The patented SureTap® Plug from STATS Group is a groundbreaking dual seal completion plug designed to eliminate a long-standing safety vulnerability in hot tapping operations. This new product brings a verified Double Block and Bleed (DBB) isolation capability to the final stage of hot tapping, a critical advancement that aligns completion practices with modern pipeline safety expectations.
Hot tapping is an essential technique in pipeline operations that allows cutting into pressurised systems without interrupting flow to add a new connection or install a temporary line stop. Currently, at hot tapping completion, temporary valves are removed and a blind flange is installed. Industry standard completion plugs compromise this carefully established safety barrier with a single O-ring seal that does not meet modern industry-accepted double block and bleed criteria. This single barrier has historically been an accepted but recognised safety risk, particularly where personnel exposure and high-pressure or hydrocarbon pipelines are involved.
Technical innovation: dual seals with testable annulus
The SureTap Plug fundamentally changes this standard by introducing two independent compression seals with an intermediate testable annulus. This design allows operators to:
- Verify seal integrity on both barriers before creating a differential pressure, each seal tested to pipeline pressure.
- Confirmation of correct plug positioning prior to removal of temporary valves.
- Completion plug seals will not be activated if incorrectly positioned in the flange, addressing installation errors that could compromise isolation efficacy.
These features replace the uncertainty inherent in single-seal O-ring designs with a verifiable, high-integrity barrier for hot tap fittings.
The hydraulically actuated SureTap Plug incorporates multiple fail-safe systems to ensure correct plug positioning and dual seal verification. Internal lock segments engage with a machined groove in the completion flange, and a compression prevention plate ensures that the seals cannot activate unless the locks are fully engaged. It is therefore impossible to establish differential pressure across the plug unless all safety mechanisms are correctly in place and verified, substantially reducing the risk of unintended pressure release or seal failure.
Enhanced sealing and operational efficiency
Beyond the safety verification capabilities, the SureTap Plug’s seal profile has been engineered for high performance even on imperfect or damaged flange inner diameters. The increased surface contact area of the dual compression seals delivers significantly improved sealing performance compared to conventional single O-ring solutions.
Operational efficiency has also been carefully considered in the design:
- The plug’s reduced diameter allows gas/fluid to flow around it during deployment, eliminating the need for bypass check valves, simplifying installation, and preventing the build-up of differential pressure during deployment.
- Seals are protected during insertion and can pass through standard valve bores, enhancing compatibility across existing hot tap systems.
- An optional hydraulic launcher simplifies deployment and allows early demobilisation or utilisation of the hot tap machine at other locations.
Importantly, the internal locking design avoids external actuators or penetrations on the completion flange, reducing potential leak paths and simplifying flange configuration.
Subsea operations
Subsea applications represent the most demanding environment for completion plugs, where diver safety regulations mandate double block and bleed isolation for all intervention work. The SureTap Plug is the first completion plug designed specifically to meet IMCA subsea isolation requirements, providing the dual seal capability that single O-ring designs cannot achieve.
Diver safety is paramount in subsea operations. Traditional single-seal completion plugs create unacceptable risks because seal integrity cannot be verified before divers begin removing temporary valves. The testable annulus eliminates this uncertainty, allowing operators to confirm both seals are leak-tight before exposing divers to potential pressure release hazards.
A new safety benchmark
The development of the SureTap Plug marks a significant step change in completion plug technology. Operators have invested in robust DBB isolation throughout hot tapping and line stopping operations for decades, only to accept a single-seal barrier at completion. By enabling independently verifiable dual isolation at this critical stage, STATS Group has bridged a major gap in pipeline safety and operational assurance.
As hydrocarbon pipeline networks continue to age and operational complexity grows with the introduction of alternative fuels like hydrogen and high-pressure liquid CO2, the benefits of verifiable isolation cannot be overstated. With the SureTap Plug, operators now have a solution that aligns completion practices with today’s heightened safety expectations, reduces project risk, and enhances overall project efficiency.