Completion Plugs for Valve Replacement

Hot tapping creates a pressurized connection point on a live pipeline, while line stopping goes further by inserting a plugging head through that connection to temporarily block flow in a specific section. Once the line stop equipment is removed, a completion plug — which is a component housed within the Line Stop Flange — is seated and locked into the flange body to permanently seal the fitting and finalize the valve replacement or repair job.

The hot tap procedure involves welding or clamping a fitting and valve onto the live pipe, attaching a tapping machine, drilling through the pipe wall under pressure, retracting the cutter, and closing the valve. The connection point is then ready for line stopping or future access. Completion plug setters seal the fitting once the operation is complete.

Schallert offers three plug setter models: the PS0410 for 4" to 10" pipes, the PS0616 for 6" to 16" pipes, and the PS1836 for 18" to 36" pipes. Line Stop Flanges are available in sizes from 4" to 48", with additional sizes available on request, covering a wide range of pipeline diameters.

All three Schallert plug setter models — PS0410, PS0616, and PS1836 — are rated to 500 psi. This high pressure rating ensures reliable performance across demanding water, wastewater, and industrial pipeline applications where maintaining a secure seal after valve replacement is critical.

Yes. Schallert's plug setter tools feature compact designs that allow technicians to set completion plugs as a standalone operation, without needing a large tapping machine on site. This reduces equipment mobilization costs and simplifies job completion, particularly on smaller to medium diameter pipelines where setup efficiency is important.

Completion plugs are a component in the Line Stop Flange — the plug is inserted and locked within the flange body using set pins accessible from the outer diameter. Schallert Line Stop Flanges are designed primarily for use with Schallert completion plug setting tools but can be adapted to virtually any method of plug setting. Optional features include o-ring sealing set pins, contoured nozzles for direct pipe welding, and compatibility with blind flanges and bolt kits available upon request.