Elkhorn Construction, Inc.

Safety Manual
Title: Hot Tap Safety Procedure
Revie !ate: "#$"%$#&&'
". !efinitions:
"." Hot tappin( is a )ethod of addin( a *ranch connection to pressuri+ed e,uip)ent
ithout re)ovin( the e,uip)ent fro) service.
".# Hot tap operations are to *e per)itted only hen:
".#." Continuity of service is essential.
".#.# Shutdon of the syste) is i)practical.
".#.- !ocu)ented procedures are folloed and special e,uip)ent is used.
".#.. E/a)ples:
".#..." Stora(e tank leaks that ould re,uire a lon( ti)e to safely
drain the tank *y other )eans.
".#...# Co)ple/ process shutdons and start$ups that ould pose
and increased safety risk to personnel due to e,uip)ent
interruptions that )ay cause e/plosions or releases of
ha+ardous )aterial.
".#...- Co)plete process shut dons that result in additional
personnel e/posure and have a (reater potential for in0ury
than does hot tappin(.
".- This e,uip)ent is desi(ned to provide proven protection for e)ployees.
".. The hot tap procedure includes the attach)ent eld, hydrostatic or pneu)atic test
of the hot tap *ar and associated pipe and the actual drillin( of the pipe.
# 1 cold tap is a )ethod of addin( a *ranch connection to e,uip)ent that has *een *locked,
depressuri+ed, pur(ed and is open to at)osphere.
#." 1 cold tap )ay *e co)pleted ithout the use of a valve to tap throu(h.
- Safety Precautions and Rules
-." Hot tappin( is not alloed on 1SME. Coded vessels.
-.# The hot tap )achine )ust *e rated for the orkin( te)perature and pressure of the
line to *e penetrated. The seals and )aterial that the )achine is )ade of )ust *e
co)pati*le ith the )aterial that is contained in the line.
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Elkhorn Construction, Inc. Safety Manual
Title: Hot Tap Safety Procedure
Revie !ate: "#$"%$#&&'
-.- 4efore each hot tap operation a co)petent person )ust inspect the *ar, cutter and
pilot *it.
-.. 5essels or lines to *e hot tapped )ust *e inspected to deter)ine proper all
thickness and to insure that there are no )aterial i)perfections or la)inations in the
)aterial.
-.% The o/y(en level in the e,uip)ent )ust *e controlled to prevent for)ation of an
e/plosive or fla))a*le )i/ture.
-.3 6elders )ust *e ,ualified in accordance ith the applica*le code and specification.
-.7 Personnel that are operatin( the hot tap )achine shall *e fa)iliar ith the operation
of the )achine and the proper procedure to use.
-.' Hot tappin( closer than "' inches to a flan(e or threaded connection or ithin -
inches of a elded sea) is not per)itted.
-.8 6hen hot tappin( tanks the li,uid level shall *e )aintained - feet hi(her than
here the hot tap ill penetrate the tank all. 1ll suction and dischar(e lines as
ell as a(itation devices that can cause the conditions in the tank to chan(e shall *e
isolated *y *lindin( or ener(y isolation *efore the hot tap procedures can start.
-."& Hot tap procedures cannot *e perfor)ed on co)pressed air lines ith air
re)ainin( in the line. This is due to the e/plosive )i/ture that )ay *e created *y
the lu*e oil that )ay re)ain in the syste). Cleanin( or flushin( ith inert (ases
)ay *e re,uired *efore startin( to eld on a *ranch connection.
-."" 6eldin( on lo te)perature e,uip)ent 9*elo$#& :.; shall *e revieed since
*rittle fractures can occur in so)e steels at lo te)peratures.
. Procedures:
.." Client safety policies concernin( hot taps )ust *e revieed and all personnel that
are involved in the hot tap procedure )ust understand and a(ree to a*ide *y these
rules.
..# If the client does not have a hot tap policy then at a )ini)u) the folloin(
conditions shall *e satisfied:
..#." The desi(nated client representative shall *e present durin( the hot tap
and shall have the authori+ation to oversee the pro0ect.
..#.# The location on the all )ust *e clearly )arked.
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Elkhorn Construction, Inc. Safety Manual
Title: Hot Tap Safety Procedure
Revie !ate: "#$"%$#&&'
..#.- The all thickness )ust *e )easured and the a*sence of any
i)perfection or la)ination )ust *e verified.
..#.. 1ll applica*le per)its )ust *e o*tained, a fire atch shall *e assi(ned
and the appropriate safety e,uip)ent shall *e placed in the ork area.
..#.% Si(ns and *arricades )ust *e placed to keep non$essential personnel
out of the ork area.
..#.3 1ffected personnel that are on site shall *e notified and the nearest
isolation valves and shutdon devices shall *e identified. Procedures
shall *e developed in case of a line failure.
..#.7 1ll personnel that are assi(ned to the hot tap cre shall ear :la)e
retardant clothin(.
..- 1 safety )eetin( shall *e held to discuss hot tap procedures and hat to do in the
event of an e)er(ency. 1ll personnel that are assi(ned to the hot tap pro0ect shall
attend the safety )eetin(.
... 1 verification of pipe thickness is re,uired *efore an attach)ent eld can *e )ade.
..% 1ny variations in the pipe all thickness in e/cess of "&< )ust *e reported to the
Safety !epart)ent and a ritten approval )ust *e (iven *efore the hot tap can
proceed.
..3 The su*stance that is in the line to *e hot tapped )ust *e deter)ined prior to
eldin( on the line.
..7 The operatin( pressure that is on the line to *e tapped )ust *e deter)ined.
..' =ine si+e and (rade as ell as all thickness and outside dia)eter )ust *e
deter)ined.
..8 The sa)e infor)ation )ust *e (athered for the pipe that ill *e used for the *ranch
connections plus the flan(e si+e if a flan(e fittin( is used
.."& 1 deter)ination )ust *e )ade as to hether or not additional reinforce)ent is
re,uired *eteen the *ranch connection and the pipe.
.."" 1fter the stu* is elded on and the reinforce)ent pad is elded, the *orin( *ar
ith a drill *it is attached to the valve and stu*. The entire asse)*ly )ust *e
pressure tested to at least "&&< of the operatin( line pressure.
.."# The hot tap )achine and the *it )ust *e )easured and the thickness of the pipe
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Elkhorn Construction, Inc. Safety Manual
Title: Hot Tap Safety Procedure
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)ust *e deter)ined. The calculation fro) these fi(ures ill deter)ine the
stoppin( point so that there is no possi*ility of drillin( throu(h the other side of
the pipe that is *ein( drilled.
.."- The *orin( *ar cutter asse)*ly )ust *e run throu(h the full port valve to insure
that there is no 0a) or dra( *eteen the valve *ody and the cutter.
2ote: The manufacturers recommendations must be followed when making a
cut. If the blank coupon is lost, no attempt should be made to find it
unless the line is isolated and depressurized.
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Elkhorn Construction, Inc. Safety Manual
Title: Hot Tap Safety Procedure
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Hot Tap Safety Check List and Report
Supervisor >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>> !ate >>>>>>>>>>>>>>>>>>>>
:ield?:acility >>>>>>>>>>>>>>>>>>>>>>>>>> =ocation?=ine >>>>>>>>>>>>>>>>>>>>>>>>>>
Main Pipe/Spool Line Information
Pipe Si+e: >>>>>>> Schedule: >>>>>>>> @utside !ia)eter:>>>>>>> 6all Thickness: >>>>>>>>
Branch Connection Information
Pipe Si+eA>>>>>>>> Schedule:>>>>>>>> @utside !ia)eter: >>>>>>>>
6all Thickness: >>>>>> :lan(e Si+e: >>>>>> Ratin(: >>>>>>>>>>>>>>>>>
Calculations and Inspections
";. Entire cre trained and ,ualified to perfor) Hot TapB 2CCER Module 9&'.&'; Ces
#;. Have reinforce)ent calculations *een perfor)edB Ces 2o 2?1
-;. Is Repad Re,uiredB B Ces 2o 2?1
.;. 6hat is the operatin( pressure on the line to *e penetratedB >>>>>>>>>>>> PSI
%;. 6hat as the line pressure at the ti)e of the attach)ent eldB >>>>>>>>>>>> PSI
3;. 6hat as the line pressure at the ti)e of the penetrationB >>>>>>>>>>>> PSI
7;. 6hat si+e of *it ill *e used to )ake the penetrationB >>>>>>>>>>>> Inch
Test Results
';. 6hat is the test pressure on the *ar, stu* and valveB >>>>>>>>>>>> PSI
8;. 6hat is the )a/i)u) test pressure to *e used on the stu*B >>>>>>>>>>>> PSI
"&;. 6hat pressure as the hot Tap Machine Tested toB >>>>>>>>>>>> PSI
Approals and Acceptance
Supervisor >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>> !ate: >>>>>>>>>>>>>>>
Pro0ect?Safety Mana(er >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>> !ate >>>>>>>>>>>>>>>
Client >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>> !ate >>>>>>>>>>>>>>>
2otes:
a;. 1ll test pressures )ust *e "&&< of operatin( pressure at a )ini)u).
*;. 5ariations in e/cess of "& < in pipe all thickness re,uire safety depart)ent approval
*efore hot tap can *e )ade.
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Elkhorn Construction, Inc. Safety Manual
Title: Hot Tap Safety Procedure
Revie !ate: "#$"%$#&&'
!ocu)ent 2o: -E$&".- Revision &
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