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RISK IN THE HOT-TAP OPERATION

Conference Paper · June 2015

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 RISK IN THE HOT-TAP OPERATION
Dr. Cevat ÖZARPA
Director of Maintenance and Metering,
İGDAŞ, Istanbul Gas Distribution Industry and Trade Inc. Co., İstanbul, Turkey
[email protected]

M. Serhat ELHAN
Metallurgical Engineer, M.Sc.
UGETAM, International Gas Training, Technology and Research Center, İstanbul, Turkey
[email protected]

ABSTRACT
Hot-tap is a connection technique to take new branches from the existing pipeline which is
under pressure or in service. A special procedure is required to make a branch on the pipe
without leaking any of the line contents. There are also some problems that may arise of
situation during Hot-tap fittings welding operations and hot drilling, tapping and plugging
process. There are two primary concerns with welding on to the pipelines. The first concern
is to avoid “burning through” where the welding arc causes the pipe wall to be breached and
the second concern is the hydrogen cracking.
In the process, fracture of drilling Hole Saws, damage of the O-ring in the plugging,
mismatching of Plugging because of the absence of exact measures taken by the operators
and due to misalignment caused by manufacturing defects can be challenging at the hot-tap
fitting.
Qualification of Hot-tap fitting welders, drilling and plugging operators, occupational health
and safety and the quality of work are the important criteria for setting up procedures of
operations.
Since in-service welds that contact the carrier pipe are particularly susceptible to under
break or delayed hydrogen cracking, an inspection method that is capable of detecting these
cracks, particularly at the carrier pipe weld toe, should be used.
On the other hand, implementing the most updated new technological equipments
produced for high pressure gas transmission system brings some risk, problems and
prospects. It needs to increase the effectiveness of technology transfer by 3 steps. First step
covers Detection, Selection and Implementation. Second step covers Learning and
Assimilation and third step covers Development and Reproduction. In this study, we focus on
risk in the hot tap operation and our experience of the implementation of hot tapping
technologies by our company and describe how these were successfully applied in the
transmission of gas in Turkey.

Key Words: Hot-Tap Operation, Hot-tap fittings welding risk, burning through risk, hydrogen
cracking, drilling and plugging, effectiveness of new technology transfer.
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1. Introduction
A network of sophisticated pipeline systems transports oil, natural gas, and petroleum
products from fields of production and refineries around the world to consumers nearly in
every country.
It is well known that using pipelines is the best and cheapest way to carry both liquid and gas
products to very long distances. The cheapest transportation of natural gas or oil is pipeline
system. Because of that, thousand kilometers of pipeline have been constructed depending
on the number of oil and gas discoveries and their locations and on where markets are
growing. The ever-increasing demand for energy worldwide requires the constructions of
high-pressure gas transmission lines with maximized transport efficiency as well, so that the
cost of pipeline construction and gas transportation is limited.
There are three pipeline systems for natural gas supply. These are transmission lines,
distribution lines and domestic lines. Small diameter pipelines within house, called domestic
lines, are operated at very low pressure such as 21-300 mbar gauge. Gas transmission lines
carry natural gas from production areas to city utility companies and other customers. Gas
transmission lines deliver high pressure gas about 70 bar in Turkey. Distribution lines are
utilized to distribute natural gas to commercial, residential, and industrial users with a
pressure of 12-19 bar.
2. BACKGROUND
To maintain these systems effectively without interrupting the supply of products in the
pipelines, several techniques have been developed, such as line stopping and hot tapping. As
using an on-stream and under pressure drilling machine to cut a hole in an operating
pipeline allowing for a new take-off from the existing pipes. This process is done without any
product leakage or loss. Line stopping is a means of temporarily stopping flow in an
operating pipeline. Line stopping can be used to isolate piping system for repairs, alterations,
or relocations. Since the fittings need to be connected to the pipeline while in operation,
welding techniques XXI have to be carefully considered in order to obtain a reliable
connection between the fitting and the pipe. There are two welding seams to be carried out
on live pipe. The first one is longitudinal and the second one is circumferential. Not using
weld backing strips during welding for Longitudinal weld and excessive penetration will
cause a penetration on the wall of pipe in serves. This is also an increase in the longitudinal
stress in the pipe, causing inability of turning into drilling position of the hot-tap fitting
before the circumferential weld. While four welders are working in mutual on the Large-
scale hot-tap fittings, unbalanced heat input and unbalanced heat distribution of weld may
cause hydrogen cracks on the weld.
There are no particular difficulties for the longitudinal one but special care must be given to
the second one due to both risk of burn through and cooling effect of flowing products as
well as formation of hydrogen cracking in the weld. Application standards and codes of
practice ensure that a structure or component will have an acceptable level of quality and
satisfaction for the intended purpose. (4)

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The usage of recent technological process like hot-tap operation during taking branch from a
pipeline, relocation or repairing of pipelines keep gas in the pipes that would provide
economic and environmental advantages. (1)
3. ELEMENTS OF WELDING ON PIPELINE IN-SERVICE
The welding of hot-tap fittings on the active pipelines and drilling business are the last
proper techniques in terms of economy. On the other hand, companies can face some
difficulties, when applying this technology in their transmission and distribution lines.
Especially because of the difficulties in welding operation, the fittings manufacturers have
tried to adapt themselves to the special manufacturing programs and improved welding
manufacturing system.
An effective in-service welding program is one that includes sufficient safeguards to assure
that in-service welding is carried out in a safe manner and that sound welds fit for their
intended service are produced. (3)

The following is a list of topics that are common to many company standards for in-service
welding, along with some examples of specific elements and the important issues in practice
(3)

• Technical design – e.g., repair sleeve thickness, type of hot tap fitting for various
applications
• Restrictions and limitations – e.g., minimum required wall thicknesses, fire-safe work
environment
• Determination of critical parameters – e.g., flow rate, pressure, pipe material carbon
equivalent
• Selection of qualified welding procedure – e.g., appropriate for the application, qualified to
the appropriate code
• Preparation for welding – e.g., ensuring the welder has ample room to work and
electrodes are properly conditioned
• Welding requirements in the field – e.g., proper weld sequence is being followed, welding
parameters ranges are being observed
• Inspection and testing – e.g., inspection method, pressure testing of branches prior to
tapping
• Safety – e.g., precautions that should be taken for a given application, etc.

There are a number of commonly overlooked or misunderstood issues pertaining to welding

onto
in-service pipelines, which are often the subject of elements in company standards. These
include:

• Wall thickness limits to prevent burnthrough

• Pressure limits/pressure reduction requirements
• Flow rate limits
• HAZ hardness limits
• The importance of pipe material chemical composition

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• The importance of low hydrogen electrodes procurement, storage, and handling
• The importance of heat input level control
• Time delay prior to inspection (3)

Some remarks before making a Hot Tap can be stated as follows:

•A hot tap shall not be considered a routine procedure, but shall be used only when there is
no practical alternative.
•Hot Taps shall be installed by trained and experienced crews.
•It should be noted that hot tapping of sour gas lines presents special health and
metallurgical concerns and shall be done only to written operating company approved plans.
•For each hottap shall be ensured that the pipe that is drilled or sawed has sufficient wall
thickness, which can be measured with ultrasonic thickness gauges. The existing pipe wall
thickness (actual) needs to be at least equal to the required thickness for pressure plus a
reasonable thickness allowance for welding. If the actual thickness is barely more than that
required for pressure, then loss of containment at the weld pool is a risk.(2)
•Welding on in-service pipelines requires weld procedure development and qualification, as
well as a highly trained workforce to ensure integrity of welds when pipelines are operating
at full pressure and under full flow conditions. (2)

Wall thickness limits to prevent burnthrough;

Problems can occur with hot tapping when the risk of burn-through, unstable decomposition
of the flowing product and the risk of hydrogen cracking are not considered adequately.

Figure 1. Typical burnthrough on thick pipe

Burn-through occurs when welding onto a pressurised pipe if the unmelted area beneath the
weld pool is not strong enough to contain the internal pressure of the pipe. The greater the
wall thickness of the pipe, the less the risk of burn-through. Unstable decomposition of the
flowing product can cause violent reactions when heated under pressure; this is prevented
by taking special precautions to prevent the internal wall temperature exceeding a critical
temperature. This critical temperature is dependent on the nature of the flowing product.
(1)

Prior to in-service welding, the wall thickness should be checked using appropriate ultrasonic
testing equipment to ensure that the actual wall thickness does not differ greatly from the

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nominal wall thickness as a result of corrosion or erosion and that there are no material
defects in the repair area. (3)

Welding onto thinner wall materials is possible and considered routine by many companies
although special precautions are often specified. These precautions include minimizing the
penetration of the arc into the pipe wall by using a low-hydrogen process and a procedure
that limits heat input. For in-service welding applications where the wall thickness is less
than 6.4 mm (0.250 in.), thermal analysis computer models, such as the Battelle model or
the PRCI model can be used to predict safe heat input levels. For welding onto in-service
pipelines with wall thicknesses less than 6.4 mm (0.250 in.), it is inadequate to specify a wall
thickness limit alone. (3)

The minimum weldable thickness is numerically assessed in Battelle model work, as a

function of pressure during the welding operations of a corroded gas pipeline, according to
the approach by Battelle. The minimum weldable thickness is found to increase when the
flow rate of the transported gas in the section being repaired increases
- Increasing the thickness of the reinforcement the thickness of the pipe decreases the
stresses in the root area of the girth weld.
- Reducing the size of the fillet weld increases radial and hoop stresses, but longitudinal
stresses remain almost constant.
It is concluded that the minimum weldable thickness is 5 mm, for a nominal pipe thickness of
7.1 mm at Battelle model. Therefore, it is important to ensure that NDT (nondestructive
testing) inspection of the area to be welded would detect thickness losses of less than 2 mm
with precision, especially in the presence of corrosion pits and other defects of difficult
access with the normal ultrasonic transducers. Once minimum thickness is verified, abrupt
thickness changes should be eliminated by grinding to clean metal. (6)

The minimum weldable thickness strongly depends on weld penetration. Therefore,

deviations from the qualified weld procedure should be minimized. For the weld procedure
with 3 mm basic electrodes assessed in Battelle model, maintaining welding current in the
range around 120 A, strait beads and a weld speed of at least 10 cm/min is mandatory.

Figure 2. Hot Tap Welding

When the pressure during the welding operations is 100 % of the operative pressure, the
minimum weldable thickness is 4.65 mm, according to the approach by Battelle. For gas
pressures during welding

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of 80 % and 60 % of the operative pressure, the minimum thickness is 4.80 mm and 5.30
mm, respectively. The minimum weldable thickness increases when the flow rate of the
transported gas in the section being repaired (hot-tap fitting welding) increases. (6)

Pressure limit can be in the form of absolute pressure limits or formulas for calculating a
required pressure reduction prior to in-service welding. Pressure reductions are relatively
ineffective at preventing burnthrough and are often unnecessary. When the unmelted area
beneath the weld pool has been heated to a sufficient temperature (i.e., significantly above
982ºC), a burnthrough will occur even at very low pressures. Pressure reductions are,
therefore, relatively ineffective at preventing burnthrough. A more appropriate approach to
preventing burnthrough is to control inside surface temperature by limiting heat input to
that which is appropriate for a given application. Pressure reduction should be based on the
safety of the repair crew while working in the vicinity of a known defect in an operating
pipeline. (3)
(𝑡 − 𝑐)0.72
𝑃 = 2𝑆
𝐷
where
P = pressure (psi)
S = specified minimum yield strength of pipe (psi)
t = nominal pipe wall thickness (in.)
0.72 = pipeline design factor
D = nominal pipe diameter (in.)
c = allowance for heated metal loss of strength (3)

The stresses in sleeve material (fittings) increase when repair of hot-tap welding is done at
low pressure. (6)

Hydrogen cracking in weld metals;

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 Figure 3. Typical appearance of hydrogen cracking
The risk of hydrogen cracking is increased for hot tapping in comparison to other welding
situations, due to the flowing product increasing the rate of heat flow from the weld region.
This leads to shorter cooling times, with an associated increased risk of forming hard
microstructures and thus greater susceptibility to hydrogen cracking. The cracking risk can
be reduced by the use of low-hydrogen electrodes, and through careful selection of heat
input. Preheat control is sometimes possible, but the cooling capacity of the flowing
contents can make this an inefficient approach. Temper bead deposition sequences can be
used to control hardness. (1)

Figure 4. Welder qualification test assembly

The designation “H4R” following a SMAW electrode classification indicates an electrode with
a moisture resistant flux coating capable of producing hydrogen contents of 4 ml/100 gm of
deposited weld metal in the as‐received condition. In comparison, cellulosic flux covered
electrodes, for example AWS EXX10 type electrodes, deposit weld metal with up to 10 times
as much hydrogen. Maintaining the designated hydrogen content is dependent upon
atmospheric conditions, time of exposure to the atmosphere, and storage conditions.
Electrodes are typically rated for a certain number of hours of exposure to standard
atmospheric conditions before the electrode moisture content increases to unacceptable
levels. More severe (hot and humid) atmospheric conditions can reduce the recommended
exposure time. Exposure time limits also relate to weld metal tensile strength, with higher
strengths having shorter exposure time limits. Storage in a holding oven heated to about
120‐150°C after removal from hermetically sealed cans effectively prevents moisture
absorption. As a result, the atmospheric exposure “clock” does not start until the electrodes
are removed from the holding oven. However, atmospheric exposure time is cumulative.
Two separate exposures of six hours separated by a day of storage in a heated storage oven
are the same as a single exposure of 12 hours.(9)

HAZ hardness limits;

Traditionally, it has been common to specify that hardness of the heat affected zone not
exceed HV 350 when qualifying welding procedures for use on in‐service piping. CSA Z662
states that for fillet welds and branch connections made onto piping containing flowing fluid,

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“…weld metal or HAZ hardness values in excess of 350 HV shall require an evaluation of the
welding procedure specifications to determine that they are suitable for the avoidance of
hydrogen‐induced cracking”. However, it is not the hardness, but rather the presence of a
crack susceptible microstructure that influences the likelihood of cracking. Hardness limits
are merely used as indicators of detrimental amounts of martensite. (9)

Figure 5. Welder qualification test

Table 1. Effect of Heat Input on Inside Surface Temperature and Critical Cooling Rate of Fillet
Weld[Calculated Using Model from Ref.9]
kJ/in (kJ/mm) Inside surface Cooling time
temperature, °F (°C) (800‐500°C, seconds)
25 (0.98) 1248 (676) 9.07
30 (1.18) 1355 (735) 11.60
35 (1.38) 1485 (807) 14.01

Conditions: 5.56 mm pipe with matching thickness full encirclement sleeve. Pipe carrying
400 psig (2758 kPa) natural gas at 13°C, flowing at 10 ft/sec (3 m/sec)

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 Figure 6. Hardness criterion for thick materials (>9.5‐mm) having >0.1%C, based on CEIIW

Figure 7. Hardness criterion for thin materials (≤9.5‐mm) having >0.1%C, based on CEIIW
Welds of good structural integrity can be made safely onto in‐service pipelines and piping
systems by selecting welding procedures that balance the susceptibility to hydrogen cracking
with the susceptibility to burning through. Adjusting heat inputs to maintain acceptably low
inside surface temperatures while still minimizing the likelihood of forming martensite and
using low hydrogen welding practices are keys to success. (9)
Flow rate limits;
Safe procedures for hot tap welding can be devised using computer heat flow modelling
techniques, and qualified using flow loops. Part of this approach is to match and/or control
the cooling capacity of the live pipeline, for which measurement techniques are available. (1)
The weld cooling rate is a balance between the amount of heat that is being introduced by
the welding process and the amount of heat that is being removed by the flow of the
contents.(3)
One flow rate range that is specified by some companies is:
Minimum-required flow rate - 1.3 ft/sec. (0.40 m/sec)
Maximum-allowable flow rate - 4.0 ft/sec. (1.22 m/sec)

If flow rate limits are specified, they should not be arbitrary, but should be based on the
following:

The need for specifying a minimum-required flow rate depends on whether or not there is a
burnthrough risk. If the risk of burnthrough at no flow is negligible for a given application, in-
service welding under no-flow conditions acceptable.

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The need for specifying a maximum-allowable flow rate depends on the chemical
composition of the materials being welded and on the amount of heat that can be
introduced by the welding process (i.e., the welding heat input). It may be necessary to limit
flow rate if weld cooling rates are unacceptably high for the material being welded even at
the highest manageable heat input level. (3)

In the turbulence of the gas in the pipeline, showing an increase in high-speed, vibrations
may occur. Prevention of vibration by keeping the minimum level of the fluid velocity is a
basic method for the welding quality. The amount of flow can be reduced by reducing the
flow velocity.

The lower gas flow rates also generate lower weld heat dissipation and both the depth of
the molten pool and the temperature in the inner wall surface increase slightly. Therefore,
repair (hot-tap welding) procedures that allow to weld smaller thicknesses could be
developed. For doing this, high gas flow rates at the maximum gas pressure compatible with
safety regulations should be attained and small diameter electrodes with currents up to 80
Amp should be used. (6)

The models show that reducing the pressure in gas pipelines can increase the susceptibility
to burning through because thermal conductivity of gas is lower at lower pressure. As a
result, the heat is conducted away from the weld zone more slowly, so maximum inside
surface temperatures rise.

Heat input (HI) is influenced by welding current, voltage and travel speed in accordance with
the following equation:

𝐻𝐼 (𝑘𝐽/𝑚𝑚) = 0.06 𝑥 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑥 𝑉𝑜𝑙𝑡𝑎𝑔𝑒/ 𝑇𝑟𝑎𝑣𝑒𝑙 𝑠𝑝𝑒𝑒𝑑 (𝑚𝑚/𝑚𝑖𝑛)

Researchers found that there was increased resistance to burning through when desired
heat inputs were obtained by using slow travel speed and low welding current, rather than
by using faster travel speed and higher current (9)

It would be desirable to repair in winter, when large gas flows are transported at lower
environmental temperatures. It is possible in principle to evaluate alternative measures,
among them maneuvers with the blocking and venting valves at the ends of the sector being
repaired, that would allow to momentarily increase the transported flow reducing at the
same time the pressure in the repaired area of hot-tap fittings welding.(6)

Because of low flow rate of gas in the pipe, hot-tap fittings welding is not preferred in our
country in the summer time. It is preferred especially to weld fittings on the pipe during
higher flow rate.

4. HOT TAPS EQUIPMENT FOR IN SERVICE PIPELINE

For a hot tap, there are three key components necessary to safely drill into a pipe; the
fitting, the valve, and the hot tap machine. The fitting is attached to the pipe, mostly by
welding.
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The fitting/valve combination, is attached to the pipe, and is normally pressure tested. The
pressure test is very important, so as to make sure that there are no structural problems
with the fitting, and so that there are no leaks in the welds.
The hot tap cutter, is a specialized type of hole saw, with a pilot bit in the middle, mounted
inside of a hot tap adapter housing.
The hot tap cutter is attached to a cutter holder, with the pilot bit, and is attached to the
working end of the hot tap machine, so that it fits into the inside of the tapping adapter.

Figure 8. Cutter and pilot

The tapping adapter will contain the pressure of the pipe system, while the pipe is being cut,
it houses the cutter, cutter holder and bolts to the valve.
Cutter includes eroding the time incisors and blunt. Another problem is then cutter
breakage. Hot-tap breakage of teeth and atrophy as a result of the operation's coupon cut or
partially exposed to the pressure of the cut pipe plug adapter operation will cause
operational difficulties. In this regard, hot-tap operations should be checked before the
cutter is cutting capability and broken teeth.
During one or more teeth on the cutter pipe cutting coupon if stuck in the pipe causes the
breaking of the other cutter teeth. Cutter teeth can be used until broken by 25 %.
The Coupon is the section of pipe that is removed, to establish service. It is very highly
desirable to "retain" the coupon, and remove it from the pipe, and in the vast majority of
hot taps, this is the case.
Please note, short of not performing the hot tap, there is no way to absolutely guarantee
that the coupon will not be "dropped".(2)

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 Figure 9. Coupon
Coupon retention is mostly the "job" of the u-wires. These are wires which run through the
pilot bit, and are cut and bent, so that they can fold back against the bit, into a relief area
milled into the bit, and then fold out, when the pilot bit has cut through the pipe.
If the u-wires are not be folded, we cannot take out from the coupon section of the pipe.
The outside of the u-wire folded pilot bit should be checked to be folded. In almost all cases,
multiple u-wires are used, to act as insurance against losing the coupon. (2)

It may cause negations that falling coupon into the active pipe. Fundamentally for calculating
flow in pipes, Bernoulli equations are used. From this equation; especially relationships
between gas flow in pipe, pipe diameter, ex. are shown with Renaud Formulations. More
information can be found about this equation in the norms TS 7363 and TS 6565.

At constant flow, throttling the diameter (shrinkage the diameter or some particles remain
in pipeline) in an active pipeline can cause an increase in the gas flow rate. Increasing flow
rate provoke locally dropping pressure/ decreasing pressure locally. Narrowing the diameter
will decrease flow at constant pressure.

Essential starting point of the aforementioned formulas and equations is Reynolds number.
For gas diameter, pressure, flow can be in any event Reynolds Number is not required to
exceed a certain value. Because of that the maximum gas flow rate is limited to 25 m/s in
steel natural gas pipelines. Above this value, Reynolds number will increase. If this number
exceeds a certain threshold, flow will be in turbulence. Particles in pipe are dragged faster
than 25 m/s. Narrowing the diameter at constant flow will increase the gas flow rate and
also increase Reynolds Number. Flow will become turbulent. Slog, residuum, sand which
which will be scattered as fast as bullet, remained in pipe will cause damage to inside of
pipelines, tee, elbow, valve fittings.

Coupon could fall into pipe after hot tap operation, it causes same damages. And also it will
scattered with high speed so it will caused narrowing the diameter, jam in same calibre.
Because of that, flow rate will be failed. On the other hand coupon will damage a pipe
whose diameter is bigger than coupon’s.
After installation, problems may occur while drilling and taking off coupon because hot tap
fittings is eccentric. Coupons may break by full cut. Pipe axis must be same hot tap fitting
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axis. Cutting of coupon will not be started simultaneously because fitting is eccentric.
Interrupted cuts will take place, and cutter’s knives are damaged. Cutting may be
incompletion or the tear portion break can be seen. Because of the appropriate cut made
Rubber material near the stopple sleeve will be damaged while it is plugging in pipe and it
cannot provide tightness.

Figure 10. 12 mm difference detected between hot tap fitting and pipe axis.

Figure 11. Plugging heads

In the hot-tap operation after drilling, during the process of plugging, the plug must not be
moved forcibly. Due to the attachment plug valves or fittings in the process of plugging
stoppers overstrain and it has been found strain on the core shaft. In the case of jam
sandwich completion plug under the valve, it is need to stop gas flow or you will need to
purge of gas. There must be no damage in the plug o-ring. Surfaces must be clean and o-ring
should not be deformed. Otherwise deformation of o-ring may result in a gas leakage.

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 Figure 12. Completion plug

Figure 13. Line stop equipment

When stopple is pulling down, there should not flow between the two sides. If you are
making bypass line or gunning up branch, flow speed can be maximum 5 m/s. If there is no
bypass line, you have to shut off valve on steel natural gas pipeline from one side. And then
on the other side, if you make stopple, flow speed must be 0 m/s. If stopple didn’t place
correctly in pipe when stopple transaction is processed and pressure in pipeline couldn’t be
decreased in stages, stopple’s miles could be damaged because of loading all power to the
mile.
5. TECHNOLOGICAL ADAPTATION
Technology includes theory and practical implementation of various techniques. Products
and machines create the visible and palpable face of technology. At the same time there is
another side of technology that cannot be seen and touched by people only located just in
people's minds. This part is usually called know-how. Science for the implementation,
organization and management requires a new technology in the production area. It is not
sufficient to transfer the produced technology. The companies expected to do transfers, play
an important role on adaptation time to technology, education level, technical capacities of
professionals, financial and trade systems. 5
Creating a technology is by itself not enough for its transfer. Adaptation rates, education
level, technical capacity of employees, substructures of the countries that are planned to
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transfer of technology are important parameters in the transfer of technology. As a result,
every type of technologies cannot be a solution for any specific country. International
technology transfer is made up of the following:

1. Being up to date on technological development in the world,

2. Choosing of technology that is needed (Knowledge, ability, machine system etc.),
3. The importation of the chosen technology,
4. The customization of technology and importation to the national conditions,
5. Improvement
6. Spreading

The phase of customization of transferred technology to our conditions includes the

rearrangements of required engineering and implementations.

Countries, strategies and politics have a direct effect on the R&D activity and the capacity of
innovation. Thence, national technologic exertions have a determining role in achieving their
technological capabilities. It is not possible that countries establish an R&D system or the
transfer technology is reproduced without national exertions. In other words, national
technological expertise is determining factor of the transfer of technology. Although,
technology transfer is an important resource in terms of improving technological ability,
politics which only focus on technology transfer are not enough for improving and providing
abilities. The promotion effect of technology transfer on the national technological ability
depends on the capacity and assimilation that is improved at the national level.
The labor force and its profitability play a determining role on all phases of choosing of
technology that is wanted to be transferred. Arranging, using, re-planning and providing the
erudition of technological ability is important. (8)
Providing the requirement of technical staff who is educated, certificated and well-qualified
for hot-tap operations are mandatory. When displaced or branch line is needed to take from
the steel pipe without stopping the gas flow, obligation of fittings welding on the pipe arises.
This action that is considerably dangerous and must be made by experienced staffs on the
live-line.
The advantageous of TS EN ISO IEC 17024 standard is taking into account of staff’s abilities
seriously. This approach increases the business performance and expresses the importance
of certification. For disabling the psychological pressure that occurs through risks of welding
on steel line that includes fluid, welders must be trained on similar mechanism. As a result of
these trainings, welders do their job without fear or excitement and perform high quality.
(10)

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 Figure 14.
Throughout the technologic development that is necessary for closing gaps between two
countries, improvements of products consecutively increase quality, reliability and
performance and decrease the cost. Distribution line operation pressure is medial pressure
system in Turkey (12-19 bar). HOT-TAP drilling equipment that fit with medial pressure
system was not used at the high pressure system. By purchasing new equipment, hot-tap
fitting drilling can be done safely.
In order to create a science and technology vision for Turkey, identifying strategic
technologies and R & D priority areas, will create a science and technology policy for the
next 20 years for Turkey. Getting their support by including beneficiaries of the studies in a
wide range, socio-economic development in the community to raise awareness about the
importance of science and technology, Vision 2023 project is the one of the foresight studies
in Turkey. (8)
Taking into account the structural issue, Turkish manufacturing industry, production
technology, advanced use of technology try to minimize the impact of these structural
problems. Learning to provide a high level of technology transfer is an important resource
for technological development. Speeding up the process of structural transformation,
learning-based system has created an effective technology transfer.

Figure 15. Hot-tap fitting welding (11)

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WGC Paris 2015 Dr. Cevat ÖZARPA RISK IN THE HOT-TAP OPERATION
Increasing the effectiveness of technology transfer is possible with following ways;

 First Step: Detection, selection, obtaining

University, industry and government cooperation activities should be increased.

 Second Step: Learning and assimilation

National innovation system should included in the national learning system .

 Third Step: Development and regeneration
Scope and effectiveness of government support and incentives for domestic production
should be increased. 8

6. RESULTS AND DISCUSSION

1. Hot-tap resources proven its applicability must be manufactured using approved welding
procedure and verified source programs.
2. Improper hot-tap welding processes will involve high risk and will generate problems for
agency employee alike.
3. Improper hot-tap source applications increase the costs.
4. Personnel certification according to the standards of international resources, transactions
with the appropriate welding and standard welding equipment will affect the supply and
manufacture of quality hot tap.
5. The staff provided the training and qualification, and sufficient knowledge, where the hot-
tap conditions should be subjected to 4-5 applications including artificial risks will learn
overcoming the problems and to address the problems in fittings welding and assembly.
Welders and risks that may occur in the trial phase of the hot-tap greet operator will not
reduce productivity. This pre-treatment will improve the staff's self-confidence.
6. As new technologies are imported from abroad, communication continuity with
technology supplier and purchaser is important.
7. In our country, operating pressure is 12-19 bar in the natural gas distribution lines, pipes
are used with a minimum wall thickness of 4.37 mm. Procedures and resource programs for
hot-tap applications via live pipeline was developed and implemented successfully.
8. Welder performance has been kept under control and assured with welder error rate of
0.2 %.
9. Although the usage of Hot-tap used equipment, some problems encountered in adapting
the old machine to new machine equipment and accessories developed by the same
company.
10. Lack of maintenance of the new equipment and getting inadequate services, the use of
new technological equipment in the gas line brings new risks.
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WGC Paris 2015 Dr. Cevat ÖZARPA RISK IN THE HOT-TAP OPERATION
 7. REFERENCES
1) http://www.twi-global.com/technical-knowledge/faqs/process-faqs/faq-what-is-hot-
tapping/
2) http://www.wermac.org/specials/hottap.html
3) Bruce W A and Etheridge B, “Essential Elements of An Effective In-Service Welding
Program 1”
4) YILDIZ,M., “Welding and non-destructive testing of naturalgas pipelines”, 2000
5) http://www.eenakdeniz.org.tr/een/TR/TeknolojikIsbirligi/Default.aspx
6) J.L. Otegui, A. Cisilino, M. Chapetti , A. Trunzo “Minimum Thickness for Repair Girth Welds
In Corroded Pipe”
7) DUYGUN,S. , AKGÜN A.E, “Teknoloji Transferi Nedir ve Teknoloji Transferindeki başari
faktorlerinin Firma Yeniligine katkisi”
8) Tiryakioğlu, M. , Demirhan E. , “Ulusal teknolojik yetenek ve teknoloji transferi ile ilişkisi:
Türk imalât sanayi örneği / National technological capability and its relation to technology
transfer: The case of Turkish manufacturing industry” Afyon Kocatepe Üniversitesi, Sosyal
Bilimler Enstitüsü, İktisat Bölümü Doktora Programı Tezi, 2013
9) Bill Amend, William A. Bruce “ , Welding on In‐service Pipelines” Originally published in
the Canadian Welding Association Journal, Spring 2013, pp 30‐39
10) Elhan M.S, Özarpa,C. , “Canli Çelik Boru Hatlarinda Hot-Tap Fitting Kaynakçi
Belgelendirmesi” 3. Kaynak Kongresi, Ankara 2011
11) http://www.br-industrial.co.uk/hot-tap-welding [accessed on 13.03.2015]

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WGC Paris 2015 Dr. Cevat ÖZARPA RISK IN THE HOT-TAP OPERATION

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