As part of the Pipeline Replacement Project, ONGC and its EPC contractor undertook a critical offshore infrastructure upgrade at the NQP Platform. A major requirement was to perform a Hot Tapping operation on a live 16-inch pipeline to introduce a new 12-inch branch connection.
Given the complexity and high-risk nature of the task, TRITORC was selected as the specialized engineering partner for executing the operation without interrupting ongoing hydrocarbon flow.
Hot Tapping Challenge in an Offshore Environment
Offshore Hot Tapping presents multiple operational challenges. The confined working area on the platform, dynamic marine environment, and continuous pipeline pressure required a solution that ensured precision, safety, and minimal disruption.
The target pipeline was a 16” line operating at a pressure of 7.5 to 9 bar, made of ASTM A106 Gr. B material, requiring exacting weld procedures and equipment configuration. Moreover, safety compliance, detailed documentation, and third-party inspections by both the EPC contractor and ONGC were non-negotiable parts of the workflow.
Custom-Engineered Solution
TRITORC’s team, led by Project Manager Sarfaraz Nawaz Taj, Operations Coordinator Imran Ansari, and Design Engineer Rohit Harpude, devised a comprehensive execution strategy. The team selected a 16” x 12” weld-on branch fitting fabricated to ASME B31.3 standards and supported it with a custom saddle clamp to prevent stress during cutting and tapping.
The hot tapping machine, a 16” full-bore hydraulic system, was configured to execute the operation while maintaining structural integrity and ensuring accurate coupon retrieval.
Every component used was pre-tested, including the branch tee and the split flange setup. A custom-designed guide support system was installed to ensure alignment under offshore conditions. Multiple approval cycles from L&T and ONGC ensured that all safety, material, and weld parameters were meticulously reviewed and cleared before execution.
Execution and Operations
The operation began with the welding of the branch tee onto the live 16” line, followed by hydrotesting and NDT (Non-Destructive Testing) of the weld joint. Once integrity was confirmed, TRITORC mounted the hot tapping equipment and initiated the tapping process. The hydraulic power pack and cutting system operated smoothly, maintaining consistent feed and torque.
The coupon was successfully cut and retrieved, ensuring that no debris entered the pipeline. The tapping process was completed well within the stipulated time, despite challenging offshore conditions. Throughout the operation, the TRITORC team followed a strict Job Safety Analysis (JSA), with offshore HSE representatives from both the client and end user monitoring and approving each step.
Successful Completion and Impact
The Hot Tapping operation was completed without any shutdown, downtime, or safety incident. ONGC’s hydrocarbon supply remained uninterrupted throughout, showcasing TRITORC’s ability to execute high-risk interventions safely and efficiently. The operation not only met all technical specifications but also earned commendations from both L&T and ONGC for its smooth execution and attention to detail.
The collaboration between TRITORC’s technical and field teams played a key role in the successful completion. Rohit Harpude ensured that all engineering calculations and equipment specs were aligned with offshore requirements. Imran Ansari coordinated operations and logistics with precision, while Sarfaraz Nawaz Taj led the execution with clarity and strong site leadership.
Conclusion
TRITORC’s successful execution of the Hot Tapping operation at the NQP Platform reinforces its position as a leader in live-line and specialized offshore services. The company’s engineered approach, strict safety practices, and experienced team enabled a flawless operation under demanding offshore conditions.
As India continues to invest in critical oil and gas infrastructure, TRITORC remains a reliable partner for complex field interventions that demand expertise, safety, and speed.
Whether for emergency tie-ins, system modifications, or pressure containment work, the company’s track record in delivering high-integrity solutions in active systems reflects a deep-rooted commitment to operational excellence, asset protection, and project timelines.
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