How to choose right equipment for pipeline tapping

Pipeline tapping, commonly referred to as hot tapping, is the practice of creating new connections to an operational pressurized pipeline without disrupting flow. Hot tapping is a standard practice in industries such as water, gas, oil, and chemical processing as it allows system expansions, maintenance work and sensor installations without disrupting operations.

Selecting the appropriate equipment is vital for both safety and efficiency. Selecting appropriate hot tapping equipment helps prevent leaks, manage pressure, and ensure controlled, precise taps - whether working on municipal water lines or industrial high-pressure systems, it reduces risks and supports reliable pipeline modification.

What Is Pipeline Tapping Procedure?

Pipeline tapping, or hot tapping, is a procedure for cutting into a live, pressurized pipe. The primary advantage is that the main pipeline remains operational during the process.

The procedure varies based on the system. Water pipe tapping often uses lower pressures and must adhere to sanitary requirements, particularly for drinking water. Tapping in oil, gas, or chemical pipelines frequently requires higher pressure ratings and stronger safety regulations due to the nature of the contents.

Pipeline tapping procedure is typically done for the following reasons:

  • Adding new branch lines.
  • Install flow meters, valves, or other components.
  • Making system modifications or repairs without stopping operations.

Understanding the Piping Hot Tapping Process

Hot tapping allows you to make modifications to a pressurized pipeline without shutting it down. Here's a step-by-step explanation of how the procedure usually works:

  • Prepare the Pipe: Clean the pipe surface and attach a hot tap saddle or sleeve to secure the tapping equipment.
  • Attach the Hot Tap Machine: Securely mount the tapping machine to the saddle or sleeve.
  • Drill the Tap Hole: Using a specialized cutter, drill through the pipe wall while keeping pressure under control.
  • Retrieve the Cutter: Once the hole has been created, retract the cutter into the machine.
  • Install the Branch Connection: Seal the opening and attach the new pipeline or equipment.

When performing hot tapping, it is essential to consider the pipeline's working pressure, flow, material type (steel, ductile iron, PVC, etc.), and temperature. Each element affects the selection of equipment and safety measures.

Essential Equipment Required for Pipeline Tapping

The use of the appropriate equipment is critical for successful pipeline tapping. The major tools are:

  • Tapping Machines: These come in three types: mechanical, pneumatic, and hydraulic, and allow operators to drill safely into pressurized pipes of various sizes and materials.
  • Hot Tap Saddles and Fittings: These attach the tapping equipment to the pipeline and offer a secure, leak-free connecting point.
  • Valves: Selecting the right valve is critical for managing flow after the tap. Ball valves, gate valves, and plug valves are common options, each with a different pressure and flow requirements.
  • Line Stopping Systems and Bypass Equipment: These enable sections of a pipeline to be isolated or bypassed during repairs or changes without shutting down the entire system.
  • Cutters and Pilot Drills: Precision cutting tools make the tap hole, while pilot drills guide the cutter to ensure accuracy and smooth operation.

A safe and effective tapping process requires equipment that is appropriate for the pipeline's size, pressure, and material.

Factors To Consider When Choosing Tapping Equipment

Tapping equipment must be matched to the specific requirements of each application. Several essential factors must be examined to match the tools with the specific requirements of the pipeline and job conditions:

  • Pipe Material and Size: Different materials (steel, PVC, and ductile iron) and pipe diameters require the use of specific tools and fittings to achieve a secure and safe tap.
  • Working Pressure and Temperature: To avoid problems during tapping, equipment must be rated for the pipeline's pressure and temperature.
  • Pipeline Contents: Whether the pipeline transports water, gas, steam, or chemicals impacts the materials used and the safety precautions used.
  • Environmental and Safety Regulations: Complying with local laws and industry standards is critical for protecting workers and the environment.
  • Accessibility and Site Conditions: Limited space, weather, and underground installations can all influence equipment selection and setup.
  • Flow Interruption Requirements: Determine if the system can be temporarily shut down or if continuous service must be maintained during tapping.

Considering these factors supports a controlled and reliable tapping process.

Safety Best Practices in Pipeline Tapping

When tapping pressurized pipes, safety is the primary priority. To minimize risk, implement the following fundamental practices:

  • Calibrate Equipment: Ensure that all tapping tools are correctly calibrated to operate safely and accurately.
  • Pressure Testing: Before you turn on the tap, check for leaks in the fittings and valve.
  • Wear PPE: Wear appropriate personal protective equipment, such as gloves, eye protection, and flame-resistant clothes.
  • Emergency Preparedness: Have shut-off valves and response plans ready in case of leaks or equipment failure.

These measures help to maintain safety and operational control throughout the tapping procedure.

Get The Right Equipment for Safe Pipeline Tapping

Choosing the right pipeline tapping equipment, including as tapping machines, hot tap saddles, valves, and cutting tools, is necessary for safe and efficient operation on pressurized systems. The right tools can help you reduce risk, preserve continuous service, and ensure precision while tapping a water pipe or operating in gas, oil, or chemical lines.

For expert support in selecting the ideal hot tapping equipment for your project, contact Petersen Products today by calling at 262-692-3100 or via email at sales@petersenproducts.com. 

Disclaimer: The information may be used but with no warranty or liability. This information is believed to be correct but should always be double-checked with alternative sources. Strictly adhere to and follow all applicable national and local regulations and practices.

Regardless of these comments, it is always necessary to read and understand manufactures instructions and local regulations prior to using any item.