13.

HOT TAPPING

GENERAL:

A 'Hot Tap' is a connection that is made into a pipeline or vessel in operation. It is

accomplished by welding a nozzle to the equipment involved, then installing a gate
valve to which is attached the 'Hot Tap' or cutting machine.

After attaching the hot tapping machine, the gate valve is opened and the cutting tool
advanced through the open valve. When the cutting of the hole is complete, he tool
is withdrawn and the gate valve is closed. The 'Hot Tap' machine is detached from
the gate valve and the desired piping can then be connected to the gate valve.

The Process Supervisor must decide what process coverage, If any, is required
during the 'hot tapping' operation. Employees so assigned have the following
responsibilities.

a. Be completely familiar with the equipment to be worked on and observe on the

surrounding area for release of hydrocarbons and be prepared to take
necessary corrective action.
b. Observe operation of process equipment on which hot tap is being performed
to assure flow is continuous at point of welding, pressure is normal, or tank
level is maintained six feet above point of hot tap.
c. Observe operation of hot tap equipment so that if emergencies arise,
immediate and appropriate action can be taken.

RESTRICTION ON 'HOT TAPPING:

1. Hot tapping should not be carried out on equipment in the following services ;

a. Maintenance air.
b. Oxygen.
c. Safety valve headers.
d. Chemicals in general.
e. Flare header unless there is sufficient flow in the line and there is no
possibility of air back up from the flare.

2. No hot taps should be made in the vapour space of any tank or vessel.
3. Hot tapping is not recommended on caustic handling equipment when
conditions require stress relieving.
4. Hot tapping is not recommended on low temperature equipment.
5. Hot tapping should be avoided on air hardening alloys such as 5% chrome.
6. Hot tapping on lines or equipment containing hydrogen sulphide or other toxic
materials should be avoided.

PRECAUTIONS:

 Check available inspection records and ascertain that there is sufficient metal
thickness to permit safe welding on drum, vessel or pipe line. (As a further
precaution against burning through, the welder may test the amperage of the
 welding machine on a sample piece of metal with the same thickness as the
equipment to be welded).
 When any doubt exists as to metal thickness, suitable means should be
employed to spot check actual thickness.
 Before starting any hot tapping job, the Mechanical Department will notify the
Equipment Inspection Division, who will certify that hot tapping can be done
safely on the equipment, after inspecting the equipment.

 Ensure that the pressure and temperature of the equipment does not exceed
the safe limits for the hot tap machine manufacturer's limitations.
 Check that the correct packing is used for the hot tapping machine.
 There should be no combustible mixture in the line to be hot tapped.
 Make sure that fire fighting equipment such as fire extinguisher and water
hose, are readily available.
 A constant flow of fluid must be maintained through the equipment while
 hot tapping is going on.
 Ensure that there are no connections through which air could enter the line.
 Hot taps which do not meet welding code requirements should be replaced at
the earliest opportunity.

CUTTING PROCEDURE:

 After the nozzle has been welded on, the proper gate valve for that particular
job is bolted to the nozzle with proper gaskets.
 The drilling machine with the proper cutter and adapter ring is connected to
the gate valve and the valve is opened completely.
 An air or water pressure test should be made at this time to check tightness of
nozzle-weld, flanges, valve, adapter and cutting machine. The shaft is then
advanced by hand until the cutter point touches the pipe line or vessel wall.
The cutter is then completely withdrawn and the valve closed as a safety
check on clearances. After the clearance check, the valve is reopened, the
cutter is again advanced until it touches the pipe or vessel.
 Thereafter the drilling operation is started. The depth needed to advance the
drill to complete the cut depends on the size of pipe and nozzle. A table is
supplied by the manufacturer showing the amount of travel necessary to
complete the cut starting with the point of the pilot drill in contact with the pipe.
This must be carefully adhered to.
 The drilling is continued until the required depth has been reached. This may
be checked by advancing the cutter manually. If the cutter moves freely, the
cut is then complete.
 The cutter is now withdrawn completely and the gate valve closed. A bleeder
valve should be installed in all adapters and the pressure is relieved through
the bleeder before disconnecting the 'Hot Tap' machine from the operating ,
equipment. This valve must be checked carefully to ensure that it is in closed
position during the cutting operation.