engineered for High Pressure: Rated for up to 4.0MPa (580psi) and designed for hazardous environments, ensuring maximum safety during live pipeline interventions.

• Versatile & Precise: Covers a wide range of applications with a hot tap range from 6″ to 56″ and a long boring bar travel (up to 88 inches) for deep cuts.

•  Efficient Operation: Features a manual/automatic/ fast feed mode system (4mm/r for manual/fast, 0.096mm/r for automatic) and high rated torque (up to 9100 Nm) to handle tough materials.

2. Detailed Product Description & Technical Specifications

How It Works: A Step-by-Step Process

1. Installation: The Hydraulic Hot Tapping Machine is securely mounted onto the fitting welded to the live pipeline via an ASME standard flange connection.

2. Pressure Equalization: The built-in pressure equalization feature ensures the operation is safe and balanced before the cut begins.

3. Tapping/Stopping: The hydraulically driven boring bar, with its adjustable speed and feed mode, performs the hot tap for a branch connection or the line stop for isolation.

4. Completion: The cutter or plug is retracted, and the machine is removed, leaving the pipeline operational and the new connection or bypass secured.

Technical Specifications: AHT Series

Core Components

• Hydraulic Drive Unit: Provides smooth, powerful, and controllable rotation and feed, ideal for flammable environments where electric sparks are a concern.

• Boring Bar & Feed System: The long-travel boring bar, combined with the unique feed volume settings, allows for precise control during the cut, whether for steel, ductile iron, or other pipe materials.

• Measuring Spindle: Integrated for accurate depth control, ensuring the cut is perfectly executed every time.

3. Core Pain Points & Application Scenarios

Solving Your Biggest Challenges

• “Our pipeline is critical and cannot be shut down for maintenance.” Our Hydraulic Hot Tapping Machine is designed specifically for no shutdown operation, allowing you to perform pipeline maintenance or modifications while the line remains live.

• “We are concerned about the safety risks of welding on a live pipeline.” While the fitting is welded, the tapping operation itself is mechanical and performed under pressure. The machine’s design, with built-in pressure equalization and robust construction, provides a safe isolation tool for hazardous areas.

• “We need a versatile solution for different pipe sizes and pressures.” With two model options (AHT0616 & AHT1436), this tapping and plugging equipment covers a vast range of sizes from 6″ to 56″, making it the only pipeline hot tap system many companies will ever need.

Real-World Applications

• Scenario A: Emergency Pipeline Repair: A natural gas pipeline suffers from a third-party damage. Using our line stopping machine, the affected section is isolated, repaired, and restored without a single cubic meter of gas lost.

• Scenario B: Pipeline Network Expansion: An oil pipeline company needs to add a new branch connection for a new refinery off-take. Our hot tapping machine completes the connection while the main line continues to supply crude oil.

• Scenario C: Planned Maintenance: A petrochemical plant requires the replacement of an aging valve on a live chemical pipeline. The high pressure hot tapping machine is used to perform a line stopping operation, isolating the valve for replacement without a plant-wide shutdown.

• Scenario D: Subsea & Offshore: For offshore platform operators, the compact design and reliable hydraulic drive make this pipeline tapping machine an ideal tool for emergency shutdown or modifications in high pressure environments.

4. Comparative Advantages (Why JSW?)

JSW vs. Traditional Shutdown Methods

Why Choose the JSW Solution?

• Proven Reliability: Unlike generic pipeline isolation tools, our machines are built with a focus on high torque and robust reduction ratios to handle the toughest jobs.

• Integrated Intelligence: The combination of manual, automatic, and fast feed modes gives the operator unparalleled control, a feature often missing from simpler tapping and plugging equipment.

• Global Support: As a leading manufacturer, JSW doesn’t just sell equipment; we provide a solution. Our global service network ensures you have the support you need.

5. Certifications, Safety & Quality Standards

Built to the Highest Standards

• ASME Compliance: The flange connections conform to ASME standards, ensuring compatibility with industry-standard fittings and valves.

• Explosion-Proof Design: Suitable for operation in flammable environments and hazardous areas where safety is paramount.

• Quality Assured: Manufactured in an ISO 9001 certified factory, ensuring every machine meets rigorous quality control standards.

• Pressure Tested: Every unit undergoes extensive pressure testing to verify integrity at its maximum working pressure, ensuring pipeline safety.

6. Customer Testimonials & Success Stories

Trusted by Industry Leaders

Case Study: Major Gas Transmission Company

• Challenge: A critical gas pipeline required the installation of a new compressor station bypass. A shutdown was impossible due to supply contracts.

• Solution: JSW provided an AHT1436 Hydraulic Hot Tapping Machine and on-site support.

• Results: The bypass was successfully installed via a 36″ hot tap in under 8 hours. The client avoided an estimated $2M in lost revenue and penalties.

“The JSW team and their equipment delivered exactly as promised. The machine performed flawlessly under pressure, and the automatic feed feature made the operation smooth and precise.” – Senior Project Engineer, International Pipeline Contractor

7. Service & Support System

More Than Just Equipment, We Offer a Complete Service

• Pre-Sales Support: We offer free technical consultation and on-site price evaluation to help you select the right systems for your specific pipeline conditions.

• Training: We provide comprehensive operation and safety training for your crew, ensuring they are confident and competent with the tools.

• Global Support & Warranty:

  • Standard Warranty: 12 months

  • Core Components: Extended warranty available

  • Service Response: Global support team ready to assist.

• Flexible Commercial Models: We understand that every project is different. We offer competitive price options for equipment for sale, as well as rental and lease-to-own programs. Contact us for a customized quote.

8. FAQ (Frequently Asked Questions)

Q1: Can this machine perform both hot tapping and line stopping?
A: Yes, the JSW AHT series is a versatile pipeline hot tap system designed for both functions. The specific range depends on the model, but both the AHT0616 and AHT1436 are capable of performing hot tapping for branch connection and line stopping for bypass connection or isolation.

Q2: What is the maximum wall thickness this tapping machine can handle?
A: While the machine can handle standard pipe schedules, the limiting factor is the diameter and the cutter used. The high rated torque (up to 9100 Nm) and powerful hydraulic drive provide ample power for heavy-wall pipe. Please contact our engineering team with your specific pipe specifications for a precise answer.

Q3: Is operator training provided if we purchase this machine?
A: Absolutely. JSW provides on-site or in-factory training as part of our commitment to pipeline safety. We ensure your team understands the feed modes, safety protocols, and maintenance procedures to operate the machine effectively and safely in high pressure environments.

Q4: What are the power requirements for the hydraulic unit?
A: The hydraulic unit is typically powered by a diesel engine, making it completely self-sufficient and ideal for remote field locations. This design also makes it inherently explosion-proof for use in flammable environments.

Q5: What is the typical lead time and price for this equipment?
A: Lead times vary based on configuration and current production schedules. As a direct manufacturer, we offer competitive pricing. Please contact our sales team for a detailed quote and current availability.

9. Partner with JSW Pipeline Services

JSW is more than just a manufacturer; we are a comprehensive pipeline service provider and equipment supplier. With decades of experience serving oil pipeline, gas pipeline, and petrochemical plant operators, we understand the pressures you face. Our mission is to provide the safest, most reliable pipeline repair and modification solutions on the market.

Whether you are an engineering company looking for a reliable contractor, or a project manager seeking the best price on equipment for sale, JSW is your partner for success.

Don’t let pipeline maintenance interrupt your operations.

Contact JSW Today for a Free Consultation and Equipment Quote.