HSE/SWI-27
HOT TAPPING
Purpose/Scope of Procedure
 Ensuring
and that all hot tapping work and hot tapping tools
maintenance are carried out in accordance with a safe and
approved manner.
 Outlines
the
processes
involved
in
all
Hot
Tapping
Operations, and hot tapping tools maintenance activities in
compliance with the relevant standards.
2
Hot Tapping
Technique of attaching a branch fitting
to a pipe in service, and creating an
opening
in
this
pipe
by
trepanning/boring a portion of pipe
within the attached branch fitting.
3
Pressure Test Certification
4

Prior to commencing a hot tapping operation, the hot tapping
machine, the retriever, and the service valve shall be pressure
tested to 1.5 times the Maximum Allowable Working Pressure
(MAWP) of the lowest rated component.

The pressure test shall be maintained for at least 15 minutes.

The Certification Documents (Inspection Certificates) shall be
properly filled, signed by the ‘Inspection Engineer’ and filed
by the Permit to Work (PTW) Performing Authority.
General Requirements:

All hot tapping operations shall be undertaken in accordance
with the approved procedures and the requirements of the
Control of Work (CoW) system .

Hot tapping shall not be emergency work—if precautions
cannot be established in advance, accommodated, and
properly implemented, then the unit or equipment shall be
taken out of service or shut down.
Key Safety Measures:
Hot Taps shall not be carried out on piping that can be shut
down for sufficient time.
 The hot tap operations on in-service equipment shall be
justified as the Operations Manager could demonstrate that:
 Continuity of service is essential;
 Shutdown of the system is impractical;
 Documented procedures and special equipment are utilized
which will provide effective protection for employees.

Key Safety Measures
Hot taps shall NOT be permitted on lines containing;
 Acetylene, Amines, Ammonia, Caustic, Chlorides that
decompose on heating, Chlorine, Oxygen.
 Materials that may decompose, polymerize, explode, or
detonate upon severe heating(e.g Chlorides, Peroxides etc.)
 Combustible
vapor/air/oxygen
mixtures
within
flammable/explosive ranges.
 Hot taps shall not be made on lines that are clad or lined.
 Hot taps shall not be permitted on lines where stress
relieving is required.
Key Safety Measures

Hot taps made on breathing air or potable water lines,
upstream of machinery that is not adequately protected by
filters, and upstream of instrumentation, shall be reviewed to
ensure downstream services will not be affected by metal
shavings which may enter the lines.

Full-Port Gate or Ball Valves shall shall be tested and certified
leak-free, prior to be used in the hot tapping operations.
Key Safety Measures









The hot tap shall be located:
At least 18 inches from all flanges or threaded connections.
At least 3 inches from any weld seams.
The location of the hot tap shall provide;
Clearance and Support for the machine
Bending moments applied to the piping by the machine
Support requirements for the pipe being hot tapped due to
additional weight of the fittings and branch line
Availability of air or electric power for the hot tap machine
Easy and safe egress for personnel making the hot tap, and easy
access for emergency services.
Key Safety Measures

Thickness measurements shall be taken in the location of the
hot tap and extending out to either side for a minimum of 12
inches or the diameter of the pipe, whichever is greater.

Inspection and engineering assessment shall be carried out
to ensure that the pipeline thickness is suitable for the hot
tapping operations (A minimum base metal thickness for hot
tapping is ¼ inch).
Key Safety Measures
Suggested product velocities range during welding are:
 For liquids: from (0.4 m/sec) to (1.22 m/sec).
 For gases: from (0.4 m/sec) with no maximum limits.
 Dye penetrant examination of the surface of a stainless-steel
pipe is required to ensure that no stress cracking of the
surface.
 If stress cracking exists, ultrasonic survey shall be carried out
by the Inspection Engineer, for determination of the
suitability of the pipe for hot tapping operations.

Key Safety Measures
 All welds on pressure containing parts shall be made using
ASME Code certified welders. Proof of competence for the
Contractor’s welders (training certificates) shall be provided.

Maximum allowable operating Pressure and Temperature of
the flowing product inside the pipeline on which hot tapping
activities take place shall be established and monitored during
the whole operation.

All welds on pressure containing parts shall be made using
ASME Code certified welders. Proof of competence for the
Contractor’s welders (training certificates) shall be provided.
Key Safety Measures
 To
ensure adequate strength in the welded fittings, only
standard fittings that meet the strength requirements of the
pipe specification shall be used.
 Inspection of the welds and the weldment shall consist of the
following:
 100% of the root (first) weld pass and 100% of the final pass of
all welds shall be examined by dye penetration testing
procedures.
 If dye penetrant examination is not possible, alternate testing
methods will be determined and approved by the Inspection
Engineer.
Key Safety Measures:


All weldments, complete with flange and valve, shall be
pressure tested to assure integrity. Branch connections which
utilize a Reinforcement Pad Branch Fitting (re-pad) or split tee
reinforcement shall be hydrotested before installation of the
re-pad or split tee. A hydro test at 150% of design pressure is
preferred.
If a Hydrotest is not possible due to operating temperatures,
a pneumatic test at 110% of design pressure shall be
performed.
Key Safety Measures:



Contractor shall perform measurements and calculations to
verify that the cutter or the pilot drill shall not penetrate
beyond the center of the pipe. The Performing Authority
shall review these calculations.
The temperature of the pipeline shall be monitored, by using
heat guns, to ensure that the temperature is kept within the
safe limits.
In case of insufficient or interrupted flow, such as flare line,
it may be necessary to continually purge the line with inert
gas or hydrocarbon gas to ensure that the line doesn’t
contain a flammable mix during welding operation.
Key Safety Measures
 Never
pump in or out of a tank while
hot work is in progress.
 Turn off all heating coils during hot
tapping.
 No attempts shall be made to hot tap
atmospheric
pressure
petroleum
storage tanks above the liquid level (in
the vapor space or on the roof).
Key Safety Measures
 Maintain
at least 1 meter of liquid head above the hot work
area when welding or hot tapping is being done on a tank.
 No
hot tapping over floating tank roofs, double-walled
vessels, lined pipeline, or pipeline with casing.
 Strainers
near Pumps and Control Valves may be clogged by
the cutting debris inside the pipeline. Consideration shall be
given in such cases, and shall be covered by RA.
Key Safety Measures


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

Coupon Retrievers shall be verified by the Performing Authority.
Specific Contingency Plans shall be prepared and approved by the
Operations Manager, The plan shall include the following points as
minimum requirements:
Operational Emergency (OE) and the recovery conditions.
Contingency plans shall include readiness for emergency shutdown of the facility, distribution of operators at the main isolation
points, and fire & safety equipment, and the firefighters.
Firefighting equipment in place.
Site layouts, including the main isolation points of pipeline or
equipment.
Key Safety Measures

No other activity shall be carried out, which could affect the
safety or integrity of equipment/facility,

In case that hot tapping operation has to be carried out at a
high elevation, the scaffold shall be provided as per the
"OSHA Recommended Practice for Scaffolding.

In case that hot-tapping operation has to be carried out in
underground pit, Confined Spaces procedure shall be
followed..
Key Safety Measures

Ensure the gas test are carried out by calibrated and certified
gas testing device.

Ensuring that any area in which the fire detection/protection
has been inhibited/overridden, shall not left unattended.

Use of iron hammer shall not be used. Wooden, rubber, or
copper hammer under adequate supervision may be allowed
to be used with caution.
Key Safety Measures
21

Hot tapping machine shall be independently supported,
and its weight shall not be transferred to the
equipment/pipeline which is being tapped.

Hot tapping shall not be carried out during high windy,
stormy, dusty and wet atmospheric conditions.

Spilled hydrocarbons and Fluids shall be cleaned and
disposed of safely in an environmentally-friendly (Ecofriendly) manner.

Stand by fire truck should be present on-site.
Key Safety Measures



Mobile plant, equipment, and vehicles shall be stationed
upwind, and shall not be within the fifteen (15) meters radius
from the working spot, and their engines are switched off.
The Safety Data Sheet (SDS) of the welding electrodes shall be
reviewed for Permissible Exposure Levels (PELs) of their
fumes.
Ensure that the operating pressure and temperature of
equipment or piping being hot tapped shall not exceed the
rated pressure and temperature of the cutting machine, at any
time.
Hot Tapping Machine, Retrieval Tool &
Access Valve
The following conditions should be applied:


23
Safeguards shall be fitted in place, the safe use and testing
procedures of hot tapping machine, retrieval tool, and the
service valve, shall be maintained as per the manufacturers’
instructions manuals, and the applicable standards.
The operating conditions of the hot tapping machine, retrieval
tool, and the access valve shall be maintained as per the
manufacturers’ instructions manuals, and the applicable
standards.
Protective Clothing and Equipment
 All





personnel shall wear appropriate PPE, which shall not be
contaminated with oil or grease - may include, but are not
limited to, the following:
Cotton coverall along with suitable aprons, and sleeves.
The welder shall wear the appropriate PPEs.
The hot tapping machine operator shall also use other PPE (such
as goggles, helmet, face shield, hand gloves etc.)
As the Hot tapping Machine is a rotating equipment, therefore
all personnel should not wear loose clothing.
The Work-site Crew shall be familiar with precautionary
measures associated with breathing apparatus for safe escape.
Documentations

Hot tapping procedures shall be made available at Site for the
entire duration of the hot tapping operation.

The Manufacturer's instructions manuals shall also be
followed while performing the hot tapping operations.

Upon completing the hot tapping operation, the hot tapping
machine shall not be removed until the required inspection is
completely finished.