CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 PROCEDURE

5.1 Responsibility

5.2 General Restrictions for Hot Tapping

5.3 Preparatory Survey

5.4 Job Site Preparation and Safety

5.5 Hot Tap machines

5.6 Hot Tap Operations

5.7 Register of Hot Taps

6.0 HOT TAP CHECKLIST

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1.0 PURPOSE

The purpose of this method statement is to specify the minimum requirements for the hot
tapping activities.

2.0 SCOPE

This method statement covers the activities and / or requirements involved in fabrication
and installation of branches into existing live line by Hot Tap method. This document is
applicable only to Hot Taps on Carbon Steel and Austenitic Steel material piping and
tanks of contract no. GTC 5/173/ED, EPIC of 5NOS. New Storage Tanks and Associated
Systems at QP Refinery, Measaieed

3.0 REFERENCE

3.1 API-RP-2201 - Procedure for Welding or Hot Tapping on

Equipment in Service

3.2 ASME SEC. IX - Welding Procedure and Welder Qualifications

3.3 ASME B 31.3 - Process Piping
3.4 2166-9001 - Project HSE Plan
3.5 2166-9023 - Tie in Procedure

3.6 2166-9024 - Inspection of welding, weldments &Fabricated

Components
3.7 2166-9022 - Procedure for installation & testing of pipeworks

3.8 2166-9021 - Procedure for control of welding consumables

3.9 2166 – 9020 - Procedure for Ultrasonic Thickness measurement

3.10 ES.5.14.0010 - Spec. for the fabrication, inspection and installation of

Carbon,Carbon-Manganese and Low Alloy Ferritic
Process pipework

3.11 ES – S- 60 - Spec. for the Non Destructive Testing of welds

4.0 DEFINITIONS

4.1 Company - Qatar Petroleum (QP)

4.2 Contractor - Galfar Al Misnad Engg. & Contg. W.L.L
4.3 Sub Contractor - DOPET
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4.4 API - American Petroleum Institute
4.5 ASME - American Society of Mechanical Engineers

5.0 PROCEDURE
5.1 Responsibility
Hot Tap location on the existing process line has to be advised by the Company after
carrying out the ultrasonic thickness and lamination survey. All process operational
assistances have to be provided by the Company in order to carry out the hot tapping
safely.
Contractor is responsible for preparing tie in and construction drawings, tie in schedules
and finalization of hot tap location in consultation with Company.

The Contractor shall appoint an Engineer who shall co-ordinate all the Hot Tapping
activities and maintain a register file. Contractor shall be responsible for obtaining all
required permits before starting of the job. Hot tap unit shall precheck the tapping valve
and the hot tapping machine to assure good operable condition, including cutter and
coupon retaining device.
The Safety Engineer shall be always present during the Hot Tap operation and shall be
responsible for all the safety. Loss prevention office in the appropriate area shall be
notified of all hot tap work and provided with procedures for review.
It is the responsibility of the Construction Engineer to identify materials suitable for the
intended application and as per QP approved drawing, review of design drawings and
requirements for branch connection including approved WPS. He shall ensure pipe wall
thickness, pressure and flow requirements as identified, fit-up and preparation of
welding. Construction engineer shall ensure nozzle connections are not welded on the
inside unless the hot tap cutter is at least one pipe size smaller than the nozzle.
The QA/QC Engineer shall be responsible for all the QA/QC and NDE activities and
shall coordinate with Construction Engineer for execution of hot tapping activity. He
shall be assisted by QC Inspectors.

5.2 General Restrictions for Hot Tapping

5.2.1 Materials

Hot Tapping of run pipe materials that require Post Heat Treatment or may suffer
metallurgical/physical deterioration from heating is generally not permitted. Welding
shall not be performed on pipe that is lined or internally coated in any manner.

Hot Tapping at location upstream of rotating machinery or in line rotating instruments is

not permitted without prior written permission from the Company.
The dimensions of the connection, the hot tap valve and the clearance shall be within the
limits specified for the hot tapping equipment to be used.

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 The hot tap valve shall have a pressure test applied to the seat and body in accordance
with API 598.

Hot tapping shall not be done on surface temperatures at or below 0 deg. C and on pipe
or vessel/tank which has an corrosion or heat resistant lining.

Hot tapping on pipe or vessel containing flammable material below atmospheric pressure
or combustible mixtures shall not be made.

Hot tapping on tanks shall be made at least one meter below the liquid level

5.2.2 Process Fluids

Hot Tapping shall not be performed on piping containing any of the following process
fluids:
a) Oxygen, Oxygen enriched or Compressed air.
b) Mixture of gases or vapors within their flammable or explosive ranges, or which
may become flammable as a result of the temperatures attained during welding.
c) Acids, Chlorides, Peroxides or other chemicals likely to decompose or become
hazardous due to the heat from welding.

d) Substances such as Acetylene, Ethylene and other unsaturated hydrocarbons that may
undergo exothermic reaction or decomposition leading to a dangerous increase in
pressure or explosion.
e) Caustic or Amine.

5.2.3 Construction engineer shall ensure following Process Conditions

a) Lines to be hot tapped shall be full and flowing. In the case of insufficient or
interrupted flow, lines shall be continually purged with inert gas or steam to prevent
the formation of flammable mixtures.
b) During Hot tapping operations, internal pressure shall be maintained with in the pre-
determined maximum & minimum operating pressure at the specified flow rate as
per hot tap design calculations.

c) Compressed air piping and equipment shall not be hot tapped nor welded while in
service.
5.3 Preparatory Survey
5.3.1 A detailed drawing of the existing pipe including actual wall thickness at the tie-in point
for hot tap, orientation and elevation shall be prepared by the Contractor based on the
thickness survey. The drawing shall show all weld attachments, reinforced pad details,
pre weld and post weld procedures. This proposal shall be submitted to the company and
duly approved.

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5.3.2 The header pipe at the hot tap location shall be subjected to a detailed inspection. The
area shall be cleaned to bright metal, removing all deposits, covering, insulation, tracing,
paint and protective coatings.

5.3.3 Ultrasonic examination for wall thickness of the existing line shall be carried out before
any hot tap operation. Company will arrange ultrasonic examination and Contractor/
Subcontractor to verify the wall thickness of the pipes. If laminations or evidence of HIC
damage are indicated, the hot tap position shall be relocated.

5.3.4 All the branch pipes / components shall be visually inspected before fit-up welding.
It shall be ensured that pipe out-of roundness at hot tap location does not exceed 3mm.

5.3.5 Should any of these inspections reveal unacceptable conditions, the branch position shall
be relocated in accordance with Company’s instruction and the inspection repeated.

5.3.6 Special care must be taken so that the pipe welds and hot tap welds are not fouling.

5.3.7 Contractor to ensure the accessibility and clearances around the pipes for performing the
work safely.
5.3.8 Air lines or vessels with compressed air shall be free from hydrocarbon contamination

5.4 Job site Preparation and Safety

5.4.1 Risk assessment shall be carried out before start of the activity. The Construction engineer
shall identify the equipment in terms of service, location, pipe diameter, header and
branch pressure rating and material type. QC Inspector shall inspect materials for hot
tapping with approved for construction drawing, material specification and relevant
codes. WPS and welder qualification shall be ensured by QC Inspector before starting
the hot tapping.

5.4.2 For the purpose of safety and rapid evacuation under operational emergency, the
necessary obstructions are to be removed from hot tap locations. Safe access for both
welding and cutting operations shall be provided with sufficient scaffolding, ladders etc.

5.4.3 Emergency services and equipments shall be kept ready which includes fire fighting
equipments and first aid materials.

5.4.4 Hot tapping location shall be protected against adverse weather conditions. Construction
engineer shall mark of exact location and marl hot tap number alongside each hot tap
location.

5.4.5 Precautions against electric shock, due to induced voltage, shall be taken when installing
hot tap connections on above ground pipelines near high voltage lines.

5.4.6 Adequate support of the hot tapping machine shall be provided.

5.4.7 Appropriate barricades and warning signs shall be posted around the work site.Proper
house keeping to be ensured at the hot tap location.

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5.4.8 Precaution against H2S and other toxic/Hazardous material has to be ensured while
performing hot tap.

5.5 Hot Tap Machines

5.5.1 All hot tapping machines have maximum working pressure and temperature ratings of
the process line. The suitability of the hot tapping machine is determined by comparing
pressure and temperature of the process fluids inside the line and working limits of the
hot tap machine.

5.5.2 Hot tap machines shall be capable of positively retaining and retracting the coupon after
cutting.

5.5.3 Before start of hot tap operation, the machine, cutter and pilot bit shall be carefully
inspected for their satisfactory condition and capable of being left in service, if necessary
in the event of mechanical problems or operational emergencies.

5.5.4 Particular attention shall be paid to stem packing, gaskets, the conditions and suitability
of drills and cutters.

5.5.5 The cutter travel and diameter shall be checked as correct for the stub.

5.6 Hot Tap Operations

5.6.1 Preliminary

Before starting hot tap operations, the following conditions shall be satisfied:

a) A competent and authorized Engineer of the contractor/ sub contractor is

present during the hot tap operations.
b) The hot tap location is identified and physically marked. Ensure sufficient resources
for carrying out the hot tapping activity.
c) The metal thickness is measured and ultrasonically tested for internal soundness
(e.g. Laminations) and the reports duely signed by Company.
d) A hot work permit shall be obtained from the Company.
e) Personnel protective clothing and equipments are used when necessary.
f) A fire watch shall be established and equipped with a suitable fire extinguisher
and fire water hose.
g) Personnel shall be trained and familiar with work area, the hot tap procedure and
location of the applicable equipments.
h) Continuous gas monitoring is required during the whole operation.
j) Ensure the availability of fire water hoses /fire extinguishers at the location

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 k) The equipment being hot tapped should be thoroughly cleaned or inerted prior to
welding to avoid possibility of hydrocarbon contamination.

5.6.2 Welding
Upon completion of the steps outlined in 5.6.1, the following steps should be considered:
a. Welding process (SMAW) shall be with low hydrogen electrodes with low heat input.
b. The welders shall be qualified as per ASME Section IX, position 6G.
c. No post weld heat treatment is permitted on live lines and hot taps.No welding shall
be allowed in areas with a wall thickness below 5mm or below the pressure design
thickness of the piping being tapped to minimize possibility of “weld blow–out”.
d. Visual Examination of the root pass shall be done through the bore of branch.
e. Root MPI/DPI shall be carried out as indicated in the approved drawing.
f. Dye Penetrant Test shall be carried out on finished branch pressure weld.
g. A hot tap register shall be reviewed by field QC Engineer. The register and
related Isometrics shall form the frame work of all hot tap operations.

h. To eliminate the possibility of burn-through, the root pass shall be made with
2.4mm dia. Electrode for wall thickness less than half inch.

i. Avoid high flow rates when welding (refer clause 5.2.3 b).
j. Exercise care to see that the fitting is properly positioned and supported before
welding so that misalignment of the hot tap machine will not occur.
k. The weld area shall be covered, sheltered or protected from blowing sand, dirt or rain
during cleaning, preparation and welding. A continuous UT scan shall be conducted
around the circumference of the pipe weld area to ensure wall thickness and free
from lamination.

l. Welding on pipelines under pressure

The hot tapping procedure shall set limits for the max. internal pressure in the
pipeline. The pressure in the pipe during welding shall not exceed that calculated
by the following formula:
Pmax. = 2S(t – 0.10)F
OD
Where :
Pmax. = Max. operating pressure of the pipeline during welding,psig
S = Specified min. yield strength of the pipe , psi
t = Min. measured wall thickness of the weld area, inch
F = Design factor of the pipeline
OD = Outside diameter of the pipe ,inch
m. The sticker and reinforcing pad/split tee welds may be inspected by MPI.

5.6.3 Testing the weld

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 Before start of the cutting, the weld attachment shall be tested as follows:
a) Reinforcement pad shall be pneumatically tested.
b) Hydrostatic test shall be conducted in accordance with the applicable code
and drawings. The hydro test pressure shall be 1.1 times the maximum operating
pressure. Calibration of pressure gauges and relief valve shall be verified by QC
Inspector.
c) Check tightness of bolts, packing, packing nuts and bypass lines if any to avoid
possible leakage of the machine.
d) The temperature of the metal should be considered to prevent brittle fracture.
e) Air or nitrogen with soap solution on the weld can be substituted for a hydrostatic
test if the temperature precludes the hydrostatic test. At elevated temperatures, air
should be used only after careful consideration to avoid the possibility of a
combustible mixture. Special attention shall be given to the possibility of boiling or
flashing of test fluid if the surface to be tapped is hot.
Reinstatement
During hydro test any flange leaks, valve gland leaks or other such defects shall been
corrected to the satisfaction of contractor and company. After completion of the
testing, piping components shall completely be drained. Any repair observed during
visual inspection shall be rectified by grinding and welding prior to testing the weld.

5.6.4 Hot Tap Machine Installation and Cutting

The hot tap machine manufacturer’s instructions for installation and removal of the
machine shall be followed and the following points shall be checked:

a) The hot tap valve must be of adequate size and should be properly centered.
b) Run the boring bar through the valve opening to ensure that the cutter does not
jam or drag.

c) Carefully calculate the travel of the cutter to ensure that the tap can be completed
within those dimensional limits, that the cut will be stopped before the cutter touches
the opposite side of the tapped pipe and that the cutter can be retracted far enough to
allow unhindered closure of the tapping valve. Bleed-off valve shall be checked to
hold pressure and is not plugged.
d) Ensure safe bleed-off and disposal of material collected in the machine above the hot
tap valve. Isolating valve performance shall be monitored by the pressure at the
bleed-off valve.
e) The effectiveness of the blank or coupon capturing device shall be demonstrated.
f) Identified, trained and qualified operators shall only be permitted to operate the
machine.
g) The manufacturers instructions should be followed when retracting the bore and
closing the valve.
h) Ensure the retrieval coupon oil is disposed off as per the HSE requisition.
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5.7 Register of Hot Taps
5.7.1 The register of hot taps is intended to be a dossier, built up as the work proceeds, in
which detailed hold points and witness points are recorded.

5.7.2 An index of tie-ins shall be maintained

5.7.3 A request for hot tapping shall be made prior to hot tapping activity and shall got signed
by Company’s Operations, Engineering and Inspection departments, to be closed out
after hot tap completion.

6.0 Hot Tap Checklist

This checklist shall be used as a reminder to accomplish the steps in order.

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 Hot Tap Checklist

Location : _________________________________________

Date : _________________________________________

Before Starting Hot Tap

1. Has properly approved work permit been obtained?

2. Does the tapping machine have a suitable pressure and temp. rating for the job?
3. Has the exact location of the hot tap on the line or vessel been identified or marked?
4. Has the area to be welded been inspected for thickness and freedom from lamination or
HIC?
5. Has the need for stress relieving the weld area been considered?
6. Do the flanges,bolts,gaskets,pipe and valve to be installed meet the piping code for the
line or vessel to be hot tapped?
7. Is there sufficient clearance to accommodate operation of the hot tap machine?
8. Is the hot tap fitting of the proper length to accommodate operation of the hot tap
machine?
9. Have combustible and /or toxic gas tests been conducted in the area of hot tapping?
10. Has the chemical composition of the contents in the line or vessel been considered to
avoid welding or equipment containing flammable mixtures,hydrogen or chemicals
which could affect metal strength?
11. Is the contents in the line stable under heated conditions and free of oxygen?
12. Has the fire fighting equipment been provided?
13. Has suitable protective equipment been provided to all exposed personnel in the hot tap
area?
14. Is the area to hot be tapped located below the liquid level of a tank or on a line or piece
of equipment in which the fluid flow has been established?

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Before Starting Welding

1. Is preheat of the weld area required?

2. Is the fitting properly positioned so misalignment of the hot tap machine will not occur?

Before Starting Cutting

1. Has the weld been tested?

2. Have the hot tap valve, gaskets, and bolts been checked?
3. Has the picking on the hot tap machine been checked?
4. Has the bleed off valve been checked to be sure it will hold and is not stopped up?
5. Are all bolts on the cutter and pilot bit tight and is the coupon catcher on the pilot bit?
6. Is the valve centered on the flange?
7. Has the cutting depth been calculated to avoid cutting the opposite side of the pipe?
8. Has the boring bar been run through the valve several times to ensure free passage?
9. Has the pressure and temperature of the contained material been reduced as much as the
process operations will allow?
10. Is there liquid or flowing gas in contact with the area to be hot tapped?

Before Removing the Hot Tap machine

1. Follow the manufacturer’s instructions to be sure the boring baris fully retracted before
closing the valve
2. Close the valve
3. Make sure any necessary nitrogen purging is completed
4. Open the bleeder valve and be sure all pressure is off the hot tap machine before removing
bolts from the flange. If flow or pressure persists, the main valve is probably leaking.
5. Remove the hot tap machine from the tapping valve.
6. Remove the coupon and from the pilot drill and wire to the tapping valve.
7. Ensure the completed hot tap is blinded or plugged before leaving the jobsite.
8. Operations Supervisor is to ensure that the coupon is forwarded to the responsible
operations inspection unit to verify wall thickness or corrosion patterns.

After Removing the Hot Tap Machine

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1. The hot tap machine should be cleaned, removing the hydrocarbons/chemicals from the
line or equipment.
2. All rags, absorbent pads, and other cleaning materials must be disposed of properly.

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