SureTap® Hot Tapping

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Deployed by 4 companies

Hot Tap Drilling Machines

Page last modified
April 11 2024

Hot Tapping is the method of making a connection to an existing pipeline while it remains operating and under pressure. The installation of a welded fitting or mechanical hot tap clamp provides a branch or off-take allowing connection to be made to process piping or a pipeline safely, without interrupting or depressurising the system.

The SureTap® range of proprietary hot tapping machines provide performance and reliability for critical, pressurised tapping operations. Designed and built to incorporate industry-leading features, the SureTap range incorporates a double block and bleed sealing configuration, allowing taps to be performed safely on a wide range of pipeline materials and mediums, including use with sour (H2S) products. A positive retention pilot drill system has been incorporated to ensure robust securing and recovery of the cut pipeline coupon. As standard, all SureTap machines are suitable for onshore, topsides or subsea operations and are fully compatible with industry-standard tapping equipment; including the deployment and recovery of completion plugs.


Pros & Limitations
SureTap machines are suitable for onshore, topsides or subsea operations
Provide full bore access - for BISEP line stopping isolation plug, while production continues
Provide access for pipeline tie-in / re-routing or abandonment
Provide access for pipeline blockage removal / cleaning / flushing
Fully compatible with industry-standard tapping equipment; including the deployment and recovery of completion plugs
Welded or mechanical fitting remains on the pipeline after hot tapping
Specification Title Specification Description
Size Range
2" - 66"
Pressure Range
Up to 153 bar / 2220 psi
-20oC to 150oC


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Technology Readiness Level

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Development Technology demonstration Mature / Proven
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STATS Group are market leaders in the supply of pressurised pipeline isolation, hot tapping and plugging services to the global energy industry. DNV type approved isolation tools provide leak-tight double block and bleed isolation that enables safe and efficient maintenance and repair of onshore, topsides and subsea pipeline infrastructure.

Process Plant Solutions offer hot-work barriers and localised hydrostatic weld test tools to verifying the integrity of welds or fittings, reducing system downtime, minimising environmental impact and increasing worksite safety. Mechanical repair clamps and pipe connectors replace the need for welding, significantly reducing expenditure and associated risks with hot-work providing the tie-in, repair or end-capping of pipelines.

STATS has gained an excellent reputation for providing a responsive, client-centred approach combined with expertise and innovative products which:

  • Drive higher levels of safety in the industry  
  • Enhance environmental performance by reducing flaring and venting activities
  • Improve asset performance while reducing system or plant downtime
  • Support the industry transition to a low carbon future

Project management and engineering services are provided to support client needs including turnaround scopes, feasibility studies and contingency planning. In-house expertise extends over the entire lifecycle of hydrocarbon assets from construction, maintenance, asset life extension, through to decommissioning and on to hydrogen transportation, carbon capture and storage.

STATS provide high quality, fit-for-purpose solutions to ensure that the pipework and pipeline infrastructure of its clients meet the technical, safety and environmental standards required.

Headquartered in Aberdeen, Scotland, STATS Group operate globally through a growing network of operational bases, including Canada, USA, Qatar, the UAE, Oman, Saudi Arabia, Malaysia and Australia.  

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