The Client: Smooth Track Solutions, on behalf of Novelis UK Ltd
Novelis, a leading aluminium recycling company, were carrying out improvement works on their compressed air system with the support of Smooth Track Solutions (STS), specialist compressed air engineers.
To optimise performance and efficiency, Novelis required accurate output measurements from their industrial air compressors. STS specified the installation of insertion flow meters to achieve this.
However, due to continuous production demands, the compressed air system could not be shut down. To overcome this challenge, STS appointed Ormond Pipework Services to carry out live tapping’s on compressed air.
Accurate airflow measurement was required.
Insertion flow meters needed to be installed.
The system could not be isolated or depressurised due to production requirements.
Any shutdown would have resulted in costly downtime.
Custom Pipe Preparation
A heavy-gauge branch pipe was fabricated to suit the existing installation: 3/4” branch onto a 6” compressed air main.
Surface Preparation
The 6” main was prepared by removing paint to provide a clean, contamination-free welding surface.
Ultrasonic Thickness Testing
Before any welding took place, an ultrasonic wall thickness test was carried out to confirm the pipe integrity and ensure it was safe for live welding.
Branch Welding & Pressure Testing
The branch was welded onto the live main and subsequently pressure tested to 7 bar to verify the integrity of both the weld and the valve.
Under-Pressure Drilling Setup
The under-pressure drilling machine was assembled and fitted with a retaining pilot. This is a critical component, as it prevents the steel coupon from falling into the system and damaging downstream equipment. As experienced hot tapping contractors, we ensure pilots are positioned with absolute precision: too far and it risks penetrating the opposite pipe wall, too short and the coupon will not be safely retained.
Live Pipework Tapping
The drilling machine was mounted onto the full-bore compressed air valve, and the live pipe tapping operation was successfully completed under pressure.
Flow Meter Installation
Once tapping was complete, Smooth Track Solutions installed their insertion flow meter, allowing Novelis to immediately begin monitoring compressed air flow and system performance.
No system shutdown required
No production downtime
Accurate compressed air flow data achieved
Significant time and cost savings
Safe live working under pressure
Depressurising and restarting the compressed air system would have taken significantly longer and caused unnecessary disruption. Hot tapping provided the safest and most efficient solution.
Live hot tapping on compressed air
Commercial pipework modification
