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
Capabilities
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Hot Tap Range: DN20 (¾") to DN1200 (48") — including custom sizes
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Standards: Compliant with ASME and DIN
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Operating Pressure: Up to 1,100 PSI
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Operating Temperature: Up to 500°F (260°C)
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Material Compatibility: Suitable for virtually any pipe material
Hot Tapping Products
