Hot tapping: cost effective

pipeline modification
and repair
- without the need for shutdown

1 Furmanite Confidential - 1/9/04

 Hot tapping

What is hot tapping?

Hot tapping is a method of making a connection
Definition:
into an existing pipe or vessel which is still under
pressure or live

What is it Additional branches allowing supply to and from

other areas of plant etc
used for?
Entry points for isolation equipment line stops,
inflatable isolation equipment, etc
Monitoring points for temperature probes etc.

What are the Can be performed without the need to shut down
the plant. No need for loss of production or
advantages?
supply to other areas

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 Hot tapping

Where can hot tapping

be used?
Oil and gas setor
 Onshore, offshore and subsea
Petrochemical industry
 Hydrocarbons – crude & heavy oils
 Light oils, diesel, kerosene, petroleum,
motor oils
 Various chemicals
Power generating industry
 Steam and water
Pharmaceutical & food industry
 Compressed air
 Food products
Water industry
 Potable water and sewerage
24” hot tap machine in position

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 Hot tapping

Hot tapping: the Furmanite

IPSCO advantage
 Specialist engineering services provider
 Vast global experience in pipeline intervention
techniques
 Suitably qualified experienced personnel (SQEP)
 Extensive inventory and personnel enable multiple
hot tap projects to be undertaken simultaneously
 Large diameter capability
 Full range of fittings and equipment in stock
at all times

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 Hot tapping

Hot tapping: basic procedure

 The hot tapping machine consists of a telescopic
boring bar, mechanically driven, advancing a
cutting tool
 The full bore valve (acting as a control valve)
allows the drilling machine to be removed
 Connection to existing pipe is made through a
full encirclement split tee (welded or mechanical)
which contains system pressure and provides a
connector outlet
 Cutter and pilot with coupon are removed from
existing pipe. The coupon is retained by pilot
drill mechanism

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 Hot tapping

The Furmanite IPSCO

folding head system
The benefits
 Equipment is lighter and more
readily transported to site
 Reduced workspace required
around the pipe
 Sizes up to 72” (ND 1800 mm)
 Pressures up to 145psi (10 bar)

60” folding head

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 Hot tapping

The hot tapping procedure

Step 1:
The hot tapping
machine is mounted
on to the tapping valve

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 Hot tapping

The hot tapping procedure

Step 2:
The cutter/pilot assembly
is advanced until it
touches the parent pipe,
then the hot tap is
started

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

Step 3:
When the pilot breaks through
product fills the void. Air is
expelled through the tapping
machine purge valve, and valve
is then closed to retain the
pressure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

Step 4:
When pilot is completely
through stop rotation and
advance to allow u-wires
to drop

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

Step 5:
When cutter touches top
of pipe the machine is
restarted so that the cut can
be completed

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

Step 6:
When the cut is complete
the machine is stopped and
cutter advanced to confirm
that the tap is complete

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

Step 7:
Coupon and cutter
are withdrawn with
the coupon or cut out
retained by the u-wires

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

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 Hot tapping

The hot tapping procedure

Step 8:
The tapping valve is
then closed and the
machine can be
removed

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 Hot tapping

How is the coupon retained?

Standard option: U-wires
 Pilot drill has u-wires which prevent the coupon
from falling into the line
 This method is suitable for the vast majority of
hot taps
 The limitations are;
- Gas velocities up to 10 m/s (20 mph)
- Liquid velocities up to 5 m/s (10 mph)

53 Furmanite Confidential - 1/9/04

 Hot tapping

The coupon catcher process in

operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

in operation

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 Hot tapping

The coupon catcher process

Positive retention pilot drill

Cutting head and pilot drill

with coupon retained

Removal of
coupon on
36” hot tap

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 Hot tapping

Hot tapping: Preferred

angles of tap
Standard vertical tap - no unusual problems

Angled vertical tap - no problems for

angles less than 45 degrees

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 withdrawing
the cutter fully

The measuring rod will tend to fall out. It is

also considerably harder to install the
drilling machine into position

74 Furmanite Confidential - 1/9/04

 Hot tapping

Non-standard hot taps

Tank taps

TANK CUTTER

PILOT DRILL

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 Hot tapping

Non-standard hot taps

Lateral or
angled taps
COMPENSATING PAD

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 Hot tapping

Non-standard hot taps

Hillside taps
COMPENSATING PAD

 Compensated pad required

to provide flat face for the
pilot drill
 Weld compensating pad in
position prior to welding
branch connection
 Extended cutter may be
required

77 Furmanite Confidential - 1/9/04

 Hot tapping

Non-standard hot taps

Elbow taps
COMPENSATING PAD

 Compensated pad
required to provide flat
face for the pilot drill
 Weld compensating pad
in position prior to
welding branch
connection
 Extended cutter may be
required

78 Furmanite Confidential - 1/9/04

 Hot tapping

Hot tap limitations

Maximum pressure
 Equipment is rated to 1440 PSI (100 bar) @ 100°F (38°C)
 Pressures above this can be hot tapped, specialist procedures
and equipment required (refer to your Furmanite contact)

Maximum temperature
 Equipment is rated to 700°F (371°C) @ 700 PSI (48 bar)

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 Hot tapping

What information is required?

Line details
 Nominal size
 Wall thickness
 Design parameters -contents,
pressure & temperature
 Operating conditions - if different

Branch details
 Nominal size
 Wall thickness
 Length
 Flange/interface specification
 Clearance space for hot tapping machine

Valve details
 Valve type - e.g. ball, gate, etc
 Valve bore
 Overall length

80 Furmanite Confidential - 1/9/04

 Hot tapping

Equipment preparation
Machine Selection
 Size of branch to be hot tapped and cutter to be used
 Size of parent pipe (type of cutter)
 Wall thickness of parent pipe (power required)
 Material of parent pipe (cutting material & form)
 Total combined length of valve and branch (travel)
 Contents, pressure and temperature (seal suitability)
 Clearance space for machine

Machine Preparation
 Valve adapter
 Cutter type
 Pilot drill
 Cutter holder

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 Hot tapping

Clearance required for

hot tap machines
Note:
Not just X and Y
but how to get the
X
machine into
position

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 Hot tapping

Hot tapping applications

Typical hot tap
locations

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 Hot tapping

Hot tapping fittings and equipment

Extensive inventory
for
customer use
 Close-sure completion
flanges
 Split tees
 Purge equalisation fittings
 Topping machines
 Mechanical line stop fittings
 Sure stop tees with bottom
outlet prepped for welding
 Spherical three-way tees
 Three-way line stop tees

84 Furmanite Confidential - 1/9/04

 Hot tapping: cost effective
pipeline modification and
repair
- without the need for shutdown

85 Furmanite Confidential - 1/9/04