Hot Tapping

The hot tapping process for a district heating or cooling pipeline always begins with a thorough evaluation of the required connection. To prepare an accurate plan and quote, we ask our customers to provide the following information:

• What is the size and material of the main pipeline?

• What is the wall thickness of the main?

• What are the design pressure and design temperature?

• What are the operational pressure and temperature?

• What is the required hot tap size and pressure class?

• Is the use of electric tools allowed on the worksite?

Once our team at Tonisco receives this basic information, we can provide you with a budgetary quote for the hot tapping process. We always make recommendations for the most suitable valves and fittings to ensure safety and efficiency, but we can also work with components supplied by the customer if preferred.

The Tonisco hot tap process is designed for maximum flexibility, allowing us to use any approved hot tap component available on the market. In low- and medium-pressure networks, a standard combination of a weldolet and a hot tap valve is often a sufficient and reliable solution. This approach gives each project more adaptability and enables smooth cooperation between contractors.

The most common hot tapping solutions for heating and cooling networks include:

• Branch size DN10 to DN200: Tonisco valve or hot tap ball valve

• Branch size DN150 to DN600: Tonisco valve for the hot tap and a shut-off valve with air releases installed further along the line

Tonisco Service can perform hot tapping on all pipeline materials used in district heating and cooling systems. The most common hot tapping methods are:

• Steel pipelines: Welding a reinforcement plate or a weldolet with a hot tap valve

• PE pipelines: Fusion-welded hot tap saddle with a shut-off valve (gate or ball valve)

• Other materials: Mechanical hot tap clamp with a shut-off valve (gate or ball valve)

To learn more about the different hot tapping options and technical details, please download the brochure.

Key Features of Tonisco Hot Tapping Service

• No need for service interruptions — pipelines stay fully operational

• No treated water or medium is lost during the process

• No need to wait for the line to be completely emptied, significantly reducing refill time

• Avoids costly redesigns and reduces planning expenses

• Eliminates the need to notify customers of heating or cooling outages

• Enables flexible cooperation, including shared stages such as welding

• Turnkey planning and execution available when needed

Operational Parameters — Basic Service Package

• Maximum operational pressure: 60 bar at 40 °C

• Maximum operational temperature: 200 °C at 16 bar

• Hot tap size range: DN10 (3/8″) to DN1600 (64″)

• Compatible with both ASME and DIN standards

Operational Parameters — Special Service Package

• Maximum operational pressure: 1480 PSI at 40 °C

• Maximum operational temperature: 371 °C at 700 PSI

• Hot tap size range: DN25 (1″) to DN1600 (64″)

• Compatible with both ASME and DIN standards