HOT TAPPING GAS PIPELINE AND PLUGGING

PROCEDURE IN PETROLEUM INDUSTRY

 Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry

Overview
Hot Tapping is defined as a method for installing connections on live equipment (pipeline, piping, storage tank,
vessel etc). Since drilling/circular-cutting is done on live pipe/equipment, it is called ‘Hot Tapping’. What is the
purpose of Hot Tapping? This procedure is an essential step for installing bypass in a pipeline to enable the
removal of a section of piping, for its repair or installation of new equipment therein, with the process system in
operation. The repair of the affected portion is necessitated due to corrosion, material defect etc or its replace-
ment warranted to instal some additional components such as instruments, control valves, pipe-branching to
distribute the fluid somewhere else. For the bypass to work and to divert the flow of the pipeline fluid so that
the isolated pipeline section is safe to remove/work in, at least two hot-tapped holes are used on either side of
the isolatable section to insert inflatable plugs.

Since stoppage of gas flow in large installations and companies have huge national and global economic impli-
cations, this procedure of hot tapping and isolating the affected portion or the area of interest by inserting at
least two plugs one each on either side through the tapped holes is resorted to. This whole operation is highly
risky and is fraught with potential for very serious incidents like fire and explosion. Therefore, only trained
workers and supervisors must do this job under close supervision of technical managers.

This Zoe training course will empower course participants with comprehensive knowledge about ‘Hot Tapping
Gas Pipeline and Plugging Procedure in Petroleum Industry’.

Objectives
This comprehensive ‘Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry’ course, will
equip the participants to:
•• Understand the concepts of hot tapping and plugging
•• Appreciate the advantages and disadvantages of hot tapping and plugging in gas and petroleum industry
•• Comprehend the procedures for hot tapping and plugging
•• Appreciate the hazards involved during hot tapping and plugging
•• Carry out Risk Assessment and learn the ways to manage various significant risk items
•• Plan various steps involved in hot tapping and plugging
•• Study various serious incidents during hot tapping and plugging in gas and petroleum industry
•• Participate in solving the associated case studies’ and problems
•• Learn about some specialized agencies who carry out hot tapping and plugging
•• Be aware of further advanced training and certification avenues available on hot tapping and plugging

Training Methodology
This collaborative ‘Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry’ training program
will comprise the following training methods:
•• Lectures (Tutor-assisted online and classroom as per requirements)
•• Seminars & Presentations
•• Group Discussions and Workshops
•• Assignments
•• Case Studies & Functional Exercises
Zoe Talent Solutions follows the ‘Do-Review-Learn-Apply’ model.

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 Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry

Organisational Benefit
Companies who nominate their employees to participate in this ‘Hot Tapping Gas Pipeline and Plugging
Procedure in Petroleum Industry’ course can benefit in the following ways:
•• Specialized knowledge on management of these highly risky operations
•• Ensure a trouble-free and incident-free execution of Hot Tapping Gas Pipeline and Plugging Procedure
•• Huge cost advantages due to money saved by not stopping production for several days
•• Enablement of the organization for future management of change efficiently and safely while the
production is on

Personal Benefit
Individuals who participate in this ‘Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry’
course can gain from it in the following ways:
•• Gain specialized knowledge and skills in Hot Tapping Gas Pipeline and Plugging Procedure
•• Have a sense of satisfaction by being able to carry out this extremely crucial, risky but incredibly
cost-saving procedure which is used only once in a rare occasion
•• Enhance their career prospects with the highly specialized knowledge and skills achieved
•• Learn safety and trade together for Hot Tapping Gas Pipeline and Plugging Procedure
•• Join specialized agencies providing ‘Hot Tapping Gas Pipeline and Plugging’ services

Who Should Attend ?

This ‘Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry’ course would be suitable for:
•• Engineering, Fire & Safety, Maintenance, Operation, Inspection personnel at all levels, including trainees/
interns
•• Insurance, Regulatory and lending agencies
•• An introductory-version for support staff such as Human Resource Dept, Accounts, Procurement to help
them understand risks involved in such operations and prompt them to provide support to the blue-collar
personnel involved in these jobs on war-footing

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 Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry

General Notes
•• All our courses can be facilitated as Customised In-House Training courses
•• Course duration is flexible, and the contents can be modified to fit any number of days
•• Zoe’s Open Enrolment Courses offer clients the flexibility to choose their preferred location, date
and time. Our team of experts, spread around the globe, will assist in facilitating the course
•• The course fee includes facilitation, training materials, 2 coffee breaks, buffet lunch and a
Certificate of Successful Completion of Training
•• FREE Consultation and Coaching provided during and after the course

Course Outline

CONCEPTS OF HOT TAPPING AND PLUGGING

•• Gas pipeline
01 •• Petroleum pipeline
•• Other applications where Hop tapping and plugging may apply
•• Hot Tapping
•• Plugging

ADVANTAGES AND DISADVANTAGES OF HOT TAPPING AND

PLUGGING
02 •• Huge cost-saving
•• Customer satisfaction with quick results
•• Risks of fire and explosion
M ODUL ES

•• Risks of serious injuries and fatalities to workers if not planned

and executed safely

HOT TAPPING PROCEDURE - PREPARATION

•• Management Authorization
03 •• Specification of the metal to be tapped
•• Chemical and physical properties of the fluid to be tapped into
•• Calculations conformance to the applicable Code of Practice,
Standard and Local Regulations
•• Inspection and testing of the external condition of the equipment
to be tapped
•• Design and construction of the stub bases at the areas to be
tapped
•• Recommended fittings only allowed (Weldolets, Threadolets,
Sockolets, Weldends, split tees, saddles, long welding necks,
shaped nipples, reinforcing rings and pads etc.)
•• Permit to Work duly authorized, Hydrocarbon testing and
Emergency response planned

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Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry

HOT TAPPING PROCEDURE - EXECUTION

•• Check on rise in process pressure and temperature during the Hot
04 Tapping operation; preferably aim at reducing them considerably,
if feasible. Parameter monitoring with gauges
•• Weld the Stub and reinforcement using fillet welds. Post-weld
inspection
•• Maintenance of flow of product in pipeline during welding to
reduce the heat accumulation
•• Install the isolation valve (side-assembly) on the flange of the
welded stub through which the tapped hole is to be made
•• Pilot drilling and Coupon-cutting with purpose-built hot tapping
machine (motorized driller)
•• Close the isolation valve above to stop leakage of gas through the
tapped hole

CREATING A BYPASS LINE

•• Make two hot tapping connections at either side of the affected
05 portion of the pipeline
•• Attach the prefabricated bypass line
•• Perform leak, integrity and safety checks
•• Open the bypass line by opening the valves at both ends

CREATING PLUGGING PORTS

•• Make two hot tapping connections at either side of the affected
06 portion and within the bypass segment
•• Replace hot tapping machine by the plug inserting assembly (i.e.,
line stop actuator) above the isolation valves
•• Perform leak, integrity and safety checks

PLUGGING PROCEDURE TO ISOLATE THE AFFECTED AREA

•• Insert the plugs (line stops/ stopples), by opening the isolation
07 valves, through the tapped holes
•• Inflate/activate the seals around the circumference of the
cylindrical plugs to ensure gas sealing
•• Perform leak, integrity and safety checks
•• Monitor external condition to check no gas leaking internally past
the plugs

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Hot Tapping Gas Pipeline and Plugging Procedure in Petroleum Industry

REMOVAL OF THE AFFECTED AREA AND ITS REPLACEMENT

•• Pilot/test drilling gently on one side of the affected portion to
08 rule out significant continuous gas leakage into the affected area
under emergency safety preparedness
•• Suck out residual gas from the affected portion, if any
•• Complete the cut and remove the affected portion
•• Install the new pipe by welding and do integrity checks
•• Install new equipment/monitoring instrumentation/ gauges etc as
required

OPENING THE MAINLINE AND CLOSING THE BYPASS

•• Slowly and cautiously deflate/deactivate the plug seals
09 •• Slowly and cautiously retract the plugs
•• Close the isolation valves meant for the plug ports
•• Install blinds on top of the flanged stubs after removing the
plugging assemblies on both sides of the affected portion
•• Slowly and cautiously close the bypass line’s isolation valves
•• Remove bypass pipe
•• Install blinds on top of the flanged stubs after removing the
bypass line
•• Perform leak, integrity and safety checks

SERIOUS INCIDENTS DURING HOT TAPPING AND PLUGGING IN

INDUSTRY
10 •• Study of incidents
•• Analysis of problem areas, root cause analysis and corrective
actions
•• Presentation of solutions by the participants

Miscellaneous knowledge
•• Solving the associated case studies and problems
11 •• Specialized agencies who carry out hot tapping and plugging
•• Advanced training and certification avenues available for hot
tapping and plugging

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Middle East – Head Office 918,
Blue Bay Towers,
Al Abraj Street (Marasi Drive),
Business Bay, Dubai, UAE

+971 4 558 8245

+971 52 878 9387

info@zoetalentsolutions.com

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