STATS Group Unveils Dual-Seal Plug to Improve Hot Tapping Safety
STATS Group has launched a new dual-seal completion plug designed to maintain double block and bleed isolation through the final stage of hot tapping, addressing a long-standing pipeline safety risk
(P&GJ) — STATS Group has introduced a new completion plug designed to reduce safety risks during the final stage of hot tapping and line stopping operations on pipelines.
The SureTap® Plug, launched this week by STATS Group, is engineered to maintain Double Block and Bleed (DBB) isolation throughout the entire hot tapping process, including completion—an area where conventional plugs typically rely on a single, untestable seal.
The company said the technology addresses a long-recognized vulnerability in hot tapping operations, where operators establish verified DBB isolation during cutting and line stopping but lose that protection when removing temporary valves at completion.
The SureTap Plug uses two independent compression seals with a testable intermediate annulus, allowing operators to verify seal integrity and confirm plug positioning before exposing personnel or equipment to pressure.
Angus Bowie, STATS Group’s chief technology officer, said existing completion practices have forced operators to accept unnecessary risk.
“Operators invest in robust double block and bleed isolation during hot tapping and line stopping, only to accept a single, unverifiable barrier at completion. This contradiction has persisted because no alternative existed – until now,” Bowie said.
The plug is hydraulically actuated and incorporates mechanical fail-safes that prevent pressure from being applied unless locking mechanisms are fully engaged. According to the company, internal lock segments must align with a machined groove in the completion flange before seals can activate.
STATS Group said the dual-seal design also improves performance on fittings with damaged or imperfect internal diameters—conditions that can occur during hot tapping operations. The plug meets IMCA DBB requirements for subsea diver safety and can be used on hydrocarbon, hydrogen and high-pressure liquid CO₂ pipelines.
In addition to safety benefits, the SureTap Plug is designed to improve operational efficiency. Its reduced diameter allows flow around the plug during deployment, eliminating the need for bypass check valves. Optional hydraulic launch equipment can allow hot tap machines to be demobilized earlier, reducing equipment rental time and costs.
“Operators can now confirm, with tested certainty, that their pressure barrier is secure before exposing personnel to risk,” Bowie said.
STATS Group said the plug is compatible with standard hot tap machines, does not require proprietary deployment procedures and has a minimum design life of 25 years, making it suitable for permanent abandonment applications on aging pipeline assets.
The company is showcasing the SureTap Plug alongside its BISEP line stop and Tecno Plug isolation technologies this week at the Pipeline Pigging & Integrity Management Exhibition and Conference in Houston.