Few Salient Points related to Hot Tapping on operating

lines
Hot Tap or Hot tapping is a proprietary method for adding a branch connection to a hot or operating
line. A proprietary device, to be used in conjunction with a hot tap that blocks a hot line is called
Stopple.
Limitations of Hot Tap:
Hot tap connections shall not be made in any of the following cases:
Limited Fluids:

Lines carrying the following shall not be hot tapped.

Acid

Caustic

Elemental sulphur

Oxygen

Chlorine

Ammonia

Potentially toxic materials

Any material which may cause metallurgical damage when heated.

Flammability of Fluid: Hot taps are not suitable for pipe or vessels containing materials that are
flammable below atmospheric pressure or mixtures that will support combustion.

Material Degradation: Hot taps are not suitable if the pipe material to be welded may suffer
metallurgical or physical degradation from the heat of welding.

PWHT: Piping requiring post weld heat treatment, for any reason, shall not be hot tapped.

Clad or Lined: Hot tapping shall not be performed in piping, or vessels that are clad or lined

Minimum Temperature: Lines with surface temperatures at or below 0 deg. C are not suitable for hot
tapping;

Equipment Availability: There must be a hot tapping machine available for the temperature pressure
and size of the shell.

Tanks: Hot taps on tanks shall be located at least 1 m below the liquid level.

Compressed Air: Compressed air, when there is any possibility of hydrocarbon contamination, shall
not be hot tapped, without thorough internal cleaning, or the introduction of inert gas, prior to welding.
Debris Damage: Hot taps shall not be made upstream of any equipment that may be damaged by
chips, shavings, and other debris introduced into the line by the hot tapping process. Hot tapping shall
not be allowed until systems have been put in place that will positively trap foreign matter.

Minimum Wall: The minimum wall for hot tapping is 5 mm.

Hot Tap Design:

Dimensions: The dimensions of the connection, the hot tap valve, and the clearances shall
be within the limits specified for the hot tapping equipment to be used. This requires data from
the most likely contractor, or specification of a list of allowable hot tapping machines for that
project. The minimum bore of the valve used shall be large enough to pass the cutter or
stopple plug.

Size to Size Taps: A tap equal to the nominal size of the header, such as required for
stoppling of a pipeline, shall be made only when the accurate positioning of the cutter can be
guaranteed. This is accomplished by the use of a shop-fabricated split tee. In all other cases
the taps are only allowed at least one pipe size smaller than the pipe to be tapped.

Welding on Pipelines under Pressure: Before welding on lines under pressure, the existing
pipe wall shall be determined. A maximum working pressure shall be calculated in accordance
with the appropriate ASME B31 code, using the actual wall minus 2.5 mm. The 2.5 mm wall
thickness takes into account the molten and heat affected portion of the base metal which
does not contribute to pressure containment.

Control of Cuttings: When using gate valves for hot tapping, orient the valve so that chips
from the cutting procedure will not fall into areas where the action of the valve is inhibited. If
this is not possible, the hot tap valve shall be provided with a valved drain of not less than 3/4
inch NPS to permit flushing of the valve if needed.

Removal of Hot Tap Valve: When the hot tap valve is to be removed after tapping, as in the
case of stoppling, a Lock-O-Ring flange and plug, or approved equal, shall be used unless the
equipment can be depressurized and drained prior to removal of the valve.

Guide Bars: When hot taps are made in pipelines which require scraper bars, a Lock-O-Ring,
or approved equal, flange and plug and matching insert with bars attached, shall be installed

Hot Tap Fitting Installation:

Positioning: The welded branch or split tee shall be accurately positioned so that the axis of
the cutter will intersect the axis of the pipe or vessel being tapped at a 90 degree angle unless
an angled tap has been specifically approved in the hot tapping procedure. The branch
position shall be verified by the assigned inspector prior to making the cut.

Safety Procedures: The hot tapping contractor shall submit safety procedures with his
proposal. The installation, pressure testing, welding and cutting, shall be in accordance with
the approved procedures.

Pressure Testing:

Test Valve: The hot tap valve shall have a pressure test applied to the seats and body to
ensure no leaks prior to use.

Test Fluid: Special attention shall be given to the possibility of boiling or flashing of the test
liquid if the surface to be tapped is hot.
 Hot Tap Test: When the full assembly is complete, and prior to cutting the coupon, the
assembly shall be pressure tested.

Test Pressure: The test pressure for the hot tap connection shall be in accordance with the
appropriate ASME B31 code, however, not exceeding any of the following:

(i) The minimum pressure in the pipe or vessel being tapped, while the test is in progress, plus a
calculated differential pressure. The differential pressure shall be 1.25 times the allowable external
pressure calculated per the ASME SEC VIII D1, paragraph UG-28. The value of L, for this calculation
shall be the total length of the split tee or the inside diameter of the welded nozzle.

(ii) Maximum test pressure of branch connection flange, or the wall thickness.

(iii) The test pressure of the hot tap connection may be lower than the original hydrostatic test
pressure of the pipe or vessel being tapped. This is acceptable since the purpose of the test is to
provide some assurance of the integrity of the connection weld. It is not a proof test of the connection.
The system being tapped should not be derated because of the lower test pressure of the hot tap
connection.

Pad Vent Hole: The reinforcing pad of a welded branch shall be provided with a vent hole.
The hole shall be plugged with heavy grease before leaving the job.

Inspection: In addition to hydro test the reinforcing pad welds may be inspected by magnetic particle
examination. Alternatively, dye penetrant examination may be used provided surface preparation is
made as required.