A / Hot Tap
Area / Issuing Department / Document # / Approved by / Revision # / Date / Page
OPS / Safety / SSP 0004A-Hot Tap / Jeff Warmann/Wade Gauthreaux / 0 / 04/19/11 / 1 of 2
Purpose / To outline the approval process and preparation steps required to perform welding on in-service piping or equipment and during a hot tap.
Safety / This procedure applies to piping and equipment fabricated from steel. Other materials, such as aluminum, copper, plastic, and cast iron may be unsuitable for hot tapping or welding and will require additional special procedures.
References / Associated Procedures: {list if any} (JSA procedure & Form) (Hot Tap Checklist & Form)
API Recommended Practice 2201, Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries
Definition / Hot Tap: A technique which attaches a mechanical or welded fitting and valve to in-service piping or equipment and then creates an opening in the in-service piping by drilling or cutting within the attached fitting.
Responsibilities / Hot tapping or welding on any in-service piping or equipment can only be conducted with the written authorization by all below:
1.Maintenance Manager / 4. Operations Manager
2.Chief Inspector / 5. Safety Manager
3.Refinery Manager
PPE / Use
Standard (SSP-0000) / 
Eyes-Welding/Face Shield / 
Clothing-FRC / 
Clothing-Welding/Chemical / 
Gloves – Welding/Chemical / 
Boots-Steel Toe/Chemical / 
Fall Protection (Not Required) / 
Respirator-Per MSDS / 
SCBA-Per MSDS/Stand By / 
Review applicable MSDS / 
A / Hot Tap
Area / Issuing Department / Document # / Approved by / Revision # / Date / Page
OPS / Safety / SSP 0004A-Hot Tap / Jeff Warmann/Wade Gauthreaux / 0 / 04/19/11 / 1 of 2
A / Hot Tap
Area / Issuing Department / Document # / Approved by / Revision # / Date / Page
OPS / Safety / SSP 0004A-Hot Tap / Jeff Warmann/Wade Gauthreaux / 0 / 04/19/11 / 1 of 2
WARNING Hot taps should not be a routine practice and should only be used when isolation of piping or equipment is not feasible.
MANAGEMENT OF CHANGE(MOC) REVIEW AND APPROVAL FOR HOT TAP
  1. A Request for Change (RFC) must be reviewed and approved prior to any Hot Tap Procedure. This RFC must include:
  2. Review of any hazards that may be introduced to the process system as the result of the hot tap connection.
  3. Review any longer-term concerns related to the revised equipment as well as possible short-term effects during the hot tapping itself.

  1. Section 1 of the “Hot Tap and In-Service Equipment Welding Checklist” must be completed. This form requires the Chief Inspector to check and approve the following key elements of the planned work:
  2. Exact location of the Hot Tap or welding
  3. Inspection of location and piping for condition and compliance
  4. Inspection of the materials and fittings to be used to ensure metallurgical compatibility, etc.
  5. Inspection of the equipment to be used to ensure it has appropriate working pressure and temperature ratings.
  6. Review of the planned work.
  7. Record initial Inspection of work when initiated (when initial arc is struck, cutter travel and initial cut)
  8. Training of workers involved in the work.

  1. A Job Safety Analysis must be completed to identify the potential hazards for each step in the task and specify the necessary control measures to manage the potential risk.

  1. A Hot Work Permit must be issued for the work and ensure the job is prepared and the area safe for the planned activity. Operations Manager and all area operators must be made aware of hot work planned.

  1. A meeting with all individuals and contractors involved with the Hot Tap must be conducted to review the above process and forms, and to provide final approval for the work to proceed. At this meeting Section 2 – Approvals in the Hot Tap and In-Service Equipment Welding Checklist will be completed or confirmed complete.

  1. When work is initiated:
  2. All PPE and Safety barriers must be in place as identified in the Hot Work Permit and JSA
  3. The Chief Inspector or the responsible supervisor overseeing the hot tap and/or welding task must be present and must perform Section 3, 4 & 5 of the Hot Tap and In-Service Equipment Welding Checklist.
  • Section 3 -- when the initial arc is struck
  • Section 4 -- to check the cutter travel clearance
  • Section 5 -- when the initial cut/tap is made

WARNING Hot tap machine operators and welders must be qualified in accordance with applicable codes and specifications. They should be thoroughly familiar with welding and hot tap equipment and procedures to be used.
SPECIAL APPROVALS
Hot taps or welding on piping or equipment under the following conditions requires the approval of Refinery Manager, Operations Manager and Safety Manager:
  • Piping or equipment under vacuum
  • Vapor/air or vapor/oxygen mixtures near or within their flammable/explosive range
  • Services containing hydrogen, including gas mixtures where the partial pressure of hydrogen exceeds 100 psig
  • Services containing peroxides, chlorine, or other chemicals likely to violently decompose or become hazardous from the heat of welding
  • Services containing caustics, amines, nitrates, elemental sulfur, and acids (such as HF acid), if the concentration and temperatures are such that post-weld heat treatment is required
  • Services containing hazardous or toxic materials (including ethylene, acetylene, butadiene, and substances that are prone to decomposition from the heat of welding)
  • Compressed air lines or any line containing over 1% oxygen, Piping or equipment that requires post-weld heat treatment, Piping or equipment that is clad or lined, Piping upstream of rotating equipment, where the equipment is not protected by screens or filters, Tanks or vessels in service, Decks of floating roof tanks, and Welding or hot tapping in confined spaces