ILLINOIS REFINING DIVISION - STANDARD OPERATING PROCEDURES

Issued by: Safety Dept.

Revised by: SOP Focus
Group

Issued: 1/88
SOP #8
PROCEDURES FOR WELDING OR HOT
TAPPING ON EQUIPMENT NOT
DEPRESSURED TO CLEARED

Revised: 9/98
Page 1

THISPROCEDURE COVERS SOME OF THE SAFETY CONSIDERATIONS WHICH ARE

COMMON IN THE PETROLEUM INDUSTRY WHEN WELDING OR HOT TAPPING ON
EQUIPMENT THAT IS NOT DEPRESSURED AND CLEARED. IT IS NOT A SUBSTITUTE FOR
JOB PLANNING. A DETAILED WRITTEN PROCEDURE SHOULD BE PREPARED AND
REVIEWED PRIOR TO STARTING EACH JOB TO ENSURE THAT ALL PROPER STEPS ARE
TAKEN.
I.

A request for welding or hot tapping on equipment not depressured and cleared will be initiated
by the use of the Welding or Hot Tapping Approval form (RR-178). The originator on the form
is the person requesting the hot tap.

II.

The Welding or Hot Tapping Approval form will be sent to the Operations Manager or the
Products Control Manager, as appropriate, for approval. It will be the responsibility of
Operations, Products Control and Maintenance Supervision to minimize the use of hot taps and
welding on lines that are not depressured or cleared. The following alternatives must be
considered:
A.

Installation delay must be seriously considered, so that connections can be made at a time
when equipment or piping is not in service.

B.

Alternate locations for connections should be investigated to prevent the need for a hot tap
or welding.

C.

Every attempt possible must be made to isolate equipment or process systems when it is
decided to make connections which would otherwise require hot tapping or welding.

Once a hot tap or welding is deemed necessary, the Operations Manager or Products Control
Manager will sign off on the final approval section after the questions in the section have been
answered by the Unit Foreman and Area Supervisor. The location shall be identified on the pipe,
tank or vessel and approved by the Unit Foreman.
III.

The Welding or Hot Tapping Approval form will then be forwarded to Engineering. The
Engineering Manager will sign off on the final approval section after the questions in the section
have been answered by the responsible engineer. API 2201 Procedures for Welding or Hot
Tapping on Equipment Containing Flammables shall be followed where applicable.
Chemistry of Line or Vessel Contents
The oxygen level within the equipment must be controlled to prevent the formation of a vapor/air
mixture within flammable or explosive ranges. In addition, contents of the line or vessel being
hot tapped must not contain:

ILLINOIS REFINING DIVISION - STANDARD OPERATING PROCEDURES

Issued by: Safety Dept.
Revised by: SOP Focus
Group

IV.

Issued: 1/88
SOP #8
PROCEDURES FOR WELDING OR HOT
TAPPING ON EQUIPMENT NOT
DEPRESSURED TO CLEARED

Revised: 9/98
Page 2

1.

Hydrogen, if the equipment is operated above the Nelson curve limits, because of the
possibility of hydrogen attack of the metal (see API Publication 941).

2.

Vapor/air or vapor/oxygen mixtures within flammable or explosive ranges.

3.

Acids, chlorides, peroxides, or other chemicals likely to decompose or become

hazardous from the heat of welding.

4.

Caustic or amine, if the concentration and temperature are such that the fabrication
specifications call for stress relieving.

5.

Certain unsaturated hydrocarbons that may experience exothermic decomposition

reaction (ethylene for example) if the metal temperature resulting from hot tapping
could initiate such a reaction at the maximum expected pressure. Such reactions could
have the potential for causing localized hot spots on pipe walls that could lead to
failure.

The Welding or Hot Tapping Approval form will then be forwarded to the Inspection
Department. The Inspection Supervisor will sign off on the final approval after the questions in
the section have been answered by the responsible inspector. The following should be carefully
considered:
Burn Through
The risk of burn-throughs can be minimized if the equipment is properly inspected for adequate
wall thickness and absence of defects, if controlled welding techniques are done by experienced
welders to prevent overheating, and if other appropriate safety procedures are followed. A
thorough and complete inspection of each connection area must verify that the metal thickness is
adequate for the pressure and temperature involved, and that there are no laminations or other
defects. Welding or hot taps can only be made in lamination free areas. To minimize the
possibility of burn-through, the first weld pass to the equipment should be made with a 3/32 inch
diameter welding electrode, and the remaining passes should be made with electrodes not to
exceed 1/8 inch diameter if actual metal thickness does not exceed 1/2 inch.
For heavier wall thicknesses where burn-through is not a primary concern, larger diameter
electrodes may be desirable to compensate for the larger mass. This will minimize the potential
for fusion defects.
Metal Thickness
Generally, a minimum base metal thickness of 3/16 inch is recommended for hot tapping.
Exceptions to the recommended thickness may be permitted when metallurgical requirements and
pressure limitations specified by the Inspection Department are met.

ILLINOIS REFINING DIVISION - STANDARD OPERATING PROCEDURES

Issued by: Safety Dept.
Revised by: SOP Focus
Group

Issued: 1/88
SOP #8
PROCEDURES FOR WELDING OR HOT
TAPPING ON EQUIPMENT NOT
DEPRESSURED TO CLEARED

Revised: 9/98
Page 3

The Inspection Supervisor will sign off on the final approval section, after the questions in the
section have been answered by the Inspector. API 2201 Procedures for Welding or Hot Tapping
on Equipment Containing Flammables shall be followed where applicable.
V.

The Maintenance Planning Supervisor will sign off on the final approval section after the
questions in the section have been answered by the Area Planner. API 2201 Procedures for
Welding or Hot Tapping on Equipment Containing Flammables shall be followed where
applicable.
Flow in Lines
In certain cases where there may be insufficient or interrupted flow, such as a flare line, it may be
necessary to continually purge or flood the line with steam, inert gas or hydrocarbon gas to ensure
that the line or equipment does not contain a flammable mixture during the welding operation.
Suggested product velocities during welding are:
1.

Liquid - 1.3 fps minimum

4.0 fps maximum

2.

Gas - 1.3 fps minimum

No limit on maximum velocity

Hot Tap Machine Suitability

The hot tap machine can be considered suitable if the pressure and temperature of the medium
inside the line or vessel falls within the working limits of the hot tap machine.
Hot Tapping or Welding on Vessels in Service
1.

Liquid level changes

Never pump into or out of a tank while hot work is in progress. Close, tag, lock or
otherwise render inoperative all valves on liquid lines at the tank.

2.

Heating coils
Turn off all heating coils during the hot tap or welding procedure.

3.

Liquid level above the weld area

Maintain at least one meter (3 ft.) of liquid head above the hot work area when welding
or hot tapping is being done. A hand tape gage of the tank contents should be made
since automatic or remote reading gages may not be reliable enough for this
measurement.
Written Procedure Prepared
Written, detailed welding procedure, hot tap procedure, connection design, safety
instructions and other appropriate instructions should be prepared in advance of any hot
tap or welding work. If the base metal temperature is such that a preheat of the weld
area is required, this should be covered in the plan. Welding procedure requirements
are described in Section IX of the ASME Boiler and Pressure Vessel Code for various
types of steel.
The Area Planner and Planning Supervisor will sign the written procedure and attach it
to the Work Order, Welding or Hot Tapping Approval form and drawings. This
package is then forwarded to the Maintenance Manager for his review and approval.

VI.

The Maintenance Manager will sign off on the final approval after the questions in the section
have been answered.

VII.

The Work Order and Welding or Hot Tapping Approval package (form, drawings and written
procedure) will be issued to the Area Maintenance Foreman. The following procedure will be
used in the actual performance of the hot tap connection and hot tap:
Before Welding or Hot Tap Connection Begins
Before proceeding with the welding or hot tap, the following conditions must be satisfied:
1.

The Area Maintenance Foreman, Unit Foreman and Chief Operator will verify that
each section of the Welding or Hot Tapping Approval form has been filled out and
signed.

2.

The area to which a connection is to be made has been identified, physically marked
and the metal thickness measured.

3.

Review welding or hot tap connection/hot tap written procedure and attached drawings
as necessary.

4.

A Unit Operator will be at the work site during the welding or hot tapping.

5.

A work clearance permit (hot work) has been secured, and all necessary gas tests have
been made to ensure a safe environment.
A suitable fire extinguisher (preferably dry chemical or pressurized fire hose) has been
provided and a fire watch established.

6.
7.

Contact the Safety Department after the preceding steps have been completed, and
work is ready to begin.

VIII.

A Safety Department Representative will go to the work site and complete the questions under the
Safety Section of the Welding or Hot Tapping Approval form. These questions are directed
toward Maintenance/Operations personnel, as a double check, that certain items have been
completed. The Unit Foreman, Chief Operator, Maintenance Foreman and Craftsman should be
in attendance at the work site when the Safety Representative fills out this section of the
Welding or Hot Tapping Approval form. Work may begin after the Safety Representative signs
the final approval section.

IX.

Reference: API Publication 2201, Procedures for Welding or Hot Tapping on Equipment
Containing Flammables. API Standards may be found on RoadMap.

RR-178

HOT WELDING OR TAPPING APPROVAL

Revised 4/98
STEP 1

Page 1 of 2

INITIATING GROUP

Date_______________________________Originator_____________________________________________________________
Description of Hot Weld or Tap______________________________________________________________________________
________________________________________________________________________________________________________
STEP 2

OPERATIONS/PRODUCTS CONTROL DEPARTMENT

Unit_____________________________________________________ Temperature of Product___________________________

Product in Line/Tank________________________________________ Pressure of Product______________________________
Unit Responsible for Flow____________________________________ Amount of Flow________________________________
The following questions are to be answered by the Unit Foreman:

Yes

No

___

___

Alternate locations for connections were investigated to prevent the need for a hot tap?

___

___

3.

Consideration was made to isolate equipment or process systems?

___

___

4.

Is the material in the line stable under heated conditions and normally free of oxygen?

___

___

1.

Installation delay was seriously considered, so that connections could be made at a time when equipment
or piping is not in service?

2.

COMMENTS____________________________________________________________________________________________
________________________________________________________________________________________________________
Area Supervisors Signature:____________________________________________

Date_______________________________

Final Approval:______________________________________________________
(Operations/Products Control Manager)

Date_______________________________

STEP 3

ENGINEERING DEPARTMENT

The following questions are to be answered by an Engineer:

Yes

No

1.

Has a tie-in drawing package been issued including P&ID, isometric plan drawings and bill of material?

___

___

2.

Is clearance available for the hot tap machine?

___

___

3.

Are full port valves required/specified to accommodate cutter clearance?

___

___

4.

Full encirclement saddles are required for size-to-size hot taps. Is proposed hot tap size-to-size, for
example 6 tap on a 6 line?

___

___

5.

Have the line or vessel contents been considered so that welding is avoided on equipment which contains
flammable mixtures which could have been embrittled by service environments such as amines, wet
H2S, or high temperature hydrogen?

___

___

Has a tie-in walk through been completed with Operations, including tagging of the tie-in location?

___

___

6.

COMMENTS_____________________________________________________________________________________________
_______________________________________________________________________________________________________
Engineering Signature:________________________________________________

Date_______________________________

Final Approval:______________________________________________________
(Engineering Manager)

Date_______________________________

STEP 4

INSPECTION

The following questions are to be answered by the Planner

Yes

No

1.

Has the area to be welded been inspected for metal thickness (3/16 minimum)?

___

___

2.

Does the welded area need to be stress relieved?

___

___

3.

Do the flanges, bolts, gasket, pipe and valve to be installed meet the piping code for the line or vessel
to be hot tapped?

___

___

4.

The welding rod to be used is (type and size)________________________________________________________________.

Thickness measurements (actual)_____________________________________(design)______________________________.

COMMENTS_____________________________________________________________________________________________
_______________________________________________________________________________________________________
Inspector Signature:__________________________________________________

Date_______________________________

Final Approval:_____________________________________________________
(Inspection Supervisor)

Date_______________________________

STEP 5

PLANNING

The following questions are to be answered by the Planner:

Yes

No

1.

Are the following drawings attached to this form: Isometric, Plan and P&ID?

___

___

2.

Has a written detailed procedure been developed for this weld or hot tap and has it been attached to this
approval form? (API 2201 should be followed)

___

___

3.

Has the exact location of the hot tap on the line or vessel been identified and marked?

___

___

COMMENTS_____________________________________________________________________________________________
______________________________________________________________________________________________________

RR-178

HOT WELDING OR TAPPING APPROVAL

Page 2 of 2

Planner Signature:___________________________________________________

Date_______________________________

Final Approval:_____________________________________________________
(Planning Supervisor)

Date_______________________________

STEP 6

MAINTENANCE DEPARTMENT

The following questions are to be answered by Maintenance:

Yes

No

1.

Have all the previous sections of the approval form been filled out?

___

___

2.

Is the detailed written procedure for the hot tap connection and hot tap attached to this form?

___

___

COMMENTS____________________________________________________________________________________________
_______________________________________________________________________________________________________
Approval:_________________________________________________________
(Maintenance Manager)

Date_______________________________

STEP 7

PLANNING SUPERVISOR CAN NOW ISSUE WORK ORDER FOR HOT TAP
CONNECTIONS/HOT TAP

STEP 8

MAINTENANCE CRAFTSMAN WILL TAKE THIS FORM AND ALL ATTACHMENTS TO UNIT CHIEF
OPERATOR AND OBTAIN WORK CLEARANCE PERMIT. HOT TAP BEGINS WHEN WELDING
SADDLE ONTO LINE/VESSEL

STEP 9

MAINTENANCE FOREMAN, UNIT FOREMAN, CHIEF OPERATOR WILL VERIFY PROPER LINE
HAS BEEN IDENTIFIED. THEY WILL THEN CONTACT SAFETY DEPARTMENT FOR FINAL
CHECK

STEP 10

PLANNER/SAFETY (PERMISSION TO ACTUALLY MAKE WELD OR HOT TAP)

Prior to commencing the work, the planner will meet with the Unit Foreman, Chief Operator, Maintenance Foreman, Craftsman,
Inspector and Safety to ensure the Approval Form has been filled out properly. At this time Safety will answer the following
questions:
Yes
No
A. Hot Weld
1.

Has the line/vessel been properly identified?

___

___

2.

Is a detailed procedure for the hot weld available?

___

___

3.

Are the isometric and P&ID drawings attached?

___

___

4.

Is suitable PPE available?

___

___

5.

Is fire fighting equipment available?

___

___

6.

(a) If on tank or vessel is hot weld at least 3 below liquid level?

(b) If on process line has flow been established?

___
___

___
___

Liquid level________________________________Verified by____________________________________________

Flow______________________________________Verified by____________________________________________
7.

Has Work Clearance Permit been obtained?

___

___

COMMENTS____________________________________________________________________________________________
________________________________________________________________________________________________________
B. Hot Tap
1.

Has the line/vessel been properly identified?

___

___

2.

Is a detailed procedure for the hot tap available?

___

___

3.

Are the isometric and P&ID drawings available?

___

___

4.

Does tapping machine have a proper pressure and temperature rating?

___

___

5.

Is suitable PPE available?

___

___

6.

Is fire fighting equipment available?

___

___

7.

(a) If on tank or vessel is hot tap at least 3 below liquid level?

(b) If on process line has flow been established?

___
___

___
___

8.

Liquid level_________________________________ Verified by___________________________________________

Flow______________________________________ Verified by___________________________________________
Has Work Clearance Permit been obtained?
___
___

COMMENTS____________________________________________________________________________________________
_______________________________________________________________________________________________________

Final Approval (Planner):___________________________________________

Final Approval (Safety):____________________________________________

Date__________________________________
Date__________________________________

THIS FORM SHALL BE SENT TO THE SAFETY DEPARTMENT FOR FILING UPON COMPLETION OF JOB.