Hottappingrequirement1 160722152313

Hot Tapping Requirement
Prepared by Eng. Wael Elariny

Course contents
Module 1
1. Pipes
2. Flanges
3. Fitting and branch connections
4. Gaskets
Module 2
1. Types of welding processes
2. Welding symbols
3. Welding electrodes identifications
4. Welding procedure specifications
5. Welding Discontinuities
6. Introduction to non destructive test
Module 3
1. Hot tapping Requirements.
Module 4
1. Hot tapping Simulation.
MODULE 1
PIPING
1- Pipeline specification.
Piping is an assembly of components that include

pipe, valves, fitting ,flanges, bolts, gaskets and
supports used to convey distribute and control flow
of fluid.
Piping must also contain the conveyed fluid and
accommodate internally and externally imposed
loads and thermal movements.
Page 4
Materials .
1. Carbon steels: used for normal corrosion conditions within a

temperature range of -29 C to 426 C.
example: ASTM A 106-GR.B
2. Killed carbon steels: used for corrosion conditions within a temperature
range of -29 C to -46 C.
example: ASTM A333-GR.6
3. Alloy steels: used for higher temperature and higher corrosion rates.
example: ASTM A335-P9 (9cr 1 mo)
4. Stainless steels: groups of steels having a minimum of 10.5%chromium
used for excessive corrosion conditions.
example: ASTM A312-TP 316L (18cr-8Ni-2mo)
Page 5
Materials
5. Cast irons: used for underground utilities, sewers and process drainage
systems.
example: grey cast iron, ductile iron.
6. Non metallic: used for better corrosion resistance at low pressure and
normal temperature conditions. Limited to a maximum temperature of
100C.
example: GRP (glass reinforced plastic) polyethylene.
7. Plastic lined: Used for chemical resistance, limited to maximum service
temperature of 100C.
8. Cement lined: used for high corrosion conditions ,low pressure and
normal temperatures, such as seawater.
Page 6
ASTM Material Groups & Specifications
Page 7
ASTM Material Groups & Specifications, ASTM A105
Page 8
ASTM Material Groups & Specifications, ASTM A106
Page 9
Commonly used Material
Page 10
Commonly used Material
Page 11
Pipe size.
Nominal pipe size (NPS) is a dimensionless designator of pipe size. It

indicates standard pipe size when followed by the specific size
designation number with out an inch symbol. For example, NPS 2
indicates a pipe whose outside diameter is 2.375 in. The NPS 12 and
smaller pipe has outside diameter greater than the size designator (say, 2,
4, 6, . . .). However, the outside diameter of NPS 14 and larger pipe is the
same as the size designator in inches. For example, NPS 14 pipe has an
outside diameter equal to 14 in. The inside diameter will depend upon the
pipe wall thickness specified by the schedule number. Refer to ASME
B36.10 .
Page 12
ASME B36.10
Page 13
ISO Standard
Diameter nominal (DN) is also a dimensionless designator of pipe size in

the metric unit system, developed by the International Standards
Organization (ISO).It indicates standard pipe size when followed by the
specific size designation number.
NPS DN NPS DN
1/8 6 4 100
1/2 15 6 150
3/4 20 12 300
1 25 24 600
1 1/2 40 40 1000
2 50 42 1050
3 80 60 1500
Page 14
2- Flanges
A flange is a piping element that connects pipes, fitting or valves together.

Design codes
1. ASME/ANSI B16.5 : Steel flanges sizes to 24.
2. ASME/ANSI B 16.47: large size steel flanges 26 to 60.
3. API 605: large size flanges 26 to 60.
4. ASME B 16.36: Orifice flange
Page 15
Flange types
No. Flange type Service conditions

1 Welding neck For high pressure process conditions
2 Socket weld For low pressure process and utilities
3 Screwed For small pressure utility condition and small sizes
4 Slip on For large sizes and limited pressures
5 Lap joint For special corrosive conditions
6 Blind For all pressure process and utilities
7 Orifice For instrumentation reasons , all pressure sizes 2 and
larger.
Page 16
Flange types
Page 17
Flange types
Orifice flange ASME B 16.36
Page 18
Flange facing
Flat face (FF)

Raised face (RF)
Ring joint (RJ)
Lap joint (LJ)
Tongue and groove (T&G)
Male and female (M&F)
Page 19
Flange facing .
Page 20
Flange pressure / temperature ratings
As per ASME B16.5 / ASME B 16.47 these are combinations of pressure

and temperature design conditions, combined with flanges materials.
There are seven classes of pressure/temperature rating in ASME B16.5 /
ASME 16.47 they are classes 150 300 400 600 900 1500 & 2500.
For higher pressure / temperature rating, API 6A Code (well head flanges)
classes 5000&10000 PSI shall be used.
Page 21
Temperature and pressure ratings of flanges
conforming dimensions ASME B16.5 and materials
specification ASTM A-105
Page 22
ASME B16.5 Flange Rating Chart
Page 23
API flanges, API 6A
As per API 6A , Classes of flanges as below
API 6A - Type - 6B 13.8 MPA (2000 psi)
API 6A - Type - 6BX 13.8 MPA (2000 psi)
Page 24
API Flanges
Page 25
3- Pipe fittings and branch connections
A fitting is a piping element that connects a pipe or flange in order to

facilitate the flow direction change.
A branch connection is a piping element that connects two pipes with a
specified angle i.e not the same centerline.
Steel fittings may be classified as:
1. Forged (socket weld or screwed : for small sizes.)
2. Welded for all pipe sizes.
3. Flanged for special purposes.
Page 26
Branch connections.
Page 27
Pipe fittings
Page 28
Pipe fittings and branch connections
Codes of design:
1. ASME/ANSI B16.9: Wrought steel butt weld fittings.
2. ASME/ANSI B 16.11: Socket weld and threaded fittings.
3. ASME/ANSI B 16.15: Cast bronze threaded fittings .
4. ASME/ANSI B 16.4: Cast iron threaded fittings .
Page 29
Pipe fittings and branch connections
Wall Thickness
1. Socket weld and screwed fittings specified by rating (2000#, 3000#,
6000#, 9000#)
2. Butt welding fitting thickness is generally equal to pipe to which the
fitting is welded as per ASME 36.10
Page 30
4- Gaskets
Gaskets are used to create a static seal between two stationary members
of a mechanical assembly and to maintain that seal under operating
conditions which may vary dependent upon changes in pressures and
temperatures.
Page 31
Gasket Types- Metallic Gaskets
Shape: Octagonal and Oval
Size: R, RX or BX number
Material: SS-304/316/321/347/410/F-5, Soft iron D, Hasteloy

Inconel & Monel
Maximum P-T rating: 150-5000 Class
Standard: ASME B16.20
Application: Flanges of ASME B 16.5, ASME B 16.47, or API
Specification 6A).
Page 32
Page 33
Page 34
Gasket Types- Semi Metallic - Spiral Wound
Application: Flanges of ASME B16.5 & B16.47

Standard: ASME B16.20
Page 35
Page 36
Page 37
Page 38
Page 39
MODULE 2
WELDING
1-Welding Processes
41
Shielded Metal Arc Welding
Page 42
42
Tungsten Arc Welding
Page 43
43
Gas Metal Arc Welding
Page 44
44
Submerged Arc Welding
Page 45
45
2-Welding symbols
Page 46
Page 47
Page 48
COPYRIGHT 1999 American Welding Society, Inc. Information Handling Services,
September 10, 1999 06:07:26
06:07:26
Page 49
COPYRIGHT 1999 American Welding Society, Inc. Information Handling Services,
September 10, 1999 06:07:26
06:07:26
3-Welding electrodes identification
AWS 5.1 Electrodes, SMAW Carbon steel Electrodes
The American Welding Society (AWS) numbering system can tell a welder
quite a bit about a specific stick electrode including what application it
works best in and how it should be used to maximize performance. With
that in mind, let's take a look at the system and how it works.
The prefix "E" designates an arc welding electrode. The first two digits of
a 4-digit number indicate minimum tensile strength. For example, E6010
is a 60,000 psi tensile strength electrode.
E 60 1 0
Electrode Tensile Strength Position Type of Coating and Current
Page 50
Welding electrodes identification
The next to last digit indicates position. The "1" designates an all position
electrode, "2" is for flat and horizontal positions only; while "4" indicates
an electrode that can be used for flat, horizontal, vertical down and
overhead. The last 2 digits taken together indicate the type of coating and
the correct polarity or current to use.
E6010
DC only and designed for putting the root bead on the inside of a piece of
pipe, this is the most penetrating arc of all. It is tops to dig through rust, oil,
paint or dirt. It is an all-position electrode .
E7018
A low-hydrogen, usually DC, all-position electrode used when quality is an
issue or for hard-to-weld metals. It has the capability of producing more
uniform weld metal, which has better impact properties at temperatures
below zero.
Page 51
Page 52
Page 53
AWS 5.18 Electrodes, GTAW Carbon steel Electrodes
ER70S-3
(ER) Electrode Rod that will produce weld metal of a minimum 70,000psi
tensile strength (70); (S) is a solid bare wire or welding rod; of a specific
chemical composition (3) .
Page 54
Page 55
4-Welding procedure specifications
Page 56
5-Discontinuities.
Typical discontinuities found in welds are:
1. Porosity 5. Overlap
2. Incomplete fusion 6. Cracks

7. Slag inclusions
3. Incomplete penetration
8. Excessive reinforcement
4. Undercut
While code requirements may permit limited

amounts of some of these discontinuities, cracks,
and incomplete fusion defects are never allowed.
Page 57
57
Page 58
Page 59
6-Introduction to NDT.
Overview of Six Most Common NDT Methods
Page 60
Definition of NDT
The use of noninvasive

techniques to determine
the integrity of a material,
component or structure
or
quantitatively measure
some characteristic of
an object.
i.e. Inspect or measure without doing harm.
Page 61
What are Some Uses
of NDE Methods?
Flaw Detection and Evaluation

Leak Detection
Location Determination
Dimensional Measurements
Structure and Microstructure Characterization
Estimation of Mechanical and Physical Properties
Stress (Strain) and Dynamic Response Measurements
Material Sorting and Chemical Composition Determination
Page 62
When are NDE Methods Used?
There are NDE application at almost any stage

in the production or life cycle of a component.
To assist in product development
To screen or sort incoming materials
To monitor, improve or control manufacturing
processes
To verify proper processing such as heat treating
To verify proper assembly
To inspect for in-service damage
Page 63
Six Most Common NDT Methods
Visual
Liquid Penetrant
Magnetic
Ultrasonic
Eddy Current
X-ray
Page 64
Liquid Penetrant Inspection
A liquid with high surface wetting characteristics is

applied to the surface of the part and allowed time to
seep into surface breaking defects.
The excess liquid is removed from the surface of
the part.
A developer (powder) is applied to pull the
trapped penetrant out the defect and spread it on
the surface where it can be seen.
Visual inspection is the final step in the process.
The penetrant used is often loaded with a
fluorescent dye and the inspection is done under
UV light to increase test sensitivity.
Page 65
Magnetic Particle Inspection
The part is magnetized. Finely milled iron particles coated with a dye
pigment are then applied to the specimen. These particles are attracted
to magnetic flux leakage fields and will cluster to form an indication
directly over the discontinuity. This indication can be visually detected
under proper lighting conditions.
Page 66
Radiography
The radiation used in radiography testing

is a higher energy (shorter wavelength)
High Electrical Potential
version of the electromagnetic waves that
we
see as visible light. The radiation can Electrons
come from an X-ray generator or a + -
radioactive source.
X-ray Generator
or Radioactive
Source Creates
Radiation
Radiation
Penetrate
the Sample
Exposure Recording Device
Page 67
Film Radiography
The part is placed between the radiation

source and a piece of film. The part will
stop some of the radiation. Thicker and
more dense area will stop more of the
radiation.
The film darkness
(density) will vary with
the amount of radiation
X-ray film reaching the film through
the test object.
= less exposure
= more exposure
Page 68 Top view of developed film
Radiographic Images
Page 69
Eddy Current Testing
Coil's
Coil magnetic field
Eddy current's
magnetic field
Eddy
currents
Conductive
material
Page 70
Eddy Current Testing
Eddy current testing is particularly well suited for detecting surface

cracks but can also be used to make electrical conductivity and coating
thickness measurements. Here a small surface probe is scanned over
the part surface in an attempt to detect a crack.
Page 71
Ultrasonic Inspection (Pulse-Echo)
High frequency sound waves are introduced into a material

and they are reflected back from surfaces or flaws.
Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
showing the depth of features that reflect sound. f
initial
pulse
back surface
echo
crack
echo
crack
0 2 4 6 8 10 plate
Oscilloscope, or
Page 72
flaw detector
screen
Module 3
Hot Tapping Requirements
1- Definition
Hot Tapping is the precise process of drilling a hole in an on- stream piping
system without spilling its contents or interrupting its flow.
or in a practical sense
Hot Tapping is a means by which access is made to the inside of an
operational pipeline, using either a drill or a circular cutter. Applications
include attachment of a branch connection to the line, installation of an
internal probe or monitor, and to stop or redirect flow in a line for
maintenance or repair purposes.
Implies positioning a branch fitting on an operating pressurized line,
flowing or stagnant. Then cutting a hole in the run through the branch to
allow connection to the flowing media. Normally implies using a welded
fitting.
Page 74

Typical Hot Tapping Procedure
(Shown: Standard Valve used 3.A Tapping Machine is installed on 4.The valve is closed, and
when tapping to install lateral
the fitting, and the valve is opened. After the tapping machine is
lines.
pilot drill penetrates, the tapping machine removed. A branch
SANDWICH Valve fills with product, and air is purged
Option allows temporary connection is added, and the
from the housing. The tap is make valve is opened. The new
plugging operation.) through the line and the coupon is connection is ready to put
retained.
1.A fitting is permanently into service. This field-
secured to the line. proven Procedure is quick
2. A permanent valve is and precise.
installed on the fitting.
Page 75

Coupon is removed by Tapping Cutter
Coupon is Retained by Pilot Drill U-Rods
Page 76
2- Purpose of Hot Tapping.
Hot tapping is usually performed when it is not feasible, or is impractical,

to take the equipment or piping out of service, or to purge or clean it by
conventional methods. With proper review to determine that a hot tap is
appropriate, and development and conformance to job specic
procedures, many hot tap connections have been safely made without
interfering with the process operation.
Page 77
3-Parameters that affect Hot Tapping.
3.1Internal pipeline condition
3.1.1Content :
Welding and hot tapping should not be performed on piping or equipment
containing the following materials:
a. Vapor/air or vapor/oxygen mixtures near or within their ammable
explosive range.
b. Oxygen or oxygen enriched atmosphere.
c. Compressed air systems, unless known to be free of ammables and
combustibles
d. Hydrogen
e. Temperature-sensitive, chemically reactive materials
f. Caustics, amines, and acids (such as HF acid)
g. Certain unsaturated hydrocarbons (such as ethylene)
Page 78
3.1.2 Flow in lines
Higher ow increases the weld cooling rate and the risk of cracking.
Therefore, when welding, it is desirable to provide some minimum level of
ow while avoiding high ow rates. The need for a minimum level of ow
is a trade-off between the need to minimize the risks of burn-through and
cracking.
For metal thickness between 1/4 in. (6.4 mm) and 1/2 in.(12.7 mm), ow
also increases the weld cooling rate and risk of cracking. Minimizing the
ow rate reduces the risk of cracking and keeps the risk of burn through
low. For metal thickness greater than 1/2 in. (12.7 mm), the effect of ow
on both weld cooling rates and the risk of burn-through may be negligible.
Recommended flow rate during welding
0.4<X<1.2 m/s in case of liquid.
0.4< X< NOLIMIT in case of Gas.
Page 79
3.1.3 Pipe Line content pressure & Temperature
The pipeline content pressure and temperature should not exceed the
allowable pressure / temperature rating of the used hot tapping machine.
the leak test pressure for tapping machine and fitting should not exceed 1.1
of the pipeline operating pressure during tapping operation.
3.2 Pipeline Specification
3.2.1 pipeline material and grade.
Pipeline material and grade should be identified in order to select :
1. Suitable pilot drill and cutter material.
2. Suitable welding procedure specification.
Page 80
3.2.2 pipeline metal thickness and outer diameter
The piping or equipment base metal thickness must provide support for
the new connection and the hot tapping machine. Alternately, reinforcing
pads or auxiliary support of the hot tapping machine may be provided.
A minimum base metal thickness of 3/16 in. (4.8 mm) is recommended for
most applications of welding and hot tapping. The actual minimum
thickness is a function of the thickness required for strength, plus a safety
factor, usually 3/32 in. (2.4 mm), to prevent burn through.
Pipeline outer diameter , wall thickness and the required branch
connection diameter are determined the selection of branch connection
type (weldolet , split tee , --), and also determined the type of cutter to be
used in case of flat plate condition.
Page 81
3.3 branch connection

3.3.1 branch connection size & internal diameter
It Should be specified as it affect cutter size and tapping machine
selection.
3.3.2 branch connection length
Branch connection length (top of flange top of pipe) should be
measured .
Page 82
3-Parameters that affect Hot Tapping
3.4 valves
The hot tap valve to be used must be of adequate size and rating, be of
proper metallurgy, and be a full opening valve.
The hot tap valve should be tested for seat leakage prior to installation
(see API Std 598).
During installation the valve should be centered on the nozzle ange or
xture.
Run the boring bar through the valve opening to be sure the cutter does
not jam or drag.
Valve face to face dimensions must be determined.
Page 83
Hot Tapping Application Data Sheet
Page 84
4- Hot Tapping Check List
Page 85
Page 86
Page 87
Hot Tapping Simulation
Simulate tapping machine in workshop
Tapping machine cutter & pilot drill
Page 89
Standard cutter & tank cutter
Page 90
Machine installation
Page 91
Coupon
Page 92
References
ASME B 16.5
ASME B 16.47
ASME B 36.10
AWS A 5.1
AWS A 2.4
AWS A 5.18
API 6A
API RP 2201
TDW hot tapping procedure and application by William Jarvis
Piping fundamentals by Mohinder L Nayyar, Bechtel Power Corporation
Page 93
Prepared by Eng.Wael Elariny
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Hot Tapping Requirement

Prepared by Eng. Wael Elariny

Piping is an assembly of components that include

1. Carbon steels: used for normal corrosion conditions within a

Nominal pipe size (NPS) is a dimensionless designator of pipe size. It

Diameter nominal (DN) is also a dimensionless designator of pipe size in

A flange is a piping element that connects pipes, fitting or valves together.

No. Flange type Service conditions

Orifice flange ASME B 16.36

Flat face (FF)

As per ASME B16.5 / ASME B 16.47 these are combinations of pressure

A fitting is a piping element that connects a pipe or flange in order to

Material: SS-304/316/321/347/410/F-5, Soft iron D, Hasteloy

Application: Flanges of ASME B16.5 & B16.47

Typical discontinuities found in welds are:

2. Incomplete fusion 6. Cracks

While code requirements may permit limited

Overview of Six Most Common NDT Methods

The use of noninvasive

i.e. Inspect or measure without doing harm.

Flaw Detection and Evaluation

There are NDE application at almost any stage

A liquid with high surface wetting characteristics is

The radiation used in radiography testing

Exposure Recording Device

The part is placed between the radiation

Eddy current testing is particularly well suited for detecting surface

High frequency sound waves are introduced into a material

Typical Hot Tapping Procedure

Coupon is removed by Tapping Cutter

Coupon is Retained by Pilot Drill U-Rods

Hot tapping is usually performed when it is not feasible, or is impractical,

3.3 branch connection

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