REMOTE-CONTROLLED

HOT TAPPING SUBSEA

George Lim, T.D. Williamson, the Netherlands,

discusses a new remote-controlled

hottapping machine that can be used to

facilitate pipeline tie-ins by tapping into

pre and post-installed tees, without diver

assistance.

H
ot tapping subsea pipelines plays a critical role in facilitating repair work
(scheduled and unexpected), tie-ins, flow assurance, chemical injection
and insertion of intelligent tools. But as new pipeline systems are
constructed in increasingly deep waters, carrying out pipeline interventions,
such as hot tapping, has become increasingly complex. Deepwater pipelines
that lie 3000m subsea demand interventions that can be carried out without
divers, who can only work in depths to 300 m. To provide operators of
deepwater developments with a solution that does not rely upon divers or
expose them to risk, the Subsea 1200RC Tapping Machine was developed.
(See Figure 1). The system is operated by remote control from a laptop
onboard a Diving Support Vessel (DSV). By doing so, the hot tapping process
is more accurate and diver safety and execution speed are enhanced.

Figure 1. Hot tapping is carried out via remote control with the
Subsea 1200RC Tapping Machine.
Figure 2. The tapping machine is designed so that technicians
control the system, and have a continuous view of subsea
operations through a laptop computer onboard the DSV.
Reprinted from OILFIELD TECHNOLOGY
August 2012
When pre-installed tees are present on the pipeline, the
system is operated without divers. If pre-installed tees are
not present, divers are required, but only to install the hot tap
fitting and the tapping assembly; not to operate the system.
The system makes it possible to access subsea
pipelines in any water depth for operational, construction or
maintenance purposes, changing the face of offshore pipeline
intervention and maintenance.
Subsea hot tapping: how it works
Hot tapping involves drilling a hole into a live pipeline without
shutting it down or releasing its contents. Todays subsea hot
tap operations are carried out from a DSV that carries the
equipment and divers to the hot tap location. Divers enter the
water and the hot tap assembly is lowered to the pipeline.
The typical hot tap is as follows: first, the hot tap
assembly, which consists of a hot tap machine, permanent
isolation valve and hot tap fitting bolted together, is
pre-tested on the deck of the DSV. The fittings are two
mechanically-bolted clamp-halves. The assembly is lowered
with the two clamp-halves in open position over the pipeline,
and divers bolt the clamp-halves shut. To ensure integrity,
the annulus between pipe and fitting is leak-tested against
the tapping machine while the valve is open. To begin the
tapping procedure, a pilot drill is positioned in front of the
hot tap cutter to make a small hole in the pipeline. This hole
helps stabilise the larger hot tap cutter and retain the portion
of cut pipe (coupon) after the larger cutter completes the
hole. The primary tap is then made into the pipeline with the
appropriate size cutter. The valve is closed, and the coupon
and tapping machine are recovered. If preparing for a tie-in,
the permanent hot tap valve may be connected to a spur line.
When the valve is opened, the new connection is ready to be
put into service.
Hot tapping challenges subsea
The greatest concern associated with subsea hot tapping is
that divers - not experienced tapping professionals - perform
the hot tap, which is the most delicate aspect of a subsea
tie-in operation: when the pilot drill penetrates the pipeline
and the live pipeline is cut. The divers are supervised by a
hot tapping professional on the vessel, and this professional
communicates via the vessel intercom during the tapping
process. Although they are trained in hot tapping during the
mock-up testing prior to the operation, the divers are not hot
tapping experts. Another concern is the limited number of
telltale sensors on todays subsea machines, with minimal
topside visibility. These sensors are used to monitor activity
inside the fitting while the line is cut. Without maximum
viewing capability, the ability of the diver and hot tapping
technician to monitor and control the tapping process may be
compromised. Fortunately, new systems can overcome these
challenges.
Adapting field-proven technology
The Subsea 1200RC Tapping Machine is a self-contained
tapping machine with a built-in hydraulic and control system
powered by a stationary remotely operated vehicle (ROV),
and operated by a technician from a laptop that offers a
continuous view of all subsea operations. (See Figure2). The
tapping operation is completely controlled by thetechnician.
Figure 3. The remotely operated vehicle stabs into the tapping machine control panel. A technician controls all tapping functions from a laptop computer.
Figure 4. The view of an actual hot tapping operation taking place.
Technicians have a clear, continuous view of the entire subsea hot
tapping process through the main window of the control program.
Figure 5. Tapping through a pre-installed tee.
The stationary ROV concept is an improvement over the
standard deepwater method that uses ROV arms to operate
separate valve functions.
During the hot tapping process, the ROV draws upon its own
hydraulic power unit (HPU) to stab into the tapping machine
control panel and latch onto the grabber bar. (See Figure 3).
The ROV provides hydraulic power (closed loop) to engage
a motor/pump unit placed on the tapping machine frame. The
motor/pump unit then sends hydraulics through a valve pack to
the appropriate motor/hydraulic function.
The software control program may be operated manually
- or automatically - to manipulate all tapping machine functions
from a laptop. Its primary functions are to run the feed and drive
motors, and engage/disengage the clutch. Sensors transmit data
to the laptop on all parameters, including temperature, pressure,
cutter position and proximity, rotation speed, and movement of
the boring bar and cutter. (See Figure 4).
The camera on the ROV panel is used to monitor some of
the key pressures that have a manometer (pressure gauge).
The supply and return hydraulic pressures, and motor and drill
pressures are monitored by a network of sensors. Two cameras
on the tapping machine offer around-the-clock observation of a)
the rotation and position of the boring bar, and b) the position of
the clutch cylinder.
Should hydraulics, electronics or machine parts fail, several
contingencies including overrides by ROV mechanical
interfaces and duplicate monitoring system - are installed on the
tapping machine.
Depending on the internal pipeline operating pressures, the
tappingmachine can operate in depths down to 3000 m.
If tees have not been pre-installed on the pipeline, divers are
required to install the tapping assembly and the hot tap fitting.
However, no divers are required when a) pre-installed tees are
present or b) post-installed tees are incorporated into the hot
tap assembly and the integrated assembly can be lowered and
connected to the pipeline by remote control.
Reprinted from OILFIELD TECHNOLOGY
August 2012

Figure 6. Tapping through a post-installed tee.
Tapping into pre-installed tees
Operators often pre-install tees on the pipeline in anticipation
of tying in future oil and gas field developments in neighbouring
fields. By doing so, output can be routed through the pipeline
without going to the expense of laying a new export line that
extends to the shore or nearest hydrocarbon collection point.
Pre-installed tees are put in place during the pipe laying
process. Working from a laybarge, the tee is placed at the
leading end of the new pipe string and welded to the string,
while the other end is welded to the next pipe joint placed in the
line. The tee is then lowered as part of the pipe string.
A tee is typically an in-line pipe fitting that features a short
branch connection, which sports a standard flange used to bolt
on a tapping machine in the event that it is located in water
depths accessible by divers. In deep water, however, the branch
sports a hub designed for subsea mechanical quick connectors
(MQC), such as collet connectors, to latch on. Inside the short
branch is a tappable steel membrane.
When the tie-in is required, the hot tap assembly is lowered
and connected to the hub in diverless mode in order to tap
away the membrane, creating access to the pipeline. (See
Figure 5). In this case, the hot tap assembly consists of four
fixtures: hot tap machine, upper MQC, isolation valve, and
lower MQC. The latter is connected to the tee hub, secured
and leak-tested to ensure tightness, and the tapping operation
commences. After the tap is complete, the coupon is retracted
into the tapping machine, the isolation valve closed. The tapping
machine is disconnected at the isolation valve interface, by
disengaging the upper MQC, and then returned to the surface.
All activities are conducted with built-in remote control systems
supported by an ROV.
The hot tap assembly is prepared topside. All connections
can be leak-tested and all functions pre-tested before the
assembly is deployed subsea. The entire underwater process
is conducted in diverless mode and controlled topside from the
laptop through the control program.
Tapping into post-installed tees
A post-installed hot tap tee is one that is installed after the pipe
is laid. (See Figure 6). It typically consists of two clamp-halves.
The tee is welded or bolted to the isolation valve, and forms part
of the integrated assembly. This assembly is lowered over the
pipeline, and the two clamp-halves are hydraulically shut and the
bolts are tightened. The sealing elements and mechanical grips
are energised by tightening longitudinal bolts. All bolting actions
are conducted by hydraulic cylinders actuated by remote control
using the ROV, with the tapping machine set in diverless mode.
Remote-controlled subsea fitting installation
To install the post-installed tee in diverless mode, remote
controlled subsea fitting installation methodologies exist in the
industry. Such methodologies utilise ROVs during the operation.
The ROV activates hydraulic cylinders pre-installed on the fitting
halves to close the fitting onto the pipeline. Then a series of bolt
spinning and tensioning functions further secure the fitting in
place, utilising mechanisms pre-installed on the fitting halves.
After pressure testing the installed fitting, the assembly is now
ready to tap. After tapping is completed, the tapping machine is
disconnected at the valve interface and recovered to the surface.
Separating man from machine
Building pipeline developments in deepwater environments only
makes sense if they can be maintained and operated safely
and cost-effectively. With the development of remote-controlled
systems and remote fitting installation methodologies, subsea
pipeline operators stand to benefit in many ways.
By offering solutions that make it possible to carry out hot
tapping operations for repair and intervention, and on lines with
pre and post-installed tees, safety and efficiency are enhanced,
and costs are reduced. As operators delve into deeper and
deeper waters, these innovative remote-controlled systems that
separate man from machine are poised to revolutionise subsea
pipeline maintenance and intervention. O T