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Up-Dated 01/25/01
HOT TAPPING
I. SCOPE
Hot tapping and/or line Plugging is a last resort process required for on-line connections or
isolating a piece of equipment or piping system. This procedure covers all hot tapping
and/or plugging. Valve packing by tapping and injecting is not included. A connection
will be defined as a hot tap on a case by case bases.
II. PROCEDURE
Introduction
Hot taps and hot line plugging are permissible "only" as a last resort; i.e., when safety, the
time required and/or expense of isolation and decontamination is unreasonable or either of
the preceding are less safe. If the facility is a covered process" as defined by OSHA
1910.119, then the sites Management of Change (MOC) Procedure must be followed. If a
facility is not a covered process" then an appropriate safety review/audit should be
performed prior to the execution of the hot tapping/plugging. A special permit is required
for all hot taps according to Safety Procedures, Fire Permits and Vessel Entry/Fire Permits.
Checklists (Attachment #3 H/T and Plugging Data Sheet, [7 pages]) are provided to assure
pertinent questions are answered and due consideration is given to back-up drills, cutters,
etc.
III. RESPONSIBILITIES
A. Engineering
Engineering responsibility includes design of nozzle and its support, type of
inspection of the parent wall e.g. radio graph and/or ultra-sonic inspection, welding
method and procedure, valve selection and specification of test pressures, method of
testing and the test media, appropriate drawings and files up-dated.
Special consideration must be given to testing media due to parent wall temperature
and thickness. The engineer or tapping technician will assist other involved groups
in the evaluation, planning, and execution.
The parent metal, at the immediate location of the hot tap, shall be inspected prior
to the welding of the nozzle onto the line, vessel, etc. The type, design and
temperature of the parent metal will determine the type of wall inspection.
page 2 of 2
B. Inspection Group
D. Operations
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ATTACHMENT 1
page 1 of 2
HOT TAP REQUIREMENTS
1. Data sheets and job plans sent to the Operations Manager a minimum of 48 hours prior to
the starting of welding.
2. Hot Tap Valve and Fittings to be ordered and witness tested to API specifications, "0"
leakage is preferred.
4. Two(2)points of egression.
11. Checklist of valve and hot tap machine after installed on nozzle.
a. Ensure proper orientation of valve. If the tap is to be performed in the horizontal
plane the preferred orientation is for the valve to be turned inverted i.e. the valve
stem pointing at the ground, (hand wheel on the bottom).
b. Check nozzle, valve and hot tap machine alignment.
c. Verify diametrical clearance.
d. Ensure valve will close when cutter is in retracted position.
e. Ensure valve is open prior to initiating tap.
f. Check lube oil PSV setting on hot tap machine.
g. Check travel and turns of hot tap machine. Determine depth of cut and number of
turns necessary.
h. Have power source available for hot tap machine.
i. Verify the hot tap machine has travel indicator.
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ATTACHMENT 1
page 2 of 2
HOT TAP REQUIREMENTS
**** On process lines, air free machine prior to tapping. The nozzle and machine must be
air freed. With the hot tap valve open, pressure and de-pressure (typically at 100
psig) the assembly with an inert gas a minimum of three (3) times. The inert gas
media used is typically nitrogen. Based on the process the machine may have to
remain pressured with the inert gas or it may be de-pressured and the tapping
machine bleed valve closed. After the Tapping machine and nozzle assembly air
freed are the connection valve should be closed and the inert media supply line
disconnected from the nozzle or the tapping machine.
13. Contact Production/Operations to reduce flow in line (to be hot tapped) during the actual
tapping process, if possible. Low flow rates are desirable.
14. Notify Production/Operations and Safety when the hot tap is ready to begin.
15. Notify Production/Operations and Safety when hot tap is complete.
16. After Hot Tap is complete:
a. Send coupon to Inspection Group.
b. Prepare report on results.
See Item 10, 11 and Note under "Requirements for Tapping Contractor".
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ATTACHMENT 2
page 1 of 1
HOT TAP COMPANY REQUIREMENTS
Note: Items 10 and 11 must be used when tapping process lines or equipment.
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ATTACHMENT 3
page 1 of 7
HOT TAPPING And PLUGGING DATA SHEETS
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ATTACHMENT 3
Page 2 of 7
DATA SHEETS
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ATTACHMENT 3
Page 3 of 7
DATA SHEETS
Engineer Representative:__________________________________________
Hot Tap Technician:_______________________________________________
Approved Tapping Contractor Executing Work _______________________
Nozzle Details: Size ________,Length ________,Sch. ______________
Flange Rtg. _____________,Face ______________________________
Note: All Butt Weld Construction.
Maximum Allowable Bending Moment on the Nozzle
____________in-lbs.
(If the Tapping is Not in Vertical Plane)
Mechanical Support Requirements: P - Permanent, T - Temporary
Parent System: ( ) Yes ( ) No ( )P ( ) T
Nozzle: ( ) Yes ( ) No ( )P ( ) T
( ) Yes ( ) No ( )P ( ) T
Repad Details: ( ) No;ID = ______",OD = ______", Thickness ______"
Can a Weld-O-Let Be Used: ( ) Yes ( ) No
Split Tee: ( ) No; ID = ______", t = ______", Length = _________"
Forged: ( ) Yes ( ) No,
Note: A fabricated split tee may be used only after being
approved by Plant Engineering and special Inspection
techniques are followed.
Type Of Flange on Split Tee _____________________________________
Test Pressures
Leak Test: _______________psig Hydrostatic ( ) Pneumatic ( )
Strength Test: ___________psig Hydrostatic ( ) Pneumatic ( )
MAWP of the System,(this is used after the tapping machine is
bolted to the nozzle):__________psig Hydrostatic ( ) Pneumatic ( )
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ATTACHMENT 3
Page 4 of 7
DATA SHEETS
Representative: ___________________________________________________________
Wall conditions at location of tap t = _________" MIN. t = ___________"
MAX. t = _________" ACTUAL
by ( ) X-ray ( ) Ultra-sonic
Pitting: ( )Yes ( )No Scale: ( )Yes ( )No
Welding Procedure No._____________________________________________________
Special Notes: ___________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
Valve Inspection: ( )X-Ray ( )X-ray waived in lieu of Hydro test & Examination
Hot Tap Nozzle To Vessel/Piping Weld Inspection Requirements:
Visual Only ( ) Yes ( ) No
Radiography Inspection Requirements ________________________________________
Ultrasonic Inspection Requirements __________________________________________
Dye Penetrant Requirements________________________________________________
Magnetic Particle Requirements _____________________________________________
Review NDE Requirements with Qualified Inspection Service
( ) Yes, ( ) No
Qualified Inspection Service To Be Used _____________________________________
Note: Some of the Services That Can Be Tapped Using Special Procedures and
Extreme Caution are: Air, Chlorine, Acetylene and Oxygen.
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ATTACHMENT 3
Page 5 of 7
DATA SHEETS
Hydrostatic
Hydrostatic pressure testing is a full strength test of the nozzle and is defined as 1.5 times
the Maximum Allowable Working (temperature compensated) Pressure (MAWP). A
hydrostatic test shall be used when:
A. the process is compatible with water or the free water and moisture can be
removed from the nozzle and/or the tapping machine.
B. the parent metal is less than 212oF or above 35oF.
The material of construction should be carefully checked to ensure that the water
used in the hydrostatic test does not have to be heated prior to and during the test.
Special water may be required (e.g. demineralized water) for the hydrostatic test.
Pneumatic
Pneumatic pressure testing is a full strength test of the nozzle and is defined as 1.25 times
the Maximum Allowable Working Pressure (MAWP). An additional special permit is
required if the test pressure is above 100 psig. A pneumatic test shall be used when:
A. The process is not compatible with water or the free water and moisture cannot
be removed from the nozzle and/or the tapping machine.
B. The parent metal is greater than 212oF or less than 35oF.
Normally a system is brought to operating conditions slowly. Since the hot tap nozzle
will immediately see operating conditions, special precautions are required in addition to
those normally taken for and during a pneumatic test.
All butt welds shall be radio-graphed, the valve shall be hydrostatically tested, and the
fillet welds dye checked (where applicable) prior to the pneumatic test.
If a relief valve protects the line or vessel, the pneumatic test shall be defined as 1.25
times the MAWP of the system, temperature corrected. (MAWP is typically the relief
valve setting.)
If the line can be isolated from a vessel relief then the nozzle must be tested at 1.15 times
the maximum design pressure. Inert Gas Media Preferred (argon or nitrogen).
-----------------------------------------
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ATTACHMENT 3
Page 6 of 7
DATA SHEETS
Step 1 Initially 25 psig hold 10 minutes. Snoop test if possible, use other leak detection
methods (ultrasonic leak detector, etc.) as required if unable to snoop test.
Step 2 Barricade the area - there shall be no personnel in the immediate area once the
initial 25 psig test and snoop check (where applicable) is completed.
Step 3 Pressurize to 75 psig and hold 10 minutes.
Step 4 Pressurize to 150 psig and hold 10 minutes.
Step 5 Pressurize in 100 psig increments and hold 10 minutes at each increment until the
specified pneumatic test pressure has been reached.
Step 6 Hold at the specified test pressure for 30 minutes.
Step 7 Slowly de-pressure and visually inspect after depressuring is complete.
The sequence of welding and the depth of heat penetration must be closely
controlled to maintain safety and trouble free reliability of the split tee hot tap
fitting on the subject piping. The following will minimize the potential for burn
through and will reduce the residual stresses, which could cause cracking of the
attachment welds.
A. Use small (3/32") welding rods or gas tungsten arc to reduce the area of heating
and temperature penetration through the header wall.
B. All edges shall be beveled 15o, per normal welding practice, and the inside edges
of the long seams shall be back beveled 15o to prevent the split tee long seams
from becoming welded to the parent pipe.
C. The welding sequence should be as follows:
1. Tack the bottom half of the split tee into position.
2. Tack the top half of the split tee (with the branch connection) into
position. The tack points should be along the long seam.
3. Cut loose both ends of the split tee by grinding off the tacks.
4. Complete (weld out) the long seam of the tee on ONE side and allow the
fitting to cool to the parent pipe temperature. Note: During the welding
process verify that the other long seam gap is not spreading and inspection
of the root pass by a plant inspector is required.
5. Complete (weld out) the other tee long seam weld and again allow the tee
to reach the parent pipe temperature.
6. Weld out one circumferential weld on the tee end and again allow the
fitting to cool to the parent pipe temperature.
7. Weld out the remaining end of the tee to the pipe
and allow the fitting to cool to the parent pipe temperature.
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ATTACHMENT 3
Page 7 of 7
DATA SHEETS
A. The preferred orientation of a hot tap is to tap in the vertical plane from the
bottom side of the pipe. Most of the metal shavings will fall into the tapping
machine. The possibility of losing the coupon is minimized and the potential of
metal shavings preventing the valve from seating is also minimized. Some types
of line stops or plugs, if the hot tap is being performed to stop the flow in the line,
may not operate properly if inserted up-side-down therefor a vertical tap may be
executed.
B. The next preferred orientation of a hot tap is in the horizontal direction, where the
tapping machine is parallel to the ground. To minimize the possibility of shavings
or chips from preventing the valve from seating properly the valve must be
inverted (the valve stem pointing towards the ground), the valve should be
righted at the next opportunity. This method does not eliminate the risk of losing
the coupon. If the tap is being performed to insert a line stop or plug to stop the
flow in the line the machine to perform this function must be evaluated because
not all plugging machines will function properly in the horizontal position.
C. The last and least preferred orientation of a hot tap is in the vertical plane from the
topside of the pipe. The chips fall into the line and the coupon has a highest
probability of falling into the line.
The above types of line plugs use the cut surface of the pipe wall to seal against unlike
the typical line plug that uses the internal pipe wall as the sealing surface with the line
plug.
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ATTACHMENT 4
Page 1 of 3
EXECUTION GUIDELINES
B. Data sheet sent to the Operations Manager, a minimum of 48 hours prior to the
starting of the welding. Operation Engr.
_____________________________________________________________
C. Maintenance/Project communication:
1. Mechanical Foreman Contacted Operation Engr.
2. Welding Preparation Mechanical Foreman
3. Hot tap and fittings to be ordered Mechanical Foreman
4. Materials: Gasket, Studs, etc., necessary for the job. Mechanical Foreman
5. Lifting Equipment
a. Crane
b. Cherry Picker Mechanical Foreman
6. Scaffolding Required
a. Personnel
b. Hot Tap Machine and Hydraulic Driver Mechanical Foreman
______________________________________________________________________
______________________________________________________________________
FITTINGS AND VALVES
The following items shall be reviewed by the respective personnel, as listed below, in
order to maintain safe execution of the hot-tapping procedures.
B. Permits Required:
1. Special permit
2. Entry permit (vehicle)
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ATTACHMENT 4
Page 2 of 3
EXECUTION GUIDELINES
3. Welding machine
4. Hot Tap machine
5. Other machines or power equipment Shift Foreman
H. Personnel
1. Technicians to assist where needed. Mechanical Execution Foreman
_____________________________________________________________
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ATTACHMENT 4
Page 3 of 3
EXECUTION GUIDELINES
I. Checklist of valve and hot tap machine after it is installed on the nozzle.
1. Ensure the proper orientation of the valve.
2. Check nozzle, valve and hot tap machine alignment.
3. Verify diametrical clearance.
4. Ensure the valve will close when the cutter is in the retracted position.
5. Ensure the valve is open prior to starting the tap.
6. Check the lube oil PSV setting on the tapping machine.
7. Check the travel and the turns of the tap machine. Determine the depth of
the cut and the number of turns necessary.
8. Have power source available or the hot tap machine.
9. Verify the hot tap machine has a travel indicator.
Mechanical Execution Foreman
_____________________________________________________________
J. Nozzle, valve, and hot tap machine (Hydrostatic or Pneumatic) shall be tested
after installation, prior to making the hot tap.
Mechanical Execution Foreman
K. Nozzle, valve and the hot tap machine shall be air freed. See Attachement 1 page
2 of 2. After air feeing is complete, disconnect the inert media supply from the
nozzle and/or the tapping machine.
Mechanical Execution Forman
_____________________________________________________________
M. Notify Production/Operations and Safety when the hot tap is ready to begin.
Mechanical Execution Foreman
_____________________________________________________________
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By experiment the inside wall temperature is 700 oF.
Tested on a 4” sch. 40 pipe with a wall thickness of 0.237”
Dead Air (non-Flowing)
Heli-arch diameter of hot spot was 0.748” or 0.439 in2
Stick-arch weld the diameter of the hot spot was 0.950” or 0.709 in.2
Material - SA-516_70
Thickness - 0.8125”
Repad - 1” Thick and 15” Diameter
Nozzle - 8”, SCH 1000, SA-106B
Test Plate - 27” square, to minimize heat sink potential
Air Flow - Air flow minimized to reduce convection cooling effects
Temperature Measurement - Taken on the shell plate opposite of the weld are and
adjacent to the weld area to confirm temperature comparability.
Goal - Develop a weld procedure which would keep the inside wall temperature
below 500oF on the interior of the column.
PROCEDURE
Weld Rod - 3/32” low hydrogen with minimal weaving
Time - 1 minute interval between the time one rod was completed and the next
rod began
Technique - Alternating quadrants are required on the nozzle/column and
nozzle/repad joints
- Outer repad fillet weld skip welding between adjacent quadrants without
1 minute pause
RESULTS:
1. Heat effected zone (400oF to 500oF) no wider than 1-1/2” per weld pass
2. Brinell Hardness on the welds and the heat effected zone did not exceed 203 BHN,
(It is recommended not to exceed 215 BHN on carbon steel)
Note:
If a process has the properties that will result in auto-refrigeration, e.g. ethylene, or heat
generation, e.g. hydrogen the tapping machine must be pressured to the operating
pressure of the parent system using a medium that is compatible with the process.
Typically this is an inert gas such as nitrogen.
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Processes that Require Special Consideration
1. AIR – In the presence of oil or carbon, will support combustion if the metal wall
is heated to the metal is heated to the auto ignition.
2. Caustic – If the concentration and temperature are such that the fabrication
specifications call for stress relieving, stress corrosion of the base metal can occur
upon the addition of localized heat, if material specification requires Pre or Post Heat
Treating.
3. Chlorine – Carbon steel will burn in the presents of chlorine and a high localized
heat. Metal temperature must be less than 3000F.
4. Hydrogen – If pressure is above the Nelson curve limit (see API 941) due to the
possibility of hydrogen attach of the base metal.
5. Chlorinated Hydrocarbons ( VCM/EDC) – May experience exothermic
decomposition reactions if the metal temperature resulting from welding and hot
tapping could initiate such a reaction at the maximum expected pressure. Such
reactions could have the potential for causing localized hot spots on the pipe wall
and could lead to sudden failure.
6. Hydrochloric Acid & Phosphoric Acid – HCL and metal will burn similar to
chlorine at high temperatures. Acids, chlorides, peroxides, or other chemicals likely
to decompose or become hazardous from the heat induced by welding.
7. Oxygen & Oxygen Enriched Process – With the application of heat, the metal
may auto-ignite.
8. Freons – Likely to decompose from heat induced by the welding, rapid weld
cooling rate could cause cold lapping and excessive shrinkage.
9. Ethylene & Propylene – May experience exothermic decomposition reactions if
the metal temperature resulting from the welding and/or hot tapping could initiate
such a reaction at the maximum expected pressure. A reaction such as this could
have the potential for causing localized hot spots on the pipe walls and could result
in a sudden failure.
10. Ammonia – Anhydrous – May decompose from the heat induced during
welding.
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Material Restrictions
Carbon steel (if the process or thickness does not require post weld heat treatment) and
austenitic steels are generally the only materials which can be effectively welded on
while in service. The following alloys should be restricted or reviewed carefully from in
service welding or hot tapping for the following reasons:
1. Chrome Steels – Typically, these steels require Pre & Post weld heat treatment
which may be difficult to do effectively with process flow removing the required
heat.
2. Aluminum – The flowing characteristics of this metal during welding makes it
extremely susceptible to a blow out.
3. Stress Relieved Carbon Steel – The inability to PWHT would damage the required
material properties.
4. Lined or Cladded Materials – The purpose of the internal liner or cladding is
negated when a hot tap is performed.
Flow Considerations
1. To define the maximum allowable internal pressure of the line or equipment while
welding use the following:
Modified Barlow Equation:
P= 2SE(t-c)/D o Where:
P = Maximum allowable internal pressure, psi
S = Maximum allowable tensile stress at the actual internal
temperature, psi (applicable code governs)
E = Joint Efficiency
t = Actual minimum wall thickness, inches
D o = Outside diameter, inches
c = A correction factor for the depth of the weld penetration. A
correction of 3/32 inches has been recommended by ASME
Gas Standards Committee. Note: If the maximum allowable
pressure calculated is greater than the actual internal pressure,
the hot tap can be made. Typically 60% of the wall is
considered molten.
2. Metal temperatures during the welding process must be above the atmospheric dew
point to exclude moisture from the weld.
3. Lines to be hot tapped shall be full (gas or liquid) and flowing. On lines e.g. flare
headers where there may be insufficient or no flow, it will be necessary to “flood”
the line with steam, inert gas or hydrocarbons to maintain a steady flow in the line
during the welding operation. The following are general recommended velocities
during welding.
a. Liquid-
1.3 feet per second minimum
4.0 feet per second maximum
b. Gas-
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1.3 feet per second minimum
No maximum velocity
Physical Limitations
1. Pitting or Laminations – Welding should not be performed with a pitted area because
of the possibility of a blow out. A lamination may rupture if a fluid is vaporized in
the trapped pocket.
2. Proximity to a Point – Welding should be restricted within 18 inches of a flange or
threaded connection, 3 inches weld seam, and 24 inches of a riveted joint. Welding
within these limits could distort the metal sufficiently to result in leakage.
3. Metal Thickness Greater than 0.75 inches – Difficulty has been experienced when
hot tapping thick steels, in excess of 0.75 inches, if the hot tap is made horizontally,
or on the underside of the pipe, metal shavings may present a problem. Stress
relieving may be required for carbon steel due to its thickness, which could not be
performed effectively.
4. Atmospheric Storage Tanks (Hydrocarbons) – Prior to any attempt should to hot tap
or weld on tanks above the liquid, i.e. vapor space, requires special review due to the
possibility of ignition within the vapor space. Vessels on tanks to be hot tapped
should contain a liquid level 2 feet above the highest point of the welding.
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THE HOT TAPPING LAMENT
Here Ye Here Ye
Let It Be Known
And Forever More
Cast In Stone
If on the Horizontal
A Tapping Machine is Inserted
The Valve Stem
MUST Always Be Inverted
Anonymous
7/29/88
19
REFERENCES
Service.
2. API Pipe Plugging Practices Publication 2209 First Edition, October 1978
1991.
Models” 1991.
1, 1977.
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