HOT TAP & STOPPLE

OPERATIONS PRESENTATION

PRESENTED BY: SAAD M. AL OTAIBI

August 2006

OUTLINE

Introduction- Hot Tap & Stopple Unit (HTSU)

Hot Tapping Definition
Stoppling Definition
Related equipments
Case: Sequence of double stopple operation
Animation
Hot Tap & Stopple Engineer Roles
Related Technical Standard

DEFINITION OF HOT TAPPING

Hot tapping is a technique, performed using
specialized equipment for cutting a hole in a
pipe or tank through a welded or bolted
branch connection while the pipe or tank is
under pressure.

DEFINITION OF STOPPLING
It is the method of temporarily plugging a
pipeline in normal operation to isolate a
segment for repair or modification purposes.

Related Equipment:
(Split Tee Fitting)

Split tee is a fabricated sleeve with

attached lock o-ring flange.
There are two kinds of split tees:
hot tap split tee and stopple split
tee, similar in design but stopple
split tees have precise clearances
and tolerances.

Related Equipment:
(Sandwich Valves)
special gate valve that has a
smaller face to face
dimension than conventional
valves.

Bi-directional valve
Can only be operated at
equal pressure across its
gates.

Positive Gate Sealing Seat.

Related Equipment:
(Cutters)

Cutter is a tool used with the

hot tap machine to cut a hole
in a pipe or tank.

Cutters come in different

types and sizes:
Standard (hot tap)
Stopple
Special (high wall

thickness)

Cutter vs Tapping Valve Clearance

Inside diameter of tapping valve must maintain minimum
clearance to the cutter in accordance with the following
table:

Hot Tap Size

MINIMUM TOLERANCE
BETWEEN VALVE ID
AND CUTTER OD
(INCH)

Up to 8

0.125

10 to 48

0.250

50 and Greater

0.375

NOTE: This table applies on hot tap jobs only and may differ In
stopple activities.

SEQUENCE OF DOUBLE STOPPLE

OPERATION

Case: Valve Replacement

PREPARATION & SPLITE TEE WELDING

Split tee welding and hydrotest

HOT TAP OPERATION

Sandwich Valves Installation
Sandwich Valves

HOT TAP OPERATION

Hot Tap Machines installation

Hot Tap Machine

2 Welding Boss
Cuter
Sandwich valve

BY PASS INSTALLATION
By pass installation after hot taping
Divert the flow toward the by pass

Full flow by pass

STOPPLE OPERATION
Install Stopple Machines

Stopple Machine

STOPPLE OPERATION
Insert Plugging Heads.

Stopple Machine

Stopple plug

VALVE REPLACEMENT
Vent or Drain the isolated segment
Replace the defected valve.
Stopple Machine

New Valve

STOPPLE RETRIEVING
Pressurize the isolated segment
Retrieve the plugging heads

Remove stopple equipments

L.O.R FITTING INSTALLATION

Install hot tap machines & insert LOR Plugs in stopple
fittings.
Vent or drain & remove the by pass
Install hot tap machines & insert LOR Plugs in hot tap
fittings
Lock O-Ring Plugs

BLIND FLANGE BOLTENING

Install blind flanges on all split tees
The line is continuously in service
Blind Flanges

ANIMATION
For Double Stopple Operation.

HOT TAP & STOPPLE ENGINEER

ROLES
Review, comment and process calculation sheets & data

checklists for new requests.

Review and discuss material lists with costumers (job requesters)
for proposed jobs.
Prepare cost estimates for new requests.
Follow up and update BI-19 items of the unit.
Review new equipment design drawings Non Material
Requisitions (NMR)
Coordinate with costumers prior and during activities to assure
achieving the required work.
Consult CSD on selecting the right material for the sealing
elements.
Coordinate with Dhahran Shops in repairing hot tap and stopple
equipments.

Saudi Aramco Related Standards

SAEP-311, Installation of Hot Tapped

Connections

SAEP-315, Installation of Stopple Fitting

SAES-L-052, Hot Tap Connections
SAES-L-056, Pressure Testing of Plant Piping
and Pipelines

End
Thank You