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G # 7
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Revised 12/13/99



To establish safety guidelines for hot tapping or in-service welding at this facility.


This S.H.G. will be applied to all hot taps and/or in-service welding on vessels, lines, etc., which
have not been properly isolated, emptied and gas freed. This Safety and Health Guide applies to
anyone working at this facility.


Hot Tap: The welding and mechanical procedure that enables a connection to be made to
a line or vessel while that line or vessel remains in service.

In Service Welding: The practice of welding on equipment (e.g., tank, pipe, vessel,
exchanger, etc.) which has not been purged (gas freed) and has not been removed from
service. This includes but is not limited to grinding, burning or welding.

Coupon: That piece of pipe or vessel cut away during the hot tap procedure.


Individual/Group Assigned Responsibilities

Maintenance Director, Engineering Review and approve all hot tap and in-service
Director, Operations Director, E&SA welding at this facility.
Director, and Plant Manager Will consider other means of accomplishing the
(Or their designee) objectives.
Owning Area Supervisor Will be responsible for assuring work area and
(Or a designee) equipment are ready for hot tap or in-service
Assure a hot work permit is written with all
special requirements listed.
Provide the needed information and get
approval from all departments required on the
Hot Tap/In-Service Welding Authorization Sheet
(See Attached).
Maintenance Director Confirm code status is maintained.
(Or a designee)
Tech Service Manager Provide assistance when special consideration
(Or a designee) or procedures are required.
Maintenance Inspection Provide proper non-destructive testing, gauging
and marking of the in-service equipment.
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Revised 12/13/99

Individual/Group Assigned Responsibilities

Safety Representative Job site inspection prior to signing
authorization form to ensure that this and other
applicable safety guidelines are met.
Maintenance Supervisor Will follow this and other applicable guidelines.
(or a designee) Ensure that all applicable permits,
requirements, and safety precautions are met
prior to the start of work.
Ensure that the completed Hot Tap/In Service
authorization is at the work site.
Will be present during actual hot tap and
testing to ensure safety and retrieval of
Retrieve the coupon and save for reference.
Immediately notify the PF/Supervisor if the
coupon is not recovered.
Ensure affected Maintenance personnel are
trained in the use of the mechanical hot tap
Pipe Fitter/Welder Technician Will follow this and applicable guidelines.
Will be trained in the use of this equipment.


Consideration will be given to other means of accomplishing the objectives. This

includes such methods as delaying the work until the unit or equipment is out of
service, depressurizing and evacuating the line, use of inert gasses, etc.

All Hot Work Guidelines will be followed when preparing the area for in-service welding or
hot tapping.

Lines or vessels to be hot tapped or requiring in-service welding will be operating at

minimum pressure and temperatures. Hot tap equipment must be designed for the
pressures and temperatures to be encountered.

Hot taps will not be made on vessels or lines containing compressed air, oxygen or
oxygen rich air, amine, chlorine, ammonia, caustic soda, lines that contain oxidizing
agents or equipment operating below atmospheric pressure.

In-service welding will not be performed on lines or equipment containing

oxygen-hydrocarbon mixtures unless the oxygen content is known and is at a safe level
which can be controlled (0-5% O2). Air lines which may contain oil cannot be welded in
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Revised 12/13/99

Minimum flow will be maintained in lines during welding or hot tapping. In general, for gas
and vapor service the minimum is 3ft/sec. For liquids, velocities between 1.3 ft/sec and
8ft/sec are required. In certain cases such as flare lines where there may be insufficient or
no flow, it is necessary to maintain flow in the line with steam or gas during the welding

Equipment that has contained or is suspected of containing hydrogen sulfide (H2S) above
the TLV (10-ppm) will require the availability and/or use of breathing air at the job site
depending on permit requirements.

Tanks to be hot tapped or welded on will contain a liquid level at least 3 feet above the
weld in order to cool the heat-affected area.

A tank will not be pumped into, pumped out, or agitated while welding or hot tapping is
being performed.

Prior to welding, maintenance inspection will determine by non-destructive testing, such

as X-ray or ultrasonic testing, that the metal is of sufficient thickness to prevent burn
through. The minimum thickness for welding shall be the minimum retirement thickness
or 0.19 inches, which ever is greater. Maintenance inspection will mark the specific area
in which the weld can be made safely. The welder will be informed of the minimum wall
thickness and its location by maintenance prior to striking an arc.

All nozzle and reinforcement pad welds for hot taps will be tested prior to cutting the hole
with valve and hot tap machine in place. The maintenance inspection group will
determine test medium and pressure.

Emergency Variance - Should a condition exist where needed Department Managers are
not available for immediate approval, the Plant Manager or his designee will be contacted
for authorizing the hot tap or the in-service welding to proceed. All procedures outlined in
Section 5.0 must be followed to assure a safe hot tap or in-service weld. The supervisor,
in charge at the time of the emergency, will assure that all requirements are followed.
Normal documentation will be completed as soon as it is feasible.
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Revised 12/13/99


Proper notification and approvals will be given before any work is begun. The person who has requested the work
must assure all notifications and approvals, with special conditions given (if required). Once this approval sheet has
been completed, a copy will be maintained at the work site.
Work Date: Time (if known)
Work Order Number: MOCA Number
Description of the Work:

Special Considerations: Hot taps will not generally be made on vessels or lines containing compressed air, oxygen or oxygen
rich air, amine, chlorine, ammonia, caustic soda, lines containing oxidizing agents or equipment operating below atmospheric
Equipment Information:
A. Product in Equipment ___________________
B. Equipment pressure ________________ psi
C. Equipment temperature _________________ F
D. Line size to be tapped _____________ inches
E. New line size _____________ inches
F. Is the weld location properly marked? _______yes _______no
G. Metal thickness at the weld site ___________________
H. Requirements to meet minimum flow

Thickness Tested By: Date:

The following Department Directors must review each hot tap or in-service welding request and give their written
approval for each job. Inspection of the equipment to be worked on and the work area is required by each
department representative before approval is given.
Plant Manager
Operations Director
Maintenance Director
Tech Service Manager
E&SA Director
*Area Supervisor
* PF/W Supervisor
*Safety Representative
*A job site inspection is required before signing this authorization form.
Job Completion Checks:
Test Medium Test Pressure
Test completed satisfactory (with
valve and tapping machine in place). Signature of PF/W Lead Tech.
Coupon retrieved and labeled
Yes ________ No _________ Signature of PF/W Lead Tech.
Coupon Received (for Maintenance records)
Yes ________ No ______ Signature of PF/W Supervisor
Form revised 10/18/99