Hot tapping is the process of creating a new branch connection on a pressurized, live pipeline without shutting down or draining the system. A hot tap machine cuts into the pipe safely through a welded fitting and valve, allowing a controlled, zero-downtime tie-in.

Why is hot tapping used?

Hot tapping eliminates the need for system shutdowns. It allows buildings, mechanical plants, and district-energy networks to add new lines, valves, sensors, or equipment without service interruption, saving time, cost, and operational downtime.

Will there be any downtime?

No. Hot tapping is specifically designed for zero downtime and does not require draining, isolation, or shutting off the system.

Do you provide engineering and fittings?

Yes. WellFab supplies the branch fittings , isolation valves, welding, equipment, pressure calculations, and all required documentation.

Hot Tapping

Upgrade without interruption: professional hot tapping to create new branches and access points on pressurized piping, safely and on schedule.

EXPLORE OUR PRODUCTS

PIPE FREEZING

MECHANICAL CONSTRUCTION

ENGINEERING & FABRICATION

At WellFab, we perform safe, engineered hot taps on live piping and pressure systems—so you can add new branches, access points, or monitoring ports without shutting down operations. Our team installs the fitting and isolation valve, completes the controlled cut under pressure, and delivers a clean, sealed, code-compliant connection that’s ready for service.

Hot tapping supports system expansion, inspection, repair, flow metering, sampling, and bypass work on heating and chilled water, district energy, domestic water, fire protection, and industrial/process lines. From planning and welding to pressure testing and documentation, we manage the full scope so your system stays online.

Why Hot Tapping

Hot tapping is a safe and efficient method for connecting to existing pressurized pipelines without shutdowns or system interruptions. It allows maintenance, tie-ins, or modifications to be performed while the system remains live — preventing costly downtime, product loss, and operational disruption.

Where it Applies

Oil & Gas Networks

Natural Gas and Gasoline Systems

District Energy (Heating & Cooling)

Process Piping Systems

Heating and Cooling Lines

HVAC, Water, Glycol, and Steam Systems

Wastewater and Sewer Infrastructure

Maintenance & Facility Services

Natural Gas Plants

Hot Tapping Solutions

Create permanent branches to existing mains while systems remain in service. We plan and execute tie-ins on live, pressurized systems to eliminate shutdowns, protect critical operations, and compress project timelines. From design to verification, our team manages heat input, alignment, and fit-up to deliver clean, code-compliant connections that are ready for immediate use.
Welded, flanged, or grooved tie-ins with engineered fittings
Prefabricated branch assemblies and controlled isolation/pressure management
Maintain flow during upgrades or repairs with temporary pump-around or gravity bypasses. We size and configure bypass circuits to keep temperature, pressure, and flow within spec while primary lines are modified—minimizing risk to occupants, production, and building systems. On completion, we decommission safely and return the site to its original condition.
Sizing and layout of temporary lines and valves
Safe commissioning/decommissioning and site restoration
Add future-proof entry points for inspection and maintenance. Access ports enable couponing, borescope inspections, and condition monitoring without future outages—supporting predictive maintenance and lifecycle planning. Every outlet is tagged, documented, and pressure-tested for traceable, repeatable use.
Hot-tap saddles with valves for couponing/borescope access
Tagged, capped outlets with leak-tested installation
Extend networks or add services without outages. We integrate new branches, risers, and laterals into existing HVAC, district energy, water, and process systems under live conditions—coordinating permits, sequences, and safety so the cutover is seamless. Post-work verification confirms integrity, alignment, and flow readiness.
Small-bore to large-diameter connections on steel, stainless, copper, or HDPE (as applicable)
Coordinated permits, isolation plans, and post-work verification
Collect representative fluid samples to support Quality Assurance and Quality Control. Properly located, dedicated sample ports reduce contamination risk, speed up testing, and improve compliance with water treatment and process standards. We provide clear labeling and procedures so operators can sample safely and consistently.
Strategically located sampling ports with quick-connects or valves
Flush/bleed provisions, labeling, and documentation
Install metering without interrupting service. We hot-tap for meters and build spools that meet manufacturer straight-run requirements, ensuring accurate baseline and ongoing measurement for energy billing, system balancing, and performance monitoring. Isolation and calibration ports are included for easy maintenance.
Hot-tapped meter tees or spools for electromagnetic (mag), ultrasonic, or turbine meters
Required straight-run allowances, isolation valves, and calibration ports
Solve non-standard constraints with fit-for-purpose designs. From limited access and specialty materials to unusual pressures and temperatures, our engineers produce stamped drawings (where required), method statements, and risk controls that fit your site and schedule. We coordinate rigging, access, confined spaces, and QA records end-to-end.
Method statements, risk assessments, and engineered drawings (stamped where required)
Access/rigging plans, confined-space coordination, and Quality Assurance documentation