NEXT REVIEW

CODE REVISION PAGES EFFECTIVE DATE

DATE
PV-P-32807 0 9 2022-03-30
2027-03-30

SCOPE: Pueblo Viejo Dominicana Corporation

PROCEDURE

MINIMUM REQUIREMENTS FOR WELDING IN

HOT TAPPING
Table of Contents

1. OBJETIVES ............................................................................................................2
2. SCOPE ...................................................................................................................2
3. REFERENCE DOCUMENTS ..................................................................................2
4. ABBREVIATIONS AND DEFINITIONS ...................................................................2
5. LEADERS AND DEPARTMENTS INVOLVED ........................................................3
6. PROCESS DESCRIPTION .....................................................................................3
7. RECORD KEEPING ...............................................................................................5
8. APPENDICES.........................................................................................................7

PARTICIPANTS TITLE/DEPARMENT SIGNATURE DATE

Fabian Senior Supervisor

APPROVED BY
Bernand SMP
Milton
REVIEWED BY QA Engineer
Pimentel
Daniel
PREPARED BY Welding QA Engineer
Quintero

REVISION HISTORY

REVISIÓN FECHA DESCRIPCIÓN DE CAMBIOS Y/O MODIFICACIONES

0 03/20/2022 Issued by Use

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 2 of 9

1. OBJETIVES

Establishing minimum requirements to must comply with a contractor when welding in Tie-in
and hot taping are involved taking into consideration the understanding of potential hazards
of this practice when operating equipment and piping are on site and to minimize the
probability of incidents.

2. SCOPE

Thru the correct application of process and NDE examination assure the quality of welding
according to design and standard requirements.

3. REFERENCE DOCUMENTS

PV-0793-SP-0000-16-0002-A General Welding

API RP 2201 Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries

API 570 Piping Inspection Code: In-Service Inspection, Rating, Repair, and Alteration of
Piping System

API 577 Welding Processes, Inspection and Metallurgy

API RP 12R1 Recommended Practice for Setting, Maintenance, Inspection, Operation and
Repair of Tanks in Production Service

4. ABBREVIATIONS AND DEFINITIONS

API: American Petroleum Institute

WPS: Welding Procedure Specification

WPQ: Welder Performance Qualification

PQR: Procedure Qualification Record

Burn-Through: Hole or depression in the root bead of a single-groove weld due excess
penetration

Crack: A fracture-type discontinuity characterized by a sharp tip and high ratio of length and
width to opening displacement.

OWNER: PV Expansion

FCAW: Flux Core Arc Welding

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 3 of 9

Hot-Tapping: The technique of attaching a mechanical or welded branch fitting to pipping or

equipment in service, and creating an opening in that piping or equipment by drilling or
cutting a portion of the piping or equipment within the attached fitting

5. LEADERS AND DEPARTMENTS INVOLVED

List the functional areas/departments, job titles of the persons who have the authority and
responsibility for the implementation and coordination or exceptions of the Procedure.

Role Description
• Verify compliance with the procedure by the
contractor
Expansion Project
• Review and control the records issued by the
contractor
• Implement, execute, and control the process
through the correct application of the approved procedures.
Contractor
• Issue test records and required formats
• Monitor activities during the execution process
Engineering
Issue, modify or revise the procedure

6. PROCESS DESCRIPTION

6.1 Contractor Writen Procedure

Each contractor shall submit for approval a procedure with different steps, sequence, materials,
equipment, inspection personnel qualification, demonstrated welding procedures and qualified
welder. It mentions all precautions used for hot work and safety measures.

The checklist mentioned in Appendix A of API RP 2201 (see appendices) shall be used for each
hot tapping and attached to the documents issued for approval of the owner. In case existing a
lack of this document the process, it will not start.

6.2 Material Certificates

All materials such as fittings, pipe, plates, gasket, welding consumables and gases shall have
traceability according to the manufacturer certificate approved by the owner and according to
specification and drawing requirements.

6.3 General Welding

Welding procedure qualification and in-process welding shall be according to PV-0793

specification. WPS, PQR and WPQ pretend to be used in the process shall be previously
approved by the owner.
FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 4 of 9

Low-hydrogen process and electrodes shall be used. Extra low-hydrogen consumables such as
EXXXX-H4 should be used for welding carbon steel.

6.4 Metal Thickness

The piping or tank base metal thickness shall provide support for the new connection and the
hot tapping machines, so thickness must be measured and recorded in a report before the hot
tapping procedure is performed. The results shall be compared with engineering requirements
in drawings.

The base metal must be free of lamination, hydrogen attack or stress corrosion cracking.

The minimum base metal thickness suggested by the standard is 3/16 in. (4.8 mm).

For metal thickness less than ¼ in. (6 mm) the contractor shall demonstrate with mock-up
coupon representing the actual material, thickness, and the welding parameters according WPS
approved. The weld penetration is verified by etching and reported.

6.5 Principal defects in Hot tapping welding

There are two main concerns when welding in services piping: burn-through and cracking.

To avoid overheating and burn- burn-through, the first weld pass to tank or pipes less than ¼ in
(6 mm) thick should be made with 3/32’’ in (2.4 mm) or smaller diameter welding electrode to
limit heat input. Subsequent passes should be made with a 1/8 in. (3.2 mm) diameter electrode,
or smaller if the metal thickness does not exceed ½’’ in. (12.7 mm).

For shell and pipe thicknesses greater than ½ in. (12.7 mm) large diameter electrodes could be
used avoiding the use of excessive welding current outside limits of approved WPS.

The Thickness mentioned in this paragraph refers to real thickness obtained by measurements
by ultrasonic or suitable inspection method.

In the case of cracking this is related mainly to the high cooling rate. When service fluid (non-
flammable) is present in welding, a low rate minimizes the probability of crack in piping with
thickness up to ½ in. (12.7 mm). Under certain condition, it may be necessary to purge or flood
the line with steam, inert gas to prevent the formation of flammable mixtures.

6.6 Welding Process Forbidden

FCAW process in material thickness less than ½’’ is not allowed.

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 5 of 9

6.7 Metal Temperature

Preheating may be required by the welding procedure to avoid cracking, whenever the base
metal has high carbon equivalency or high tensile strength. See welding procedure applicable.

6.8 Liquid Level

For tanks, liquid level shall be maintained at least 3 ft (1 m) above the area where the work is
being performed when welding or hot tapping on atmospheric tanks in service (because of the
potential danger of creating an explosive atmosphere inside the tank vapor space)

Welding should not be conducted on a vessel which is double walled and/or has an internal
lining.

6.9 Inspecting the Weld

Visually inspect all attachment welds after welding and before attaching the hot tap machine. Dy
penetrant or magnetic particles shall be used for the initial and final passes. Special care shall
be taken cleaning the weld area after inspection and before subsequent passes.

Personnel performing NDE shall be qualified according SNT-TC-1A as level II or level III.

Procedure shall be in accordance with ASME BPVC Section V.

Acceptance criteria for initial weld pass is ‘’zero discontinuities’’.

6.10 Testing the Weld and Hot tapping machine

The welded attachment and hot tapping machine shall be tested as follow:

• Check the tightness of bolts. Reports shall be submitted to approval.

• If the current temperature of the line or vessel will permit, conduct a hydrostatic test of
the welded attachment and hot tapping machine to a pressure equal to the operating
pressure of the line to be tapped. The temperature of the metal should be considered to
avoid brittle fracture.
• If hydrotesting is not feasible, air or nitrogen with soap solution on the weld can be used.

7. RECORD KEEPING
The contractor is responsible for issuing daily records and reports where the tests performed by
each procedure can be appreciated. These registrations must be signed and approved by
PVDC

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 6 of 9

Table 7-1 Record Keeping Requirements

Forms Tipo Responsible Location Hold Time

Controlled Register Electronic Document Control PV Expansion Permanent

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 7 of 9

8. APPENDICES

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 8 of 9

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06
 Code PV-P-32807
PROCEDURE Revision # 0
Effective Date 2022-03-30
MINIMUM REQUIREMENTS FOR WELD IN Next Review Date 2027-03-30
HOT TAPING
Pages 9 of 9

FOR DOCUMENT CONTROL USE ONLY. Uncontrolled when printed. Refer to Operations Controlled Document
Governance Document Register for most up to date revision information before use.
Code: PV-T-90018 Rev:6 Effective Date: 2019-11-06 Next Review Date: 2022-11-06