10/10/21, 6:32 PM Hot Tapping and Line Stopping - Overview - EPCM Holdings

HOT TAPPING AND LINE

STOPPING – OVERVIEW
Hot Tapping: Zero Down Time Modification &
Remedial Work with Pressure Vessels
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INTRODUCTION TO HOT
TAPPING
Few engineering procedures can modify, repair, and
improve operating equipment while they remain in
service; far less are the number of procedures that
are also environmentally friendly, involve less risk,
and firmly claim a 60%-80% expense reduction when
compared with competing procedures. Nearly a
century of widely practised hot tapping and plugging
techniques confidently generate these facts. While
hot tapping is not a recent invention of industries
which use pipelines, piping, tanks, and other
pressure vessels, its regularity of use has only
increased over time; under the often uttered maxim,
“Work smarter, not harder.” Leading authorities in
the energy field, such as TransCanada Corp. (TC
Energy) have extensively employed and refined the
safe, highly effective, and economically beneficial
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uses of hot tapping for decades*, while the United

States Environmental Protection Agency (EPA) has
favourably evaluated hot taps for emission
reduction and increased revenue in comparison to
historical methods of achieving the same result*.

Making new connections to equipment while it

remains in service and under pressure, is the end
goal of any hot tapping enterprise; in the case of
pipelines and piping, it is primarily used to tie in
other pipeline systems. Existing, operational loaded
facilities (usually tanks, piping, pipelines or water
lines) undergo hot tapping to efficiently achieve
several important goals. Remedial work without
shutdowns, disruption of service, product loss,
emission negation, and added risk to workers is
achieved with this ingenious technique. Sometimes
referred to as pressure tapping, wet tapping, or line
tapping, the process involves an experienced crew,
specialized equipment, and meticulously detailed
analysis.

Hot tapping as an industry term originates from two

distinct aspects of the procedure; hot work and
precise drilling (tapping). Hot work encompasses
heat generating or spark-producing equipment –
welding, portable grinders, burning torches,
abrasive blasting, etc. – which may be employed in a
given “hot” procedure while tapping refers to the
use of a hot tapping machine, which removes and
recovers a curved cutout (coupon) of the pipe wall.
Line stopping allows for greater degrees of
modification and remedial work and uses different
machinery to achieve this. This technique makes use
of line stop machines, plugging heads, and a bypass

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line to maintain the complete operation of the

loaded facilities while repair activities and further
operations fully commence.

1.1 PIPELINE AND PIPING

MODIFICATION
Though hot tapping is versatile in its application to
pressure vessels and storage tanks, the ability to
engage in modification and remedial work without
interrupting services makes it an indispensable skill
in dozens, perhaps hundreds, of industries. Hot
tapping can be applied to a broad spectrum of
materials, including carbon steel, cement, and PVC –
on land or underwater. Whether carrying crude oil,
gasoline, water, natural gas, or sewage, commodity
transportation and pressure remain unchanged, no
matter how extensive modifications or repairs are.
Broadly speaking, modification, could be defined as
any planned and executed addition to an existing
facility, though a distinction is worth noting for
remedial work, or repairs (addressed later in detail),
which technically could fall within such a general
definition. The list of various modifications
performed in the near-century through hot tapping
exercises is lengthy, but there are several crucial,
commonly performed modifications worth taking
note of.

Tie in connections are among the most referenced

concerning hot tapping, with sound reason. These
common connections are essential to expanding
existing infrastructure and utility of piping or
pipeline – among the more routine modifications
are extensions, bypass lines, main relocations, or
even pig launcher and receiver stations. Perhaps
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less frequently, yet regularly installed modifications

include: sample points, air relief points, pressure
control switches, sensor installations, lateral lines,
metering devices, sales taps, and much more can be
added to existing facilities by way of hot tapping.  As
a versatile method for enacting timely modifications
(or repairs), routine or rarified, “hot” connections
have proven to be an invaluable service in industry
toolkits around the world.

2 HOT TAPPING:
PREPARATION, RISK, AND
RISK MITIGATION
Historical cold tee (shutdown interconnect) methods
for creating pipeline connections or remedial work
are still used, though often at the cost of disruption
of service for days, increased emissions (particularly
in the Natural Gas industry), millions of dollars in
expense, and arguably more risk*. The decision to
choose between a hot tap or a shutdown
interconnect, hinges upon a comparative analysis of
pros and cons. Potential installation difficulties and
long term operating issues, against the beneficial
economic, environmental, and operating impacts of
either route. Though the comfort and familiarity of
cold connections may hold some appeal, the regular
use of hot connections has steadily increased.
Largely due to ninety years of continuous
refinement to standards, techniques, and
regulations, risks associated with hot tapping have
been mitigated to a significant degree. These
advances have so significantly reduced hot
connection risks that it is commonly deemed
superior to the available alternatives.
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Despite the “hot” nature of hot tapping and risks

inherent in pressurized operational tanks, piping,
and pipelines, it remains a thoroughly planned,
calculated, and controlled procedure; exceptional
investments in preparation, design, and proper
installation are paramount in mitigating risk while
completing a project.

Before commencing a hot tap, job-specific plans are

written out in generous detail, and include a host of
specifications which are intimately related to the
procedure, at a minimum they include:

1. Connection Location and Design (including

gaskets, valves, and bolts)
2. Thickness and Materials of the Vessel, Piping, or
Pipeline to be tapped
3. Detailed, Written Welding Procedures
4. Health, Safety, Fire Protection, Emergency
Response, Procedures and Instructions
5. Owner and User Requirements
6. Emergency Shut Off Procedures
7. Contingency Seal Off and Isolation Plans (that
maintain integrity for the system’s life)

When preparing for a hot tapping procedure, every

minute detail must be rigorously accounted for, to
ensure safe and effective operation. The highly
trained and experienced crews that carry out hot
connections address metallurgical concerns related
to each operation, specifically as it pertains to
welding. The wall thickness of these vessels can be
measured with ultrasonic gauges, to properly marry
welding techniques, temperature, and pressure

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concerns, to avoid a potential loss of containment

near weld pools. Calculations are made regarding
heat transfer. flow speed, and other variables to
reduce any risk (of burn-through, hydrogen cracking,
etc.) when welding branch connections onto pipe
systems.

2.1 BRANCH CONNECTIONS, HIGH

PRESSURE, AND LOW-PRESSURE
FITTINGS
Aside from valves and hot tapping machines, fittings
are one of the primary components of any hot
tapping exercise; as the name suggests, they are
designed with tremendous variety to make branch
connections – a fit for every occasion. Dimensions
such as the size and pressure of a vessel, as well as
the bore size of the tap itself, are fundamental to
determining the type of fitting. Expertly qualified
personnel select a sized fitting to accommodate the
operating pipeline. Once the appropriate fitting is
selected, it is welded with incredible nuance and
attention to detail, although mechanically attached
fittings are rated as an alternative in instances
where welds are not feasible.

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High and low-pressure fittings are specialized for

pressure variant used on pipelines, tanks, and
storage vessels and can range from a welded nipple
to a full-encirclement. The need for a case-by-case
evaluation of appropriate fittings can be aided with
the use of comprehensive equipment catalogues,
vendor manuals, or graphs (similar to the T.D.
Williamson charts below). These volumes are
customarily broad spanning compendiums of
relevant parts and their performance specifications.
Branch connections are not, however, exclusively
manufactured, quite often they are fabricated
adaptively to an exacting specification, which can
reduce project costs.
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2.2 VALVES
The humble and ever-present valve plays out its
critical role between the fitting and the hot tapping
machine. As with most aspects of a hot connection,
this part of the hot tapping assembly is selected to
perfectly conform with the specifics of a given vessel
or line. Material composition, pressure,
temperature, and size are some of the essential
recurring factors. This valve must have adequate
dimensions to allow the coupon retrieval after the
cutting operation and can take the form of either a
block or control valve.

While valves are genuinely ancient technology, many

varieties have been masterfully adapted to the 20th
and 21st-century tasks of regulating pressure and
flow. Typically globular in shape, the stout, round-
bodied silhouette of a gate valve (sometimes a ball
valve) is found employed on pipelines, though many
operations call for planed or flat (sandwich) valves to
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reduce the travel distance of a tap. Sandwich type

valves are optimally applied in circumstances where
space is a premium; they are fabricated and
manufactured to exceed the necessary performance
standards. Although these two valves do not
exclusively dominate the hot-tap-horizon, they are
prominent contenders.

The selected valve is properly secured to the fitting

using one of several methods, usually welded
(bolted or bonded), attached with a collar, or
strapping device – depending on the need. Once
attached structural and leak testing begins, usually
in the form of hydrostatic pressure testing, though
ultrasonic and X-ray techniques (among others) are
possibilities.

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3 HOT TAPPING MACHINES

Capable workhorses, tapping machines avail
themselves to hot tapping crews in a variety of sizes;
dutifully persisting for 15 to 20 years with routine
maintenance, they can be purchased from
manufacturers or fabricated in-house.
Pneumatically, hydraulically, electrically, or manually
powered, these machines specialize in penetrating
through vessel and piping walls while – critically –
retaining and extracting the cutout or coupon once
the cutting is completed. As with previous aspects of
hot connections, hot tapping machines must be
assessed by their merit for a particular job; accurate
accounts must be taken of temperature, pressure,
material compatibility, and mechanical stress
parameters.

3.1 HOT TAPPING MACHINE

CONSIDERATIONS
Given the range of possible dimensions with vessels,
piping, and pipelines a hot tapping machine may
encounter the need for adaptability. This naturally
promotes an equally large variety of adapter, cutter
holder, cutter, and pilot drill sizes. Nested within the
recess of the tapping adapter, the cutter and pilot
bit await operation; specially designed with coupon
retrieval in mind, these unique pilot bits feature a
retention wire (often designated a U-wire), which
toggles after cutting, catching the coupon and
preventing its possible escape. This bent wire is
recessed into a milled relief area on the bit,
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preventing its activation in the initial perforation of a

pipe wall. Before saddling the machine to its
designated valve, it is essential to scrupulously
measure and detail these cutting dimensions: from
pilot tip to cutter tip, from cutter tip to cutter base,
from top of flange to pipe surface, and a wall
thickness of the pipe.

For further reading on performing a successful hot

tap follow the link below:

Hot Tapping – Advice on Successful Pipeline Tapping

3.2 THE HOT TAPPING PROCESS: STEP-

BY-STEP
Married to the valve by the tapping adapter – which
contains the pressure of the pipe system – the
tapping machine stands at the ready. The machine is
telescoped into cutting position on the surface of
the pipe before actuation. The hot tap is then
created with a smooth and continuous process, until
the cutter clears the pipe wall, removing a section or
coupon, which is swiftly captured and soon
removed. The machine ceases cutting immediately
upon piercing through the pipe wall, as proceeding
could trap the cutter within the vessel.
Subsequently, the cutting assembly is retracted.
Pressure retained within the tapping adapter is bled
out through a purpose-built relief valve, enabling a
safe disconnection of the machine and the collection
of a prized coupon – the token of a job well done.

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The coupon may not be redeemed for a discount,

but it certainly buys a successfully installed valve
and shiny, new connection point to the network to
other systems. Alternatively, it signifies the start of
another hot tap, in a series of taps, for further
action. During the lifetime of piping and pipelines
damages are occasionally sustained due to natural
events, flaws in maintenance, or exposure to
corrosive elements and electrical forces –
sometimes due to lack of applying for thorough
cathodic protection. These damages can be resolved
without interruption to service. Creating an
additional hot tap is the first step towards
conducting this sort of remedial work. Having two
such taps presents the optimum scenario for
establishing a line stop and bypass line to continue
service, uninterrupted while work proceeds.

To read more about cathodic protection check out

these EPCM articles below:

Cathodic Protection Basics

Cathodic Protection Case Study – Padma Bangladesh

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4 INTRODUCTION TO LINE
STOPPING
Involving multiple hot taps, the service of line
stopping is an essential part of modifying, repairing,
or otherwise significantly adjusting piping and
pipelines. Somewhat more involved than a hot tap,
this operation uses multiple hot taps, line stop
actuators, plugging heads, and a bypass line. Line
stopping performs the temporary function of a
valve, to isolate and neutralize a section of the pipe
system, while allowing the commodity to freely flow
through the bypass structure, into the rest of the
pipe system.

Often requiring an even pipe-to-pipe, or size on size,

fitting to accommodate the plugging heads large
size, the latter two hot taps are typically larger in
dimension. A line stop actuator and plugging head
serve as a temporary valve – and as with hot taps –
can be utilized with materials ranging from iron to

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PVC, concrete, steel, copper, and others. Relating to

the size of piping and pipelines, line stops can be
performed from ¾ of an inch to 80 inches, leaving
little unaccounted for.

As with hot tapping, line stopping services have their

origins in the early 20th century, though
technologies had advanced considerably, the same
techniques and principles apply – with notable
advancements. Tried and true technologies related
to line plugging are still commonly used, and serve
the same undeniably central role when performing
refurbishment, alteration, relocations, tie-ins,
maintenance, or retrofits.

4.1 LINE STOPPING MACHINES AND

PLUGGING HEADS
The machines used in line plugging and stopping
bear a strong resemblance to the previously
discussed aspects and equipment used in hot
tapping – they are always suited precisely to the job
at hand. Relatively straightforward in terms of
machinery, line stop actuators can be manually – or
more often hydraulically powered. Many
applications that use line plugging machines require
a size on size fitting, usually a welded tee fitting, to
allow entry of a pivoting plug head. Whether
employed in water lines, natural gas, oil, sewage, or
other pipeline systems, these tools range a large
span of dimensions, weights, pressure tolerances,
and heat tolerances. Each line stopping machine is
manufactured or fabricated with specifications for
use with a range of piping or pipeline sizes (e.g.
14’’-20’’ or 36’’-48’’) and use complementary sized
stopping heads.
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Plugging heads are a varied technology, the

selection of which hinges on the type of pressure
vessel, piping, or pipeline at hand; selections are
available for every material type and size of piping
on the market, for commercial or industrial
application. Though several common stopping
heads have persisted throughout decades of use,
they have all benefited from technological
enhancement.

A pivoting plugging head is among the oldest

employed, yet most widely used for its effectiveness,
simplicity, and reliability. Folding headline stoppers
can be used with a reduced branch hot tap,
requiring a smaller entry point into the piping than a
pivoting head.

There are well over a dozen widely used techniques

for line plugging or stopping – including Sure-Stop,
HTP Stop, freeze stops, triple line stops, positive
sealing stops, inflatable stops, across-the-header
stops, and many other specialities stops; these
techniques are custom services for specific

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operations, and not as commonly employed as a

double block and bleed line stop, regularly used for
isolating a section of piping for work.

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5 PERFORMING A-LINE STOP

WHILE REMAINING IN
SERVICE
Though line stopping is occasionally used as a single
or emergency valve, to cease transport of a
commodity and abandon a shutdown, it is most
often employed with multiple hot taps, a pair of line
stopping machines, and a bypass line. Engaging in a
line stop operation helps a prospective company:

Avoid Interruptions to Service

Avoid Shutdowns and Associated Costs
Prevent Emissions
Prevent Loss of Product
Provide Engineered Modifications
Provide Increased Safety
Provide Maintenance
Reduce Operating Costs

5.1 BYPASS LINES

Whether a few feet or a few miles, simple bypass
lines are critical for companies wishing to stay in
service throughout remedial work and modification.
A bypass line has a simple function initially; maintain
uninterrupted transportation of commodities.
Several industries will opt to keep these bypass lines
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in place, as they often have a degree of utility with

certain products.

Water lines, steam pipes, production facilities, and

sewer systems frequently make use of bypass lines
as a type of manifold or trap; in the case of
municipal water supply, a bypass creates the
possibility of diverting flow around a break,
blockage, repair, or other issues. This application
can provide a timely and secure flow of water,
despite difficulties with infrastructure. Sewage or
similar bypass lines may require a pump to move
material through the line, yet they accomplish the
same goal of continuing service, long after their
installation.

Completing the necessary (usually four tapping

points) hot taps allows the installation of a bypass
line and the requisite valves for saddling up a pair of
line stopping machines. Once the bypass line is in
place and the line stopping actuators are fitted with
housing, the line stopping procedure can begin in
earnest.

5.2 LINE STOPPING SERVICE

Selected far in advance of the procedure, the
machine, housing, and accompanying components
are chosen for their application to the unique
circumstance of a given pressure vessel. Bolted to a
line stop housing of appropriate length, the line stop
actuator is secured to a line stop valve. Sandwich
valves are the optimal choice in a line stopping
operation, as they keep the travel distance for an
actuator to the bare minimum.

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Once actuated, the machine pushes the plugging

head into the piping or pipeline. Pivoting-head
stoppers feature a small wheel that makes contact
with the pipe wall. When contact is made, the head
rotates into the direction of the flow to form a leak-
proof barrier, redirecting flow into the bypass line.
At the same juncture, the second line stop machine
performs an identical function, safely isolating the
flow in a bypassed section of piping and effectively
forming a temporary double block and bleed valve.
Double bleed and block valves hold a particularly
important role in oil and gas facilities, though they
are broadly used across industries with piping to
isolate sections for work on machinery or other
aspects of the pipe system.

For more on double block and bleed (along with

double block and isolation) valves, click the links
below.

Introduction to Double Block and Bleed Valves

True Meaning of Double Block and Bleed

Left with an isolated section of the pipeline,

containing product, bleeding or depressurizing must
take place. Venting the isolated section of piping can
take several forms, depending on the substance
contained within, sometimes a temporary flare is
used, other times the material may be piped into a
containment vessel. This isolated section of pipeline
is now available for extensive modification,
replacement, or repair – while the pipe system
remains incomplete operation.

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6 REMEDIAL WORK AND

MODIFICATIONS
Skilled and experienced crews always begin with the
end in mind –  ends that always include
considerations for the anticipated remedial work.
Complex systems such as those found in multi-
product pipelines may require the addition of
maintenance facilities, such as launching and
receiving stations for pigging, pipe repair, complete
replacement of pipeline sections, or any other
modifications, including but not limited to:

Valve Fitting
Valve Replacement
Decommissioning
Leak Testing for Recommissioning
Cold Cutting
Pipe Welding and Weld Repairs
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Consulting Services
Non-destructive Testing
Risk Assessment
Whole Site Procedures
Redundant Line Sealing
Relocations
Retrofits
Establishment of Routine Maintenance

After remedial work or other modification, the

stopping heads are removed and completion plugs
are set in place. These plugs seal at the flange on the
pipe fitting, allowing removal of the gate valve. Once
the valve is removed, a blind flange is securely
installed, finishing the operation.

6.1 PIPELINE REPAIR

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Throughout the life of a pressure vessel, natural

wear and tear necessitate the need for regular
maintenance. Immediate intervention is required in
instances where substantial damage is sustained to
pipe systems. These situations call for a swift
response with safety as a priority to prevent loss of
containment. Isolating sections of piping with hot
tapping and line stopping is a routinely indexed
industry-standard put into frequent use around the
globe.

A host of meticulously drafted regulations and high

industry standards are closely observed during
these operations. Once the isolated section is
depressurized and ready for work, the required
work is undertaken without hesitation. Cold cutting
of the isolated section can begin, in the event of a
replacement section of piping or pipeline; welding
repairs, valve replacement, and other remedial work
are safely completed.

6.2 PIPELINE MODIFICATION

Modifications to pipelines or piping can include an
array of systems, devices, or improvements to a
running pipeline, each of which requires a skilled
hot tapping team and the requisite knowledge to
carry out these often highly beneficial and often
necessary modifications.

Pipe systems are often comprised of relatively

simple configurations, though this is not always the
case. A veritable panoply of modifications is
available once a double block and bleed are
established. Retrofits, relocations, and maintenance
additions are performed at this stage. Full site

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procedures can now take place while service

continues, regardless of size or complication.
Creating facilities for routine maintenance such as
launching and receiving bays for pigging is an
option, while consultation and extensive testing can
freely move forward without impingement.

7 KNOWING PARAMETERS:
PIPELINES AND PIPING
A properly trained, experienced, and equipped crew
can enact quick and reliable execution of both hot
tapping and line stopping services on nearly any
pressure vessel. The preparation for a hot tapping
or line stopping job is both serious and thorough, as
mistakes in some instances could be injurious or
fatal in extreme cases. More than adequately
prepared for, these parameters are checked in
triplicate, if not more, as a standard operating
procedure, to ensure the highest degrees of
adherence to quality control and safety protocols.

Adapting underlying principles to a given scenario is

the source and substance of engineering as a
discipline. Adjusting techniques, machinery, and
materials to adapt to a job are commonplace for
these seasoned professionals; despite the routine
nature of such changes, expert engineers know that
the key to successful operations is to never
underestimate the importance of these subtle
changes, to ruthlessly observe the research,
planning, and preparation for the job.

Hot tapping and line plugging projects are highly

specific by nature. The tools and equipment used for
each operation can be ordered from manufacturers
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or fabricated as needed. Manufacturers can be

sourced for any number of fittings, valves,
machines, pilot bits, or anything else required for
these operations. Fabricating these tools is also
routine, boasting the added benefit of being cost-
effective and capable of providing a large degree of
adaptability for both parties. Specialized for
operation within finite ranges of size, temperate,
and pressure, each tool and corresponding aspect of
hot tapping and line stopping is planned for,
configured, and accounted for at every step in the
process.

8 HERE TO STAY
It is with the advent of such efficient and effective
methods, safely enacted, that modern industry
continues to thrive. This technique, almost a century
old, is more relevant to energy systems at the
present day than ever before. As the technologies
used in these procedures become increasingly
advanced, and techniques further refined, the
degree of safety and reliable execution rises. The
inevitable result is that the use of hot tapping and
line stopping is growing across every sector it
applies to.

Aside from the cost-saving practicality of hot tapping

and line stopping, these practices represent a
significant benefit to the environment. That benefit
in the environment comes from a reduction of
emissions associated with the venting of miles of
pipeline necessary for cold tee shutdown
procedures. This sort of environmental damage
alone would likely dissuade most prospective parties

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from accommodating historical engineering

practices. If, however, it did not – the enormous sum
of expenses that arise from shutdowns, disruption
of workers, lack of service to customers, and added
risk posed to employees – through unnecessary
transportation and installation using additional
equipment – should more than serve as convincing
arguments.

9 HOT TAPPING: FURTHER

READING
For details on special fittings, components, and
techniques involved in hot tapping and line
stopping, investigate the Submenu Specials on this
informative website:

Wermac.org

10 RELATED TOPICS
Hot Tapping – Advice on Successful Pipeline Tapping

Multi-Product Pipelines

Cathodic Protection Basics

Cathodic Protection Case Study – Padma Bangladesh

11 SOURCES
Full Flow High-Pressure Hot Taps: The New
Technology and Why It’s Indispensable to Industry
or

Use of Hot Taps for Gas Pipelines Can Be Expanded

EPA.gov – Using Hot Taps For In-Service Pipeline

Connections
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10/10/21, 6:32 PM Hot Tapping and Line Stopping - Overview - EPCM Holdings

Performing Hot Taps

TransCanada Case Study: Emissions Management

System

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