Why Inflatable Line Stops Fit Through Smaller Hot Taps Than Mechanical Plugs?

A line stop is a technique for temporarily blocking flow in a pressurized pipeline, allowing maintenance, repairs, or valve replacements without shutting down the entire system.  To install a line stop, a hot tap is conducted, which involves cutting into the pipeline under pressure to allow the stopping device to be safely placed.

 There are two types of line stop plugs: mechanical and inflatable .  While both can isolate pipeline sections, inflatable line stops have a significant benefit over mechanical plugs in that they can fit through tiny hot taps, making them especially helpful where space is limited or pipeline conditions are more complex.

Understanding Hot Tapping and Line Stops

Hot tapping is a technique that allows workers to safely cut into a pressurized pipeline without interrupting the system. This procedure generates an opening, also known as a hot tap, through which a line stop device can be put.

Line stopping is required when maintenance or repairs must be conducted on a pipeline portion without disrupting service to the entire system. Workers can replace valves, repair leaks, or reroute flow by temporarily restricting it while the remainder of the pipeline continues to operate.

The size of the hot tap has a direct impact on the type of line stop equipment used and the total project cost.  Larger taps are more expensive and require larger equipment.  Inflatable line stop plugs are beneficial in this aspect since they can be put through smaller hot taps than mechanical plugs, reducing both complexity and cost.

Mechanical Line Stops – Limitations of Size

Mechanical line stop plugs include inflexible, expanding heads that are put into the pipeline via a hot tap opening.  Once inside, the head expands to press against the pipe wall, forming a tight seal that prevents the flow of pressured product.

Mechanical plugs require wider hot tap openings for installation due to their hard nature.  This requires more extensive pipe cutting and welding, as well as specialised equipment to manage the size and weight of the plug assembly.

Larger taps create many challenges :

• More cutting and preparation of the pipeline, which extends installation time.
• Increased project expenses due to the requirement for larger tapping equipment and materials.

Larger openings expose more of the pressurized system throughout the procedure, increasing the risk of product loss or spills.

Mechanical plugs are less practical in situations when space is limited, costs must be kept under control, or environmental safety is a priority.

Inflatable Line Stops – Compact and Flexible Design

PeteStop® Inflatable line stop plugs are designed to be inserted into a pipeline using a hot tap while folded or compact. Their flexible design allows them to fit through far smaller openings than mechanical plugs.

Once within the pipe, the plug is inflated and pressed firmly against the pipe wall, forming a strong barrier that prevents flow. This inflating approach reduces the need for rigid components, resulting in a smaller hot tap and less installation equipment.

Inflatable plugs are versatile enough to meet most size, pressure, chemical, and temperature requirements. They are an economical and reliable solution for restricting flow in pipelines carrying water, gas, or oil, particularly when smaller hot taps and less environmental concerns are important.

Choosing Between Inflatable and Mechanical Line Stops

Mechanical and inflatable line stops have their uses in pipeline maintenance, and the best choice depends on the project requirements.

Mechanical plugs may still be preferred for:

• Simple, low-pressure applications in which huge hot taps are not an issue.
• Pipelines with certain diameters make rigid plugs easier to apply.
• Projects in which the cost of a larger tap and equipment is less of a barrier.

Inflatable line stops are the best option when:

• Smaller hot taps are necessary to reduce cutting, costs, and product waste.
• Pressurized systems must remain operational throughout repairs or valve replacements.
• Large mechanical assembly cannot be used due to limited space.
• A project requires flexibility to various sizes, pressures, chemicals, and temperatures.

Each project is unique, and the safest and most effective option is chosen by the pipeline's specifications. That is why it is critical to contact with professionals who can evaluate the situation and determine whether a mechanical or inflatable line stop is the best fit for your requirements.

Inflatable line stops provide a major advantage over mechanical plugs by fitting through smaller hot taps , which helps reduce installation time, lower project costs, and minimize the risk of product loss. For many pipeline maintenance and repair applications, they offer a more efficient and flexible solution.

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• Pipeline Installation & Maintenance
• Pipes and Pipelines
• Pipe Products