IBP1121_19

SUBSEA PIPELINE DIVERLESS HOT TAPPING

Mariela Carrillo1, Mauricio D’Andrea2,
Gustavo Franco3, Simao Silva4

Copyright 2019, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exhibition 2019, held
between 03 and 05 of September, in Rio de Janeiro. This Technical Paper was selected for presentation by the
Technical Committee of the event according to the information contained in the final paper submitted by the
author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’ opinion, or that of its
Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline
Conference and Exhibition 2019.

Abstract

Pipelines are a critical component of the subsea infrastructure, as they are used to transport oil
and gas to the shore or to offshore facilities. They are also the component that enables water,
chemicals, or gas injection into the production system. Maintaining pipeline integrity is a
recurring concern for asset managers in order to maintain their production flowing and to avoid
costly shutdowns that could cause a significant impact and revenue losses. Many advances have
been made in recent years related to the inspection, maintenance, and repair (IMR) techniques,
as well as to subsea interventions in both shallow water and deepwater pipelines. New materials,
techniques, and operational procedures have increased the safety, integrity, and reliability of
operational results, as well as reduced project costs. With the growing requirement to carry out
diverless subsea installations, the equipment and procedures necessary to conduct a wide
variety of interventions (such as repairs, hot tapping, or decommissioning) need to perform
safely and reliably under different conditions.

Keywords: Subsea. Offshore. Subsea Pipeline. Hot Tapping. Pipeline Repair. Pipeline
Integrity. Tie in. Intervention. Diver-assisted. Diverless.

1. Introduction

This paper describes diver and diverless subsea hot tapping methods, with an overview
of the typical activities that take place during the execution to enable safe tie-in or intervention
operations.

2. Subsea Hot Tapping

Hot tapping is defined in API 2201 as the technique of attaching a mechanical or welded
branch fitting to piping or equipment in service, and creating an opening in that piping or
______________________________
1
Bachelors of Science, Electrical Engineer, Sales Account Manager PCRS – OCEANEERING
2
Bachelors of Science, Mechanical Production Engineering, Technical Solutions Manager – OCEANEERING
3
Master of Business Administration, Bachelor of Science in Industrial Engineering, Technical Solutions Manager
– OCEANEERING
4
Bachelor in Business Management, Project Management Professional, Business Development Manager –
OCEANEERING
 Rio Pipeline Conference and Exhibition 2019

equipment by drilling or cutting a portion of the piping or equipment within the attached fitting.
This technique is often used in oil and gas applications for onshore and offshore pipeline repair,
intervention, and tie-in operations.
Subsea hot tapping is performed with the intent to (1) create an access point to the subsea
pipeline for blockage remediation, (2) enable a bypass in order to resume production while the
main line is blocked, (3) provide means for a temporary bypass line to tie into an existing
pipeline and maintain production during a repair scenario, and (4) create a permanent re-routing
of a pipeline. These scenarios allow the asset managers to recover quickly from a blockage
caused by hydrates, wax, asphaltene buildups, or other issues. They also provide for a more
economical approach to bring a new production system online via tie in, or to improve the
utilization of a subsea asset.
Most subsea hot tapping intervention activities are performed with the assistance of
divers for pipelines located in shallow water. However, due to the inherent risk that diving
operations involve, and the elevated vessel operating cost, as compared to unmanned subsea
intervention vessels, or by new large oil and gas discoveries being located in remote, deeper
waters- pipeline owners and operators are often looking at subsea hot tapping by unmanned
means, using remotely operated vehicles (ROVs).

2.1. Diver-Assisted Hot Tapping

Hot tapping in shallow water may be performed by means of divers or ROVs. Diver-
assisted hot tapping is a more common practice for shallow water pipelines worldwide. A hot
tap assembly in shallow water most often consists of a mechanical fitting also named smart tap,
an isolation valve, and a hot tapping machine. Welded fittings are less common in subsea hot
tapping, due to the costs associated with subsea welding.

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Figure 1. Subsea hot tap assembly with mechanical fitting

Figure 2. Hot tap machine with ball valve and smart tap mechanical fitting.

2.1.1 Typical Diver-Assisted Hot Tapping Operations

The initial operations of diver-assisted hot tapping typically begin with inspecting the
pipeline to understand the integrity of the tie-in point. After that, engineering the field layout
allows for a better view of the necessary interfaces so the execution team can initiate procuring
and preparing the necessary items to perform the hot tapping operations. Diver-assisted hot
tapping equipment is often maintained in inventory by specialized service providers or pipeline
repair equipment manufacturers for certain pressure classes. The equipment is typically
available for ASME Class 600 pressure classes. Higher pressures are not uncommon, but may
require the components to be manufactured. Once equipment is on hand and ready for operation,
and after performing the onsite fit test and training diving personnel for the hot tapping
operations, the hot tap machine is mounted onto the mechanical fitting. The mechanical fitting
branch will have a valve in order to block the unwanted exit of production fluid once the hot
tap machine is removed after hot tapping operations.
The hot tap machine with a mechanical fitting assembly is deployed subsea and set on
the pipeline that has been previously prepared for the intervention. Operations to expose the
pipeline (such as pipe lifting, dredging, and coating removal among others) need to take place
prior to setting the mechanical fitting onto the pipeline. Once the smart tap clamp is installed

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on the pipeline, the valve part of the assembly is opened and the cutter/pilot is activated to
advance until it reaches the pipe outer wall. This is when the hot tapping operation starts.
The cutters are equipped with a pilot drill bit for the initial break through. As the pilot
completely penetrates the pipeline wall, the hot tapping machine will stop rotation, it is
advanced so the latching mechanism can get in place to retain the coupon (the pipe segment cut
out by the hot tapping machine) so that it can be retrieved and does not fall inside the pipeline.

Figure 3 & 4. Coupon retrieved by the hot tapping machine.

The advancement of the cutting interface is continued without rotation until the cutter
touches the wall of the pipeline. At this point, the machine starts the rotation again and the cut
is completed. Once the cut is complete, the machine is stopped and only advanced to confirm
that a successful tap has been completed. The distance and timing to do the advancement and
rotation of the tapping machine are determined by the calculations previously done by the hot
tap experts.
After the tap is confirmed, then retracting the tapping machine retrieves the coupon.
The valve can now be closed and the hot tap machine removed from the assembly. The
interface where the hot tap machine was installed becomes now the access point to the
existing pipeline for one of the desired interventions or tie-in activities to be performed.

2.1.2 Diver-Assisted Line Stops

Line stop is a mechanical device that is designed to isolate a pipeline segment in order
to perform intervention activities. In some instances, line stops may be used with or without a
production fluid bypass depending on whether the pipeline operator desires to continue
production for the duration of the intervention.
Line stop without a bypass. In cases where the pipeline can be shut down while a repair
is performed, following the hot tapping operations described in Section 2.1.1 of this document,
a line stop – an isolation head actuated by a pneumatic actuator – is introduced in the pipeline.
The line stop is designed to contain pipeline pressure, and is compatible with production fluid.
The line stop head is held in place downstream of the mechanical fitting while the repair is
performed on the pipeline. Once the repair is complete, the upper assembly (also known as
head) is removed from the line and the hot tap machine is used to set the completion plug in
place. The tapping machine and temporary hot tap valves are removed and a blind flange is set
in place, completing the job.
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Line stop with a bypass. When shutting down production is not a viable alternative
during repair activities, then a production bypass is required. This is performed by using four
mechanical fittings and two line stops. The outer mechanical fittings are used for the bypass,
and the inner mechanical fittings will isolate the pipeline segment. The main advantage of this
type of bypass is that it can be up to the same nominal size as the main pipeline, so the
operator will not sacrifice flow during bypass and hot tap operation. The pipe segment in
between the line stop heads is purged from the line in order to perform the repair. Once
complete, the line is pressurized between the heads and the line stops are removed. Valves on
the bypass are closed, the bypass pipeline is removed, completion plugs are set, and blind
flanges are installed.

Figure 5. Bypass using four fittings.

The bypass can also be done in other ways when there is not enough space or when a
less-costly repair needs to be done. If the operator can live with a bypass that is not the same
size as the main pipeline, then a smaller pipeline can be installed on the tapping adapters of the
tapping machine.

Figure 6. Bypass through the tapping adapters.

Also, three-way tap fittings can be used and a bypass installed through them. A three-
way tap fitting will have a longer neck, along with an outlet where the bypass can be
connected.

Figure 7. Three-way mechanical fitting

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2.2 Diverless Hot Tapping Operations

Subsea hot tapping may also be performed through ROVs for shallow and deepwater
operations. ROV hot tapping is continuously growing in popularity due to the cost and safety
hazards inherent from diver-assisted intervention activities; especially on deeper waters.
Field development economics also play a major role for pipeline owners or operators in
determining whether to use divers or ROVs for hot tapping work. In some instances, asset
managers may have long term contracts with intervention vessels that have ROVs mobilized
onboard so they can perform the hot tapping operations, rather than mobilizing a saturated
diving vessel solely to perform the hot tapping operations.
Diverless hot tapping is typically safer, but offer other challenges that have to be
overcome by design and engineering, as diver-assisted operations are more effective in
providing meticulous operations, especially working in confined spaces. The need is for hot
tapping equipment modified to be ROV-friendly, along with additional hardware (such as
mechanical pipe lifting frames and alignment frames) for the proper installation of the hot
tapping system onto the pipeline.

Figure 8. ROV-friendly hot tap machine with mechanical fitting assembly.

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Figure 9. Typical cross-section of mechanical fitting.

Figure 10. ROV-friendly hot tap machine with mechanical fitting assembly with installation and alignment aides.

2.2.1 Typical Diverless Hot Tapping Operations

Diverless hot tapping operations do not differ significantly from diver-assisted

operations, as diverless operations will also begin with procuring and preparing the necessary
items to perform the hot tapping operations. ROV-friendly equipment is often not readily
available, thus long leads may vary based on the extent of the adjustments required to make the
hardware ROV-operable.
ROV-operable valves, subsea diverless connection systems and installation and
alignment aids for ROV-operable hot tapping equipment, are the main long-lead deliverables;
thus, asset managers must do proper planning for the procurement of the necessary equipment
to perform hot tapping operations within their intervention schedule. After all items are
procured and tested, and all relevant personnel are trained, the hot tap machine is mounted onto
the mechanical fitting assembly (the same as in diver-assisted operations), along with any
applicable installation and alignment ends for the hot tap machine with mechanical fitting
assembly.
The ROV-friendly hot tap machine with mechanical fitting assembly, and installation
and alignment aids (as applicable), are deployed subsea and set on the pipeline that will be
intervened. As with diver-assisted hot tapping, operations to expose the pipeline (such as pipe
lifting, dredging, and coating removal, etc.) need to take place prior to setting the mechanical
fitting onto the pipeline. The valve in the assembly is opened by the ROV and the cutter/pilot
is engaged to advance until it reaches the pipeline. This is when the hot tapping operation starts.
Hot tapping operations for cutting and retrieving the coupon will follow a similar methodology
to the diver-assisted operation. Once the tap is confirmed and the coupon is retrieved by the
tapping machine, then the ROV closes the valve and the hot tapping machine is removed from
the assembly. The open branch to the existing pipeline will allow for future interventions or tie-
in activities. Pipeline segment isolation through line stops and bypasses may also be used by
means of an ROV, considering that the respective modifications and auxiliary hardware are in
place for installation, alignment, and operation of the system.

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3. Benefits of Subsea Hot Tapping

Subsea hot tapping certainly provides benefits to pipeline owners and operators. Subsea
hot tapping allows intervention or repair activities to be performed while production continues,
which avoids costly shutdowns and loss of revenue associated with the lack of production.
Additionally, subsea hot tapping provides for new intervention points on pipelines for
monitoring; inhibition or remediation activities amongst others. For subsea tie-ins, it provides
significant savings in capital expenditure as new lines can tie in to an existing pipeline.
There are certain pros and cons comparing diverless to diver-assisted subsea hot
tapping. Diver-assisted hot tapping is a more common operation with a solid track record on
applications worldwide whereas diverless hot tapping continues being a relatively new frontier
to the industry that poses its challenges; diver-assisted operations provide more flexibility,
accessibility to confined spaces as compared to ROV work and less expenditure on specialty
installation and handling aids for hot tapping equipment. Conversely, diverless hot tapping
eliminates risk associated with diving work and eliminate cost of saturated diving as hot tapping
operations can be performed by ROV on its entirety.

4. Conclusion

The decision between diverless and diver-assisted hot tapping often depends on the field
economics, project-specific conditions, and operator risk tolerance. As the industry drives
towards better safety for workers, service companies continue their relentless efforts in
providing more cost effective solutions. Diverless hot tapping becomes a more attractive
solution for asset managers in this case. Deeper and more remote field developments may also
be attributed to the rising interest of the industry for diverless hot tapping. Although, it is clear
that diver-assisted hot tapping will continue to play a role in applications worldwide, especially
due to overall lower cost, diverless hot tapping will continue gaining ground in offshore pipeline
intervention activities due to the safety aspect and the ability to perform the work regardless of
water depth.

5. References

API 2201 – Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries. API
Recommended Practice 2201, Fifth Edition, July 2003, reaffirmed, October 2010.
ASME B31.8-2014 – Gas Transmission and Distribution Piping Systems. ASME Code for
Pressure Piping, B31, 2014.
DNV-OS-F101 – Subsea Pipeline Systems. Offshore Standard 2012. Det Norske Veritas AS,
August 2012.
DNV-RP-F113 – Pipeline Subsea Repair. Det Norske Veritas AS Recommended Practice DNV-
RP-F113, October 2007.