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Flow Through Pipe Packers: Ideal Solution for Live Pipe Repairs

Flow Through Pipe Packers

When a pipeline flow must not be blocked and no shutdown is allowed, Flow‑Through Pipe Packers (FTP) offer the perfect trenchless repair solution. Designed to enable continuous flow while applying repairs, these packers are essential for utility systems, sewage networks, and industrial pipelines where downtime is not an option.

What Are Flow‑Through Pipe Packers?

Flow-Through Packers (FTP models) are inflatable carriers constructed from double‑layer reinforced rubber. They feature an integrated bypass (flow‑restoration) line and stabilization wheels, allowing them to be positioned at the exact repair site while the pipeline remains in service.

Ideal for live systems where shutting down flow is not possible, Flow-Through Packers offer a trenchless option to patch cracks, leaks, or damaged joints efficiently and economically.

PlugCo: Available Models

PlugCo offers a wide range of Flow-Through Packers depending mainly on the pipe diameter and patch length;

  • Pipe Diameter Range: PlugCo offers multi-sized Flow-Through Packers, which means that you can use the same model for different pipe diameters. The range offered by PlugCo is starting from 150 mm (6″) and going up to 1500mm (60″).
  • Repair Length: PlugCo offers Flow-Through Packers with lengths varying between 1 m and 5 m.
  • Stabilization Wheels: Mounted around the packer to ensure even inflation and protect against pipe misalignment. This feature is included in all Flow-Through Packers.

How Flow-Through Packers Work?

  1. Inspection & Measurement

    Using CCTV, map the damaged area and mark distances for precise packer placement.

  2. Packer Insertion & Positioning

    The packer, bypass hose, and patch wrapped around it, is pushed or pulled to the damage point using rods, pull‑cable, or a robot.

  3. Inflation & Patch Deployment

    Inflate the packer to the predetermined pressure. The bypass line carries ongoing flow, while the patch is firmly pressed against the pipe, filling cracks.

  4. Curing & Deflation

    Maintain pressure during resin cure (per manufacturer guidelines), then deflate via the valve on the air control device and remove the packer.

  5. Inspection & Validation

    Conduct a follow-up CCTV survey to confirm patch seating and sealing integrity.

Why Choose Flow-Through Packers?

There are many reasons why you should choose Flow-Through Packers;

  • Zero Downtime Repairs: Enables service continuity even during repair.
  • High Precision Point Repair: Localized patching eliminates need for full pipe replacement.
  • Trenchless Advantage: Minimizes excavation, reducing restoration costs.
  • Versatility: Works in straight runs and larger junctions, adapting to most pipe sizes and conditions.
  • Durable Results: When paired with resin‑impregnated fiberglass, the patch becomes a permanent structural rehabilitation featuring >50-year life expectancy.

Tips for Best Results

In order to get a satisfactory result while repairing a pipeline with Flow-Through Packers, you need to follow some tips;

  • Pre-cleaning is crucial: Remove debris, roots, scale, and sharp protrusions before insertion.
  • Confirm inflation pressure: Refer to the label on the packer or to the catalog of PlugCo to avoid under‑ or over‑inflation.
  • Monitor flow continuity: Ensure bypass line remains clear and functional throughout repair.
  • Time the resin cure: Observe ambient conditions as cure times vary by temperature and resin type.
  • Inspect post-installation: CCTV inspection ensures successful repair and aids documentation.