Introduction to Hot Tapping in Piping

Hot tapping is the technique used to attach a branch connection to a pipe while the
system is in service, and then creating an opening in that pipe by drilling or cutting.
While hot taps are most often done in piping system, they may also be done on
pressure vessels and storage tanks to add nozzles. Hot tapping permit adding
connections without depressurization or disruption of process operations. They
may also be used to make piping connections where it would be inconvenient to
prepare the system for hot work. Hot tapping is also used to isolate pipe sections
for maintenance by plugging or stoppling the line.

Hot tapping is an inherently dangerous operation. Therefore, hot tapping should

generally be used only when it is impractical to take the system out of service.
When specifying hot tapping, care is required in inspection, design, and testing to
ensure that this operation is done in a safe and reliable manner. Therefore, a hot
tapping should be considered only after other options are evaluated and rejected.
Each hot tapping should be properly designed, the hot tapping location thoroughly
inspected, and the installation procedures reviewed.

Advantage
Hot Tapping makes it possible for pipeline owners and operators to isolate and
bypass sections of pipeline so they can complete their projects without shutting
down the system or losing product.

Hot Tapping Procedure

1. Mount the hot tapping machine to the piping system.
2. Advance cutter/pilot assembly until it touches the parent pipe, then start
the hot tap.
3. When cutter/pilot is completely through, stop rotation & advance to allow u-
wires to drop.
4. Coupon and cutter are withdrawn with the coupon or cut out retained by the
u-wires.
5. The fluid flow in the pipe is stopped between the two consecutive hot tap
locations and a by-pass arrangement is made for maintaining the regular flow
in piping system.
6. The fluid present between the two consecutive hot tap locations is drained
out using a vent (for gaseous fluid) or a drain (for liquid fluid).
7. Modification between the two hot tap locations are completed using cutting
and welding. This can be installation of any valve or a pipe piece.
8. Fluid is again filled between the two hot tap locations ensuring the original
pressure is maintained.
9. Fluid flow is started again from the main pipe and by-pass arrangement and
hot tapping machine is removed.

When to Avoid Hot Tapping

Hot tapping is not recommended under any of the following conditions:

 Piping containing a combustible or flammable mixture.

 Piping containing acids, chlorides, peroxides, or other chemicals that are likely
to decompose or become hazardous from the heat of welding (e.g., sulfuric
acid or acetylene).
 Piping containing caustic.
 Piping that contains pure oxygen or chlorine.
 Air lines where the absence of hydrocarbon cannot be assured.
 Monel piping handling sulfur compounds.
 Stainless steel piping containing catacarb solution.