SureTap® Plug: Double Block and Bleed Completion Plug

World’s first dual seal completion plug for safe pipeline hot tapping operations. SureTap® Plug provides double block and bleed isolation throughout the entire hot tapping process, maintaining verified pressure barrier integrity when removing temporary valves and installing blinds. STATS Group has developed the SureTap Plug to address this long-standing safety concern - bringing completion technology and procedures in line with the double block and bleed standards that govern the safe working practices of the energy industry, all while avoiding external penetrations in the fitting completion flange. The SureTap Plug fundamentally changes completion plug design by introducing true double block and bleed capability for deploying and setting completion plugs in hot tap fittings at the end of the workscope. This is the first completion plug engineered to maintain the same level of isolation integrity established during the hot tapping (with STATS SureTap Hot Tap Machines) and line stopping (with STATS BISEP Line Stop) process. Two independent compression seals with a testable intermediate annulus provide verified confirmation of both seal integrity and correct plug positioning before the deployment system is disconnected and vented. Verifying the plug integrity before applying an ejection load onto the plug is a significant safety feature. The hydraulically actuated plug incorporates multiple fail-safe mechanisms. Lock segments engage with a machined groove in the completion flange, and a compression prevention plate ensures seals cannot activate unless the plug is correctly positioned with locks fully engaged. The dual seals and hydraulically activated locks allow operators to confirm, with tested certainty, that the pressure barrier is secure and tested before exposing personnel to risk. Unlike earlier attempts at improved completion plugs, the SureTap Plug achieves this enhanced safety without requiring special licensing or proprietary deployment procedures that limit operational flexibility. This isn't an incremental improvement - it represents a radical change in completion plug philosophy, bringing the final stage of hot tapping operations in line with the double block and bleed standards that govern today’s energy industry. When safety matters, trust STATS Group. Size Range: 6" to 56" (covers majority of hot tapping applications) Pressure Ratings: 300#, 600#, 900# as standard | 1500# available on request Deployment Options: Standard SureTap hot tap machines | Dedicated hydraulic launcher system (available for rent or purchase) Seal Configuration: Dual independently testable compression seals with intermediate annulus Product Compatibility: Hydrocarbons, hydrogen, high-pressure liquid CO2 Design Life: 25-year minimum (suitable for permanent abandonment) Locking Mechanism: Internal radial lock segments engaging with standard industry completion flange groove (no external penetrations) Standards Compliance: IMCA subsea diver safety requirements for double block and bleed isolation Patent Status: Patent pending Applications: Onshore/topsides and subsea environments More Information: https://www.statsgroup.com/products/suretap-plug-dual-seal-hot-tap-completion-plug