Hot Tap Clamps For Topsides & Offshore Environments

Hot Tap Safely And Confidently

When welded fittings are not an option, STATS hot tap clamps provide a safe basis for hot tapping, with high-quality, verifiable sealing, reliable locking and easy installation.

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The alternative to welded fittings when welding is not viable or as an economic, temporary access solution, STATS' hot tap clamps can be used to create an access point for hot tapping and new pipework connection.

Although this may seem like a routine procedure these days, risks and difficulties are still present. One key challenge is to assure leak-tight performance. Another is to keep the time cost to a minimum.

Gold Standard System For A Complete Service

STATS answers all concerns with its hot tap clamps which, together with related products like the STATS' SureTap hot tapping tool and the BISEP line plugging tool, offer a ‘gold standard’ system for a complete service.

Clamp installation is easy, with minimal disruption. Our advanced dual seals, with inbuilt verification of integrity, are totally reliable. For the most critical and challenging applications, we add the advantages of our ‘lock cage’ option.

Key Takeaways

Best in class, high quality clamps and seals
Choice of branch size and angle to suit application
Removes the need for welding
Easy to install
Dual seal allows full pressure test of assembly, even if no pressure in pipeline during assembly
Grout injection available in the annulus between the seals. Inhibiter or gel injection into the lock cavity if required
Lock cage option for higher pressures, larger diameters, irregularly shaped or vulnerable pipes, or corrosive fluids
Complete hot tapping service available

Info Sheet - Hot Tap Clamps vs. Welding

Case Study - Jet Fuel Line Isolation & Re-route

BISEPs were deployed through mechanical hot tap clamps to isolate jet fuel lines and avoid welding within an exclusion zone at Abu Dhabi International airport.

Read The Case Study

Mechanical Hot Tap Clamp, Brent Platform

Case Study - Innovative Isolation for Brent Cell Line Replacement

A pioneering effort resulted in successfully replacing Brent Bravo and Delta cell fill lines in the North Sea. Challenges included unreliable valves and no line access.

Read The Case Study

Hot tap clamps are an essential element of the equipment needed for hot tapping into a pressurised pipeline. We use them routinely to provide a flanged tee branch or off-take from the existing infrastructure. A hot tapping machine, like the STATS SureTap®, is then connected to the flange, which serves as a safe and pressure-containing access point for the hot tapping process.

This approach enables new branch pipework to be connected to the live pipeline, without interrupting production and with no need for welding. The same principle also enables a double block and bleed BISEP line plugging tool, to be deployed, when isolation is required for repair or maintenance tasks.

To minimise time and labour costs, we make clamping and hot tapping quick and simple. We also minimise the chances of leakage, to avoid expensive reworks and repairs.

Design Enables Full Pressure Test of Assembly Prior to Hot Tapping

A variety of factors must be addressed to guarantee tight and reliable sealing. Crucially, our clamps feature a dual seal arrangement with an annulus cavity which allows pressure testing to verify leak tightness before hot tapping begins.

To deploy our system, the two halves of the clamp are first wrapped around the pipeline with hydraulic assistance. Compression flanges mechanically actuate the seals and drive taper locks which grip the pipe. The assembly is then bolted together. Grout injection can provide extra support for the pipe where appropriate.

30" Hot Tap Clamp Shetland Islands

Hot tap clamps must be firmly locked onto the pipe, to prevent movement and maintain sealing. The consistency of a clamp’s grip can be compromised by various aspects of the pipeline structure. For optimum results in difficult applications, we have clamps with an external lock cage design. This places the locks outside the clamp’s pressure boundary, which brings important advantages.

One key benefit is that the lock setting load doesn’t add to the internal pressure on the pipe. This reduces the bolting requirements – saving on time and materials.

The lock cage design enables even loading around the pipe, regardless of irregularities in its shape. It counters such issues as ovality, weld seals and raised caps. Each lock segment engages independently and fully to take its fair share of the load.

In our system, the seal activation and locking steps are separate and independent. Sealing comes first, and then the locks are set.

By separating these steps, we avoid combining the seal and lock setting loads and accidentally crushing the pipe. Separation also allows the seals to be tested before the locks are set – avoiding the risk of having to remove and replace the assembly to deal with a sealing problem.

In some competitors’ clamps, a high spot on a pipe can lead to two locks taking most of the load while the others are barely engaged. We encourage clients to provide UT (ultrasonic testing) and survey data so we can assess pipe wall thickness, deformation and other factors - and then select the best choice of clamp. This ensures both leak-tightness, optimum load-bearing efficiency and safety.

After hot tapping, completion plugs may be used to isolate the resulting flanged tee branch permanently, enabling removal of the slab valve and fitting of a blind flange to the clamp.

Onshore And Topsides

Hot Tap Clamps for Onshore and Topsides Operations

We have clamp specifications to match a variety of pipeline diameters, wall thicknesses, fluid types and flow characteristics. Branch sizes and angles can be specified to suit your application.

STATS hot tap clamps are compatible with a wide range of pipe materials, including carbon steel, stainless steel and duplex. We use HNBR (hydrogenated nitrile butadiene rubber) seals as standard, with alternatives available on request – to withstand extremely high temperatures, for example. We can optionally supply a DNV Design Review Certificate to confirm our clamps’ suitability for your application.

Standards

ASME Boiler and Pressure Vessel Code, Section VIII, Div 2
API 5L, Specification for Line Pipe
ASME B16.5, Pipe Flanges and Flanged Fittings
ASME B31.8, Gas Transmission and Distribution Systems
ASME B31.4, Pipeline Transportation Systems for Liquid Hydrocarbons
API 6H, Specification on End Closures, Connectors and Swivels
External coating in accordance with Norsok M501 System 7

Hot Tap Clamps Specified to suit your application

Why choose our lock cage design?

We offer both external lock cage and internal locking options. The choice is entirely yours.

As described above, the lock cage’s advantages include lower bolting requirements, less risk of crushing pipes, and reliably even loading – regardless of ovality and other pipe irregularities.

Importantly, because the lock cage makes the clamp lighter, there is a distinct advantage for high pressure clamps as there are no additional up front costs to consider.

The lock cage design is preferred for higher pressures and larger diameters. As a rough guide, this would include anything above 24” for the 150/300 lb class, or above 12” for the 600 lb class.

In addition, we recommend these external locks for pipelines carrying sour (H2S) or caustic products which can corrode hardened locks. The same applies to hydrogen, which can cause embrittlement. External locks also avoid flow disturbance and turbulence issues.

Naturally, the cage lock option costs more up front. However, it’s often more economical overall as it can achieve the desired result with a smaller, lighter clamp, less material and less installation effort. It’s also far less expensive than rectifying the fallout from a failed clamp.

Pipeline and Process Pipe Repair

Self-Energised Strap Clamps: Patented Hot Tapping Connection

STATS' patented strap clamps represent a highly specialised and innovative connection for small bore hot tapping operations. Ideal for pressure testing, venting or depressurising systems.

STATS' Strap Clamps: What You Need To Know

Temporary Access: Create temporary access points for integrity management activities where welding is not feasible, like venting/draining or purging pipework prior to removal (dead legs, abandoned lines).
Installation: Light weight and low profile allows ease of installation even in restricted spaces.
Localised Sealing: Reduces loads that need to be restrained, they are therefore lighter and easier to handle than traditional, full encirclement clamps.
Superior Pipe Surface Accommodation: Dual elastomeric seals accommodates poor exterior surface finish.
Secure and Pressure Independent Seal for Hot Tapping: The seal housing can be configured with a flange for safe penetrations into live pipes.

Unique Self-Energised Sealing Mechanism

The core differentiator of STATS' strap clamps is their self-energised sealing capability. Once pressure is applied to the seal housing, the pipe seal becomes energised by the differential area acting across the cartridge. This "piston effect" ensures that the seal maintains continuous contact with the pipe, even if the straps stretch, which is especially beneficial for thin pipe walls.

This patented technology provides a reliable dual seal that is superior to conventional strap clamps, which can lose pressure and seal integrity as straps stretch under load.

Temporary Access Solutions

These clamps are highly effective for creating temporary access points for hot tapping and various integrity management activities. Applications include venting / draining or purging pipework prior to removal, such as dead legs or abandoned lines, or other operations where welding is not feasible, offering a quick and secure connection.

Strap Clamp Hot Tapping

Design and Installation

Lightweight and Low Profile: These clamps are designed to be lightweight and offer a low profile, allowing for quick and efficient installation even in restricted spaces.

Localised Sealing: They provide a localised dual seal on the pipe surface using a circular ‘D’ seal mounted in a profiled groove that conforms to the pipes outside diameter. This localised sealing area reduces the loads that need to be restrained, making them much lighter and easier to handle than traditional full encirclement repair clamps.

Pipe Surface Accommodation: The elastomeric dual seals can accommodate a poor surface finish on the pipe's exterior, though coatings must be fully removed and deep gouges must not impinge on the seal contact area.

Subsea Mech Clamp Hot Tapping, Barracouta Australia

Subsea Hot Tap Clamps

For harsh undersea conditions, including full pipe separation loads and corrosive environments our subsea hot tap clamps are available in specifications to match a variety of pipeline diameters, wall thicknesses, fluid types and flow characteristics.

All are compatible with a wide range of pipe materials, including carbon steel, stainless steel and duplex. We use HNBR (hydrogenated nitrile butadiene rubber) seals as standard, with alternatives available on request. We can optionally supply a DNV Design Review Certificate to confirm our clamps’ suitability.

A Complete Hot Tap and Line Stopping System

All designed for ease of installation and minimal disruption to either the pipework or the system to which they are fitted, STATS provides a complete system for tapping and line stopping operations, with our complementary, proprietary range of SureTap hot tapping machines and the dual seal BISEP line stopping technology.

Engineer working in workshop on BISEP tool

SureTap® Hot Tapping Machines

Performance and reliability for critical, high-pressure tapping operations. Double block and bleed sealing configuration allows taps to be performed safely on a wide range of pipeline materials and mediums, including use with sour (H2S) products.

img__bisep-engineer-working-workshop--576x324

BISEP® Line Plugging Tool

Using patented and DNV Type Approved technology, BISEP provides fail-safe double block and bleed isolation. Deployed through a single full bore hot tap intervention, leak-tight isolation of live, pressurised pipelines is achieved via hydraulically activated dual seals.

Local Everywhere

Instead of flying people and equipment all over the world, we've set up fully-functional bases in nine strategic locations. These bases enable us to employ local technicians, work with local manufacturers, and invest in local economies. They're a significant investment, but our regional bases are key to delivering the best possible service for our clients - and minimising the environmental impact of our work.

Reliable, Leak-Free Hot Tapping Access Made Easy

For Thin Walled Pipe Applications where welding not permitted

Use In hazardous or zoned areas No Hot Work Required

API 5L tolerances on OD and ovality Can be designed for Higher

External Lock Cage Option Safe, Light, Economical

Can be held in stock for emergency installation