TES-ME-STRHO-GL Pipe Stress Engineering Analysis and Design of Hot Tap Branch Connections (CAN-US-MEX)

TransCanada Engineering Specification
TES-ME-STRHO-GL Pipe Stress Engineering

Analysis and Design of Hot Tap Branch
Connections Specification (CAN-US-MEX)
EDMS No.: 7913244 Rev.: 01 Status: Issued Effective Date: 2017-Jun-01
Next Review Date: 2019-Jun-01
WARNING
Hot tapping a pipe is not a routine procedure. Since hot tapping involves cutting or drilling into a pressurized
system while the pipe is still in service, there is a potential for product release, operator error, and injury to
occur. Hot taps should only be performed by trained and qualified staff, and when there is no practical
alternative.
PURPOSE
This Specification defines the requirements for the design and stress analysis of hot
taps, which involves cutting or drilling into a pressurized system while the pipe is still in
service. Hot tapping should only be performed after all other practical alternatives, such
as isolation and shutdown, have been considered.
The objective of this Specification is to ensure:
1. The hot tap connection is defendable to the code to which it was designed.
2. The Company’s operating experience has been communicated through the
requirements, recommendations and preferences.
3. Structural integrity and optimization has been provided.
4. Guidance and acceptability on the design and the location of the hot tap has been
considered.
5. Consistent principles are being implemented and applied across the Company.
6. The rationale and requirements for the hot tap connection has been documented
and acknowledgment has been provided that a hot tap connection cannot be
avoided by:
 diverting flow
 supplying customers from other sources
 coordinating outages with customers
SCOPE / APPLICABILITY
This Specification applies to all divisions of the Company and its wholly-owned
subsidiaries, and all operated entities/facilities in Canada (CAN), United States (U.S.),
and Mexico (MEX).
Unless otherwise specified, the Authenticating Engineer(s) is the subject for all the
considerations and requirements included in this Specification.
The Authenticating Engineer(s) is also responsible for ensuring that the hot tap
connection is defendable to the code to which it was designed.
This Specification applies to steel pipe of all grades, wall thicknesses, and diameters
of run and branch connections.
This Specification applies to the following hot tap connections in all configurations:
Classification: DE-16 UNCONTROLLED IF PRINTED – LATEST CONTROLLED COPY IN FILENET P8 Page 1 of 72

 Sockolets, Thredolets, Weldolets

 split tees
 STOPPLE fitting
 full encirclement reinforced saddles
This Specification does not apply to piping covered under B31.1 Power Piping.
This Specification does not apply to plastic piping.
Within this Specification, TransCanada is referred to as the Company.
Within this Specification, the following terms and definitions apply for requirements:
 Shall—expresses a requirement, i.e., a provision that the user is obliged to satisfy
in order to comply with the standard. Shall is not a recommendation but a
requirement.
 Should—expresses a strong preference, recommendation or that which is
advised, but not required.
 Must—denotes a requirement of the Company, for which no deviation or variance
would be granted.
 May— expresses an option or that which is permissible within the limits of the
standard.
 Consider―assumes that a competent person will evaluate options to fulfill the
intent of the requirement and make a documented decision supported by evidence
to ensure protection of people, equipment and the environment by achieving the
appropriate level of functional integrity.
Wherein the Manufacturer’s literature, governmental or regulatory requirements conflict
with this Specification, the more stringent requirement shall govern.
The long-term operability, reliability and maintenance of the entire system shall be
considered when deviating from the requirements and recommendations denoted as a
“Should”. The direction to deviate from the denoted “Should” statement is provided in a
document authenticated by the Company’s Engineer(s) and approved by the
Company's Project Manager describing the new requirements and recommendations.

Table of Contents
GLOSSARY.............................................................................................................................................................. 7
EVALUATION OF HOT TAPS AS A DESIGN SOLUTION..................................................................................... 11
2.1 Requirement for Documenting a Hot Tap Connection .......................................................................... 11
2.2 In-Service Welding Assessment ........................................................................................................... 12
2.3 Tapping Requirements ......................................................................................................................... 13
2.4 Horizontally Oriented Hot Tap Stub Lengths ........................................................................................ 13
STRESS ANALYSIS REQUIREMENTS................................................................................................................. 14
3.1 General Stress Analysis Requirements ................................................................................................ 14
3.2 Units of Measure .................................................................................................................................. 15
BRANCH CONNECTION REINFORCEMENT REQUIREMENTS ......................................................................... 15
4.1 Branch Diameter NPS 1-1/2 or Less .................................................................................................... 15
4.2 Branch Diameter NPS 2 or Greater ...................................................................................................... 16
4.3 Full Encirclement Reinforcement Saddles............................................................................................ 16
4.4 Split Tees ............................................................................................................................................. 17
4.5 STOPPLE Fittings ................................................................................................................................ 18
TAPPING VALVES................................................................................................................................................. 18
5.1 General Requirements ......................................................................................................................... 18
5.2 Valves for Branch Connections Diameter NPS 2 and Smaller ............................................................. 18
5.3 Valves for Branch Connection Diameters Greater Than NPS 2 ........................................................... 22
5.4 Valves for STOPPLE Installation .......................................................................................................... 22
LOCATION REQUIREMENTS OF HOT TAPS ...................................................................................................... 23
6.1 Overview .............................................................................................................................................. 23
6.2 Dynamic, Natural Frequency and Pulsation Analysis Conditions ......................................................... 23
6.3 Hot Tap Location - Guidelines .............................................................................................................. 24
6.4 Hot Tap Location and requirement - Restrictions ................................................................................. 28
6.5 Branch Configuration Requirements .................................................................................................... 29
DESIGN REQUIREMENTS .................................................................................................................................... 32
7.2 Support Locations ................................................................................................................................ 32
7.3 Supporting Vertical Assemblies NPS 2 or less with Structural Supports .............................................. 35

7.4 Supporting Horizontal Assemblies with Structural Supports................................................................. 35

7.5 Supporting Horizontally Oriented Assemblies with Imported Backfill ................................................... 36
7.6 Anchors/Line Stops .............................................................................................................................. 40
7.7 Backfill and Compaction ....................................................................................................................... 40
7.8 Isolation Medium Between Piping and Supports .................................................................................. 42
ACCEPTABLE STRESS MITIGATION METHODS REQUIREMENTS .................................................................. 43
8.1 Expansion Joint(s) ................................................................................................................................ 43
8.2 Expansion Mitigation ............................................................................................................................ 43
8.3 Mitigation for Excessive Overburden Weight........................................................................................ 45
8.4 Mitigation for Excessive Bending Moment............................................................................................ 45
STRESS PIPING ANALYSIS ................................................................................................................................. 46
9.1 General................................................................................................................................................. 46
9.2 Pipe Analysis Software......................................................................................................................... 47
9.3 Restraint ............................................................................................................................................... 47
9.4 Load Cases .......................................................................................................................................... 47
9.5 Operational Case ................................................................................................................................. 48
9.6 Cold Case............................................................................................................................................. 48
9.7 Occasional Case .................................................................................................................................. 48
9.8 Load Combinations and Allowable Stress Requirements ..................................................................... 49
9.9 Content Weight..................................................................................................................................... 52
9.10 Thermal Analysis Conditions ................................................................................................................ 52
9.11 Soil Modelling Requirements ................................................................................................................ 53
9.12 Soil Settlement Modeling...................................................................................................................... 54
9.13 Pipe Support Loads .............................................................................................................................. 55
9.14 Pipe Support Location .......................................................................................................................... 57
9.15 Pipe Support Coefficient of Friction ...................................................................................................... 57
9.16 Hot Tap Bending Moment Criteria ........................................................................................................ 58
9.17 Allowable Pipe Displacements ............................................................................................................. 58
9.18 Allowable Pipe Support Displacement.................................................................................................. 58
9.19 Fittings .................................................................................................................................................. 59
9.20 Flange Analysis .................................................................................................................................... 60

9.21 Discontinuity Stresses .......................................................................................................................... 61

9.22 Mitigation for Stress Issues .................................................................................................................. 61
9.23 Evaluation of Existing Piping Impacted by New Piping or Piping Modifications ................................... 61
MECHANICAL DOCUMENTATION AND RECORDKEEPING .............................................................................. 62
10.1 Mechanical Report Requirements ........................................................................................................ 62
PIPE STRESS DOCUMENTATION AND REPORT REQUIREMENTS ................................................................. 63
11.1 Analyst and Experience........................................................................................................................ 63
11.2 Initial Procedural Requirements ........................................................................................................... 63
11.3 Hot Tap Stress Analysis Report ........................................................................................................... 64
SIGN-OFF AND FOLLOW-UP ............................................................................................................................... 67
VARIANCES........................................................................................................................................................... 67
ROLES AND RESPONSIBILITIES ......................................................................................................................... 67
REFERENCES ....................................................................................................................................................... 69
DOCUMENT HISTORY.......................................................................................................................................... 71
DESCRIPTION OF CHANGE................................................................................................................................. 71
APPROVALS.......................................................................................................................................................... 71
List of Tables
Table 2-1: Typical Hot Tap Stub Length and Valve Assembly .....................................................................................13
Table 7-1: Minimum Mainline Excavation Length Requirements for Installing Reinforcement Saddle Hot Tap for
Pipelines NPS 24, 30, 36, 42, and 48 ..........................................................................................................................38
Table 7-2: Minimum Mainline Excavation Length Requirements for Installing Reinforcement Saddle Hot Tap for
Pipelines NPS 12, 16 and 20 .......................................................................................................................................38
Table 9-1: Code Combinations ....................................................................................................................................50
Table 9-2: Descriptions for Code Combinations...........................................................................................................52
Table 9-3: Pipe Support Coefficient of Friction.............................................................................................................57
Table 9-4: Allowable Pipe Support Displacement at Aboveground Pipe Support ........................................................59
Table 9-5: Allowable Pipe Support Displacement at Belowground Pipe Support.........................................................59
Table 14-1: Roles and Responsibilities ........................................................................................................................67
Table 15-1: Regulatory References .............................................................................................................................69
Table 15-2: External Industry References ....................................................................................................................69

Table 15-3: Internal References...................................................................................................................................69
List of Figures
Figure 2-1: Horizontally Oriented Hot Tap Stub Length ...............................................................................................14
Figure 5-1: Typical Configuration for Small Diameter Hot Taps Less Than NPS 2 ......................................................20
Figure 5-2: Typical Configuration for NPS 2 Small Diameter Hot Taps with Pipe Stress Approval ..............................21
Figure 6-1: Preferred Distance from Bend to Hot Tap.................................................................................................25
Figure 6-2: Horizontal Hot Tap Assembly Located in a Structural Foam Box ..............................................................30
Figure 6-3: Graphic Illustration of a Horizontal Hot Tap Assembly Branch Connect Offset .........................................31
Figure 6-4: Graphic Illustration of a Vertical Hot Tap Assembly Branch Connect Offset .............................................31
Figure 7-1: Horizontal Hot Tap Assembly Supported Run Pipe ...................................................................................33
Figure 7-2: Horizontal Hot Tap Assembly Supported Branch Connection and Hot Tap Machine ................................35
Figure 7-3: Horizontal Hot Tap Assembly Supported Branch Connection and Run Pipe.............................................36
Figure 7-4: Horizontal Hot Tap Assembly Supported Branch Piping with Excavation Limits .......................................39
Figure 7-5: Horizontal Hot Tap Assembly Showing Areas of Critical Compaction .......................................................41
Figure 8-1: The Foam around Horizontal Hot Tap Assembly .......................................................................................44

GLOSSARY
Abaqus (formerly ABAQUS)
Finite element analysis software that is used to simulate interactions of all applied
loads and boundary conditions to determine stresses, strains and displacements.
Accountable
The person who is obliged to report, explain or justify the pipe stress analysis.
ANSYS
Finite element analysis software that is used to simulate interactions of all applied
loads and boundary conditions to determine stresses, strains and displacements.
ASME
American Society of Mechanical Engineers
Authentication or Authenticated
Application of the professional engineer or geoscientist’s stamp/seal, signature and
date.
AutoPIPE
Linear elastic finite element analysis software with a focus on piping, used to simulate
interactions of all applied loads and boundary conditions to determine piping stresses,
strains and displacements.
Boundary conditions
The set of conditions used for the behavior of the solution to the model or analysis at
the boundary of its domain. Boundary conditions are important in determining the
mathematical solutions to the physical problem.
Caesar II
A linear elastic finite element analysis software program with a focus on piping, used
to simulate interactions of all applied loads and boundary conditions to determine
piping stresses, strains and displacements.
Competent
Qualified, trained and experienced to perform the required duties.
Competent engineering judgment
Judgment based on qualified, trained and experienced engineering knowledge.
Concrete pad
A flat concrete pad that pipe rests on to limit pipe settlement. Concrete pads are
typically located underground.

Demonstrate
Verify, or describe and explain, by the use of records, measurements, tests,
comparison of specimens, experiments, or analysis by a competent person,
supported by documentation.
Ethafoam 220
A soft foam material used to mitigate elevated forces and stress concentration.
Expansion jog
An off-set in pipe made up of two elbows or bends with enough flexibility to absorb
thermal expansion and reduce temperature-induced pipe stress and displacement to
an acceptable level.
Expansion loop
A loop in pipe made up of four elbows or bends with enough flexibility to absorb
thermal expansion and reduce temperature-induced pipe stress and displacement to
an acceptable level.
Flexibility
A piping system that allows for thermal expansion, contraction, or other movement
without causing excessive stress in the piping, components, or equipment.
Foam
Three types of foam have been referenced within the pipe stress analysis section of
this Specification.
 Ethafoam 220 is a soft material used to mitigate elevated forces and stresses
concentration.
 Polystyrene geofoam blocks are a harder material used as a backfill replacement
to mitigate overburden on underground piping.
 High density polyurethane foam box used to structurally reduce the backfill weight
and reduce settlement on small diameter piping.
Full encirclement reinforced saddle
Similar in appearance to split tees, full encirclement reinforced saddles perform a
more limited function. The full encirclement reinforced saddle is split in half with a side
outlet, but the outlet has no flange and is sized to fit around a separately welded
branch pipe. The full encirclement reinforced saddle is not intended to hold internal
pressure like the split tee, but rather to reinforce a branch-to-header connection.
Gas service
Transportation of natural gas (in the vapour phase) at the operating pressures and
temperatures of the system.
Hot tap

A hole made through a Sockolet, Thredolet, Weldolet, split tee, STOPPLE fitting, or
full encirclement reinforced saddle to a pipe while the piping is under internal
pressure.
In-service piping
Piping that contains service fluid (liquid hydrocarbon or natural gas) at any pressure
or flow rate.
Liquids service
Transportation of hydrocarbon (in a liquid, quasi-liquid, or multi-phase state) at the
operating pressures and temperatures of the system.
Lock-O-Ring flange
A split tee branch fitting with a flanged branch connection commercially manufactured
and trademarked by T.D. Williamson, Inc. A Lock-O-Ring may be fitted with flow-
through assembly guide bars to allow full flow into a branch line while permitting pigs
to traverse the opening, or a plug to isolate a branch for removal of the tapping valve.
Membrane (contact) stresses
Local longitudinal and circumferential stresses generated in the area of the pipe shell
adjacent to the tip of the pipe support.
Polystyrene geofoam blocks
A dense foam material used as a backfill replacement to mitigate overburden on
underground piping.
Polyurethane foam box
High density foam used to structurally reduce the backfill weight and reduce
settlement on small diameter piping.
Saddle
A structural saddle used for supporting pipe (i.e. saddle support). A saddle is not to
be confused with a full encirclement reinforced saddle, which is actually a hot tap
fitting. The industry term for a saddle is a fitting that does not completely encircle the
pipe. Saddles (i.e., pads, half soles, and reinforcing saddles) are prohibited by the
Company’s system.
Saddle support
A support that encompasses 120° to 180° of the pipe.
SIF
Stress Intensity Factor

Sleeve
A metal fitting that is installed around a pipe for reinforcement and pressure
containment when a pipeline repair is required. There are two different types of full
encirclement sleeves: type A for reinforcement, and type B for pressure retaining
reinforcement. In this Specification, a full encirclement reinforcement used as part of
a hot tap is referred to as full encirclement reinforced saddle.
Sockolet
A commercially manufactured integral branch fitting shaped to be welded onto a pipe,
and with the branch end ready for socket welding to the adjoining branch pipe.
Split tee
A split tee is a pressure containing tee that is split in half in order to be welded to a
pipeline, and includes a STOPPLE fitting.
Springline
The horizontal centreline of the pipe.
STOPPLE
A plug that is placed through a STOPPLE fitting to stop or redirect the flow in a
pipeline. STOPPLE is a trademark of T.D. Williamson, Inc.
STOPPLE fitting
A STOPPLE fitting is a split tee fitting that is used to install a sealing element to stop
the flow in a pipeline. STOPPLE fittings are used to facilitate the insertion of a
STOPPLE to temporarily halt fluid flow in the run pipe. These fittings are straight with
the run and branch being of equal size.
Thread-O-Ring (TOR)
A fitting used as a purge and/or equalization fitting in a variety of hot tapping and
plugging applications.
Thredolet
A commercially manufactured branch fitting shaped to be welded onto a pipe, and
with the branch end threaded to accept the adjoining branch piping.
Vendor
Any outside source hired by the Company to complete work.
Virtual Anchor (VA) length
Length of pipe (boundary condition) required such that the point of interest is not
influenced by temperature or pressure and is dependent on soil friction properties.
Weldolet
A commercially manufactured branch fitting shaped to be welded onto a pipe and with
the branch end prepared to be butt-welded to the adjoining branch piping.

Clarification: All material mentioned in this document manufactured by T.D.

Williamson, Inc are used as examples. Company approved equivalent can be used.
EVALUATION OF HOT TAPS AS A DESIGN SOLUTION

2.1 Requirement for Documenting a Hot Tap Connection
2.1.1 Hot taps using Sockolets, Thredolets, Weldolets, split tees, STOPPLE fittings or full
encirclement reinforced saddles may be used on the Company’s pipeline and piping
system when the following conditions have occurred:
 an uninterrupted supply to customers on the pipe or pipeline proposed to be
tapped is validated
 a site-specific engineering design and analysis has been conducted and
completed, along with the addition of engineering controls during construction
2.1.2 The rationale for installing Sockolet, Thredolet, Weldolet, split tee, STOPPLE fitting or
full encirclement reinforced saddle hot taps versus a conventionally installed tee or
branch connection shall be documented as an engineering decision.
2.1.3 The engineering decision shall be documented in project DBM with input from the
Company’s System Design Commercial Operations or Oil Movements departments, as
well as the Outage Coordinator.
2.1.4 The documented rationale for a hot tap over a conventional installation requiring an
outage shall consider the following:
 locational requirement and restrictions
 existing isolation
 availability of double-block and bleed isolation for hot work
 alternate flow paths
 seasonality (whether customers can be supplied through secondary flow paths at
times of the year when demand is lower)
 coordination of outages with planned customer outages (e.g., plant turn-arounds
usually applicable to large industrial customers)
 volume of product required to be purged (i.e., length of line between isolation
valves)
 product handling, collection and disposal
 overall cost of hot tap operation vs. cost of outage
Clarification: Additional analysis, components, equipment and construction
coordination are required to properly and successfully execute a hot tap.

2.1.5 Hot taps connections should be avoided when:

 flow can be diverted to install a conventional tee
 customers can be supplied from other sources
 outages can be coordinated with customers
2.1.6 The engineering decision shall be used to document the proposed engineering design
and analysis including locational guidelines, requirements and restrictions.
2.1.7 A pipe stress analysis shall be completed for the proposed engineering design of every
split tee, STOPPLE fitting and full encirclement reinforced saddle installation with or
without a branch connection.
2.1.8 The Company’s Engineering personnel shall reserve the right to replace a full
encirclement reinforced saddle branch connection with a split tee or conventional tee
based on location and the probability of significant bending moments acting on the
connection from operational or external loading.
2.1.9 The rationale for installing Sockolet, Thredolet, Weldolet, split tee, STOPPLE fitting and
full encirclement reinforced saddle hot taps versus a conventionally installed tee or
branch connection shall be revisited as the design and analysis develops.
2.1.10 The documented engineering decision providing the rationale for the hot tap shall be
archived in the project files.
2.2 In-Service Welding Assessment
2.2.1 An in-service welding assessment for the proposed hot tap installation shall be
performed by the Company’s Welding Specialist(s).
2.2.2 The Company’s Project Manager shall ensure that the Company’s Welding
Specialist(s) are consulted in order to conduct a weld assessment of the split tees,
STOPPLE fittings and full encirclement reinforced saddles to determine the required
operating conditions for welding, and to provide applicable welding procedures.
2.2.3 Due to the wall thickness of the mainline pipe and welding restrictions, the locations of
the split tee, STOPPLE fitting and full encirclement reinforced saddle may be limited.
Contact the Company’s Welding Engineers for a wall thickness assessment.
Clarification: It is preferred to place the split tee, STOPPLE fitting, and full
encirclement reinforced saddle on heavy wall sections of the pipeline. Welding may
limit or restrict the location of the hot tap based on wall thickness and grade of the
pipeline.
2.2.4 The Company’s Project Manager shall ensure that the design parameters for the
proposed hot tap for an In Service Welding Assessment are communicated to the
Company’s Welding Specialist(s) for assessment.
2.2.5 The in-service welding assessment shall confirm that in-service welding to the run pipe
(pipeline) is acceptable.

2.2.6 The in-service welding assessment shall provide any line pressure restrictions and any
limiting parameters with welding, as well as a welding procedure.
2.3 Tapping Requirements
2.3.1 The required clearance of hot tapping machines between pipelines running parallel to
each other at similar elevations, or other structures and features that may interfere with
the tapping operation, shall be considered.
2.3.2 The measuring rod included with large-bore tapping machines shall be included in the
clearance considerations when required.
Clarification: The measuring rod adds significant additional length to the tapping
assembly. While the measuring rod is useful for determining cutter depth, the
measurement function may be carried out by a trained and competent operator using
a tape measure. In some cases, the measuring rod may be removed to allow for tapping
in constrained spaces. This practice increases the probability of human error and
sacrifices some accuracy.
2.3.3 The required stroke of the cutting tool for the tapping machines shall be calculated to
ensure that the total length of the branch connection from the valve face (where the
tapping machine is connected) through the run pipe wall is less than the available
stroke.
2.3.4 The required stroke calculation shall include the distance required to complete a full
thickness tap through the run pipe around the full circumference of the cutting tool (i.e.,
the branch internal circumference), as well as the length of the tapping valve.
2.4 Horizontally Oriented Hot Tap Stub Lengths
2.4.1 Typical hot tap stub length and valve assembly dimensions are provided in Table 2-1
(with corresponding Figure 2-1) and should be considered for the branch connection
size unless the other lengths are sufficient for weld spacing and the hot tap machine,
and meet the pipe stress requirements.
Clarification: The stub and valve assembly dimensions are designed to allow
acceptable weld spacing between welds, and to ensure the flange to run pipe face
dimension is acceptable for the reach of the hot tap machine.
Table 2-1: Typical Hot Tap Stub Length and Valve Assembly
Branch Pipe A A B B C C
(NPS) (mm) (in) (mm) (in) (mm) (in)
2 592 23.3 442 17.4 150 5.9
4 932 36.7 732 28.8 200 7.9
6 1059 41.7 859 33.8 200 7.9
8 1160 45.7 960 37.8 200 7.9

Branch Pipe A A B B C C
(NPS) (mm) (in) (mm) (in) (mm) (in)
10 1287 50.7 1087 42.8 200 7.9
12 1338 52.7 1138 44.8 200 7.9
16 1741 68.5 1491 58.7 250 9.8
20 1944 76.5 1694 66.7 250 9.8
24 2147 84.5 1897 74.7 250 9.8
30 2451 96.5 2151 84.7 300 11.8
Legend:
A = Dimension from the edge of run pipe to the face of the flange on the branch valve (Maximum
Length)
B = Dimension of the valve assembly from end of pipe to the face of the flange on the branch valve
C = Dimension of stub from the edge of run pipe to the start of the valve assembly
Figure 2-1: Horizontally Oriented Hot Tap Stub Length
STRESS ANALYSIS REQUIREMENTS

3.1 General Stress Analysis Requirements
3.1.1 Piping stress modeling and analysis shall be conducted for all new hot tap connections
equal to or greater than NPS 4.
3.1.2 A piping stress model and analysis shall be conducted if modifications are made to the
branch connection or mainline piping that could affect the external loading of an existing
hot tap equal to or greater than NPS 4.

Clarification: If it can be determined based on competent engineering judgment that

modifications to the hot tap and pipe support(s) affect neither the stiffness of the support
structure nor the flexibility of the piping, then a stress model and analysis may not be
required.
3.1.3 A stress model and analysis based on competent engineering judgment may not be
required for ancillary piping, such as power gas and drain lines.
3.1.4 All exemptions shall be considered using competent engineering judgment, and
formally documented.
3.2 Units of Measure
The units used for pipe stress analysis shall be based on the location of the project as
follows:
 Projects located within Canada and Mexico shall use the International System of
Units (SI).
 Projects located within the United States shall use Imperial units of measure.
BRANCH CONNECTION REINFORCEMENT REQUIREMENTS

4.1 Branch Diameter NPS 1-1/2 or Less
4.1.1 Permanent hot tap connections with a branch diameter of NPS 1-1/2 or less shall use
a Sockolet.
Exception: Mueller Tees for sales taps.
4.1.2 Mueller Tees, NPS 1-1/2 or less, may be used as permanent hot tap connections for
sales taps.
4.1.3 Thread-O-Rings (TORs) may be used for special applications, provided full written
approval is obtained from Company’s Mechanical Engineering personnel.
Clarification: Special applications for the use of Thread-O-Rings include temporary
gas ports for gas monitoring.
Clarification: Thread-O-Ring and Mueller “Safety Nipple” fittings must have a
completion plug installed before the line can be placed back in service. Leaving a
Thread-O-Ring or Safety Nipple fitting in place without a completion plug is prohibited.
Some tapping tee fittings, such as those manufactured by Mueller, have an integral
cutter that actually makes the tap and can act as a shutoff. This cutter needs to be left
in place even if the tap is made with a drill. Removal of the cutter before placing the
pipeline back in service is prohibited.
4.1.4 A Thredolet may be used as a temporary hot-tapped branch connection for expelling
operations only.
4.1.5 A Thredolet may be used as a permanent aboveground branch connection to
instrumentation by tubing.

4.1.6 The Thredolet used for a belowground, temporary hot-tapped branch connection shall
be plugged and seal welded after use.
4.2 Branch Diameter NPS 2 or Greater
4.2.1 Hot tap branch connections shall be reinforced as required by the applicable regulations
in the jurisdiction having authority, and in accordance with the applicable design codes.
4.2.2 Hot tap connections with a branch diameter NPS 3 and greater shall have full
encirclement reinforcement or split tee.
4.2.3 An NPS 2 hot tap connection may be made with a encirclement reinforcement or
Weldolet with approval from the Company’s Mechanical Design personnel, in
consultation with the Company’s Stress Engineering personnel and the Company’s
Welding Specialist(s) on a case-by-case basis.
4.2.4 Branch connection structural reinforcements shall be selected based on the ratio of
branch diameter to run piping diameter.
4.2.5 Full encirclement, consisting of either a full-encirclement saddle or a split tee, shall be
used for the structural reinforcement of a hot tap branch connection.
Clarification: Any reinforcement pad or saddle that does not provide full encirclement
cannot be used.
4.2.6 All full encirclement reinforced saddle branch connections shall be two-thirds (2/3) or
smaller of the nominal outer diameter of the mainline pipeline.
4.2.7 If the branch connection is required to be greater than two-thirds (2/3) of the mainline
pipeline split tee, a STOPPLE fitting, or a conventional tee shall be used.
4.2.8 The use of a full encirclement reinforced saddle for hot tap branch connection greater
than two-thirds (2/3) of the mainline pipeline shall not be allowed, there will be no
exceptions.
4.2.9 For branch-to-run ratios greater than two-thirds (2/3), a split tee complete with a
Lock-O-Ring flange shall be specified to facilitate installation of flow through fittings
complete with scrapper bars to allow future pigging of the run pipe.
Clarification: A Lock-O-Ring plug would be required after a STOPPLE operation or
on a split tee not requiring a permanent branch connection.
4.3 Full Encirclement Reinforcement Saddles
4.3.1 Design formulas specified in the applicable code shall be used for the design of full
encirclement reinforcement saddles.
4.3.2 The minimum length and minimum thickness of full encirclement reinforcement saddles
shall be based on the Area Replacement Method described by the applicable code.
Clarification: The Area Replacement Method is based on providing sufficient
reinforcement material to replace the material removed in making the hole in the run
pipe for the branch connection.

4.3.3 The minimum length of full thickness reinforcement based on the Area Replacement
calculation shall be specified.
4.3.4 The actual reinforcement thickness shall be specified by rounding up to the next
available standard plate thickness (usually in 1/8 in. increments).
4.3.5 Calculated minimum thickness shall not be rounded down to achieve a standard plate
thickness.
4.3.6 The grade of the reinforcement material used in the area replacement calculation shall
not be greater than the lowest grade of the branch pipe or the run pipe.
4.3.7 The grade of the reinforcement material shall not be assumed to be less than 241 MPa
(35 ksi).
4.3.8 Credit shall not be given if the grade of the actual reinforcement fitting is greater than
that assumed in the area replacement grade, in accordance with the applicable code.
4.3.9 Drawings submitted by the manufacturer of the full encirclement reinforcement saddle
shall be evaluated against the relevant code requirements, the area reinforcement
calculation document, and Company’s Specification to ensure conformance with
regulatory and design requirements.
4.4 Split Tees
4.4.1 Split Tees shall only be designed by the Company’s approved Fitting Vendor, based on
design inputs supplied by the Mechanical Designer.
4.4.2 The design input shall specify the following:
 nominal diameter, wall thickness and grade of the run pipe
 nominal diameter and pressure rating of branch flange
 service fluid
 design code
 design pressure
 design factor per the applicable regulations
 location factor (applicable to Canadian code only)
 minimum and maximum design temperatures
 branch connection type (e.g., weld neck, flange and Vendor options)
Example: Some vendors (such as T.D. Williamson, Inc.) will provide an electronic
questionnaire for data collection, which may be updated from time to time.
4.4.3 Authenticated reinforcement calculations shall be supplied by the manufacturer based
on the design rules for full encirclement (Tee-Type) reinforcement as specified in the
relevant design codes.

4.4.4 Drawings and calculations submitted by the manufacturer shall be evaluated against
the design inputs specified to ensure that the drawings conform to the design
requirements.
4.4.5 The drawings and calculations submitted by the manufacturer shall conform to the
relevant design code requirements.
4.5 STOPPLE Fittings
4.5.1 STOPPLE fittings may be used as a bypass to facilitate continued flow around a work
area, or without a bypass for isolation purposes not requiring a bypass.
4.5.2 STOPPLE fittings shall only be designed by the Company’s approved fitting Vendor,
based on design inputs supplied by the Mechanical Designer.
4.5.3 STOPPLE fittings shall be subject to the same requirements as a split tee.
4.5.4 The design inputs shall be validated before providing the STOPPLE fitting Vendor with
the design data.
4.5.5 The Company’s Outage Coordinator, Isolation Coordinator, and Operational Planning
staff shall be consulted before identifying the following pressure ranges to the
STOPPLE fitting Vendor:
 operating pressure range and flow velocity range during tapping operation
 operating pressure range and flow velocity range during insertion of the STOPPLE
 operating pressure range and flow velocity range while the STOPPLE plug is in
place
TAPPING VALVES
5.1 General Requirements
5.1.1 All hot taps shall be equipped with a valve through which the tapping is conducted.
5.1.2 The hot tap valve shall be used for providing isolation of the run pipe once the tapping
machine is removed.
5.1.3 The hot tap valve shall remain in place subsequent to the tap for branch connection
installation.
Exception: STOPPLE operations where a branch connection is not required and the
pipe can be re-sealed through use of a Lock-O-Ring Plug and a blind flange.
5.1.4 The length of the tapping valve shall be accounted for when specifying a tapping valve,
since it makes up a significant portion of the required stroke.
5.2 Valves for Branch Connections Diameter NPS 2 and Smaller
5.2.1 The hot tap valves that remain in place for a branch connection shall conform to the
Company’s Material Specifications.

5.2.2 The hot tap valves for a branch connection diameter of NPS 2 and smaller used for
power gas risers and small diameter sales taps may not require double block and bleed
functionality.
5.2.3 If the tapping valve does not have double block and bleed functionality, the final
assembly connection shall be specified and completed without welding. Typical
configurations are illustrated in Figure 5-1 and Figure 5-2.
Clarification: The hot tap tapping valve downstream of the piping connection needs to
be flanged. Trunnion mounted ball valves are not available in sizes less than NPS 2.
Floating ball valves are not double block and bleed. Therefore, all hot work on the piping
downstream of the hot tap valve needs be completed prior to connection to the hot tap
valve, and the final connection of the downstream assembly and the hot tap valve may
not be welded. A flanged connection is required in these cases, as illustrated in Figure
5-1 and Figure 5-2.
Caution: Tapping machines for smaller diameter branch connections have a
proportionally shorter stroke. Therefore, tapping assembly length for small diameter hot
taps is of special concern. The configuration as illustrated in Figure 5-1 is for an NPS
1½ tap, where a socket weld x flange valve is used and, for certain run pipe diameter
and thickness combinations, this configuration is too long to allow for a successful tap.
In such cases, selecting an NPS 2 tapping valve, which is available with a butt-weld x
flange end connection, as illustrated in Figure 5-2, can allow for the elimination of the
76.2 mm (3.0 in.) long nipple (by welding the valve directly to a Weldolet) and thus a
shorter required stroke. It is preferred to include the 76.2 mm (3 in.) pipe nipple so that
the assembly can be pretested prior to installation and reduce the possibility of the
valve seat being damaged during welding.
Clarification: Since 101XL tapping machine is available in TransCanada now, socket
weld x socket weld valve with nipple and socket weld flange can be considered for
some applications.

Figure 5-1: Typical Configuration for Small Diameter Hot Taps Less Than NPS 2

Figure 5-2: Typical Configuration for NPS 2 Small Diameter Hot Taps with Pipe Stress
Approval
Note 1:
Figure 5-1 and Figure 5-2, depicted in the vertical orientation, can be oriented in either
the horizontal or vertical plane.
Note 2:
Figure 5-2 does not indicate a nipple between the Weldolet and the valve, which is
allowed.
Caution: For underground situations, the current configuration is preferred due to the
capacity for increased bending moments. The addition of the nipple may be limiting,
requiring an increased wall thickness or diameter.

5.3 Valves for Branch Connection Diameters Greater Than NPS 2

5.3.1 The hot tap valves that remain in place for branch connections shall conform to the
Company’s specifications.
5.3.2 The hot tap valves for branch connections diameter greater than NPS 2 shall be full-
bore.
Clarification: Full bore is required to facilitate passage of the cutting head through the
valve for execution of the tap. Taps may be made through reduced port valves but in
such cases, the hole cut in the run pipe will be smaller than the branch diameter and
will act as a flow restriction.
5.3.3 The hot tap valves for branch connection diameters greater than NPS 2 shall have
double block and bleed capabilities.
Clarification: Double block and bleed functionality is required to allow hot work to be
performed safely behind the hot tap valve once the tap is completed and the branch
assembly is in communication with the service fluid.
5.3.4 If the full-bore valve is to remain on the split tee, the internal diameter of the valve shall
be communicated to the split tee and Lock-O-Ring supplier to ensure that the Lock-O-
Ring diameter (including the O-ring) is smaller than the valve bore.
5.4 Valves for STOPPLE Installation
5.4.1 Valves for STOPPLE installation, where the STOPPLE connection will not be used as
a permanent branch connection subsequent to the STOPPLE, may be provided by the
Stoppling Contractor.
5.4.2 Due to their short face-to-face length, the Stoppling Contractor may opt to use a
sandwich valve as a tapping valve for Stoppling operations.
5.4.3 Upon removal of the STOPPLE, the taps shall be closed through use of a Lock-O-Ring
plug inserted through the tapping valve and set in the Lock-O-Ring flange of the
STOPPLE fitting. This allows for removal of the tapping valve.
5.4.4 A scarfed nipple shall be welded to the Lock-O-Ring plug. The scarfed nipple is
normally supplied by the split tee Vendor.
Clarification: The scarfed nipple and coupon is intended to ensure that pigs can travel
by the tap without getting stuck. This only applies to branch connections that will have
a blind flange installed and the valve removed. A scarfed nipple is typically half of one
pipe diameter of the branch connection, to a maximum of NPS 16, to which the run
pipe coupon is welded to cover the hot tap hole when the Lock-O-Ring Plug is set in
place in the Lock-O-Ring Flange.
5.4.5 After removal of the tapping valve, a blind flange shall be installed over the Lock-O-Ring
plug.
5.4.6 The blind flange shall be drilled and tapped to NPS 1 NPT and an NPS 1 vented plug
shall be installed. The blind flange shall be supplied with lifting lugs.

5.4.7 The blind flange, studs, nuts and gaskets supplied by Stopple fitting vendor shall be per
Company Specification or as specified in the Purchase Order.
5.4.8 The blind flange shall be torqued per TES-ME-FBT-GL Flange Bolt Tightening
Specification (EDMS no. 6489784).
LOCATION REQUIREMENTS OF HOT TAPS

6.1 Overview
Note:
The acceptability of the location of the split tees, STOPPLE fittings and full encirclement
reinforced saddle connections are dependent on the following conditions:
 Wall thickness of the mainline pipe – the amount of welding required is a function
of the pipe wall thickness. The volume of welding (heat) applies a very complex
assortment of thermal residual stresses within the shell of the mainline pipe.
Thermal residual stress is a function of the wall thickness. Therefore, the
allowable wall thickness of the mainline pipeline is dictated by welding.
 Thermal displacement of the mainline pipe – the displacement from thermal
expansion and contraction at a location, and equilibrium of the forces, is a function
of pipeline geometry, the proximity to a bend, and pipe anchoring which is
proportional to the surrounding soil properties and piping configuration upstream
or downstream of the location. Therefore, the pipeline geometry and the proximity
to a hot tap is dictated by pipe stress.
 Geotechnical conditions – soil properties are a major factor that affects pipeline
restrain from excessive thermal displacement. A critical component is to ensure
competent soil conditions such that the hot tap is not affected by settlement and
inconsistent soil properties within the virtual anchor (VA) length of the pipeline.
Therefore, the geotechnical conditions surrounding the hot tap are dictated by
pipe stress.
6.2 Dynamic, Natural Frequency and Pulsation Analysis Conditions
Note: For some hot tap locations (aboveground or underground), it is prudent that the
pipe stress analysis includes dynamic/pulsation analysis and a detailed Finite Element
Analysis (FEA) with shell or solid elements to determine the fatigue life and flaw
acceptance criteria through fracture analysis and pipe wall displacement.
6.2.1 A dynamic, pulsation, and detailed Finite Element Analysis (FEA) should be performed
if the location of a split tee, STOPPLE fitting or full encirclement reinforced saddle
connection is within:
 3.2 km (2.0 miles) of a reciprocating gas compressor station
 1.0 km (0.6 miles) of a liquid pump station
 centrifugal gas compressor station facility piping (within suction and discharge
valves)

 one hundred pipe diameters (100D) of a liquid control valve

Clarification: Avoid installing station suction and discharge valves by hot tapping for
both compressor stations and pump stations.
Exception: The above limitation does not include Sockolet or Weldolet connections of
NPS 2 and less.
Clarification: Pressure fluctuations and thermal cycling loading from compressors
(reciprocating units being more critical) or pumps need to be accounted for, which
requires a complex type of FEA design analysis with the use of shell elements and
heavy computational requirements conducted by specialized Contractors.
Clarification: If pressure fluctuations and thermal cycle loading from the reciprocating
compressor or pump are low enough according to sound engineering judgement, the
hot tap may be designed and analyzed under normal static type of stress analysis.
6.2.2 Locations that require the consideration of dynamic and pulsation analysis should be
reviewed with the Company’s Project Manager and the Company’s Stress Engineering
personnel.
6.3 Hot Tap Location - Guidelines
These hot tap guidelines are intended to assist in the site selection of a hot tap for
preliminary design. Hot tap locations not meeting these guidelines will require an
increased amount of engineering vigilance by the Project, and approval would be
dependent on the site conditions, piping configuration and pipe stress analysis.
However, a detailed Finite Element Analysis (FEA) of the pipe (shell theory) might be
required for some conditions as well as a complete geotechnical study of the site. In
some cases, it might be preferred to utilize a buttwelded tee fitting or look for a more
suitable tie-in location. The guidelines on the locations of hot taps are based on
competent soil properties, the nominal operating temperature differential, the allowable
bending moment criteria and Company experience.
6.3.1 A split tee, STOPPLE fitting, or full encirclement reinforced saddle should not be placed
within 6 m (20 ft.) of any other branch connections NPS 2 and greater, hot tap or
otherwise, including buttwelded tee fittings on the mainline pipe.
such that it is within 60 m (196 ft.) of any transition from the belowground to
aboveground section of the mainline pipe.
Clarification: The minimum distance of the hot tap from belowground to aboveground
transition on the mainline is dependent on the level of restraint provided by the soil.
Special design requirements need to be implemented for the amount of expected
displacement.
6.3.3 A split tee, STOPPLE fitting or full encirclement reinforced saddle should not be placed
within 60 m (196 ft.) from the start of any elbow fitting or end cap on the main pipeline.
Clarification: The section of the pipeline near an elbow or end cap may be subject to
high displacement for pipeline thermal expansion, which can exceed the loading

capacity of the hot tap connection or place a very high bending moment on the hot tap.
The displacement is highly dependent on the pipe-soil interaction and the restraint
provided by the type of soil at the location. Special design requirements, such as sliding
saddles, need to be implemented in such cases.
within the required length or 60 m (196 ft.), whichever is the lesser, from the start or
end of any cold bend or induction bend on the main pipeline.
 𝑙 = (5 (𝑚) + ( 5 (𝑚/𝑑𝑒𝑔) ∙ 𝐵𝑒𝑛𝑑 𝐴𝑛𝑔𝑙𝑒 (𝑑𝑒𝑔) ) ) in metres
 𝑙 = (16.4 (𝑓𝑡) + ( 16.5 (𝑓𝑡/d𝑒𝑔) ∙ 𝐵𝑒𝑛𝑑 𝐴𝑛𝑔𝑙𝑒 (𝑑𝑒𝑔) ) ) in feet
Where:
𝑙 = the length from the edge of the hot tap to the start or end of the bend, as
illustrated in Figure 6-1.
Clarification: This requirement includes any overbends or sag bends that may not
appear in the drawing or alignment sheets, therefore, survey data, as-built data and ILI
should be used if available.
Figure 6-1: Preferred Distance from Bend to Hot Tap

6.3.5 Underground permanent vertical hot tap connections with a branch diameter of NPS 2
or less should not be placed in a section of the main pipeline if the depth of cover is
greater than 1.5 m (5 ft.).

Clarification: Fine balance is required between the added structural stiffness required
for bracing of the branch connection due to the deeper cover and the flexibility needed
for the thermal displacement of the main pipeline.
6.3.6 A split tee, STOPPLE fitting or full encirclement reinforced saddle assembly should not
be placed in a section of the main pipeline if the depth of cover is greater than 2 m (6.5
ft.).
Clarification: The deep cover increases the dead load on the assembly making it
difficult to stay within allowable limits. For hot tap locations with excessive amounts of
cover, a large geofoam void may be placed over top of the hot tap and mainline piping,
reducing the soil load.
6.3.7 Unless a pulsation, fatigue, and fracture analysis have been conducted by the
Company’s Specialized Contractors approved for this type of design work, a hot tap
should not be placed within:
 3.2 km (2 miles) of a reciprocating compressor station
 1 km (0.6 miles) of a pump station
 centrifugal compressor station facility piping
 one hundred pipe diameters (100D) of a liquid control valve
Clarification: If a reason is required (i.e., sound engineering justification and
monitoring) to justify that the pressure fluctuations and thermal cycling loading from the
compressor or pump are low enough, the hot tap may be designed and analyzed under
a normal static type of stress analysis.
in sections of the pipeline that are within the virtual anchor (VA) length or 200 m (650
ft.) of a section of the pipeline that experiences buoyancy effects, or have no underlying
load bearing material or low soil friction (e.g., muskeg, swamp, or any organic soil
types, etc.).
Clarification: Some areas of shallow muskeg and wet areas can be mitigated with
extra analysis, vigilance, design and construction mitigation.
6.3.9 A split tee, STOPPLE fitting, or full encirclement reinforced saddle assembly should not
be placed within 30 m (100 ft.) of an access road.
Clarification: Settlement of the pipeline within the designated road, laneway or travel
surface, and the added stresses within the wall of the pipe from surface loading cannot
always be accurately accounted for. Combined with the additional complexity of a split
tee, STOPPLE fitting or full encirclement reinforced saddle, it is prudent to ensure a
minimum distance.
be placed within 10 m (32 ft.) from the edge of a section of pipe encased or partly
encased in concrete type fills such as fill-crete/flowable fill.

Clarification: Settlement, heave, or shifting of the concrete and the associated

displacement of the pipeline, as well as the change in stiffness of the surrounding
matrix, increases the complexity of and adds additional stresses to the pipe that cannot
always be accurately accounted for. Summated with the additional complexity of a split
tee, STOPPLE fitting or full encirclement reinforced saddle, it is prudent to ensure a
minimum distance.
be placed on a section of the main pipeline if the wall thickness is less than 5.6 mm
(0.221 in.).
Clarification: Due to bending and the membrane stress requirements at a pipe
support, wall thicknesses below 5.6 mm (0.221 in.) require extra engineering vigilance.
Adding to the complication is the volume of welding (heat) being applied to the pipeline
(which is a function of the wall thickness) which causes a very complex assortment of
thermal residual stresses within the wall (shell) of the mainline pipe and is impossible
to account for. Combined with the level of bending stress, ovalization around the
supports and the contact stresses may be excessive.
6.3.12 A new split tee, STOPPLE fitting or full encirclement reinforced saddle should only be
designed and installed within the virtual anchor (VA) length of an existing belowground
or aboveground pipeline anchor or line stop after the stiffness, function and integrity of
the anchor or line stop has been validated.
Clarification: The validation is only required if a functioning anchor is required for the
hot tap to meet allowable stress criteria. Pipe displacement at anchors has been
problematic in the past, due to soil disturbance, soil creeping and the anchor flange
pushing through the concrete anchor. As such, pipeline anchors cannot be relied upon
to react as designed. The thermal restraint effects of a pipe anchor or line stop should
be ignored when selecting a hot tap location.
6.3.13 An existing belowground or aboveground pipe anchor or line stop within the virtual
anchor (VA) length of a new split tee, STOPPLE fitting or full encirclement reinforced
saddle should only be included in the pipe stress analysis if the pipe anchor or line stop
is functioning as designed. Verification of the function of the pipe anchor or line stop
should include:
 the pipe anchor or line stop is attached to a flange joint or an anchor flange is
hard-connected to a steel structural component
Clarification: Anchor or line stops connected to the pipeline by flange joints or
anchor flanges connected to, or encased in concrete should not be considered
functioning as designed.
 an integrity reassessment has been conducted in order to validate the operational
condition of the pipe anchor or line stop
Clarification: The integrity reassessment should consist of evaluating the welded
or bolted joint and may include more engineering assessments to be defined by
the Company’s integrity personnel.

6.4 Hot Tap Location and requirement - Restrictions

Note: Locating a hot tap within these restrictions requires a tremendous amount of
engineering vigilance by the Project and is highly dependent on the site conditions,
situations and pipe stress analysis. A detailed Finite Element Analysis (FEA) of the pipe
(shell theory) should be conducted for most conditions, as well as a complete
geotechnical study of the site. Seeking less hospitable locations is preferred.
6.4.1 A new split tee, STOPPLE fitting or full encirclement reinforced saddle should not be
located within thirty pipe diameters (30D) from the edge of an existing underground or
aboveground pipe anchor or line stop without considering all of the following:
 surrounding soil conditions to restrain the run pipe
 thermal expansion of the aboveground
 belowground piping and the effects of any bending moments onto the hot tap
Clarification: An existing underground or aboveground pipe anchor or line stop cannot
be assumed to fully withstand the axial displacement for the pipeline so there will be an
uncertainty in the compressive stresses within the pipe determined from the analysis.
Combining the uncertainty in the compressive stresses caused from the condition of
the anchor with the additional complexity stress state caused by the split tee, STOPPLE
fitting or full encirclement reinforced saddle, a minimum distance would be consider
prudent.
be placed within an area that would receive continuous loading from surface
disturbances such as vehicular loading on designated roads or laneways, unless the
effects of the vehicular loading have been considered and mitigated.
be placed within an area that would receive any type of influence from geotechnical soil
movements such as slope stability, upheaval, river crossings or overbends unless the
effects of the geotechnical soil movements have been considered.
in sections of the pipeline that are within the virtual anchor (VA) length of a location that
has experienced or will experience the effects of continuous or discontinuous
permafrost unless the effects of the continuous or discontinuous permafrost (i.e. frost
heave and thaw settlement) have been considered.
in sections of a pipeline that are within the virtual anchor (VA) length or within 200 m
(650 ft) of a location that has experienced or will experience the effects of no underlying
load bearing material such as deep muskeg or deep organic types of soil, unless the
effects of loss of soil support (i.e. excessive settlement) have been considered.
Clarification: Muskeg and organic soils are considered deep when their depth is below
the bottom of the pipeline.

be placed within a section of the main pipeline that was installed as a Horizontal
Direction Drill (HDD), bored or cased section, unless the effects of excessive lateral
and axial displacement and loss of restraint have been considered.
6.4.7 A split tee, STOPPLE fitting, or full encirclement reinforced saddle assembly should not
be placed within any section of the main pipeline that would receive any type of stress
or displacement influence from a Horizontal Direction Drill (HDD), bored or cased
section, unless the effects of excessive lateral and axial displacement and loss of
restraint have been considered.
be installed on fittings or fabricated headers, unless the effects of the decreased
capacity of the fittings or fabricated headers have been considered.
6.4.9 The suction or discharge valve into a compressor station or pump station shall not be
installed onto a split tee or full encirclement reinforced saddle assembly.
Clarification: The suction or discharge valves can only be installed onto a tee
assembly.
6.5 Branch Configuration Requirements
6.5.1 The piping analysis shall include the branch connections for the STOPPLE fittings, if
the attached branch connections are going to be left in place for an extended period of
time.
Clarification: STOPPLE fittings are assumed to only have temporary (a few days)
branch connections in order to facilitate the removal of a section of the pipeline. A piping
analysis may not be required for temporary branch connections.
6.5.2 Small diameter piping should not be run underground without consideration given to
pipe settlement, piping flexibility when transitioning belowground or branching off a
large diameter pipe, soil compaction and constructability.
Clarification: Running small diameter piping underground has been problematic due
to pipe settlement and overstressed because of limited piping flexibility when
transitioning belowground. If small diameter piping needs to be run underground, using
a foam box, increased compaction, or sleeper foundations are acceptable options. The
foam box has been especially useful at horizontal branch connections to large diameter
pipe. See Figure 6-2 to protect the piping and welded connection from settlement and
overburden.
Caution: Granular weight may have to be added as the foam box may become buoyant
under the right conditions.

Figure 6-2: Horizontal Hot Tap Assembly Located in a Structural Foam Box
Note: The foam box needs to have 13 mm (0.5 in.) diameter holes punched at a
maximum of 100 mm (4 in.) on centre for cathodic protection (CP), which is the same
requirements as sheet type expansion medium, Ethafoam 220.
6.5.3 The vertical branch piping connected to a split tee or a full encirclement reinforced
saddle assembly should be wrapped with foam to allow for lateral displacement.
6.5.4 NPS 4 to NPS 8 branch piping connected to horizontally oriented split tees or full
encirclement reinforced saddle assemblies should not reduce down to a lesser pipe
size within 5 m (16.5 ft.) from the edge of the run pipe.
6.5.5 NPS 2 to NPS 6 branch piping connected to vertically oriented split tees or full
encirclement reinforced saddle assemblies should not reduce down to a lesser pipe
size within 2 m (6.5 ft.) from the edge of the run pipe.
6.5.6 The branch piping into the split tee or full encirclement reinforced saddle assembly
should be horizontal (rolled) (Figure 6-2) or vertical offset (Figure 6-3) jog consisting of
two 90° (degree) elbows to mitigate thermal expansion (thrust loads on the hot tap from
the branch pipe), and to allow for field adjustment due to any elevation differences to
ensure a stress-free tie-in.
6.5.7 The branch piping offset, for a vertical or horizontal split tee or full encirclement
reinforced saddle assembly should be within sixteen pipe diameters (16D) of the
centreline of the run pipe if there is no support within ten pipe diameters (10D) of the
pipe support on the flange.
Clarification: Without the support under the branch piping, any differential settlement
of the branch piping and the mainline could cause excessive loading on the hot tap.

Figure 6-3: Graphic Illustration of a Horizontal Hot Tap Assembly Branch Connect Offset
Figure 6-4: Graphic Illustration of a Vertical Hot Tap Assembly Branch Connect Offset
6.5.8 The branch piping offset of a vertical or horizontal split tee or full encirclement
reinforced saddle assembly should be within twenty-five pipe diameters (25D) of the
centreline of the run pipe, even with a support under the valve flange and the branch
piping.
Clarification: The offset is for minimizing thermal thrust loads on the hot tap.

DESIGN REQUIREMENTS
7.1.1 The void space between the full encirclement reinforced saddle and the mainline pipe
shall be filled with an epoxy grout, for branch connections of NPS 10 and greater.
Clarification: The epoxy grout fills the void space between the full encirclement
reinforced saddle and the pipe, increasing the effectiveness of load transfer of the full
encirclement reinforced saddle. The epoxy grouting is a Company proprietary
process. Refer to Branch Connection Epoxy Grout Injection Procedure (EDMS no.
5434950) for more detailed information.
7.1.2 STOPPLE fittings should not be horizontally oriented.
Clarification: Orienting a STOPPLE fitting in the horizontal plane would have the same
requirement as a split tee or full encirclement reinforced saddles oriented in the
horizontal plane.
7.2 Support Locations
7.2.1 Structural supports of any type shall not be welded directly to the carrier pipe or any
other pressure containing components at any location. This includes welding a
structural type support onto a split tee, STOPPLE fitting, full encirclement reinforced
saddle or the piping.
Clarification: The welding of lifting lugs onto a split tee, STOPPLE fitting or full
encirclement reinforced saddle by the manufacturer, i.e., the welding of temporary lifting
lugs that will be only be used during construction, manufacturing or transporting, are
exempt from this requirement.
7.2.2 The edge of the pipe support shall be designed to be a minimum of one diameter (1D)
away from any pipe girth weld.
Clarification: The one pipe diameter requirement does not apply when a support is
placed under a fitting (i.e., flange or a vertically-oriented tee).
7.2.3 For situations where the edge of the pipe support is less than a half of one pipe diameter
(0.5D) away from any pipe girth weld due to design or construction errors, the support
or girth weld shall be relocated.
7.2.4 For situations where the edge of the pipe support is less than one pipe diameter (1D)
away from any pipe girth weld but greater than half of one pipe diameter (0.5D) due to
design or construction errors, the support or girth weld should be relocated.
Consideration: If the edge of support is less than one diameter (1D) but greater than
half the diameter (0.5D) away from any pipe girth weld, a detailed Finite Element
Analysis (FEA) of the shell may be required. An FEA ensures that the axial and shear
membrane stresses applied to the piping by the pipe support and auxiliary loads do not
influence the maximum allowable weld defects by code. The pipe girth weld should be
ultrasonically inspected.

Clarification: The shear distribution pattern is not well understood in the area
extending one pipe diameter (1D) on each side of the support, which has been referred
to as the fuzzy zone by some references. When combined with any residual weld
stresses, indication (flaws) in the weld joint, there is a probability/risk that the indications
(flaws) within the weld joint may propagate given these factors. Even if a fatigue
analysis was conducted, it does not cover fracture initiation points or stress risers from
weld flaws.
Figure 7-1: Horizontal Hot Tap Assembly Supported Run Pipe

7.2.5 Supports should not be located under reducers, elbows or horizontal tees, unless
structural stress discontinuities and their effects have been considered.
Clarification: Supports can be placed under pressure relief(s), blowdowns, flanges
and vertical tees. Beam analysis may underestimate the stresses within a fitting
combined with structural loading.
7.2.6 Supports for split tees, STOPPLE fittings or full encirclement reinforced saddles
(temporary and non-temporary) should be placed on driven piles, unless the support
stiffness of an alternative, along with cost effectiveness and sound engineering, has
been considered to be equivalent.
Clarification: If the assumptions used in the hot tap configuration, design and
engineering analysis were based on the vertical and lateral stiffness of driven piles and
the stiffness of the supports is altered, the design and engineering analysis needs to
reflect this change.
7.2.7 The use of any supports other than driven piles should be approved by the Company’s
Stress Engineering and Structural/Civil personnel.
7.2.8 Other locations of supports on fittings shall be subject to the approval of the Company’s
Stress Engineering personnel.

7.2.9 Vertically oriented split tees or STOPPLE fittings should be supported from under the
split tees or STOPPLE fittings with a saddle type support.
Clarification: Vertical oriented split tees or STOPPLE fittings shall always be
supported under the fitting and fully compacted to the spring line of the pipe. Excavation
limits for the mainline piping are not required for vertical oriented split tees or STOPPLE
fittings.
7.2.10 A horizontally oriented split tee should be supported by structural supports placed on
either side of the hot tap on the mainline pipe and a support under the flange of the
valve on the branch connection.
7.2.11 Horizontally oriented full encirclement reinforced saddle configurations should be
supported by any of the following configurations:
1. Structural supports placed on either side of the hot tap on the mainline pipe and
a support under the flange of the valve on the branch connection.
2. Competent engineering backfill placed on the back side of the hot tap on the
mainline pipe and under the branch piping, utilization of excavation limits under
the mainline piping, a temporary support under the flange of the valve on the
branch connection, and a pipe support under the branch piping just past the hot
tap valve.
Clarification: The second option requires in-depth knowledge of the soil properties
surrounding the mainline pipe and the branch connection.
7.2.12 For horizontally oriented split tee or full encirclement reinforced saddle configurations,
a temporary or permanent support should be placed directly underneath the branch
connection valve flange to support the weight of the hot tap machine during the
installation of horizontal oriented hot taps for branch connections NPS 8 and greater.
Exception: This step is not required if the added weight and resulting bending moment
to the hot tap fitting has already been considered. See Figure 7-2.

Figure 7-2: Horizontal Hot Tap Assembly Supported Branch Connection and Hot Tap
Machine
7.3 Supporting Vertical Assemblies NPS 2 or less with Structural Supports
7.3.1 Underground, permanent, vertically oriented hot tap connections with branch diameters
of NPS 2 or less should be supported aboveground.
7.3.2 The aboveground structural supports should be available to support the piping before
hot tapping a connection of NPS 2 or less.
7.4 Supporting Horizontal Assemblies with Structural Supports
7.4.1 Horizontal oriented split tee, STOPPLE fitting or full encirclement reinforced saddle
configurations should have 120° saddle supports placed on either side of the hot tap
under the mainline piping.
Clarification: The mainline piping needs to be fully supported to reduce the risk of
settlement in order to allow for a support under the valve flange. The saddle support
allows for larger excavations that may vary depending on soil type and sloping
requirements for a safe working ditch.
7.4.2 Horizontally oriented split tee, STOPPLE fitting or full encirclement reinforced saddle
configurations should have a support placed on the valve flange (outboard flange in the
case of Flange x Flange valve) to support the weight of the valve and the hot tap
machine. See Figure 7-3.

Figure 7-3: Horizontal Hot Tap Assembly Supported Branch Connection and Run Pipe
7.4.3 A 120° saddle support should be placed on the branch piping away from the valve
flange as an added support and to reduce excessive bending loads on the flange that
may be caused by settlement of the branch piping.
Clarification: Excessive bending loads on flanges may cause leaks.
7.5 Supporting Horizontally Oriented Assemblies with Imported Backfill
7.5.1 The method of not supporting the mainline pipe should only be used if excavation size
can be tightly controlled.
7.5.2 The model shall consider the size of the expected excavation to determine soil
settlement assumptions.
7.5.3 Supporting with imported compacted backfill and excavation limits at bottom of pipe
(BOP) should be used for horizontally oriented, full encirclement reinforced saddle
configurations.
7.5.4 Supporting the horizontally oriented, full encirclement reinforced saddle with
compacted backfill and excavation limits at bottom of pipe (BOP) should be approved
by the Company’s Stress Engineering and Structural/Civil personnel.

7.5.5 Supporting the horizontally oriented split tee or full encirclement reinforced saddle
configurations with compacted backfill and excavation limits should require a
geotechnical analysis of the surrounding soil properties.
7.5.6 Horizontal split tee or full encirclement reinforced saddle configurations should have
excavation limits on either side of the hot tap on the mainline piping.
7.5.7 The excavation limit for the bottom of the mainline piping for the installation of a split
tee or full encirclement reinforced saddle assembly should be determined through
stress analysis modelling, including settlement of the mainline pipe.
Clarification: The bending stress in the mainline pipe is dependent on the unsupported
length of piping. If the bending stress or allowable bending moment on the branch
connection is not within allowable limits as per code for the required excavation length,
supports are required under the mainline pipe.
7.5.8 When excavation limits are used, the excavation limits of the mainline piping for the
installation of a split tee or full encirclement reinforced saddle assembly shall be
indicated on the project-specific drawings.
7.5.9 The excavation limits of the mainline piping for the installation of a split tee or full
encirclement reinforced saddle assembly should not be less than the length of the
reinforcement fitting.
7.5.10 For constructability and welding space requirements, the excavation limit for the bottom
of mainline piping for the installation of a split tee or full encirclement reinforced saddle
assembly should not be less than that listed in Table 7-1 and Table 7-2.

Table 7-1: Minimum Mainline Excavation Length Requirements for Installing Reinforcement
Saddle Hot Tap for Pipelines NPS 24, 30, 36, 42, and 48
Reinforcement Hot
Minimum Excavation Length
Tap Size on Minimum Reinforcement
at Bottom of Mainline (BOP)
Pipelines NPS 24, Saddle Length, End to End
from Hot Tap Centerline
30, 36, 42, and 48
Branch NPS (m) (ft) (m) (ft)
4 0.306 1.0 1 3.3
6 0.31 1.0 1 3.3
8 0.405 1.3 1.5 4.9
10 0.495 1.6 1.5 4.9
12 0.597 2.0 1.5 4.9
16 0.756 2.5 1.5 4.9
Table 7-2: Minimum Mainline Excavation Length Requirements for Installing Reinforcement
Saddle Hot Tap for Pipelines NPS 12, 16 and 20
Reinforcement Minimum Excavation Length at

Minimum Reinforcement Saddle
Hot Tap Size Bottom of Mainline (BOP) from
Length, End to End
with Branch Hot Tap Centerline
(m) (ft) (m) (ft)
NPS 12 x 4 0.306 1.0 1.0 3.3
NPS 12 x 6 0.310 1.0 1.0 3.3
NPS 12 x 8 0.405 1.3 1.5 4.9
NPS 16 x 4 0.306 1.0 1.0 3.3
NPS 16 x 6 0.310 1.0 1.0 3.3
NPS 16 x 8 0.405 1.3 1.5 4.9
NPS 16 x 10 0.495 1.6 1.5 4.9
NPS 20 x 4 0.306 1.0 1.0 3.3
NPS 20 x 6 0.310 1.0 1.0 3.3
NPS 20 x 8 0.405 1.3 1.5 4.9
NPS 20 x 10 0.495 1.6 1.5 4.9
NPS 20 x 12 0.597 2.0 1.5 4.9

7.5.11 For the installation of a split tee or full encirclement reinforced saddle assembly, the
excavation limits for the bottom of the mainline piping should not be greater than three
(3) times the length of the reinforcement fitting, without supporting the mainline piping.
7.5.12 Horizontally oriented split tee or full encirclement reinforced saddle configurations
should have a support placed on the branch piping as well as a temporary support
under the valve flange. See Figure 7-4.
Figure 7-4: Horizontal Hot Tap Assembly Supported Branch Piping with Excavation
Limits
7.5.13 The temporary support for a horizontally oriented split tee or full encirclement reinforced
saddle assembly should be placed under the valve flange of the branch connect for
branch piping NPS 8 and greater.
Clarification: Having the permanent branch pipe support further from the valve flange
reduces the bending moments on the hot tap from settlement loads. However, a
temporary support is needed for the weight of the valve and hot tapping machine during
the hot tapping operation, prior to installation of the rest of the branch pipe. The
mainline piping needs to be fully supported to reduce the risk of settlement in order to
allow for a support under the valve flange to be permanent.
7.5.14 The temporary support under the valve flange required to support the hot tap machine
should be cut off 300 mm (12 in.) below the flange to render the support ineffective
before backfilling.
7.5.15 The temporary support required to support the hot tap machine during the installation
of the hot tap should not be included in the pipe stress model as a support other than
to determine the temporary structural load on the support.

7.5.16 A 120° saddle support should be placed on the branch piping away from the valve
flange for added support and stability.
Recommendation: A 120° saddle should be placed on the branch connection about
1.0 m (3.3 ft.) to 1.5 m (5.0 ft.) from the horizontal oriented full encirclement reinforced
saddle valve flange when not supporting the mainline pipeline to reduce the probability
of settlement of the valve.
Note: This recommendation needs to be verified by the pipe stress model.
7.6 Anchors/Line Stops
7.6.1 Anchors or line stops shall not be added to control stress, or thermal and other
displacements for the installation of split tees, STOPPLE fittings or full encirclement
reinforced saddles.
7.6.2 A new split tee, STOPPLE fitting or full encirclement reinforced saddle shall only be
designed and installed within the virtual anchor (VA) length of an existing belowground
or aboveground pipe anchor or line stop with the assumption that the anchor is
functioning as designed if the flange joint or anchor flange is attached to steel structure.
Clarification: Anchor or line stops welded, bolted, or connected to the pipeline other
than by flange joints or anchor flanges become problematic. It cannot be assumed that
an anchor or a line stop is functioning as designed unless the flange joint or anchor
flange is attached to steel structure.
7.7 Backfill and Compaction
7.7.1 The backfill from the springline of the pipe and below shall be fully compacted to ensure
that there is low probability of pipe settlement.
Clarification: Once the backfill is fully compacted from the springline and below, or the
pipe is sitting on in-situ material (non-compacted native fill), there is a decreased
probability of pipe settlement.
7.7.2 Increased compaction efforts should be used when compacting the backfill from the
springline and below for underground fittings, valves, elbows and transitions.
7.7.3 The branch connection piping between the mainline pipe and the valve, as well as the
valve for the horizontal oriented split tee or full encirclement reinforced saddle
assemblies, shall only be compacted to the base of the pipe and valve.
7.7.4 The branch connection piping between the mainline pipe and the valve, as well as the
valve for the horizontal oriented split tee or full encirclement reinforced saddle
assemblies, should only be compacted to the bottom of the pipe and valve, unless the
added lateral restraint has been considered.
Clarification: The split tee or full encirclement reinforced saddle assembly is expected
to displace laterally as the mainline pipe displaces axially with fluctuation to
temperature. Constraining the assembly could elevate the stresses within the branch
connection piping.

7.7.5 The fill material on either side of the split tee, STOPPLE fitting or full encirclement
reinforced saddle assembly on the mainline piping should be compacted from the
springline and below. See Figure 7-5.
7.7.6 The fill material on the backside of the mainline piping (i.e., the opposite side of the hot
tap) should be compacted to the top of the pipe. See Figure 7-5.
7.7.7 The fill material above the springline for a horizontal oriented split tee or full
encirclement reinforced saddle should not be compacted, unless the effects of the
added vertical restraint onto the hot tap have been considered.
Figure 7-5: Horizontal Hot Tap Assembly Showing Areas of Critical Compaction
7.7.8 The areas of emphasized compaction and the compaction limits shall be indicated on
the project-specific drawings for critical sections of piping and components.
Clarification: Areas under split tees and elbows require an increased focus on
compaction rather than just a general note on compaction in the drawing.
7.7.9 A compaction procedure shall be specified and indicated on the project-specific
drawings.
7.7.10 Compaction requirements shall be indicated in the drawings along with any imported
fill requirements, if required.
7.7.11 Overly compressing the foam expansion medium should be considered.
7.7.12 Vertical split tees or STOPPLE fitting should always be backfilled and fully compacted
to the spring line of the mainline pipe for 5 m (16.4 ft.) on either side of the vertical split
tees or STOPPLE fitting before hot tapping.
Clarification: If the excavation on the mainline length is shorter, then the compaction
would extend to the end of the excavation.

7.7.13 Concrete type fills such as fill-crete/flowable fill should not be used for the backfill
around or partly encasing the split tee, STOPPLE fitting, or full encirclement reinforced
saddle assembly on the mainline piping or the branch piping.
7.7.14 The use of concrete type fills as backfill below the split tee, STOPPLE fitting, or full
encirclement reinforced saddle assembly on the mainline piping or the branch piping
should have a minimum clearance of 300 mm (12 in.) between the bottom of the piping
and the concrete fill.
7.7.15 The use of concrete type fills as backfill below the split tee, STOPPLE fitting or full
encirclement reinforced saddle assembly on the mainline piping or the branch piping
should only be used in the construction, design and analysis if approved by the
Company’s Stress Engineering and Structural/Civil personnel or the Project Engineer
and Project Manager.
7.8 Isolation Medium Between Piping and Supports
7.8.1 Isolation medium should be used between all piping and supports.
Clarification: Isolation material is also required to reduce vibrations and reverberating
noise resonating through the piping system, and to reduce the probability of magnifying
the noise and allowing the noise attenuation along the pipeline at low frequency. Also,
the isolation medium between the piping and supports is to prevent any hard surface-
to-surface contact or fretting that can damage the coating, as well as isolation of the
cathodic protection (CP) circuit.
7.8.2 Isolation medium may not be required between the anchor flange and the support.
Clarification: Isolation material might hamper the installation and function of the
anchor flange and is not required unless necessary for isolation of the cathodic
protection (CP) circuit.
7.8.3 Isolation medium should be designed with a gap to accommodate the weld seam,
unless consideration has been given to the effects of the contact pressure on the weld
seam.
Clarification: The gap to accommodate the weld seam will reduce the contact pressure
on the weld seam.
7.8.4 The design thickness of the isolation medium should be enough to prevent fit-up issues
due to pipe seam welds for a saddle or a clamp support.
7.8.5 Isolation medium between all piping and supports should be any of the following, unless
the long-term functionality during installation and operations of another material has
been considered:
 Polytetrafluoroethylene (PTFE)/Teflon
 Ultra-High Molecular Weight Polyethylene (UHMW)
 Neoprene (Durometer Shore Hardness between A65 to A85)

7.8.6 Isolation medium should be designed and used with a minimum thickness of the
following, unless the long-term functionality during installation and operations of
another minimum thickness has been considered:
 3.0 mm (0.13 in.) for NPS 1-1/2 and smaller
 6.0 mm (0.25 in.) for NPS 2 and greater
7.8.7 The radius of a saddle or clamp shall be designed with consideration of the thickness
and compressibility of the isolation medium.
Note: Some off-the-shelf pipe clamp products are designed exactly to the nominal pipe
outside diameter, and cannot fit a layer of isolation medium.
ACCEPTABLE STRESS MITIGATION METHODS REQUIREMENTS

8.1 Expansion Joint(s)
8.1.1 Expansion joint(s) should not be used on the piping systems that are covered by this
Specification, unless consideration has been given to the long-term cyclic operating
requirement.
8.2 Expansion Mitigation
8.2.1 Expansion medium should be used on either side of the hot tap branch connection to
mitigate elevated forces and stresses concentration in the hot tap branch connection
due to thermal expansion on the mainline pipe. See Figure 8-1.
8.2.2 Expansion medium should be used to wrap the top half of a STOPPLE fitting to mitigate
elevated forces and stress concentration due to thermal expansion on the mainline pipe
and the fitting.
8.2.3 Expansion medium should be used for mitigating isolated areas of concentrated stress
or allowing bending moments on the branch connection due to expansion of
underground piping and fittings.
8.2.4 Acceptable expansion medium for mitigating isolated areas of concentrated stress due
to expansion of short sections of underground piping and fittings should be Ethafoam
220.
8.2.5 The use of alternative medium other than Ethafoam 220 shall only be used in the
construction, design and analysis if approved by the Company’s Stress Engineering
personnel, Project Engineer and the Project Manager.
8.2.6 Expansion medium should be designed for a maximum compressive deflection of 25%
of the material thickness.
8.2.7 Expansion medium should not be used on straight sections of underground piping for
lengths greater than 5.0 m (16.4 ft.).
8.2.8 Expansion medium should not be used on, under or around the mainline piping.

8.2.9 Expansion medium should not be used under the pipe or wrapped around the branch
pipe unless it can be demonstrated that there is a benefit to reducing isolated areas of
concentrated stress.
Clarification: Expansion medium at the base of the pipe or wrapped around the pipe
causes settlement and increases bending stress because the medium cannot support
the weight of the piping.
Caution: When reviewing construction drawings, be careful to ensure that the
expansion medium is not under the pipe or wrapped around the pipe.
8.2.10 Expansion medium should be a sheet type.
8.2.11 Spray applied expansion medium shall not be used.
Clarification: Spray applied expansion media applied under uncontrolled
environmental conditions has been known to have issues for long-term reliability and
shields cathodic protection (CP).
8.2.12 The sheet type expansion medium should be punched with 13 mm (0.5 in.) diameter
holes at a maximum of 100 mm (4 in.) on centre lengthwise and widthwise for cathodic
protection (CP).
8.2.13 Backfilling over top of the expansion medium shall take into consideration
compressibility of the expansion medium.
Clarification: Overly compressing the foam expansion medium is an issue that needs
to be considered and addressed.
Figure 8-1: The Foam around Horizontal Hot Tap Assembly

8.3 Mitigation for Excessive Overburden Weight

8.3.1 An excessive amount of overburden weight caused by high depth of cover should be
mitigated with the use of polystyrene geofoam blocks for a split tee, STOPPLE fitting
or full encirclement reinforced saddle assembly in a location with excessive amounts
of cover in order to reduce the density of the overburden.
Clarification: The deep cover increases the dead load on the assembly, as well as the
pipe supports, making it difficult for the pipe to stay within code allowable stress limits.
8.3.2 Spray-applied expansion medium should not be used, unless the long-term
functionality and expansion of the material under uncontrolled environmental conditions
has been considered and addressed.
Clarification: Spray applied expansion media applied under uncontrolled
environmental conditions has been known to have issues for long-term reliability.
Ethafoam 220 is not surface load bearing and will crush.
8.3.3 The polystyrene geofoam blocks should not be used as an expansion medium.
8.3.4 The polystyrene geofoam blocks should have a minimum of cover of 600 mm (24 in.) if
the hot tap is located within a fenced area.
8.3.5 The polystyrene geofoam blocks should have a minimum depth of cover of 900 mm (36
in.) if the hot tap is not located within a fenced area.
8.3.6 Buoyancy of the polystyrene geofoam blocks shall be considered.
8.3.7 The polystyrene geofoam blocks should be placed a minimum of 300 mm (12 in.) to a
maximum of 600 mm (24 in.) from top of pipe.
8.3.8 The polystyrene geofoam blocks should not be placed below 300 mm (12 in.) from top
of pipe.
Clarification: The polystyrene geofoam has been known to shield cathodic protection.
8.3.9 The polystyrene geofoam blocks should be extended past the edge of the pipe, the
assembly and/or pipe support a minimum of 900 mm (36 in.).
8.4 Mitigation for Excessive Bending Moment
8.4.1 If there are significant bending moments acting on the encirclement saddle branch
connection, the encirclement saddle branch connection should be increased in
diameter or the design should be changed to a split tee or conventional tee.
Clarification: The full encirclement reinforced saddle branch connections have a low
bending moment capacity and if there is a probability of significant bending moments
acting on the connection from operational or external loading, the diameter of the
branch connection needs to be increased or the design changed to a split tee or
conventional tee fitting.

STRESS PIPING ANALYSIS

9.1 General
9.1.1 All competent engineering judgment, including boundary conditions and assumptions,
shall be documented in the Stress Analysis Report.
9.1.2 If applicable to the analysis, all boundary conditions obtained from project documents
such as the Design Basis Memorandum (DBM), and all assumptions shall be
referenced.
9.1.3 A formal pipe stress analysis shall be conducted for all hot taps NPS 4 and greater and
documented in the Stress Analysis Report.
9.1.4 The pipe stress model shall include mainline piping on both sides of the split tee,
STOPPLE fitting, or full encirclement reinforced saddle assembly up to the virtual
anchor (VA) length or 100 m (330 ft.), whichever is longer.
9.1.5 For the pipeline, the pipe stress model shall include branch piping up to virtual anchor
(VA) length.
9.1.6 For the facility, the pipe stress model shall include branch piping up to a point where
the piping does not influence the connection based on engineering judgment.
9.1.7 The pipe stress model shall contain any other branch connections, if any exist, within
the virtual anchor (VA) length.
9.1.8 The piping stress model shall include the hot tap and adjoining pipe or pipeline up to
the virtual anchor (VA) length.
Clarification: Knowledge of the surrounding pipe loads is required to provide a
defendable piping/pipe analysis.
9.1.9 All separating location factors shall be clearly indicated in the drawings and the Stress
Analysis Report.
9.1.10 The Company’s Project Manager, with competent authenticated engineering
justification, shall provide the following information:
 maximum design temperature
 minimum underground temperature
 minimum aboveground temperature
 maximum design pressure
 maximum licensed operating pressure
9.1.11 Increasing the wall thickness for the added reinforcement on a full encirclement
reinforced saddle assembly should not be included in the model.
9.1.12 The pipe stress model shall include all pertinent pipeline geometry like undulations, sag
bends, over bends, side bends, other fittings and stress discontinuities that could
influence the displacement and stress within the piping.

9.1.13 The pipe stress model shall include the split tee or full encirclement reinforced saddle
assembly with both the branch piping and pipeline modelled with the nominal wall
thicknesses of the pipes.
9.1.14 For STOPPLE fittings, the pipe stress model shall include the STOPPLE flange and
assembly to ensure enough flexibility after backfilling.
9.2 Pipe Analysis Software
9.2.1 Either of the following software should be used for pipe stress modeling and analysis:
 AutoPIPE by Bentley Inc. (preferred)
 Caesar II by COADE Inc.
9.2.2 Alternative software for conducting stress analysis on compressor stations should be
able to ensure code compliance checking and be approved by the Company’s Stress
Engineering personnel, unless the Project Engineer accepts responsibility for the use
of alternative software.
9.2.3 Specialty programs (FEA) should only be used in conjunction with programs that have
code-checked integration, unless code-checking has been considered using another
method.
9.2.4 All software files and models (original and convertible to AutoPIPE) should be supplied
and attached to the soft copy of the report.
9.2.5 The Bourdon Effects for both translational and rotational displacements shall be
accounted for in the analysis.
9.2.6 The Calculated Pressure Extension shall be accounted for in the analysis.
9.2.7 If available, Liberal Stresses Allowable shall be disabled in the software used to create
the pipe stress model.
9.3 Restraint
9.3.1 Both aboveground and belowground piping shall be modeled and evaluated assuming
unrestrained loading conditions, and that the pipe is able to move.
Clarification: The use of partial restraint from soil or pipe supports is insufficient in
preventing the pipe from moving.
9.4 Load Cases
9.4.1 As part of the stress analysis and the Company’s long-term commitment to
performance, loading cases shall comply with both code compliance cases and the
Company’s loading requirements.
9.4.2 The operational case, cold case and occasional case shall be analysed.
9.4.3 The minimum and maximum temperatures defined in the Design Basis Memorandum
(DBM) shall be used in the analysis.

9.5 Operational Case

9.5.1 The operational case shall include the following:
 effects of pressure (maximum operating pressure)
 operating temperatures (maximum operational temperature)
 pipe weight (including insulation, content, backfill overburden, underground pipe
settlement and other externally imposed displacements)
9.5.2 Settlement shall be applied to the analysis for all disturbed sections of underground
piping.
9.6 Cold Case
9.6.1 The cold case shall be analyzed to determine whether the pipe stresses and loads on
the pipe supports are within the allowable limits for cold conditions.
9.6.2 The cold case shall include the following:
 effects of pressure (maximum design pressure for all piping)
 operating temperatures (minimum temperature for all piping)
 pipe weight (including insulation, content, backfill overburden, underground pipe
settlement and other externally imposed displacements)
9.7 Occasional Case
9.7.1 The occasional case shall be analyzed to determine whether the piping system
complies with the regulatory code for occasional stresses.
9.7.2 The occasional case shall include the operational case combined with the effect of
external forces (wind and seismic) where each shall be analyzed independently.
9.7.3 Wind - the building code (Canada, United States and Mexico) shall be used for the area
where the meter station is to be located to determine the maximum wind speed (km/h
for Canada and Mexico and mph for the United States) for a 50-year occurrence.
9.7.4 Wind - the predominant wind direction shall be used for the analysis.
9.7.5 Static Seismic (Earthquake) - the seismic loading shall be considered along with the
operational case.
Clarification: A seismic event is most likely to occur while the piping system is in
operation.
9.7.6 Static Seismic (Earthquake) - the seismic load shall be reported as Peak Gravity
Acceleration (PGA), multiple in gravity acceleration equivalent (multiple of g-force).
Clarification: The seismic loading in conjunction with the standard operating case to
segregate the effect of the seismic load, which then is combined with the static
sustained load case for code compliance considerations.

9.8 Load Combinations and Allowable Stress Requirements

9.8.1 Bending stress from pressure elongation shall be accounted for in the analysis.
Clarification: The default AutoPIPE settings for CSA Z662 - Oil and Gas Pipeline
Systems, tensile 2, may be missing the bending stress from pressure elongation. A
custom code case may need to be added manually to ensure that the bending stress
from pressure elongation is accounted for.
9.8.2 The code combinations for American Society of Mechanical Engineers (ASME) B31.8
- Gas Transmission and Distribution Piping Systems, ASME B31.4 - Pipeline
Transportation Systems for Liquid Hydrocarbons and Slurries, and CSA Z662 - Oil and
Gas Pipeline Systems, provided in Table 9-1 shall be analyzed depending on facility
location.
9.8.3 A bi-axial combined stress case shall be included in the analysis, in addition to any
code requirements, considering all operational load cases.
9.8.4 The bi-axial combined stress may be calculated using a Tresca or a Von Mises stress
criterion.
9.8.5 Additional combinations should be added based on operating modes of piping systems.
The code combinations provided are the base cases only.
9.8.6 All load case combinations shall be analyzed as presented in order of load sequence.
9.8.7 Local stresses caused by structural discontinuities and sites of local loadings combined
with load case combinations should not exceed 0.9 of the Specified Minimum Yield
Strength (SMYS).
Clarification: Often, local stresses are disregarded because the stresses are localized
in influence, may be self-limiting or relieved by local deformation. This includes stresses
in branch connections caused by pressure or external loads, or stresses at structural
discontinuities, as well as the contact stress caused by pipe supports. The codes do
not fully address the maximum allowable value for local stresses or excessive stresses.
However, not exceeding 0.9 of the Specified Minimum Yield Strength (SMYS) ensures
that the design is defendable to the code.

Table 9-1: Code Combinations
Case
No. Load Combination Stress Type Description Allowable
Hoop stress
ASME B31.4 Para. 401.2.2.2, 403.2.1 SMYS x 0.72 x E
1 Max P Hoop
ASME B31.8 Para. 841.1.1 SMYS x E x F x T
CSA Z662, Clause 4.3.5.1 SMYS x F x L x T
Stress due to Sustained Loads
ASME B31.4, Para 401.1.2, 401.2.3, 403.3.1 SMYS x 0.54 x E
2 GR + Max P Longitudinal
ASME B31.8 Para 833.6 0.75 x SMYS x T
CSA Z662, Clause 4.8.5 SMYS x F x L x T
Thermal stress range from restraint temp to
the maximum temperature
ASME B31.4, Para. 403.3.1, 403.9 SMYS x 0.72 x E
3 Amb T to Max T Longitudinal
f[1.25(Sc+Sh)-
ASME B31.8, Para. 833.8 SL]
CSA Z662, Clause 4.8.4 0.72 x SMYS x T
Thermal stress range from the minimum
temperature to the maximum temperature
(refer to all combinations)
Max Range (Max T to Min ASME B31.4, Para. 403.3.1 SMYS x 0.72 x E
4 Longitudinal
T)
f[1.25(Sc+Sh)-
ASME B31.8, Para. 833.8 SL]
CSA Z662, Clause 4.8.4 0.72 x SMYS x T
Stress due to Sustained Load and
Occasional (i.e.: Load earthquake, wind,
blowdown forces, etc.)
5 GR + Max P + U2 Longitudinal
ASME B31.4, Para. 401.1.3, 401.2.3,
403.3.1 SMYS x 0.80 x E
ASME B31.8, Para. 833.8 0.75 x SMYS x T
CSA Z662, Clause 4.8.5 SMYS x F x L x T

Case
No. Load Combination Stress Type Description Allowable
Combined Stress Without Bending Stress

GR + Max P + Max T Combined, Bi-axial ASME B31.4, Para. 403.3.1 0.90 x SMYS x T
6
ASME B31.8, Para. 833.3 (a)
CSA Z662, Clause 4.7.1
Combined Stress
ASME B31.4, n/a
7 GR + Max P + Max T Combined, Bi-axial 1.0 x SMYS x T
ASME B31.8, Para. 833.4 (c)
CSA Z662, Clause 4.7.2.1
Combined Stress with Soil Settlement
ASME B31.4, n/a 0.90 x SMYS x T
8 GR + Max P + Max T + U1 Combined, Bi-axial
ASME B31.8, Para. 833.4 (c) 0.90 x SMYS x T
CSA Z662, Clause 4.7.2.1 1.0 x SMYS x T
Combined Stress with Soil Settlement and
Occasional Load
GR + Max P + Max T + U1 ASME B31.4, n/a 0.90 x SMYS x T
9 Combined, Bi-axial
+ U2
ASME B31.8, Para. 833.4 (c) 0.90 x SMYS x T
CSA Z662, Clause 4.7.2.1 1.0 x SMYS x T

Table 9-2: Descriptions for Code Combinations
Load Description
GR Weight of piping system due to gravity and soil overburden
Max P Maximum operating pressure.
Max T Maximum operating temperature. (may vary based on section of piping)
Min T Minimum operating temperature. (may vary based on section of piping)
Amb T Ambient temperature.
U1 Soil settlement
U2 Occasional loads (e.g., earthquake, wind, blowdown forces, etc.)
E weld joint factor
T temperature derating factor
F design factor
L location (Z662 only)
f fatigue factor
Sc defined in the codes
Sh defined in the codes
Sl defined in the codes
SMYS specified minimum yield strength
9.9 Content Weight

9.9.1 The content weight (i.e., density) shall be applied to all piping analyzed.
Clarification: Some models have assumed the contents of the pipe to be weightless;
this weight (i.e., density) content may not affect the results of the model. However, this
approach cannot be defended.
9.9.2 The content weight (i.e., density) shall be the value calculated at the maximum
pressure.
9.10 Thermal Analysis Conditions
9.10.1 The maximum design temperature shall be defined as the highest temperature for the
station (the maximum licensed operating temperature) as provided in the Design Basis
Memorandum (DBM) or by the Company’s Project Manager.
9.10.2 The minimum temperature for the underground portions of the pipe stress model shall
be the lowest expected metal temperature at the time of restraint.

9.10.3 The minimum temperature for the underground portions of the pipe stress model should
be as follows, unless an alternative definable minimum underground temperature has
been provided:
 For Canada and the northern part of the United States, the minimum temperature
for the underground portions of a piping system should be assumed -10°C (14°F),
unless otherwise specified.
 For the southern part of the United States and Mexico, the minimum temperature
for the underground portions of a piping system should be assumed +5°C (41°F),
9.10.4 The minimum temperature for the aboveground portions of the pipe stress model shall
be the lowest expected temperature for the region during operation.
9.10.5 The minimum temperature for the aboveground portions of the pipe stress model
should be as follows, unless an alternative definable minimum temperature has been
provided tracking environmental data for the past 50 years:
 For Canada and the northern part of the United States, the minimum temperature
for the aboveground portions of a piping system should be assumed -45°C (-
49°F), unless otherwise specified.
 For the southern part of the United States and Mexico, the minimum temperature
for the aboveground portions of a piping system should be assumed -20°C (-4°F),
9.10.6 The ambient/installation temperature shall be the lowest expected temperature for the
region during construction:
 For buried piping the ambient/installation temperature should be the lowest
expected ground consolidation temperature at the time of construction.
 For above ground piping the ambient/installation temperature should be the
lowest expected air temperature at the time of construction.
9.10.7 The maximum temperature differential shall be the difference between the maximum
operational temperature and the minimum temperature or the ambient/installation
temperature, whichever is lower.
9.10.8 The maximum temperature differential shall be considered for the expansion case.
9.11 Soil Modelling Requirements
9.11.1 If a facility or project-specific soil analysis report is not available, all soil assumptions
shall be based on competent geotechnical engineering judgment and supplied in the
Stress Report.
9.11.2 The soil constraints implemented in the pipe stress model shall be determined at the
pipe depth of cover, soil properties, and soil types typical for the area of construction.

9.11.3 Soil spring properties should be estimated using the methodology outlined in American
Lifelines Alliance, Guideline for the Design of Buried Steel Pipe – July 2001, Appendix
B, unless justification can be given for the consideration of an alternative.
9.11.4 Soil spring properties determined from the stress analysis program, such as the
Underground Pipe Modeler, Buried Pipe Modeler, or any other methodology used to
determine the soil stiffness through use of the program, should be checked and
evaluated by hand calculations, unless a consideration can be given why conducting
hand calculations as a validation is not required.
Clarification: A plug-and-play type of approach to determining soil properties for
underground piping analysis leads to over and underestimating the influences onto the
piping. Without a good understanding of the black box the soil calculating programs
cannot be used.
9.11.5 Overburden weight shall be added as a uniform distributed load (to the computer
model) to all underground piping, both new and existing.
9.11.6 The overburden compaction multiplier, defined in CAESAR II, shall not be used for
stress analysis unless the following is provided:
 approval from the Company’s Stress Engineering personnel
 the derivation of the overburden compaction multiplier
 a completed understanding of the interaction and influence the multiplier has on
soil spring properties
9.12 Soil Settlement Modeling
9.12.1 Soil settlement displacement shall be applied to all new piping and newly excavated
sections of existing underground piping.
9.12.2 Soil settlement displacement should not be applied to existing sections of piping that
have not been excavated.
Clarification: The existing pipe is assumed to have already settled prior to being tied
into the new piping.
9.12.3 A soil settlement displacement or void space under piping of 25.4 mm (1.000 in.) or
greater should be applied to new and existing excavated sections of piping where there
is a low probability of over-excavation and where compaction is being called for in the
design.
Clarification: The amount of soil settlement is dependent on the soil properties, soil
type and site conditions. The minimum settlement assumes that good construction
practices have been followed and the strict compaction requirements have been
achieved using competent, compactable, unfrozen backfill.
Clarification: Settlement of underground piping can occur even with the best
procedures in place for the following reasons:

 Geotechnical analysis has determined that the elastic rebound from the removal
of the soil to the ditch bottom causes an upward displacement of around
12.7 mm (0.500 in.), which causes settlement after backfilling and reconsolidation.
 Over-excavation of the ditch bottom to ensure proper pipe alignment and tie-ins
will settle as the soil reconsolidates.
 Practical difficulties in achieving compaction under large diameter pipe, simply as
a function of their size, can result in void space under large diameter pipe.
9.12.4 A soil settlement displacement greater than 25.4 mm (1.0 in.) should be applied to new
and excavated existing sections of piping where there is a high probability of over-
excavation, such as areas where pipe transitions between belowground and
aboveground.
Clarification: Pipe settlement greater than 25.4 mm (1.0 in.) is a real possibility if the
pipe is over-excavated. The amount of settlement is a site-specific issue and should be
based on competent engineering judgment and supplied in the Stress Report.
Note: The individual(s) conducting the pipe stress analysis have a responsibility to
understand the construction process, through discussions with the project team, to
determine the locations where there is a low and/or high probability of over-excavation.
9.13 Pipe Support Loads
9.13.1 Support loads shall include, but are not limited to the following:
 soil settlement
 pipe weight
 overburden
 vehicle loads
 inspection tools
 pressure
 temperature
 hydro
 wind
9.13.2 All pipe supports that would be affected by the weight of an inline inspection tool shall
include the weight in the design.
9.13.3 The heaviest inline inspection tool anticipated shall be used in the design, and in the
design calculations.

9.13.4 The pipe support loads provided by the piping stress analysis should be unfactored for
the Civil Designer.
Clarification: The appropriate factoring is to be determined by the Civil Designer
based on the applicable design codes.
9.13.5 The maximum pipe support load should be divided into two load types: dead (gravity)
load and live (all other loads).
9.13.6 Blowdown loads should be unfactored.
9.13.7 Soil overburden loads should be included as a dead load.
9.13.8 To validate the support type for both aboveground and belowground, localized
membrane stresses shall be determined for unfactored support loads.
Clarification: With the pipe resting on a support, high localized stresses in both the
circumferential and longitudinal directions are generated within the pipe wall adjacent
to the edge of the support.
9.13.9 Localized pipe wall membrane stresses should be determined using Roark’s Formulas.
Clarification: Allowing for a more detailed correlation of the localized membrane
stresses through detailed Finite Element Analysis (FEA) is time consuming and
resource intensive when an analytical solution is just as effective.
Recommendation: Determine the maximum allowable support load for each support
type, pipe size, wall thickness and grade at the initial stage of the Project to ensure that
the loads are not exceeded, and tabulate the allowable loads in the report.
9.13.10 Alternative methods for determining localized membrane stresses require pre-approval
from the Company’s stress engineering personnel or the Project Engineer and Project
Manager.
9.13.11 Localized pipe wall membrane stresses shall be combined with the circumferential and
longitudinal stresses to ensure that the allowable stress requirements are not
exceeded.
Clarification: Determination of localized pipe wall membrane stresses combined with
the circumferential and longitudinal stresses is a very important calculation and will be
a focus in the Initial Procedural Document.
9.13.12 Beneficial effects gained from restraining soil that reduces localized membrane
stresses should be ignored in the calculation.
9.13.13 The stiffnesses of the supports in the vertical, lateral and axial directions used in the
Piping Stress Analysis Model should be estimated based on competent engineering
judgment.
Recommendation: Predetermine the approximate stiffness of a support type or
structural assembly, within an order of magnitude, by a structural engineer. The point
of determining the support stiffness is to have an idea of the structural rigidity of the
support and to attain realistic loads.

9.14 Pipe Support Location

9.14.1 The location and type of the pipe supports shall be validated and verified by the pipe
stress model.
9.15 Pipe Support Coefficient of Friction
9.15.1 The coefficient of friction should not be lower than the following minimum requirements,
unless consideration has been given to the long-term functionality of the coefficient of
friction and determining the coefficient of friction experientially under multiple
environmental conditions, as per Table 9-3.
Table 9-3: Pipe Support Coefficient of Friction
Environmental Conditions Minimum Coefficient of Friction

Teflon-to-Teflon 0.1
Teflon-to-Steel (steel is coated or painted pipe) 0.1
UHMW-to-UHMW (Ultra-High Molecular Weight 0.2
polyethylene)
UHMW-to-Steel (steel is coated or painted pipe) 0.2
Neoprene-to-Steel (steel is coated or painted pipe) 0.4
Steel-to-Steel (steel is coated or painted support to 0.4 to 0.8 (check both cases as a minimum)
steel of coated or painted pipe)
Concrete-to-Steel (concrete support to steel of coated 0.4 to 0.8 (check both cases as a minimum)
or painted pipe)
Recommendation: The use of steel-to-steel (i.e., support-to-pipe) and concrete-to-

steel (i.e., support-to-pipe) contact is not recommended. Interfacial corrosion and
adhesion would make the coefficient of friction unpredictable and the long-term
environmentally exposed interface would be unreliable.
9.15.2 If steel-to-steel (i.e., support-to-pipe) and concrete-to-steel (i.e., support-to-pipe)
surface contact are to be used, two extreme cases should be investigated: 1) the
lower friction case of 0.4 to 0.8 and 2) a higher friction case greater than 1.2.
Clarification: If there is a chance that the support could seize and due to rust,
corrosion, or surface roughness conducting the analysis over the range will help
determine the risk to the piping system.
9.15.3 The coefficient of friction for steel-to-steel (i.e., support-to-pipe) and concrete-to-steel
(i.e., support-to-pipe) contact should be tested under environmental conditions and
surface roughness expected over the life of the support to ensure that the analysis is
defendable.

9.16 Hot Tap Bending Moment Criteria

9.16.1 The allowable bending moment on the branch connection of the split tee, STOPPLE
fitting or full encirclement reinforced saddle assembly shall be limited to 15% of the
yield stress of the piping of the branch connection determined by:
My
 allowable  0.15   yield 
I
Where:
M = the maximum bending moment of the branch connection
y = is the outer radius of the branch connection
I = is the moment of inertia of the branch piping
 yield = is the yield stress of the branch connection
9.16.2 The nominal wall thickness and material grade of the branch piping shall be used for
determining the allowable bending moment on the branch connection.
Clarification: No additional factors such as design factor or location factor are required
to be added to this calculation.
9.17 Allowable Pipe Displacements
The branch piping into the split tee, STOPPLE fitting, or full encirclement reinforced
saddle assembly should not have an uplift displacement greater than 3 mm (0.118 in.)
at the split tees, STOPPLE fittings or full encirclement reinforced saddles connection,
due to thermal expansion.
Clarification: Uplift of the hot tap location may be caused by thermal expansion of
nearby overbends on the pipeline.
9.18 Allowable Pipe Support Displacement
9.18.1 The Company’s Engineering personnel should be contacted for guidance if the piping
displacements determined from the initial layout and analysis are outside of the
recommended displacements.
9.18.2 The maximum piping displacement at the location of aboveground pipe support should
not exceed the absolute value of the following, unless consideration has been given to
the long-term functionality of the support, regulatory compliance concerns,
maintenance, and operational concerns as per Table 9-4.

Table 9-4: Allowable Pipe Support Displacement at Aboveground Pipe Support
Direction Maximum Pipe Displacement

Axial direction 63.5 mm (2.50 in.)
Lateral direction (sliding support) 25.4 mm (1.00 in.)
Lateral direction (non-sliding support) 6.0 mm (0.25 in.)
Vertical upward direction 4.0 mm (0.15 in.)
Vertical upward direction (blowdowns and valves) 3.0 mm (0.12 in.)
Vertical upward direction (first support from riser) 12.0 mm (0.47 in.)
Vertical downward direction 6.0 mm (0.25 in.)
Clarification: The first support aboveground, after the riser, may experience vertical
lift due to thermal displacement. Care needs to be taken to ensure that piping is not
over stressed and the support is functional for the operational range.
9.18.3 The maximum piping displacement at the location of belowground pipe support should
not exceed the absolute value of the following, unless consideration has been given to
the long-term functionality of the support and soil ratcheting as per Table 9-5.
Table 9-5: Allowable Pipe Support Displacement at Belowground Pipe Support
Direction Maximum Pipe Displacement

Axial direction 63.5 mm (2.50 in.)
Lateral direction (sliding support) 25.4 mm (1.00 in.)
Lateral direction (non-sliding support) 6.0 mm (0.25 in.)
Vertical upward direction 4.0 mm (0.15 in.)
Vertical downward direction 6.0 mm (0.25 in.)
9.18.4 A new split tee, STOPPLE fitting, or full encirclement reinforced saddle should be
located on the mainline piping where the thermal movement is at a minimum, unless
consideration has been given to the increased displacement.
9.19 Fittings
9.19.1 Fittings should be modeled as pipe, unless the stresses of the fittings exceed the
allowable code stresses.
9.19.2 The wall thickness of fittings NPS 16 and greater may be increased up to 1.4 times the
nominal pipe wall thickness for tees and up to 1.2 times the nominal pipe wall thickness
for elbows, once approved by the Project Manager.
9.19.3 Elbow and tee fittings smaller than NPS 16 shall be modeled with a wall thickness the
same as the adjoining pipe.

9.19.4 The assumption of increasing the wall thickness of the fitting in the analysis shall be
documented in the Stress Analysis Report and validated through the procurement
process.
9.19.5 The assumption of increasing the wall thickness of the fitting in the analysis shall be
approved by the Company’s Stress and Mechanical Engineering personnel or the
Project Engineer and Project Manager.
9.19.6 For each type of fitting used, the Stress Intensity Factors (SIFs) shall be documented
along with the assumption for that fitting.
9.19.7 The SIFs for full encirclement reinforced saddle should be determined as a reinforced
fabricated tee with pad or saddle.
9.19.8 The SIFs for a split tee may be based off of the design of the split tee fitting shown in
the fitting Vendor drawing(s); typically, a welded tee or unreinforced fabricated tee.
9.19.9 Additional SIFs should be added at the weld locations between the mainline pipe and
the split tee fitting as fillet welded joint.
9.19.10 The SIFs provided in CSA Z662 - Oil and Gas Pipeline Systems, Gas Transmission
and Distribution Piping Systems, ASME B31.8 - Gas Transmission and Distribution
Piping Systems or ASME B31.4 - Pipeline Transportation Systems for Liquid
Hydrocarbons and Slurries shall be used unless approved by the Company’s Stress
and Mechanical Engineering personnel or the Project Engineer and Project Manager.
9.20 Flange Analysis
9.20.1 Flange Analysis shall be conducted for all piping greater than NPS 6.
9.20.2 ASME Boiler and Pressure Vessel Code (BPVC) Section VIII, Division 1, Rules for
Construction of Pressure Vessels - Appendix 2, Rules for Bolted Flange Connections
with Ring Type Gaskets shall be used for conducting the flange analysis.
9.20.3 The calculated or determined externally induced forces and moments shall be included
in all flange analyses conducted.
Clarification: The flange analysis is a very important calculation and will be a focus in
the Initial Procedural Document.
9.20.4 Flanges not meeting the flange analysis criteria of ASME BPVC-VIII, Division 1,
Appendix 2 after reasonable efforts have been made to mitigate by relocation, piping
re-design and/or rating increase, may consider ASME BPVC-VIII, Division 2, Section
4.16 - Design Rules for Flanged Joints, including the calculated or determined
externally induced forces and moments.
9.20.5 Written approval from the Company’s Stress Engineering personnel, Mechanical
Engineering personnel, Project Engineer and Project Manager shall be obtained before
using ASME BPVC-VIII, Division 2, Section 4.16 as a flange analysis criteria.
9.20.6 Alternative methodologies for conducting flange analysis should not be considered.

Note: The direct design requirement to conduct a flange analysis may not be
specifically listed in the piping design code as a design requirement. However,
inspecting, identifying, monitoring, tracking, preventing and eliminating fugitive
emissions or leaks are regulatory and legal requirements, and are essential to
ensuring the Company’s commitment to the environment. In part, flange connections
have been identified as a source for fugitive emissions that require continuous
annually monitoring and, in certain jurisdictions, prompt repair or mitigation. Therefore,
increased engineering vigilance to ensure that the flange joint meets the flange analysis
requirements for the location reduces the probability of the flange joint being an integrity
concern.
9.21 Discontinuity Stresses
9.21.1 Protection shall be provided against membrane stresses, ratcheting, and fatigue failure
for discontinuity conditions using sound engineering judgement and practices.
9.22 Mitigation for Stress Issues
9.22.1 Expansion medium may be used for underground piping to mitigate stress
concentrations issues, soil ratcheting, and displacement concerns.
9.22.2 Expansion medium (e.g., Ethafoam 220) may be modeled by any of the following
methods:
 applying a stiffness coefficient for the expansion medium
 removing the soil stiffness coefficient and leaving a void for the area where
expansion medium is planned
9.22.3 Flanges that do not meet the flange analysis criteria should be relocated and
reevaluated.
9.22.4 Flanges not meeting the flange analysis criteria after being relocated and reevaluated
may be upgraded or removed with the approval of the Company’s Stress Engineering
personnel, Mechanical Engineering personnel, Project Engineer and the Project
Manager.
9.22.5 If the pipe displacement at the location of a pipe support or hot tap is greater than
allowed, the following methods may be applied:
 relocation and re-evaluation of the hot tap
 change and re-evaluation of the pipe support type
 addition of flexibility to the piping
 adjustment and modification of the pipe support
 completion of the risk assessment
9.23 Evaluation of Existing Piping Impacted by New Piping or Piping Modifications
9.23.1 A model of the original un-modified piping should be developed.

9.23.2 The stress on existing piping shall be checked to meet the code of compliance.
9.23.3 Any areas on existing piping not meeting code of compliance shall be noted and
documented.
9.23.4 The Company’s Project Manager and Pipe Stress Analyst shall ensure that the
modifications do not cause additional and detrimental stress to the existing piping.
9.23.5 If the original piping exceeds the current code of compliance, the original piping shall
be evaluated against the code of compliance at the time of design.
9.23.6 A structural pipe support evaluation shall be conducted if there is a significant increase
in the support loads.
MECHANICAL DOCUMENTATION AND RECORDKEEPING

10.1 Mechanical Report Requirements
10.1.1 A Mechanical Hot Tap Report shall be filed in the project folder.
10.1.2 The Mechanical Hot Tap Report shall include the following:
 Authenticated reinforcement calculations for Full Encirclement Saddle.
 Applicable documentation, as supplied by the manufacturer, for design validation
of Split Tee and Stopple Fitting.
 Hot tapping clearances checks.
 The clearances of hot tapping machine between pipelines running parallel
to each other at similar elevations, or other structures or features that may
interfere with the tapping operation have been checked.
 The measuring rod included with large-bore tapping machines, which adds
significant additional length to the tapping assembly, has been checked.
 The required stroke of the cutting tool for the tapping machines, calculated
to ensure that the total length of the branch connection from the valve face
through the run pipe wall is less than the available stroke, has been
checked.
 Engineering decision of hot tapping, as stated in the Design Basis
Memorandum (DBM).
 The design parameters for the proposed hot tap have been checked and
Completed In Service Welding Assessment (TEF-WELD-INSERV or applicable).
 Any drawings submitted by the manufacturer.

PIPE STRESS DOCUMENTATION AND REPORT REQUIREMENTS

11.1 Analyst and Experience
11.1.1 Pipe Stress Analysts require a Bachelor’s in Mechanical or Civil Engineering, followed
by a minimum of 5 years of project training in a piping department responsible for
design, while under the supervision of Senior or Principal Pipe Stress Engineers.
11.1.2 Pipe Stress Analysts with less formal education shall have 10-15 years of practice and
supervision to be responsible for the design (pipe stress analysis).
11.1.3 The names of the individual(s) conducting the pipe stress analysis shall be listed in the
Initial Procedural Document and the reports.
11.1.4 The experience of the competent individual(s) with demonstrated understanding and
experience in the application of pipe stress analysis shall be listed.
11.2 Initial Procedural Requirements
11.2.1 Competency of the individual(s) conducting the stress analysis and the individual(s)
checking their work shall be demonstrated and documented at the initial stage of the
Project, prior to the 30% design review.
11.2.2 The Project Engineer or Project Manager should provide a list of Company-approved
support types at the kick-off meeting.
11.2.3 An Initial Procedural Document shall be provided to the Company during vendor
qualification and updated whenever a stress analysis is being conducted as part of the
Project.
11.2.4 A written Initial Procedural Document describing the method for conducting the stress
analysis shall be completed prior to engineering analysis being conducted.
11.2.5 The written Initial Procedural Document shall include the following:
 general information listing (e.g., purpose, method, assumptions, supplemental
calculations, references, and analysis theories)
 information required from the Geotechnical report (e.g., soil properties, terrain
and mapping)
 quality control procedure which describes the process of reviewing, checking
and authenticating the stress analysis report, analysis and calculations
Clarification: A common problem is the lack of communication and understanding of
the analysis to be conducted, and the procedural approach that will be followed during
the engineering analysis. This includes the documentation required to ensure the
analysis was conducted methodically and reviewed, checked and authenticated by
competent individual(s) with experience to demonstrate understanding in the
application of stress analysis.
11.2.6 The written Initial Procedural Document for this Specification shall also include, at a
minimum, the methodology for calculating the following:

 pressure and temperature assumptions

 pipe weight with the added operational contents weight
 list of piping systems to be modeled
 method for applying overburden loads
 soil spring properties and methodology
 extent of the piping to be modeled, including existing piping
 soil settlement modeling methodology
 load cases to be run in the model
 outline of any supplemental calculations or modeling being done that is unique
to the Project
 list of the pipe support types that are going to be used for the Project
aboveground and belowground with corresponding support stiffness
 method for determining localized membrane stresses
11.2.7 The written Initial Procedural Document procedure shall be reviewed, checked,
authenticated and delivered to the Project Manager for review.
11.2.8 The written Initial Procedural Document procedure and approach should be reviewed
to ensure it meets the Company’s minimum requirements and is based on solid
engineering judgment before engineering analysis is conducted.
11.2.9 Any changes and comments made by the Company to the written procedures and
approach should be implemented before engineering analysis is conducted.
11.3 Hot Tap Stress Analysis Report
11.3.1 A draft of the Stress Analysis Report should be delivered to the Company’s Project
Manager for comments prior to the 60% Project Review Meeting.
11.3.2 Any changes and comments made by the Company to the Stress Analysis Report
should be implemented, amended and reissued prior to the 90% Project Review
Meeting.
11.3.3 A Stress Analysis Report shall be provided for the installation of split tees, STOPPLE
fittings and full encirclement reinforced saddles.
11.3.4 A detailed pipe stress analysis with a report shall be completed for every split tee and
full encirclement reinforced saddle installation with a branch connection pipe diameter
NPS 8 and greater.
11.3.5 A detailed pipe stress analysis with a report shall be completed for every STOPPLE
fitting installation.
11.3.6 The full Stress Analysis Report shall be delivered to the Project Manager for comments
prior to any mechanical drawings being issued for construction (IFC).

11.3.7 Any changes and comments made by the Company to the Stress Analysis Report shall
be implemented and reissued before mechanical drawings are issued for construction
(IFC).
11.3.8 The Stress Analysis Report shall include, but not be limited to the following:
1. General Information
 short description of the project
 description of software used for Piping Stress Analysis Model
 piping code used (e.g., CSA Z662, B31.4, and B31.8.)
 maximum allowable pipe stress, equipment loads, etc.
 documentation
2. A Summary of Stress Analysis Model
 pipe sizes, wall thickness, material properties, SIFs assumed/calculated, etc.
 sketch or drawing with dimensions used for Piping Stress Analysis Model
 pipe support types used
 pipe support stiffness and other values
 soil assumptions and properties
 depths of soil cover
 soil spring calculations
 any stress mitigation methods and estimated stiffnesses (e.g., Ethafoam 220)
including a list of the physical properties and test methods
 Virtual Anchor (VA) length
 assumed operating conditions
 load cases
 maximum pipe temperature
 ambient temperature, soil temperature
 minimum pipe temperature
 pressures
3. Assumed External Loads
 soil overburden
 soil settlement (areas of model affected)
 sustained forces (weight of pipe, components, cover)
 images of the Entire Piping Stress Analysis Model from Stress Analysis
Software
 stress magnitude spectrum in piping
 location of nodes in Piping Stress Analysis Model

 locations of supports and support types

 distance of pipe support from reference points such as flange, or centreline of
mainline pipe, etc.
 locations of installed stress mitigation methods (e.g., Ethafoam 220, etc.)
4. A summary of Areas of High Stress, Areas of Stress Concern and Support
Types/Loads, including:
 table of pipe stress ratios/values at nodes
 table of support loads referencing a labelled picture for support location
 changes made to piping arrangement to reduce stresses, if any
 list of fittings and valves with maximum displacements under normal
operating conditions
 recommendations
5. Calculations
 calculations of soil overburden load
 Virtual Anchor (VA) length calculations
 soil spring calculations
 membrane stress calculations for pipe sizes, wall thicknesses, grades and
support types
 flanges leakage calculation
 SIF calculations or table showing what was used in the program
6. Extras
 written Compaction plan or procedure
7. Discussion
 Include general issues that were addressed by the analysis, complete with
examples, sketches and illustrations to communicate issues and limitations of
the designed system.
8. Analyst and Experience
 The names of the individual(s) conducting the pipe stress analysis shall be
listed.
 The experience of the competent individual(s) with demonstrated
understanding and experience in the application of pipe stress analysis shall
be listed.

SIGN-OFF AND FOLLOW-UP

12.1.1 The individual(s) conducting the pipe stress analysis shall demonstrate and provide
documentation that a review, a check and an authentication has been conducted to
ensure that the stamped engineering, Issued for Construction (IFC) drawings, the pipe
stress model, and the analysis conducted are in agreement and compatible.
VARIANCES
Any deviation shall follow the TransCanada Management of Change (MOC) Variance
Procedure. External Vendors must contact the TransCanada Project Engineer for
variance approval.
ROLES AND RESPONSIBILITIES

Table 14-1 below outlines the roles and responsibilities required for the use of this
Specification.
Table 14-1: Roles and Responsibilities
Role Responsibilities
Pipe Stress Analyst and Pipe Stress The individual(s) conducting and checking the pipe stress analysis are
Checker responsible for:
 ensuring the hot tap is located based on acceptable geotechnical
conditions and pipeline geometry conditions
Note: It is recommended to survey the pipeline to determine the
elevation profile to check for the location of overbends and sag
bends, as well as review the ILI inertial geo-PIG data if available.
 validating all software used for the piping stress analysis
 ensuring code compliance by addressing and taking action on all
errors, issues, concerns, bugs or other problems encountered with
the software used for conducting the stress analysis
 reducing mechanical and civil complexity
 reducing the stresses with the pipeline
 ensuring long-term operation through the range of operating
conditions
 ensuring an increase the flexibility of the piping system
 complying with all applicable codes and specifications
 ensuring adequate pipe supports for the space provided
 completing all required documentation

Role Responsibilities
Mechanical Designer and Mechanical The individual(s) conducting and checking the mechanical design are
Design Checker responsible for:
 Use original spec language:
 Evaluating hot tap as a design solution for a particular project,
coordinating and bridging the gaps between Company's System
Design, Welding, Pipe Stress, Construction and Project
Management Disciplines to confirm or eliminate hot tapping as an
appropriate design solution
 specifying the required branch connection reinforcement, including
reinforcement calculations for saddle reinforcement and datasheet
completion for split-tees
 reviewing Vendor submissions, including calculations and drawings,
for reinforcement parts such as saddles, stopple fittings and split
tees.
 Completing Project Mechanical Hot Tap Report
Civil Designer and Civil Design The individual(s) conducting and checking the civil design are responsible
Checker for:
 determining the support stiffness for the site soil condition
 incorporating the support loads (as determined by the stress
analysis) into the design of the pipe supports.
Project Engineer and Project The Project Manager (PM) and Project Engineer (PE) are responsible for:
Manager  ensuring designers comply with the competency requirements of this
Specification and retaining proof of such in the project records.
 ensuring that the individual(s) conducting the pipe stress analysis,
mechanical design and civil design, and the individual(s) checking
the work adhere to this Specification, and that those individual(s) are
competent and are able to demonstrate competencies
 documenting the engineering decision for the installation of hot of
taps versus a conventionally installed tee or branch connection
 ensuring the Company’s Welding Engineers are consulted to
conduct a weld assessment of the Sockolets, Thredolets, Weldolets,
split tees, STOPPLE fittings and full encirclement reinforced saddles
to determine the required operating conditions for welding, and to
provide applicable welding procedures
 ensuring the location of the hot tap is in a section of the pipeline that
has competent and constant soil properties within the virtual anchor
(VA) length of the section to restrain the pipe from excessive thermal
displacement
 ensuring all considerations have been documented
 documenting of any areas where the Project Engineer (PE) and/
Project Manager (PM) has assumed any type of responsibility

REFERENCES
This document relies on a number of references to regulation, industry codes and
standards, general industry guidance as well as internal references. These documents
are detailed below in Table 15-1, Table 15-2 and Table 15 3.
Use the latest document revision, unless otherwise approved by TransCanada.
Table 15-1: Regulatory References
Organization/Document No. Title
CFR Title 49 Part 192 Transportation of Natural and Other Gas by Pipeline: Minimum Safety
Standards and any amendment or errata issued by DOT
CFR Title 49 Part 195 Transportation of Hazardous Liquids by Pipeline and any amendment or
errata issued by DOT
NEB OPR SOR/99-294 National Energy Board Onshore Pipeline Regulations (NEB OPR)
NORMA Oficial Mexicana NOM- Transporte de gas natural and any amendment or errata issued by CRE
007-SECRE-2010
Table 15-2: External Industry References
Organization/Document No. Title
ALA ALA (2002) Guideline for the Design of Buried Steel Pipe – July 2001,
American Lifelines Alliance.
API RP 2201 American Petroleum Institute - Safe Hot Tapping Practices in the Petroleum
& Petrochemical Industries
ASME B31.4 American Society of Mechanical Engineers - Pipeline Transportation

Systems for Liquids and Slurries
ASME B31.8 American Society of Mechanical Engineers - Gas Transmission and

Distribution Piping Systems
CSA Z662 Construction Safety Association - Oil and Gas Pipeline Systems
Young, W.C. Roark’s Formulas for Stress and Strain, 6th ed., McGraw-Hill Book Co., New
York, 1989.
Table 15-3: Internal References
Document No. Title
STDS-02-ML-02-001 Typical Hot Tap Installations
STDS-02-ML-02-001 Typical Hot Tap Installations NPS 6 and Larger

Document No. Title
STDS-02-MS-03-001 NPS 4 to NPS 8 Hot Tap Valves Typical Installation
STDS-02-MS-03-100 Pile Support Details for NPS 4, NPS 6 and NPS 8 Hot Tap Valves
EDMS No. 007076183 TED-MATL-FRAC Materials Fracture Control Plan (CDN-US-MEX)
EDMS No. 000006457 TES-CI-EARTH-GLE Facility Earthwork Specification (CAN-US)
EDMS No. 003779258 TES-FITG-SAD Full Encirclement Reinforcing Saddles Specification (CDN-
US-MEX)
EDMS No. 006717380 TES-WL-APIIS-GL Welding on In-Service Pipelines Specification (US-MEX)
EDMS No. 003886791 TES-INSERV-CSA Welding on In-Service Pipelines Specification (CDN)
EDMS No. 003764909 TES-MATL-MD1 Piping System Materials for Pipeline, Compression and
Metering Facilities
EDMS No. 007935312 TES-MATL-MD1-L Piping System Materials for Pipeline, Pump, Metering
and Terminal Facilities (CDN-US-MEX)
EDMS No. 004471280 TES-MATL-MD1-US Piping System Materials for Pipeline, Compression and
Metering Facilities Design to -50 ͦ F
EDMS No. 007073999 TES-MATL-MD2-US Piping System Materials for Pipeline, Compression and
Metering Facilities Design to -20 ͦ F (US-MEX)
EDMS No. 007913242 TES-MECH-BRCH-LIQ Liquid Line Branch Connection Specification (CDN-
US-MEX)
EDMS No. 006489784 TES-ME-FBT-GL Flange Bolt Tightening Specification (CAN-US-MEX)
EDMS No. 005890120 TES-PROJ-EXC Excavation Specification (CDN-US-MEX)
EDMS No. 005434950 TOP Branch Connection Epoxy Grout Injection Procedure

DOCUMENT HISTORY
Rev.
01 Description Effective Date
Revised to reflect the new engineering specifications template and to ensure
2017-June-01
compliance with CSA Z662.
Rationale Statement Responsible Engineer
This document was revised in order to address the following requirements:
 Consolidation of specifications. The following specifications/documents
have been combined into this document:
 TES-MECH-HOT Mechanical Design of Hot Tap Branch
Connections (CDN-US-MEX)
 TES-STRS-HOT Pipe Stress Analysis of Hot Taps (CDN-US-
MEX)
Michael Martens
Note: TES-STRS-HOT Pipe Stress Analysis of Hot Taps (CDN-
US-MEX) was a draft at the time of the writing of this
specification
 CPG Design of Welded Branch Connections and Taps
DS.290.001
 TED-STRESS-D01 Guidelines for the Design of Small Diameter
Branch Connections
Impact Assessment Summary Document Owner
This specification has added requirements for increased documentation to
Michael Martens
ensure concordance with code requirements.
DESCRIPTION OF CHANGE
Section Description of Change
Regulatory
N/A N/A
Industry Standards
N/A N/A
General
N/A This Specification is a new document.
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TransCanada Engineering Specification

TES-ME-STRHO-GL Pipe Stress Engineering

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 Sockolets, Thredolets, Weldolets

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7.4 Supporting Horizontal Assemblies with Structural Supports................................................................. 35

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9.21 Discontinuity Stresses .......................................................................................................................... 61

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Table 15-3: Internal References...................................................................................................................................69

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Clarification: All material mentioned in this document manufactured by T.D.

EVALUATION OF HOT TAPS AS A DESIGN SOLUTION

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2.1.5 Hot taps connections should be avoided when:

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2 592 23.3 442 17.4 150 5.9

4 932 36.7 732 28.8 200 7.9

6 1059 41.7 859 33.8 200 7.9

8 1160 45.7 960 37.8 200 7.9

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10 1287 50.7 1087 42.8 200 7.9

12 1338 52.7 1138 44.8 200 7.9

16 1741 68.5 1491 58.7 250 9.8

20 1944 76.5 1694 66.7 250 9.8

24 2147 84.5 1897 74.7 250 9.8

30 2451 96.5 2151 84.7 300 11.8

Figure 2-1: Horizontally Oriented Hot Tap Stub Length

STRESS ANALYSIS REQUIREMENTS

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Clarification: If it can be determined based on competent engineering judgment that

BRANCH CONNECTION REINFORCEMENT REQUIREMENTS

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5.3 Valves for Branch Connection Diameters Greater Than NPS 2

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LOCATION REQUIREMENTS OF HOT TAPS

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 one hundred pipe diameters (100D) of a liquid control valve

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Figure 6-1: Preferred Distance from Bend to Hot Tap

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Clarification: Settlement, heave, or shifting of the concrete and the associated

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6.4 Hot Tap Location and requirement - Restrictions

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