Lessons

Learned
From Natural Gas STAR Partners

USING HOT TAPS FOR IN SERVICE PIPELINE CONNECTIONS

Executive Summary
Natural gas transmission and distribution companies need to make new connections to pipelines many times a
year to expand or modify their existing system. Historically, this has necessitated shutting down a portion of the
system and purging the gas to the atmosphere to ensure a safe connection. This procedure, referred to as a
shutdown interconnect, results in methane emissions, loss of product and sales, occasionally customer incon­
venience, and costs associated with evacuating the existing piping system.

Hot tapping is an alternative procedure that makes a new pipeline connection while the pipeline remains in
service, flowing natural gas under pressure. The hot tap procedure involves attaching a branch connection and
valve on the outside of an operating pipeline, and then cutting out the pipe-line wall within the branch and
removing the wall section through the valve. Hot tapping avoids product loss, methane emissions, and disruption
of service to customers.

While hot tapping is not a new practice, recent design improvements have reduced the complications and uncer­
tainty operators might have experienced in the past. Several Natural Gas STAR transmission and distribution
partners report using hot tap procedures routinely—small jobs are performed almost daily while larger taps
(greater than 12 inches) are made two or three times per year.

By performing hot taps, Natural Gas Star partners have achieved methane emissions reductions and increased
revenues. Gas savings are generally sufficient to justify making all new connections to operating lines by hot
tapping. The payback period for utilizing hot tapping is often immediate.

Method for Volume of NG Value of NG Other Capital Other Payback

Reducing Gas Savings Savings Savings Cost Cost 4 (Months)
Loss (Mcf/yr) ($/yr) ($) ($) ($/yr)

Hot Tap 24,400 73,3202 6,8403 36,200 43,000 12

Connection 1

1
Annual savings and costs are based on an average 320 hot taps (of various sizes) per year.
2
Assumes a natural gas price of $3.00/Mcf.
3
Other savings shown are for inert gas.
4
Other cost includes the O&M and contract services cost.

This is one of a series of Lessons Learned Summaries developed by EPA in cooperation with the natural gas industry on superior
applications of Natural Gas STAR Program Best Management Practices (BMPs) and Partner Reported Opportunities (PROs).
 In natural gas transmission and distribution systems, it is frequently neces­
Technology sary to relocate or expand existing pipelines, install new valves or repair old
Background ones, install new laterals, perform maintenance, or access lines during emer­
gencies. Historically, it has been common practice to shut down the portion
of the system during the alteration, vent the gas within the isolated segment,
and purge the pipeline with inert gas to ensure a safe connection.

The procedure for performing the shutdown interconnect differs slightly de-
pending on system pressure. In high-pressure systems, the surrounding
valves are closed to isolate the pipeline segment and additional stoppels
(inserted plugs) are placed next to the valves to prevent natural gas leakage
and improve the safety conditions at the interconnection site. In a low-pres­
sure system, the length of pipeline that is shutdown is typically much shorter.
Rather than shutting the surrounding valves, stoppels are used to isolate the
portion of the pipeline directly around the area of the tap. In both cases, the
gas in the isolated pipeline segment is vented and the line is purged.

The impacts associated with performing a shutdown interconnect are both

economic and environmental. Gas vented from the pipeline segment repre­
sents a loss of product and an increase in methane emissions. In addition,
removing a pipeline segment from service can occasionally cause gas serv­
ice interruptions to customers. For example, a shutdown connection on a
steel line can require one to three or more days of pipeline outage and pos­
sible interruption of natural gas shipments in addition to the release of
methane to the atmosphere.

Hot tapping is an alternative technique that allows the connection to be

made without shutting down the system and venting gas to the atmosphere.
Hot tapping is also referred to as line tapping, pressure tapping, pressure
cutting, and side cutting. The process involves attaching branch connections
and cutting holes into the operating pipeline without interruption of gas flow,
and with no release or loss of product. Hot taps permit new tie-ins to exist­
ing systems, the insertion of devices into the flow stream, permanent or
temporary bypasses, and is the preparatory stage for line plugging with
inflatable, temporary balloon plugs (stoppels).

Hot tapping equipment is available for almost any pipeline size, pipe mate-
rial, and pressure rating found in transmission and distribution systems. The
primary equipment for a typical hot tap application includes a drilling ma-
chine, a branch fitting, and a valve. Hot tapping equipment is described be-
low and shown in Exhibit 1.

2
★ Drilling machine. The drilling machine generally consists of a mechani­
cally driven telescoping boring bar that controls a cutting tool. The cut­
ting tool is used to bore a pilot hole into the pipeline wall in order to cen­
ter a hole saw that cuts out the “coupon,” or curved section of pipeline
wall.
★ Fitting. Connection to the existing pipe is made within a fitting, which
can be a simple welded nipple for small (e.g., one inch) connection to a
larger pipeline, or a full-encirclement split-sleeve tee for extra support
when the branch is the same size as the parent pipeline. The tee wraps
completely around the pipeline, and when welded, provides mechanical
reinforcement of the branch and carrier pipe.
★ Valve. The valve on a hot tap connection can be either a block valve or
a control valve for the new connection, and must allow the coupon (sec­
tion of pipeline wall cut out by the drilling machine) to be removed after
the cutting operation. Suitable valves include a ball or gate valve, but not
a plug or butterfly valve.

Exhibit 1: Schematic of Hot Tapping Machine with Profile

3
 Exhibit 2 provides a general schematic of a hot tapping procedure. The
basic steps to perform a hot tap are:

1. Connect the fitting on the existing pipeline by welding (steel), bolting

(cast iron), or bonding (plastic) and install the valve.
2. Install the hot tap machine through the permanent valve.
3. Perform the hot tap by cutting the coupon from the pipeline through
the open valve. A special device retains the “coupon” for removal af­
ter the hot tap operation. Withdraw the coupon through the valve
and close the valve.
4. Remove the tapping machine and add the branch pipeline. Purge
oxygen, open the valve, and the new connection is put into service.

Exhibit 2: Schematic of Hot Tapping Procedure

Hot taps can be vertical, horizontal, or at any angle around the pipe as long
as there is sufficient room to install the valve, fitting, and tapping machine.
Current technology allows for taps to be made on all types of pipelines, at all
pressures, diameters, and compositions, even older pipes merging with
new. New, lightweight tapping machines are also available that allow a hot
tap to be performed by a single operator, without additional blocking or
bracing.

4
 Safety manuals and procedural outlines are available from the American Pe­
troleum Institute (API), American Society of Mechanical Engineers (ASME),
and other organizations for welding on in-service pipelines for all sizes, flow
rates, and locations. These manuals provide information on what to consider
during welding, including burn-through prevention, flow in lines, metal thick­
ness, fittings, post weld heat treatment, metal temperature, hot tap connec­
tion and welding design, and piping and equipment contents.

Vendor manuals and equipment catalogues are also good sources for deter-
mining which size and type of equipment is most appropriate. Several ven­
dors have published comprehensive outlines and guides for performing hot
tap procedures, including information on tapping on various materials, job-
site evaluation and preparation, selection and installation of fittings and other
equipment, and safety precautions. Most importantly, because this is a haz­
ardous procedure, each potential hot tap must be evaluated on a case-by-
case basis and a detailed, written procedure should be prepared or
reviewed before starting each job to ensure that all steps are taken properly
and safely.

Key economic and environmental benefits of employing hot tapping proce­

Economic and dures instead of shutdown connections include:
Environmental
★ Continuous system operation—shutdown and service interruptions are
Benefits avoided.
★ No gas released to the atmosphere.
★ Avoided cutting, realignment and re-welding of pipeline sections.
★ Reduction of costs associated with planning and coordination—meet­
ings, schedules, paperwork, lost production, and direct manpower.
★ Increased worker safety.
★ Elimination of obligations to notify customers of gas outages.
By ensuring that best practices are followed when performing a hot tap, the
time required for the procedure, as well as the potential for failure, is re­
duced.

Operators can assess the economics of performing a hot tap as an alterna­

Decision tive to a shutdown connection by following the five steps below:
Process
Step 1: Determine physical conditions of the existing line. In preparation
for a hot tap project, operators will need to determine the maximum operat­
ing pressure (during the hot tap), type of pipe material (steel, cast iron, plas­
tic), and condition of the parent pipeline (internal/external corrosion, wall
thickness) to assure a safe project. A hot tap connection can be made on a
pipeline only where the parent pipe material is in good condition. Other
conditions to evaluate include the location of nearby valves for emergency

5
 isolation in the event of an accident, the desired tap diameter, working space
Five Steps for Assessing Hot Tap around the connection, location of other pipeline welds, and imperfections or
Economics: obstructions. Operators should also determine if the line is “looped,” as
many gas transmission companies avoid operational disruptions by shifting
I. Determine physical conditions of existing
line. the load to a parallel line. It is advisable to develop and follow a written plan
2. Calculate cost of performing a shutdown to assure full and proper evaluation of a future connection.
interconnect.
3. Calculate the cost of a hot tap procedure.
Step 2: Calculate cost of performing a shutdown interconnect. The cost
of an actual project would include direct costs such as material and equip­
4. Evaluate the gas savings benefits of hot
tapping. ment, welding requirements, quality control, blowdown and purge costs,
5. Compare the options and determine the labor, and scheduling expenses. Additional indirect expenses or “hidden”
economics of hot tapping. costs might include the cost of shut-off valves, advertising if service is to be
interrupted, relighting of customer services, and excavating for stopples and
purge connections. Operators would be advised to reference historical data
to determine these costs.

For the purposes of this scoping analysis, material and labor costs for cut­
ting out the line section and welding in a tee connection in the shutdown
method are assumed to be comparable to the cost of welding on the fitting
and performing the hot tap when the branch connection is the same size as
the pipeline. However, the costs of the gas lost through venting and inert
gas purging are unique to the shutdown interconnect.

The formulas used to determine the cost of a shutdown interconnect are

shown in Exhibit 3. For these calculations, low pressure is defined as less
than 2 psig.

For comparative purposes, calculating the cost of a shutdown interconnect

should take into consideration a multiple-project scenario. This multiple-proj­
ect perspective allows for a more complete comparative cost analysis given
the up-front capital costs of owning and operating a hot tap machine and
the need to perform several interconnections throughout a given year. Exhibit
4 illustrates how the cost calculations in Exhibit 3 can be applied in a multi­
ple connection scenario. The hypothetical situation presented includes sev­
eral projects on pipelines of various sizes and pressures. Cost calculations,
however, are only provided for the 4-inch pipeline scenario and only cover
direct costs.

6
Exhibit 3: Calculating the Cost of Shutdown Interconnect

Given:
D = diameter of pipeline (inches)
T = taphole diameter (inches) - for low pressure shutdown with tapholes for stoppers
L = length of pipeline between tapholes (feet) - for high pressure shutdown
P = line pressure (psia for low pressure, psig for high pressure)
Ppgas = current purge gas market price ($/Mcf) - assumed $4/Mcf

Pg = current gas market price ($/Mcf) - assumed $3/Mcf

Ce = cost of extra excavation, use company records ($)

Cp = cost of purge connections and excavation

Cs = cost of hidden shutdown expenditures, see Appendix ($)

Cf = cost of fittings, see Appendix ($)

Time Taphole is open = from prior experience (minutes)

Calculate Direct Costs:

1.

2.

3.
4.

5.

6.

Calculate Indirect Costs:

1. Calculate Ce = cost of extra excavation for tie-in ($)

2. Calculate Cp = cost of purge connections ($)

3. Calculate Cs = cost of hidden shutdown expenditures ($)

4. Calculate Cf = cost of fittings ($)

5. Calculate Ci = indirect costs ($) = Ce + Cp + Cs + Cf

Calculate Total Costs:

Calculate Ctotal = total cost ($) = Cg + Cpgas + Ci

Source: Pipeline Rules of Thumb, p. 270 and p. 278

7
 Exhibit 4: Hypothetical Scenario and Example Calculation of Lost Gas and
Purge Gas Costs for a Shutdown Interconnect

Given:
A pipeline company requires numerous shutdown or hot tap connections as follows:
Pipeline Diameters, Inches 4 8 10 18
Pipeline Pressures, psig 350 100 1,000 200
Pipeline Lengths , miles
1 2
2 1 3 2
Annual Taps , number
3
250 30 25 15
(1) Calculate: Vg = Volume of Natural Gas Lost

Vg (Mcf)

Vg

Vg

(2) Calculate: Vpgas = Volume of Purge Gas 4

Vpgas (Mcf)

Vpgas

Vpgas

(3) Calculate: Value of Gas Lost by Shutdown Interconnects (Including Purge Gas)
Cost
Cost
Cost = $74 for each of the 4 inch pipeline shutdown interconnects

1
Isolation length between block valves or stoppers
2
Formula requires length in feet. 1mile = 5,280 feet.
3
Scenario is based on partner and vendor information
4
Inert gas assumed to be nitrogen

Again, individual operators will need to reference company records to deter-

mine the exact procedures and factors to use when performing shutdown
interconnects. The procedures described above are general guidelines for
preliminary economic assessment and can differ from company to company.
Additional factors that are company specific include gas leakage past the
pipeline valves on both ends of the shutdown, number of stoppers, tap
holes for venting and purging, and type of purge gas. Leakage is particularly
important as large pipeline block valves can leak significant volumes of gas
because they are used infrequently and the valve seat can accumulate
debris that inhibits a tight seal. The volume of leakage is highly variable,
dependent on valve type, age, pipeline pressure and service (dry gas causes
much less corrosion and accumulation of debris than wet gas). If a partner’s
individual evaluation following this lesson learned results in marginal eco­
nomic justification, then company experience on pipeline valve leakage
should be factored in to improve the economics.

Step 3: Calculate the cost of a hot tap procedure. When comparing the
up-front costs of hot tapping with shutdown interconnects the only signifi­
cant difference is the cost of the hot tap equipment. The tee fitting or full
encirclement sleeve, and the valve have nearly the same cost for either
method when the branch is essentially the same size as the pipeline (infor­
mation on fitting types and costs is shown in the Appendix). The cost of
welding a full encirclement sleeve is nearly the same as the cost of welding a
tee fitting in a line. Labor cost for cold cutting the pipeline and hot tap cut­
ting out a coupon are sufficiently close for this type of feasibility evaluation.
Maintenance costs apply only to hot tap equipment, such as drill sharpening
and other equipment care and replacement.

Tapping machines come in several sizes, and a single machine can perform
hot taps from 3 to 12 inches. Less expensive machines can be purchased
to perform small (e.g., 1 to 3 inch) taps. In general, capital costs for purchas­
ing the hot tap machines typically used by gas companies for the most
common sized connections range from $13,200 to $23,000.

Equipment cost is normally a one-time capital expenditure and can be de­

preciated over the life of the equipment, typically 15 to 20 years. Each com­
pany, however, should calculate the depreciation in the same manner used
for other equipment purchases (e.g., amortized, over a fixed period of time).
This should be considered in conjunction with how often the machine will be
used in the future. To make this determination, operators should look at

9
 company records to determine the number of times similar connections
have been performed.

Typically, a company that performs several hot taps a year will find it eco­
nomical to own the equipment, especially in sizes up to 12 inches, and to
maintain trained personnel to perform the service. These jobs are usually
simpler and require less specialized training than larger hot tap jobs. For
larger and less frequent hot taps a company might consider it more cost
effective to hire a contractor who will supply the equipment and trained
personnel. Most hot tap vendors will supply all necessary tapping equip­
ment, including the drilling machine, fittings, valves, cutters, and repair
services. The majority of vendors also offer contract services for larger or
infrequent jobs, or will rent out the tapping equipment. Supplying support
services, such as excavation, welding, and cranes, can reduce the costs of
using an outside contractor.

Other factors, such as the line material and thickness, system pressure, and
temperature, should also be considered when determining the alterna-tives
of purchasing hot tapping equipment or hiring contractors. A company
should evaluate how often the tapping equipment would be used and if they
would realize savings by owning and maintaining the equipment and training
operators.

Exhibit 5 presents ranges of hot tapping costs for both equipment purchase
and contracted services. The cost ranges shown include all materials;
addi-tional expenses will result from labor and maintenance expenditures,
as dis-cussed above. Vendors state that the operations and maintenance
(O&M) costs can vary greatly, depending on the number of taps performed
and equipment and procedural care.

10
 Exhibit 5: Hot Tap Expenses
Connection Capital Cost ($) Contracting Equipment
Size Service Cost O&M Cost
Machine 1 Material ($) ($/yr)

Small Taps 13,200 -

(<12”) 23,000 - - 500 - 5,000

Large Taps 100,000 -

(>12”) 200,0002 2,000 - 9,1202 1,000 - 4,000 -

1
Hot tap machines can last from 5 to 40 years. A company can perform as many as 400
small taps per year.
2
Most companies will find it more economical to contract out large hot tapping jobs, and
would not therefore incur these costs.
Note: Cost information provided by Hot Tap manufacturers and contractors. Prices are only
provided for the most economic options.

Exhibit 6 shows the equipment, O&M, and contractor services cost to per-
form the 320 taps per year in the hypothetical scenario first described in
Exhibit 4. The assumption is made that the 4”, 8”, and 10” taps (a total of
305 taps) would be performed by the company. Because few taps equal to
or larger than 18 inches are performed each year, these taps (a total of 15
taps) would be contracted to vendors. The equipment cost includes the
purchase cost of two small (<12”) tap machines. For the purpose of this
lessons learned, the average value of the purchase, O&M, and contracting
service costs listed in Exhibit 5 are used to complete the cost analysis for
the hypothetical scenario. Based on these assumptions the total equipment
cost is calculated at $36,200, the O&M cost at $5,500 and the contract
services cost at $37,500.

11
 Exhibit 6: Estimated Annual Hot Tap Costs for the Hypothetical Scenario
Given:
Equipment Cost per machine = $18,100 1
Operations and Maintenance (O&M) Cost per Machine = $2,750 1
Contract Services cost per tap = $2,500 1
Number of hot tap machines = 2
Number of contracted taps = 15 (all taps 12 inches and larger)
Calculate:
Total Equipment Cost = $18,100 * 2 = $36,200
Total O&M Cost = $2,750 * 2 = $5,500
Contract Services Cost = $2,500 * 15 = $37,500
1
Average costs from ranges in Exhibit 5

Step 4: Evaluate the gas savings benefits of hot tapping. Exhibit 7 pres­
ents the natural gas and purge gas savings associated with hot tapping on
small and large diameter high-pressure pipelines in the hypothetical scenario
of 320 taps per year. The values are calculated using the equations in exhibit
3, multiplied by the number of annual connections. Gas losses associated
with shutdown interconnects are the primary savings when these connec­
tions are made by hot tapping.

Exhibit 7: Estimated Annual Gas Savings for the Hypothetical Scenario

Tap Scenario 1 Annual Natural Gas Savings Purge Gas Savings 2 Total Gas
Savings 3
Taps
Pipelines Number Per Tap Mcf Annual Mcf Per Tap Mcf Annual Mcf $

4” pipeline 250 22 5,500 2 500 18,500

350 psig, 2 mile line

8” pipeline100 psig, 1 30 13 390 4 120 1,650

mile line

10” pipeline1,000 25 589 14,725 19 475 46,075

psig, 3 mile line

18” pipeline200 psig, 15 255 3,825 41 615 13,935

2 mile line

Total Annual 320 24,440 1,710 80,160

1
The sizes and number of taps from scenario given in Exhibit 4.
2
Example for 4-inch pipe interconnect shown in Exhibit 4.
3
Natural gas valued as $3 per Mcf, inert gas (nitrogen) valued at $4 per Mcf.

12
Step 5: Compare the options and determine the economics of hot tap-
ping. The economic analysis shown in Exhibit 8 compares the significant
cost and benefit differences between hot tapping and shutdown intercon­
nections for the hypothetical scenario of 320 taps per year. The significant
costs are the purchase, operation and maintenance of hot tapping equip­
ment and/or contracting for hot tapping services. In this scenario, both costs
are included: the purchase of two hot tapping machines for $36,200 for the
smaller sizes and contracting the 15 large taps at $37,500 per year. The
purchased hot tap machines are operated and maintained at $5,500 per
year. All these costs are calculated in Exhibit 6. Many expenses, including
the cost of fittings, valves and basic labor, are assumed to be similar in both
hot tap and shutdown procedures, and therefore can be excluded in the
comparative analysis. A more complete analysis can be done by evaluating
and including the company specific “hidden” costs per Exhibit 3.

The significant benefit differences are the reduction in natural gas loss by
eliminating venting and the inert purge gas used in the shutdown intercon­
nect procedure. As summarized in Exhibit 7, annual natural gas savings total
24,440 Mcf for the hypothetical hot tapping scenario, worth $73,320 per
year at $3 per Mcf gas price. The annual inert gas savings of 1,710 Mcf is
worth $6,840 per year at $4 per Mcf of nitrogen, for a total annual benefit of
$80,160. Additional benefits from avoiding gas leakage through pipeline
block valves during shutdown interconnect would further improve the hot
tapping economics.

Exhibit 8: Economic Analysis of Hot Tap Versus Shutdown

Year 0 Year 1 Year 2 Year 3 Year 4 Year 5

Capital Cost, $ (36,200) 0 0 0 0 0

Contract Service Cost, $ 0 (37,500) (37,500) (37,500) (37,500) (37,500)

O&M Cost. $ 0 (5,500) (5,500) (5,500) (5,500) (5,500)

Total Cost. $ (36,200) (43,000) (43,000) (43,000) (43,000) (43,000)

Natural Gas Savings. ($) 73,320 73,320 73,320 73,320 73,320

Inert Gas Savings, ($) 6,840 6,840 6,840 6,840 6,840

Net Benefit $ (36,200) 37,160 37,160 37,160 37,160 37,160

Payback (months) 12

IRR 113%

NPV1 $104,665

1
Net Present Value (NPV) based on 10% discount rate for 5 years.

13
 In conclusion, hot tapping has been found to be more cost effective than
shutdown interconnects. Even when the system must be taken out of serv­
ice, hot tapping presents opportunities for both time and cost savings. While
hot tapping is a practice that has historically been performed by companies
for reasons other than the gas savings, consideration of the methane reduc­
tion benefits can often serve to justify hot tapping over the shutdown inter-
connect procedure in a variety of circumstances.

One Vendor’s Experience

A vendor reports that, for a gas transmission client, one day of gas service in a
36” natural gas pipeline operating at 1,000 psig is worth $365,000 in gross rev­
enue. It would take approximately 4 days to perform a shut down connection at a
cost of $1.5 million, not including the cost of venting the pipeline contents in
order to perform the tie-in with shutdown. A hot tap connection would eliminate
this loss of revenue by enabling uninterrupted service.

Pipelines typically undergo several transformations each year. Performing hot

Lessons taps to make these connections and installations can reduce methane emis­
sions from pipelines and increase savings and efficiency. The following are
Learned
several lessons learned offered by partners and hot tap vendors:

★ Hot tapping has been performed by transmission and distribution com­

panies for decades. By evaluating the gas savings associated with this
practice, hot tapping can be used in many situations where it would not
ordinarily have been used.
★ The site for the branch weld must be free of general corrosion, stress
corrosion cracking, and laminations.
★ Hot tap should not be performed immediately upstream of rotating
equipment or automatic control valves, unless such equipment is pro­
tected from the cuttings by filters or traps.
★ For tapping on steel pipes, fittings generally consist of a welded branch
connection. However, when tapping into cast iron, asbestos cement, or
concrete, the fitting cannot be welded onto the existing header. Alterna­
tive fitting attachment techniques, such as a split cast iron compression
sleeve or a mechanical joint saddle, must be employed.
★ For plastic systems, the operator should ensure that the hot tapping fit­
tings are compatible with the type of plastic pipe in the system and ap­
propriate joining methods are used. Vendors can supply suitable fittings
and tools for almost every kind of plastic system.
★ If hot tapping has not been performed in the past, a hot tapping proce­
dure should be developed and personnel trained. Be sure to include in-

14
 structions concerning possible burn through or hydrogen cracking dur­
ing welding.
★ All equipment must meet minimum industry and federal standards for
pressure, temperature, and operating requirements.
★ If conditions of temperature, pressure, pipe composition, or tap diameter
are encountered that are unusual for your system, be sure to consult the
manufacturer of the tapping equipment or fittings.
★ Industry and federal codes and standards should be consulted for more
specific specifications (e.g., ASME B31.8, API 2201, API 1104, API
D12750, 49 CFR 192).
★ Record emissions reductions associated with using hot taps and submit
them with your Natural Gas STAR Annual Report.

15
 American Petroleum Institute. Procedures for Welding or Hot Tapping on
References Equipment in Service. API Recommended Practice 2201, Third and Fourth
Editions, October 1985 and September 1995.

American Petroleum Institute. Welding of Pipelines and Related Facilities,

Publication No. 1104, 19th Edition, September 1999.

American Society of Mechanical Engineers (ASME). ASME Code for Pressure

Piping, B3I, ASME B31.8-1995 Edition.

Bruce, William A. Edison Welding Institute. Personal contact.

Burns, David. TransCanada Hot Taps. Personal contact.

Chaput, James. Michigan Gas. Personal contact.

Chila, Vern. International Piping Services Company. Personal contact.

Davaney, Tom. Con Edison. Personal contact.

Doig, Deanna. TransCanada Alberta System, TransCanada Pipelines.

Personal contact.

Hranicka, Anthony. Con Edison. Personal contact.

Hydra-Stop, Inc. A Pressure Installation Primer: Basic Information and

Procedures for Line Tapping and Linestopping.

LaShoto, Paul. Bay State Gas. Personal contact.

McAllister, E.W. Editor. Pipeline Rules of Thumb Handbook. Fourth Edition,

Gulf Publishing Company.

McElligott, John A., John Delanty, and Burke Delanty, “Use of Hot Taps for
Gas Pipelines Can be Expanded,” Oil and Gas Journal, 11/30/98.

McMicken, Mike and Brian Boucher. Team Industrial Services, Inc. Personal
contact.

Petolick, Don and Gary Vanderhye. Hydra-Stop, Inc. Personal contact.

Rodgers, Erick. Topaz Inc. Personal contact.

Smith, Sharlye. Mueller Co. Personal contact.

Vandervort, Dal and T.D. Williamson. Inc. Personal contact.

Venugopal, Shrikanth. TransCanada Transmission. Personal contact.

Tingley, Kevin. EPA Natural Gas STAR Program. Personal contact.

U.S. Code of Federal Regulations. Title 49, Part 192 (49 CFR 192), Subpart
D, “Transportation of Natural and Other Gas by Pipeline: Minimum Federal
Safety Standards; Design of Pipeline Components”.

16
 Valves. Valves used in hot tapping are typically full opening ball or wedge
Appendix: gate valves. Pipe suppliers can usually supply prices for valves and fittings, if
provided with the scenario information including pipe size, outlet size, and
Supplemental line content, pressure, and material.
Information
Tees/Fittings. There are several different types of mechanical and welded
fittings applicable to hot tapping including weldolet, threadolet, scarfed nip­
ple, tapping tee, or full encirclement saddle. The most common tapping fit­
ting is a split cast iron sleeve. Fittings are typically priced by size, flange
(ANSI/pressure) rating, and any special characteristics. Typical vendor fitting
costs are presented below.

TD Williamson - Full Split Tee Costs ($)

Size (pipeline x outlet)

16”x16” $2,000

18”x18” $3,000

20”x20” $5,000

24”x24” $6,000

30”x30” $9,000

40”x16” $2,500

60”x16” $2,500

Price estimates are for a 300# rating.

Fittings are also available for 150#, 400#, 600#, 900#, and 1,500# flange ratings and sizes
1” x 1” to 96” x 96”.

Topaz - Tapping Tee Costs ($)

Size (pipeline x outlet) 150# Flange Rating 300# Flange Rating 600# Flange Rating

2”x2” $386 $399 $443

4”x4” $407 $428 $481

12”x12” $1,394 $1,484 $1,624

20”x20” $3,645 $3,857 $4,290

12”x4” $1,248 $1,251 $1,347

20”x8” $1,428 $1,468 $1,521

Fittings are available for other sizes.

17
 Topaz - Full Encirclement Saddle Costs ($)
Size (pipeline x outlet) Part 1 Part 2

2”x2” $227 $189

4”x4” $227 $189

12”x12” $645 $539

20”x20” N/A $1,306

12”x4” $594 $495

20”x8” $1,303 $1,076

40”x16” N/A $3,493

Fittings are available for other sizes.

One of the possible hidden costs of a shutdown connection, if gas cannot

be supplied from alternate sources, can be the cost of relighting customers.
This process would require two visits, one to shut down and the second to
turn on and relight. Typically, a visit to a residential customer would take 15
to 30 minutes, and a visit to a commercial or industrial customer would take
approximately 1 hour. According to the Bureau of Labor Statistics, an
employee would be paid approximately $9.75 per hour for this work.

Cost of Relighting = [(No. of residential customers) * (0.38 hrs)]

+ [(No. of commercial/industrial customers) * (1 hr)] * $9.75/hr

It might not be possible to perform a shutdown connection during optimal

hours. Scheduling and additional planning might have to be completed to
arrange the construction and additional excavation necessary to shut
down the line, pay employees overtime, and advertise the shutdown to
customers. These costs are variable and will depend on the company and
internal fac-tors.

Other additional costs exist, such as scheduling, labor, overtime, and adver­
tising, but are unique to each company, and beyond the scope of this study.
These costs can be estimated based on past shutdown experience. An
operator should examine past records to determine what, if any, costs are
being avoided by performing a hot tap versus a shutdown connection.

18
1EPA
United States
Environmental Protection Agency
Air and Radiation (6202J)
1200 Pennsylvania Ave., NW
Washington, DC 20460

EPA430-B-03-010
December 2003