Reviewed: 09/06 Effective: 10/01/06 Revision: New Preparer: Health & Safety Member Owner: Health & Safety Manager Approver: Plant Manager Signed copy on file Signed copy on file Signed copy on file
Document Revision Change Table Revision Number Revision Description Revised By Revision Date New
Title: Hot Tap and Stopple Procedure Function: Health & Safety
BASF Corporation
Beaumont Site Beaumont, TX No.: BMEHS-002.016 Page:2 of 15
Reviewed: 09/06 Effective: 10/01/06 Revision: New
1. PURPOSE
To establish a clear set of guidelines to be followed when performing Hot Tap and Stopple installations.
2. DEFINITIONS
Coupon The part of the pipe that is removed during the Hot Tap operation.
Hot Tap The method of making a mechanical tie-in by welding an attachment to the pipe that is in service; then installing a valve and cutting a hole in the existing pipe through the new valve using a tapping machine specifically designed for such a purpose.
Stopple The installation of a flow-blocking device in a piping system that cannot otherwise be isolated depressurized or cleared.
Contractor the Company that supplies the Hot Tap and/or Stopple machine and its operating personnel.
Hot Tap/Stopple Document Package A collection of documentation required to obtain Hot Tap approval:
Weldment Calculation (if applicable) Hot Tap Penetration Calculation Hot Tap Checklist Form A (Sections 1 Hot Work & 2 Owner Approval) Hot Tap Checklist Form B Stopple Checklist Form C (If applicable) Piping and/or Structural Stress Analysis (if applicable) Welding Procedure Thickness Testing Report Dye Penetrant Testing Report (Stainless Steel tie-ins only) Deviation Approval(s) (if applicable) Piping Iso of tie-in (Hand sketch is acceptable) J SA (Provided by Operations) Approved MOC
Completion Plug - A metal plug sometimes installed in the tie-in piping after a stopple is completed, in order to isolate the process from the tie-in entry point without the use of a valve.
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)
J ob Coordinator Person assigned by the Operations Manager to coordinate a job. This is typically the Operations Coordinator.
Title: Hot Tap and Stopple Procedure Function: Health & Safety
BASF Corporation
Beaumont Site Beaumont, TX No.: BMEHS-002.016 Page:3 of 15
Reviewed: 09/06 Effective: 10/01/06 Revision: New
Maintenance/Construction Representative Person assigned by the TES Manager to follow a job, depending on whether the job is part of maintenance or a capital project.
3. SCOPE
Hot Taps and Stopples shall only be installed on piping that cannot be safely cleared and/or isolated due to operational and/or system design constraints. It must also be evaluated to see if the Hot Tap or Stopple could be avoided by delaying the job until an upcoming planned Outage or Turnaround. Any Hot Tap and/or Stopple must be part of an approved MOC with Hot Tap/Stopple Document Package and shall require a PSSR prior to being put into service.
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 TES 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.
Title: Hot Tap and Stopple Procedure Function: Health & Safety
BASF Corporation
Beaumont Site Beaumont, TX No.: BMEHS-002.016 Page:4 of 15
Reviewed: 09/06 Effective: 10/01/06 Revision: New
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. 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. 4.1.6 When feasible, Hot Taps should be made on the top of the pipe vs. the bottom, in horizontal pipe runs.
4.2 Design Considerations
4.2.1 All piping components used in a Hot Tap or Stopple installation shall be in accordance with the relevant Beaumont Site Piping Standards, with the exception of weldments which shall be in accordance with Table 1 of this procedure Any proposed piping component deviation will require approval from the TES Manager 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 required for Hot Tap and Stopple installations, the Hot Tap Contractor will supply the cutter diameter to be used for the Hot Tap and Stopple. BASF will confirm the cutter will fit through the valve without damaging the seat. These valves shall comply with the appropriate Beaumont Site Piping Standard. 4.2.4 The preferred method for completion of a Hot Tap and Stopple is a full port valve with a blind. If a completion plug is to be used in the case of a Stopple, the elastomer components shall require review and approval by the TES Group or Process Technology Group to ensure compatibility with the process. 4.2.5 The piping and supporting structure must have an engineering review of the stress loading from the weight of the hot tap and stopple machine. 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, the TES Group must review and approve. 4.2.7 The location of the Hot Tap should be more that 18 away from all flanges or threaded connections, plus more than three inches from any existing weld seam. Deviations from these requirements must have the approval of the TES Manager or designee. 4.2.8 The design of the hot tap will allow for adequate purging after the Hot Tap and Stopple is complete. 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER --
Title: Hot Tap and Stopple Procedure Function: Health & Safety
BASF Corporation
Beaumont Site Beaumont, TX No.: BMEHS-002.016 Page:5 of 15
Reviewed: 09/06 Effective: 10/01/06 Revision: New
4.3 Preparation
4.3.1 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 J SA, 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. 4.3.3 The 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 shall be taken 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 TES 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 If stress cracking is possible in the service, shear wave examination of the surface of a stainless steel pipe is required. If stress cracking exists, a qualified engineer/technician shall determine the suitability of the existing pipe for the Hot Tap. 4.3.6 The attainable flow velocity in the line being Hot Tapped shall be verified. 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. The TES Group shall evaluate required flow in vapor lines on a case-by-case basis. 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER --
Title: Hot Tap and Stopple Procedure Function: Health & Safety
BASF Corporation
Beaumont Site Beaumont, TX No.: BMEHS-002.016 Page:6 of 15
Reviewed: 09/06 Effective: 10/01/06 Revision: New
4.3.7 The WPS (Weld Procedure Specification) must be selected by the BASFs QA/QC department and attached to the checklist Form A. Welding will be performed by BASF site or Maintenance Contractor.
4.4 Hot Tap and Stopple Approval
4.4.1 Section 1 and 2 of the Hot Tap Checklist Form A shall be completely filled and approved as noted on the form, prior to the issuance of a hot work permit for the Hot Tap weldment. 4.4.2 In some cases several days or even weeks may elapse between the completion of the hot work step and the actual hot tap line cutting. Prior to issuing a Safe Work Permit for the Hot Tap, the Shift Supervisor and the Maintenance/Construction Representative shall sign off on the Hot Tap Checklist Form B, denoting the Hot Tap can safely commence. 4.4.3 The Hot Tap Checklist Form B shall be completed as the job progresses in the field. It is the responsibility of the Maintenance/Construction Representative to ensure the Contractor provides all required information and signs off in the sequential order noted. 4.4.4 Prior to issuing a Safe Work Permit for a Stopple, the Shift Supervisor, Contractor Representative, Maintenance/Construction Representative and J ob Coordinator shall sign off on the Stopple Checklist Form C, denoting the Stopple work can safely commence.
4.5 Hot Tap and Stopple Field Work
4.5.1 The J ob Coordinator together with the Maintenance/Construction Representative shall ensure the planned location of a Hot Tap as being correct and clearly marked in the field. The Hot Tap location shall have been cleaned as necessary to bare metal. This includes removal of paint, insulation, and any other debris that could interfere with potential Hot Tap operations. 4.5.2 The TES Manager, together with the Operations Manager, are responsible for ensuring that an emergency plan has been identified and communicated appropriately. The emergency plan must cover potential risks such as burn through during welding. Radio communication with the control room is required while installing a Hot Tap and while installing a Stopple. 4.5.3 All required documentation should be presented to the person issuing the hot work permit. 4.5.4 The person issuing the hot work permit shall confirm that no unusual process conditions exist, and the flow rate, temperature, and pressure ranges specified on the Hot Tap Hot Work Checklist A form exist in the field. 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER --
Title: Hot Tap and Stopple Procedure Function: Health & Safety
BASF Corporation
Beaumont Site Beaumont, TX No.: BMEHS-002.016 Page:7 of 15
Reviewed: 09/06 Effective: 10/01/06 Revision: New
4.5.5 A pressure test of the installation shall be witnessed by the Maintenance/QC representative upon completion of the Hot Tap welding. Valves utilized in conjunction with the Hot Tap shall be pressure tested prior to installation. 4.5.6 After completion of the Hot Tap/Stopple, the Maintenance/Construction Representative shall witness flow from the leak off valve on the Hot Tap/Stopple machine. 4.5.7 Before removing the Hot Tap/Stopple machine, the Maintenance/Construction Representative shall have the Contractor verify that the requirements of the Hot Tap/Stopple have been completed and have the technician sign the hot work permit prior to the removal of the Hot Tap/Stopple machine. 4.5.8 For maintenance jobs, the Maintenance Department will retain the complete Hot Tap Stopple documentation package on file for one month. For projects, the Project Manager will provide a copy of the documentation package in the project job books, upon completion. 4.5.9 The Maintenance/Construction Representative shall witness removal of the coupon. If the coupon is lost, he/she shall immediately notify the shift coordinator and initiate an Incident Report. The coupon shall be inspected by the J ob Coordinator and properly disposed of, if there is nothing unusual about its condition.
5. Responsibilities
Maintenance/Construction Representative Ensure Section 1 of the Hot Tap Checklist Form A is accurate and closely monitor Contractor activities in the field.
Job Coordinator Ensure process conditions needed to perform the job safely exist, and ensure adequate communication occurs between the Contractor, Maintenance/Project, and Operations. Ensure Section 2 of the Hot Tap Checklist Form B is accurate.
Contractor Provide equipment in good working order and properly trained personnel, in additional to strictly following all safety and operations rules and procedures. Complete Checklist Forms B and/or C if applicable.
Operations Manager Ensure there are no other alternative to performing the Hot Tap and/or Stopple work. Evaluate potential risks associated with the job and establish an emergency plan to cope with these risks.
TES Manager Ensure the job has been properly engineered and that all required preparations have been carried out.
Safety Department Manager Review the job scope and set-up in the field from a safety perspective to help ensure all identifiable precautions have been taken.
Title: Hot Tap and Stopple Procedure Function: Health & Safety
BASF Corporation
Beaumont Site Beaumont, TX No.: BMEHS-002.016 Page:8 of 15
Reviewed: 09/06 Effective: 10/01/06 Revision: New
6. 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 Beaumont Management of Change Procedure Beaumont Pre-Startup Safety Review Procedure Beaumont Hot Work Procedure 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER -- 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.
HEADER PIPE SIZE BRANCH SIZE 1" 1-1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 1" T or W
1-1/2" T or W T or W
2" W T or W T or W
3" W W T or W T 4" W W W T T 6" W W W T T T 8" W W W P T T T 10" W W W P P T T T 12" W W W P P T T T T 14" W W W P P T T T T T 16" W W W P P P T T T T T 18" W W W P P P T T T T T T 20" W W W P P P P T T T T T T 24" W W W P P P P T T T T T T T
SYMBOLS W - Integrally reinforced fitting (weld-o-let). T - Full encirclement split tee. P - Reinforcement 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 repad 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. Repads 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. 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER -- SECTION 1 (Hot Work) Hot Tap Checklist Form A To be completed by the Maintenance/Construction Representative Prior to Welding
Plant Section MOC No. ______________ Project No. ______________ MWO No. ______________ Existing Line To Be Hot Tapped:
Line Number: Pipe Specification: Design Pipe sch./thickness: ___________
Pipe Material: Corrosion Allowance: ___________ Actual Pipe sch./thickness: ___________
TES Manager or Designee Print Name: Signature: Date:
Safety Department Manager or Designee Print Name: Signature: Date:
A hot work permit CANNOT be issued if Sections 1 & 2 are not signed and/or there are any No answers. 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER -- SECTION 2 (Owner Approval) Hot Tap Checklist Form A To be completed by the Job Coordinator Prior to Welding
( ) Y ( ) N ( ) n/a Has a J SA been completed and attached to this form?
( ) Y ( ) N ( ) n/a Does the J SA address the risks associated with losing a coupon or introducing metal shavings?
( ) Y ( ) N ( ) n/a Does the J SA 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 J SA address measures to be taken if the stopple fails?
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:
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:
Job Coordinator Print Name: Signature: Date:
A hot work permit CANNOT be issued if Sections 1 & 2 are not signed and/or there are any No answers. 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER -- Hot Tap Checklist Form B
To be completed by the Hot Tap Contractor Prior to Drilling the Coupon
Valve Tested Before Installation? Y ( ) Name of Shop performing Test _______________________________ Pressure Test of branch weld: ( ) Hydro ( ) Pneumatic Test Pressure _________ psig ( ) Passed ( ) Failed ( ) Radiography ( ) Other __________________ ( ) Passed ( ) Failed ( ) n/a
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 Wt lb Max Working pr psig Test date__________
Boring bar travel set at " Do-not-exceed dimension " to prevent drill through
Coupon holding pins on cutter ( ) Y ( ) N Number ______
Machine bleed off verified: ( ) Y ( ) N
Coupon Retrieved: ( ) Y ( ) N
Signatures
Hot Tap Contractor Representative Print Name: Signature: Date:
To be completed by the Stopple Contractor Prior to Installing the Stopple
Machine support arrangement approved by the TES Engineer? ( ) Y ( ) N
Stopple o-ring material acceptable for service? ( ) Y ( ) N
Expected o-ring life at process conditions: ____________________
Stopple Machine Used Wt lb Max Working Pressure psig Test date__________
Machine support arrangement approved by the J ob Coordinator? ( ) Y ( ) N
Completion Plug to be used ( ) Y ( ) N; If yes, elastomer material: ___________________ If an existing completion plug is to be removed, the integrity of the o-rings must be verified before starting the job.
Prior to proceeding with the Stopple the above information shall be signed off, and radio communication established with the Control Room 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER -- HOT TAP MACHINE DIMENSION & CALCULATION SHEET
BRANCH TAP SIZE " FLANGE RATING lb DIMENSION DIMENSION DIMENSION TOPAZ WEIGHT SIZE " 'A' MAX " 'B' MIN " 'C' MIN " MODEL lbs 1 All 15 67 28 T-101 50 1-1/4 1-1/2 All 15 67 28 T-101 50 2 1-7/16 All 16 53 28 T-101 50 150 19 3 2-7/16 300 20 54 29 360 600 20 250
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.
1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER -- HOT TAP MACHINE
R T F A B C E D Adaptor Tapping Machine
Hot Tap Machine Used Pipe OD to face of valve flange (A) " Machine end to adapter flange (B) " Machine width (C) ". Check Clearance to operate machine ( )Y Valve flange to plug/gate (D) " Header pipe inside radius (R) " Header pipe nominal thickness (T) " Retract boring bar: adapter flange to drill tip (E) " E <D to allow valve to close ( ) Y Drill tip projection from cutter (F) ". F<R to prevent contact with back of pipe ( )Y. Boring bar travel - Drill to touch pipe OD (A-E) - = " Cutter to touch pipe OD (A-E+F) - + = " To prevent drill from going through other side of pipe: Do not exceed (A-E+R+T) - + + = " Only for size-on-size and one size smaller: Do not exceed (A-E+T+2R) - + +2 X = " Boring bar travel stops set to limit travel to " Boring bar travel is less than Do-not-exceed dimension ? ( ) Y 1:37 pm 01/31/2013 CONTROLLED DOCUMENT- 24 HRS -- UNCONTROLLED THEREAFTER --