WE CAN WORK UNDER PRESSURE

HOT TAPPING:
What does the Procedure say?

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 International Definition:

Hot Tapping:

“Hot Tapping is the precise process of drilling a hole in an on-stream operational piping
system without spilling its contents or interrupting its flow.”

or in practical terms
“Hot Tapping is a means by which access is made to the inside of an operational pipeline,
using either a drill or a circular cutter.”

Hot Tap Applications include:

•Attachment of a branch connection to the line,

•Installation of an internal probe or monitor,
•To stop or redirect flow in a line for maintenance or repair purposes.
•Implies positioning a branch fitting on an operating pressurised line, flowing or stagnant.
Followed by cutting a hole in the header through the branch to allow connection to the
flowing media. Normally implies using a welded fitting,

•Can also be applied as a repair method to remove defects, i.e. dents.

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 Extract from SASOL SGR-MOR-000011

Factors, which govern standard, hot tapping

 
a) Size on size hot taps is not permitted. The size of the hot tap branch shall be limited to a
maximum of two pipe sizes smaller than the header size.
 
b) Hot tapping nearer than 460 mm to flange or threaded connection or approximately 70 mm to
a weld seam should be avoided.
 
c) Hot taps shall not be made on circumferential or longitudinal welds.
 
d) A hot tap shall not be made on the radius of any fitting.

e) Tie-ins with a bore of more than one-half the header shall require the use of a split tee (full
encirclement fitting). Those on one half the headers bore or smaller shall be an integrally
reinforced branch fitting, e.g. a weldolet or saddle type sweepolet whenever reinforcing is
required.
 
f) Some of the older hot tap equipment only allows hot tapping to be performed in the vertical
up and down position. Enough free space with no obstruction above the pipe to be tapped shall
be provided in these cases. Modern hot tapping machines do not have this restriction.

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HOT TAPPING

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Hot tap Configuration

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 Non Standard Taps
Off-Set Tap
Angle Tap

Inverted Tap
Bend Tap

Blind Tap

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Hot Tap Orientation
Standard vertical tap - no unusual problems

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Hot Tap Orientation

Angled vertical tap - no problems for

angles less than 45 degrees

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Hot Tap Orientation

As the angle of tap rotates around there

becomes more chance of the swarf from the
tap coming back towards the valve and the
tapping machine adapter resulting in
problems closing the valve and with
drawing the cutter fully.

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Hot Tap Orientation

As the angle of tap rotates around there becomes

more chance of the swarf from the tap coming back
towards the valve and the tapping machine adapter
resulting in problems closing the valve and with
drawing the cutter fully.

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Hot Tap Orientation

The measuring rod will tend to fall out. It is

also considerably harder to install the drilling
machine into position.

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 Clearance for Hot Tap

Longitudinal weld access

restricted by adjacent pipes

Longitudinal weld location at an alternative position in

order to improve weld access
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Hot Tap Fittings

Hot Tap fittings are either bolted or welded to the header pipe line. A
tapping/drilling machine is attached to the valve, which is attached to the hot tap fitting. A
cutter, attached to the tapping machine is inserted into the hot tap fitting through the valve
and the tap is made. In the case of a permanent valve, a branch connection
can be made, allowing flow through the outlet.

Rules of Thumb:

For reduced-branch taps, weldneck flanges on a weld-o-let can be used, but the size of the
branch must not exceed 50% of the header diameter, to ensure remaining strength is not
compromised.
Where the branch will exceed 50% of the header diameter, Hot Tap fittings are full-branch
or reduced-branch split tees, designed for use with Tapping Machines.

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Fabrication

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 Fit up of split tee for AIA
inspection before welding

Spit tee being machined to

clients specification

12” #600 Line Stop valve being

pressure tested.

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 HOT TAP - CLASS 150

Fabrication & Test Plan

Compliance to ISO 9001: 2008

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CST29 Drilling Machine

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Hot Tap Fittings

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Hot Tap Fittings:

Are equipped with ANSI Class 150, 300, 600, 900 or 1500 (SI PN 20, 50, 100, 150 or 250) weld
neck RF or RTJ flanges.

The reduced-branch split tee fittings can also be furnished with “Completion-plug” flanges for
use as bypass fittings.

Full-branch fittings are available in 2" - 60"(63mm-1,500 mm).

Reduced-branch fittings are available in any size or pressure configuration to meet customer
needs.
Plugging (Stopple) Fittings allow a means of isolating the flow in a
piping system for repair, maintenance or pipe relocation activities,
by incorporating a completion plug inside the flange on the branch.

The only real difference between a hot tap and line stop split tee fitting is mostly the use of a
“completion plug” flange in the neck of the line stop fitting.

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On Site Welding

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In-Service Welding for Hot Taps:

Welding onto an in-service piping system requires specially qualified welding

procedures and trained personnel.

The main concerns for in-service welding are:

•Burn through
•Hydrogen Cracking of Fillet Welds
•Chemical Reactions from Heat

With modern day low hydrogen welding techniques and properly qualified
procedures and welders, the above are not normally a concern, within tested limits.

In practice pipe wall thickness' down to 4mm (0.156") have been successfully welded
in-service, with the appropriate procedures, and in special circumferences 3mm
(0.125”). However, the normally accepted practical minimum is 4.8 mm (0.188”).

On pipelines the weld procedure and welding qualification includes the

provision for qualification and testing with highest expected rate of heat
loss, or restraint levels, and maximum carbon equivalent of the materials to
be welding.

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In-Service Welding for Hot Taps (Continued):

Pipeline fittings are also normally also required to meet the CSA Z245.11 Steel fittings & CSA Z245.12
Steel flanges codes, where applicable. These specifications imply that all welds must be to ASME IX and
subject 100% radiography to, ASME acceptance criteria.

On pressure piping systems (i.e. ASME B31.3 & ASME B31.1) there is no code, or regulatory requirement
to consider any in-service welding consideration. It was highly recommended that ASME IX welding
qualifications be supplemented by API recommended Practice 1107 for maintenance, however, API 1107
was due to be replaced by Appendix B in API 1104.

API 570 :
Requires that all repairs and alterations to the piping system must be done by an
organisation acceptable to the jurisdiction and must be authorized by the
inspector prior to its commencement.

All repairs and welding shall be done in accordance to the principles of ASME B31.3, or the code to
which the piping system was built.

Any welding on piping components must be done in accordance with API Recommended Practice 2201,
Procedures for Welding or Hot Tapping on Equipment Containing Flammable or combustible liquids.

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In-Service Welding for Hot Taps (Continued):

API 2201 specifically indicates that ASME IX does not cover in-service welding
conditions and that API 1107 should be used to qualify both welding
procedures and welders on pipe containing flammable or combustible liquids.

In addition, API 570 requires that the inspector shall use, as a minimum the
"Suggested Hot Tap Checklist" contained in API 2201 for hot tapping
performed on piping components.

API 2201 requires:

In advance of "hot tap" work the following should be prepared:
•A detailed in-service welding procedure.
•A hot-tap procedure.
•A connection design.
•Health, safety, fire protection, and other appropriate instructions.

*Always verify the header pipe wall thickness prior to in-

service welding.

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Welding Sequence of Split Tee Fitting (Split Sleeves):
Sequence of welding is important. Weld the longitudinal-type seams of full-encirclement
fittings first. If factors permit, weld both longitudinal-seams simultaneously. Should factors
prohibit this, alternate side-to-side to avoid excessive distortion.

Do not weld both circumferential-type seams simultaneously. This may introduce excessive
stresses into the fitting and piping system.

Longitudinal- seams should never be welded to the header/carrier pipe.

Where a full penetration longitudinal weld is desired, the use of a Backing Strip is strongly
recommended, which should be specified when doing the design.

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Pressure Testing

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Pressure Testing of a Hot Tap Fitting or Split tee:

Prior to tapping the fitting should be pressure or leak tested. The pressure, or leak test, will
subject the header pipe wall to an external pressure.
The intention of the appropriate design code requirement may be for the hot tapping/line stop
fittings to be internally pressure tested .
Exceeding the piping system internal pressure may cause damage to the header pipe, making
it difficult or impossible to complete the hot tapping and/or line stop operation, thereby
compromising the integrity of the piping system .

The allowed safe external test pressure depends on :

•The header (carrier) pipe diameter to thickness ratio,

•Grade of material,
•Roundness of the pipe
•Local wall thickness loss
•Corrosion
•Mechanical damage, should also be a consideration.

*ASME VIII external pressures design principles can be applied, but there is a need to consider
local deformation as well, which may result in causing a dent on the header pipe at the fitting
branch opening location, during the pressure test.

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 Quality Management System: On Site - Inspection, Preparation, Works Instruction, Log
Sheet
Hot Tapping and Linestopping
         
Tapping Machine Ser. No.  

Class Rating  

ALL C.S.T. HOT Size

Date of Last Service
 

TAPPING EQUIPMENT CHECKLIST

IS DONE AGAINST A
Tick Applicable
Sequence TAPPING MACHINE YES NO N /A

QUALITY CONTROL   Do You have a Job Card? If not, get one before proceeding

PLAN  
 
Is there a Green Ticket and Pressure Test Certificate?
If NO, pressure test the assembly first before proceeding
     

1Enough head Room above the tap for the tapping machine      
2Enough travel for completing the Hot Tap      
3Correct Tapping adapter fitted      
4All bolts/ threads fastened      
5Enough travel for completing the tap      
6Correct Tapping adapter selected      
7Tapping adapter aligned with cutter in center of adapter      
8Correct Pilot installed      
9Catch wires move freely on pilot      
10At least two catch wires will catch coupon      
11Correct Cutter Selected      
12Cutter teeth in good condition      
13Cutter Holder secured to cutter    
14Pilot secured to cutter Holder    
15Pilot retracts into tapping adapter      
16Tapping Dimensions taken and recorded      
17Completion Plug setting distances taken and recorded      
18No openings to atmosphere for accidental product release      
19Bleeder Valve Correct Pressure rating      

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Hot Tap Animation

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Coupon retained
by ‘U’ Wire

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Coupon retained
by ‘U’ Wire

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Coupon and cutter
are withdrawn

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Vent off
Product

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Product
cleared

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Thank You

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