Hot-Tap Components.jpg_1
ULTRA TOUGH Hot Tap Assembly (Full Sensor Encapsulation) ULTRA TOUGH Insertion Rod Assembly (Full Sensor Encapsulation) ULTRA TOUGH Hot Tap Assembly (Full Sensor Encapsulation)
ULTRA TOUGH Hot Tap Assembly (Full Sensor Encapsulation)

ULTRA TOUGH - Hot Tap Assembly


The Turtle Tough "ULTRA TOUGH" Series hot tap valve retractable assembly provides the most extreme form of protection for sensors in tough applications that require ease of access in/out of an application. Tough applications require more frequent access for cleaning and maintenance, and its imperartive this can be done easily and safely.   The ULTRA TOUGH hot tap assembly permits fast and easy insertion & removal of sensors directly into process tanks or pipes at pressures of up to 100 PSIG.   This hot tap assemby is highly customisable for extreme applications, offerering single or double block and bleed configurations, single or dual flush and a wide variety of material selection.

  • Safely insert or remove sensors live from the process
  • Sinlge or double block and bleed
  • Single drain or dual flush
  • 316 Stainless Steel, Titanium, Super Duplex (SAF) or KYNAR
  • 2" Configuration Standard

The Turtle Tough "ULTRA TOUGH" Series hot tap assembly is our most trusted valve retractable assembly for tough applications.  The hot tap asembly is designed to work with any Turtle Tough hot tap inline sensors that feature the part number (-SAN), indicating the inline sanitary sensor style.  This double wall thickness sensor with the temperature compensation located in the tip and front end sealing o-rings, is exclusively designed to work with the ULTRA TOUGH insertion rod assembly that fully encapsulates the sensor for the ultimate in protection and longevity.  The hot tap assembly consists of 3 main components:

  1. the main body consiting of a ball valve with adjacent retractable chamber with drain valve
  2. insertion rod and sensor holder assembly
  3. mating fittings that provide sealing at each end of the assembly


Main Body Assembly

  • Safely operate at pressures up to 100 PSIG
  • Standard 2" assembly designed for viscous slurries
  • Front end mating thread 2" MNPT (flange optional)
  • Drain valve to flush the retractable chamber or release pressure (dual flush optional)
  • Supports the use of any Turtle Tough Sanitary Inline (SAN) sensor body type with 3/4" rear end threads 
  • Materials of construction 316 SS. Optional: Titanium, Super Duplex (SAF), KYNAR

Insertion Rod and Sensor holder 

  • Rod diameter: 1" diameter extension tube with FULL LENGTH sensor encapsulation  
  • Extension rod length: 900mm standard length. Optional: 1200mm, 1500mm
  • 1 1/4"x1.00" step down for BLOWOUT PROTECTION (fundamental safety feature) 
  • Standard material of construction 316 SS. Optional: Titanium, Super Duplex (SAF)

Mating Fittings

  • Stainless Steel Compression Fitting and 1 1/4" to 1" reducing bush (rear end fitment)    
  • Note: these items are integral parts of the complete hot tap assembly. They are listed separately as they can suffer from wear and tear and require period replacement. 

Optional Mating Fittigs:

  • Flange for process side mating connection. For those requiring a flange for process side connection this can be supplied. Must specified at time of order (POA).


Please review all Turtle Tough guidelines with regards to installation recommendations.  Many sensors (particularly pH) are position sensitive and need to be installed at the appropriate angle. Never exceeed the stated specifications or physcial limits of either the sensor or the hardware, and always apply the lowest limit rating as the maximum threshold. This assembly is not to be used with any 3rd party equipment. 



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