52’’ X 52’’ Horizontal Hot Tap Completed on India’s Largest Flare Stack

Client	Leading Petrochemical Company
Country	India
Year	2023
Service details	Wellube’s hot tapping and line stopping service is a cost-effective way of enabling repairs, maintenance, modifications, or reconfiguration work on existing piping systems – on either a planned or emergency basis. Our hot tap operation prevents unwanted shutdowns and keeps critical piping and pipeline systems online during tie-ins, relocations, repairs, retrofits, and routine maintenance. To know more, get in touch with us at enquiries@wellube.com

Summary of the Project

Wellube provided an integrated solution including engineering, design, manufacture of a 52’ x 52” 150# Hot Tap Split Tee and execution of horizontal hot tap on one of the India’s largest flare stack at a height of 15m from ground level.

Client Requirement

The client presented a unique requirement of wanting to connect one of India’s largest flare Stack with an existing pipeline. This required a 52’’connection from the 52’’ mainline, requiring two hot taps on two different pipelines. 

Challenges faced

• A main challenge was the location of the site. The existing 52’’ pipeline was positioned 15 meters above ground level, making installation a daunting task.
• Additionally, the orientation of the tapping was horizontal, further complicating the installation of the Gate Valve and Hot Tap machine. The team faced considerable difficulties in providing support due to the complex orientation of the tapping and limited approach available for Crane positioning.

Unique Solution Delivered

Wellube’s engineering and operations team worked closely with the customer to work out a complete execution plan which included the planning, risk assessment, QHSE requirements and overall implementation of the project taking into consideration the challenges.

We engineered, designed and supplied the massive 52 x 52”150# Hot tap fitting and also performed the hot tap operation on the flare stack enabling to have the connection made.

Additionally, in-service welding was also performed by our team thus providing the client with an integrated solution package from end to end of the project involving engineering, design and execution.

Benefits Delivered

• The project was executed with complete QHSE compliance and safety.
• End to end integrated solution provided.
• Technical support provided by Wellube’s team of specialists.
• The client was satisfied with the project completion.