ELECTRONIC DOCUMENT CHANGE HISTORY

Title:

Safety Standard M62: Hot Tapping

Document Owner:

Texas EH&S Delivery FIT

Author/Creation Team:
Disclaimer:

Rob Baker/Safety Process Leader NWT

This electronic document is READ-ONLY and is intended for copying or

printing purposes only. Do not make changes to this document. Document
may be copied onto a personal hard drive or another file server or folder,
retaining the READ-ONLY designation of this document. This electronic
version is the official Texas Operations Safety & Health Process Leaders
document.

Change Procedure:

Notify owner of document for revisions: Texas EH&S Delivery FIT.

ELECTRONIC DOCUMENT CHANGE HISTORY

PAGE/LINE

General
General
General
General

i-ii

CHANGE
Incorporated changes required by Global Hot Tap LER Team
to include:
1. Approval by specific roles to proceed with
engineering evaluations for a Hot Tap,
2. Approval by specific roles to perform a Hot Tap,
3. Definition of hot welding, lower hazard service and
higher hazard service,
4. Updates to Hot Tap EMETL documents,
5. Example Hot Tapping Request Form
6. Hot Tap checklist aids for performing hazard
assessment and developing work plans, and
7. Example Contingency Action Plan.
Changed the title from Non-Electrical to HOT Tapping and
removed all sections that referenced not work.
Deleted Hot Work References and Kept Hot Tapping Sections
Safety standard were revised for organizational terminology.
Safety Standard M-62 has been revised to include
references to new Global Design Aids for Hot Tapping as
well as an authorization level change.

Added the document change history & disclaimer pages.

FIT Team Reviewed Standard

DOW RESTRICTED - For internal use only

DATE
6/2008

3/2002
12/13/01
2/14/00
2/1/97

1/1/97
1/05

DOW RESTRICTED - For internal use only

M-62

Electronic Availability:
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document
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available
electronically
on
the
\\Txnt56\ehs_texas\Approved\RspCareEmployee Health & Safety\Texas
Operations Safety Standards. Updates, if any, will be made to the electronic
version of this document..

Disclaimer:
The Dow Chemical Company has provided for the compilation of the
information in this document as a part of an effort by its employees to collect
and share their experience and expertise in safety, loss prevention and security.
The contributors to this document believe the information provided is accurate,
and they have provided this information in good faith. However, no warranty,
express or implied, is given by The Dow Chemical Company. Other than The
Dow Chemical Company employees, those who use this document should use
their independent judgment in evaluating information contained herein, and
assume the risk for using the information provided in this document. The user is
solely responsible for compliance with applicable laws and regulations.

Retention:
Until superseded. Audit all documents annually.

SAFETY STANDARD NO. M-62

HOT TAPPING EQUIPMENT CONTAINING
HAZARDOUS MATERIAL OR PRESSURE
I.

SCOPE
This standard covers the minimum requirements and considerations for hot tapping or hot
welding on equipment containing hazardous material or pressure.

II.

DEFINITIONS
HOT TAPPING is mechanical cutting, drilling, boring, etc. into a line or equipment
containing hazardous material or pressure.
HOT WELDING is welding on any process line or vessel containing material or operating
under pressure or vacuum.
LOWER HAZARD SERVICE is Potable Water, Process Water, Brine (not containing
caustic), Nitrogen, Cooling Tower Water, Low Pressure Steam / Condensate (<10 Barg).
HIGHER HAZARD SERVICE All others.

III.

REQUIRED REFERENCES
A. The following EMETL Standards contain the engineering evaluation, design,
welding procedure and post testing requirements for hot taps:

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1.

General Specification for hot tapping EMETL G4S-4201-01

2.

Design Stress Specifications for hot tapping EMETL G4S-4201-02

3.

Welding Requirements & Considerations for hot tapping EMETL G4S4201-03

Note: These EMETL standards are based on the following Recognized and
Generally Accepted Good Engineering Practices:
American Petroleum Institute (API) Recommended Practice (RP) 2201; Safe
Hot Tapping Practices in the Petroleum and Petrochemical Industries.
API RP 2009; Safe Welding, Cutting, and Hot Work Practices in the Petroleum
and Petrochemical Industries.
B. Link to the Global Hot Tap Website.
IV.

PROCEDURES
A. OWNER RESPONSIBILITIES
1.

Hot Tapping or hot welding is not permitted on the following before being
cleared:
1) Equipment containing materials such as Chlorine that will react with iron or
steel at elevated temperatures and/or pressures;
2) Equipment containing material having an upper flammable limit of 40
percent or above, or which contains its own oxygen sufficient to cause a
spontaneous reaction;
3) Steam lines above 475 psig (32.7 barg);
4) Ethylene lines.
5) Additional restrictions are found in General Specification for hot tapping
EMETL G4S-4201-01, (see Section 3.3 and Appendix A in the EMETL
document)

Please see Attachment A for information on using a plug as a means of isolation.

2.

Obtain approval of proposed Hot Tap for further engineering evaluation.

Approval for performing an engineering evaluation of a proposed hot tap is
initiated by obtaining approval from the reviewers listed below (see Appendix E
for an example Hot Tapping Request Form) and performing the appropriate nondestructive examination (NDE). The following personnel (or their designee)
review, approve and are notified of proposed hot taps for further engineering
evaluation:
Lower Hazard Service

Higher Hazard Service

Reviewers

Maintenance Leader

Technology Center Director, Maint.

Ldr

Approvers

Production Leader

Production Leader, Site RCL,

Notification PSTL, Site RCL, Eng. Rep. Site Leader, BML , Eng. Rep., PSTL
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Notes:
.A
Welding and/or hot tapping on lines containing the materials listed in EMETL G4S4201-01 Section 3.3; should not be performed unless the prescribed reviews are
conducted.
.B
Welding and/ or hot tapping on lines under vacuum is not recommended and should not
be performed unless the prescribed reviews n EMETL G4S-4201-01 are conducted.
.C
Hot taps on piping systems (e.g., utilities, vent headers) could impact other facilities.
Consideration must be given to the impact of the loss of the functionality of these systems
on those facilities.

3.

Obtain engineering calculations that support performing and provide operating

conditions for the Hot Tap.

4.

Perform a hazard assessment, have a written job procedure and a contingency

action plan (see Appendix G for an example Hot Tap Contingency Plan). The
Hot Tap procedure should address possible loss of product containment and
initial emergency response. On-line leak repair jobs shall also have a written job
procedure.

5.

Comply with the requirements of the following EMTL Standards for Hot Taps
that contain the engineering evaluation, design, welding procedure and post
testing requirements. EMETL G4S-4201-01 requires the completion of the
Global Hot Tap Checklists (Appendix F) or an equivalent.

General Specification for hot tapping EMETL G4S-4201-01

Design Stress Specifications for hot tapping EMETL G4S-4201-02
Welding Requirements & Considerations for hot tapping EMETL G4S-4201-03
6.

Obtain final approval to proceed with the Hot Tap. The following personnel
(or their designee) are responsible for the final review and approval for
performing the hot tap. The intent is to ensure that the hazard assessment and
work plans have been completed, the identified risk is acceptable and the
contingency plans are adequate. The MOC process shall be utilized to
document final approvals prior to initiating the Hot Tap.
Lower Hazard Service

Higher Hazard Service

Reviewers

Maintenance Leader, EH&S

Delivery

Production Leader,
Production Leader(s) of
other impacted facilities. Site
RCL, Technology Center
Director, Maintenance
Leader, PSTL

Approvers

Production Leader of Facility,

Production Leader(s) of other
impacted facilities. Site RCL

Site Leader, BML

Note:

Safety Standard M-62

Revisions 6/08

The appropriate technology center is always involved in higher hazard hot

taps, including Reactive Chemicals / Process Safety / Engineering reviews.

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M-62
7.

Assure the work area is cleared of flammable materials before work covered by
this standard begins. Special considerations must be given to underground
sumps and drains.

8.

Vacate all non-essential personnel from the affected area prior to the Hot Tap.

9.

Assure all test instruments are operable before and after each use.

10. Test the work area with a combustible gas indicator before allowing Hot Tapping
and/or Hot Welding to begin. The readings shall be essentially zero. (Consider
using a continuous combustible monitor.)
11. Provide an appropriate fire extinguisher (both size and type) and assure that the
workers know how to use it.
12. A Safe Work Permit must be issued before any work is started.

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C. WORK PREPARATION METHODS FOR EQUIPMENT AND/OR PIPING
Use one or both of the following methods to prepare the equipment and piping for
HOT TAPPING ON EQUIPMENT CONTAINING HAZARDOUS MATERIALS
OR PRESSURE.
1.

Assure oxygen is excluded from the equipment to be worked on by:

a.

Applying a purge or pad when oxygen may be present, sufficient to remove

oxygen above four percent by volume if clearing the equipment of
flammable is not feasible
1)
2)
3)

b.

Nitrogen is the preferred material.

Test the equipment with an oxygen meter.
Test the area with a combustible gas detector.

Monitoring for oxygen to assure there is none present. Consider continuous

monitoring. (Example: On fuel gas and other flammable product lines.)

D. PRECAUTIONS
1.

Any vents or leaks from the equipment into the area may be flammable and
present a hazard. If an inert purge is being used, assure there is adequate
ventilation.

2.

A qualified person to act as a fire watch should be considered if appropriate.

3.

Take appropriate precautions to prevent sparks from igniting flammables or

combustibles, such as oil, scaffold boards, or tarps.

Please contact your EH&S Delivery Leader for additional information.

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M-62
ATTACHMENT A
When using a plug (i.e.; sewer plug, plumber's plug, inflatable bag), be sure the following precautions
are met: (See Appendix A-D)
1.

Develop specific procedures for installation of the plug assembly.

2.

Ensure the plug is properly secured and sealed so that it does not become a projectile or
does not leak.

3.

Assure there is a sufficiently sized opening upstream to prevent overpressuring. It should

be on the top or the side of the line. Verify opening is not plugged.

4.

Have a continuous purge of an inert gas or water to give a constant safe pressure. Do not
allow pressure to build up or fall to zero.
a.

Continuously monitor pressure with a device sized to measure a few inches of water
(such as a manometer), or have a "safety attendant" responsible for observing the
pressure gauge to assure the inert gas sweep is constant.

b.

Purging may be initiated from either side of the plug. Place pressure monitor between
point where purge is introduced and the sewer plug, or on the purge line downstream
of the purge supply valve.

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APPENDIX A

CLAMP

CHAIN

COUPLING

BAR STOCK

SEWER PLUG

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M-62

APPENDIX B

Manometer

Nitrogen Purge
Sewer Plug

Water

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Appendix E - HOT TAPPING REQUEST FORM

HOT TAP REQUEST FOR EQUIPMENT IN SERVICE Engineering/Design Request (Page 1 of 2)
Note:. A separate request is required for each individual hot tap.

From (Initiator) ___________________________________ Department _____________________

To:

Production Leader, Maintenance Leader, Site RCL, PSTL, Engineering rep. (All Hot Taps)
Technology Center Director / Designee, BML, Site Leader

(Higher Hazard Hot Taps)

The following hot tap is proposed for your approval on piping, vessels, tanks, etc., in service in your area, or in an
area affecting your operations:
Unit or Area _____________________________________________________________
Location:______________________________________________________________________________________
_____________________________________________________________________________________________
_______
Project Description:
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
____________
Alternate solutions considered:
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
____________
TYPE OF PROPOSED INSTALLATION
HEADER OR VESSEL INFORMATION
LINE SIZE (cm or in.) ___________________ METALLURGY __________________
OPERATING PRESSURE __________ TEMPERATURE ______________
PROCESS DESCRIPTION____________________________________________
BRANCH CONNECTION INFORMATION
LINE SIZE (cm or in.) _______________________. FLANGE RATING _________ (Barg or Psig)
GASKET MATERIAL ______________ METALLURGY ___________________
A location sketch of the proposed hot tap is recommended. The hot tap location must have scaffolding (where
required for access), insulation must be removed and the equipment must be marked for the exact hot tap location
prior to notifying Pressure Equipment Inspection.

Continued on next page

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M-62

HOT TAP REQUEST FOR EQUIPMENT IN SERVICE (Page 2 of 2)

PRELIMINARY NONDESTRUCTIVE EXAMINATION OF HOT TAP LOCATION
To be filled out by the Qualified Inspector and the PCE or Piping Engineer
The proposed location of the hot tap must be examined within 28 days before performing the hot tap to determine
the variation in thickness along the line of welding and to examine the pipe wall for laminar defects, transverse
cracks, and internal pitting. The usual NDE techniques are a combination of radiography, shear-wave ultrasonics,
magnetic particle or dye penetrant examination, and ultrasonic thickness. If the hot tap takes place more than 28
days after this preliminary NDE, the NDE should be repeated within 7 days before performing the hot tap.
WALL THICKNESS AT HOT TAP LOCATION: Minimum: _______ (cm or in.) Maximum: _______ (cm or in.)
DETERMINED by (NDT Technique): ____________________________________. Attach copies of the NDE
reports.
Date of testing: ________
Is there any additional NDE required before the hot tap, based on conditions revealed by these examinations?
_____________________________________________________________________________________________
__
_____________________________________________________________________________________________
__

AREA INSPECTOR_____________________________________________________________DATE
____________
PRESSURE EQUIPMENT ENGINEER_____________________________________________DATE
____________

APPROVAL TO BEGIN ENGINEERING/DESIGN WORK ON THIS HOT TAP

Approved by _________________________________________________________________ Date_____________
(Production Leader of equipment involved)
To _______________________________________________________ Date____________
(Site Responsible Care Leader) (Higher Hazard Hot Taps)

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M-62

Appendix F - HOT TAP CHECKLISTS

This checklist is an example of a type of aid some facilities use as a reminder to accomplish the steps involved in
hot tap operations in an orderly manner. It is recommended that these be utilized in the development of Work
Procedures. Particular circumstances of jobs may dictate additional preparatory steps. This checklist can be retained
as a record of the job preparation. Checklists such as these are required by G4S-4201-01 and will assist in
performing the hazard assessment and developing procedures.
Note: All of the checklists included in these tables are provided only as examples. They are
not intended for adoption without review and customizing for individual circumstances. The
titles and responsibilities used in these checklists are representative of practice used by
some facilities in the petroleum and petrochemical industry. Facilities choosing to adopt a
similar list should base it on their own organization structure, titles, assigned
responsibilities, and specific hot tap and work permitting procedures.

Location _____________________________________________
Date ________________________________________________
Job _________________________________________________
Prepared by _____________________________________________
Table 1 - Before Starting the Hot Tap
Each of the following considerations shall be satisfied BEFORE STARTING THE
HOT TAP
1

Review/ follow hot tap machine manufacturers operating instructions

Have the contents of the line or vessel to be hot tapped or welded been assessed, and
MSDSs reviewed for health hazards, to assure procedure is appropriate?

Is the material in the line or vessel stable under heated conditions?

Has the connection been designed per EMETL G4S-4201-01 Section 7 requirements?

Do the flanges, bolts, gaskets, pipe, and valve to be installed meet the code for the line
or vessel to be hot tapped?

Has the welding procedure specification been developed as covered in EMETL G4S4201-03?

Have approved work permits (e.g., Hot Work, Confined Space Entry) been obtained?

Review manufacturers instructions to ensure that the hot tapping machine has
suitable pressure, temperature ratings, and adequate cutter travel for this job.

Step Included
in Procedures?

Initials
Checked by

Continued on next page

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M-62
Table 1 - Before Starting the Hot Tap (continued)
9

Has the valve been pressure tested and the cover fitted to assure that it will work and
fit properly?

10

Has the exact location of the hot tap been identified and marked on the line or
equipment?

11

Is the area to be hot tapped located on a line in which flow has been established or
below the liquid level of the tank or vessel?

12

Has the area to be welded been inspected for thickness and freedom from existing
welds, internal pitting, laminations, hydrogen attack, or other metallurgical
imperfections?

13

Are NDE test and inspections current?

14

If laminations or defects have been found, has a thorough engineering evaluation been
made by a qualified piping or vessel designer and welding SME to determine if and
how to proceed with the work?

15

Has the metallurgy of the line or vessel been established, and is it compatible with the
connecting fitting? Verified with Positive Materials Identification (PMI)?

16

Can the welding and tapping area support the weight of the hot tapping machine,
reaction forces during cutting. Is there adequate hoisting and support for the hot
tapping machine and subsequent piping?

17

Is there sufficient external clearance to install the hot tapping machine and extract the
cutter through the valve?

18

Is there sufficient internal clearance to retract the cutter and coupon through the
valve?

19

Is the hot tap fitting of the proper length to accommodate operation of the hot tapping
machine?

20

Have oxygen, combustible gas, and atmosphere contamination tests been conducted in
the hot tap area?

21

Has a dedicated fire watch person been assigned and appropriate training and fire
fighting equipment provided?

22

Has the Fire Watch person been provided with a list of duties as outlined in Table 2?

23

Are all personnel in the area equipped appropriate personal protective equipment?

24

Is there adequate storage area and room for operational needs and emergency access or
egress?

25

Has a procedure been prepared and in place to isolate the work area in the event of a
failure and material release?

26

Are personnel trained to implement the contingency procedure?

27

Have the requirements been defined for weld inspection and for pressure testing. Is all
of the testing equipment on hand and in good working condition?

Continued on next page

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Table 2 - Fire Watch Duties

FIRE WATCH DUTIES INCLUDE

Being able to communicate effectively with personnel in area

Watching for fires in all exposed areas

Knowing how to use the required fire suppressions equipment

Knowing how to activate the facility fire alarm

Trying to extinguish a fire only when obviously within the capacity of the equipment
available (extinguisher or hose)

Activating the fire alarm when available equipment is not sufficient to suppress minor
fire.

Maintaining a watch for at least hour after completion of welding, hot tapping, or
other hot work until the area has been inspected and found to be free of leaks and
ignition sources (fires, hot spots, or smoldering material)

Step Included Initials

in Procedures? Checked
by

Table 3 - Before Welding

Each of the following considerations should shall be satisfied BEFORE
WELDING:
1

Are the welders qualified for the approved welding procedure specification (WPS) to
be used?

Is a preheat of the weld area required?

Is the fitting properly positioned to prevent misalignment of the hot tapping machine?

Have the pressure and temperature of the contained materials been reduced as much as
the process operation will allow?

Have the flow, pressure, and level considerations of EMETL G4S-4201-01, Sections 4
and 5 been addressed?

Prior to welding, discuss proper clearance for hot tap machine to ensure access for hot
tapping equipment.

Step Included
in Procedures?

Initials
Checked
by

Continued on next page

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Table 4 - WELDERS INSTRUCTIONS PRIOR TO HOT TAPPING

WELDING SAFETY TASK REVIEW (WSTR)

TAPPING

- PREPARATION FOR HOT

Step
Included in
Procedures?

Initials
Checked
by

Review the Hot Tap plan and verify that all workers understand their duties. (All members
of the crew are to be present for the Welding Safety Task Review (WSTR) including piping
supervisor, welding supervisor, pipe welder(s), pipefitter(s), and helper(s).)
Discuss hot tap information and requirements (thickness of pipe to be welded, temperature
of pipe to be welded, pressure in line and product in line to be welded).
Discuss proper welding procedure with welder or welders that are going to be involved
with welding process (location of machine plus setting of amperage on machine).
Verify that the right location or area was examined for thickness and defects and marked
for weld attachment of hot tap fitting.
Discuss how to clean the area to be welded prior to welding.
Discuss required tools to be used for cleaning pipe, grinding tacks, grinding stringer. (If
power tools are not recommended, what alternative tools must be used?)
Discuss gap needed for root pass between stub and existing header.
Discuss need to electrically bond (ground) ground cable to hot tap fitting
Discuss amount of penetration needed on stringer bead. (Avoid excess amount of weld
penetration which could interfere with drilling of hot tap; don't back weld fittings.)
Discuss requirement to clean out Hot tap stub and remove all debris at completion of weld.

Note: WELDING SUPERVISOR MUST BE PRESENT FROM WSTR MEETING THROUGH COMPLETION OF
WELDING.

Continued on next page

Table 5 - Before Cutting

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M-62
Each of the following considerations shall be satisfied BEFORE CUTTING:

Has the weld been inspected and tested?

Has the hot tap fitting been pressure tested?

Have the hot tap valve, packing, gasket, and bolts been checked for leakage?

Has the packing or seals on the hot tapping machine been checked?

Has the bleed off valve been checked to assure it will hold, is operable, and is not
obstructed?

Are all bolts on the pilot and cutter bit tight? (e.g., torque to specifications)

Is the coupon catcher on the pilot bit?

Is the valve centered on the flange?

Has cutting depth been calculated to avoid cutting the opposite side of the pipe?

10

Has the boring bar been run through the valve to assure free passage?

11

Have the hot tapping machine and valve been purged, if recommended?

Step Included
in Procedures?

Initials
Checked
by

Step Included
in Procedures?

Initials
Checked
by

Table 6 - Before Removing the Hot Tapping Machine

Each of the following considerations shall be satisfied
BEFORE REMOVING THE HOT TAPPING MACHINE:

Have the manufacturers instructions been followed to be sure that the boring bar is
fully retracted before closing the hot tap valve?

Has the hot tap valve been closed?

Has the bleeder valve been opened?

Has all of the pressure been bled from the hot tapping machine before removing the
bolts from the flange?

Have provisions been made to contain or control any liquid or gas in the hot tapping
machine?

Continued on next page

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Table 7- After Removing the Hot Tapping Machine

AFTER REMOVING THE HOT TAPPING MACHINE

The hot tapping machine should be cleaned, removing the hydrocarbons/chemicals

from the line or equipment.

All rags, absorbent pads, and other cleaning materials must be disposed of properly.

When the work is completed a follow-up job site visit should be done by operations
and craft personnel to see that:

3a

The work is complete,

3b

No safety hazards have been introduced during the work activity.

Safety Standard M-62

Revisions 6/08

Step Included
in Procedures?

Page 19

Initials
Checked
by

M-62
Appendix G - IN-SERVICE HOT TAP CONTINGENCY ACTION PLAN
A Hot Tap Contingency Plan does not replace the Sites established emergency action plan, but rather is a
supplement for this special type of work. The plan addresses what specific problems could arise and what to do if
things go wrong during a Hot Tap. (Some examples include: burn-through during welding, with ignition of
flammable contents; leaks; losing the hot tap coupon; hot tap machine becoming stuck and unable to be
withdrawn; cutting through the opposite side of a pipe; or significant loss of containment of process materials.)
1. This plan has been communicated to all parties involved:
( ) Operations ( ) Craft persons ( ) Fire watch
2. Fire watch has been familiarized with equipment on site:
( ) Fire watch Equipment: ( ) Contractor Equipment ( ) Facility Equipment ( ) Emergency PPE
3. Emergency Action Plan:
A. Emergency Equipment Description, including personal protective equipment for emergency response (such
as
SCBA, specific gloves, bunker gear, chemical suit, etc.):
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
B. All non-Essential personnel have been vacated from the affected area.
C.

Exact Location:
______________________________________________________________________________

D.

Process Material: _____________________________________________

Temperature: ___________
Pressure: ___________

MSDS Hazard Ratings

Fire____ Reactivity _______
Health ____ Other _______

E. Attach field sketch of isolation points to be used in the event of an emergency situation. (Isolation points
must
be tagged.) ______________________________
F.

List action steps to be taken in the event of an emergency. (Provide reference sketch when appropriate and
specify PPE)
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________

G.

If storage tank, note isolation valves to be chained and locked on sketch:

Is liquid level 3 ft above weld location? ( ) Yes ( ) No

H.

List predefined actions to be taken if the Tap Coupon is not recovered during the hot tap machine removal.
______________________________________________________________________________________
_____________________________________________________________________________________

I.

Plant representative coordinating emergency action plan response:

Name of Plant Representative: _________________________ Phone ___________
Alternate Plant Representative: _________________________ Phone ___________

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