Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

Preparer:
EHS Team Member

4/14

Effective:

Owner:
EHS Team Member

Page:

1 of 19

4/14
Supersedes: 8/13
(Rev.06)
(Rev.05)
Approver:
EHS Manager

Document Revision Change Table

Revision
Number
01
02
03
04
05
06

Revision Description

Revised By

Changed Header and Footer

Added Freeze Plug Procedure
Changes in Scope - Section 3 and Section 4.3.8
Attachment B for additional review and approvals due to
Incident 0126 UTIL 12-0016
Responsibility changes on Attachment A
Responsibility and Requirements Changes
4.4.1 Requires a meeting of Hot Tap approvers to approve and
sign off

VB
DLS
DLS
DLS

Revision
Date
05/08
04/09
10/10
3/13

DLS
DLS

08/13
04/14

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4/14

Effective:

Page: 2 of 19
4/14
(Rev.06)

Supersedes:

1.

PURPOSE
To establish a clear set of guidelines to be followed when performing Hot Tap
and Stopple installations in piping systems that cannot be safely cleared and
isolated to make an out-of-service tie-in.

2.

DEFINITIONS

8/13
(Rev.05)

2.1.

Coupon The part of the pipe that is removed during the Hot Tap
operation.

2.2.

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.

2.3.

Stopple The installation of a flow-blocking device in a piping system that

cannot otherwise be isolated depressurized or cleared.

2.4.

Contractor the Company that supplies the Hot Tap and/or Stopple
machine and its operating personnel.

2.5.

Hot Tap/Stopple Document Package A collection of documentation

required to obtain Hot Tap approval. All documentation should be
attached within the appropriate sections of the MOC. The Stationary
Equipment engineer is responsible for ensuring all documentation is
correct and maintaining the appropriate files.
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)
TSA (Provided by Operations)
Approved MOC

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

2.

3.

4/14

Effective:

Page: 3 of 19
4/14
(Rev.06)

Supersedes:

8/13
(Rev.05)

DEFINITIONS contd
2.6.

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.

2.7.

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)

2.8.

Job Coordinator Person assigned by the Operations Manager to

coordinate a job. This is typically the Operations or Maintenance
Coordinator.

2.9.

Maintenance/Construction Representative Person assigned by either

the Maintenance or Project Manager to follow a job, depending on
whether the job is part of maintenance or a capital project. This is
typically a Maintenance Planner for maintenance jobs, or the Construction
Coordinator for capital jobs.

2.10.

Freeze Plug/Line Freeze Use of cryogenic fluid to create a flow

blockage of process fluid that cannot otherwise be isolated depressurized
or cleared.

SCOPE
Hot Taps, Stopples, and Freeze Plugs shall only be installed on piping that
cannot be safely cleared and/or isolated due to operational and/or system
design constraints, Hot Taps and Stopples represent a potential danger to
personnel and to plant operations. Any Hot Tap and/or Stopple must be part of
an approved MOC. All Hot Taps shall require a PSSR prior to being put into
service. This procedure shall apply to all facilities located at the Port Arthur Site.
All Hot Tap/Stopple installation work requests must be reviewed for potential risk.
This review is required even for nonhazardous fluid service. Hot Taps that are
part of a defined project must indicate and reference Hot Tap documentation
within the project MOC. The project hot taps must be in a separate MOC and
approved by the Operations Manager as required.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

3/13

Effective:

Page: 4 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

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 Operations 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.
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 through the PICS
system. New vendors for this work should provide at least two
references for his type work. 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.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4.

3/13

Effective:

Page: 5 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

PROCEDURE contd
4.1

General contd
4.1.6. When feasible, Hot Taps should be made on the top of the pipe
vs. the bottom, in horizontal pipe runs. This makes it easier and
safer to install/remove the Hot Tap Machine.

4.2.

Design Considerations
4.2.1. All piping components used in a Hot Tap, Stopple or Line Freeze
installation shall be in accordance with the relevant Port Arthur
Site Piping Standards, with the exception of weldments will shall
be in accordance with the Table 1 of this procedure Any
proposed piping component deviation will require approval from
the Technical Services Director 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 recommended for Hot Tap and
Stopple installations, the Hot Tap Contractor will be consulted
when a normal trim valve is the only/best option. These valves
shall comply with the appropriate Port Arthur Site Piping Standard.
4.2.4. If a completion plug is to be used in the case of a Stopple, the
elastomer components shall be reviewed and approved by Site
Engineering to ensure compatibility with the process.
4.2.5. Due to the weight of Hot Tap and Stopple machines, the force
exerted on the piping and supporting structure must have an
engineering review of the stress loading. 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, an Engineering
Standards Deviation Request must be approved.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4.

3/13

Effective:

Page: 6 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

PROCEDURE contd
4.2

Design Considerations contd

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 Technical Services Director or designee.
4.2.8. To minimize burn through, the first weld pass to equipment or
piping less than (6.4 mm) thick should be made with a 3/32
(2.4 mm) or smaller diameter welding electrode to limit heat input.
4.2.9. When performing a line freeze, the piping service Minimum
Design Metal Temperature should be noted and discussed.

4.3.

Preparation
4.3.1. In consideration of the significance of the effort and expense
involved in the preparation for a Stopple, Line Freeze, and/or Hot
Tap, 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 TSA, 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.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4.

3/13

Effective:

Page: 7 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

PROCEDURE contd
4.3

Preparation contd
4.3.3. Drilling through the opposite side of the piping is a serious
concern. The appointed 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 and all associated piping inspections
shall be made by the facility QA group 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 qualified engineer and approved by the facility
Fixed Equipment 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. Dye penetrant examination of the surface of a stainless steel pipe
is required to ensure there is no stress cracking at the surface. If
stress cracking exists, a qualified engineer/technician shall
perform ultrasonic thickness testing to determine the suitability of
the existing pipe for the Hot Tap.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4.

3/13

Effective:

Page: 8 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

PROCEDURE contd
4.3

Preparation contd
4.3.6. The attainable flow velocity in the line being Hot Tapped shall be
verified by the Stationary Equipment Engineer. 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.
Site Engineering shall evaluate required flow in vapor lines on a
case-by-case basis.
4.3.7. The WPS (Weld Procedure Specification) must be selected by the
contractors QA/QC department and attached to the checklist
Form A. This procedure must be reviewed by the contractors
QA/QC Representative and the Certified Welder prior to
performing the work.
4.3.8. For Line Freezes on piping with wall thickness greater than
inch, special precautionary measures must be taken.

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.
Approvers of the Hot Tap (Hot Tap Checklist Form A) must meet
to discuss all aspects of the procedure and sign their approval at
that time.
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. At least 1 day prior to issuing a Safe Work Permit for the
Hot Tap, the Shift Coordinator and the Maintenance/Construction
Representative shall meet and discuss all aspects of the proposed
hot tap and sign off on the Hot Tap Checklist Form B, denoting the
Hot Tap can safely commence.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4.

3/13

Effective:

Page: 9 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

PROCEDURE contd
4.4.

Hot Tap and Stopple Approval contd

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 or Line Freeze,
the Shift Coordinator, Contractor Representative and the
Maintenance/Construction Representative shall sign off on the
Stopple/Line Freeze Checklist Form C, denoting the work can
safely commence.
NOTE: If a section of this form does not apply, please mark NA in the
appropriate space

4.5.

Hot Tap and Stopple Field Work

4.5.1. The Job 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 by a tie-point tag as
specified in Port Arthur Safety Procedure PA-020-0002. 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 Job Coordinator together with the Maintenance/Construction
Representative shall ensure the planned location of the Line
Freeze as being correct and clearly marked in the field.
4.5.3. The Maintenance Manager or Project Manager, together with the
Operations Manager, are responsible for ensuring that an
emergency plan has been identified and communicated
appropriately. This is a part of the Hot Tap/Stopple package
presented during permitting and is reviewed as part of the 4 eyes
system walk-through. 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 or Freeze Plug.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4.

3/13

Effective:

Page: 10 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

PROCEDURE contd
4.5.

Hot Tap and Stopple Field Work contd

4.5.4. All required documentation should be presented to the person
issuing the hot work permit.
4.5.5. 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.
4.5.6. During line freeze operations temperature measurements shall be
documented on an interval of 5 minute intervals. This record will
accompany the work order and permit to job completion.
4.5.7. A pressure test of the installation shall be witnessed by the
Maintenance/Construction representative upon completion of the
Hot Tap welding. Valves utilized in conjunction with the Hot Tap
shall be pressure tested prior to installation.
4.5.8. 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.
4.5.9. Before removing the Hot Tap/Stopple machine, the
Maintenance/Construction Representative shall have the Hot
Tap/Stopple technician 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.
4.5.10. For maintenance jobs, the Maintenance Department will retain the
complete Hot Tap Stopple documentation package on file for one
year. For projects, the Project Manager will provide a copy of the
documentation package to the site Fixed Equipment engineer and
upon completion put a copy in the project job book.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

4.

3/13

Effective:

Page: 11 of 19
3/15/13 Supersedes:
(Rev.04)

10/01/10
(Rev.03)

PROCEDURE contd
4.5.

Hot Tap and Stopple Field Work contd

4.5.11. 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 Job Coordinator
and properly disposed of, if there is nothing unusual about its
condition. Upon completion of the Hot Tap, the PSSR section of
the MOC (required for all hot taps and listed in section 2.5 as part
of the job book) must be completed before the equipment is put
back into service.

5.

RESPONSIBILITIES
5.1.

Maintenance/Construction Representative Ensure Section 1 of the

Hot Tap Checklist Form A is accurate and closely monitor Contractor
activities in the field.

5.2.

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.

5.3.

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.

5.4.

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.

5.5.

Maintenance/Project Manager Ensure the job has been properly

engineered and that all required preparations have been carried out.

5.6.

Environmental, Health, and Safety Manager Review the job scope

and set-up in the field from a safety perspective to help ensure all
identifiable precautions have been taken.

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Title:

Hot Tap and Stopple Procedure

Individual Unit
Procedure

Function: Health and Safety

PA-020-0014
No.:

Port Arthur, TX.

Reviewed:

6.

3/13

Effective:

Page: 12 of 19
3/15/13 Supersedes:
(Rev.04)

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
Port Arthur Facility Procedure PA-020-0029 Management of Change
Port Arthur Facility Procedure PA-020-0028 Pre-Startup Safety Reviews
Port Arthur Facility Procedure PA-020-0002 Hot Work
Table 1- Fitting Selection Table
Attachment A-Hot Tap Checklist
Attachment B-Hot Tap Checklist
Attachment C-Stopple Checklist
Attachment D- Hot Tap Machine Dimension

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10/01/10
(Rev.03)

PA-020-0014
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.
BRANCH SIZE

HEADER
PIPE
SIZE
1"

1-1/2"

2"

3"

4"

6"

8"

10"

12"

14"

16"

18"

20"

1"

T or
W

1-1/2"

T or
W

T or
W

2"

T or
W

T or
W

3"

T or
W

4"

6"

8"

10"

12"

14"

16"

18"

20"

24"

SYMBOLS
WIntegrally reinforced fitting (weld-o-let).
TFull encirclement split tee.
PReinforcement 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 reinforcement
pad 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. Reinforcement pads 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.

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24"

Attachment A

PA-020-0014

SECTION 1 (Hot Work)

Hot Tap Checklist Form A

To be completed by the Maintenance/Construction Representative Prior to Welding

Plant Section

MOC No. ________________

Existing Line To Be Hot Tapped:

Line Number:

Pipe Specification:

Pipe Material:

Design Pipe sch./thickness: ___________

Corrosion Allowance: ___________

Actual Pipe sch./thickness: ___________

Process Fluid: ______________________________

Fluid Flow velocity:

ft/s

Operating Pressure:

psig

Liquid ( )

Gas/vapor ( )

Mass Fluid Flow ________________lbs/h

Temperature:_____________ deg F

Test Requirements for Weldment:

NDE required ( )Root pass dye check ( )Final pass dye check ( ) Radiography ( ) Ultrasonic
( )Hydrostatic test @
psig ( )Pneumatic test @
psig ( ) Test Medium ___________
( ) Y ( ) N ( ) n/a

Does this job fully comply with the Site Hot Tap/Stopple Procedure?

( ) Y ( ) N ( ) n/a

Are approved welding procedures included with the Hot Tap/Stopple Document Package?

( ) Y ( ) N ( ) n/a

Does the new installation fully comply with Site Piping Standards and/or approved deviations?

( ) Y ( ) N ( ) n/a

Has the Hot Tap location been clearly marked in the field and the pipe cleaned to bare metal?

( ) Y ( ) N ( ) n/a

Has the added stress loading on the existing pipe and support structure been addressed?

( ) Y ( ) N ( ) n/a

Does the Hot Tap/Stopple location allow for sufficient clearance and easy access/egress?

( ) Y ( ) N ( ) n/a

Have thickness and dye penetrant (per Section 4.3.3) results been reviewed and determined to be
satisfactory?

( ) Y ( ) N ( ) n/a

Has the weldment been either selected from Table 1 or approved by Site Engineering?

( ) Y ( ) N ( ) n/a

Has Site Engineering confirmed the required flow, and is it available for the Hot Work?

Signatures:
Maintenance/Construction Representative
Print Name:
Signature:
Mechanical QA Department
Print Name:
Signature:

Date:

Date:
Maintenance/Project Manager
Print Name:
Signature:
Job Coordinator
Print Name:
Signature:

Date:

Date:
A hot work permit CANNOT be issued if Sections 1 & 2 are not signed and/or there are any No answers.

Effective: 3/13

Approved by: EHS Manager

Attachment A

PA-020-0014

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 TSA been completed and attached to this form?

( ) Y ( ) N ( ) n/a

Does the TSA address the risks associated with losing a coupon or introducing metal
shavings?

( ) Y ( ) N ( ) n/a

Does the TSA 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 JSA address measures to be taken if the
stopple fails?

( ) Y ( ) N ( ) n/a

Welder is Code Certified?; Welder's Name:

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:
Continuity of service is essential shutdown of the system is impractical
documented procedures and special equipment are utilized which will provide effective protection for
employees
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:

EHS 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.

Effective: 3/13

Approved by: EHS Manager

Attachment B

PA-020-0014
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 _______________________________

Hot Tap Operator _____________________ # of Years Experience ___________________

Pressure Test of branch weld: ( ) Hydro ( ) Pneumatic Test Pressure _________ psig ( ) Passed ( ) Failed
( ) Radiography ( ) Other __________________

( ) Passed ( ) Failed ( ) n/a

Fluid Flow velocity:

ft/s Liquid ( ) Gas/vapor ( ) Mass Fluid Flow ______________lbs/h
Machine support arrangement approved by the Job Coordinator? ( ) Y
Machine bit rated for the maximum flow velocity of the process? ( ) Y
Dimensional Checks Completed (see machine dimension sheet)? ( ) Y
If conditions (including equipment performance level) All work must stop and contact the Shift
Coordinator
Shift Coordinator
Print Name:
Signature:

Date:

Maintenance/Construction Representative
Print Name:
Signature:

Date:

TES Director
Print Name:
Signature:

Date:

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
Boring bar travel set at

Wt
"

lb Max Working pr

psig Test date__________

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
Hot Tap Contractor Representative
Print Name:
Signature:

Date:

Maintenance/Construction Representative
Print Name:
Signature:

Date:

Effective: 3/13

Approved by: EHS Manager

Attachment C

PA-020-0014
Stopple/Line Freeze Checklist Form C
To be completed by the Contractor Prior to Installation

Machine support arrangement approved by the Job Coordinator? ( ) 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 Job 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.
Signatures
Shift Coordinator
Print Name:
Signature:

Date:

Maintenance/Construction Representative
Print Name:
Signature:

Date:

Stopple Contractor Representative

Print Name:
Signature:

Date:

Prior to proceeding with the Stopple the above information shall and signed off, and radio
communication established with the Control Room

Effective: 3/13

Approved by: EHS Manager

Attachment D

PA-020-0014
HOT TAP MACHINE DIMENSION & CALCULATION SHEET

BRANCH
SIZE "

TAP
SIZE "

FLANGE
RATING lb

DIMENSION DIMENSION DIMENSION

'A' MAX "
'B' MIN "
'C' MIN "

TOPAZ
MODEL

WEIGHT
lbs

All

15

67

28

T-101

50

1-1/4
1-1/2

All

15

67

28

T-101

50

1-7/16

All

16

53

28

T-101

50

2-7/16

150
300
600

19
20
20

54

29

360

250

3-7/16

150
300
600

18
19
37 (61)

54
54
78 (102)

29
29
31

360
360
660 (760)

250
250
700 (900)

5-15/32

150
300
600

35 (59)
34 (58)
32 (56)

80 (104)
80 (104)
82 (106)

31

660 (760)

700 (900)

7-5/16

150
300
600

32 (56)
33 (57)
33 (57)

82 (106)

31

660 (760)

700 (900)

10

9-1/2

150
300
600

30 (54)
36 (60)
29 (53)

84 (108)
79 (103)
85 (109)

31

660 (760)

700 (900)

12

11-1/2

150
300
600

33 (57)
34 (58)
32 (56)

82 (106)

31

660 (760)

700 (900)

14

12-3/4

150
300
600

35 (59)
60

80 (104)
132
126

31
56
56

660 (760)
1200
1200

700 (900)
3000
3000

16

14-9/16

150
300
600

59
56
60

132
135
131

56

1200

3000

18

15-1/16

150
300
600

56
60

133
133
130

56

1200

3000

17

150
300
600

57

20

133
130
133

56

1200

3000

150
300
600

53

136
132
132

56

1200

3000

24

21

56

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.

Effective: 3/13

Approved by: EHS Manager

Attachment D

PA-020-0014
HOT TAP MACHINE

T
R

Adaptor

F
E

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)

Drill tip projection from cutter (F)

" E < D to allow valve to close ( ) Y

". 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)

Boring bar travel stops set to limit travel to

+2X

"

"

Boring bar travel is less than Do-not-exceed dimension ? ( ) Y

Effective: 3/13

Approved by: EHS Manager