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Hot Tap 24,400 per $73,200 $122,000 $170,800 $13,680 per $62,222
$47,409 15 10 7
Connectiona year per year per year per year yearb per yearc
General Assumptions:
a Annual savings and costs are based on an average 320 hot taps (of various sizes) per year.
b Other savings shown are for inert gas.
c Other costs includes the O&M and contract services costs.
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Using Hot Taps For In Service Pipeline Connections
(Contd)
addition, removing a pipeline segment from service can Exhibit 1: Schematic of Hot Tapping
occasionally cause gas service interruptions to customers. Machine with Profile
For example, a shutdown connection on a steel line can
require one to three or more days of pipeline outage and
possible interruption of natural gas shipments in addition
to the release of methane to the atmosphere.
2
Using Hot Taps For In Service Pipeline Connections
(Contd)
3
Using Hot Taps For In Service Pipeline Connections
(Contd)
4
Using Hot Taps For In Service Pipeline Connections
(Contd)
Given:
T = taphole diameter (inches) - for low pressure shutdown with tapholes for stoppers
P = line pressure (psia for low pressure, psig for high pressure)
3. Calculate Vpgas = volume of purge gas = VP * 2.2 (shutdown + restore + 20% wasted)
5
Using Hot Taps For In Service Pipeline Connections
(Contd)
2 L
D P 0.372
1,000
Vg (Mcf) =
1,000
2 2 5,280
4 350 1,000 0.372
Vg =
1,000
Vg = 22 Mcf
D2 L
Vpgas (Mcf) = 183 2.2
1,000
4 2 2 5,280
Vpgas = 183 2.2
1,000
Vpgas = 2 Mcf
(3) Calculate: Value of Gas Lost by Shutdown Interconnects (Including Purge Gas)
6
Using Hot Taps For In Service Pipeline Connections
(Contd)
7
Using Hot Taps For In Service Pipeline Connections
(Contd)
each year, these taps (a total of 15 taps) would be Exhibit 7: Estimated Annual Gas Savings for the
contracted to vendors. The equipment cost includes the Hypothetical Scenario
purchase cost of two small (<12) tap machines. For the
Total
purpose of this Lessons Learned, the average value of the Tap Natural Gas Purge Gas
Gas
purchase, O&M, and contracting service costs listed in Scenario 1 Annual Savings Savingsb
Savingsc
Taps
Exhibit 5 are used to complete the cost analysis for the Number
Per
Annual
Per
Annual
hypothetical scenario. Based on these assumptions the Pipelinesa Tap Tap $
Mcf Mcf
Mcf Mcf
total equipment cost is calculated at $47,409, the O&M
4 pipeline
cost at $7,959 and the contract services cost at $54,263. 350 psig, 250 22 5,500 2 500 42,500
2 mile line
Step 4: Evaluate the gas savings benefits of hot 8 pipeline
tapping. 100 psig, 30 13 390 4 120 3,690
1 mile line
Exhibit 7 presents the natural gas and purge gas savings 10 pipeline
associated with hot tapping on small and large diameter 1,000 psig, 25 589 14,725 19 475 106,875
3 mile line
high-pressure pipelines in the hypothetical scenario of 320 18 pipeline
taps per year. The values are calculated using the 200 psig, 15 255 3,825 41 615 31,695
equations in Exhibit 3, multiplied by the number of annual 2 mile line
connections. Gas losses associated with shutdown Total Annual 320 24,440 1,710 184,760
interconnects are the primary savings when these
connections are made by hot tapping. a The sizes and number of taps from scenario given in Exhibit 4.
b Example for 4-inch pipe interconnect shown in Exhibit 4.
c Natural gas valued as $7 per Mcf, inert gas (nitrogen) valued at $8 per Mcf.
Step 5: Compare the options and determine the
economics of hot tapping. tapping equipment and/or contracting for hot tapping
The economic analysis shown in Exhibit 8 compares the services. In this scenario, both costs are included: the
significant cost and benefit differences between hot purchase of two hot tapping machines for $47,409 for the
tapping and shutdown interconnections for the smaller sizes and contracting the 15 large taps at $54,263
hypothetical scenario of 320 taps per year. The significant per year. The purchased hot tap machines are operated
costs are the purchase, operation and maintenance of hot and maintained at $7,959 per year. All these costs are
Payback (months) 5
IRR 258%
NPVa $417,107
a Net Present Value (NPV) based on 10% discount rate for 5 years.
8
Using Hot Taps For In Service Pipeline Connections
(Contd)
9
Using Hot Taps For In Service Pipeline Connections
(Contd)
McElligott, John A., John Delanty, and Burke Delanty, Use of Hot Taps for
All equipment must meet minimum industry and
Gas Pipelines Can be Expanded, Oil and Gas Journal, 11/30/98.
federal standards for pressure, temperature, and
operating requirements. McMicken, Mike and Brian Boucher. Team Industrial Services, Inc.
Personal contact.
If conditions of temperature, pressure, pipe
composition, or tap diameter are encountered that Petolick, Don and Gary Vanderhye. Hydra-Stop, Inc. Personal contact.
are unusual for your system, be sure to consult the
manufacturer of the tapping equipment or fittings. Rodgers, Erick. Topaz Inc. Personal contact.
Record emissions reductions associated with using Tingley, Kevin. EPA Natural Gas STAR Program. Personal contact.
hot taps and submit them with your Natural Gas
STAR Annual Report. U.S. Code of Federal Regulations. Title 49, Part 192 (49 CFR 192),
Subpart D, Transportation of Natural and Other Gas by Pipeline:
Minimum Federal Safety Standards; Design of Pipeline Components.
References
10
Using Hot Taps For In Service Pipeline Connections
(Contd)
TD Williamson - Full Split Tee Costs ($) One of the possible hidden costs of a shutdown connection,
if gas cannot be supplied from alternate sources, can be the
Size (pipeline x outlet) cost of relighting customers. This process would require
two visits, one to shut down and the second to turn on and
16 x 16 $2,000 relight. Typically, a visit to a residential customer would
take 15 to 30 minutes, and a visit to a commercial or
18 x 18 $3,000 industrial customer would take approximately 1 hour.
According to the Bureau of Labor Statistics, an employee
20 x 20 $5,000
would be paid approximately $9.75 per hour for this work.
24 x 24 $6,000
Cost of Relighting = [(No. of residential customers) * (0.38
30 x 30 $9,000
hrs)] + [(No. of commercial/industrial customers) * (1 hr)] *
$9.75/hr
40 x 16 $2,500
It might not be possible to perform a shutdown connection
60 x 16 $2,500 during optimal hours. Scheduling and additional planning
might have to be completed to arrange the construction
Price estimates are for a 300# rating.
Fittings are also available for 150#, 400#, 600#, 900#, and 1,500# flange ratings and sizes 1 x 1 to and additional excavation necessary to shut down the line,
96 x 96. pay employees overtime, and advertise the shutdown to
customers. These costs are variable and will depend on the
company and internal factors.
Topaz - Tapping Tee Costs ($)
Other additional costs exist, such as scheduling, labor,
Size (pipeline 150# Flange 300# Flange 600# Flange
x outlet) Rating Rating Rating
overtime, and advertising, but are unique to each
company, and beyond the scope of this study. These costs
2 x 2 $386 $399 $443
can be estimated based on past shutdown experience. An
4 x 4 $407 $428 $481 operator should examine past records to determine what, if
any, costs are being avoided by performing a hot tap
12 x 12 $1,394 $1,484 $1,624 versus a shutdown connection.
20 x 20 $3,645 $3,857 $4,290
11
Using Hot Taps For In Service Pipeline Connections
(Contd)
United States
Environmental Protection Agency
Air and Radiation (6202J)
1200 Pennsylvania Ave., NW
Washington, DC 20460
October 2006
EPA provides the suggested methane emissions estimating methods contained in this document as a tool to develop basic methane emissions estimates only. As
regulatory reporting demands a higher-level of accuracy, the methane emission estimating methods and terminology contained in this document may not conform to
the Greenhouse Gas Reporting Rule, 40 CFR Part 98, Subpart W methods or those in other EPA regulations.
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