Maintaining reliable water service while upgrading aging infrastructure is an ongoing challenge for municipalities and utility operators. A recent 24×16-inch hot tap completed by the Flow Control Grroup team demonstrates how live pipeline intervention techniques can be used to modify critical transmission infrastructure without interrupting service.
Large-diameter PCCP transmission mains form the backbone of many municipal water systems throughout North America. These pipelines transport treated water from treatment facilities to communities, healthcare facilities, industrial sites, airports, and other essential users. Because they serve such critical functions, shutting them down for maintenance or expansion work can create significant operational challenges.
For this reason, many utilities rely on hot tapping to make system modifications while keeping water flowing.
Understanding PCCP Transmission Mains
Prestressed Concrete Cylinder Pipe, commonly referred to as PCCP, has been widely used for large water transmission systems for decades. Manufactured to AWWA C301 standards, PCCP combines concrete, steel, and prestressing wire to create a strong and durable pipeline capable of handling high operating pressures.
Today, PCCP can be found in:
• Municipal transmission systems
• Regional water supply networks
• Water treatment facilities
• Major infrastructure projects
• Long-distance water conveyance systems
Many of these pipelines remain in service after decades of operation, making maintenance and expansion strategies increasingly important for utilities.
How Hot Tapping Works
Hot tapping is a specialized process that allows a new connection to be added to a pressurized pipeline without taking the system out of service.
Rather than draining the line or shutting down operations, technicians install a fitting and valve assembly directly onto the active pipeline. A hot tap machine is then used to create the opening while maintaining pressure containment throughout the process.
The procedure typically involves:
• Engineering review and project planning
• Installation of the hot tap fitting
• Valve installation and testing
• Controlled cutting of the live pipeline
• Coupon retrieval
• Activation of the new branch connection
The result is a safe and efficient method of modifying infrastructure while maintaining continuous operation.
Why Choose PCCP Hot Tapping
Large transmission mains often supply water to thousands of customers and critical facilities. Any outage can have significant operational and financial consequences.
Hot tapping helps reduce these impacts by providing:
• Continuous water service during construction
• Reduced customer disruption
• Lower project costs
• Improved flexibility for future growth
• Safer infrastructure modifications
• Reduced operational downtime
These advantages make hot tapping one of the most effective solutions for upgrading active transmission systems.
Meeting the Challenges of Aging Infrastructure
As water systems continue to age, municipalities are increasingly investing in infrastructure improvements to support future demand and maintain reliability.
Common reasons for performing PCCP hot taps include:
• Installing new transmission connections
• Expanding existing systems
• Adding isolation valves
• Connecting new developments
• Improving system redundancy
• Increasing operational flexibility
By utilizing live pipeline intervention techniques, utilities can complete these improvements while minimizing impacts on customers and operations.
Where We Work
Pacific Flow Control supports municipal, utility, industrial, and infrastructure projects throughout Western Canada.
Alberta
Calgary, Edmonton, Red Deer, Lethbridge, Medicine Hat, Grande Prairie, Airdrie, Fort McMurray, and surrounding communities.
British Columbia Lower Mainland
Vancouver, Burnaby, Surrey, Richmond, Langley, Coquitlam, Delta, Maple Ridge, and neighbouring municipalities.
Vancouver Island
Victoria, Nanaimo, Courtenay, Campbell River, Duncan, and surrounding areas.
BC Interior
Kelowna, Kamloops, Vernon, Penticton, Salmon Arm, and nearby communities.
Saskatchewan
Regina, Saskatoon, Prince Albert, Moose Jaw, Swift Current, and surrounding regions.
Planning a PCCP Hot Tap Project?
Projects such as this 24×16 inch PCCP hot tap highlight the value of experienced planning, specialized equipment, and proven field procedures when working on critical water infrastructure.
Whether your project involves PCCP, BWCCP, steel pipe, ductile iron pipe, or other transmission infrastructure, Flow Control Group delivers safe, efficient, and reliable hot tapping solutions designed to keep essential systems operating while infrastructure improvements are completed.
Contact us to discuss your upcoming hot tapping or live pipeline project.