Requirements in Executing A Hot Tap - ION PRO
Requirements in Executing A Hot Tap - ION PRO
1. Introduction
This article details the technical and safety requirements for
executing a hot tap on hydrocarbon pipelines, piping or tanks.
Hot tapping has found wide application in the oil and gas sector. It is
often difficult to shut down pipelines due to disruptions it causes in
product supply to customers and other facilities. Hot tapping can be
used to tie in new connections to an existing pipeline in operation
without disruption to flow. And in combination with line plugging can
be used to divert flow around a pipeline or piping section that is
under repair or maintenance.
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etc.
Material Take-off. This is a document that will aid the procurement
of all materials required to execute the hot tap successfully. It will
show the required quantities of valves, bolts and nuts, flanges,
pipes for branch connection, etc.
Safety plan and documentation which shall include a detailed Job
Hazard Analysis. The safety plan should, at minimum, cover
escape routes, firefighting, safety equipment, gas detectors and
first aid facilities.
Transportation procedures. Shall cover how the hot tap machines,
components and personnel will be transported to and from the
site. This can become crucial if the hot tap location is remote or
hard to reach.
Site preparation procedures. For hot tap locations in congested
areas, the site shall be cleared. In the absence of an access road to
the hot tap location, temporary roads shall be created (if feasible).
For buried pipelines excavation shall be carried out around the
pipeline.
Hot tapping procedures. The procedure shall indicate the general
information about the activities, including the angle of tap,
machine operation procedure, etc.
Welding procedures. The welding procedure is a critical document
showing the type of welding, type of electrodes to use for welding,
welding current, requirements for preheating, welding
temperature, welding machines, etc.
Non-Destructive Testing (NDT) procedures. This document usually
will highlight how the welded joints integrity shall be validated. It
may cover activities including hydrotest, UT, MPI, etc.
Hydrotest procedures. This may be part of the NDT Procedure or a
stand-alone document. This will show the test pressure, medium
to use for the test, duration of the test, etc.
Hot tap checklist. A summary of all the activities that have to be
completed before the commencement of hot tapping. It is usually
in a tabular form with activities completed checked and the
personnel responsible indicated.
Hot tapping close-out report. After successful completion of a hot
tap the close-out report is a summary of all activities that where
performed, a summary of lessons learned etc.
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The pipe material and the fittings used for the hot tapping
operation shall be compatible with the material of the run pipe.
The pipes and fittings shall have a rating equal or higher than that
of the existing run pipe.
Welding procedures shall be prepared and reviewed by an
experienced engineer to confirm that the welding can be
successfully performed on the pipeline or piping.
Hot tapping shall be performed preferably in position vertically
downward on horizontal pipelines. Before an angled hot tap is
performed a detailed job hazard analysis and technical analysis
shall be performed.
Hot tapping and welding should not be performed on flare/vent
lines because there is the possibility of oxygen ingress, thereby
leading to the formation of flammable mixture. If tapping must be
performed on flare lines, it must be confirmed that the line is free
of oxygen ingress – if this cannot be confirmed the line must be
continuously purged with inert gas or steam during a welding
operation. Gas detectors shall be used to check continuously for
oxygen and other hazardous gas ingresses.
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Note, when the flow rate is too high, there is a tendency of rapid
cooling of the welding area, which will affect the welding process and
weld quality.
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Also, the thickness of the pipeline goes a long way in influencing the
success of the hot taping operation. For pipelines with thickness less
than ¼ in the probability of burn-through occurring is very high.
However, this may be mitigated to an extent by maintaining an
appropriate fluid flow rate, using electrodes with a diameter of 3/32
in or smaller for the first weld pass to limit heat input, etc.
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Hot tapping should only start after wall thickness verification has
been performed.
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TTD = VL + FL + CL + PBL
CL = Cutter Length
tap machine
1
manufacturer’s
operating instructions.
under heated
conditions?
Review manufacturer’s
instructions to ensure
that the hot tapping
8 machine has suitable
pressure, temperature
ratings, and adequate
cutter travel for this job.
welds, laminations,
hydrogen attack, or
other metallurgical
imperfections?
If laminations or defects
have been found, has a
thorough engineering
14 evaluation been made
by a qualified person to
determine if and how to
proceed with the work?
Is there sufficient
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external clearance to
install the hot tapping
18
machine and extract the
cutter through the
valve?
Is there sufficient
internal clearance to
18 retract the cutter and
coupon through the
valve?
20 Have oxygen,
combustible gas, and
atmosphere
contamination tests
been conducted in the
hot tap area?
Is there adequate
storage area and room
24 for operational needs
and emergency access
or egress?
implement the
contingency procedure?
FIRE
WATCH
DUTIES
INCLUDE:
Being able to
communicate effectively
1 Date Time
with personnel in the
area
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Trying to extinguish a
fire only when obviously
5 within the capacity of
the equipment available
(extinguisher or hose)
when available
equipment is not
sufficient to suppress a
minor fire.
EACH OF THE
FOLLOWING
CONSIDERATIONS Date Time
SHOULD BE SATISFIED
BEFORE WELDING:
EACH OF THE
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EACH OF THE
FOLLOWING
CONSIDERATIONS
SHOULD BE SATISFIED
BEFORE CUTTING:
EACH OF THE
FOLLOWING
CONSIDERATIONS
SHOULD BE SATISFIED
BEFORE REMOVING
Have the
manufacturer’s
instructions been
1 followed to be sure that
the boring bar is fully
retracted before closing
the hot tap valve?
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7. References
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