Front-End Engineering Design and 14” Hot Tapping on 42” & 52” Natural Gas Pipeline
| Client | Oil & Gas Client |
| Country | United Arab Emirates (UAE) |
| Year | 2024 |
| Details | Hot tapping solution enables seamless intervention on live pipeline systems, facilitating planned or emergency repair, maintenance, and system modifications without disruption. Our specialized hot tap operations prevent costly shutdowns while maintaining system integrity, keeping critical pipeline networks online during tie-ins, relocations, retrofits, and essential maintenance activities. To know more, contact us |
Project Summary
Wellube successfully delivered a comprehensive 14” (DN350) hot tapping solution for a 42” (DN1050) and 52” (DN1300) natural gas pipeline, enhancing operational reliability for a client in the oil & gas sector. The project included full front-end engineering design (FEED), fabrication, in-service welding, and complete on-site support. Wellube provided a turnkey, end-to-end solution that seamlessly integrated with the existing infrastructure.
Client Requirement
The client needed to expand their critical infrastructure by adding 14″ branch lines to existing 42″ and 52″ natural gas pipelines to meet new plant requirements while maintaining continuous operations. A traditional shutdown for these modifications would have resulted in substantial production and revenue losses.
Consequently, they required Wellube’s expertise to perform hot tapping without interrupting the system. Adding to the engineering complexity was the requirement to complete all welding and connection work within a compressed timeframe of less than 72 hours.
Bespoke Solution Delivered
Leveraging Wellube’s global engineering expertise and extensive project management capabilities, we successfully delivered a turnkey hot tapping solution within a highly compressed timeline, precisely tailored to the client’s requirements. In Q1 2024, an initial front-end engineering design (FEED) study was conducted to assess the onsite pipeline conditions and evaluate the feasibility of extending the line using the hot tapping method.
Following a positive FEED report, we proceeded with the design and fabrication of the hot tap fitting, incorporating a comprehensive testing suite to ensure operational integrity at the plant. Specialized weld procedures were also developed to mitigate potential pipeline breaks and accommodate flow variations, ensuring minimal disruption during operations.
Concurrently, the project team collaborated closely with key client contacts to establish efficient communication, streamline documentation processes, and expedite procurement to ensure timely material sourcing.
Once mobilized, our specialized team of on-site engineers executed the two hot taps in full compliance with client specifications and safety protocols. A post-project inspection and final validation walk-through confirmed the client’s satisfaction and ensured all deliverables met industry standards and operational requirements.
Key Highlights
- Turnkey Solution – Wellube delivered high-quality engineering solutions, from initial design through to successful implementation.
- Rapid Project Execution – All welding and connection work was completed within the challenging 72-hour timeframe, minimizing disruption.
- Integrated Design-to-Installation Capability – Our team designed, manufactured, and installed custom fittings specifically engineered for this complex intervention within the stipulated time frame.
- Zero Operational Disruption – Line extension was completed while maintaining continuous flow through the live pipeline system.
- Full QHSSE Compliance – Project execution adhered fully to all safety protocols and standards throughout the entire operation.
- Code-Compliant Implementation – All work scope satisfied applicable industry standards, design specifications, and operational parameters.
