intsallation of hot tap fittings saep0311 2003
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Engineering Procedure
SAEP-311 29 January, 2003
Installation of Hot Tapped Connetions
Piping Standards Committee Members
Al-Sannaa, M.S., Chairman
Al-Dossary, M.B.
Al-Nasri, N.I.
Al-Sabti, R.A.
Al-Sharif, T.M.
Al-Teraiki, A.M.
Balhareth, N.M.
Chen, J.T.
Faley, !.".
Ismail, A.A.
#hashab, J.M.
#im, S.$.
"e%is, T.
Mahmo&, #.A.
M&llen, M.A.
'han, (.C.
Solaiman, M.).
Stark, !.D.
Previous Issue: 29 February, 2000 Next Planned pdate: ! Mar"#, 200$
%evised paragrap#s are indi"ated in t#e rig#t margin Page ! o& $$
Primary "onta"t: Mu#sen S' (l)Sannaa on p#one *+)--+9
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
Saudi Aramco DeskTop Standards
Table of Contents
1 Sope!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! 2
2 Applia"le #ou$ents!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! 2
3 Instrutions!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! 3
% &esponsi"ilities!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! 1%
Appendi' I - (ltrasoni T)i*ness
+easure$ents 1
Appendi' II - Hot Tap C)e*list!!!!!!!!!!!!!!!!!!!!!!!!!! 1
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
1 Scope
This SAEP provides the installation procedures for hot tapping pipe, pressure
vessels and tanks. It assigns responsibilities for the work required and the safety
precautions to be taken. Any deviation to this procedure requires the approval of
the anager, !onsulting Services "epart#ent, "hahran.
2 Applicable Documents
$.% Saudi Ara#co &eferences
Saudi Ara#co Engineering Procedure
SAEP-310 Pipeline Repair and Maintenance
Saudi Ara#co Engineering Standards
SAES-A-004 Pressure Testing
SAES-L-052 Hot Tap onnections
SAES-L-05! Pressure Testing o" Plant Piping and Pipelines
SAES-#-010 #elding Re$uire%ents "or Pressure &essels
SAES-#-011 #elding Re$uire%ents "or 'n-Plot Piping
SAES-#-012 #elding Re$uire%ents "or Pipelines
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
Saudi Ara#co Standard "rawings
A(-03!)1* Rein"orce%ent o" #elded (ranc+ onnections
A(-03!)15 ,etail o" Hea. #elding (oss "or T+readed
onnections
A(-03!!43 ,etail o" Hea. #elding (oss "or Soc/et #eld
onnections
Saudi Ara#co 'or#s and "ata Sheets
or% SA )235-E Hot Tap ,ata and +ec/listor% SA )!2)-E Hot TapStopple Rein"orce%ent alculation
S+eet
Saudi Ara#co (eneral Instructions
-00026100 #or/ Per%its
-00026102 Sa"et. Precautions "or Pressure Testing
-00026)11 ire and Sa"et. #atc+
-1)706001 At%osp+ere-Suppl.ing Respirators
$.$ Industry !odes and Standards
A#erican Petroleu# Institute
AP ST, 5*7 &ale nspection and Test
AP RP 2201 Procedures "or #elding or Hot Tapping on
E$uip%ent ontaining la%%a8les
A#erican Society of echanical Engineers)*oiler and Pressure +essel !ode
ASME SE & ,1 Pressure &essels
ASME (3163 Process Piping
ASME (3164 Li$uid Transportation S.ste%s "or
H.drocar8ons
ASME (3167 as Trans%ission and ,istri8ution Piping
S.ste%s
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3 Instructions
.% "efinitions
-ot Tap The technique of attaching a welded branch fitting to piping or
equip#ent in service, and creating an opening in that piping or equip#ent
by drilling or cutting a portion of the piping or equip#ent within the
attached fitting.
.$ (eneral &equire#ents
.$.% -ot tap connections shall be designed and installed to #eet all
require#ents of this SAEP, and SAES/0/12$, 3-ot Tap
!onnections3.
.$.$ The hot tapping operations are initiated, designed, and controlled
by
.$.$.% 4perations Engineering 4rgani5ation in the case of e6isting
facilities.
.$.$.$ Pro7ect anager with the approval of the Area 4perations
Superintendent and 4perations Engineering (eneral
Supervisor) Superintendent in the case of tying in newinstallations to e6isting facilities.
.$. The appropriate #anage#ent shall appoint an Initiating Engineer.
The Initiating Engineer shall be #ade responsible for the overall
coordination of the hot tapping activities. This is to ensure that
designers, construction)#aintenance installation unit, hot tap,
stopple and valve crew, operations and)or pro7ect #anage#ent,
engineering staff, and inspection staff cooperate closely during all
phases of the hot tapping operations.
.$.8 The Initiating Engineer shall identify the equip#ent in ter#s ofservice, location, pipe dia#eter, header and branch pressure
rating, and #aterial type and notify the -ot Tap, Stopple and
+alve 9nit of this infor#ation.
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.$.2 The construction or #aintenance units are responsible for
ensuring that approved welding procedures and qualified welders
are e#ployed. The Piping : +alves 9nit):!E")!S" shall
verify this.
.$.; 'or carbon steels with #ini#u# specified yield stresses less than
or equal to ;1 ksi, pre/approved welding procedures #ay be used.
.$.< 'or carbon steels with #ini#u# specified yield stresses greater
than ;1 ksi, the !onsulting Services "epart#ent shall be contacted
for welding procedure approval.
.$.= 'or hardenable or high strength steels and for piping where pipe
or fitting wall thickness requires preheat, the !onsulting Services
"epart#ent shall be contacted for welding procedure approval.
.$.> !o#pressed air piping and equip#ent shall not be hot tapped nor
welded while in service. &efer to SAES/0/12$, paragraph 8..
.$.%1 -ot tapping lines upstrea# of rotating equip#ent shall be avoided
unless such equip#ent is protected fro# the cuttings by #eans of
filters or traps. The nor#al in/line suction screens are not
considered adequate for this purpose.
.$.%% -ot tap connections are not allowed for certain cases ?refer to
SAES/0/12$paragraph 8.%@, unless a detailed design and
installation procedure has received prior approval fro# the
anager of !S" and concurrence fro# the 0oss Prevention
"epart#ent.
.$.%$ All hot tap connections, valves, and hot tap #achines shall be
pressure tested in accordance with this SAEP. ?&efer to Para. .=@
.$.% Precautions against electric shock, due to induced voltage, shall be
taken when installing hot tap connections on above ground
pipelines near high voltage power lines. &efer to SAEP/%1,3
Pipelines &epair and aintenance3.
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.$.%8 Adequate support of the hot tap #achine shall be provided to
prevent overstressing of the pipe and)or fitting, particularly in
cases where the hot tap sticker is not installed in a vertical position.
.$.%2 -ot tapping shall not be per#itted
a@ within 82< ## ?%= inches@ of a flange ?or threaded
connection@ as #easured fro# the toe of the reinforce#ent
sleeve, or split tee circu#ferential fillet weld to the toe of the
flange circu#ferential butt weld ?or the closest edge of the
threaded connection@
Commentary Note:
If this requirement can not be met the placement of the hot
tap may be positioned closer than 457 mm (18 inches)
proided there is enou!h room to allo" for the installation#
operation and remoal of the hot tap machine# and the
remoal of the pipin! or pipeline flan!e bolts$
b@ within %> ## ?1.
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.$.%;. -ot tapping is not per#itted on cone or floating roofs of
in/service tanks.
.$.%;.8 4n tanks, connections larger than $ inch BPS require
written approval of the anager, !S".
.$.%< Chen hot taps are being #ade to obtain coupons for -I!
deter#ination, the Saudi Ara#co 'or# SA Appropriate barricades and warning signs shall be posted around
the worksite to #ini#i5e the nu#ber of personnel in the work area
while perfor#ing the hot tapping operation.
.$.$1 !o#pact steel gate valves with e6tended body ends shall not be
used for hot tap connections.
. Precautions against -$S and other To6ic)-a5ardous aterials
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
..% If a potential e6ists for a -ydrogen Sulfide ?or other To6ic
#aterial@ release at a work site, all personnel involved shall be
provided with an appropriate breathing apparatus. ?&efer to (I/
%
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.8 Preparation of -ot Tap Specification and Test !alculations
.8.% The Initiating Engineer shall provide 'or# SA
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Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.2 0ocate and Inspect -ot Tap Position
.2.% The Initiating Engineer shall #ake all necessary arrange#ents for
the preparation of hot tapping ?i.e., location, e6cavation, pipe
inspection, surface preparation, etc.@
.2.$ The Initiating Engineer shall arrange for a tea#, consisting of
hi#self, operations, the responsible inspector, and a representative
of the -ot Tap and Stoppling crew, to survey the general hot tap
location in order to specify and #ark the hot tap locations in
detail.
.2. The Initiating Engineer shall #ark of the e6act hot tap locations,
and #ark the hot tap nu#ber alongside each hot tap location,
ensuring the hot tap locations are at a position where the pipe out/
of/roundness does not e6ceed ##. ?4ut of roundness criteria
only applies to split tee or full encircle#ent sleeves@.
.2.8 The hot tap nu#ber is obtained fro# 'or# SA
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
%hen hot tappin! components containin! non&ha'ardous material
such as "ater at less than 14 *+a (15 psi) and belo" ,5-C#
then the components "ith "all thic*nesses less than 5 mm ($.
inch) may be hot tapped proided precautions a!ainst burn&
throu!h are ta*en$ (/0I C2N3I/I2N /I 6I6 9 %9I6
/2 ;6 +2C663 /0 C3)$
.2.< If ultrasonic readings indicate a la#ination or evidence of
hydrogen induced cracking ?-I!@ da#age, the hot tap position
shall be relocated after consultation with the Initiating Engineer
and the responsible 4perations Engineering 4rgani5ation. !S"
and the proponent group shall be notified of this condition.
.2.= The Piping : +alves 9nit):!E")!S" shall co#plete Section
of for# SA
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Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
"rawings and specifications prepared by the responsible
engineering group shall include the length, dia#eter, wall
thickness, flange rating and #aterial of the new connection plus
the type and di#ensions of the connection reinforce#ent, if
required ?&efer to Std. "wg. A*/1;@ and the Celd Procedure
Specifications approved by the !onsulting Services "epart#ent.
.;. After the responsible engineering group has obtained the
appropriate approvals, a record copy shall be retained in a
per#anent central file, and the design package forwarded to the
Initiating Engineer for construction.
.;.8 4nce approval is obtained, the Initiating engineer shall distribute
copies of each 'or# SA
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.;.; The Initiating Engineer is responsible for revising e6isting Saudi
Ara#co drawings, P:I"s, or preparing new drawings, as #ay be
required, as a result of the hot tap installation.
.< Safety &equire#ents
.$8/$@ shall
have recorded under the 34ther precaution3 section the #a6i#u#allowable line pressure, #ini#u# and #a6i#u# flow rates, and
level li#itations during welding)cutting plus the nu#ber of this
SAEP.
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.=. a6i#u# hydrostatic test pressure applied to the branch ?or hot
tap@ connection shall be in accordance with SAES/0/12$,
paragraph D! is not per#itted unless approved by the anager,
!onsulting Services "epart#ent.
.=.2 -ot tap connections installed on hot lines where hydrostatic testing
with water is not practical shall be hydrostatically tested using
high te#perature turbine oil or silicone fluid, as follows
$ine Temperature %&drotest Fluid Stock 'o(
93:C to 290:C Tur"ine 4il 2;-001-330
2;-001-3%0
45er 290:C Silione
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
Commentary Note:
Chec* to ensure compatibility of fluids used in hot tappin! "ith
that of the line bein! hot tapped$
.=.; A body and high pressure seat test ?on both sides of the seat@ shall
be perfor#ed in the shop on all hot tap valves prior to installation.
&esilient ?soft@ seat valves shall have 5ero leakage. +alves with
#etal to #etal seats shall #eet the leakage criteria of API ST" 2>=.
A back seat test and low pressure seat test is not required. A tag
shall be attached to the valve indicating test date, test pressure and
Inspectors na#e.
Commentary Note:
/his seat test does not apply to sand"ich ales$
.=.< After installation of the branch connection, but prior to installing
the reinforcing pad or full encircle#ent ring, a full hydrostatic
pressure test shall be applied to the branch connection. This test
pressure shall be the lower value shown in 8.8c or 8.8e on Saudi
Ara#co 'or# SA
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Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.=.> Install the hot tap valve and apply another high pressure closure
test ?seat test@ per para. .=.; above, with the valve in the closed
position. The test pressure shall be the lower value shown in 8.8c
or 8.8d on Saudi Ara#co 'or# SA
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.>.$ a6i#u# internal pressure of the piping)equip#ent during
welding shall be in accordance with SAES/0/12$paragraph 2. on
welding of pipelines under pressure. A positive pressure and flow
shall be #aintained at all ti#es while welding and hot tapping is in
progress.
.>. The #ini#u# flow rates per para. .>.8 or the #a6i#u#
attainable flow under nor#al working pressure, whichever is less,
shall be #aintained during all welding operations.
.>..% 'low in a line shall be #aintained while welding is being
perfor#ed, unless approved otherwise by the
4perations Superintendent. In certain cases, such as
flare lines with insufficient or inter#ittent flow, the line
shall be purged with stea#, inert gas, or hydrocarbon
gas. This stea# or gas shall be kept flowing through the
line during the entire welding operation.
.>..$ In syste#s where hydrocarbon and o6ygen #i6tures are
definitely not a possibility, flow is not required ?e.g., sea
water in7ection lines@. -owever, to weld with 3B4/
'04C3 conditions, the following #ust be satisfied
.>..$.% 'or new construction tie/ins to e6isting
lines, approval shall be obtained fro# the
responsible Pro7ect anager, (eneral
Supervisor)Superintendent 4perations
Engineering, and the 4perations
Superintendent.
.>..$.$ 'or nor#al #aintenance tie/ins to e6isting
syste#s not involving new construction,
approval shall be obtained fro# the
(eneral Supervisor)Superintendent
4perations Engineering, and the
4perations Superintendent.
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.>..$. Prior to and during any welding,
4perations shall verify a non/co#bustible
#i6ture in the line. This shall be stated in
the re#arks section of the Cork Per#it.
.>.8 a6i#u# and #ini#u# flow rates during hot tapping shall be as
follows
a4 5i6uid 7 0'0 m8se" minimum
o)P#ase '30 m8se" maximum
b4 as 0'0 m8se" minimum
9'!0 m8se" maximum
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
however, if the branch connection si5e is less than 21F of the si5e
of the line being hot tapped, then the #ini#u# values do not apply
but a positive flow shall be #aintained.
Commentary Notes:
1) /$3$ %illiamson has established the aboe ma>imum flo" elocity
in lines durin! the hot tappin! operation$
.) mall diameter hot taps (i$e$# . inch and less) hae no ma>imum
or minimum flo" limitations$ +ressure requirements still apply$
.>.2 Chile hot tap work and pressure testing is in/progress, an operator
shall re#ain in a location where he can control operating
conditions such as flow, pressure, and liquid level within the li#its
specified in the hot tap design infor#ation. An additional operator
shall standby at the 7ob site while the work is in progress, if
dee#ed necessary by the 4perations Superintendent. !ontinuous
radio co##unications between the 7ob site operator and the
!ontrol &oo# is required.
.>.; Cork shall be i##ediately stopped when constant flow and
pressure as noted in paragraphs .>.$ and .>. cannot be
#aintained during the welding and hot tapping operations.
Pressure testing shall also stop if pressure in the header )
equip#ent is lost.
.%1 -ot Tap 'ittings)Sandwich +alve Installation &equire#ents
.%1.% The Initiating Engineer shall coordinate all activities.
.%1.$ The 4perations Superintendent shall ensure co#pliance with the
safety precautions arranged under paragraph .> of this SAEP,
including acceptance of the work per#it.
.%1. The Inspector shall perfor# the following
.%1..% +erify a !S" approved welding procedure specification
is utili5ed for installation of the connection ?&efer para.
.2.>@.
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Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
.%1..$ +erify that .$ ## dia#eter cellulose weld electrodes
are utili5ed only for the root pass and low hydrogen
electrodes are used for all other passes for carbon steel
branch connection welds.
.%1.. Inspect the branch connection)split tee, before and
during the installation, for co#pliance with the
approved drawings and welding procedures.
.%1..8 +erify that a calibrated pressure gauge and relief valve
are properly installed for testing.
.%1..2 !onfir# that the hydrostatic test pressure for the
branch connection is correct at the ti#e of the test, as
prescribed in Section 8 of 'or# SA +aint>
Beneral &e=uire$ents are $et! Constr
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
%!11!3 C)e* t)at t)e loation of t)e installation is t)at 4pers>+aint>
loation speified "y t)e initiatin. En.ineer 8it) t)e Constr
onurrene of t)e 4perations Supt!
%!11!% 4"tain an appro5ed Hot ?or* Per$it, Saudi Ara$o Init! En.>+aint>
CS#>
flus) 8it) t)e surfae of t)e pipe ta*in. are not to Constr
redue t)e pipe 8all t)i*ness! C)e* pipe 8all
t)i*ness ensurin. it does not 5iolate para! 3!!;!
%!11!; Ensure t)e pressure and flo8 re=uire$ents as identified Init En.>CS#>
in setion % of Constr
prior to any 8eldin.! 4pers
%!11! Po8er 8ire "rus) t)e area for atta)$ent 8elds to +aint>Constr>
re$o5e all traes of paint, rust and sale! T)e fit-up CS#
of t)e onnetion to t)e )eader s)all pro5ide for a
standard pipe "e5el and 1>1; in) $ini$u$ root .ap!
Install t)e nole or "oss onnetion usin. full
penetration 8elds in t)e e'at loation s)o8n on t)e
Page 2$ o& $$
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
appro5ed dra8in., usin. a =ualified 8elder and a CS#
appro5ed 8eldin. proedure! T)e Pipin. 7 Fal5es (nit>
+7CE#>CS# 8ill 5erify proper 8eld oint fit-up!
%!11! Ensure t)at t)e nole onnetions are not 8elded on CS#>Init En.>
t)e inside unless t)e )ot tap utter is at least one pipe +aint>Constr
sie s$aller t)an t)e nole! T)e utters so$eti$es
"rea* if t)e ut is $ade t)rou.) a 8eld!
%!11!9 Pre)e* t)e tappin. 5al5e and t)e )ot tap $a)ine Hot Tap (nit
to assure .ood opera"le ondition, inludin. t)e utter
and oupon retainin. de5ie!
%!11!10 Confir$ t)at t)e s)op ratin. test of t)e )ot tap $a)ine CS#>Hot Tap (nit
is urrent per para! 3!!2!
%!11!11 +ount t)e 5al5e on t)e fittin. ensurin. t)at its ali.n$ent CS#>Hot Tap (nit
is 8it)in t)e $anufaturerGs tolerane
%!11!12 Close t)e 5al5e and perfor$ t)e )ydrostati test +aint>Constr>Hot
aordin. to t)is instrution! Tap>CS#
%!11!13 C)e* t)e 5al5e "y openin. and t)e )ot tap $a)ine Hot Tap (nit>+aint>
for opera"ility and e'a$ine t)e ondition of t)e utter Constr
and oupon retainin. de5ie!
Page 2 o& $$
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
%!11!1% +ount t)e )ot tap $a)ine on t)e 5al5e! Hot Tap (nit>+aint>
Constr
%!11!1 Ensure t)at t)e tappin. 5al5e is tested in aordane Hot Tap (nit>CS#
8it) para.rap) 3!!9 and 8ill easily pass t)e )ot tap
utter! T)is $ay re=uire .rindin. of t)e lu.s on t)e
5al5e seat rin.s to pro5ide ade=uate learane!
Ensure t)at t)e di$ension fro$ t)e fae of t)e 5al5e
flan.e to t)e surfae to "e )ot tapped 8ill per$it
enou.) utter tra5el to o$pletely ut out t)e oupon
and not tra5el to t)e opposite side of t)e )eader!
%!11!1; Apply )ydrostati and pneu$ati pressure tests to t)e Hot Tap (nit>ICS#>
)ot tap $a)ine, 5al5e, and 8elded onnetion in +aint>Constr
8it) t)e testin. proedure speified in t)is SAEP and
SAES--02, para.rap) !
%!11!1 Install and seal 8eld a t)readed plu. in t)e 8eld "oss +aint>Constr
on t)e onnetion after all testin. )as "een o$pleted!
&efer to para.rap) 3!!12
%!11!1 After asse$"ly of t)e )ot tap $a)ine on t)e tappin.
5al5e and "efore t)e tappin. operation is started6
Page 23 o& $$
http://var/www/apps/conversion/tmp/scratch_4/..%5C%5CSaes%5C%5CAESL052.RTFhttp://var/www/apps/conversion/tmp/scratch_4/..%5C%5CSaes%5C%5CAESL052.RTF -
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
%!11!1!1 Co$pletely lose and t)en o$pletely open Hot Tap (nit
5al5e to ensure t)at it Is opera"le, and t)at
t)e utter an "e 8it)dra8n a suffiient
distane to per$it losure of t)e 5al5e!
%!11!1!2 Set t)e utter tra5el indiator to pre5ent o5er Hot Tap (nit
tra5el and onse=uent da$a.e to t)e opposite
side of t)e )eader "ein. )ot tapped!
%!11!19 #rill and ut oupon! Hot Tap (nit
%!11!20 &etrat t)e )ot tap $a)ine "orin. "ar! Hot Tap (nit
%!11!21 Close t)e 5al5e, pur.e 8it) nitro.en, if re=uired, and Hot Tap (nit
depressurie t)e )ot tap $a)ine adaptor!
%!11!22 &e$o5e t)e )ot tap $a)ine fro$ t)e line! Hot Tap (nit>
+aint>Constr
%!11!23 &e$o5e t)e oupon fro$ t)e pilot drill and ta. and Hot Tap (nit>
8ire t)e oupon to t)e tappin. 5al5e on t)e onnetion +aint>Constr
after )ot tap is o$pleted!
%!11!2% T)e oupon s)all "e re$o5ed only "y t)e 4perations 4pers
Super5isor and for8arded to t)e responsi"le 4perations
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
Pipin. 7 Fal5es (nit>+7CE#>CS#!
%!11!2 Ensure t)at t)e o$pleted onnetion is "linded or Hot Tap (nit>CS#>
plu..ed "efore lea5in. t)e o" site! +aint>Constr
*e+ision Summar&
1 #een5er, 199;Editorial re5ision to on5ert dou$ent to ne8 for$at!
30 Septe$"er, 199 +inor re5ision to para.rap)s 2, 3!1, 3!2!9, 3!2!11, 3!2!1, 3!;!1, 3!;!2, 3!!3, 3!!; 7 3!9!2
29 April, 199 Added BI-10!001 in t)e referene!
29
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
Appendi, I - .ltrasonic T/ickness 0easurements
1ot ap ;
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
STICE* 0EAS.*E0E'T
+in6 +a'!6
CA
B
ED
FLOW
D E 4CATI4D-------#ESC&IPTI4D
Point A------------ran) Center
Cirle -----------ran) #ia$eter
Cirle C-----------&einfr! Pad #ia!
- ----------&ESP4DSIE PIPIDB 7 FAFES (DIT>+7CE#>CS#6 EDBIDEE&6
&E
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
Page $0 o& $$
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
Appendi, II - %ot Tap C/ecklist
This checklist should be used as a re#inder to acco#plish the steps in order, but
should not be considered as including all preparation steps which #ay be dictated
by the particular circu#stances of the 7ob. It should be kept as a part of the final
docu#entation package.
04!ATI4BGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG
"ATEGGGGGGGGGGGGGGGGGGGG
*efore Starting -ot Tap
%. -as the properly approved work per#it been obtainedH
$. "oes the tapping #achine have a suitable pressure and te#perature rating
for the 7obH
. -as the e6act location of the hot tap on the line or vessel been identified or
#arkedH
8. -as the area to be welded been inspected for thickness and freedo# fro#
la#ination or -I!H
2. -as the need for stress relieving the weld area been consideredH
;. "o the flanges, bolts, gaskets, pipe, and valve to be installed #eet the piping
code for the line or vessel to be hot tappedH
. -ave co#bustible and)or to6ic gas tests been conducted in the area of hot
tappingH
%1. -as the che#ical co#position of the contents in the line or vessel been
considered to avoid welding or equip#ent containing fla##able #i6tures,
hydrogen or che#icals which could affect #etal strengthH
%%. Is the contents in the line stable under heated conditions and free of o6ygenH
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
%$. -as fire fighting equip#ent been providedH
%. -as suitable protective equip#ent been provided to all e6posed personnel in
the hot tap areaH
%8. Is the area to be hot tapped located below the liquid level of a tank or on a
line or piece of equip#ent in which fluid flow has been establishedH
*efore Starting Celding
%. Is preheat of the weld area requiredH
$. Is the fitting properly positioned so #isalign#ent of the hot tap #achine willnot occurH
*efore Starting !utting
%. -as the weld been testedH
$. -ave the hot tap valve, gaskets, and bolts been checked for possible leakageH
. -as the packing on the hot tap #achine been checkedH
8. -as the bleed off valve been checked to be sure it will hold and is not stopped
upH
2. Are all bolts on the cutter and pilot bit tight and is the coupon catcher on the
pilot bitH
;. Is the valve centered on the flangeH
. -as the pressure and te#perature of the contained #aterial been reduced as
#uch as the process operations will allowH
%1. Is there liquid or flowing gas in contact with the area to be hot tappedH
*efore &e#oving the -ot Tap achine
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.o"ument %esponsibility: Piping S(/P)$!!
Issue .ate: 29 anuary, 200$
Next Planned pdate: ! Mar"#, 200$ Installation o& 1ot apped Conne"tions
%. 'ollow the #anufacturers instructions to be sure the boring bar is fully
retracted before closing the valve.
$. !lose the valve.
. ake sure any necessary nitrogen purging is co#pleted.
8. 4pen the bleeder valve and be sure all pressure is off the hot tap #achine
before re#oving bolts fro# the flange. If flow or pressure persists, the #ain
valve is probably leaking.
2. &e#ove the hot tap #achine fro# the tapping valve.
;. &e#ove the coupon and fro# the pilot drill and wire to the tapping valve.
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