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Free Download Hot Tapping & In-Service Modification
Published 8/2026
Created by ProjectEngPro Engineering and Project Management
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Level: Intermediate | Genre: eLearning | Language: English | Duration: 20 Lectures ( 3h 50m ) | Size: 2.3 GB
Burn-through and hydrogen cracking control, fittings and machines, stopples, permits and completion
What you'll learn
Assess whether a proposed hot tap should proceed, and on what evidence Explain burn-through and hydrogen cracking, and how a procedure controls each one Recognise the services and conditions where live welding must not be used Review a hot tap procedure critically instead of accepting the one used last time Follow the full sequence from fitting installation to machine withdrawal and coupon retrieval Select branch fittings and isolation valves suitable for the size, pressure and service Verify material, wall thickness and pipe condition before approval Set permit, process condition and abort criteria for the operation Understand stopples, line stops and freeze plugs, and when each is the right method Complete the work properly - testing, reinstatement, drawing updates and inspection follow-upRequirements
No welding engineering background is required - heat input, cooling rate and hardness are built up from the start Any engineering, technical or operations background is enough to follow the course No mathematics beyond arithmetic - the thermal principles are explained rather than derived Helpful but not essential: some exposure to an operating plant, a permit system or a turnaround No software or purchases needed - no standard needs to be bought to follow the courseDescription
This course contains the use of artificial intelligence.
▸ Somebody has to sign the approval for welding on a live hydrocarbon line.
Hot tapping is done thousands of times a year without incident, which is exactly what makes it dangerous. It becomes routine. The fitting gets ordered, the contractor arrives, the procedure is the one that was used last time, and the engineer approving it is relying on the fact that it worked before.
Two mechanisms control whether it works. Burn-through, where the remaining wall cannot support the internal pressure at welding temperature - governed by thickness, heat input and how much heat the flowing contents remove. And hydrogen cracking, where the flowing contents chill the weld so fast that hardness rises and hydrogen has nowhere to go. Both are predictable. Both are controlled by the procedure, and the procedure is only as good as the person who assessed it.
This course teaches the engineering: the decision to tap rather than shut down, the sequence and its equipment, the two failure mechanisms and how they are controlled, fittings and their design, the assessment that must precede approval, and the permit, execution and reinstatement work that surrounds it.
▸ Written for the person who has to approve it
Most available material on this subject is written by the companies that perform the work. This course is written from the owner and engineer's side of the table - what to verify before agreeing to a tap, what a competent procedure looks like, which services should never be tapped, what the abort criteria are, and what has to happen after the machine comes off.
Stopples, line stops and freeze plugs are included because the real question is rarely whether a hot tap is possible. It is which live intervention method is appropriate, and whether conventional isolation was genuinely unavailable in the first place.
Five focused sections, worked through in an afternoon.
▸ What you will master
• Make the hot tap versus shutdown decision on engineering grounds rather than schedule pressure
• Follow the full hot tap sequence - fitting, valve, machine, drilling, coupon retrieval and withdrawal
• Explain the burn-through mechanism and the interaction of wall thickness, heat input and flow condition
• Explain hydrogen cracking in accelerated cooling, and how consumables, technique and chemistry control it
• Recognise the services and conditions where hot tapping must not be used
• Assess a proposed tap location - material, thickness survey, corrosion and lamination screening
• Select and review branch fittings, from split tee and full encirclement to weldolet type connections
• Specify the isolation valve and understand why cutter clearance and testing matter
• Understand the tapping machine, cutter and pilot drill, and why coupon retention is a control point
• Take the work through permit, execution, abort criteria, testing, reinstatement and integrity follow-up
▸
Who this course is for
Integrity, inspection and piping engineers assessing and approving live-plant intervention Welding engineers qualifying and reviewing in-service welding procedures Maintenance, turnaround and project engineers planning tie-ins on operating plant Operations engineers and supervisors holding the permit and the process conditions Construction and execution engineers supervising hot tapping and stopple work Process safety engineers assessing the risk of live interventionHomepage
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