10 September 2024
Hot tapping is essential for maintaining service continuity in water and gas distribution. And using high-quality under pressure drilling equipment is not only crucial for ensuring precision, safety, and efficiency. It also reduces the risk of leaks, minimises downtime, and keeps costs low.
Hy-Ram’s DrillMaster range is leading the way in revolutionising mains and service hot tapping, providing durable, reliable, and expertly engineered tools that make the process smoother and safer. Backed by more than 40 years of industry expertise, the DrillMaster under pressure drill kit means engineers can confidently perform live pipeline taps, ensuring uninterrupted service whilst maintaining pipeline integrity.
What is hot tapping?
Hot tapping, also known as under pressure drilling and pressure tapping, is a method used to add connections to pipelines without having to shut them down. This technique is critical for utility companies as it allows maintenance and expansion to the networks, without disrupting the supply of essential services like water or gas to end users.
Completing connections under pressure is also proven to mitigate other negative effects of traditional operations, such as mains shutdowns, including transient pressures within water mains. Transient pressures can be caused when water mains are depressurised and repressurised, and studies in recent years have illustrated the necessity to eradicate them where possible, due to their role in causing other network issues such as leaks and even pipe bursts.
By creating a new branch connection on an operational pipeline, hot tapping minimises service interruptions, avoids unnecessary costs, and reduces downtime. Customer ratings are also generally more positive where works includes zero supply interruption, smaller excavations and a shorter timescale for works to be completed. All of this is possible with the application of the DrillMaster under pressure drill range high-quality under pressure drilling equipment.
What is the process for pipeline tapping?
The hot tapping process involves several steps to ensure that a new branch can be safely added to a live pipeline:
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- Preparation: First, you’ll need to assess the site and determine the equipment you’ll need, complete measurements. Then, clean and sterilise the area down, and install the correct fitting or under pressure tee onto the pipeline where the branch will be added. This should be suitable for the pipeline and its contents.
- Valve Installation: Typically, you’ll then need to mount a valve onto the fitting, which allows the new connection to be safely controlled once you’ve tapped the pipeline.
- Pressure Test: The setup is now pressure tested, which can be done via our drill once everything is in place.
- Drilling: With the pressure test successfully completed, the operator can now complete the drilling, then retract and isolate the drill safely. This process can be made incredibly simple on water mains, by using our Hi-Flow Drilling saddles where appropriate.
- Branch Connection: Attach the applicable new fittings or assets, and complete relevant tests before putting the new asset into service.
Hot tapping is widely used for creating new connections or installing other assets including hydrants, air valves, flow meters and other devices without taking the entire pipeline out of service.
How are under pressure drills used for mains hot tapping?
Under pressure drills are integral to the hot tapping process. These drills are designed to cut through the pipeline wall while it is still under pressure, ensuring no disruption to the flow within the pipeline. The precision of these drills ensures clean cuts and a tight seal, which is critical to maintaining pipeline integrity and preventing leaks.
We’ve designed the DrillMaster tools to handle different pipe materials and sizes, making them suitable for a wide range of applications in water, gas, and other utility sectors. Their ability to operate under pressure and in confined spaces makes them indispensable for engineers working in live environments.
What makes Hy-Ram’s DrillMaster range the best under pressure drill for hot tapping pipelines?
With decades of experience in the design and manufacture of tools for the utility sector under our belt, Hy-Ram has refined the DrillMaster range to meet the highest standards of quality and performance. As such, our DrillMaster mains hot tapping equipment stands out for several reasons:
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- Precision engineering: The DrillMaster drills are meticulously designed for accuracy and reliability. Whether drilling into cast iron, asbestos cement or plastic pipes, these tools ensure a clean, precise cut that minimises the risk of leaks or faults.
- Ease of use: Hy-Ram has designed the DrillMaster tools to be user-friendly. Their lightweight and compact design make them easy to handle, even in tight or awkward spaces.
- Durability: Built with high-quality materials, DrillMaster drills are rugged and durable, standing up to the tough conditions often encountered in pipeline maintenance.
- Operator comfort & safety: With all drills in the range now designed for use with various power options, manual drilling is thankfully a task of the past. Our DrillMaster range therefore significantly reduce musculoskeletal stress, due to the removal of manual ratchet drilling processes.
- Efficiency: Innovative new designs and drive options mean our DrillMaster range can now complete drilling connections from as little as 30 seconds, whilst ensuring compliance and operator safety.
What DrillMaster drilling tools are available?
The DrillMaster range offers several tools for mains and service branch drilling, each tailored for different pipeline sizes:
DrillMaster Service 2.5
This robust and cost-effective hot tapping tool is made for under pressure drilling on service type fittings. This option is particularly useful when making connections through saddle straps, clamps and welded nipples where inserting directly into the main is not possible.
DrillMaster Branch 4
This tool is designed for drilling through 80mm & 100mm under pressure tees on potable water, including the Hy-Ram’s Hi-Flow Drilling Saddles. It’s compact and easy to handle, perfect for operations where space is limited.
DrillMaster Branch 6
This compact and lightweight under pressure drilling machine is hand-fed and available with metallic and plastic pipe cutters, and the power source can be either electric or hydraulic. The DrillMaster 6 Branch Drill drills through a gate valve and is supplied as standard with 3 x ‘screw-on’ Flanges to suit 80, 100 & 150 NP16 Flanged Valves.
DrillMaster Branch 8
For larger mains pipelines, the DrillMaster Branch 8 kit offers the power and precision needed to safely and effectively tap into large-diameter (80, 100, 150 and 200mm) pipelines. We’ll supply cutters for both metallic and plastic pipes.
What other tools and equipment are required for hot tapping?
Hot tapping requires more than just a drill. Several other tools and accessories are essential for a successful operation:
- Hi-Flow Drilling saddles: These are mounted on the pipeline to create a secure fitting for the drill. Hy-Ram offers a range of high-quality saddles designed for different pipe materials and sizes. The unique feature being the inbuilt valve in the riser of the fitting, which can offer a reduction in cost, riser height and fittings required.
- Sandwich Valves: These are installed to isolate the flow from the new branch connection, or provide a means of future isolate for the maintenance or replacement of key assets such as hydrants or air valves. They ensure that the pipeline can be safely tapped and sealed during the drilling process.
- Holesaw Cutters: Specialised cutters are used to create a clean, circular hole in the pipeline wall. You’ll receive a range of hole saws within your DrillMaster kit to use with plastic and metallic pipes, ensuring that the drilling process is efficient and safe.
What’s the difference between mains and service under pressure drilling?
While mains and service drilling both involve tapping into live pipelines, there are some key differences…
Mains branch under pressure drilling
This refers to drilling into distribution main supply pipelines that carry large volumes of gas or water. Mains pipelines are typically larger in diameter and operate under higher pressure.
Service under pressure drilling
Service drilling, on the other hand, involves tapping into smaller pipelines that connect the mains supply to individual buildings or properties. These pipes are smaller in diameter and usually operate at lower pressures, therefore they require different tools for hot tapping.
Both types of drilling require precision and safety, but mains drilling tends to involve more complex equipment due to the higher pressures involved.
Discover the DrillMaster under pressure drill
The DrillMaster under pressure drilling range is revolutionising mains hot tapping by making the process more efficient, safe, and reliable. With these precision-engineered kits, engineers can confidently perform live pipeline taps without disrupting essential services. Whether you’re working on water, gas, or other utility pipelines, get the job done right with DrillMaster.
If you’re interested in learning more about investing in or hiring equipment in the DrillMaster range or need support with the calibration, maintenance, or repair of your pipeline equipment, download our brochure or get in touch with Hy-Ram today. Our team of experts is here to assist you with all your pipeline needs!
