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Hot tapping: cost effective pipeline modification

and repair

- without the need for shutdown

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Hot tapping is a method of making a connection

into an existing pipe or vessel which is still under

pressure or live

Can be performed without the need to shut down

the plant. No need for loss of production or

supply to other areas

Additional branches allowing supply to and from

other areas of plant etc

Entry points for isolation equipment line stops,

inflatable isolation equipment, etc

Monitoring points for temperature probes etc.

Definition:

What is it used for?

What are the advantages?

What is hot tapping?

Hot tapping

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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

Where can hot tapping be used?

Hot tapping

24” hot tap machine in position

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Hot tapping: the Furmanite IPSCO advantage

Hot tapping

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: basic procedure

Hot tapping

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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The Furmanite IPSCO folding head system

Hot tapping

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)

The benefits

60” folding head

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Step 1:The hot tapping

machine is mounted

on to the tapping valve

The hot tapping procedure

Hot tapping

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Step 2:The cutter/pilot assembly

is advanced until it

touches the parent pipe,

then the hot tap is

started

Hot tapping

The hot tapping procedure

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The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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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

The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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Step 4:When pilot is completely

through stop rotation and

advance to allow u-wires

to drop

The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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Step 5:When cutter touches top

of pipe the machine is

restarted so that the cut can

be completed

The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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Step 6:When the cut is complete

the machine is stopped and

cutter advanced to confirm

that the tap is complete

The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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Step 7:Coupon and cutter

are withdrawn with

the coupon or cut out

retained by the u-wires

The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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The hot tapping procedure

Hot tapping

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Step 8:The tapping valve is

then closed and the

machine can be

removed

The hot tapping procedure

Hot tapping

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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)

How is the coupon retained?

Hot tapping

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The coupon catcher process in operation

Hot tapping

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The coupon catcher process in operation

Hot tapping

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The coupon catcher process in operation

Hot tapping

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Hot tapping

The coupon catcher process in operation

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The coupon catcher process in operation

Hot tapping

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The coupon catcher process in operation

Hot tapping

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The coupon catcher process in operation

Hot tapping

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The coupon catcher process in operation

Hot tapping

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The coupon catcher process in operation

Hot tapping

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The coupon catcher process

Positive retention pilot drill

Hot tapping

Removal of coupon on36” hot tap

Cutting head and pilot drill with coupon retained

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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

Hot tapping: Preferred angles of tap

Hot tapping

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Non-standard hot taps

Tank taps

Hot tapping

PILOT DRILL

TANK CUTTER

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Non-standard hot taps

Hot tapping

Lateral or angled taps

COMPENSATING PAD

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Non-standard hot tapsHillside taps

Hot tapping

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

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Non-standard hot tapsElbow taps

Hot tapping

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

COMPENSATING PAD

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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)

Hot tap limitations

Hot tapping

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

Line details Nominal size Wall thickness Design parameters -contents,

pressure & temperature Operating conditions - if different

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

What information is required?

Hot tapping

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Machine Preparation Valve adapter Cutter type Pilot drill Cutter holder

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

Equipment preparation

Hot tapping

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Note:Not just X and Y

but how to get the

machine into

position

Y

X

Clearance required for hot tap machines

Hot tapping

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Hot tapping applications

Typical hot tap locations

Hot tapping

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Hot tapping fittings and equipment

Extensive inventory for customer use

Hot tapping

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

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Hot tapping: cost effective pipeline modification and

repair

- without the need for shutdown