Successful Completion of Hot Tapping Works on an In-Service Lube Oil Storage Tank at HPC Plant Bahrain
Integrity Flow Solutions is pleased to announce the successful completion of a specialized hot tapping project on an in-service lube oil storage tank at HPC Plant Bahrain.
The project involved the installation of two 2.5-inch hot tapping connections on a lube oil storage tank measuring approximately 5 m × 5 m × 5 m. The new connections were provided to serve as dedicated drain points, allowing accumulated water to be removed from the tank in a more controlled and efficient manner.
What made this project particularly significant was the requirement to carry out the work while the storage tank remained in service. This called for careful planning, coordination with plant operations, and disciplined execution at every stage of the work.
Hot Tapping Works
Hot Tapping on an In-Service Storage Tank
Hot tapping is a specialized intervention technique used to create a new connection on existing equipment or piping while the system remains operational.
For facilities where shutting down equipment is impractical or would result in significant production disruption, hot tapping can provide a valuable alternative—provided the application is technically suitable and the work is properly engineered, assessed, and executed.
At HPC Plant Bahrain, the objective was straightforward: introduce dedicated drain connections to the existing lube oil storage tank without taking the tank out of service.
The tank, approximately 5 metres in length, 5 metres in width, and 5 metres in height, remained operational throughout the intervention. This meant the work had to be approached with particular attention to the existing service conditions, site requirements, work controls, and coordination with the client's operations team.
Integrity Flow Solutions brought its experience in hot tapping and in-service intervention to the project, ensuring that the work was carried out in a controlled and methodical manner.
Hot Tapping Works 1
Project Scope
The completed scope included:
- Hot tapping on an in-service lube oil storage tank
- Installation of 02 Nos. 2.5-inch hot tapping connections
- Provision of dedicated drain connections for water removal
- Site preparation and work-area setup
- Coordination with plant operations
- Execution of the hot tapping activities
- Inspection and completion of the installed connections
The newly installed connections provide HPC Plant Bahrain with dedicated points for draining accumulated water from the lube oil storage tank.
Water accumulation in oil storage systems can become an important maintenance concern. Providing a dedicated and accessible drainage arrangement helps make routine water removal more practical and supports better overall management of the storage system.
Hot Tapping Works 2
Planning an In-Service Hot Tapping Operation
Carrying out hot tapping on operating equipment requires more than simply installing a new connection. The work must be planned around the existing equipment, operating conditions, site restrictions, safety requirements, and the selected execution methodology.
Before commencing the work, coordination with the client's team was essential to establish the required work controls and ensure that the intervention could be undertaken safely within the operating environment.
The execution was therefore approached as a planned in-service intervention rather than a conventional modification carried out during a shutdown.
This type of work requires close communication between the specialist contractor and plant personnel. Clear understanding of the equipment, work location, operating conditions, permits, access requirements, and site procedures helps ensure that the intervention progresses in a controlled manner.
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Safety and Quality at the Core of the Work
Safety remained a key consideration throughout the project.
Hot tapping activities on in-service equipment require careful attention to the condition and service of the equipment, the working environment, equipment readiness, work permits, and the approved execution procedure.
Integrity Flow Solutions worked closely with the client to coordinate the work and maintain the required site controls throughout the operation.
The team followed the applicable permit-to-work requirements, site safety procedures, work controls, and approved methodology established for the project.
Particular attention was given to maintaining controlled working conditions around the tank and ensuring that each stage of the intervention was carried out with the necessary level of care and precision.
Quality was equally important. From preparation through completion, the work was executed with a focus on the integrity of the new connections and the requirements of the existing storage system.
Minimizing Disruption to Plant Operations
One of the key advantages of a properly planned in-service intervention is the ability to carry out essential modifications without requiring a complete shutdown of the equipment.
For operating facilities, shutdowns can involve considerable planning, lost production time, additional resources, and complex coordination between multiple departments.
Where technically suitable, hot tapping can help reduce this operational disruption by allowing a new connection to be introduced while the existing system remains in service.
The HPC Plant Bahrain project is a practical example of how this approach can be applied to an existing industrial storage system.
By providing the required drain connections through an in-service intervention, the project addressed a specific maintenance requirement while avoiding the need to take the lube oil storage tank completely out of operation for the modification.
Delivering a Practical Drainage Solution
The primary purpose of the new connections was to provide dedicated points for water removal from the lube oil storage tank.
The installation gives the plant a more practical means of managing water that may accumulate within the tank, supporting routine maintenance activities and helping maintain the reliability of the storage system.
Although the connections themselves are relatively compact, the modification addresses an important operational requirement. In industrial facilities, seemingly small modifications can make a meaningful difference to accessibility, maintainability, and the effectiveness of routine maintenance.
This is where specialized in-service intervention capabilities can provide significant value—particularly when modifications need to be made to equipment that is already integrated into an operating facility.
A Successful Project Outcome
The successful completion of the two 2.5-inch hot tapping connections marks another completed in-service intervention for Integrity Flow Solutions.
The project demonstrates our ability to undertake specialized hot tapping work on operating industrial equipment while working within the requirements of an active plant environment.
For HPC Plant Bahrain, the completed modification provides dedicated drain connections that can be used for controlled water removal from the lube oil storage tank.
For Integrity Flow Solutions, the project reflects our continued focus on delivering safe, practical, and technically sound integrity solutions for industrial clients.
Integrity Flow Solutions – In-Service Integrity Expertise
Integrity Flow Solutions provides specialized services for clients requiring maintenance, modification, and integrity solutions without unnecessary disruption to ongoing operations.
Our capabilities include hot tapping, line stopping, pipeline integrity, and other in-service intervention services for industrial and energy-sector applications.
Every project presents its own operating conditions and technical requirements. Our approach is therefore centered on understanding the application, planning the intervention carefully, coordinating with the client, and executing the work with safety and quality as priorities.
The successful completion of the hot tapping works at HPC Plant Bahrain is another example of this approach in practice.
Looking Ahead
As industrial facilities continue to focus on reliability, asset availability, and efficient maintenance, the demand for specialized in-service intervention solutions continues to grow.
Hot tapping can play an important role in this area when the application is technically suitable and the work is properly engineered and controlled.
Integrity Flow Solutions is proud to support clients across Bahrain and the wider region with specialized integrity services designed around the practical requirements of operating facilities.
We remain committed to delivering every project with the same focus on safety, technical excellence, quality, and customer satisfaction.
Integrity Flow Solutions — delivering specialized integrity solutions where operational continuity matters.
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