HSE GUIDE

Issue: 01 Rev: 0
Page: 1-4 PART 1 SAFETY
Section 1.13 Hot Tapping Date: September 2001
HSE Guide Section 1.13
1.13.1 Introduction...................................................................................................2
1.13.2 Approvals .....................................................................................................2
1.13.3 Preparation...................................................................................................2
1.13.4 Prohibiting Factors........................................................................................3
1.13.5 Procedures ...................................................................................................3
1.13.6 Precautions ..................................................................................................4
HSE GUIDE
Issue: 01 Rev: 0
Page: 2-4 PART 1 SAFETY
Section 1.13 Hot Tapping Date: September 2001
HSE Guide Section 1.13
1.13.1 Introduction
The term hot tapping refers to a method of making a connection into a pipeline,
tank or vessel whilst it is service.
This guide is concerned with safety aspects of this specialised operation in which
a stub piece incorporating a valve is welded to a pipeline, tank or vessel, and the
connection is made by trepanning a hole using a special cutting machine.
The operation calls for a high degree of expertise and experience and should be
undertaken only in special circumstances, and then only after all other means of
making a connection have been explored. It is intended for those situations
where it is extremely difficult to isolate, clean and gas free the equipment, for
example on very long pipe runs.
1.13.2 Approvals
Hot tapping may only be performed with the prior written approval of the Asset
Manager. He must satisfy himself that adequate controls and procedures are in
place to ensure the work is carried out safely.
Clear and concise instructions must be prepared for the whole operation and
these must be approved by the Site Manager/Team Leader and the appropriate
operations Superintendent.
NOTE: Before undertaking a modification involving hot tapping, the
recommended check-out procedure for modifications, i.e. the sizing of the safety
devices, should be followed. This ensures that the modification does not affect
the integrity of the system or its pressure-relieving capability, i.e. sizing of safety
devices.
1.13.3 Preparation
Before welding begins, it must be established that the equipment, pipeline, etc.
has sufficient thickness and strength. In any event, the metal thickness should
not be less than 5mm and the material must be free from laminations, cracks or
other injurious defects. In some cases the equipment may require strengthening
to take the new connection.
The atmosphere round the hot tap area must be gas free and the area free from
combustible material.
As a general guide, the atmosphere for 2m above deck level, or above the point
at which the operation is to take place (whichever is greater) and within 15m
around it up to this height should remain free at all times from dangerous
concentrations of gas or vapour. Wind direction should be taken into account.
The deck within 15m of the welding should be free from any flammable liquids or
HSE GUIDE
Issue: 01 Rev: 0
Page: 3-4 PART 1 SAFETY
Section 1.13 Hot Tapping Date: September 2001
HSE Guide Section 1.13
other combustible material. Continuous combustible gas monitoring is strongly
recommended.
When welding is being carried out on equipment, the temperature and pressure
inside it are governed by the reduced strength zone and the measured wall
thickness. These factors must be determined in each individual case. This
ensures that at all times during the welding operation sufficient thickness of metal
in the area remains unaffected and is able to contain the internal pressure. As a
guide, the pressure and temperature in the system, where practicable, should be
kept below 3.3bar and 120
o
C.
The operation must not be carried out when the internal pressure is less than
atmospheric or the temperature less than 0
o
C.
1.13.4 Prohibiting Factors
Hot tapping operations should never be carried out on equipment that contains:
Any flammable mixture of gases or vapours
Any substances that may undergo any reaction or decomposition leading to a
dangerous increase of pressure, an explosion or an attack on the metal. This
should be checked before planning the use of the hot tapping method.
Compressed air in the presence of hydrocarbons or other flammable
materials such as lubricating oil carry-over from an air compressor.
Products in cryogenic service.
Pure oxygen, in either liquid or gas form.
Welding on pipelines and equipment in service is not permitted in circumstances
where the materials of construction are such that post-weld heat treatment is
necessary.
Hot tapping should not be carried out on pipelines or equipment lined with special
materials. This applies directly to gas plant vessels that are internally coated with
an epoxy material.
1.13.5 Procedures
Welding procedures are extremely important and must be established and
approved by the appropriate Senior Site Engineer before any hot tapping begins.
Paint or other contaminants must be removed from the surface of the pipeline or
equipment prior to welding.
Hot tapping must not be carried out on pipelines or equipment where effective
control over its contents cannot be exercised, for example any part of a flare line
system. Such lack of control could make the operation dangerous.
HSE GUIDE
Issue: 01 Rev: 0
Page: 4-4 PART 1 SAFETY
Section 1.13 Hot Tapping Date: September 2001
HSE Guide Section 1.13
1.13.6 Precautions
Drains in the vicinity of the welding operations must be effectively sealed.
Flow must be established in the line to be tapped before operations commence.
The flow must be maintained at least until after welding is complete and the metal
has been cooled to the temperature of the flowing liquid.
All connections must be fitted with block valves. The material of construction,
flange rating, jointing and gland packing of these should be suitable for the
equipment design and operating conditions. Each connection and valve is to be
strength tested, in accordance with the code requirements, to prove the fitting
welds and valve flange gaskets. Before commencing cutting operations, test the
machine flange gasket and spindle stuffing box gland to prove that they are leak-
tight under the operating conditions.
After the hydraulic test fluid has been drained from the stool, the assembly
should be purged with nitrogen to prevent the formation of a flammable
atmosphere during the cutting operation. The strength of the section to which the
connection is to be welded must be established, before applying the strength
test, as adequate to withstand the external pressure loading.
Because of the heavy weight of valves and drilling equipment used in these
operations, it is preferable to mount them vertically. Where this cannot be done
the engineering design should take into account how heavy this weight is. In all
cases the connection should be suitably supported.
Before beginning hot tapping, the cutter and its pilot bit should be inspected to
ensure that they are in satisfactory condition and that the coupon recovery
attachment is fitted correctly.
Care should be taken in the design and selection of the branch connection. It
should be long enough to accommodate the cutter and pilot and be designed to
the appropriate code.
Appropriate protective clothing should be specified and worn.
Welding must be done by the electric arc welding process and carried out by an
experienced coded welding operator under skilled supervision.
Before any part of the hot tapping procedure begins, the necessary permits are to
be prepared and issued in accordance with the sire permit procedure. The
Senior Engineer on site is required to acknowledge the permit documentation.
The appropriate Area Authority and the Senior Engineer on site should be
present whilst hot tapping is in progress.