Successful Completion of 4-Inch Hot Tapping on a 6-Inch Glycol Pipeline in Bahrain
Project Case Study | Integrity Flow Solutions (IFS)
Integrity Flow Solutions (IFS) has successfully completed specialized hot tapping works at a food production factory in Bahrain, involving the installation of two 4-inch hot tapping connections on an existing 6-inch glycol pipeline system.
The project involved a temperature-controlled industrial utility system operating under pressure at a low temperature. The reported operating conditions were 6 bar in the glycol supply line, 4 bar in the glycol return line, and an operating temperature of approximately 1°C.
Hot tapping on an operating industrial pipeline requires careful engineering assessment, appropriate equipment selection, and controlled execution. These considerations are particularly important in food production facilities, where reliable utility systems support process cooling and temperature-sensitive manufacturing operations.
This project highlights IFS's experience in specialized pipeline intervention services and its commitment to delivering practical engineering solutions for industrial clients in Bahrain and the wider Gulf region.
1. Project Overview
The project involved performing two 4-inch hot tapping operations on an existing 6-inch glycol pipeline system at a food production facility in Bahrain.
The work required consideration of the existing pipeline operating conditions, the required branch connection sizes, and the technical requirements associated with carrying out hot tapping on a pressurized, low-temperature utility line.
Project Details
Parameter
Project Information
Client facility
Food production factory
Project location
Bahrain
Service provider
Integrity Flow Solutions (IFS)
Existing pipeline size
6 inches
Hot tapping connection size
4 inches
Glycol supply line pressure
6 bar
Glycol return line pressure
4 bar
Operating temperature
Approximately 1°C
Main scope
Two 4-inch hot tapping operations
The project required an approach tailored to the existing pipeline conditions and the technical requirements of the proposed connections.
2. Project Scope of Work
The principal scope of work was the execution of two 4-inch hot tapping operations on the existing 6-inch glycol pipeline system.
Hot tapping enables a new branch connection to be created on a suitable pipeline without requiring the entire system to be shut down, subject to engineering approval and the suitability of the pipeline and installation arrangement.
For industrial facilities, this method can help reduce disruption associated with pipeline modifications and support the continuity of utility services when a shutdown is not practical.
The main project requirements included consideration of:
- Existing pipeline size and configuration.
- Glycol supply and return operating pressures.
- Low-temperature operating conditions.
- Required 4-inch branch connection sizes.
- Suitability of the proposed hot tapping equipment and connection assembly.
- Applicable engineering, safety, and quality requirements.
The exact fabrication, welding, valve installation, inspection, testing, and documentation activities should be confirmed against the approved purchase order and completed project records before being attributed to the executed scope.
3. Understanding the Glycol Pipeline System
Glycol systems are widely used in industrial cooling and temperature-control applications. In food manufacturing facilities, these systems may provide cooling for production equipment, process operations, and other temperature-sensitive applications.
The glycol supply line delivers the cooling medium to the relevant equipment or process, while the return line carries the fluid back through the circulation system for recooling and reuse.
For this project, the reported operating conditions were:
- Glycol supply line: 6 bar.
- Glycol return line: 4 bar.
- Operating temperature: Approximately 1°C.
These conditions are important when assessing the feasibility and execution requirements of a hot tapping operation.
Pressure differences between the supply and return lines, glycol properties, operating temperature, pipeline material, and existing pipe condition must all be considered during engineering assessment and equipment preparation.
Understanding these factors helps establish the appropriate requirements for the connection assembly and the planned intervention.
4. Technical Considerations for Hot Tapping on a Glycol Line
Hot tapping on a glycol pipeline requires a project-specific engineering assessment to establish the suitability of the proposed intervention.
Several technical factors are particularly important when working on a pressurized utility system operating at approximately 1°C.
4.1 Operating Pressure
The reported operating pressures for the glycol supply and return lines were 6 bar and 4 bar, respectively.
The hot tapping machine, fittings, valve, and associated pressure-containing components must be suitable for the applicable design conditions and approved operating limits.
Operating pressure alone is not sufficient to establish the allowable working pressure of the complete assembly. The assessment should also consider the pipeline design pressure, component ratings, temperature limitations, and applicable engineering requirements.
4.2 Low Operating Temperature
The reported glycol temperature of approximately 1°C makes temperature suitability an important consideration.
The pipe material, connection configuration, sealing components, and hot tapping equipment must be evaluated for the actual service conditions.
Where welding is required, the applicable welding procedure, material requirements, and relevant temperature-related controls must be reviewed as part of the engineering and execution planning.
4.3 Pipeline Material and Wall Thickness
The existing pipe material, wall thickness, and physical condition are essential inputs to the hot tapping assessment.
These parameters influence the suitability of the proposed fitting, pressure containment, welding requirements where applicable, and selection of the cutting equipment.
Available pipeline drawings, material specifications, and inspection records should be reviewed. Where required, additional inspection and wall-thickness measurements should be completed before proceeding.
4.4 Fitting, Valve, and Equipment Compatibility
The proposed hot tapping fitting, isolation valve, machine, and connection assembly must be compatible with the pipeline dimensions and approved design conditions.
The equipment arrangement should provide suitable pressure containment and allow the operation to be performed within the approved operating limits.
The final configuration must be established through the applicable engineering review and approved work procedures.
5. Safety and Quality Considerations
Safety is a fundamental requirement when performing hot tapping on an operating industrial pipeline.
The work involves potential hazards associated with pressurized fluid, pipeline integrity, equipment installation, and hot work where applicable. A suitable execution plan must address these hazards and define the controls required for the specific pipeline and facility.
Key considerations include:
- Reviewing pipeline drawings, operating conditions, and available inspection records.
- Verifying the pipe material, wall thickness, and condition.
- Confirming the approved fitting design and equipment pressure ratings.
- Reviewing welding procedures and welder qualifications where welding is required.
- Performing required inspections and nondestructive testing in accordance with project specifications.
- Complying with the facility's permit-to-work system, risk assessments, and method statement requirements.
- Inspecting the hot tapping machine, valve, fittings, and pressure-containing components before use.
- Verifying the completed connection and compiling the applicable quality documentation.
The inspections, tests, approvals, and safety controls actually implemented during this project should be confirmed through the relevant project records.
A structured approach to engineering, safety, and quality helps ensure that pipeline intervention activities are planned and executed in accordance with the approved requirements.
6. Delivering Pipeline Intervention Solutions for Industrial Facilities
Industrial facilities often need to modify existing utility systems to accommodate new equipment, process requirements, or changes to plant infrastructure.
Hot tapping can provide a practical solution when a new branch connection is required and maintaining system operation is a priority. However, each application requires an assessment of pipeline suitability, operating conditions, equipment compatibility, and execution risks.
Through specialized pipeline intervention services, Integrity Flow Solutions supports industrial clients seeking practical solutions for pipeline modification and maintenance requirements.
The Bahrain glycol pipeline project demonstrates the application of hot tapping services to a temperature-controlled industrial utility system with defined operating pressure and temperature conditions.
About Integrity Flow Solutions (IFS)
Integrity Flow Solutions (IFS) is a specialized industrial service provider supporting pipeline intervention, maintenance, and modification requirements across Saudi Arabia, Bahrain, and the wider region.
Our service portfolio includes:
- Hot Tapping Services: Installation of branch connections on suitable existing pipelines under approved operating conditions.
- Pipe Freezing and Cryogenic Pipeline Isolation: Specialized isolation solutions for suitable pipeline applications.
- Line Stopping and Temporary Pipeline Isolation: Pipeline isolation solutions designed around project-specific requirements.
- Industrial and In-Service Welding: Welding services subject to material suitability, approved procedures, and applicable project requirements.
- Thermowell Installation: Installation services supporting temperature measurement in industrial process systems.
- Tank Maintenance and Fabrication: Industrial tank-related maintenance and fabrication services.
- Mechanical Shutdown Services: Mechanical support for planned industrial maintenance and shutdown activities.
IFS focuses on practical engineering solutions, safe work execution, quality, and reliable field support for manufacturing plants, industrial facilities, utilities, and other sectors.
Looking for Hot Tapping Services in Bahrain or Saudi Arabia?
Are you planning a new branch connection or pipeline modification on an existing industrial utility system?
Integrity Flow Solutions (IFS) provides specialized hot tapping services tailored to the technical requirements of industrial pipeline applications.
Our team can discuss your project requirements, including:
- Existing pipeline size and material.
- Fluid type and service conditions.
- Operating and design pressures.
- Operating temperature.
- Proposed branch connection size.
- Project location and execution requirements.
Each application is subject to technical assessment to determine the suitability of the proposed hot tapping solution.
Contact Integrity Flow Solutions today to discuss your pipeline intervention requirements.
Integrity Flow Solutions (IFS)
- Website: www.integrityflowsolutions.com
- Email: sales@integrityflowsolutions.com
- Phone / WhatsApp: +966 54 428 1689
- Service Locations: Saudi Arabia and Bahrain
Integrity Flow Solutions — Specialized pipeline intervention and industrial maintenance solutions.
