PDVSA

ENGINEERING DESIGN MANUAL

VOLUME 13III

ENGINEERING GUIDE

PDVSA N TITLE

10606.1.401 GUIDELINES FOR HOT TAPPING

0 OCT.99 APPROVED 13 Y. K. A. A. J. E. R.

REV. DATE DESCRIPTION PAG. REV. APPD. APPD.

APPD.BY Alexis Arvalo DATE OCT.99 APPD.BY Jess E. Rojas DATE OCT.99

E PDVSA, 1983 ESPECIALISTAS

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Index
Page

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Petrleos de Venezuela S.A. (PDVSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 American Petroleum Institute (API) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 American Society of Mechanical Engineers (ASME) . . . . . . . . . . . . . . . . . 2
3 HOT TAPPING DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5 DESIGN CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6 BRANCH CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7 HOT TAPPING PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 6
8 FORMAT A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9 SPECIAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.1 Lined Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.2 Rotating Equipment Upstream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.3 Welding Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1 SCOPE
1.1 This document provides guidelines to develop hot tapping connections during
basic and detail engineering phases, up to its approval. It also includes
engineering notes and recommendations that must be considered for a good final
work and for an appropriate behavior of the connection during the operation.
1.2 This document is not intended for tiein construction purposes.

2 REFERENCES
2.1 Petrleos de Venezuela S.A. (PDVSA)
H221 Materiales de Tuberas
H231 Piping Fabrication Requirements
HG252 Criterios de Diseo de Esfuerzos en Sistemas de Tuberas
O201 Seleccin y Especificaciones de Aplicacin de Pinturas
Industriales.
IRS04 Gua para la Elaboracin de Permisos de Trabajo
IRS06 Gua para Cambios o Modificaciones de Instalaciones o Equipos.
2.2 American Petroleum Institute (API)
2200 Repairing Crude Oil, Liquefied Petroleum Gas, and Product
Pipelines.
2201 Procedures for Welding or Hot Tapping on Equipment in Service.
5L Specifications for Line pipe
Std. 1104 Welding of Pipelines and Related Facilities
RP 1107 Recommended Pipeline Maintenance Welding Practices.
2.3 American Society of Mechanical Engineers (ASME)
Section II Materials
Section VIII Div. I and II Rules for Construction of Pressure Vessels
Section IX Welding and Brazing Qualifications
B31.1 Power Piping
B31.3 Process Piping
B31.4 Liquid Transportation System for Hydrocarbons,
Liquid Petroleum Gas.
B31.8 Gas Transmission and Distribution Piping System.

3 HOT TAPPING DEFINITION

Hot tapping is a method used to perform tiein connections using tools (see
Fig. 1) and fittings while the piping system or equipment is in operation. Hot tap
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shall be done by an appropriate Contractor or PDVSA specialized construction

group. PDVSA Engineering representative approval is required prior to start.

4 TECHNICAL INFORMATION
Technical information for hot taps such as clearance requirements, weights and
special fittings, shall be based on catalog information from the equipment
manufacturer.

5 DESIGN CONSIDERATIONS
5.1 A hot tap connection shall be permitted only if all the alternatives of cold cuts have
been ruled out. Process Engineer is responsible for identifying the exact position
of tiein and for determining all the alternatives, including hot taps.

5.2 The detailed design of both cold cut and hot tap connections is recommended if:
S The decision of the kind of connection depends on the shutdown of a unit,
system or piping.
S No firm date for shutdown or unavailable information.
S Scarce, poor defined or lack of unit, system or piping data or information.
S For critical facilities only, it is recommended to purchase materials for both
connections.
S There are economic, safety and/or environmental risk advantages.
5.3 Hot tapping shall only be permitted under the following conditions:
S The contained process fluid remains stable when subjected to the high metal
temperatures during welding.
S The contained process fluid remains stable when in contact with air during
drilling and perforation.
S There is not decomposition or chemical reaction between the fluid and the hot
containing wall.

5.4 Hot tapping shall not be permitted under the following conditions:
S When the process fluid is a mixture of gases or vapors within their flammable
range or may become flammable as a result of heat input in welding operations.
S When the process fluid may undergo reaction or decomposition leading too
dangerous increases in pressure, explosion or attack on metal.
S There is compressed air in the presence of hydrocarbons, which may be
present either in the air or deposited on interior surfaces of pipe.
S A gaseous mixture in which the hydrogen partial pressures exceeds 100 psig.
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S Where the process fluid is one of the following substances:

Acetylene
Butadiene
Caustic soda
Chlorine
Ethylene
Ethylene oxide
Rich/lean DEA/MEA
High pressure steam (greater than 700 psig)
Hydrogen
Hydrogen sulfide
Hydrofluoric acid
Oxygen
Sulfuric acid
Toxic substances.
S Noflow or intermittent flow condition.
S High liquid flow which can cause rapid cooling of the weld area during the
hottap welding. It is recommended a maximum velocity of the process fluid not
greater than 6 ft/sec.
For safety reasons, the operating pressure inside the run pipe shall not exceed
1000 psig, the maximum allowable pressure of the line at the welding metal
temperature or the maximum allowable pressure of the hottap equipment,
whichever is the lower.

5.5 Process and Design Engineers shall verify several critical data required for
performing a hot tap such as, in accordance with API 2201:
S Safety
S Condition of the pipe under consideration
S Configuration of the connection
S Code requirements
S Operating conditions
S Capability of the drilling equipment under the pipe operating conditions
(pressure, temperature, process fluid, etc.).
S Possible welding problems
S Environmental risk
S Economic aspects
S PWHT of HAZ (heat affected zones) requirement.
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S Vacuum condition.
S Presence of prohibited contained products. PDVSA Metallurgical or Equipment
inspection Engineer may be consulted.
S Minimum and maximum flow required in the line during the hot tap performing.

5.6 The hottap location shall be selected taking account the following factors:
Diameter and ovality
Pipe wall thickness
Internal and external corrosion
Defects in the pipe
Adjacent welds and connections
Internal deposits, lining and coating
Minimum clearances above the hot tap valve connection taking in account the
catalog information of the equipment manufacturer. This clearance varies from
size to size and can range from 1,8 m (6 ft) to 4,6 m (15 ft).

5.7 The design calculations shall include at least the following:

Process data limitations
Pipe data and welding suitability
Maximum temperature and pressure
Loading:
Piping transmitted loads (runpipe and branch)
Hot tapping equipment loads
Configuration requirements
Test pressure

5.8 Hot tap valve shall be full port and field hydrotested.

5.9 Prior to perform any hot tap work, Design Engineer shall request PDVSA
Equipment Inspection to check the pipe in order to determine if suitable for hot
taps.

5.10 The pipe must be metallurgical suitable for welding. The base metal must be free
of laminations, blistering, fissuring or other defects, which could cause
burnthrough.

5.11 Ultrasonic examination shall be performed to determine the wall thickness of the
pipe at the point and general surrounding zone of the proposed hot tap. This
information shall be available to the Contractor.
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5.12 The pipe wall thickness must be at least the minimum required, considering the
design pressure and temperature involved. A minimum base metal thickness of
3,81 mm (0,150 inch) is recommended for hot line work. Welding on too thin
material could result on overheating and burnthrough. Depending on the
service, it is sometimes possible to temporarily reduce the pressure and/or
temperature within the piping system to provide an additional safety factor while
welding takes place.

6 BRANCH CONNECTION
6.1 Branch connection weld fittings shall be in accordance with Table 1 and Figs. 2,
3 and 4, of this specification. Beside, always shall comply with all the other
specifications mentioned in paragraph 2 and the metallurgy shall be in
accordance with PDVSA H221 Materiales de Tuberas.
The hot tap machine shall be of the proper size and rating to accommodate the
required pipe branch connection and size.

6.2 Branch connection shall be 90 degrees.

6.3 Hot tapping closer than 18 inches to a flange or threaded connection, or closer
than 3 inches to a welded seam, shall require PDVSA Engineering representative
prior written approval.

7 HOT TAPPING PRESSURE TESTING

The Design Engineer shall consider the following stages of a hot tapping work, in
order to determine the pressure testing:

7.1 Once the branch nozzle has been welded (without the reinforcement), a
hydrostatic test shall be done, with water or oil test fluid, depending on the
temperature on the header.

7.2 The test pressure shall be the lesser of the following cases:

7.2.1 The external pressure calculated for the header, in accordance with the applicable
code.
7.2.2 The internal pressure calculated for the branch, in accordance with the applicable
code.

7.3 The test pressure shall not exceed the 110% of the line or equipment internal
pressure.
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7.4 Reinforcing pads shall be provided with a 1/8 in. NPT hole for pneumatic test
purposes.

8 FORMAT A
8.1 Once compiled all the information required in this document, Process and Design
Engineer shall fill out the Format A, including all the additional information
mentioned herein.

8.2 PDVSA Operational or Unit Owner representative must approve the Format A, in
order to continue with the hot tap construction phase.

9 SPECIAL CONSIDERATIONS
9.1 Lined Piping
Hot tapping shall not be done on piping with cladding or linings such as glass lead,
refractory plastic and stop lining.

9.2 Rotating Equipment Upstream

Avoid hot tapping upstream of rotating equipment unless properly protected from
cutting debris by suction strainers, filters or screen cones.

9.3 Welding Preparation

9.3.1 Preparation of the run pipe.
a. Coating removal.
Paint, coating or wrapping material shall be completely removed from the run pipe
in the hottap area at least 20 inches each side of the location.
b. Surface cleaning and visual inspection.
The hottap location shall be thoroughly cleaned wire mesh and inspected for
laps, cracks, pitting and mechanical damage.
c. Ovality test.
The expose run pipe shall be checked for compliant with the ovality limits specified
in the line pipe specification.
d. Defects.
The overall area of the pipe shall be ultrasonic tested for the presence of
laminations or other defects which may interfere with the hottapping operations.
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TABLE 1. HOT TAPPING BRANCH REQUERIMENTS.

Branch nozzles for hottapping on existing piping shall meet the requirements
indicated on the following chart and legend:
no
no no
1 T
1 T
2 T
3 T
4 T
hes

6 T
S), iinch

8 T
10 T
NPS

12 nT T
H derr Sixxe (N

14 sr nT T
16 s nT T
18 nT T
Hea

20 w nT T
24 nT T
26 nT T
30 nT T
36 nT T
42 nT T
48 nT T
1/2 3/4 1 1 2 3 4 6 8 10 12 16 18 20 24 26 30 36 38 42 48
Branch Size (NPS), inches

Legend
no = Hot tapping is not allowed for this headerandbranch size.
sr = Use 1 NPS sockolet, niple, flange and valve for hottap nozzle, with wall thickness as indicated
on the piping class specification for the branch; use reducer after valve to bring branch diameter
to 1/2 o 3/4 NPS.
s = Use sockolet, nipple and flange with wall thickness as indicated on the piping class specification1
for the branch.
w = Provided header wall thickness is greather than, or equal to standard (STD; according to
ANSI B36.10), use weldolet and flange with wall thickness and bore as indicated on the piping
class specification1 for the branch; no reinforcing pad is required. If header wall thickness is smaller
than STD, use extra strong (XS; ANSI B36.10) nipple and flange, as a minimun, and a reinforcing
pad designed according to the latest applicable ASME/ANSI code (B31.3; B31.4 or B31.8).
T = Use split tee and flange; wall thickness for run shall be as indicated on the piping class
specification1 for the header, wall thickness for branch and flange bore shall be XS, as a minimun.
No reinforcing pad is required.
nT = Use XS nipple and flange, as a minimun, and a reinforcing pad designed according to the latest
ANSI B31.3 code. Use split tee as indicated on note T above, as an alternative.
1: Wall thickness calculation in accordance with ASME/ANSI Code B31.3.
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To fill the data sheet, click here

FORMAT A
FORMATO PARA ACEPTACIN DEL SITIO DE LOCALIZACIN DEL HOT TAP Y
DEL PROCEDIMIENTO DE EJECUCIN.
Proyecto
Tiein N
Ubicacin
Servicio

CONDICIONES PRESION TEMPERATURA

N de la Lnea Operacin Barg C
Nueva Diseo Barg C
N de la Lnea Operacin Barg C
Existente/Equipo Diseo Barg C

Dimetro Nominal de la Conexin:

Tiempo disponible para efectuar la conexin
Caudal mnimo necesario para minimizar riesgos
Duracin aproximada del trabajo

Lista de Verificacion de Anexos Obligatorios.

Disponibilidad
Procedimiento de Ejecucin de la Conexin
DTI mostrando ubicacin del Hot Tap
Plano de Planta de Tuberas, con la ubicacin fsica del Hot Tap
Clculo del espesor de tubera mnimo requerido para la lnea existente
Clculo de la Prueba Hidrosttica (presiones interna y externa)
Ruteo preliminar de la lnea nueva
Detalle de la placa de identificacin de la conexin
Fotografas del sitio de ubicacin

Observaciones:

Registro de Conformidad
Nombre Firma Fecha
Ingeniero de Proceso
Ingeniero de Diseo
Representante de Operaciones
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Fig 1. TAPPING MACHINE SCHEMATIC.

valve adapter

Cutter holder
Cutter

Pilot drill

Sandwich valve

Seton branch / split tee

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Fig 2.

1. Reduced branch fitting

Branchpipe

Reduced branch fitting

(weldolet, nippolet etc.)

Run pipe

2. Reinforced seton branch Top half of

reinforcing sleeve
Note: 1. Fluid is not in contact with
the reinforcing sleeves
2. Branch pipe flange not
shown
Branch pipe
Run pipe

Dashed lines show

final configuration of
reinforcing sleeve

Bottom half of
reinforcing sleeve

3. Preformed split tee

Flange
Either forged
outlet or factory
weld Run pipe

Longitudinal weld
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Fig 3.

NOTES: 1. Welding of longitudinal welds to commence

in the centre of sleeve. Weld starts shall be
overlapped and ground. Welding to continue in
this manner until 10 mm to 12 mm in cross
sectional thickness is deposited.

Fig 4.

WELDING SEQUENCE FOR SPLIT TESS

NOTES: Welding of longitudinal welds to commence in

the centre of tee. Weld starts shall be
overlapped and ground. Welding to continue in
this manner until 10 mm to 12 mm in cross
sectional thickness is deposited.