Engineering Services by KBR Technical Services, Inc

CONSTRUCTION STANDARD
PLANNING AND EXECUTION OF HOT TAPS
DATE: 01 APR 2003
ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.
5-2CS
PAGE 1 OF 12
TABLE OF CONTENTS
Section
1.
1.1
1.2
2.
2.1
2.2
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4.
Title
Page No.
GENERAL ......................................................................................................................................1
Scope..............................................................................................................................................1
Codes and Industry Standards .......................................................................................................1
CONSIDERATIONS/RESTRICTIONS ...........................................................................................2
Procedural Considerations/Restrictions .........................................................................................2
Flow Media, Operation Conditions, and Piping: Considerations/Restrictions ...............................2
PROCEDURE .................................................................................................................................4
Engineering Requirement ...............................................................................................................4
Welding ...........................................................................................................................................4
Branch Connection Design .............................................................................................................5
Pre-Welding Inspection and Testing...............................................................................................5
Authorization ...................................................................................................................................6
Hot Tap Set-Up ...............................................................................................................................6
Inspection and Testing....................................................................................................................6
Execution of the Hot Tap ................................................................................................................6
CHECKLISTS .................................................................................................................................7
APPENDIX 1: ENGINEERING HOT TAP DATA SHEET .............................................................8
APPENDIX 2: HOT TAP PRE-WELDING INSPECTION ...........................................................10
APPENDIX 3: CONTRACTOR HOT TAP CHECKLIST .............................................................11
1. GENERAL
1.1 Scope
1.1.1 This specification establishes procedures to be followed when it is necessary to weld on petrochemical
plant piping or equipment that is in service. It is intended to apply, whether a tap is drilled into the line or not,
when the purpose is to place a "stopple" in the line or when tapping into a line or equipment item that has been
taken out of service but has not been purged or cleaned. It may not cover all contingencies which may be
encountered and additional requirements or restrictions should be imposed if needed. This specification is
intended to apply to piping or equipment fabricated from ferritic and austenitic steel.
1.1.2 This specification is written to provide guidance and KBR requirements for hot taps. It draws heavily on
the requirements of API RP 2201 which should be reviewed in conjunction with this specification.
1.2 Codes and Industry Standards
1.2.1 The following documents are referenced herein:
AMERICAN PETROLEUM INSTITUTE (API)
API 570,
"Piping Inspection Code; Inspection, Repair, Alteration, and Rerating of In-Service Piping
Systems"
API 945,
"Avoiding Environmental Cracking in Amine Units"
API RP 2201, "Welding or Hot Tapping on Equipment in Service"
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)
ASME B31.3,
"Process Piping"
BATTELLE INSTITUTE, "Investigation and Prediction of Cooling Rates During Pipeline Maintenance Welding"
EDISON WELDING INSTITUTE, "Guide Lines for Welding Onto In-Service Pipelines"
DATE: 01 APR 2003
5-2CS
PAGE 2 OF 12
1.2.2 API Recommended Practice 2201, Procedures for Welding or Hot Tapping on Equipment in Service.
This recommended practice contains a number of reference publications which will be helpful in evaluating hot
tapping conditions.
1.2.3 The applicable standard for revamping piping is API 570, Piping Inspection Code: Inspection, Repair,
Alteration, and Re-rating of In-Service Piping Systems. The design of the hot tap nozzle should also be in
accordance with the original Code of construction of the piping system, such as ASME B31.3, however, use of a
later code is allowed.
2. CONSIDERATIONS/RESTRICTIONS
2.1 Procedural Considerations/Restrictions
2.1.1 Hot tapping piping in service can be performed safely provided proper planning is done and appropriate
procedures are followed. Conversely, there are opportunities for significant events if things are not done
correctly. Because of the nature of hot taps, the decision to execute a hot tap must be driven by the Owner,
with formal approval obtained.
2.1.2 When determining if a hot tap will be permitted the following considerations will be taken into account:
a.
The OSHA lockout/tagout regulation, 29 CFR 1910.147 (a)(2)(iii)(B) states that the OSHA lockout/tagout
regulation does not apply to hot taps when it is demonstrated that:
1.
2.
3.
4.
continuity of service is essential,

shutdown of the system is impractical,
documented procedures are followed, and
Special equipment is used which will provide effective protection for employees.
2.1.3 Planning and execution of a hot tap involves a number of different technology and craft areas, often from
different companies. Care should be taken to ensure that a responsible individual is identified to provide
oversight, including; planning, coordination, execution and approval verification for the entire process. A job
safety analysis is required for each individual hot tap and shall include the total team involved including the
Contractor, Subcontractor and Owner.
2.1.4 No "in service" welding shall be done on ASME Code vessels. The potential for jurisdictional problems,
as well as execution problems, (e.g. prediction of flow rates required for cooling during welding), prohibit KBR
approval of hot tapping ASME Code vessels.
2.1.5 Proposals for "in service" welding to equipment other than ASME Code vessels shall be reviewed by the
Office of the Chief Engineer. Procedures shall be reviewed by Construction Quality Management.
2.1.6 A detailed, written procedure for hot tapping shall be prepared before starting each job. The procedure
shall address the entire process from planning through approvals, execution, documentation and completion.
Checklists for documentation of data and approvals should be included. Suggested checklists as Appendixes 1,
2 and 3 are included in this document.
2.2 Flow Media, Operation Conditions, and Piping: Considerations/Restrictions
2.2.1 When determining if a hot tap will be permitted, the following considerations of flow media shall be taken
into account;
2.2.2 Welding or hot tapping should not be performed on piping which is:
a.
Operating at less than atmospheric pressure: Vacuum service introduces the potential for introducing air
into the process in the event of burn through.
DATE: 01 APR 2003
5-2CS
PAGE 3 OF 12
b.
Operating temperature greater that 450F (232C): As service temperature increases, the risk of burn
through increases. Welding can generally be performed on piping with operating metal temperatures up to
450F (232C) provided the material thickness is at least 0.25 inch (6 mm). When the working environment
is the only consideration for hot tapping above 450oF (232C) and a suitable environment can be assured,
hot taps may be done on lines to 500oF (260C).
c.
Is lined or has internal insulation
d.
Systems where post weld heat treatment is required
2.2.3 Hot taps into piping in any of the following services and similar services must be approached with care
and may be prohibited because of the special hazards in each case. Prior to permitting welding on such piping,
the hazards must be ascertained and evaluated and the steps to control them, introduced and enforced.
Hazards may be due to reactions within the system, either of the flow media or on the containment itself; as well
as those should leakage occur, to personnel, or the outside of the containment in the ambient environment.
a.
b.
c.
d.
e.
High Pressure Systems

Toxic Systems
Highly Corrosive
Flammable Mixtures
Combustible Mixtures
2.2.4 Specific cautions are provided for the following:

a.
The data listed below is to provide a background on the considerations for each of the services noted.
Exclusion of any process or identified risk should not be interpreted to mean that there are no risks or no
additional risks. Competent materials specialists should review all potential processes.
1.
Vapor/air or vapor/oxygen mixtures near or within their flammable explosive range. The heat of
welding may cause a vapor mixture to enter the flammable range.
2.
Hydrogen: High temperature hydrogen attack of susceptible materials such as carbon and alloy steels
which operate within the Nelson Curve criteria may have cumulative damage. Special techniques are
required to assess this damage prior to welding.
3.
Ammonia: Welding on gaseous ammonia at conditions which exceed 40 psig (275 kPag) or 100oF
(38C) or on liquid ammonia which exceed 200 psig (1380 kPag) or 100oF (38C) should be avoided.
4.
Peroxides, chlorine, ethylene oxide and propylene oxide or other chemicals which can violently
decompose or become hazardous from the heat of welding.
5.
Caustics, amines (rich/lean DEA/MEA), and acids (such as hydrofluoric acid), if the concentrations and
temperatures are such that the fabrication specifications require post weld heat treatment (PWHT).
These services may cause stress corrosion cracking in the weld area or the heat affected zone either
during or subsequent to welding depending on the concentration and temperature of the process.
Refer to API 945 for other services which may currently require PWHT but may not have originally. Hot
taps into lines containing caustic, caustic soda, sulfuric acid, hydrochloric acid (hydrogen chloride),
hydrofluoric acid, hydrogen fluoride, other strong acids and bases, and other highly corrosive materials
should not be performed. This is due both to the corrosive and hazardous nature of these materials
which may be enhanced due to exposure to atmospheric water/moisture should leakage occur.
6.
Certain unsaturated hydrocarbons such as ethylene, acetylene, butadiene and propylene or LPG
containing propylene. These may experience exothermic decomposition due to temperatures caused
by welding, creating localized hot spots on piping walls that could lead to failure.
DATE: 01 APR 2003
5-2CS
PAGE 4 OF 12
7.
Oxygen or oxygen enriched atmospheres. The amount of oxygen needed for an enriched atmosphere
varies with each products flammable limits. The oxygen may cause a vapor mixture to enter the
flammable range and may affect the base metal being welded. Also, lines containing pure oxygen can
burn internally if brought to ignition temperature.
8.
Compressed air, unless known to be free of flammables and combustibles, such as lubricating oil
residues.
9.
No flow lines which cannot rely on the heat of welding to be dissipated by the flow.
10. Hot taps into lines containing highly toxic materials such as acryonitrile, acetonitrile, acrolein, hydrogen
cyanide, and hydrogen sulfide should not be performed due to the highly toxic nature of these
materials. Also the nitriles and acrolein are highly reactive. Similarly lines which may contain reactive
residue should not be hot tapped because localized hot spots may cause line failure.
11. Hot taps on liquid sulfur lines should be avoided due to possible burn through caused by the high
operating temperature.
3. PROCEDURE
3.1 Engineering Requirement
3.1.1 The existing piping system should be reviewed to confirm the mechanical configuration, including size;
thickness and corrosion allowance, as well as materials and any heat treatment requirements. Design and
operating temperatures and pressures as well as flow media and rates should be reviewed and recorded. The
area of the proposed hot tap should be reviewed for accessibility of workers and equipment as well as for
emergency egress.
3.1.2 Confirm the size of the hot tap required. In some cases, an inch or less tapping machine can get hung up
in small valves. While a full size tap is specified pressure drop may allow a smaller connection. Review
potential problems if the coupon or metal shavings get into the piping system. The potential for interference
caused by movement of the line and surrounding lines as temperature cycles occur should be considered.
3.2 Welding
3.2.1 Some flow during welding for hot tapping minimizes the potential of several undesirable conditions.
Overheating liquids, burn through caused by elevated metal temperatures, and fluid thermal expansion in closed
systems are less likely when flow is maintained. However, higher flow increases the weld cooling rate and the
risk of cracking. Therefore, when welding, it is desirable to provide some minimum level of flow while avoiding
high flow rates.
3.2.2 The two primary concerns when welding on in-service piping are burn through and cracking.
a.
Burn-through will occur if the un-melted area beneath the weld pool can no longer contain the pressure
within the pipe. Operating and welding temperatures affect the possibility of burn-through. The welding
procedure should be based on experience on performing welding operations on similar piping and/or based
on heat transfer analysis. To minimize burn-through the first weld pass to pipe less than 1/4 inch (6 mm)
thick should be made with a 3/32 inch (2.4 mm) or smaller diameter low hydrogen welding electrode to limit
heat input. (Note: Use of low heat input levels can increase the risk of cracking in high carbon equivalent
materials.) Subsequent passes should be made with 1/8 inch (3 mm) diameter electrode, or smaller if the
metal thickness does not exceed 1/2 inch (12 mm). For piping wall thickness greater than 1/2 inch
(12 mm), where burn-through is not a primary concern, larger diameter electrodes may be used. Whenever
burn-through is a concern, care should be taken by avoiding the use of excessive welding current and
amperage at the welding lead should be monitored during the welding operation. In many situations the
use of low hydrogen electrodes may be preferable to reduce the possibility of burn-through.
DATE: 01 APR 2003
5-2CS
PAGE 5 OF 12
b.
Weld cracking results when fast weld cooling rates produce a hard, crack-susceptible weld microstructure in
susceptible steels and weldments. Fast cooling rates can be caused by flowing contents inside the pipe
which remove heat quickly. Consideration should be given to evaluating the expected cooling rate of the
weld to determine the heat inputs required to produce welds and heat affected zones which are free of
cracking.
c.
In order to minimize the possibility of burn through, hard welds or combustion, the following suggested
velocities limits usually apply:
d.
Liquids
1.3 ft/sec (0.4 m/s) minimum

4.0 ft/sec (1.2 m/s) maximum
Gases
1.2 ft/sec (0.36 m/s) minimum

No established maximum
Investigation and Prediction of Cooling Rates During Pipeline Maintenance Welding by the Battelle
Institute provides documentation for predicting these cooling rates. Additional information can be found in
"Guidelines for Welding Onto In-Service Pipelines" by W. A. Bruce PE, Edison Welding Institute.
3.3 Branch Connection Design

3.3.1 The new system should be designed considering the appropriate Code, design pressure and temperature.
The new system may require branch reinforcement. Stresses at the weld location, both residual and applied,
should be evaluated for any unusually high values. Reductions through lowering pressure or adding temporary
supports should be considered. Final system flexibility as well as physical clearances required for the "as
modified" system should be considered, clearances will be different as the "Hot Tapped" system cools for
shutdown, etc.
3.3.2 For a "size on size" hot tap connection, a full encirclement saddle is required. A split-tee type full
encirclement may be used, however, it shall be replaced with a straight tee at the first opportunity. Any fittings
shall be confirmed suitable for the pressure rating required as well as any additional external loads that may be
applied.
3.3.3 Any proposed fittings shall be confirmed suitable for the pressure rating required as well as any additional
external loads that may be applied.
3.4 Pre-Welding Inspection and Testing
3.4.1 The pipe is to be examined after the hot tap nozzle is designed. A detailed sketch should be given to the
inspector to clearly define the hot tap weld zones. UT examination is to be used to confirm there are no
lamination or step wise cracking present as well as to determine actual metal thickness. This is to minimize the
risk of burn through and insufficient mechanical strength. The final design and location of the hot tap can be
approved after the results of this examination are reviewed. Actual UT examination locations and results are to
be shown on this sketch.
3.4.2 The closure and body of the block valve shall be hydrostatically tested prior to installation.
3.4.3 The pressure-temperature rating of the hot tap machine should be confirmed suitable for the process flow
condition. The seals and materials of construction must be compatible with the contents in the piping. It should
be inspected to verify it is capable of satisfactory performance and could be left in service in the event of
mechanical problems or valve leakage. Dimension for operation shall be reviewed to confirm the cutter and tap
will not touch the opposite side and sufficient space for the coupon exists when retracted. The cutter shall be
inspected to assure it is free from defects and suitable for the service. A current test affidavit shall be provided.
The experience level of the machine operator(s) should also be reviewed.
3.4.4 Adequate lift and support equipment for the hot machine shall be considered.
DATE: 01 APR 2003
5-2CS
PAGE 6 OF 12
3.5 Authorization
Hot tap authorization is required. Owner's administrative controls and sign off authorization shall be followed. In
the event these are not available, direction shall be obtained from the Office of the Chief Engineer.
3.6 Hot Tap Set-Up
a.
Controls as required should be in place to assure process variables are monitored and controlled to the
extent necessary during the hot tap execution.
b.
All necessary testing for flammable vapors, oxygen, and hazardous air contaminants has been conducted
to insure a safe environment.
c.
Potential safety and health hazards have been assessed, a contingency plan has been developed and
reviewed with HSE (Health, Safety and Environment) operation personnel. Personnel protective equipment
has been provided and fire retardant clothing used as necessary.
d.
Confined space entry and hot work permits have been issued if the area in which the hot tapping or welding
is to be done requires such permits.
e.
A fire watch has been established and equipped with a suitable dry-chemicals fire extinguisher or
pressurized fire hose.
f.
Signs and barriers have been provided when warranted to isolate the job site from the public and
unauthorized personnel.
g.
Procedures have been prepared and are in place to isolate the work area in the event of an emergency.
h.
Provisions shall be made to assure that adequate containment and disposal provisions are available for
liquids and vapors which remain in the machine after the block valve is closed.
i.
Proper personnel protective equipment (PPE) for personnel performing the hot tap will be established by
Plant Safety and Operations.
3.7 Inspection and Testing

3.7.1 Where Code inspection and testing cannot be performed, supplemental inspection and testing methods
should be used. The weld connecting the new pipe to the existing pipe is generally not capable of being
radiographed. This weld should be either liquid penetrant or magnetic particle examined. Examination of the
root pass and the final pass is required.
3.7.2 The connection shall be pressure tested before the blank in the existing line is cut. Note that this
pressure test is in reality a leak test. It does not subject the branch connection to the same stress field as it will
experience after the blank is removed. The pressure stresses in the branch connection after the blank is
removed are expected to be considerably greater than that for a pressure test with the blank in place. This test
will be external pressure to that section of pipe so it must be reviewed to confirm it will not cause buckling to that
portion of the pipe. API RP 2201 recommends that the branch connection be tested at a pressure at least equal
to the operating pressure of the line being tapped but not more than 1.1 times the operating pressure present
prior to cutting the blank. A 15 psig (103 kPag) leak test of the reinforcing pad is typically performed.
3.8 Execution of the Hot Tap
a.
Welders and weld procedures shall be qualified and approved for the specific application and correct
welding consumable available. Amperage at the welding lead shall be constantly monitored during the
welding operation.
DATE: 01 APR 2003

b.
5-2CS
PAGE 7 OF 12
Assure that the fitting is supported and properly positioned so misalignment of the hot tapping machine will
not occur and the area is protected against environmental problems.
4. CHECKLISTS
a.
Engineering Hot Tap Data Sheet - Appendix 1 (Sheets 1 and 2)
b.
Hot Tap Pre-Welding Inspection - Appendix 2 (Sheet 1)
c.
Contractor Hot Tap Checklist - Appendix 3 (Sheets 1 and 2)
DATE: 01 APR 2003
APPENDIX 1
5-2CS
PAGE 8 OF 12
ENGINEERING HOT TAP DATA SHEET

(Sheet 1 of 2)
OWNER:______________________
JOB NO.:____________________________
TIE-IN NO.:__________________________
ENGINEERING COMPANY:__________________________________________________________________
CODE:_____________________________________________ DATA SHEET REF:____________________
HEADER/LINE NO.:_______________ SIZE:_____ SCHEDULE/WT.:_______________________________
FLUID:_________________________
PRESSURE:_______________ TEMP:________________________
BRANCH OR NOZZLE/SIZE:___________________________ SCHEDULE/WT.:______________________
LOCATION OF BRANCH OR NOZZLE:_________________________________________________________
REQUIRED MINIMUM THICKNESS OF HOT TAP AREA:___________________________________________
LINE PRESSURE REDUCTION REQUIRED:
YES ____ NO ____TO__________________________
LINE TEMPERATURE REDUCTION REQUIRED:
YES ____ NO ____TO _________________________
TEMPORARY STRAINER REQUIRED:
YES ____ NO ____
DESIGNATE TYPE AND LOCATION OF TEMPORARY STRAINER IF NOT ON DRAWING _______________
_________________________________________________________________________________________
FLOW RATE LIMITS:
MIN:_______
MAX:_______
PURGE GAS REQUIRED:
YES____ NO ____ NITROGEN _______
ARGON _______
PURGE GAS SPECIAL REQUIREMENTS SUCH AS DEW POINT AND PURITY (Normally Not Required):____
_________________________________________________________________________________________
HOT TAP MACHINE BLEEDER OUTLET:
TO ATMOSPHERE ____
PIPE TO REMOTE AREA ____
PIPE TO CLOSED BLOWDOWN SYSTEM: ________ DESIGNATE WHERE: _________________________
_________________________________________________________________________________________
BRANCH OR NOZZLE WELD EXAMINATION REQUIRED
RADIOGRAPHY:______________ ULTRASONIC:____________ MAGNETIC PARTICLE: _______________
LIQUID PENETRANT :_____________ HIGH TEMPERATURE LIQUID PENETRANT:______________
PRESSURE LEAK TEST REQUIRED
HYDROSTATIC____ PNEUMATIC____ NITROGEN____ AIR___ BUBBLE FORMATION __ or
ULTRASONIC DETECTOR____
TEST PRESSURE:________________________
SPECIAL REQUIREMENTS:
DATE: 01 APR 2003

APPENDIX 1
OWNER:
5-2CS
PAGE 9 OF 12
ENGINEERING HOT TAP DATA SHEET

(Sheet 2 of 2)
_______________________
JOB NO.:_____________________________
TIE-IN NO.:___________________________
OPERATIONS REPRESENTATIVE
GAS MASKS REQUIRED: YES____
WEAR:
YES____
OR
AVAILABLE FOR IMMEDIATE USE:
NO ____
NO ____
YES ____
SELF CONTAINED BREATHING APPARATUS REQUIRED:
NO ____
YES ____
NO ____
OTHER SPECIAL REQUIREMENTS:__________________________________________________________

________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
__________________________________________
OPERATIONS REPRESENTATIVE'S APPROVAL
______________
DATE
DATE: 01 APR 2003
5-2CS
PAGE 10 OF 12
APPENDIX 2
HOT TAP PRE-WELDING INSPECTION

(Sheet 1 of 1)
OWNER:___________________
DATE:_____________________
JOB NO.:__________________
TIE-IN NO.:________________
ENGINEERING DATA SHEET REFERENCE: _________________
ULTRASONIC EXAMINE THE AREA WHERE THE BRANCH OR NOZZLE WILL BE ATTACHED FOR WALL
THICKNESS AND LAMINATIONS. THE AREA INSPECTED SHALL INCLUDE ONE INCH INSIDE THE
BRANCH ID AND THREE INCHES OUTSIDE THE BRANCH OD. IF A REINFORCEMENT PAD IS
REQUIRED, ALSO EXAMINE THE HEADER WHERE THE PAD WILL BE WELDED ON ITS PERIPHERY.
ORIGINAL THICKNESS SPECIFIED: ___________Inches
MEASURED MINIMUM THICKNESS: ___________inches
ARE LAMINATIONS PRESENT?
YES ____
NO ____
ARE EXISTING WELD SEAMS

AT LEAST 3 INCHES FROM HOT TAP OD?
YES ____
NO ____
IS THE LOCATION SUITABLE FOR WELDING? YES ____
NO ____
PRINTED NAME AND SIGNATURE OF INSPECTOR: ___________________________________

DATE OF INSPECTION ____________________ NAME OF COMPANY _____________________
IF NOT SUITABLE, EXAMINE AREA TO LEFT OR RIGHT AS APPROPRIATE FOR RELOCATION.
DESCRIBE OR SKETCH SUGGESTED RELOCATION.
RELOCATION MEASURED MINIMUM THICKNESS: ___________inches
ARE LAMINATIONS PRESENT?
YES ____
NO ____
ARE EXISTING WELD SEAMS

AT LEAST 3 INCHES FROM HOT TAP OD?
YES ____
NO ____
IS THE LOCATION SUITABLE FOR WELDING? YES ____
NO ____
RELOCATION PER SKETCH IS SUITABLE

FOR WELDING?
NO ____
YES ____
PRINTED NAME AND SIGNATURE OF INSPECTOR: ___________________________________

DATE OF INSPECTION ____________________
NAME OF COMPANY __________________
REFERENCE NOZZLE LOCATION DRAWINGS
____________________________________
TRANSMIT THIS FORM TO ENGINEERING CONTRACTOR.
DATE: 01 APR 2003
5-2CS
PAGE 11 OF 12
APPENDIX 3
CONTRACTOR HOT TAP CHECKLIST

(Sheet 1 of 2)
OWNER:__________________________
JOB NO.:__________________________________
CONTRACTOR:____________________
TIE-IN NO.:________________________________
HOT TAP SUBCONTRACTOR:_______________________________________________________________
1.
VERIFY LINE NO. OR ITEM IS CORRECT AND

LOCATION CORRECT
2. VERIFY VALVE IS FULL OPENING TYPE
SEAT RING LUGS SHOULD BE REMOVED
IF REQUIRED FOR HOT TAP MACHINE
3. VERIFY VALVE PRESSURE TESTED (CLOSURE
AND PACKING) AND LEAK TIGHT
4. VERIFY HOT TAP MACHINE 'PRESSURETEMPERATURE RATING SUITABLE
5. VERIFY HOT TAP MACHINE MATERIALS AND
SEALS ARE COMPATIBLE AND SUITABLE FOR
FLUID SERVICE FOR EXTENDED TIME
6. VERIFY WORK AREA ISOLATION PLAN IS WRITTEN
7. VERIFY WELDING PROCEDURE APPROVED
8. VERIFY WELDER QUALIFIED AND INSTRUCTED IN
TECHNIQUE
9. VERIFY ALL PERSONNEL ARE PROPERLY
TRAINED IN FIT AND USE OF RESPIRATORY
PROTECTION REQUIRED AND PERSONNEL
ARE APPROVED FOR USE OF SAME
10. ATTACH APPROVED HOT TAP AUTHORIZATION
(Ref: 3.5)
11. VERIFY HOT TAP EQUIPMENT IN GOOD CONDITION
12. VERIFY "HOT WORK, AND CONFINED SPACE ENTRY
PERMIT" SECURED FROM OWNER'S OPERATIONS
REPRESENTATIVE
PRE-FITUP FOR WELDING
1. VERIFY PRESSURE REDUCED TO REQUIREMENT (BY
OWNER'S OPERATORS)
2. VERIFY UNNECESSARY PERSONNEL CLEARED FROM
AREA
3. VERIFY FIRE EXTINGUISHER AND/OR PRESSURIZED
FIREWATER HOSE REQUIRED BY PERMIT READY
AND WATCHES POSTED
4. VERIFY FLOW MAINTAINED IN LINES (BY OWNER'S
OPERATORS)
5. VERIFY ESCAPE ROUTE PLANNED AND ALL
PERSONNEL INVOLVED UNDERSTAND
6. VERIFY PERSONNEL HAVE REQUIRED BREATHING
APPARATUS
7. COMMUNICATIONS WITH OPERATIONS
ESTABLISHED
8. VERIFY PERSONNEL PROTECTIVE EQUIPMENT
SPECIFIED AND UTILIZED
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
DATE: 01 APR 2003
5-2CS
PAGE 12 OF 12
APPENDIX 3
CONTRACTOR HOT TAP CHECKLIST

(Sheet 2 of 2)
OWNER:__________________________
JOB NO.:__________________________________
CONTRACTOR:____________________
TIE-IN NO.:________________________________
HOT TAP SUBCONTRACTOR:_______________________________________________________________
POST BRANCH OR NOZZLE WELDING

1. VISUAL EXAMINATION
2. LPE ____ MPE ____ UT ____ RE ____
3. PRESSURE TEST ____
POST REINFORCEMENT PAD WELDING
1. VISUAL EXAMINATION
2. LPE ____ MPE ____ UT ____ RE ____
3. PRESSURE TEST WITH HOT TAP MACHINE
MOUNTED
PRE-HOT TAP
1. CUTTER AND PILOT BIT ARE SATISFACTORY
AND COUPON RETRACTOR FUNCTIONAL
2. REQUIRED STRAINER IN PLACE
3 PURGE GAS ESTABLISHED & AT REQUIRED RATE
4: HOT TAP MACHINE BLEEDER OUTLET PIPED AS
REQUIRED
5. UNNECESSARY PERSONNEL CLEARED FROM AREA
6. HOT WORK PERMIT RE-ESTABLISHED
7. FIRE EXTINGUISHER AND/OR PRESSURIZED
FIREWATER HOSE REQUIRED BY PERMIT READY
8. LINE OPERATING CONDITIONS ESTABLISHED
9. RECHECK CALCULATIONS FOR BORING MACHINE
TRAVEL TO VERIFY COUPON WILL BE FULLY
CUT AND OPPOSITE WALL WILL NOT BE CUT.
10. CHECK ALIGNMENT OF HOT TAP MACHINE
11. MOVE TRAVEL IN AND OUT SEVERAL TIMES TO
VERIFY BORING BAR DOES NOT JAM OR DRAG
12. STOP ON HOT TAP MACHINE SET CORRECT AND
LOCKED
13. COMMUNICATIONS WITH OPERATIONS
ESTABLISHED
POST HOT TAP
1. BORING MACHINE RETRACTED AND VALVE CLOSED
2. VERIFY COUPON RETRACTED (DO NOT FISH FOR
COUPON. NOTIFY OWNER'S OPERATORS
IMMEDIATELY IF COUPON WAS NOT RETRACTED
SO THEY CAN LOOK FOR COUPON AND VERIFY
SUCCESSFUL HOT TAP)
3. BLEEDER VALVE OPENED
4. COUPON ATTACHED TO BLOCK VALVE
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
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Engineering Services by KBR Technical Services, Inc

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CONSTRUCTION STANDARD

PLANNING AND EXECUTION OF HOT TAPS

DATE: 01 APR 2003