1.13 - Hot Tapping Rev A0

OPERATIONS HSE MANUAL
SECTION 1.13 – HOT TAPPING

The only official version of any procedure is that published on the ZADCO Intranet
Z0000-GL-GEN-N-011-013
Revision A0
DATE: 5 May 2013
ISSUED FOR: IMPLEMENTATION

HEALTH , SAFETY AND ENVIRONMENT Z0000-GL-GEN-N-011-013
Rev: A0
HEALTH, SAFETY AND ENVIRONMENT Date:26 April 2015
HOT TAPPING Page: 2/19
TABLE OF CONTENTS
1 INTRODUCTION AND PURPOSE .................................................................. 4
2 SCOPE ............................................................................................... 4
2.1 Scope - Inclusions .................................................................................. 4
2.2 Scope - Exclusions .................................................................................. 4
3 LAW, STANDARDS AND CODES OF PRACTICE ................................................. 4

3.1 U.A.E. Federal Laws and Regulations ........................................................... 4
3.2 International Laws and Regulations ............................................................. 4
3.2.1 UK Legislation .............................................................................. 4
3.2.2 USA Code Of Federal Regulations ....................................................... 4
3.2.3 USA Standards .............................................................................. 5
3.2.4 British Standards........................................................................... 5
3.2.5 International Standards and Codes of Practice ....................................... 5
3.3 Company Standards ................................................................................ 5
3.3.1 ADNOC Standards .......................................................................... 5
4 ACRONYMS AND DEFINITIONS ................................................................... 6

4.1 Acronyms ............................................................................................ 6
4.2 Definitions ........................................................................................... 7
5 ROLES AND RESPONSIBILITIES .................................................................. 8
6 OPERATIONS HSE MANUAL FLOW CHART ................................................... 11
7 OPERATIONS HSE MANUAL ON HOT TAPPING .............................................. 12

7.1 What is Hot Tapping ?............................................................................ 12
7.1.1 Hazards of Hot tapping ................................................................. 13
7.2 Preparation of Hot Tap Data Sheet ............................................................ 13
7.2.1 Hot Tap Data Package .................................................................. 13
7.2.2 Calculations .............................................................................. 13
7.3 Verification Prior to Hot Tapping .............................................................. 13
7.3.1 Site Job officer .......................................................................... 13
7.3.2 Operations and Inspection Departments ............................................. 14
7.3.3 Contractor ................................................................................ 14
7.4 Conditions which restrict performing Hot Tapping activity ................................ 14
7.4.1 Limitations for Hot Tapping ............................................................ 14
7.4.2 Flammable Mixture ...................................................................... 15
7.4.3 Confined Spaces ......................................................................... 15
7.5 Location and Inspection of Hot Tap Connection ............................................. 16
Rev: A0
7.6 Testing of the Hot Tap Valves, Weld / Hot Tap Machine ................................... 16
7.7 Completion of Hot Tapping Activity ........................................................... 16
8 REFERENCES ..................................................................................... 17
9 APPENDIX ......................................................................................... 18
LIST OF FIGURES
FIGURE 1 – OPERATIONS HSE MANUAL FLOW CYCLE ON HOT TAPPING .................... 11

FIGURE 2 – HOT TAPPING MACHINE (COURTESY API RP 2201) ............................. 12
Rev: A0
1 Introduction and Purpose

ZADCO recognizes that its employees and contractors may be exposed to a variety of health and
safety hazards as part of their function either within the offices or at the remote offshore
locations. The main purpose of the Operations HSE Manual is to provide a basic set of guidelines,
instructions, rules and precautions to protect people and the natural environment from harm in the
course of their normal work activities as well as prevent the occurrence of process and material
losses.
The purpose of this Operations HSE Manual is to establish the minimum requirements for
performing hot tapping operations in a safe manner and to provide all the concerned personnel
with a clear understanding of the job being done.
2 Scope
2.1 Scope - Inclusions

This Operations HSE Manual outlines HSE requirements for performing hot tapping operations at
ZADCO onshore and offshore facilities, equipment vessels, tanks, and piping containing
liquid/gaseous hydrocarbons, steam, air, water, and chemical solutions, etc. It applies to
equipment and piping fabricated only from ferritic and austenitic material. Hot tapping on
materials requiring post weld heat treatment (PWHT) is not permitted.
2.2 Scope - Exclusions

This Operations HSE Manual is specific to hot tapping activities and cannot be used as alternate to
Permit to Work (Operations HSE Manual Section 1.29).
3 Law, Standards and Codes of Practice
3.1 U.A.E. Federal Laws and Regulations

Protection and the Health Article 91 states that ‘Every employer must provide adequate means of
protection for the employee from the hazards of injuries and vocational diseases’.
Regulation of Labor Ministerial Decree no. 32 of 1982 on Protection of Employees Against
Occupational Hazards
3.2 International Laws and Regulations
3.2.1 UK Legislation
UK Workplace Regulations 1992 The Workplace (Health, Safety and Welfare) Regulation
UK Workplace Regulations 1999 The Management of Health and Safety at Work Regulations, article no. 16.
UK Occupational Health and

Section 179 on Hot Work and Section 170 on Hot Taps.
Safety Explanation Guide 2009
3.2.2 USA Code Of Federal Regulations

The requirements are further explained as follows:
Rev: A0
29 CFR 1910.252 Code of Federal Regulation on Welding or Hot Tapping containing hazardous
material
49 CFR 192.627 Tapping pipeline under pressure
3.2.3 USA Standards
API 598, 2009 Valve Inspection & Test
API 653, 2009 Tank Inspection, repair and alteration and construction
API 510, 1997 Pressure Vessel Inspection Code
API 570, 2007 Piping Inspection Code
API 2201, 2003 Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries
ASME (American Society of Boiler and Pressure Vessels Code:

Mechanical Engineers)
Section VIII, Division 1, and Pressure Vessels
Code and Standards
Section IX, Welding and Brazing Qualifications
B 31.1 Power Piping
B 31.3 Chemical Plant and Petroleum Refinery Piping
ASME b 31.8 for gas pipeline
ANSI Z49.1-1967 Safety in Welding and Hot Tapping
3.2.4 British Standards
BS PD 6686: 2006 Guidelines on Safety at Work
3.2.5 International Standards and Codes of Practice
ILO convention C-155 of International Labor Organization, Article 16, 18 and 19

1981
ILO-OSH (Occupational International Labor Organization Guidelines on Occupational Safety and Health
Safety and Health), 2001 Management Systems
EEMUA PUB NO 185 This Publication applies to hot tapping into metallic piping systems containing
process fluids or their residues. It also covers the information for special hot
tapping applications such as on storage tanks
3.3 Company Standards

In order of precedence the Company standards are:
3.3.1 ADNOC Standards
ADNOC COPV4-02 Work Equipment Risk Assessnent and Control

Rev: A0
ADNOC COPV4-05 Non-Routine Operations
ZADCO Operations Risk Management

HSE Manual Section
1.30
ZADCO Operations Job Safety Analysis

HSE Manual Section
1.55
4 Acronyms and Definitions
4.1 Acronyms
Acronyms are words formed from the initial letters or groups of letters of words in a set phrase or
series of words. Acronyms may have more than one connotation, therefore the definitions listed in
this section shall apply.
Acronym /
Description
Abbreviation
ADNOC Abu Dhabi National Oil Company
ALARP As Low As Reasonably Practicable
API American Petroleum Institute
ANSI American National Standards Institute
C&F Consequence and Frequency Analysis
CFR Code of Federal Regulations – USA
CoP Code of Practice
DIN Deutsche Industrial Norms (German standards agency)
ERP Emergency Response Plan
F&G Fire and Gas
HSE Health, Safety and Environment
ILO International Labour Organization
ISO International Organization for Standardization
JSA Job Safety Analysis
MSDS Material Safety Data Sheet
OSHA Occupational Safety and Health Administration – USA
PHA Process Hazard Analysis
PPE Personal Protective Equipment
PR Probability Ranking
PRV Pressure Relief Valve
PTW Permit to Work
PSV Pressure Safety Valve
RAM Risk Assessment Matrix
RR Risk Ranking
Rev: A0
Acronym /
Description
Abbreviation
RI Risk Index
SIMOPS Simultaneous Operations
SR Severity Ranking
U.A.E. United Arab Emirates
UK HSE
United Kingdom Regulations on Health, Safety and Environment
Regulations
ZADCO Zakum Development Company
4.2 Definitions
Definitions are the formal statement of the meaning or significance of a word or phrase. Key
phrases or words may have more than one connotation; therefore the definitions listed in this
section shall apply.
Key word(s) Description
Accident An undesired event that results in personal injury, property or equipment damage,
production downtime or harm to the environment. The term has generally been
substituted with Incident as the preferred term.
Acceptable Risk Risk that has been reduced to a level that can be tolerated by the organization having
regard to its legal obligations and its own OH&S policy
Cause A reason for resulting action or an undesirable condition.
Consequence Adverse effects or harm which causes the quality of human health or the environment
to be impaired.
Corrective Action Action to eliminate the cause of a detected nonconformity or other undesirable
situation
Contributing Factors Additional failures which allow the situation established by the root cause to go
unchecked leading either to an incident or to an incident with more severe
consequences than otherwise. These can be "active failures" but are more often
"latent failures".
Coupon The piece of pipe or vessel that is removed or cut away during the hot tap procedure
Hazard Any substance, physical effect, or condition with potential to harm people, property
or the environment or affect on the company reputation.
Hot tap The welding and mechanical procedure that enables a connection to be made to a line
or vessel while that line or vessel is in service.
Incident An event or chain of events which has caused or could have caused fatality, injury,
illness and/or damage (loss) to assets, the environment, company reputation or third
parties.
In service welding The practice of welding on equipment (e.g., tank, pipe, vessel etc.) which has not
been purged (gas freed) and has not been removed from service. This includes but is
not limited to grinding, burning or welding
JSA Review Team The team consists of members for ZADCO HSE Department, and employees from
relevant departments such as, Operations, Maintenance, Process, inspection and
contractor representative. This team prepares a list of all jobs (and relevant steps)
being performed in all work areas
Rev: A0
Key word(s) Description
Non-conformance Non-fulfilment of a requirement

Note: It can be any deviation from relevant work standards, practices, procedures,
legal requirements, etc.
Permit-to-work system A permit to work system is a formal written system used to control certain types of
work, which are identified as involving significant risk (Refer to ZADCO Operations
HSE Manual Section 1.29)
Record Document stating results achieved or providing evidence of activities performed
Risk Combination of the likelihood of an occurrence of a hazardous event or exposure and

the severity of injury or ill health that can be caused by the event or exposure
5 Roles and Responsibilities
Department / Person Responsibility
Ensure that their employees are aware of the requirements of this Operations
HSE Manual. The hazards and mitigation measures circulated and explained to
the performers
Contractors Permit to Work (Refer to ZADCO Operations HSE Manual Section 1.29) have been
obtained before commencement of work.
Risk assessments have been carried out and documented in line with the
requirements of ZADCO Operations HSE Manual Section 1.30.
Ensure that safety precautions as stipulated in this Operations HSE Manual are
followed in accordance with the requirements of this Operations HSE Manual.
Ensure Hot Tapping Crew composed of employees who have previous training
and experience on this type of specialized work activities.
Closely monitor and ensure that the detailed hot tap data sheet and
sketches/drawings or all hot tap data package are reviewed, checked, followed,
necessary integrity checks done prior to start of the job and implemented to
Site Inspection Department the letter.
Ensure that all workers are properly briefed and knowledgeable of the detailed
job specifications and work procedures required by the particular hot tap.
Shall order the workers to stop if an unsafe condition occurs, which might result
in an accident, explosion or fire.
Shall summon for help and evacuate the persons involved in the hot tapping
activity, as per ZADCO Emergency Response Procedure.
Development and issuance of the Operations HSE Manual.
Periodical audits are conducted and documented.

HQ HSE Department Provided the understanding through Operations HSE Manuals and training.
Organize training covering all topics in this Operations HSE Manual.
Ensuring that this Operations HSE Manual (and controls identified herein) are in
Rev: A0
place and documented under ISO 14001 and OHSAS 18001.
Follow up on all internal and external non-conformances to activities in this

Operations HSE Manual.
Analyze, update, and implement this procedure
Issue notices on non-compliance (to activities in this Operations HSE Manual),

where necessary.
Develop and implement corrective action plans resulting from non-compliance

investigations.
Ensure that safety precautions as stipulated in this Operations HSE Manual are
followed in accordance with the requirements of this Operations HSE Manual.
Closely monitor and ensure that the detailed hot tap data sheet and
sketches/drawings or all hot tap data package are reviewed, checked, followed
Site Operations Department and implemented to the letter.
Ensure that all workers are properly briefed and knowledgeable of the detailed
job specifications and work procedures required by the particular hot tap.
Ensure that the flow rate of hydrocarbons is within the safe limit
Ensure implementation of Operations HSE Manuals on their site / platform.

Ensure that concerned employees are aware of the requirements of this
Operations HSE Manual.
Ensure that the hot tap data package is in place and shall ensure that all
specifications and procedures to be used are in conformance with the process
and safety requirements job.
Ensure that all personal protective equipment, gas detection equipment, fire
protection equipment, work permit and all other safety requirements are
provided and used.
Site HSE Department Coordinate with Site Inspection Department, Site Operations Department for all
necessary safety requirements and conditions which must be complied and
conformed with and are properly acted upon and completed prior to the start of
the hot tap.
Regularly monitor the job and ensure complete compliance to all agreed safety
measures provided in the hot tapping safe work authorization.
Responsible for conduct of safety audits on the proper implementation of the
hot tapping procedure in all areas of the plant to ensure its efficiency and
reliability and shall recommend and incorporate useful and practical revision to
the procedure so as to further improve the system
The Site Manager/Team Leader, or his authorized representative, ensures that

all activities in his area meet the requirements of this guide and are carried out
Site Manager
by competent persons under proper supervision.
Ensure that Permit to Work (PTW) has been obtained before commencement of
work.
Use appropriate personal protective equipment.

ZADCO employees
Participating in JSAs, Ssafety Meetings, such as Tool Box Talks.
Rev: A0
Follow instruction given in the Work Permit before commencement of work.
Asking for explanation of special hazards or risks associated with unfamiliar or

hazardous activities.
Reporting any unsafe condition noticed at a work site to the supervisor / Team
Leader responsible for the work.
Rev: A0
6 Operations HSE Manual Flow Chart

In order to understand this guide section the illustrative diagram below explains the flow cycle of
the (section name) Operations HSE Manual.
Prepare Hot Tap

Data Sheet –
Section 7.2
Verification
conditions for Hot
Tapping –
Section 7.3
OK Not OK
Check conditions
that restrict Hot
Not OK
Tapping activity –
Section 7.4
OK
Check location
and inspection of
Hot Tap
connections
activity –
Section 7.5
Testing of hot tap

valves, weld / hot
Not OK
tap machines –
Section 7.6
OK
Completion of Hot
Tapping Activity-
Section 7.7
Figure 1 – Operations HSE Manual Flow Cycle on Hot Tapping

Rev: A0
7 Operations HSE Manual on Hot Tapping
7.1 What is Hot Tapping ?

The term “hot tap “ as used in this procedure applies to welding and mechanical procedure that
enables a connection to be made to a pipeline or a vessel while it is (1) under pressure or (2) has
been depressurized but has not been cleared for conventional construction method. Hot tapping
shall be considered as a last option where it is impractical to take equipment / pipeline out of
service. Hot tapping is a cost effective but possibly hazardous and complex method for installing
connections on vessel, tanks, piping and other equipment while these are in operation. A decision
to perform a hot tap should be made only after careful consideration of the alternatives. The
decision should only be made when (1) continuity of service is essential, (2) shutdown of the
system is impractical, (3) documented procedures are followed, and (4) special equipment is used
which will provide effective protection for employees.
The method consists of welding a flanged, or threaded fitting to existing piping or equipment,
attaching a valve and a cutting tool and mechanically cutting out a coupon.
Figure 2 – Hot tapping machine (courtesy API RP 2201)

Rev: A0
7.1.1 Hazards of Hot tapping

The hazards associated with hot tapping mainly include:
 Fire
 Explosion
 Equipment damage
 Loss of containment
 Welding related hazards
7.2 Preparation of Hot Tap Data Sheet
7.2.1 Hot Tap Data Package

A hot tap data package shall be prepared prior to the hot tap job being done. The hot tap data
package shall consist of:
 Hot tap data sheet (Appendix A of this Operations HSE Manual)
 A sketch or an isometric drawing showing the location and orientation of the hot tap.
The hot tap data package shall be approved and signed by the Site Inspection, Maintenance,
Operations and HSE Departments.
7.2.2 Calculations
Calculations should be made in accordance with ASME B31.3, ASME Section VIII. DIV. I and other
applicable codes/standards to determine that the supporting attachments and fittings have the
required thickness and strength. Inspections should specify and approve the minimum required flow
Calculations should be done by inspection department.
7.3 Verification Prior to Hot Tapping
7.3.1 Site Job officer

An experienced and qualified Site Job officer shall be assigned to verify that the hot tap equipment
is rated for the design temperature and pressure of the line or equipment to be tapped. This design
data shall be supplied by the Site job officer assigned to the job.
The Site Job officer shall also verify that:
 The hot tap equipment is in good working condition and that the cutter’s travel is calculated
and adjusted to prevent cutting the opposite side of the piping.
 The use of full encirclement (such as a split tee) should also be confirmed if a full line size hot
tap is required. After the engineer has verified these items, he shall sign the appropriate place
on the hot tap data sheet.
 Use only the welder or equipment qualified for the approved welding procedure.
 Assure that the fitting is positioned and supported before welding so that misalignment of hot
tapping machine will not occur.
Rev: A0
 Work shall be immediately stopped when constant flow and pressure cannot be maintained
during welding and hot tapping operations. Pressure testing shall also stop if pressure in the
header/ equipment is lost.
7.3.2 Operations and Inspection Departments

The Operations and Inspection Departments shall verify the following safety precautions:
 Care is to be taken to ensure that neither the 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 or piping being hot tapped.
 Flow in hot tapped lines should be maintained during the welding operations to reduce heat
accumulation. A minimum velocity is recommended in gas lines. The velocity shall be
determined by the Process Engineer or inspection Engineer prior to start of hot work. Also the
velocity calculation needs conversion of operating pressure & flow to NTP condition.
 The general work area around the hot tap work site should be hydrocarbon, vapor and gas free.
Continuous monitoring for presence of any HC gas around the work area is compulsory.
 If the hot tap is to be done on a flare line, ensure adequate velocity by additional purging
either with HC gas or Inert gas. It is recommended that the pressure be reduced to one-third to
one-half the normal operating pressure during the hot tapping operation, which may also be
limited by the rating of hot tapping equipment.
 The contents of storage tanks shall not be circulated during hot tapping. Tank inlet and outlet
valves shall be closed, locked out and tagged. There should be at least 1 m (3.3 ft.) liquid level
above the highest weld on the hot tap connection reinforcing pad. Hot tapping in the vapor
space of a tank is permissible only when an inert gas blanket is maintained. Even then,
frequent testing shall insure that the gas in the vapor space is at no time in the flammable
range. When it is not possible to have the product liquid level above the hot tap weld, water
may be pumped into the tank to raise the liquid level.
 Hot tap connections larger than 2 inches on storage tanks are in violation of API-620 and API-
650, and would require written approval from the Site Manager.
7.3.3 Contractor
An experienced and competent Contractor shall be assigned for conducting Hot Tapping activity.
The Contractor crew will be composed of employees who have previous training and experience on
this type of specialized work activities.
7.4 Conditions which restrict performing Hot Tapping activity
7.4.1 Limitations for Hot Tapping

A hot tap shall not be made in the following cases:
 Equipment and piping containing a flammable gas and air mixture.
 Equipment and piping under vacuum or containing toxic materials.

Rev: A0
 Equipment and pipelines containing compressed air, oxygen, amine, chlorine and other
oxidizing agents
 Upstream of rotating equipment or automatic control valves unless such equipment is protected
from the cutting by filters/traps.
 Hot tapping closer than 18 inch to a flange joint of threaded connection or approximately 3
inch to a welded seam should be avoided.
 Hot tapping is not permitted in cone or floating roof of in-service tanks.
 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 containing acids, ammonia, chlorine, or chlorine compounds which may
decompose due to heat of welding.
 Equipment and piping in hydrofluoric acid service where formation of iron fluoride could occur
thus causing metallurgical damage.
 Equipment and piping containing hot hydrogen and sour gas when hydrogen can cause
embrittlement of the welds.
 The pipeline that contains a material that will decompose at the line pressure and pipe wall
temperature.
 Where stress relief is required as part of normal procedure such as Chrome-Molly steel and 3 ½
% Nickel.
 Equipment and piping with cladding, lining or overlay such as glass, lead refractory, cement,
plastic, or alloy metal. However in an emergency, hot tapping in cement lined pipeline is
possible, provided the dia of the cutter does not exceed 0.7 times the I.D. of the cement lining.
 Jacketed equipment and piping.
7.4.2 Flammable Mixture

In certain cases, such as flare line, there may be insufficient or interrupted flow that can result in
a flammable mixture during the welding operation in such cases it may be necessary to continually
purge the line with steam, inert gas, or hydrocarbon gas to prevent the formation of flammable
mixtures.
7.4.3 Confined Spaces

Pits, buildings, and other confined places should be well ventilated to prevent the accumulation of
a flammable mixture. Pits shall be tested by means of Gas Detector prior to starting hot work. An
accessible personnel exit must be provided.
Rev: A0
7.5 Location and Inspection of Hot Tap Connection

The Site Job officer shall ensure that the hot tap location in the field matches the location shown
on the hot tap sketch/isometric drawing and they shall mark the exact field location by a tag or
paint.
At the marked area, any seam welds or other projections will need to be ground flush and also any
paint shall be removed for UT scanning and fit up. The equipment or the pipe to be tapped must be
measured by an ultrasonic thickness test shall be made before any heat is applied to it. Prior to
welding, site inspection will determine by non-destructive testing, such as X-ray or ultrasonic
testing, that the metal is of sufficient thickness to prevent burn through. The minimum thickness
for welding shall be the minimum retirement thickness or a thickness considered adequate by the
inspection Engineer. Inspection will mark the specific area in which the weld can be made safely.
The welder will be informed of the minimum wall thickness and its location prior to striking an arc.
The area to be scanned shall include the weld zone and 50mm each side of it. Hammer testing is
not acceptable.
If Ultra Sonic reading indicates a lamination, hot tap location shall be relocated (after discussion
with all concerned).
7.6 Testing of the Hot Tap Valves, Weld / Hot Tap Machine
Prior to the work being conducted the following shall be verified by the Site Inspection
Department:
The valve through which the hot tap cutter will pass must be dimensionally checked, repacked if
required and hydro-tested by the Machine Shop.
A body and seat test shall be performed on all hot tap valves prior to installation.
Hot tap machine shall be subjected to shop rated pressure test, if possible prior to each use but
essentially once in a year, and record for this testing shall be maintained by the Maintenance.
7.7 Completion of Hot Tapping Activity

After installation of branch connection (including the valve), a full hydrostatic pressure shall be
applied to the branch connection. The test pressure shall be operating pressure of the line/vessel
to be tapped but should not exceed the present internal pressure by more than 10%.
A pneumatic test shall be applied to the reinforcing pad.
X-ray or MPI (Magnetic Particle Inspection) shall be done to ensure that there is no leakage from
the pipeline / equipment, hot tapped.
Verify that calibrated pressure gauges and relief valves are properly installed for testing
After verification of the items 1 to 5 in the form H-F-045 (Attachment #1 Hot Tap Data Sheet),
Inspection, Maintenance, Operations and Safety & Fire representatives shall sign the appropriate
place on the hot tap data sheet.
After all the above steps, the Site Job officer shall review the hot tap data package with the
appropriate area operator. If the Site Job officer and area operator find no fault with the
Rev: A0
information provided and can add no additional precautions, they shall sign the appropriate place
(Item 6) on the hot tap data sheet.
The Site Job officer along with Operations supervisor and Site HSE Engineer shall finally verify all
the information and sign the appropriate place (item 6) on the hot tap data sheet.
For any hot tap job the final approval shall be given by the Site Manager, after reviewing all the
data he will sign the appropriate place (item 7) on the hot tap data sheet.
The necessary Safe Work Authorization (SWA) shall be obtained before any work may be done.
After all the requirements of the above procedure are met, the welding and hydro testing on the
fittings can proceed. The Operations Engineer and Job officer must witness the hydro-test.
After the fittings (including any valve) have been hydro-tested, the hot tapping may proceed.
Operations Engineer and Job officer shall be present throughout the duration of the hot tapping
operation.
After the hot tapping is completed, the coupon removed shall be identified and turned in to the
inspection. The hot tap data sheet should be signed and dated to verify that the job is complete
and the sheet shall be returned to the Inspection with a copy to Maintenance Superintendent.
The hot tap activities, existing drawings, isometric etc. shall be revised, after completion of the
hot tap.
8 References
 ZADCO Operations HSE Manual Section 1.30 - Risk Management
 ZADCO Operations HSE Manual Section 1.55 - Job Safety Analysis

Rev: A0
9 Appendix
Appendix A- Hot Tapping Data Sheet.
Area No:
Appendix – A - Hot Tap Data Sheet
Tap No:
1.Stub Description (To be completed by Site Inspection Department)

Nozzle Diameter (mm) Flange Type
Flange Rating (pressure at operating
Material of construction
temperature)
Bolt Size Pipe Schedule
Bolt Number Special Fitting on pad required
Distance-Flange face to top of
Bolt Material
line/equipment
2.Valve Description
Size (mm) Body Material
Pressure Rating (Kpag) Trim Material
Type
Make Signature & Name of Site Job officer
3. Description of the Line to be tapped (To be completed by Operations supervisor)

Size (mm) Operating Pressure (Kpag)
Pipe Schedule Operating Temp. ( 0C )
Nominal Wall Hydrostc. Test Pr. (Kpag)
Thickness (mm) Orientation of Tap
Material of Construction Location of Tap
Line Designation Sketch/Isom. Drawings Attached
Material inside the line Clearance for Hot Tap Machine
Design Flow Rate (m3/hr)
Design Pressure (Kpag) Signature & Name of Operations supervisor
4. Pre-Welding Test of Parent Line (To be completed by Inspection Department)

Test Method or Instrument Comments or Visual Observation
Used
Indicated Line Thickness (mm)
Min. Max. Avg. Performed By Date
(Site Inspection Department)
5.Checklist Checked By Signature Date

A. Pipe has 3m/s minimum flow velocity Operation
B. Tank has 1m liquid level above hot tap
C. Hot tap field locations matches drawings Inspection
D. Calculation verify attachments and fittings
E. Hot tap equipment rated for job verify
6. Operations Approval to Proceed 7. Final Approval to Proceed

Site Inspection Department Site HSE Department
Site Operations Department Approved by Site Manager
8. Hydro Test of Welded Stub/Split Tee

Test Starting Time (hr) Name of Welder
Starting Pressure (Kpag) Date of Last Qualifying Test
Test Ending Time (hr) Comments
Ending Pressure (Kpag)
Test Fluid Used
Test Fluid Pressure (Kpag) Witnessed By Date
9. Hot Tap Cut-Through

Date Coupon Examined By
Time Comments
Rev: A0
Area No:
Appendix – A - Hot Tap Data Sheet
Tap No:
Tapped By
Witnessed By Completion Verified By Inspection

1.13 - Hot Tapping Rev A0

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OPERATIONS HSE MANUAL

SECTION 1.13 – HOT TAPPING

DATE: 5 May 2013

ISSUED FOR: IMPLEMENTATION

1 INTRODUCTION AND PURPOSE .................................................................. 4

3 LAW, STANDARDS AND CODES OF PRACTICE ................................................. 4

4 ACRONYMS AND DEFINITIONS ................................................................... 6

5 ROLES AND RESPONSIBILITIES .................................................................. 8

6 OPERATIONS HSE MANUAL FLOW CHART ................................................... 11

7 OPERATIONS HSE MANUAL ON HOT TAPPING .............................................. 12

FIGURE 1 – OPERATIONS HSE MANUAL FLOW CYCLE ON HOT TAPPING .................... 11

1 Introduction and Purpose

2.1 Scope - Inclusions

2.2 Scope - Exclusions

3 Law, Standards and Codes of Practice

3.1 U.A.E. Federal Laws and Regulations

3.2 International Laws and Regulations

UK Occupational Health and

3.2.2 USA Code Of Federal Regulations

3.2.3 USA Standards

API 598, 2009 Valve Inspection & Test

API 510, 1997 Pressure Vessel Inspection Code

API 570, 2007 Piping Inspection Code

ASME (American Society of Boiler and Pressure Vessels Code:

B 31.1 Power Piping

B 31.3 Chemical Plant and Petroleum Refinery Piping

ASME b 31.8 for gas pipeline

ANSI Z49.1-1967 Safety in Welding and Hot Tapping

3.2.4 British Standards

BS PD 6686: 2006 Guidelines on Safety at Work

3.2.5 International Standards and Codes of Practice

ILO convention C-155 of International Labor Organization, Article 16, 18 and 19

3.3 Company Standards

3.3.1 ADNOC Standards

ADNOC COPV4-02 Work Equipment Risk Assessnent and Control

ADNOC COPV4-05 Non-Routine Operations

ZADCO Operations Risk Management

ZADCO Operations Job Safety Analysis

4 Acronyms and Definitions

Key word(s) Description

Key word(s) Description

Non-conformance Non-fulfilment of a requirement

Risk Combination of the likelihood of an occurrence of a hazardous event or exposure and

5 Roles and Responsibilities

Department / Person Responsibility

Development and issuance of the Operations HSE Manual.

Periodical audits are conducted and documented.

Organize training covering all topics in this Operations HSE Manual.

Department / Person Responsibility

place and documented under ISO 14001 and OHSAS 18001.

Follow up on all internal and external non-conformances to activities in this

Analyze, update, and implement this procedure

Issue notices on non-compliance (to activities in this Operations HSE Manual),

Develop and implement corrective action plans resulting from non-compliance

Ensure implementation of Operations HSE Manuals on their site / platform.

The Site Manager/Team Leader, or his authorized representative, ensures that

Use appropriate personal protective equipment.

Department / Person Responsibility

Follow instruction given in the Work Permit before commencement of work.

Asking for explanation of special hazards or risks associated with unfamiliar or

6 Operations HSE Manual Flow Chart

Prepare Hot Tap

Testing of hot tap