Hot Tapping

 In House Training Program for Projects Unit

 Prepared By:- Ulfat Rasool

 What Are Hot Taps?
“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,
like weldolet

 Can also be applied as a repair method to remove defects,

i.e. dents
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.
Hot Tapping code & standard
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 (turnings, chips), 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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Non Standard Taps

Off-Set Tap
Angle Tap

Inverted Tap
Bend Tap

Blind Tap

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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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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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Hot Tapping
 Hot Taps can be performed on most any type
of pipe, ranging from carbon steel to PVC.
Taps are done on lines containing water, oil,
gases, fuels, steam, and many other
chemicals. Pressures up to 1440 psig at 100º
can be Hot Tapped safely with no interruption
of service.
Schematic of Hot Tapping Machine

Typical Hot Tap installation

consists of a tapping
saddle, gate valve, and Hot
Tapping Machine.
Hot Tapping Machine
 Drilling Machine
o Consists of a mechanically driven telescopic boring bar with
a pilot drill and cutting tool (hole saw)
o Pilot drill makes a pilot hole which guides the hole saw to
cut out the curved section of the pipeline
 Branch fitting
o Consists of a simple welded nipple for a small connections
to full-encirclement split-sleeve tee for same sized
connection
 Valve Drilling Machine
o Block or gate valve (but NOT plug or butterfly valve), with
enough space to extract the coupon
Hot Tapping Procedure
 Connect fitting and permanent valve on the
existing pipeline
 Install hot tapping machine through the valve
 Perform hot tap and extract coupon
 Close valve and remove hot tapping machine
 Connect branch line
Coupon Retention
 uses the latest technology
in coupon retention
available. When a Hot Tap
is performed, the double
wired pilot drill retains the
coupon and it is recovered
when the Hot Tap is
completed.
Hot Tapping

At 90 Angle on Pipe
On Elbow & On Angle
(Any Direction)

For Removal of Pipe piece

http://
Hot Tapping
Hot Taping
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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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Hot Tap Benefits
 Continuous system operation – shutdown and
service interruptions are avoided
 No gas released to the atmosphere
 Avoided cutting, realignment and re-welding
of pipeline sections
 Reduction of costs associated with planning
and co-ordination
 Increased worker safety
 Elimination of obligations to notify of gas
outage
SPACE REQUIRED FOR HOT TAPPING
HOT TAP AND WELDING METALLURGY
AND DESIGN
 The two primary concerns when welding on
in-service piping and equipment are

1. Burn through
2. Cracking
Burn Through
 Expulsion is the forceful ejection of molten
metal from the weld. Severe expulsion may
eject enough material to create a through-
hole in the work piece, commonly termed
"burn through
Cracking

 Crack in weld or base metal

Minimum base thickness
 minimum base metal thickness of 3/16 inch
(4.8 millimeters) is recommended for most
applications of welding and hot tapping. The
actual minimum thickness is a function of the
thickness required for strength, plus a safety
factor, usually 3/32 inch (2.4 millimeters), to
prevent burn through.
Hot tap connections and welding
code & STD
 Hot tap connections and welding repairs and alterations
must be designed to the applicable code such as the
following:
a) For piping designed to ASME B31.3, refer to API 570.

b) For piping designed to ASME B31.4 and B 31.8, refer to

ASME/ANSI B31.4.
c) For oil storage tanks constructed in accordance with
API Standard 650, refer to the hot tapping requirements
in Standard API 653.
d) For Pressure Vessels built to Section VIII and the ASME
Boiler and Pressure Vessel Code, refer to API 510.
Hot Tapping or Welding on Lined Piping or Lined
Equipment or Cased Lines

 Hot tapping or welding should not be permitted on

in-service lines or equipment with cladding, or
with glass, lead, refractory, plastic, or strip linings,
unless specifically authorized by specialized
procedures or following an engineering evaluation.

 When hot tapping or welding on underground lines

which run through casings, care must be taken to
assure that the annular space is gas free and that
the work is performed on the pipeline and not on
the casing.
The End