Portable Works Limited

Hot Tapping Safety Procedure, and Checklist.

Before Welding/Prior to Hot Work/Tapping:

ABC (Always Be Careful)
• Has the correct pipeline or equipment upon which the hot tap is to be made and the correct
location been determined?
• Has the area to be welded been inspected for thickness and freedom from lamination,
hydrogen attack, or other metallurgical imperfections?
• Has the condition of the equipment or pipeline been ascertained?
• Is there sufficient external clearance to accommodate the operation of the hot tap machine?
• The preferred location for tapping is on top of the pipe so that the metal cuttings will fall into
the pipe to be carried off.
• When welding is done on hot equipment (over 400 degrees celcius) care should be taken that
the metal is not weakened to the point of failure.

Welding of the access fitting/Prior to Hot Tapping

• The Pipe will have been inspected and tested.
• The Access Fitting will have already been welded onto the line to be tapped.
• When welding is done on equipment or piping under a vacuum the welding procedure shall
be selected to avoid excessive temperatures that could result in structural collapse.
• Welding rods should be selected so that the deposited weld metal will
have yield and ultimate stresses at least equal to the lowest strength in the parent metal at
the joint.
• Attaching hot tapping connections to cast iron by brazing is not recommended except on low-
pressure water lines (less than 100psig). Bolted, clamped or screwed fittings may be used
without welding.
• Special welding procedures shall be used when welding on lines that contain hydrogen.
• The (Root pass and Final Pass of the) Weld will have been dye penetrant, magnetic particle
or ultrasonically tested to assure the quality of the weld meets the requirement of the ASME
standard.
• Has it been determined that stress relieving of the welded area is not required?
• The Access Fitting should be given a hydrostatic test prior to tapping usually
1-1/4 times the maximum operating pressure.
(If the operating temperature is above 93 degrees C and the saturation pressure of the steam
generated is above the hydrostatic test pressure, the test should be performed with a suitable
grade of oil.
When oil is used for a pressure test safety precautions should be taken to avoid a fire or
personnel injury from hot oil if a leak or failure of the newly welded connection occurs. Oil
should not be used above its auto-ignition temperature).
• A copy of the test results will be kept for records.
• The Access Fitting will be cleaned from weld slag, grease and dirt.
• The Inside of the access fitting pipe wall will be clean or interference noted.
• When cutting from the bottom there must be sufficient void under the valve to allow the metal
cuttings to fall and still retract the cutting head through the valve.
• When cutting in a horizontal position metal particles can get into the valve seat and prevent
tight closure. Junk traps are sometimes used, If the metal cuttings may cause interference
later on downstream.

Pre Checklist prior to Hot Tapping:

ABC (Always Be Careful)
Verify the LINE PRESSURE in writing
Verify the Fluid/Medium in the Line
Verify the temperature (RED FLAG if above 500 degrees F)
Verify the Access fitting rating
Verify the Pipe Wall thickness
Verify the Pipe Material

Is the fitting properly aligned at 90 degrees to the pipe.

A 9 kg Multipurpose Dry Chemical Fire extinguisher is required.
A fire blanket should be on hand.
The operability and pressure-temperature rating of the cutting machine shall be carefully checked
prior to use.
Is the full-bore/open port adequately pressure rated Valve on site?
Is the valve certified?
Has the valve been checked for damage whilst in transit?

Safety Precautions:
ABC (Always Be Careful)
• The operating pressure and temperature of equipment or piping being
Hot tapped should at no time exceed the rated pressure and temperature of the cutting
machine.
Ie: Make sure pressure in not in excess of tap machine rating.
• Care should be taken to ensure that neither pressure nor temperature will rise appreciably
during the hot tapping operation as a result of a surge of pressure or a temperature rise of the
fluid contents of the equipment being tapped.
• Flow in pipelines should be maintained during welding operations to reduce heat
accumulation.
• A minimum flow rate of 0.4 m/s(1.3 ft/s) is recommended in gas lines.
• Where flow cannot be maintained ascertain that the pressure relief valve is operational.
• It is recommended that the pressure be reduced one-third to one-half the normal operating
pressure during the tapping operation.
• The contents of storage tanks should not be circulated during hot tapping.
• There should be a three-foot minimum liquid level above the highest weld on the hot tap
connection-reinforcing pad.
• Hot tapping in the vapor space tank is permitted only when an inert gas blanket is
maintained.
• Even then frequent testing shall ensure that the gas in the vapor space is at no time in the
flammable range.
• On heated tanks heating coils shall be turned off during hot tapping.
• Have combustible and toxic gas tests been conducted in the area?
• Is there satisfactory room for operation and emergency access?
• A hot tap shall not be made on:
Vessels containing a flammable gas and air mixture.
Air receivers and air lines where lubricating oil may have entered the system resulting in a
hazardous atmosphere.
Equipment and piping in amine or caustic service where embrittlement could occur.
Equipment and piping in hydrofluoric acid service where iron fluoride could occur.
 Equipment containing acids, ammonia, chlorine, or chlorine compounds which the heat of
welding could cause to decompose.
Lines and equipment containing hot hydrogen and sour gas when hydrogen can cause
embrittlement of the welds.
Lines or equipment with cladding or linings such as glass, lead, refractory, plastic, or alloy
strip.
• Pits, Buildings, enclosures and confined spaces should be well ventilated
• All confined spaces should be tested prior to starting the work.
• Hot tap connections on pressure vessels should be no less than 460 mm (18 inches) to a
flanged or threaded connections or 75mm (3 inches) to a welded seam.
• Assurance should be taken that the hot tap equipment, including packing and elastomers will
not be affected adversely by the fluid in the pipe or equipment.

Checklist for Cutting the access:

• ABC (Always Be Careful)
• Calculate the surface distance from the outside end of the Valve to the inside diameter of the
pipe
• Note whether the tap is Vertical, Horizontal, or on the Bottom/Underside
• Check the inside condition of the access fitting to see if there is clearance
• Verify that there is clearance to mount the Valve, Tap Machine and allow for safe working
around the machine
• Verify that there is an escape route planned
• Verify that the floor area is clean of debris and of pedestrian traffic
• Rope the area off.
• Obtain a Hot Work Permit
• Determine that the tap machine has adequate cutter travel.
• Verify that the threads are clean on the inside of the access fitting

Steps for Hot Tapping (After following the steps above):

• ABC (Always Be Careful)
• Remove the protective cover from the Access Fitting
• Remove the plug from the access fitting
• Pour ½ ounce of cutting fluid/oil into the access fitting (for lubrication)
• The Cutter body may be filled with oil, which will lubricate the cutter, absorb heat, and
eliminate the air space.
• Oil should not be used when tapping air-lines. A pressure gauge should be installed
and functional to verify that the access has been made through the pipe-wall as well
as to ensure that the pressure inside the vessel is within the tap machine’s rated
capacity.
• Attach the RCS/Cosasco Tapping Valve and tighten onto the access fitting
• Open the Valve and visually inspect to determine that the port is open through the
access fitting.
• Do not over-tighten as this can swage the nipple or fitting diameter too small to set
the completion plug.
• The valve port should allow the completion plug to pass through.
• Has the bit been secured on the Hot Tap machine?
• Attach the Hot Tap Machine to the Tapping Valve. Ensure that there is a pressure
tight connection.
• Open and close the valve to ensure that it works un-obstructed.
• Ensure that the valve is in the full open position before continuing.
• Install bleeder valve and pressure gauge and vent away from personnel.
• Open bleeder valve and pressure for tightness and or pressuring in excess of line
that is being tapped.
 • Lock off valve. (Note it is normal practice to open the a bleed in the adapter, thereby
allowing the pressure in the pipe to urge out whatever air might be in the existing
components. The bleed off valve is closed as the product begins to appear and the
cut continues.
• Slowly advance the Hot Tap Feed tube in a clockwise direction to extend drill until it
makes contact with the pipe.
Begin the cutting process:
• Rotate slowly during last inch of travel to prevent damage to the drill tip.
• Turn feed tube Counter-clockwise ¾ turn to back-off drill bit.
• Attach the ratchet handle. For best results rotate the handle a full 360 degrees while
cutting. Turn clockwise only. Eight revolutions of the feed tube will lower the drill one-
inch.
• Cutting should always be at slow speed.
• The cutter should be extended through the valve opening to ensure that there is no
interference.
• Ensure that the valve can be closed when the cutter is fully retracted.
• Measure the cutter travel distance carefully and set the drilling length so as to ensure
that the opposite side of the pipe wall will not be scored.
• To cut 1/8” of the deposits/pipe-wall (This will remove any weld deposits)
• Cutting speeds will be approximately 0.006 to 0.025 inches per minute. Therefore a
½” wall pipe will take approximately 20 minutes at the fastest.

AFTER initial penetration into the line:

ABC (Always Be Careful)
• After breaking through continue feeding the cutter into the pipe for another ¼” to
remove any burrs.
• The flow should be maintained in the pipe to wash away cuttings and to remove heat
generated by the drill.
• The pressure will be felt due to the thrust load on the cutter and feed assembly.
• It will be necessary to turn the cutter slowly while doing this.
• When the pilot drill penetrates the pipe wall allow the product to fill the cutter and to
equalize the pressure.
• If machine stalls during tap, turn the feed tube counter-clockwise until drill is free.
Resume tapping (with slower speed) to clean burr from hole by turning ratchet handle
and reducing the rate of turning the feed tube.
• When second mark (total travel distance) is reached on the feed tube body tap is
complete. The “feel’ and rate of feed should confirm the tap to be complete. Rotate
the feed tube one complete revolution clockwise. Feed tube should turn freely.

Procedure AFTER cutting through:

• Close the tapping valve with a brass hammer
• Stand clear of bleeder valve
• Bleed off pressure trapped in valve adapter by opening bleeder valve on drilling
machine
• THE VENT ON THE MACHINE SHOULD BE OPEN TO RELEASE THE PRESSURE
prior to removing the machine.
• Unscrew the hot tap machine from the Tapping valve.
• The coupon is ready for insertion.
Care and Maintenance of the Hot Tap Machine:
ABC (Always Be Careful)
• The threaded areas should be inspected prior to job for nicks and kept lubricated.
• Minor thread repair should be done with thread files.
• Emery paper can be used to smooth the tops of the threads if they become sharp.
• The hot tap gland should be kept clean and lubricated.
• The Drill should not be re-sharpened.
• After high temperature taps (350 degrees F) or taps in corrosive fluids replace packing.
• Protect boring bar when machine is not in use
• After use clean and lubricate with oil
• Inspect holder, pilot for wear and damage
• Disassembly after 20 taps or every 60 days.