HOT TAPPING FOR 42 FLARE HEADER:

Introduction:
A Hot tapping of running refinery Flare header at HPCL, Mumbai refinery was conducted on 14 th
May2013 and was successfully completed on 15 th May2013 to connect the DHT project flare
header to the existing refinery flare. As the 42 DHT flare header to be connected to existing 48
refinery flare header, the hot tapping was done for 42 size, the Indias biggest Hydro carbon
line hot tapping conducted so far.
Client
PMC
Contractor

: Hindustan Petroleum Corporation Limited, Mumbai

: Jacobs Engineering India Private Limited
: Conmat Systems Private Limited

Hot Tapping is the technique of attaching a mechanical welded branch fitting to piping or
equipment in service and cutting a hole in the operating pipeline or piping system, operating
heat exchangers, vessels, columns, tanks without shutting down the system with appropriate
tapping machine.

Hot Tapping:
Initially, 48 x 42 tapping fitting was installed in the 48 existing flare header and welded by
passing Nitrogen continuously through the running flare line.
48 x 42 Tapping Fitting

Hot Tapping Machine

Tapping Machine Adaptor

42 Gate valve

After it was allowed to cool, the 42 valve was installed on the tapping fitting and then the Hot
tapping machine was installed above the valve. The tapping machine is having a 42 size cutter
along with a pilot drilling bit attached, which is having locking arrangements to hold the cut piece
of pipe after completion of hole cutting.

Once the Hot tapping machine was installed, the cutting was started on 14 th May2013 with all
adequate safety requirements by revolving the pilot drill and cutter and finally the cutting was
completed on the same day. Then the cut piece has been brought above the valve and then the
valve was kept in closed position. The next day, the tapping machine was brought di=to the
ground and the cut piece coupon plate was taken out and removed from the hot tapping
machine to attach a specially fabricated Sealtite Plug to the tapping machine.

Tapping Machine

With Cut Piece

The Sealtite Plug was assembled to the hot tapping machine and the machine was installed on
top of the 42 valve. The valve was opened and the Sealtite Plug was fitting with the Sealtite
flange of the tapping fitting installed earlier. The tapping machine was disengaged with the
Sealtite Plug holder and machine was removed. Then the valve and plug holder also removed
and finally Blind flange was installed on the tapping fitting.

Cut Piece

Sealtite Plug

Results:
Finally the 42 size hot tapping, a biggest hydro carbon line hot tapping in India was conducted
and completed successfully on 15th May, 2013, in a very safe and proper manner due to proper
planning and execution by HPCL/Jacobs/ Conmat.