pipeline Hot Tapping and Plugging Solutions

Pressure Pipeline Hot Tapping

Boru Hattı Hizmetleri
hot tapping pipeline service

Pressure pipeline hot tapping is a method of creating connections on pipelines and vessels without interrupting service. It is widely used for maintenance, modification, and emergency repairs in pipelines carrying water, crude oil, refined oil, chemicals, natural gas, and other media.

This technology offers a safe, eco-friendly, cost-effective, and efficient solution for in-service pipeline repairs, reducing downtime and environmental risks.

Pressure Pipeline Hot Tapping Technology

This advanced technology enables operations on pressurized pipelines and vessels without shutdowns, ensuring uninterrupted production and material supply.

Key Applications Include:

  • Hot tapping on pipelines carrying flammable/explosive media
  • Pressure tapping for inert material pipelines
  • High-pressure steam line hot tapping
  • Operational temperature range: T ≤ 300°C (572°F)
  • Operational pressure limit: P ≤ 10.0 MPa (1,450 psi)
  • Compatible with various pipe materials including steel, PE, and concrete (Φ32mm-Φ2000mm)
  • Available in both hydraulic and manual operation modes

Tapping Orientations:

  1. Vertical pipeline tapping
  2. Fixture-assisted pipeline tapping
  3. Angled pipeline tapping
  4. Inverted pipeline tapping
  5. Storage tank tapping
pipeline tapping withvalve installation
pipeline tapping with valve installation
pipeline tapping without valve tee connection
pipeline tapping without valve tee connection

Pioneering High-Pressure Hot Tapping with External Pressure Balance

Meet our externally pressure-balanced, modular high-pressure hot tapping machine—a testament to our in-house R&D and engineering innovation. This groundbreaking machine is engineered to perform safe and reliable hot taps on live pipelines under pressures up to 6.3MPa, covering a diameter range from DN300 to DN900.

Its revolutionary modular design significantly simplifies maintenance, disassembly, and reassembly. This not only reduces downtime but also enhances operational efficiency, setting a new standard for performance and serviceability in demanding pipeline intervention scenarios.

external-pressure-balance-modular-hot-tapping-machine
Official patent certificate for JSW's innovative external pressure balance system in high-pressure hot tapping technology.

Pipeline Pressure Plugging Technology

Boru Hattı Hizmetleri

This process is designed for maintenance, emergency repairs, pipeline replacement, and station upgrades in pressurized transmission systems.

Mechanical Plugging Techniques
The primary methods include hanging plugging, barrel-type plugging, folding plugging, and inflatable (bag-type) plugging, each suited for different operational conditions.

Flow-Dependent Plugging Options
Depending on whether the pipeline media must remain flowing, operations are classified as stoppage plugging (flow interruption) or non-stoppage plugging (continuous flow).

Field Execution Strategies
Projects may involve single plugging, double plugging with dual blocking, or quad plugging with quad blocking, selected based on risk assessment and system requirements.

Technical Specifications

  • Compatible Pipes: Steel, cast iron, ductile iron, and PE/PVC (DN25–DN2600).

  • Media Types: Refined oil, natural gas, water, ethylene, coal gas, medium oil, and jet fuel (non-corrosive).

  • Operating Ranges: Temperatures from -30°C to +250°C; pressures up to 6 MPa.
    Custom solutions are available for extreme conditions (high temp/pressure, corrosive media).

gas main pressurized isolation method

Barrel-Type Pipeline Plugging

Barrel-type plugging utilizes a cylindrical milling cutter with multiple blade teeth on one end and a connection to a perforating machine on the other. This method involves cutting a saddle-shaped hole and an inner-diameter-type hole on the pipeline to be sealed. A round rubber shell is then inserted into the pipeline center using specialized machinery. The shell’s annular surface undergoes radial, elastic, and plastic deformation to deflect the flow medium across the pipe cross-section.

Barrel-type hot tapping and plugging is ideal for long-distance pressurized pipelines transporting crude oil, natural gas, and refined petroleum products, as well as emergency pipeline repairs. It offers secure sealing, high pressure resistance, and rapid construction.

plug type pipeline isolation device
fiş tipi boru hattı izolasyon yapısı
folding type pipeline plugging construction

Folding-Type Plugging

Folding plugging utilizes a collapsible mechanism in the plugging head, enabling small-diameter access holes to seal large pipelines. This innovative method significantly reduces operational workload and improves efficiency, making it ideal for low-pressure, large-diameter pipelines and confined workspaces. It’s commonly applied in water supply mains and gas pipeline isolation projects.

folding type pipeline plugging construction
folding type pipeline plugging construction

Barrel Expansion Plugging

heavy duty pipe barrier system

The barrel expansion plugging method operates by first using a pipe-cutting machine to make a full-diameter cut on the target pipeline. A plugging device then inserts an expandable barrel through the cut opening, positioning it centrally within the pipeline. The barrel is mechanically expanded using the plugging device’s built-in drive system, effectively blocking the medium flow.

This technique’s key advantage lies in its full-diameter cutting approach, which ensures reliable sealing even when dealing with deformed pipes or pipelines containing debris – maintaining consistent performance where conventional methods might fail.

drum plugging engineering construction
drum plugging engineering construction

On-Site Machining Services

Boru Hattı Hizmetleri

On-site machining refers to mechanical processing operations performed directly at equipment installation, maintenance, or specific project locations. Our company provides comprehensive on-site machining solutions, including:

  • Marine and offshore engineering machining
  • On-site boring and taper hole machining
  • Flange face machining and measurement

  • Oversized flange milling operations

field machining for pipeline
field machining for pipeline
field machining for pipeline

Boru Hattı Ekipmanları

Boru Hattı Hizmetleri

Beyond providing expert pipeline construction and maintenance services, Beijing JSW brings a deeper solution to the industry. As both a contractor and a manufacturer of pipeline equipment, we possess an unmatched level of control and insight. This allows us to tackle complex challenges with greater efficiency and innovation, delivering integrated solutions where every component and every construction phase is perfectly aligned for superior performance and longevity.

Professional hot tapping machines for pipeline construction and repair services.
Industrial power generators for reliable on-site energy during pipeline projects.
Advanced pipeline plugging equipment for safe and efficient line isolation.

Hot Tapping Equipments

Our inventory is built to meet any challenge. We maintain a comprehensive fleet of hot tapping machines, including 2 units of KKJ1200, 2 units of KKJ800, 12 units of KKJ500, 10 units of KKJ300, 8 units of KKJ150, and 12 units of KKJ100. This powerful range allows us to perform hot taps on pipelines from DN25 all the way up to DN2600, ensuring we have the right tool for your specific project, regardless of size.

A comprehensive fleet of JSW's hot tapping machines, including KKJ500 and KKJ300 models, ready for pipeline projects.

Pipeline Plugging Equipments

Our readiness is quantified. We hold a significant inventory of pipeline plugging equipment, including 10 FDQ125 units, 10 FDQ100, 12 FDQ80, 8 FDQ70, and 4 FDQ60. This strategic allows us to execute large-scale, simultaneous isolation projects efficiently. Specifically, we can perform up to 8 concurrent plugging points on pipelines up to DN800, and 4 concurrent points on pipelines from DN800 to DN1000, ensuring minimal downtime for your most demanding maintenance or repair schedules.

Spherical Plugging Head
Revolutionizing Pipeline Isolation with Superior Technology

While single-head plugging dominates China’s pipeline maintenance industry, its limitations in pressure tolerance and sealing reliability are evident – particularly in scaled pipelines where failure risks jeopardize entire repair operations.

Addressing this critical industry gap, we proudly partnered with China University of Petroleum (Beijing) and Xuzhou Shihua Special Pipeline Services to engineer the groundbreaking 406mm Spherical Plugging Head.

This collaborative breakthrough combines:
• China University of Petroleum (Beijing): Advanced structural design and engineering
• Beijing Jinshiwan Pipeline Technology: Precision manufacturing and pressure testing
• Xuzhou Shihua: Field application and industry implementation

The result is a robust sealing solution that maintains reliable isolation even in heavily scaled pipeline environments, transforming how pressurized maintenance is performed.

While single-head plugging dominates China’s pipeline maintenance industry, its limitations in pressure tolerance and sealing reliability are evident – particularly in scaled pipelines where failure risks jeopardize entire repair operations.

Addressing this critical industry gap, we proudly partnered with China University of Petroleum (Beijing) and Xuzhou Shihua Special Pipeline Services to engineer the groundbreaking 406mm Spherical Plugging Head.

This collaborative breakthrough combines:
• China University of Petroleum (Beijing): Advanced structural design and engineering
• Beijing Jinshiwan Pipeline Technology: Precision manufacturing and pressure testing
• Xuzhou Shihua: Field application and industry implementation

The result is a robust sealing solution that maintains reliable isolation even in heavily scaled pipeline environments, transforming how pressurized maintenance is performed.

A full-side view of the spherical pipeline plugging equipment, showcasing its robust construction and design for large-diameter pipeline isolation.
Close-up detail of the innovative spherical sealing head, demonstrating how it provides superior sealing contact within a pipeline.
The spherical plugging prototype integrated with its control system during the final verification phase, ensuring all components function as designed.

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