International Pipeline Conference — Volum e II

ASME 1998

IPC1998-2095

Full Flow High Pressure Hot Taps:

The New Technology and Why It's Indispensable to Industry
ASME International Pipeline Conference
Design and Construction Category

John A. McElligott, TransCanada PipeLines Services Ltd.

Joe Delanty, TransCanada PipeLines Services Ltd.
Burke Delanty, TransCanada PipeLines Limited

ABSTRACT result in voluntary compliance objectives, incentive

The connection of a new pipeline lateral or loop to
an existing high pressure pipeline system has always
been fraught with high costs and the potential for major
system impacts. Pipeline owners and operators have
historically had to choose between a traditional cold
connection with its high associated costs and a less
expensive but more mysterious hot tap.
Although the cost savings of a hot tap have always
been considerable, they were not always sufficient to
justify the risk of complications during the branch weld
or hot tap or during the subsequent operation of the
system. Despite their extraordinary costs and
throughput impacts, the perceived certainties of cold
connections were often sufficient to justify their regular
use.
The recent Kyoto Protocol on Climate Change has
resulted in new commitments by the world's
governments to reduce greenhouse gas emissions. For
the North American gas industry, these initiatives could
based programs or legislated reforms - any of which
will have significant impacts on current practices.
TransCanada PipeLines Limited (TransCanada) has
successfully managed the risk/reward conundrum and
completed more than 700 large diameter (NPS 12 to
NPS 30) horizontal high pressure hot taps without
incident since 1960. TCPL's research and development
work has enabled it to refine its procedures to the point
where it can now complete branch welding and hot
tapping work with minimal effects on throughput,
negligible emissions and no system integrity impacts.
For TransCanada, the direct advantages of a hot tap
over a cold connection have resulted in the avoidance of
gross revenue losses of $ 1 million or more per hot tap,
no environmental emissions, seamless service and no
impacts whatsoever to shippers. TransCanada
PipeLines Services Ltd. (TPSL) has further streamlined
the supporting field procedures and now provides a
complete turn key service to industry.

WHAT IS A HOT TAP? necessary to prepare for and complete the

A hot tap is a method of joining a new tie-over pipe
to an existing and loaded facility such as a pipeline or
tank. The objective of the procedure is to cut an
interconnection hole in the facility through a valved hot
tapping assembly without the need to evacuate the
contents. A successful hot tap will minimize operations
impacts and not result in spills or emissions.
For purposes of this paper, the generic term "hot
tap" will include all of the technical operations
interconnection of a new pipeline with an operating
pipeline. The actual cutting of a hole in the pipeline
will be referred to herein simply as "tapping" or
"boring."
The design, installation and quality control
operations of a hot tap are described in more detail in
the T e ch n ical O verview ' section.

Copyright © 1998 by ASME

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 INTRODUCTION
This paper will discuss the economic and
environmental reasons for TransCanada's almost
exclusive use o f hot taps for all o f its system expansion
interconnections. It will discuss the evolution o f TPSL's
hot tapping procedures and the implications for the
system integrity o f oil or gas pipeline transmission
companies. It will also describe the critical technical
and specialty operations that are necessary for a
successful hot tap and how TransCanada has addressed
them.
The discussion will also include a general review o f
TransCanada's hot tapping practices and their
application on large diameter (NPS 12 and larger)
horizontal installations on natural gas transmission
pipelines. The principles will be similar or even simpler
for most other on-shore applications as well as for
vertical or smaller installations on oil or gas systems.
There has alw ays been a variety of options for
interconnecting new pipeline facilities with an operating
system. However, if a pre-built interconnect point such
as a plug and flange assembly or manifold does not
exist, the operator o f a high pressure pipeline can
usually only resort to either a hot tap or a cold tee.
Although each has its individual advantages,
TransCanada has concluded that the technological
evolution of hot tapping now makes it a superior choice
in almost all interconnect scenarios.
A completed hot tap is like any other component on
a high pressure pipeline system. Conclusive proof o f its
integrity can only be had when the assembly is retired
from service. Therefore, the decision to employ a hot
tap or a cold tee must be based upon an analytical
comparison o f the risks and benefits. The risk
assessment must address the potential for installation
difficulties and long term operating problems while the
benefits must consider all environmental, economic and
operating impacts.
Hot tapping a high pressure gas transmission
pipeline is widely perceived to be an inherently risky
operation. Pipeline operators have often eschewed the
obvious benefits o f hot taps in favour o f cold
connections for a variety o f risk-based reasons. A bad
hot tap experience, a comprehensive operational
analysis or the simple level o f comfort provided by the
familiarity of "cold '1 construction practices could each
rule out the choice o f a hot tap. TransCanada believes
that it has developed its practices to the point where the
risks o f a hot tap are mitigable and the benefits are
clearly superior to any alternatives.
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THE NEED FOR HOT TAPS
TransCanada's primary need for hot taps arises
during pipeline expansions, although smaller hot taps
will also be frequently required for the installation of
new laterals, ultrasonic meters or sales taps.
TransCanada's 1998 system expansion will require
approximately 26 x NPS 30 hot taps and 1 1 x NPS 24
hot taps to tie-in new parallel loops. TransCanada's
rationale for using hot taps instead o f cold connections
is based upon detailed comparative analyses of the
benefits and disadvantages of each operation with
respect to risks, direct and indirect costs, shipper and
operations impacts and environmental impacts.
Risk and Risk Mitigation
Ultimately, the true risk inherent in any individual
hot tap will depend upon the quality o f effort invested
in design, preparation and installation. The risk
management objective is to install an assembly that has
short and long term integrity characteristics that are
equal to or better than an industry standard cold tee
installation.
When discussing risk, it is important to consider
that proof of an assembly's integrity isn't conclusive
until it's final removal from service. Although
successful removal o f the carrier pipe coupon after a hot
tap effectively puts the assembly into service and is
certainly indicative o f good design and workmanship, it
is from that point forward that the integrity o f the
assembly will truly be tested.
The "hot" and otherwise specialized nature o f a hot
tap has justifiably earned it a reputation as an operation
with a "higher than average” degree o f risk. However,
when comparing the risks o f cold tees and hot taps on
gas pipelines, it is important to remember that the hot
cuts around gas/air mixtures that arise during a cold tee
installation come with a unique set of safety and
installation problems. In fact, TransCanada believes
that the safety risks during installation o f a hot tap are
better than those o f a cold tee.
TransCanada has been able to successfully manage
hot connection risks by continual research and
development and good quality control practices. As
systematic problems have been identified, they have
been eliminated wherever possible or otherwise
minimized to an acceptable level. TransCanada, is now
very confident in the technology and relies on it as a
fundamental operations tool. For industry, the efforts
have resulted in a significant difference between the
perceived risks and the actual risks o f accomplishing a
hot tap.

Direct and Indirect Costs
Overall, TransCanada estimates that the total cost
of a hot tap is approximately 60% to 80% less than the
total cost of a cold tee. The actual variance will depend
upon the variety of circumstances that will be unique to
each location or system. The cost advantages of a hot
tap occur in the three basic categories set out below.
D ire ct Cost Savings
The direct costs of a hot tap are usually
significantly less than those of a cold tee. Although the
material costs, welding requirements and quality control
expenses would be similar, a hot tap will not incur any
expenses for evacuation (blow-down) of the pipeline or
for the purging and loading process that is necessary
once a cold connection is completed.
The on-site heavy equipment and general labour
requirements would also normally be reduced for a hot
tap. This is in part because a manager has more
effective control over the schedule of work events.
During a cold tee, the requirement to minimize system
downtime usually entails a "huny-up” schedule that
results in several different trades on stand-by (and
charging) on-site for the time when they will be needed.
The scheduling flexibility inherent in a hot tap obtains
much better on-site production efficiencies.
In emergency type situations, it can often be easier
to mobilize a hot tapping crew on short notice because
of the reduced equipment requirements.
Indirect Costs - M aintenance o f Transportation
Revenues
Implicit in the reasons underlying any system
expansion is the fact that the existing plant is probably
operating at capacity. Any service reductions or
stoppages will automatically have negative effects on
revenues.
In a natural gas transmission business, interruptible
or other discretionary types of transportation are
currently the most valuable classes of service and will
also be the first ones to be affected during a system
shut-down. Therefore, any system interruption will also
have a disproportionate effect on revenues. With larger
interruptions, revenues can be further affected even
when the line is back in service since the previously
discretionary capacity may be required to re-build firm
service obligations.
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In direct Costs - Commodity Saved
In order to make a cold connection on a gas
pipeline, the operating pressure is typically reduced to
somewhere between 2,750 kPa (400 psi) and 1,700 kPa
(250 psi) before the gas is vented. For a typical 25 km
(15.5 mile) section of 1,219 mm O.D. (NPS 48) pipe,
the volume of gas at 1,700 kPa represents about 500 M
m^ (18 MM ft^) of line pack which is owned by the
operator. At $ 1.63 (Cdn) per gigaJoule, this represents
over $30,000 Cdn without including transportation
costs.
Shipper and Operations Impacts
A hot tap will usually allow an operator to avoid, or
at least reduce the service impacts of an interconnect.
When welding on new pipe, there should be no service
impacts to a shipper and on older pipe, the interruption
could be either a restricted flow or a full shut-in to
manage cooling rates. In either case, the interruption
should be limited to 5 hours or less. Depending on
operating pressures and which equipment is employed,
the tapping work should not require any flow or
pressure restrictions.
In a multiple loop system, a 5 hour shut-in should
normally be transparent to shippers. In a single line
system, a small interruption can be scheduled to
minimize or completely avoid any shipping impacts.
Alternately, a cold tee will require 3 or 4 days or more
of system shut-down that will often entail considerable
negotiations with shippers.
A system interruption for an expansion
interconnection could justifiably be perceived by a
current shipper as an unacceptable imposition on its
business for the sake of future shippers. The impacts
may not qualify as "force majeure" interruptions and
could be contrary to shipping contract provisions. The
consequential impacts of a 4 day shut-down for a cold
connection on shipping contracts and shippers'
downstream obligations could also seriously undermine
an operator's customer relations. The expense of
preparing customers for a shut-down by rearranging
contracts and subsidizing or otherwise mitigating
shippers consequential impacts could also be
extraordinary.
In most cases where pipelines less than 15 years old
are being hot tapped, system impacts are invisible to an
operator. This is especially valuable to any system that
runs at or near the 9th decile of throughput capacity
since large downtime requirements can affect several
different stake holders and demand a lot of time
consuming and potentially disruptive transportation
system planning and revision work. When a system
 restriction is required at a hot tap site for pipe chemistry
reasons (i.e., the worst case scenario), it would typically
create less than 5% o f the outage impact o f a cold tee.
Finally, the flexibility inherent in a hot tapping
operation enables an operator to adapt its schedule
quickly for variables such as weather or operating
system changes.
When compared with the costs of achieving
emissions reductions through other technological
developments such as dry low NOx controls for
compressor units, a hot tap can be a very economical
method for a gas transmission company to achieve
voluntary and potentially mandatory GHG emissions
targets.

In liquids pipelines, GHG emissions are not a

Environmental Impacts concern. However, a hot tap has the ability to isolate
The environmental advantages of a hot tap have and otherwise minimize the potential sources o f spills in
made the technology indispensable to a federally addition to all of the other downtime avoidance
regulated gas transmission company like TransCanada. advantages it offers.
Commitments made by both the American and
Canadian governments at the recent Kyoto Protocol on
Climate Change ("Kyoto") to reduce greenhouse gas TECHNICAL OVERVIEW OF HOT TAPPING
(GHG) emissions are expected to result in a variety of
incentives and penalties related to GHG emissions for Facility Design
all industries in North America. On a dollar per ton of On a mainline looping project, TransCanada
carbon equivalents investment basis, a hot tap promises typically attempts to install a new block valve parallel to
to be one of the most cost effective investments that a and adjacent with the existing block valves (see Figure
natural gas transmission company can make with 1). The new pipeline is connected to the existing
respect to emissions reductions. system with tie-overs that are upstream and downstream
o f the block valves.
Although natural gas is known as a clean burning
fuel, the American Environmental Protection Agency FIGURE 1.
reports that methane (CH 4 ) has a capacity for trapping
heat in the atmosphere that is 21 times more effective
than that o f CO 2 . In the example cited earlier herein,
the methane contained in a 25 km section o f 1219 mm
O.D. (NPS 48) pipeline at 1,700 kPa (250 psi)
represents the carbon equivalent o f approximately 8.0
kilotonnes o f CO 2 .

Based upon the foregoing, an owner/operator has

2 very important reasons for not releasing methane to
atmosphere during an interconnect. First, a significant
commodity loss is avoided and the gas remains
available for conversion to CO 2 , (i.e., CH 4 + 2 0 2 =
2 H 2 O + CO 2 ). Secondly, responsibility for the
methane or carbon dioxide GHG emissions remains
with the shipper or end consumer.

A hot tap clearly allows a gas transmission

pipeline operator to avoid the liability of a significant
GHG release. Furthermore, as Kyoto commitments are
enacted in legislation and social or industrial incentives,
an owner/operator should be able to obtain satisfaction
(at the very least) or even some form of econom ic credit
for a pro active and measurable effort in controlling
emissions. It is significant to note that emissions credits
are now a genuine commodity and major industries in
North America are already voluntarily engaged in their
purchase and sale.
For a typical NPS 16 or larger hot tap, a vertical hot
tapping alignment is usually not feasible on account of
insufficient ground cover. In addition, TransCanada has
always attempted to keep as much o f its facilities from
view as possible for security purposes. Another
advantage of a horizontal alignment is that the weight
load that would be introduced to the carrier pipe would

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 require significantly more design and installation work
to create the necessary mechanical support. Figure 2
shows TransCanada's standard horizontal hot tapping
assembly.
FIGURE 2.
TYPICAL HOT TAPPING ASSEMBLY
(EXPANDED VIEW)
© © @ ® © The circular site for the branch weld must also be
Carrier pipe
(2) Branch
(3) Vertical split reinforcing tee
3a) Split tee joining bar
Round Body Gate Valve
The main disadvantage o f a horizontal hot tapping
assembly is that it requires significant refinements to the
design and installation procedures to systematically
nullify the gravity induced complications that would not
affect a vertical hot tap.
1. - C a r r i e r P i p e
This is the one component in the assembly that
cannot be designed for and therefore, the assembly
design must be adapted to it. Consequently, the
reconnaissance exercise is an essential part o f the design
and quality control process.
Although a designer can pre-select the exact
location for a hot tap, field reconnaissance will usually
result in considerable savings to the owner/operator. A
5 metre movement o f a branch site to the adjacent pipe
joint can result in completely different flow and design
parameters for the hot weld.
The person who will supervise the investigation
must be familiar with all available as-built data for the
site as well as all of the geometric and metallurgical
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design requirements o f a hot lap. This will enable
selection o f the optimum site and minimize costs and
field work.
The branch should be located so that the end o f the
vertical split tee will be well clear of the nearest girth
weld. W herever possible, it should also avoid crossing
the longitudinal or spiral factory seam weld. However,
if there are no alternatives, then the area intersected by
the branch and factory weld should be carefully
examined for the presence o f general corrosion and
stress corrosion cracking ("SCC").
examined and be free o f general corrosion, SCC and
laminations. The portion o f the factory long seam or
spiral weld that will lie under the split tee must also be
examined and determined to be free of irreparable weld
flaws since it will be ground flush prior to fitting the
split tee.
Once the site investigator has found a preferred
branch location that is free o f flaws, he or she must
determine the pipe temperature, cooling rate and pipe
chemistry. It will also be important to note the
contemporary operating conditions o f the system to
ensure that they are similar when the branch is
eventually welded. The unanticipated start-up o f a
nearby compressor unit or cooling unit during a hot
weld could materially impair the weld quality.
A prudent weld design must be based upon the best
available information. However, unlike joining new
pipe, a branch weld is often performed on pipe o f
uncertain heritage. Therefore, as-built pipe data that
may be deficient or may not reliably or accurately
indicate a pipe's chemical composition must be rejected
and replaced with reliable information.
TransCanada has used laboratory methods to
analyze carrier pipe chemistry. This method requires
coating and pipe mill scale to be removed from a small
area inside the location o f the future branch and the use
o f an industrial burr type grinder to remove steel
particles from the pipe. A simple paper cone and
magnet system are then used to fill a 35 mm film
container approximately half full o f steel filings.
Although the field sample collection method now
produces good data, TransCanada had to spend
considerable time and effort to develop a system that
produced consistently reliable data. Occasionally, the
thin skin o f high carbon mill scale that is present on the
outside surface o f a pipe was mixing enough with
samples to skew the analysis. The errors would result in
specifications for restricted flow conditions during hot
 welding that were later proven to be unnecessary. be short enough to minimize the overall travel distance
of the hot tap cutter and long enough to enable accurate
A major disadvantage of the laboratory analysis fitting and welding.
system is the time delay between collection of the
samples and supply of results. In order to avoid the FIGURE 3.
high costs of returning to a site to examine alternate
locations, it is often prudent to collect samples from all HORIZONTAL BRANCH
possible sites in case the preferred location is
unsuitable. The additional field work and lab analyses 12 O 'clock
can increase costs considerably by reducing crew 30°
efficiencies and introducing nuisance problems while
the excavation is open. A spectrometer can eliminate
these delays and even with newer pipe and good as-built 450 [ orancn
data, it is an excellent tool for verifying metallurgical
data.

TransCanada now prefers 'real time' spectroscopic 30°

techniques to confirm local metallurgy. The technology C arrier Pipe 300 mm (Elevation)
has now advanced to the point where accurate pipe Branch
chemistry analysis can be achieved in real time. (Profile)
Although the equipment is still somewhat bulky, it has
the accuracy to make significant reductions in Held
costs and turnaround times for the operator. Redundant
investigations can be eliminated and the time delay
3. - Vertical Split Reinforcing Tee
between investigation and installation can be reduced to
The reinforcing tee is designed with a vertical split
zero in some cases.
and is welded (rather than bolted) together with a
lapping steel bar on top and bottom. Although the split
tee is also connected to the branch with a fillet weld, it
2. - Branch
is significant to note that there are no encirclement
The branch (a.k.a. stub, nipple or nozzle) is a
welds to the carrier pipe. Since a vertical split tee
component that could be easily and wrongly dismissed
cannot be pretested, it does not qualify as a pressure
as "just another piece of pipe." Although the parent
retaining device.
pipe for the branch must be compatible with the design
of the system it will connect with in terms of maximum
TransCanada also employs a supplementary
allowable operating pressure (MAOP), temperature
reinforcement system on the hot tap assembly that
rating and basic metallurgy, a few other issues must be
prevents yielding of the pipe into the annulus area
adressed to create an acceptable component
between the carrier pipe and the tee once the coupon has
been removed. This practice has significantly enhanced
A branch must be systematically fabricated in order
long term integrity by reducing the internal stresses on
to ensure its enduring integrity. The factory weld cap
the assembly. TransCanada now employs these
must eventually be removed so that the outlet half of the
assemblies as long term permanent fittings.
split tee can be fitted over it. Therefore, the weld cap
must also be removed in advance of the hydrostatic test
of the parent pipe so that the test results remain valid.
4. - Gate Valve
TransCanada's standard tie-over design uses full-
A branch welding specification must address the
bore ball valves for mainline block valves and gate
weld bevels at the valve and carrier pipe ends of the
valves in the tie-overs. A 'round body' design is used
branch (See Figure 1 .). The valve side of the branch
for the gate valve to enhance its sturdiness.
will normally be beveled for a standard field butt weld.
The weld bevel at the carrier pipe end of the branch is a
In general, a pretested weld by flange gate valve is
little more complicated on account of the scarfed edge
preferred for tapping because the cavity on the flange
of the branch. The bevel angle will vary as it follows
side will comfortably accommodate most big tapping
the scarf from 30° at the 6 and 12 O'clock positions to
cutters when the gate is closed. Gate valves have an
45° at the 3 and 9 O'clock positions. The angles will
additional advantage over ball valves because a gate
also vary with the relative difference in diameters of the
will be a little further than a ball from the pipe wall
carrier pipe and branch. The length of the branch must

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 during a tap and the gate chamber tends to catch errant
shavings. The end result is that gate valves are not as
susceptible as ball valves to seal damage from migrating
tapping cuttings. Nonetheless, ball valves are usually
adequate for vertical applications.
Hot Weld and Flow Design
The ideal hot weld for an operator is one that does
not require system flow restrictions. However,
notwithstanding the operator's needs, the primary
objective of a welding design engineer is to produce a
specification that will result in an acceptable quality
weld. The engineer's secondary objective is to
accommodate the operator by minimizing any impacts
on flow rates to the extent possible without impairing
weld quality.
As discussed earlier, knowledge of the chemistry
and the cooling rate of the earner pipe are the two
critical factors for development of a valid specification.
High cooling rates, in combination with poor quality
controls, can lead to hydrogen cracking in the weld and
the subsequent potential for its in-service failure.
Modern pipeline steels typically have a carbon
equivalence ("C.E.") below 0.38 and should be
compatible with parameter requirements for welding
under many standard operating conditions. Pre-1960
pipelines usually have high C.E.'s and require shut-in or
restricted flow conditions for welding. Regardless of
the vintage, it is always prudent to verify the C.E. of
every operating pipeline prior to a hot weld.
and quality control objectives.
Welding Quality Control
None of the 7 hot tap welds in the assembly are
normally proven by hydrostatic test. Furthermore, 6 of
the 7 are fillet welds that are very difficult to reliably
examine by X-ray or ultra sonic methods. Therefore,
rigid adherence to welding specifications is essential.
Welders with higher than average skill levels are also
preferred, especially for work on thin walled carrier
pipes.
The critical nature of the branch weld requires its
examination by magnetic particle inspection ("MPI")
methods after each weld pass. The 5 other fillet welds
are only examined by MPI when they are complete.
The branch to valve weld is the only one suitable for
examination by X-ray or ultrasonic techniques. Figure
4 shows the location of all 7 welds and their inspection
methods.
F IG U R E 4.
TYPICAL HOT TAPPING ASSEMBLY

The second critical factor for an acceptable weld is

the cooling rate at the weld location. If a 50mm (2")
diameter circle on a pipeline with a C.E. of 0.38 or
greater, cools to 100°C from a preheated level of 250°C
in less than 26 seconds, flow restrictions will almost
certainly be required during the branch weld.
For every hot tap, a qualified engineer must address
the carrier pipe's C.E. and cooling rate in development
of the weld specification. Additionally, the operator
must maintain system operating conditions that are
compatible with design assumptions during the weld.
QUALITY CONTROL ("QC") PROCEDURES
A good QC program for materials and procedures
is vital to ensuring that all components meet
specifications and integrity objectives. Welders must be
pre-qualified and technicians must be trained and
skilled in equipment maintenance, repair, set-up and
operation. All field staff must be fully familiar with
documented procedures, fundamental safety practices
@ Magnetic particle (MPI) and visual inspection
0 Radiographic, MPI & visual inspection
Tapping Quality Control
With adequate preparatory work, the tapping
operation can be one of the simplest parts of the hot
tapping process. A successful tap presumes that
equipment is in good repair and precisely adjusted, all
welds meet specifications and that the assembly is
horizontal and square to the carrier pipe.
On site, TransCanada employs a variety of
procedures to ensure a successful tap. Stiffeners arc
used to prevent the pipe coupon from springing flat
during the tap and potentially causing the cutter to bind

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 in the hole. Additionally, alignment devices are used to
bring the heavy cutter and pilot bit back onto the
horizontal dead centre of the carrier pipe. Failure to
compensate for the gravity induced deflection of the
cutter could result in breaking of cutter teeth or cutter
binding and eventual failure of the tap.
TransCanada takes particular care to maintain its
tapping equipment in peak condition. Cutters and pilot
bits are used only once before they are re-sharpened and
refurbished to very exacting standards. Seals are
replaced regularly and the machines are torn down for
full examination on a regular basis.
For large diam eter taps, TPSL owns a fleet of hot
tapping machines, including 2 TD Williamson ("TDW")
model 936 machines that are capable o f completing
large diameter taps at pressures up to 15,000 kPa (2,200
psi). TransCanada has worked on its own and with
TDW o f Tulsa, Oklahoma and Williamson Industries in
Canada to modify various equipment designs and
procedures. The effort has improved equipment and
methods and thereby reduced error sources in an
operation that can be very hard mechanically on
equipment.
FUTURE HOT TAPPING REFINEMENTS
The North American high pressure transmission
pipeline industry has not universally adopted hot
tapping technology for a variety of reasons. Primarily,
a limited, but noteworthy, number o f failure incidents
has resulted in a legitimate mistrust o f their long term
integrity. Secondarily, hot taps do not technically
comply with code requirements in Class 1 locations and
thirdly, a large diameter hot tap can create a pigging
trap and cause considerable damage to electronic
pigging equipment.
objectives o f national design codes in terms of
resistance to fracture propagation, no increase in
societal risk and maintenance of system integrity, it
cannot meet the strict requirements of the codes in Class
1 pipe locations. However, the procedure's compelling
technical, environmental and economic advantages can
be enough to receive a regulator's endorsement of the
procedure if required.
Finally, hot tapped branches can be impediments to
certain types of pigs when the 'branch to carrier pipe
diameter' ratio is large. TPSL is currently looking at
technology to install pigging bars at hot tapped
branches.
CONCLUSION
TransCanada has successfully completed over 700
hot taps on its system since 1960 without incident.
Practices have evolved to enable further downtime
reductions and enhancements to long term integrity.
TransCanada does not believe that the short or long
term operating integrity of a hot tapped tie-over are any
different than that o f a cold tee assembly.
In 1998 alone, the technology will enable
TransCanada to avoid approximately 500 kilotonnes of
CC>2 equivalent GHG emissions, the loss of
approximately $1 million worth of natural gas and the
loss o f $50 million worth of transportation service. At
the same time, TransCanada will be able to maintain
seamless service for its shipping customers.

In response to the integrity issue, hot taps simply

cannot provide an interconnection solution for all
scenarios. Nevertheless, older installations on
TransCanada's system have consistently proven the
integrity and value of the technology when constructed
appropriately and recent developments in
supplementary reinforcing technology have been proven
to further enhance the long term integrity of standard
assembly designs. In view of its incident-free record
with older designs, one should be able to conclude that
quality control and design are the critical factors in the
long term operating risk of TransCanada's hot tap
assemblies.

Currently, national design codes only permit the

completion of a hot tap in heavy wall pipe locations.
Even though the technology is compatible with the

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