A complete hot tapping setup normally requires a hot tapping machine, cutter, pilot drill, fitting, valve, adapter and suitable drive unit. Depending on the pipeline and worksite, the operation may also require pressure-testing equipment, lifting or support equipment, measuring instruments and personal protective equipment.
These components form one pressure-containing system. Every part must be suitable for the pipe material, required opening, connection type, operating medium, pressure and temperature. Choosing a machine based only on its nominal size range is not sufficient.
Tonisco manufactures hot tapping machines and related components for different connection sizes. We can supply equipment for qualified in-house teams or provide a complete hot tapping service for district heating and cooling networks.
If you already know your pipe size and operating conditions, send the details to Tonisco and we will recommend a suitable equipment configuration.
Hot tapping equipment checklist
The principal components of a hot tapping system are:
- Hot tapping machine
- Pilot drill
- Hole saw or cutter
- Pipeline fitting or saddle
- Hot tap or shut-off valve
- Machine-to-valve adapter
- Drive unit
- Pressure-testing and bleed arrangement
- Machine support or lifting equipment when required
- Measuring and personal protective equipment
The exact equipment list changes from one project to another. A small instrument connection may use a compact machine and threaded valve, while a large flanged branch can require a larger machine, powered drive unit, lifting equipment and a purpose-designed fitting.
What does the hot tapping machine do?
The hot tapping machine controls the movement of the pilot drill and cutter while containing pipeline pressure.
The machine is mounted on the valve above the fitting. After the assembly has been checked, the valve is opened and the cutting mechanism advances towards the pipe. The pilot drill first penetrates the wall and helps guide the cutter. The cutter then creates the required opening.
Once the cut has been completed, the cutter and removed piece of pipe wall, known as the coupon, are retracted into the machine. The valve can then be closed, allowing the machine to be depressurised and removed.
The machine must provide:
- Sufficient boring-bar travel to reach and cut through the pipe wall
- Capacity for the required pilot drill and cutter
- A pressure-containing connection to the valve
- A controlled feed mechanism
- Compatibility with the selected drive unit
- Sufficient strength for the required cutting operation
The machine’s stated range refers to the size of the hot tap or branch opening. It does not necessarily refer to the diameter of the main pipeline.
For a broader explanation of the method, read our guide to what hot tapping is and how it works.
Which Tonisco hot tapping machine should you choose?
Tonisco offers several machine sizes for different hot tap ranges. The correct model depends on the required opening, connection type and operating conditions.
| Tonisco machine | Hot tap range | Published maximum pressure | Published maximum temperature | Typical role |
|---|---|---|---|---|
| TONISCO Baby Hot Tap Machine – E | DN10–DN25 | 25 bar | 200 °C | Small branches and instrument connections |
| TONISCO Jr. Hot Tap Machine – E | DN20–DN100 | 60 bar | 200 °C | Small and medium branch connections |
| TONISCO B30 Hot Tap Machine – E | DN40–DN200 | 60 bar | 200 °C | Medium connections on distribution pipelines |
| TONISCO B40 Hot Tap Machine – E | DN100–DN500 | 40 bar | 200 °C | Larger branch connections and main pipelines |
The maximum pressure and maximum temperature shown for a machine must not automatically be interpreted as a simultaneous operating point. The permitted application depends on the complete assembly, including the fitting, valve, adapter, seals, cutter and drive configuration.
Always verify the pressure-temperature relationship and complete equipment specification before use.
Not sure which range you need? Contact Tonisco’s product team with your required hot tap size and operating data.
What is the pilot drill used for?
The pilot drill creates the initial opening and guides the main cutter. It also plays an important role in retaining the coupon after the cut.
The pilot drill must be selected according to:
- Machine model
- Cutter size
- Pipe material
- Pipe wall thickness
- Required cutting depth
- Coupon-retention arrangement
A worn, damaged or incorrectly selected pilot drill can affect cutting accuracy and coupon retention. Pilot drills should therefore be inspected before use and replaced according to their condition and the manufacturer’s instructions.
Tonisco supplies pilot drills and other hot tapping accessories for its machine ranges.
How do you choose the correct cutter or hole saw?
The cutter creates the main opening through the pipe wall. Its diameter determines the opening size, while its design and cutting material must be suitable for the pipeline.
Selection factors include:
- Required opening diameter
- Pipe material
- Wall thickness
- Machine capacity
- Cutter depth
- Pilot-drill compatibility
- Valve bore
- Adapter clearance
- Cutting speed and feed method
The cutter must pass freely through the valve and adapter. A machine may have sufficient power and travel for the operation while the selected valve has an internal restriction that prevents the cutter from passing through.
Tonisco’s catalogue includes hole saws, cutters and pilot drills for different machine families. Browse our hot tapping products or ask our team to build a compatible component list.
What fitting is required?
The fitting provides the structural connection between the existing pipeline and the new branch. Its design depends on the pipe material, required connection size, operating conditions and installation method.
Tonisco Service commonly uses the following methods in heating and cooling networks:
- Steel pipelines: a welded reinforcement plate or weldolet with a hot tap valve
- PE pipelines: a fusion-welded hot tap saddle with a gate or ball valve
- Other materials: a compatible mechanical hot tap clamp with a gate or ball valve
A pre-insulated district heating pipeline normally requires access to the carrier pipe before the fitting can be installed. The insulation and casing must then be restored according to the pipeline system and project requirements.
The fitting must be assessed for:
- Main pipe diameter
- Branch or hot tap size
- Pipe curvature
- Pipe material
- Actual wall thickness
- Pressure and temperature
- Joining method
- Loads from the branch and installed equipment
- Available installation space
The fitting should not be selected independently of the valve and machine. All three must create a compatible assembly.
What type of valve is needed?
The valve sits between the pipeline fitting and the hot tapping machine. It provides the passage for the pilot drill and cutter and allows the new opening to be isolated after the cut.
The valve must have:
- A sufficient internal bore for the cutter
- A suitable connection to the fitting
- A compatible adapter for the tapping machine
- The correct pressure class
- Suitable temperature and media ratings
- Enough clearance for the cutting assembly
- Reliable isolation after completion
Hot tap ball valves, gate valves and other approved shut-off valves may be used depending on the application.
A valve’s nominal size does not guarantee that the cutter will pass through it. The actual internal dimensions, seat design and opening mechanism must be checked before the operation.
Tonisco can recommend a suitable valve and fitting combination or work with approved components supplied by the customer. Request a component recommendation before ordering the complete setup.
Why is the adapter important?
The adapter connects the hot tapping machine to the valve. It must match both interfaces while preserving the required pressure rating and cutter clearance.
An adapter affects:
- Connection type
- Pressure class
- Machine position
- Available cutter travel
- Internal clearance
- Overall equipment height
- Compatibility with the selected valve
Tonisco supplies threaded, weldable and flanged adapter solutions across its machine ranges. The available B30 and B40 adapters include multiple DIN and ANSI pressure classes.
Before selecting an adapter, confirm the exact valve manufacturer, model, nominal size, flange standard and pressure class. Similar-looking valves can have different internal dimensions.
Which drive unit should you use?
The drive unit rotates the pilot drill and cutter. The best option depends on the machine, cutting diameter, material, worksite restrictions and available power sources.
Tonisco’s product range includes:
- Electric drive units
- Hydraulic drive units
- Pneumatic drive units
- Manual ratchet drive units for compatible applications
Electric drive units
Electric drives are convenient when suitable power is available and their use is permitted at the worksite. Before specifying the equipment, confirm the available voltage and any site restrictions.
Hydraulic drive units
Hydraulic drives can provide the controlled torque required for demanding cutting operations. The hydraulic power source, hoses and connections must be suitable for the machine and work environment.
Pneumatic drive units
Pneumatic drives are an option where compressed air is available or electric equipment is unsuitable for the site. Air supply and tool requirements must be confirmed in advance.
Manual drive units
Manual ratchet drives may be available for compatible machine and connection configurations. Their suitability depends on the cutter size, material and required cutting force.
The drive unit must never be selected separately from the machine and cutter. Contact Tonisco if you need help comparing electric, hydraulic, pneumatic or manual configurations.
What pressure-testing and bleed equipment is needed?
Before the pipeline wall is penetrated, the pressure-containing assembly must be checked according to the approved procedure.
The project setup may include:
- A pressure gauge suitable for the expected range
- A connection for pressure testing
- A bleed or vent valve
- Suitable test hoses and fittings
- Equipment for controlling and containing discharged medium
- Temperature measurement when required
The bleed connection is also used when depressurising the tapping-machine chamber after the valve has been closed. The machine must not be removed until the chamber has been safely depressurised and its condition verified.
The test method, test pressure and acceptance criteria must be defined for the individual operation and applicable requirements.
What support and lifting equipment may be required?
Larger hot tapping machines and fittings can create substantial loads on the valve and pipeline. Support may therefore be needed to position the machine and prevent unintended loading.
Depending on the project, this can include:
- Machine stands
- Chain blocks or hoists
- Lifting slings
- Temporary support structures
- Alignment equipment
- Excavation shoring and access platforms
The support arrangement must account for the machine’s operating movement and the forces produced during cutting. Lifting equipment must also be suitable for the site and equipment weight.
For underground district heating work, the excavation must provide enough space for the fitting, valve, adapter, machine, drive and operator. Planning solely around the pipe itself can result in insufficient working space.
What safety equipment is required?
Personal protective equipment and site controls depend on the pipeline medium, pressure, temperature and location.
A project-specific safety plan may require:
- Protective clothing appropriate for the medium and temperature
- Eye and face protection
- Suitable gloves
- Safety footwear and head protection
- Barriers around the work area
- Controlled access to the excavation
- Equipment for containing a possible release
- Communication and emergency arrangements
- Safe lifting and work-positioning equipment
Hot tapping involves live pressure and cannot be made safe simply by adding more protective equipment. The primary controls are a suitable pipeline, an engineered method, compatible pressure-rated components and trained personnel.
If your team has not previously carried out the proposed operation, contact Tonisco Service before proceeding.
How do pipeline material and connection method affect the equipment?
Different pipeline materials require different fittings, joining methods and cutters. However, equipment should not be selected from the material name alone.
For example:
- Steel pipelines commonly use welded reinforcement plates or weldolets
- PE pipelines may use fusion-welded hot tap saddles
- Pipelines that cannot be welded may use compatible mechanical clamps
- Pre-insulated systems require the outer casing and insulation to be managed separately from the carrier pipe
Stainless steel, composite materials and older pipeline systems may require additional confirmation of material properties, cutter suitability and joining methods.
Claims that one standard cutter or fitting works for every pipe material should be avoided. Tonisco evaluates the complete application before recommending components.
What information is needed to select hot tapping equipment?
To recommend a machine and compatible components, we normally need:
- Main pipeline outside diameter or nominal size
- Pipeline material
- Actual wall thickness
- Design pressure and temperature
- Current operating pressure and temperature
- Pipeline medium
- Required hot tap or branch size
- Required pressure class
- Proposed fitting type
- Valve manufacturer, model and connection type
- Available working space
- Worksite location
- Available power sources
- Whether electric tools are permitted
- Drawings or photographs of the connection point
This information allows us to check the machine range, cutter diameter, travel, valve clearance, adapter, fitting and drive method as one system.
Send your project details to Tonisco for an equipment recommendation and quotation.
Tonisco equipment or turnkey hot tapping service?
The right purchasing model depends on how often your organisation performs hot tapping and whether you have qualified personnel and established procedures.
Choose Tonisco equipment when:
- Your organisation has trained hot tapping personnel
- You perform under-pressure connections regularly
- You want equipment available for scheduled and urgent work
- You need a standardised machine and accessory system
- You can inspect and maintain the equipment appropriately
Tonisco manufactures hot tapping machines, machine sets, valves, cutters, pilot drills, adapters, drive units, saddles and clamps. Explore all Tonisco products or contact us for a configured quotation.
Choose Tonisco Service when:
- Hot tapping is not a routine in-house operation
- The connection is unusually large or technically demanding
- You need support with method selection
- You require specialist on-site execution
- You want a turnkey solution from planning to completion
- The project also involves line stopping or a temporary bypass
The published scope of Tonisco’s Basic Heating & Cooling Hot Tapping Service includes hot tap sizes from DN10 to DN1600, a maximum operational pressure of 60 bar at 40 °C and a maximum operational temperature of 200 °C at 16 bar. The service supports both ASME and DIN standards.
These are service parameters, not the limits of one individual hot tapping machine. The maximum pressure and maximum temperature also describe different operating points.
Explore Tonisco’s hot tapping service to learn more about our methods and capabilities.
Get the correct equipment for your hot tapping project
Tonisco has manufactured equipment for pressurised pipeline work since 1969. We supply customers with individual components, complete machine sets, technical guidance and professional on-site services.
Instead of building a system from separately selected components, let us verify that the machine, fitting, valve, adapter, drive, pilot drill and cutter work together for your application.
Request a hot tapping equipment quotation and include your pipeline data, required connection size and preferred project schedule.
We can help you choose between:
- TONISCO Baby for DN10 to DN25
- TONISCO Jr. for DN20 to DN100
- TONISCO B30 for DN40 to DN200
- TONISCO B40 for DN100 to DN500
- A wider Tonisco Service solution for project-specific connections up to DN1600
Whether you need equipment for your own team or complete on-site execution, we will recommend a solution based on the actual pipeline rather than a generic equipment list.