Professional Documents
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Individual Unit
Procedure
Reviewed:
Preparer:
EHS Team Member
4/14
Effective:
Owner:
EHS Team Member
Page:
1 of 19
4/14
Supersedes: 8/13
(Rev.06)
(Rev.05)
Approver:
EHS Manager
Revision Description
Revised By
VB
DLS
DLS
DLS
Revision
Date
05/08
04/09
10/10
3/13
DLS
DLS
08/13
04/14
Title:
Individual Unit
Procedure
Reviewed:
4/14
Effective:
Page: 2 of 19
4/14
(Rev.06)
Supersedes:
1.
PURPOSE
To establish a clear set of guidelines to be followed when performing Hot Tap
and Stopple installations in piping systems that cannot be safely cleared and
isolated to make an out-of-service tie-in.
2.
DEFINITIONS
8/13
(Rev.05)
2.1.
Coupon The part of the pipe that is removed during the Hot Tap
operation.
2.2.
2.3.
2.4.
Contractor the Company that supplies the Hot Tap and/or Stopple
machine and its operating personnel.
2.5.
Title:
Individual Unit
Procedure
Reviewed:
2.
3.
4/14
Effective:
Page: 3 of 19
4/14
(Rev.06)
Supersedes:
8/13
(Rev.05)
DEFINITIONS contd
2.6.
2.7.
Weldment A welded-in pipe fitting that connects the new tie-in piping
spool to the existing piping system (e.g. a split tee or a weld-o-let)
2.8.
2.9.
2.10.
SCOPE
Hot Taps, Stopples, and Freeze Plugs shall only be installed on piping that
cannot be safely cleared and/or isolated due to operational and/or system
design constraints, Hot Taps and Stopples represent a potential danger to
personnel and to plant operations. Any Hot Tap and/or Stopple must be part of
an approved MOC. All Hot Taps shall require a PSSR prior to being put into
service. This procedure shall apply to all facilities located at the Port Arthur Site.
All Hot Tap/Stopple installation work requests must be reviewed for potential risk.
This review is required even for nonhazardous fluid service. Hot Taps that are
part of a defined project must indicate and reference Hot Tap documentation
within the project MOC. The project hot taps must be in a separate MOC and
approved by the Operations Manager as required.
Title:
Individual Unit
Procedure
Reviewed:
3/13
Effective:
Page: 4 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
4. PROCEDURE
4.1.
General
4.1.1. Hot Taps are NOT to be performed on piping containing:
A.
Combustible vapor/air/oxygen mixtures with-in flammable
and/or explosive ranges.
B.
Hydrogen, if the equipment has operated above the
Nelson Curve Limits
C.
Any chemicals likely to violently decompose or become
hazardous from the heat generated by welding.
D.
Strong Caustics or Acids
E.
Oxygen or Ammonia
F.
Any process stream containing ethylene or acetylene
Streams with low concentrations of ethylene/acetylene
can be considered for Hot Tapping contingent on
concurrence from Corporate Process Safety
4.1.2. Hot Tapping shall not be performed on piping under vacuum
unless approved by the Operations Manager.
4.1.3. Hot Taps shall not be performed on piping that is lined, clad, or
where stress relieving is required.
4.1.4. Hot Taps made upstream of equipment and/or in-line
instrumentation that are not adequately protected by filters and
cannot be isolated, shall be carefully evaluated for safety and
operational risks that could arise from a coupon or metal shavings
being left behind in the piping system. A risk analysis shall be
completed and added to the Document Package if this paragraph
is applicable.
4.1.5. Hot Tap and Stopple machinery shall be operated by authorized
Contractor personnel only. Procurement maintains a list of
approved Contractors. Potential new Contractor must go through
the Sites procedure for qualifying new vendors through the PICS
system. New vendors for this work should provide at least two
references for his type work. It is the responsibility of the
Contractor to ensure such equipment is properly maintained and
in good working condition, and that their personnel are adequately
trained.
Title:
Individual Unit
Procedure
Reviewed:
4.
3/13
Effective:
Page: 5 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
PROCEDURE contd
4.1
General contd
4.1.6. When feasible, Hot Taps should be made on the top of the pipe
vs. the bottom, in horizontal pipe runs. This makes it easier and
safer to install/remove the Hot Tap Machine.
4.2.
Design Considerations
4.2.1. All piping components used in a Hot Tap, Stopple or Line Freeze
installation shall be in accordance with the relevant Port Arthur
Site Piping Standards, with the exception of weldments will shall
be in accordance with the Table 1 of this procedure Any
proposed piping component deviation will require approval from
the Technical Services Director or designee.
4.2.2. All welding on piping components used in a Hot Tap installation
shall be in accordance with approved welding procedures.
4.2.3. Full port ball or gate valves are recommended for Hot Tap and
Stopple installations, the Hot Tap Contractor will be consulted
when a normal trim valve is the only/best option. These valves
shall comply with the appropriate Port Arthur Site Piping Standard.
4.2.4. If a completion plug is to be used in the case of a Stopple, the
elastomer components shall be reviewed and approved by Site
Engineering to ensure compatibility with the process.
4.2.5. Due to the weight of Hot Tap and Stopple machines, the force
exerted on the piping and supporting structure must have an
engineering review of the stress loading. This review can be
simply good engineering judgment, or if good engineering
judgment dictates, a formal stress analysis shall be completed and
included in the Hot Tap/Stopple Document Package.
4.2.6. Table 1 has been attached as a guideline for selecting the
appropriate weldment. If this table is not used, an Engineering
Standards Deviation Request must be approved.
Title:
Individual Unit
Procedure
Reviewed:
4.
3/13
Effective:
Page: 6 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
PROCEDURE contd
4.2
4.3.
Preparation
4.3.1. In consideration of the significance of the effort and expense
involved in the preparation for a Stopple, Line Freeze, and/or Hot
Tap, Operations should be appraised of any requests prior to
proceeding with the preparations for the work. It is recommended
a minimum two weeks advanced notice be provided in order for
Operations to have adequate time to prepare a risk evaluation and
emergency plan associated with completing the TSA, while the
Contractor performs mechanical checks in the field.
4.3.2. The location of the Hot Tap shall allow for:
A.
Adequate clearance for the machine
B.
Adequate support for the machine
C.
Availability of air or electric power for the machine
D.
Easy and safe egress for personnel making the Hot Tap or
Stopple, and easy access for emergency personnel.
Title:
Individual Unit
Procedure
Reviewed:
4.
3/13
Effective:
Page: 7 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
PROCEDURE contd
4.3
Preparation contd
4.3.3. Drilling through the opposite side of the piping is a serious
concern. The appointed Contractor shall perform measurements
and calculations to verify that the cutter or the pilot drill shall not
penetrate through the opposite wall of the line being Hot Tapped.
Preferably the drill should not penetrate beyond the center of the
pipe. For size-on-size or one size smaller connections, where the
drill tip will have to move further into the pipe, measurements must
ensure that the drill will not contact the inner surface of the other
side of the pipe. The Maintenance/Construction representative
shall review these measurements.
4.3.4. Thickness measurements and all associated piping inspections
shall be made by the facility QA group in the location of the Hot
Tap, extending out to either side, a minimum of 12 inches, or the
diameter of the branch pipe, whichever is greater. If any of the
following conditions exist, a engineering evaluation shall be
performed by a qualified engineer and approved by the facility
Fixed Equipment Engineer, to determine if a Hot Tap can be
safely performed:
A.
Actual thickness < 3/16
B.
Actual thickness > 1
C.
Actual thickness < Nominal thickness corrosion
allowance
4.3.5. Dye penetrant examination of the surface of a stainless steel pipe
is required to ensure there is no stress cracking at the surface. If
stress cracking exists, a qualified engineer/technician shall
perform ultrasonic thickness testing to determine the suitability of
the existing pipe for the Hot Tap.
Title:
Individual Unit
Procedure
Reviewed:
4.
3/13
Effective:
Page: 8 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
PROCEDURE contd
4.3
Preparation contd
4.3.6. The attainable flow velocity in the line being Hot Tapped shall be
verified by the Stationary Equipment Engineer. If the flow in a line
being hot tapped is within the following velocity ranges: Liquid: 1.5
15.0 feet per second, Gas or vapor: 25.0 200.0 feet per
second, then no engineering review is required. For liquid or gas
velocities outside these ranges, Site Engineering will review the
hot tap as per API Recommended Practice 2201 Procedures for
Welding or Hot Tapping on Equipment in Service, Latest Edition.
Site Engineering shall evaluate required flow in vapor lines on a
case-by-case basis.
4.3.7. The WPS (Weld Procedure Specification) must be selected by the
contractors QA/QC department and attached to the checklist
Form A. This procedure must be reviewed by the contractors
QA/QC Representative and the Certified Welder prior to
performing the work.
4.3.8. For Line Freezes on piping with wall thickness greater than
inch, special precautionary measures must be taken.
4.4.
Title:
Individual Unit
Procedure
Reviewed:
4.
3/13
Effective:
Page: 9 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
PROCEDURE contd
4.4.
4.5.
Title:
Individual Unit
Procedure
Reviewed:
4.
3/13
Effective:
Page: 10 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
PROCEDURE contd
4.5.
Title:
Individual Unit
Procedure
Reviewed:
4.
3/13
Effective:
Page: 11 of 19
3/15/13 Supersedes:
(Rev.04)
10/01/10
(Rev.03)
PROCEDURE contd
4.5.
5.
RESPONSIBILITIES
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
Title:
Individual Unit
Procedure
Reviewed:
6.
3/13
Effective:
Page: 12 of 19
3/15/13 Supersedes:
(Rev.04)
RELATED DOCUMENTS
ANSI B31.3 Chemical Plant and Petroleum Refinery Piping
API Recommended Practice 2201 Procedures for Welding or Hot Tapping on
Equipment in Service
OSHA 1910.119 Process Safety Management of Highly Hazardous Chemicals
Port Arthur Facility Procedure PA-020-0029 Management of Change
Port Arthur Facility Procedure PA-020-0028 Pre-Startup Safety Reviews
Port Arthur Facility Procedure PA-020-0002 Hot Work
Table 1- Fitting Selection Table
Attachment A-Hot Tap Checklist
Attachment B-Hot Tap Checklist
Attachment C-Stopple Checklist
Attachment D- Hot Tap Machine Dimension
10/01/10
(Rev.03)
PA-020-0014
TABLE 1 - FITTING SELECTION TABLE
This table is to be used to select hot tap fittings for pipelines only. A selection from this table does
not require engineering review or mechanical calculations. NOTE: Incase of conflict with Pipe
Spec, Hot Tap Procedure will govern.
BRANCH SIZE
HEADER
PIPE
SIZE
1"
1-1/2"
2"
3"
4"
6"
8"
10"
12"
14"
16"
18"
20"
1"
T or
W
1-1/2"
T or
W
T or
W
2"
T or
W
T or
W
3"
T or
W
4"
6"
8"
10"
12"
14"
16"
18"
20"
24"
SYMBOLS
WIntegrally reinforced fitting (weld-o-let).
TFull encirclement split tee.
PReinforcement pad is required. Pad width shall equal half of branch nominal size, and
thickness shall be no less than the header pipe wall thickness.
NOTES
1.
For branch diameters greater than 2", reinforcement is required - either reinforcement
pad or split tee as shown in Table 1. 1/8" NPT tapped holes shall be provided in pad or
tee and shall be sealed with RTV sealer. Reinforcement pads will be pneumatically
tested at 15 psig. Where pneumatic testing is not practical (hot services), the use of
integrally reinforced fittings (O-lets) will be considered, use of these fittings must be
approved in advance by the engineer.2. All branch fittings must meet or exceed main pipe
schedule.
24"
Attachment A
PA-020-0014
Pipe Specification:
Pipe Material:
ft/s
Operating Pressure:
psig
Liquid ( )
Gas/vapor ( )
Temperature:_____________ deg F
Does this job fully comply with the Site Hot Tap/Stopple Procedure?
( ) Y ( ) N ( ) n/a
Are approved welding procedures included with the Hot Tap/Stopple Document Package?
( ) Y ( ) N ( ) n/a
Does the new installation fully comply with Site Piping Standards and/or approved deviations?
( ) Y ( ) N ( ) n/a
Has the Hot Tap location been clearly marked in the field and the pipe cleaned to bare metal?
( ) Y ( ) N ( ) n/a
Has the added stress loading on the existing pipe and support structure been addressed?
( ) Y ( ) N ( ) n/a
Does the Hot Tap/Stopple location allow for sufficient clearance and easy access/egress?
( ) Y ( ) N ( ) n/a
Have thickness and dye penetrant (per Section 4.3.3) results been reviewed and determined to be
satisfactory?
( ) Y ( ) N ( ) n/a
Has the weldment been either selected from Table 1 or approved by Site Engineering?
( ) Y ( ) N ( ) n/a
Has Site Engineering confirmed the required flow, and is it available for the Hot Work?
Signatures:
Maintenance/Construction Representative
Print Name:
Signature:
Mechanical QA Department
Print Name:
Signature:
Date:
Date:
Maintenance/Project Manager
Print Name:
Signature:
Job Coordinator
Print Name:
Signature:
Date:
Date:
A hot work permit CANNOT be issued if Sections 1 & 2 are not signed and/or there are any No answers.
Effective: 3/13
Attachment A
PA-020-0014
( ) Y ( ) N ( ) n/a
Does the TSA address the risks associated with losing a coupon or introducing metal
shavings?
( ) Y ( ) N ( ) n/a
Does the TSA denote measures taken to reduce the risk of burn through, and provide
a contingency plan in the event of burn through?
( ) Y ( ) N ( ) n/a
Will radio communication with the Control Room be available during the execution of
this work?
( ) Y ( ) N ( ) n/a
Has a complete Hot Tap/Stopple Document Package been provided to the Operations
Manager or designee?
( ) Y ( ) N ( ) n/a
If a stopple is going to be used, does the JSA address measures to be taken if the
stopple fails?
( ) Y ( ) N ( ) n/a
To ensure compliance with OSHA's Lockout/Tag-out Standard under 1910.147, the hot tap must be
justified. The OSHA standard, as proposed, stipulated that hot tap operations would be exempt from the
requirements of the standard if the employer could demonstrate that: (1) Continuity of service is essential;
(2) shutdown of the system is impractical; and (3) documented procedures and special equipment are
utilized which will provide effective protection for employees.
Details of Requirement for continuity of service and/or impracticality of system shutdown:
Continuity of service is essential shutdown of the system is impractical
documented procedures and special equipment are utilized which will provide effective protection for
employees
NOTE: Operation Signatures signify that the Hop Tap location and size are correctly
identified, that the risks of performing a hot tap and the alternatives to a hot tap have been
reviewed, and that performing a hot tap is necessary.
Signatures
Operations Manager or Designee
Print Name:
Signature:
Date:
Date:
A hot work permit CANNOT be issued if Sections 1 & 2 are not signed and/or there are any No answers.
Effective: 3/13
Attachment B
PA-020-0014
Hot Tap Checklist Form B
To be completed by the Hot Tap Contractor Prior to Drilling the Coupon
Pressure Test of branch weld: ( ) Hydro ( ) Pneumatic Test Pressure _________ psig ( ) Passed ( ) Failed
( ) Radiography ( ) Other __________________
Date:
Maintenance/Construction Representative
Print Name:
Signature:
Date:
TES Director
Print Name:
Signature:
Date:
Prior to proceeding with the Hot Tap, the above information shall be completed and confirmation of
successful test results provided, and radio communication established with the Control Room
Contractor Hot Tap Checklist:
Hot Tap Machine Used
Boring bar travel set at
Wt
"
lb Max Working pr
Do-not-exceed dimension
Date:
Maintenance/Construction Representative
Print Name:
Signature:
Date:
Effective: 3/13
Attachment C
PA-020-0014
Stopple/Line Freeze Checklist Form C
To be completed by the Contractor Prior to Installation
Wt
Date:
Maintenance/Construction Representative
Print Name:
Signature:
Date:
Date:
Prior to proceeding with the Stopple the above information shall and signed off, and radio
communication established with the Control Room
Effective: 3/13
Attachment D
PA-020-0014
HOT TAP MACHINE DIMENSION & CALCULATION SHEET
BRANCH
SIZE "
TAP
SIZE "
FLANGE
RATING lb
TOPAZ
MODEL
WEIGHT
lbs
All
15
67
28
T-101
50
1-1/4
1-1/2
All
15
67
28
T-101
50
1-7/16
All
16
53
28
T-101
50
2-7/16
150
300
600
19
20
20
54
29
360
250
3-7/16
150
300
600
18
19
37 (61)
54
54
78 (102)
29
29
31
360
360
660 (760)
250
250
700 (900)
5-15/32
150
300
600
35 (59)
34 (58)
32 (56)
80 (104)
80 (104)
82 (106)
31
660 (760)
700 (900)
7-5/16
150
300
600
32 (56)
33 (57)
33 (57)
82 (106)
31
660 (760)
700 (900)
10
9-1/2
150
300
600
30 (54)
36 (60)
29 (53)
84 (108)
79 (103)
85 (109)
31
660 (760)
700 (900)
12
11-1/2
150
300
600
33 (57)
34 (58)
32 (56)
82 (106)
31
660 (760)
700 (900)
14
12-3/4
150
300
600
35 (59)
60
80 (104)
132
126
31
56
56
660 (760)
1200
1200
700 (900)
3000
3000
16
14-9/16
150
300
600
59
56
60
132
135
131
56
1200
3000
18
15-1/16
150
300
600
56
60
133
133
130
56
1200
3000
17
150
300
600
57
20
133
130
133
56
1200
3000
150
300
600
53
136
132
132
56
1200
3000
24
21
56
NOTES:
- These are dimensions/weights for a typical (Topaz or T D Williams) machine for planning purposes only. These
parameters may vary for a different machine.
- Values given in parentheses are for a heavier and larger machine.
Effective: 3/13
Attachment D
PA-020-0014
HOT TAP MACHINE
T
R
Adaptor
F
E
Tapping Machine
"
"
".
"
"
"
=
=
"
"
"
+2X
"
"
Effective: 3/13