What is Hot Tapping?

Hot Tapping is the procedure for cutting or drilling an opening into a pipe which is carrying
product under pressure without shutdown or spillage. It is the preferred method for performing
maintenance, repairs or modification work requiring safe entry into a live, pressurized pipeline.

Why Make a Hot Tap?

Hot Tapping is used for many purposes:
• To safely tie-in to a pressurized system while under full operating conditions
• To make new Tie-Ins or Branch Connections
• To create an access point for Line Stopping Machinery
• To extract a coupon for material analysis
All of this and more can be done without interruption of the pipelines flow or transportation and
delivery service.

Hot Tapping Techniques:

Hot Tapping is used to tie into your system in many different ways. Our team of pipeline experts
will determine which technique is best for your application and will provide the optimum results.
Hot Tapping can be performed on pipe materials including:
• Carbon Steel – X80 Grade
• Stainless Steel
• Cast Iron
• Pre-stressed Concrete
• Ductile iron
• Alloys
• PVC & HDPE

Hot Tapping is an effective technique for other pipeline applications including:

• Product Sampling Point
• Flow Meter Installation
• Thermo-well Sensor Installation
• Draining of pipelines
• Pressure Control Switch Installation
• Pipeline Inspection
• Determine product in a pipeline
• Air / Product Relief Point

What is Line Plugging & Stopping?

Pipeline Plugging is the method of safely isolating and bypassing a section of pipeline enabling
modification to a pressurized system without the need to shutdown the line under operating conditions.
Why Plug a Pipeline?
Isolation may be required for several reasons:
• Replace or install a new line valve
• Repair a damaged section of pipe due to external damage or corrosion
• Repair a ruptured line
• Isolate a compressor station or plant unit
• Line requiring modification due to:
• Roadway
• Line re-route
• Plant alteration
• Tie-in new section of pipeline

Pipeline Plugging Techniques:

Isolation of a pipe is obtained by inserting a plugging head into the pipe through a hot tapped fitting and
temporary valve assembly while under pressure. After the plugging head has been set, the pressure is
relieved in the isolated section through an equalization fitting on the isolated section of pipe.

Completion:
After the modification to the pipeline or plant has been made, the equipment needs to be removed. The line
is equalized, and the plugging head is retracted. In order to remove the temporary valve a completion plug
is installed and secured into the fitting. The pressure is relieved above the plug and the equipment is
removed. A blind flange is then installed over the plug and the job is completed. If necessary the fitting can
be re-entered in the future by removing the blind flange, re-installing the temporary valve and removing
the completion plug.

Hot tapping and plugging procedures can be an effective and economic means to enable the efficient
execution of projects to relocate, modify, or repair water and waste water infrastructure as well as oil
and gas transmission lines without interrupting operations and/or services. The application can result
in significant costs savings in tens of millions of dollars when large diameter pipe lines are involved.
However, the general concepts, possible configurations, and sequences of the procedure appear to be
known to a limited number of design, construction, and operations professionals, which may be
detrimental to effective project execution or lead to the selection of another costlier option. This paper
will discuss helpful information to facilitate effective use of hot taping and plugging procedures
through a better understanding of the: general concepts and possible configurations to achieve
isolation needed to enable project execution; tapping and plugging sequences; considerations for the
design and selection of the appropriate tapping and plugging fitting corresponding to the type of pipe
to be tapped; installation of tapping and plugging fittings; sequence and control for the tapping and
plugging operation; and addressing the forces developed by the operation of the tapping and plugging
machines.

Day One: Oil and Gas Pipelines

 Introduction: Oil and gas pipelines types and standards
 Layout of oil and gas pipelines: Components and relevant functions
 Glossary of terms used in pipelines hot tapping and plugging operations
 Pipelines construction: Site preparation – Pipes transportation – Ground trenching – Pipes laying
and covering – Pipes bending – Pipes welding and joint coating – Pipes cleaning – Pipeline`
inspection and testing

Day Two: Pipelines Hot Tapping and Plugging

 The concept of hot tapping and plugging
 Hot tapping and plugging applications: Branch connection attachment – Monitor installation –
Redirect flow – Defects removal - Line stopping
 Factors affecting the hot tapping and plugging process: Pipe size – Distance flanges – Distance to
welded portions – Distance to valves
 Hot tapping orientation: Standard and non-standard
 Hot tapping and plugging standards: API and ASME related standards

Day Three: Hot Tapping and Plugging Equipment

 Types: Hand – Hydraulic – Electric – Pneumatic
 Equipment basic data and considerations
 Equipment design features and construction
 Examples of hot tapping equipment: Description, specifications, features and fitting applications
of the tapping machines – the sandwich valve
 Branch connection fitting
 Thread O-ring flanged fitting
 Spherical three-way Tee
 Composite warp
 The plugging machine
 The lock-up ring flanges & plugs
 Wedge-lock pipe plug
 Equipment test
  Freeze plugging

Day Four: Hot Tapping and Plugging Procedure

 Cases where hot tapping is prohibited
 Selection of hot tap location
 Design considerations
 Preparatory work to hot tapping
 Hot tapping operation management
 Technicians` qualifications and skills
 Hot tapping of lines pipes
 Hot tapping basic requirements and operations
 Welding preparation, procedure, and inspection
 Hot tapping machine installation
 Hot tapping operations and work completion
 Hot tapping check lists
 Line stops: Types – Layout – Operation – Completion plug

Day Five: Hot Tapping and Plugging Hazards and Risk Reduction
 In-service hot tapping emergency action plan
 Hot tapping features and relevant hazards
 Various hazards : Physical – Thermal – Chronic – Toxic – Combustible
 Hazards risk reduction
 Case studies: Hot tapping economy – Hot tapping hazards

Day One: API 2201 Scope and Job Analysis

 Hot Tapping Overview
 Scope
 Concept of Hazard vs Risk
 Job Analysis
 Job-specific Hot Tapping Review for Work Authorization
Day Two: Hazards Evaluation and Risk Reduction for Hot Tapping on In-Service
Equipment
 Physical Hazards
 Safety issues: Thermal Burn Hazards and how to mitigate
 Health Hazards during hot tapping
 Flammable Liquids, Vapors, Solids, or Dusts
 Combustible Materials and Risk Reduction

Day Three: Welding and Hot Tap Metallurgy Considerations

 Burn-through Prevention
 Flow in Lines
 Metal Thickness
 Fittings
 Post Weld Heat Treatment (PWHT)
 Metal Temperature considerations
 Welding and Hot Tap Connection Design
 Piping and Equipment Content

Day Four: Hot Tapping Machines, Preparation, and Special Considerations

 Hot Tapping Machine Considerations
 Written Plans
 Management of Change
 Personnel Competency and Qualifications
 Hot-Tapping and Welding on above ground Tanks and Pressure Vessels
 Welding and Hot Tapping on internal Lined Piping, pipelines and Lined static Equipment
 Hot Tapping on Piping
 Hot Tapping Upstream of Equipment and Valves

Day Five: Hot tap operations

 Preliminary Requirements
 Welding in Preparation for Hot Tapping
 Inspecting the Weld
 Installing the Hot Tapping Machine
 Testing the Weld and Hot Tapping Machine
  Completion
 Example of hot tap checklist

Advantages of Hot tapping equipment

 No shutdown is required and therefore no loss of production

 No loss of product within a pipe – No emission to the environment

 Reduced cost of planning of manpower and resources

 Coupled with a line stop operation, valves can be repaired/ inserted, or damaged /corroded

pipe or fittings can be replaced or long stretches of pipelines can be re-routed.

Hot tapping process consists of:

 Hot tap fitting with the required branch & flange size.

 Ball or Gate Valve

 Hot tap machine with Cutter & Adaptor

The Six-step Hot Tapping Equipment Process

Step 1: Weld the fitting to the line and bolt the valve to the pipe fitting.
Step 2: Bolt the hot tap (HT) machine to the valve.

Step 3: Check for leaks in bolted connections by pressure testing through the hot tap adaptor.
Make sure the valve is fully open throughout the testing.

Step 4: Start cutting the pipe by advancing the cutter till the cut is complete. The section of
the pipe which is removed is known as the “coupon.” This is retained by means of u-wires,
which are attached to the pilot drill.
Step 5: Once the cutter has cut through the pipe, the hot tapping equipment or machine can
be stopped. Withdraw the cutter into the hot tap adapter and close the valve.

Step 6: Prior to removing the hot tapping equipment or machine, the pressure from inside the
tapping adapter is bled off. The machine is then removed from the valve, and a new pipe
outlet is established.

The Uptime Benefits of Hot Tapping

The process can be performed on almost any type of pipe that carries fluid under pressure,
ranging from carbon steel to PVC. Adding new connections to a pipeline is not the only
reason for doing hot taps. Product sampling points, pressure control switch installations,
inspections, and draining pipes are just a few examples of hot tapping procedures. Not only it
is cost-efficient, but it is also a safe and effective way to keep facilities up and running during
repairs and upgrades to vital infrastructure.

Hot tapping risks and dangers

Hot tapping and plugging should only be considered when it is impractical or
impossible to complete repairs or add a new pipeline branch any other way. The
reason being is that there are some serious hazards and dangers that can occur
when using this process.

Hot tapping a pipeline consists of two primary phases:

1. The process in which the hot tapping machine is attached to the piping
system.

 This may be done by bolting, clamping, brazing, or welding a hot tap saddle

 Mechanically cutting a hole into the pipeline wall

 This may be done with a specialized hot tapping hole saw

The principal dangers lie in the fact that when hot tapping you don’t depressurize the
pipeline and so are dealing with high pressure and/or high temperature situations.
Plus, in certain circumstances you have to weld the hot tap machine to the pipeline,
there is also a danger of igniting combustible gases or material.

The biggest issue with welding on the saddle is that you use the pipe or vessel as a
backer for the weld. Burn through can occur when welding onto a pressurized pipe if
the area beneath the weld pool is not strong enough to contain the internal pressure
of the pipeline. Typically, the outside of the pipe can be cleaned and ultrasonically
tested (UT) to insure that the metal area under the weld is known. Unstable
decomposition of the flow material can also be a danger and result in violent
reactions when heated under pressure.

Another danger is hydrogen cracking in carbon steel pipes, which is more likely to
happen when hot tapping in comparison to other welding situations, due to the
flowing product increasing the rate of heat flow from the weld region. This leads to
shorter cooling times, with an associated increased risk of forming hard
microstructures and thus greater susceptibility to hydrogen cracking. However, this
issue can be controlled via appropriate welding procedures and understanding of the
metallurgical process.

Hot tapping can be done on non-metallic pipes such as HDPE, however, these
pipelines have other issue of concern such as lower strength and sealing with
gaskets and mechanical joints. Also, the pipes cannot carry as high of a load as
metallic pipes and vessels.
Copper pipes can also be hot-tapped. These are typically smaller in diameter and
can have the hot tap saddle brazed, welded, or bolted onto the pipe or vessel.

How to mitigate hot tapping hazards

Due to the dangerous nature of hot tapping in pipelines, it’s important to take the
proper steps to lower the risk of accidents and injuries. First, it’s crucial that
everyone involved be trained and familiar with the process, welding procedures (if
required), and the use and location of all necessary tools and equipment. Next, a
preliminary risk assessment should be done to check whether hot tapping can be
done safely at the specified location of the pipeline. OSHA has standards such as
1910.252 for welding, cutting, and brazing. Hazard communication is very important
and lock-out tagout procedures should be followed. Petersen Products follows a
variety of codes and standards such as API, ASME, ISO, and NBIC.
The following parameters should be considered before using a hot tap:

 Size and thickness of pipe or vessel wall

 Minimizing hot tap size (use Petersen Products inflatable line stop or flow stop
plugs)
 Vessel wall integrity, corrosion issues, and material
 Operating pressure and temperature
 Media flowing through pipe or in vessel
 Fluid characteristics
 Velocity / flow in pipe or vessel
 Metallurgy / chemistry compatibility of all materials in contact with fluid (such
as seals)
 Welding considerations, Metal Temp, Heat input of weld / Electrode/filler size,
etc..
 Hazards and contaminants at location / worksite
 Fire watch, permits, barriers, contingency plan, end user safety policies, as
required
 Local codes and standards
 Special considerations; above or below grade, confined space, decks of
floating roof tanks, or upstream valves, tanks in service or other.

Safety requirements before hot tapping

In metallic pipes metal thickness should be measured by ultrasound (UT) devices,
typically shear wave is preferred rather than straight beam. Any other method of
measurement needs to be approved by owner inspector. The thickness should be
exactly measured at the location where the welding is expected to be done. It is
recommended to measure thickness over a 2” band and the recommended minimum
thickness for hot tapping is about (3/16”) 5.0 mm. The material should also be
cleaned, preheated, and/or PWHT according to acceptable welding procedures. Hot
tapping should avoid the weld seam in pipeline or vessels if possible. Use extreme
caution on wall thicknesses less than ¼” thk. In thin wall carbon steel hot taps, it is
generally recommended to monitor heat input and use electrodes 3/32” or smaller on
the root pass to prevent cracking, however it may increase risk of cracking in high
carbon equivalent metals. It is recommended to use 1/8” dia or larger on subsequent
weld passes.
The metallurgy of the hot tap fitting and the filler material must be compatible with
the metallurgy of the equipment to be welded or hot tapped. For example, low
hydrogen electrodes are often advisable to minimize weld cracking problems in
carbon steel or a high purity flux and filler on brazes on copper pipe. Special welding
consideration may be needed for high tensile strength steels to avoid weld cracking
and the need for post weld heat treatment. Support of the pipe or vessel when
PWHT should also be considered. Always follow an acceptable welding procedure
for the job. Petersen Products can help guide you in your weld-on saddle
applications no matter the alloy.

Testing hot tap saddle integrity after welding

After welding, the hot tap nozzle should be tested at the pressure calculated by the
design engineer. If pressure testing is done above this calculated value, the parent
pipe can buckle inwardly. The larger the branch of the hot tap, the higher the risk of
buckling. The testing medium should be selected based on the temperature of the
fluid flowing through the pipeline system to ensure an accurate test.

The isolation valve to be installed on the hot tap flange should be hydro-tested in the
shop prior to installation to ensure seat sealing. The gland packing should be
changed prior to test to make sure that there are no leaks during the pressure test
and subsequent hot tapping operations.

Take the necessary precautions

Before beginning a hot tapping job, the maintenance, inspection, and operations
crew on-site should meet with the contractor and prepare a risk assessment for
conducting the hot tap safely. This assessment should include a contingency plan in
case of a mishap during the process and there should be clear lines of
communication between the hot tap crew, supervisors, and control room in case of
an emergency. The fire department should also be informed in case they need to
respond to an emergency fast.

Lastly, the crew should be informed of the hazards of the fluid flowing through the
pipe, ensure enough ventilation and lighting in the work area, and only keep the
minimum number of required personnel near the hot tap location while welding.

Contact the Petersen Products team with any questions concerning hot tapping
hazards and precautions.

The information may be used but with no warranty or liability. This information is
believed to be correct but should always be double checked with alternative sources.
Strictly adhere to and follow all applicable national and local regulations and
practices.
CONS OF HOT TAPS
While hot taps can help reduce downtime and costs for necessary maintenance, repairs, or branch
additions for your pipeline, it does come with some disadvantages as well. Most of these
drawbacks come down to inherent safety risks of working with live pipelines.

Hot tapping mechanical field services involve working with pipes under pressure. This can
expose people, equipment, and the environment to materials under high pressure. The materials
may also be high temperature or potentially harmful to people, processes, and the environment.

Because of the potential dangers of hot tapping, these services require extensive planning
beforehand. From mitigating risks for hot tap procedures to gathering in-depth data about the
pipeline and materials inside the pipe, this can take some time. Therefore, if you’re planning on
hot tapping your pipeline, it’s important to keep in mind that this service typically isn’t suited for
fast completion timelines.

Hot Tapping - Strategies & Effective Practices to Manage and

Mitigate Hazards
Last updated February 19, 2021 | Element: Strategies & Effective
Practices to Manage and Mitigate Hazards
Toggle table of contents visibility forHot Tapping

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Site specific written down procedure for hot tapping
 Even though there are API codes and guidelines available for
conducting welding/drilling on live systems, each facility is unique. It
is recommended that each site develop an exhaustive procedure for
carrying out hot tapping on live equipment at their premises.
 The procedure should detail the technical requirements and the
responsibilities of the various agencies/personnel involved in the
execution of the job
 The procedure should indicate fluids used at the facility for which hot
tapping is prohibited. As an example, fluids that can cause stress
corrosion cracking in metals should not be considered for hot
tapping.
Hot tapping as the last option
 Taking a branch connection or performing maintenance by welding
on live system should be the last option for any operator considering
the serious hazards posed by the activity.
 All options available other than welding on live equipment/pipelines
should be evaluated and documented.
 Considering the serious hazards, a well-documented approval matrix
should be put in place for authorization of each of the hot tapping
jobs.
Hot tap design
 A request for welding on live system should be created. The request
should include, as a minimum, parameters like:
a) Size and actual thickness of the hot tap location

b) Operating pressure and temperature

c) Fluid characteristics (flammability, toxicity, corrosivity)

d) Velocity / flow

e) Metallurgy

 Based on the request, the modification to the system should be

designed per relevant national/international codes and standards.
The site/facilities engineering standards should be followed while
designing the modification.
 The design engineer should be informed that the branch connection
should be done by Hot Tapping.
 Design engineer should design the nozzle reinforcement to meet the
machine loads during the drilling operations.
 Design engineer should do a field visit to check the location where the
welding/drilling is to be performed.
 Design engineer should discuss the hot tap procedure with service
providers/contractors entrusted with the job of welding/drilling on
the live system
 Design should be validated by persons considered competent.
 Design should include a testing requirement for the modifications.
Feasibility for safe hot tapping

 Feasibility of hot tapping should be done by a team from the process

plant facility and the service provide/contractor.
 A preliminary risk assessment should be done to check whether the
Hot Tapping can be done safely at the specified location in the
process unit.
  The service provider, based on their experience, will provide inputs
on safe execution of the hot tapping. All relevant design information
(as listed above) should be shared with the contractor in order to
make an accurate determination of feasibility.
Making sure that metallurgy of the existing pipe is suitable for hot tapping

 Hot tapping is normally only done on carbon steel piping and

equipment.
 Hot Tapping is not carried out on ferritic alloy steels where special
welding requirements like preheat, post heat and post weld heat
treatment are required.
 Hot Tapping on metallurgies other than carbon steel should need
special procedures and is outside the scope of this document.
 Positive Material Identification (PMI) on the pipeline / equipment is
necessary where hot tapping is to be done, to ensure that the material
is indeed carbon steel and there is no mix up during the original
construction.
 If there are welding joints that intersect hot taps, then PMI should be
done on the weld joints also
 Hot Tap welding should not intersect electric resistance seam weld in
the pipe.
Inspect the existing weld joints that intersects hot tap weld joint for integrity

 Hot Tap should be avoided on existing weld joints. The location

should be chosen in such a way that Hot Tap welding does not
interfere with the existing weld joints.
 Longitudinal seam weld joints should be identified by suitable in-situ
etching methods.
 If Hot Tap cannot be avoided without intersection, then the
interfering weld joint should be volumetrically inspected (either UT
or RT) to make sure that there are no defects in the weld joint that
can lead to burn through during hot tap welding. The UT or RT
should be done for the purpose of hot tapping and certified.
 The area over which hot tapping is to be done should also be checked
by the Mechanical Integrity inspector to detect sub-surface defects if
any.
Making sure that the metal thickness at the hot tap location is adequate

 The location where thickness is to be measured should be hard

punched and this should not be changed without consent from the
site inspectors.
 Thickness should be measured by devices that work based on
Ultrasound. Any other method of measurement needs to be approved
by owner inspector.
  The thickness should be exactly measured at the location where the
welding is expected to be done. It is recommended to measure
thickness over a 2” band. Recommended minimum thickness for hot
tapping is about 5.0 mm.
 A critical review of the measured thickness may be necessary if:

1. Hot tapping welding is planned on systems with thickness close

to the minimum thickness of 5.0 mm
2. Hot tapping is being considered on corroded pipelines.
(e.g. Nominal thickness is 10 mm and measured thickness is
close to minimum required thickness of 5.0 mm)
3. Hot tapping is planned on a system which has undergone a
fitness for service evaluation
 High Temperature thickness measurement should be cross-verified
adequately to ensure that the measured readings are dependable
Making sure that the metal where hot tapping is being done meets the
hardness requirements

 It is recommended to measure and certify hardness to be less than

200 BHN (Brinell Hardness Number). Higher hardness material can
crack during welding. Higher hardness can also cause problems
during drilling of coupons.
Maintaining fluid flow during hot tap operations

 Hot tapping operations are considered safe based on the fact that
molten metal during welding solidifies and cools to less than about
400 deg C very quickly. This is necessary to achieve the mechanical
properties able to withstand the system pressure. A positive flow in
the pipeline helps in conducting the welding heat away and cooling
the molten metal quickly.
 A positive flow should be ensured during the full cycle of hot tapping
operations.
 The greater the thickness reduces the dependency on flow to cool the
metal. However, flow has to be maintained.
 Operating crew will identify a direct quantitative measurement of
fluid flow in the line where hot tapping is being done. The calibration
of flow meter should be ensured.
 If the flow measurement is not available for direct determination in
the line where hot tapping is being done, an indirect method of
ensuring flow should be established. This should be validated by
competent personnel at the facility.
Ensure welding procedures are in place

 Hot tap welding should be done as per an approved WPS.

  Welders should be qualified for the material and thickness.
 Based on the thickness of the metal, heat input during welding has to
be controlled to make sure that metal does not get over heated.
 Welding heat input is dependent on the welding speed. Based on the
maximum heat input allowed, welding speed should be calculated.
 The welder should be trained on a mock up piece to comply with the
welding speed requirements.
Ensure that the new materials are used in fabrication of hot tap connection are
as per specification

 All the materials like pipe, reinforcement pads and welding

consumables should be checked by Positive Material Identification
tools to make sure that there is no mix up.
Test the integrity of the hot tap nozzle before fixing

 The hot tap nozzle should be welded to the flange and this spool
should be hydro-tested at the required values per the drawings and
appropriate codes. This should be done prior to welding the nozzle on
the existing equipment / pipeline by hot tapping.
Switch off Cathodic protection

 Cathodic protection can sometimes affect welding operations in

pipelines. Ensure the same is switched off.
Have a risk assessment done for the complete hot tap job
 Maintenance, Inspection and Operations crew on site
should meet with the contractor and prepare a risk assessment for
conducting the hot tap job safely.
 The evaluations/inspections that were completed to certify the pipe /
equipment as fit for hot tapping shall be shared with the contractor
performing the work.
 Inform the crew of the hazards of the fluid flowing through the pipe
 The risk assessment should include a contingency plan in case of a
mishap during hot tapping
 Ensure availability of communication between the hot tap crew,
supervisors and control room for emergency actions that may
be required.
 Fire department should be kept informed for responding in case of
emergencies
 Ensure that any scaffolding or platform, if erected for the hot tap job,
is large enough for personnel to back off from the work area. Plan for
alternate exits from the scaffold / platform.
 Make sure that escape routes are clear.
 Ensure that minimum personnel are present close to the hot tap
location while welding is in progress.
  Ensure enough ventilation and lighting in the work area.
 Make arrangement for gas monitoring of the hot tap location
continuously until welding is complete, approximately 30 minutes
following completion of the work.
 Prepare a briefing/toolbox talk to all the crew involved on the hot tap
jobs regarding the safety and emergency procedures
Stiffening of parent pipe

 For large size hot tapping typically greater than 20”, there is always a
possibility of the coupon springing back when the coupon cutting is
complete. If spring back happens, coupon removal can be difficult.
Consider installing welding stiffeners on the coupon to be cut prior to
drilling and cutting.
Test the integrity of the hot tap nozzle after welding

 The hot tap nozzle should be pressure tested after welding is

complete. During this pressure test, the parent pipe or part of the
equipment on which the nozzle is welded is subjected to an imposed
pressure. Hence, this test pressure has to be calculated by the design
engineer and provided to the hot tapping contractor. If pressure
testing is done above this calculated value, the parent pipe can buckle
inwardly. The larger the branch of the hot tap, the higher the risk of
buckling.
 The testing medium should be selected based on the temperature of
the fluid flowing through the pipeline / equipment.
Check and certify the isolation valve

 The isolation valve to be installed on the hot tap flange should be

hydro-tested in the shop prior to installation to ensure seat sealing.
The gland packing should be changed prior to test to make sure that
there are no leaks during the pressure test and subsequent hot
tapping operations.
Test of hot tap drilling machine

 Check the drilling machine maintenance records / date.

 Check the hydrotest certification of all pressure parts of the drilling
machine.
 Check the hydraulic hoses used in the drilling machine visually and
ensure that they have been pressure tested.
 The pressure gages installed on the drilling machine must be
calibrated and certificate should be valid.
 The packing used in the drilling machine should be new and
compatible to the operating fluid at the operating temperature of the
fluid.
Check and certify the gasket joints in the hot tap connection

 Do a pneumatic leak test and make sure that gasket joints are not
leaking / passing. Both the gaskets between valve and nozzle and the
gasket between valve and the drill machine should be tested.
 Check for gland leaks during the leak test.
Make sure that the drilling cavity is functional

 When the pilot drilling is done, the hot tap nozzle and the valve above
will become pressurized. The vent valve should be in operation to
safely vent at various stage of drilling operation.
The Hot Tapping Procedure

The hot tapping procedure consists of several crucial steps that allow the creation of
a branch connection without interrupting the flow of the pipeline. Let’s dive into each
step (method and steps can be differ as per work requirements):

1. Welding the Split Tee Fitting: A split tee fitting is meticulously welded onto the pipeline
at the desired location of the new branch connection. This fitting acts as a
penetration point, enabling the subsequent steps to be carried out without any
disruption to the pipeline’s operation.
2. Installing the Valve: Following the welding process, a specially designed valve is
installed onto the split tee fitting. This valve plays a pivotal role in controlling the flow
within the pipeline and ensuring leak-proof operations. It is imperative to select a
valve that is compatible with the pipeline material, pressure, and temperature
conditions.
3. Drilling the Hole: Once the valve is securely in place, the drilling process
commences. A specialized drill, typically operated remotely from a control panel
located outside the pipeline, is employed to create a precise hole through the valve
and the pipeline.
4. Closing the Valve: After the hole has been drilled, the drill is removed, and the valve
is closed. This step is crucial as it allows the branch connection to be made while
maintaining the flow of the pipeline. The closed valve prevents any leaks or spills
during the subsequent connection process.
5. Connecting the New Pipeline Section: With the valve securely closed, a new pipeline
section is attached to the valve, completing the branch connection. This seamless
process ensures the continuity of the pipeline’s operation without causing any
downtime or disruptions.
Hazards of Hot Tapping

Hot Tapping poses certain hazards that need to be addressed for a safe operation.
Some of the major potential hazards include:

1. Risk of fire or explosion due to the presence of flammable substances in the pipeline.
2. Exposure to hazardous chemicals, gases, or vapors during the hot tapping process.
 3. High-pressure releases that can cause injury or equipment damage.
4. Heat-related hazards, such as burns or heat stress, during welding or cutting
activities.
5. Potential damage to the existing pipeline or equipment if the hot tapping process is
not executed correctly.
Hot Tapping Safety Requirements

Ensuring the safety of personnel and maintaining the integrity of the system is of
utmost importance during hot tapping operations. The process consists of two
phases: welding the nozzle onto the line and mechanically cutting a hole in the pipe
or equipment. Here are the essential safety considerations to follow during a hot
tapping operation:

1. Specialized Contractor: Hot tapping work should always be carried out by a

specialized contractor with expertise in this field. Their experience and knowledge
are crucial in executing the task safely and efficiently.
2. Risk Assessment: A thorough risk assessment must be conducted by specialized
consultants who possess the required expertise and knowledge. This assessment
will identify potential hazards and provide necessary precautions to mitigate risks.
3. Obtain Approval: The contractor must obtain approval from the company for the
specialized contractor or consultant involved in the hot tapping operation. This
ensures that all parties are aware of the project and its associated safety measures.
4. Uninterrupted Work: Once the hot tapping process has commenced, it is crucial to
proceed without interruption until the hot tap has been completed and the valve
closed. Any interruption during the process can compromise the integrity of the
system.
5. Metal Thickness Determination: The area to be hot tapped should be visually and
physically identified. Within 48 hours prior to the work, an ultrasonic thickness test
measurement of the metal must be made at the exact location of the proposed hot
tap. This helps ensure that the metal is suitable for the hot tapping process.
6. Material Preparation: All materials used for the hot tapping, such as the nozzle and
valve, should comply with the approved specifications for the tie-in. Proper
preparation and adherence to specifications are crucial for a successful operation.
7. Valve Bench Test: Prior to installation, a bench test should be performed on all
valves. This hydro test involves subjecting the valve body to steam in the presence of
a pressure differential. This test ensures the valve’s integrity and functionality.
8. QC Approval: Approval from the Quality Control (QC) department should be
obtained before fitting the materials. This ensures that all components meet the
necessary quality standards.
9. Stress-Relieved Pipelines: Hot tapping is not applicable for stress-relieved
pipelines. Special consideration should be given to pipelines that have undergone
stress relief procedures, as they may have altered mechanical properties that can
affect the hot tapping process.
10. Flow in Lines: In cases where the line contains flammable or hazardous materials,
such as a flare line, it is essential to continuously purge or flood the line with steam,
inert gas, or hydrocarbon gas during the welding process. This prevents the
 formation of gas pockets or flammable mixtures. The suggested product velocities
during welding are:
o Liquid: 0.4 m/s (minimum), 1.75 m/s (maximum)
o Gas: 0.4 m/s (minimum), no maximum limit
o Product temperature during welding: Maximum 370°C, minimum 7°C
11. Pressure Limitations: The pressure of the fluid inside the pipe should never exceed
7000 kPa during the hot tapping operation. Additionally, hot tapping should not be
carried out on sub-atmospheric pressure.
12. Avoid Hot Tapping on Specific Pipes: Hot tapping should not be performed on
pipes that contain hydrogen, vapor/air or oxygen/vapor mixtures, acids and chlorides,
caustic and amines, unsaturated hydrocarbons such as ethylene, oxygen-enriched
atmospheres, chlorine, compressed air, equipment and piping under vacuum,
sulphuric acid, or pipes with hydrogen sulfide (H2S) levels above the toxic threshold.
13. Qualified Welders: Welders involved in the hot tapping process should be qualified
and possess expertise in butt welding joints. They should also pass a mock-up test to
ensure their competency.
14. Safe Scaffolding Platform: A working scaffolding platform should be erected by
qualified scaffolders and inspected by a approved scaffolding inspector. This ensures
a safe working environment for personnel involved in the hot tapping process.
15. Procedure Adherence: It is vital to adhere to the detailed procedure that outlines the
parameters, operating techniques, and electrode specifications for the hot tapping
process. Following the procedure precisely helps maintain safety and achieve
successful results.
Additional Safety Precautions
In addition to the previously mentioned safety precautions, the following measures
should also be taken into consideration during hot tapping operations:
1. HSE Training: All manpower involved in the work should have undergone Health,
Safety, and Environment (HSE) training to ensure they are aware of the necessary
safety protocols and procedures.
2. Valid Third Party Inspection Reports: All equipment and instruments used in the
hot tapping process should have valid third-party inspection reports, ensuring their
proper functionality and compliance with safety standards.
3. Approved PPE and Gas Monitors: All personnel should be equipped with approved
Personal Protective Equipment (PPE), including personal gas monitors. These
measures help protect individuals from potential hazards and enable early detection
of gas leaks.
4. Emergency Response Procedure: All personnel should be made aware of the
emergency response procedure specific to the hot tapping operation. This includes
knowing the nearest muster point and understanding the necessary actions to take in
case of an emergency.
5. Immediate Evacuation for Gas Leak: In the event of a gas leak, it is crucial to
prioritize the safety of all manpower. Immediate evacuation to the nearest muster
point should be carried out to ensure their well-being.
6. Emergency Standby Equipment: An emergency standby vehicle, water tanker, an
appropriate number of fire extinguishers, fire watchers, and Self-Contained Breathing
 Apparatus (SCBA) should be readily available on-site throughout the entire duration
of the hot tapping work.
7. Provision of Ambulance: An ambulance should be provided on-site to cater to any
medical emergencies that may arise during the hot tapping operation.
8. Valid Permit: Work should commence only after obtaining a valid permit from the
custodian or relevant authority. This ensures that all necessary safety measures have
been taken into account and approved.
9. Toolbox Talk Meetings: All crew members should actively participate in Toolbox Talk
meetings, where safety-related information, hazards, and precautions specific to the
hot tapping operation are discussed.
10. Competent Persons and Continuous HSE Coverage: Competent individuals with
expertise in HSE should be present throughout the hot tapping operation to provide
continuous coverage and ensure that safety protocols are followed at all times.
11. Shift Handover Procedures: Proper handover procedures should be established for
day and night shift works to ensure that incoming personnel are fully aware of the
ongoing tasks, safety considerations, and any specific instructions.
12. Approved Authorized Gas Tester (AGT): An approved authorized gas tester
equipped with a valid Multi Gas monitor should be available throughout the execution
of the hot tapping work. This ensures continuous monitoring of gas levels and
immediate detection of any potential hazards.
13. Approved Lifting Plan: An approved lifting plan should be prepared and made
available along with the permit. This ensures safe and controlled lifting operations
during the hot tapping process.
14. Barricading and Signages: The entire working area should be properly barricaded
to prevent unauthorized access. Additionally, awareness signages should be
provided to inform personnel and visitors about the ongoing work and associated
hazards.
15. Weather Monitoring: Weather conditions should be continuously monitored during
the hot tapping operation. Windsocks should be placed in the near vicinity to provide
visual indications of wind direction and strength, helping assess any potential impact
on the operation’s safety.
By incorporating these additional safety precautions, the hot tapping operation can
be conducted with enhanced safety measures, reducing the risks associated with the
process and ensuring the well-being
FAQs (Frequently Asked Questions)

Q1: Is hot tapping applicable to all types of pipelines?

Hot tapping can be applied to various types of pipelines, including those carrying oil,
gas, water, and chemicals. However, specific factors such as material, diameter, and
operating conditions should be considered during the planning phase.

Q2: Are there any size limitations for hot tapping?

While hot tapping can be performed on pipelines of various sizes, there may be
practical limitations depending on the equipment and available space for installation.
Consulting with experienced professionals can help determine the feasibility of hot
tapping for specific pipeline sizes.

Q3: Can hot tapping be performed on pressurized pipelines?

Yes, hot tapping can be performed on pressurized pipelines. The procedure includes
implementing pressure control measures and ensuring the integrity of the
connections during the tapping process.

Q4: How long does a hot tapping operation typically take?

The duration of a hot tapping operation depends on several factors, such as the size
of the cut, the complexity of the pipeline, and the specific requirements of the project.
It can range from a few hours to several days.

Q5. What is the purpose of a risk assessment in hot tapping?

A risk assessment is conducted to identify potential hazards associated with the hot
tapping operation and to determine the necessary precautions to mitigate those
risks. It helps ensure the safety of personnel and the integrity of the system.

Q6. Why is it important to have a qualified welder?

A qualified welder with expertise in welding joints is crucial for the hot tapping
process. They possess the necessary skills to perform welding tasks safely and
effectively, ensuring the integrity of the newly added connection.

Types of Hot Tapping Fittings

Cold Cutting: Understanding the Pro...

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Cold Cutting: Understanding the Process, Benefits, and Applications

There are various types of hot tapping fittings that can be used to create a
new connection in an existing pipeline. Some of the most common types of
hot tapping fittings include:

1. Split Tee
2. Flangeless fitting for welding valve
3. Split lateral Tee
4. Mechanical Tee for avoiding weld
5. Saddle with reinforced pad for low pressure
6. Threaded Olet for venting

Hot Tapping Procedure

The first step in the hot tapping process is to identify the location on the
existing pipeline where the new connection is needed. The hot tapping
equipment is then set up and the drilling machine is positioned on the
pipeline at the chosen location. The drilling machine is equipped with a
cutter that is designed to penetrate the pipe while it is still under pressure.
Once the cutter has penetrated the pipe, a pilot drill is used to create a hole
in the pipe. The pilot drill is followed by a larger cutter that is used to cut out
a section of the pipe. The removed section is then captured and removed
from the pipe.

With the section of pipe removed, a valve or other fitting is installed to

create the new connection. The valve or fitting is designed to be able to
withstand the pressure and temperature of the system.

After the valve or fitting is installed, it is tested to ensure that it is properly

sealed and capable of withstanding the pressure of the system. Once the
new connection has been tested and verified, the hot tapping equipment is
removed and the system can continue to operate as normal with the new
connection in place.
Hot tapping is a common method used in the oil and gas industry and other
industries where pipeline systems are used. It is a cost-effective and
efficient way to create new connections without the need for system
shutdowns or depressurization.

how a Hot Tap works?

The hot tapping process involves several steps:

1. Preparation: The first step is to prepare for the hot tap. This
includes selecting the location for the tap, preparing the hot
tapping equipment, and ensuring that all safety precautions are
in place.
2. Drilling: The next step is to drill a hole into the existing
pipeline. This is done while the pipeline is still in operation and
under pressure. The hot tapping equipment is used to drill the
hole, and a pilot drill is used to create a small hole in the
pipeline. The pilot drill is followed by a larger cutter that is used
to cut out a section of the pipe.
3. Removal: Once the section of pipe has been cut out, it is
removed from the pipeline. The removed section is captured
and removed from the pipe to prevent it from causing damage
or blockage further down the line.
4. Installation: With the section of pipe removed, a valve or other
fitting is installed to create the new connection. The valve or
fitting is designed to be able to withstand the pressure and
temperature of the system. Usually, new valve or fitting are
connected by welding application.
5. Testing: After the valve or fitting is installed, it is tested to
ensure that it is properly sealed and capable of withstanding
the pressure of the system. This involves pressure testing the
valve or fitting to ensure that it can handle the flow of fluid
through the new connection.
6. Completion: Once the new connection has been tested and
verified, the hot tapping equipment is removed and the system
can continue to operate as normal with the new connection in
place.
There are various types of hot tapping fittings that can be used to create a new connection in
an existing pipeline. Some of the most common types of hot tapping fittings include:

1. Split Tee
2. Flangeless fitting for welding valve
Split lateral Tee