HOT TAP PROCEDURES

OCTOBER 1993 PAGE10F16 EGS 1150 -1993

TABLE OF CONTENTS

1. Scope 5.3 Welding

2. References 5.4 Weld Inspection and Testing
3. Definition 5.5 Hot Tap Assembly Testing
4. Safety Precautions 5.6 Coupon Cutting
5. Procedures 5.7 Blinding a Hot Tap
8 5.1 Design Considerations and Inspection 5.8 Replacing a Pipe Section
5.2 Hot Tap Preparation Appendix -Hot Tap Checklist

SCOPE

This Guide covers hot tap procedures for piping and storage tanks in petroleum refineries, chemical
plants, natural gas processing plants, loading terminals, and similar installations.

This Guide applies to piping and storage tanks that are fabricated only from ferritic, austenitic, and cast
iron materials. Hot taps are not permitted on materials that require postweld heat treatment (PWHT).
Hot taps on other materials may require special procedures and shall be approved by Mobil.

REFERENCES

The following publications form a part of this Guide. The references cited with dates in this Guide
were used in its development. For all references which have been superseded, revised, and/or
8 corrected, the user of this Guide is obligated to determine if the latest versions of the cited references
have any impact on the content of this Guide or its use. MRDC (Guide Sponsor) should be consulted
if there are any concerns or questions.

Mobil Engineering Guides

EGE 00-8-21 (1993) Pressure Containing Equipment -Welding and Weld Inspection
EGE 00-8-22 (1991) Pressure Equipment -Impact Test Requirements
EGE 16-8-1 (1993) Piping -General Design
EGE 16-8-22 (1990) Piping -Process Equipment
EGE 16-8-30 (1987) Piping -Selection and Application of Piping Components and Materials
EGE 16-8-40 (1989) Piping -Fabrication, Erection, Inspection, and Testing
EGS 266 (1993) Existing Aboveground Storage Tank Inspection, Repair, Alteration, and Testing

API (American Petroleum Institute) Standards

620 (19901 Design and Construction of Large, Welded, Low-Pressure Storage Tanks
650 (1988) Welded Steel Tanks for Oil Storage

2.
 ~"OBIL ENGINEERING GUIDE

EGS 1150 -1993 PAGE 2 OF 16 OCTOBER 1993

ASME (Almerican Society of Mechanical E:ngineers) Publications

Boiler and Pressure Vessel Code:

(1992) Section IX, Welding an(j Brazing Qualifications

831.1 (1992) Power Piping

831.3 (1993) Chemical Plant and Petroleum Refinery Piping

NFPA (National Fire Protection Association) Code

321 (1991 ) Standard on Basic Classification of Flammable and Combustible Liquids

3. DEFINITION

Hot Tap -A method for installing connections on piping and storage tanks without removing the
~ng/storage tanks from operation. The method consists of welding or bolting a flanged or threaded
~ing to the piping/storage tanks, then attaching a valve and a tapping machine and mechanically
cutting and removing a coupon.

SAFETY PRECAUTIONS

4.1 Hot tapping involves certain s,3fety risks and should only be considered if modifications to
piping/storage tanks cannot be delaYled until the next shutdown, or if no shutdown can be arranged
for the required modifications. Hot tap operations shall be well coordinated among engineering,
maintenance and/or the hot tap contractor, inspection, and loss prevention personnel. Only qualified
personnel shall perform hot tap operations.

4.2 A hot tap shall not be made on:

(a) Piping and storage tanks that contain a flammable gas and air mixture.

(b) Piping and storage tanks that contain acids, ammonia, chlorine, or chlorine compounds which
could decompose from the heat of welding.

(c) Piping and storage tanks that contain hydrogen above 100°C (212°F).

(d) Piping and storage tanks that are clad, lined, or overlaid with glass, lead, refractory, cement,
plastic, or alloy metal.

(e) Piping and storage tanks that are jacketed.

(f) Piping and storage tanks that require PWHT in accordance with applicable codes, standards,
and/or Mobil Guides.

(9) Piping and storage tanks in hydrofluoric acid service.

(h) Piping and storage tanks in caustic service where concentration and temperature requirp;
PWHT.

(i) Air receivers and air lines where lubricating oil may have entered the system, resulting in a
hazardous atmosphere.

4.
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OCTOBER 1993 PAGE 3 OF 16 EGS 1150 -1993

(j) Pressure vessels and heat exchangers.

4.3 Hot tapping on piping and storage tanks in amine and sour gas services is not recommended.
When hot tapping on such piping/storage tanks is absolutely necessary, the local plant engineering
department or MRDC should be consulted prior to hot tap operations.

4.4 The operating pressure and temperature of piping/storage tanks to be hot tapped shall at no time
exceed the rated pressure and tempe,rature of the tapping or stopple plugging machines. Care should
be taken to ensure that neither the pressure nor temperature will rise appreciably during the hot tap
operation as a result of a surge of pressure or a temperature rise of the fluid contents of the
piping/storage tanks being hot tapped. Flow in hot tapped lines should be maintained during welding
operations to reduce heat accumulation; however, avoid high flowrates when welding to prevent
excessively rapid cooling of the welded area. A minimum velocity of 0.4 m/s (1.3 fils) is
recommended in gas lines. It is recommended that the pressure be reduced to within the range of
8>ne-third to one-half the normal oplarating pressure during the hot tap operation. When cutting into
the lines, it is recommended that fluicj velocities be maintained below 5 m/sec (1 5 ft/sec) in liquid lines
and below 10 m/sec (30 ft/sec) in ~,as lines.

4.5 When making a hot tap on a line, verify that the correct line is being tapped. In the case of an
underground line, verify that a sleeve is not being tapped rather than the pipe.

4.6 The contents of storage tanks shall not be circulated during hot tapping. Tank inlet and outlet
valves shall be closed and locked shut. Mechanical mixers shall be locked out and heating coils shut
oft and locked shut. There should be a 1 m (3 ft) minimum 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 ensure that the gas in the vapor
space is at no time in the flammable range. Where 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, except when
water is not compatible with the tank content.

4.7 In certain cases, such as in a flare line, there may be insufficient or interrupted flow that may
.:{esult in a flammable mixture during the welding operation. It may be necessary to continuously purge
~he line with steam, inert gas, or hydrocarbon gas to prevent the formation of flammable mixtures.

4.8 When hot tapping is performed on piping/storage tanks under vacuum, a continuous purge with
an inert gas at 4 to 6 mm Hg (2 to 3 in. H2O) should be maintained during the hot tap to ensure an
air-free operation.

4.9 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 a combustible gas meter prior to starting hot
work. An accessible exit must be provided for personnel and checked periodically during the hot tap
operation.

5. PR()CEDURES

5.1 tlesign Considerations and Inslpection

5.1.1 limitations and other requirements for hot taps of aboveground tanks are included in
EGS 266.

Size
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EGS 1150 -1993 PAGE 4 OF 16 OCTOBER 1993

5.1.2 From records or stampings, determine the chemical analysis and mechanical properties of the
material to which the hot tap connection is being attached. The Texas Nuclear Analyzer is frequently
used to identify materials of unknown chemical composition; however, when the metal temperature
is over 70°C (160°F), the accuracy of this instrument is reduced and the local plant engineering
department or MRDC Materials Engineering Section should be consulted prior to hot tapping.

5.1.3 Design the hot tap connection in accordance with the following codes, standards, and/or
Mobil Engineering Guides, whichever is applicable:

-ASME 831.1 .API 620 .EGE 1 6-8-1

.ASME 831.3 .API 650 .EGE 16-8-22

.EGE 16-8-30

cDu'ations to determine the required thicknesses for piping/storage tanks, nozzle necks or fittings,
reinforcing pads, and weld attachments should take the following into account:

(a) The design temperature and internal pressure.

(b) Possible transient temperature and/or pressure that exceed the design conditions, which may
occur during the hot tap operation.

(c) The required corrosion allowance

(d) External differential pressure applied to the existing piping/storage tanks during testing of the
hot tap fitting.

(e) The loads applied by the tapping equipment.

Hot tap connections for line bypass additions should be designed to accommodate the loads exerted
by the new piping.

Jl4 Select the proper fitting for making the connection based on the design calculations
mentioned in Paragraph 5.1.3, taking into account the pressure-temperature rating of the
piping/storage tank involved. Some of the fittings available are welded outlet fittings, split tees, long
welding necks, etc. Except when installing bypass lines, full line size hot taps are not recommended.
If a full line size hot tap is required, a full encirclement fitting (such as a split tee) should be used.

In steam and corrosive services, o-let fittings or stub-in connections are preferred. Split tees and
saddles should not be used so that trapping of the corrosive fluids between the reinforcement area and
the hot tapped piping/storage tank can be avoided.

Ascertain that the nozzle length, plus the isolating valve length and thicknesses of the gaskets, does
not exceed the maximum travel of the cutter.

5.1.5 Hot tapped connections used for temporary bypass may cause high pressure drops due to the
configuration or to the necessity for a pi~)ing connection to be less than line size; therefore, allowance
for pressure drop through the connection should be made when selecting the hot tap size.
 MOBIL ENGINEERING GUIDE

OCTOBER 1993 PAGE 5 OF 16 EGS 1150 -1993

5.1.6 When tapping a line, the preferred location is on top of the pipe so that metal cuttings will
fall into the pipe and be washed away. Potential problems with metal cuttings contaminating the
product stream should be considered. Problems arise when the hot tap must be made on the underside
or side of the pipe. When cutting from the bottom, there must be sufficient void under the valve to
allow the metal cuttings to fall and to retract the cutter and coupon through the valve. When cutting
in the horizontal position, metal particles can get into the valve seat and prevent tight closure. Junk
traps are sometimes used on the bottom of a fitting to collect metal cuttings.

5.1.7 Avoid hot tapping upstream of control valves, instruments, and rotating equipment unless
such equipment is protected by filters or traps.

5.1.8 Hot tap connections and reinforcing pads, if required, should be no less than 75 mm (3 in
from a welded seam or 460 mm (18 in.) from a flanged or threaded connection.

~.1.9 Verify that the tapping machine, including packing and elastomers, will not be affected
adversely by the fluid in the piping/storage tank.

5.1.10 Specify the cutter size that is required to:

(a) Avoid interference with the weld areas and the inside diameter of the hot tap connection

(b) Minimize the inside "lip" which may cause excessive turbulence near the piping/storage tank-
to-nozzle junction area.

5.1 .11 A full port steel gate valve shall be used as a block valve for the tapping machine even when
cast iron valves and fittings have been used for the initial installation, because the stresses imposed
on the valve by the tapping machine may result in a fracture. This valve shall be of adequate pressure
rating for the service intended and shall be pressure tested prior to the installation. When the valve
is to be left in place after completion of the hot tap, the valve body, trim, and packing materials shall
be suitable for the intended service. The adapter for mounting the tapping machine on the valve shall
also be steel. Bolting a raised-face steel flange to a flat-face cast iron flange shall be avoided.

~. 1.12 Inspect and test the condition of the piping/storage tanks prior to hot tapping. By ultrasonic
testing, ensure that the pipe or tank wall is free from laminations and the thickness is adequate for safe
welding. Ultrasonic scanning should be done over the entire hot tap area, including the area under and
around the reinforcing pad if required, and the weld periphery. The minimum thickness is dependent
upon the following:

(a) The material being welded.

(b) The operating temperature and pressure during welding

(c) The welding procedure

(d) The product inside the pipe or storage tank.

Generally, the thickness should be no less than 5 mm (0.20 in. and at least the thickness calculated
in accordance with Paragraph 5.1.3.
 MtDBIL ENGINEERING GUIDE

EGS 1150 -1993 PAGE 6 OF 16 OCTOBER 1993

The local plant engineering department or MRDC Materials Engineering Section should be consulted
prior to welding on material that is less than 5 mm (0.20 in.) thick.

If heavy pitting or localized corrosion or erosion is suspected in the area to be hot tapped, radiographic
inspection, wherever feasible, should be used in addition to ultrasonic scanning to assess the condition
of the existing piping/storage tanks.

5.2 Hot Tap Preparation

Prior to hot work, the following procedure is recommended:

(a) Develop a detailed plan to clarify all concerns applicable to the hot tap.

(d) Verify the correct piping/storage tank to be hot tapped, as well as the correct location.

(e) Verify that the condition, material, and the measured thicknesses of the piping/storage tank
to be hot tapped are adequate for \Nelding.

(f) Verify that the proposed welding procedure is suitable for the intended hot tap application

(g) Conduct all necessary hydrocarbon and oxygen tests to ensure that no flammable vapor is
present.

(h) Obtain a hot work permit.

(i) Establish a fire watch and prl:>vide at least a 12 kg (30 Ib) dry chemical extinguisher. It is
recommended that a fire hose be charged and ready for operation whenever feasible. If a charged
()1ose is provided, an additional trainelj persorl is required to use it. A fire blanket should be on hand
to extinguish clothing fires ignited by welding or preheat operations.

(j) Complete the Hot Tap Checklist (see Appendix) by verifying all the items.

5.3 Welding

5.3.1 The welding procedure to be used shall be qualified in accordance with the ASME Code,
Section IX or equivalent local regulatiolns.

5.3.2 The welding operator shall tIe qualified in accordance with ASME Code, Section IX or
equivalent local regulations.

5.3.3 Low-hydrogen rods with a minimum tensile strength of 480 MPa (70,000 psi) should be used
for hot tap welding on carbon steel piping or storage tanks.

5.3.4 To minimize the risk of burn-through, the first weld pass should be made with a 2.4 mm
(3/32 in.) diameter electrode. Subsequent passes should be made with a rod that is 3.2 mm (1/8 in.)
 MOBIL ENGINEERING GUIDE

OCTOBER 1993 PAGE 7 OF 16 EGS 1150 -1993

in diameter or less. Use welding parameters toward the lower end of the range that is recommended
by electrode manufacturers. For wall thicknesses greater than 12.8 mm (1/2 in.), where burn-through
is not a primary concern, larger diameter electrodes may be used. It is advisable to perform a test weld
on a plate of similar material and thickness using the welding procedure selected for the hot tap.

5.3.5 When the temperature of piping/storage tanks being welded is below 10°C (50°F), the metal
should be kept warm [at 38°C to 93°C (100Of to 200°F)] during the welding operation in order to avoid
cold cracking. Careful control of the metal temperature must be maintained by the use of
thermocouples, if necessary. Welding on refrigerated piping/storage tanks should be reviewed by the
local plant engineering department or MRDC.

5.3.6 Attaching hot tap connections to cast iron lines by brazing or welding is not recommended
except for low-pressure water lines [below 690 kPa gage (100 psig)]. Bolted, clamped, or screwed
fittings should be used.

~.3.; When welding on piping and storage tanks that contain materials in the vapor phase, time
should be allowed between each weld pass to allow the parent metal to cool. Continuous welding may
cause a temperature rise that could impair the properties of the metal.

5.3.8 For piping/storage tanks that contain hydrogen, a hot tap is permitted only when the fluid
temperature does not exceed 100°C (212°F). Check piping/storage tank temperature with a magnetic
surface thermometer immediately before welding. Restrict the interpass temperature to 149°C (300°F)
maximum.

5.3.9 Before welding, the fitting shall be checked to ascertain that it is properly positioned to
prevent misalignment of the tapping machine when the cut is made. For cuts at an angle other than
90 degrees, a drill pilot guide sleeve shall be welded to the part being tapped.

The fitting shall be welded in- place using the specified rod, required number of passes, and proper
welding procedure. Welding on piping shall be in accordance with EGE 00-8-21 and EGE 16-8-40.
Welding on storage tanks shall be per EGS 266. Any weld made on the inside of fittings shall be
~round smooth to permit free passage of the cutter. When internal grinding is difficult (for example,
~n small bore connections), root pass welds should be made using the gas tungsten arc welding
process (GTAW) or using E60XX stick electrodes. longitudinal welds on split tees should be
completed prior to circumferential welds. The fillet weld sizes for split tees and saddles should not
exceed 1.5 times the pipe wall thickness.

5.4 Weld Inspection and Testing

The welded attachment shall be inspected during and after welding and shall be pressure tested before
installing the tapping machine as follows:

(a) The root pass and final pass of all welds shall be dye penetrant, magnetic particle, or
ultrasonically tested to assure that the quality of welds meets the requirements of the applicable
codes.

(b) Connections shall be hydrostatically tested prior to cutting the coupon. The test pressure
shall be as required by the applicable code. If calculations show that the test pressure required by
the code may cause local yielding, the test pressure may be reduced to the maximum pressure that
will not result in stresses exceeding the yield strength at test temperature. The test pressure shall
 MOBIL ENGINEERING GUIDE

EGS 11 50 -1993 PAGE 8 OF 16 OCTOBER 1993

be at least equal to the maximum operating pressure of the hot tapped piping/storage tank and
should not exceed the pressure ratings of the isolating valve and tapping machine. When the
operating temperature is above 93°C (200OF) and the saturation pressure of the steam generated
is above the hydrostatic test pres~iure, the test should be performed with a light oil. At high
temperatures, or if the water is not ,compatible with the content of the piping/storage tank being
hot tapped, a pressure test using air or an inert gas may be performed instead of a water test.

When oil is used for a pressure test, ~)afety precautions should be taken to avoid a fire or injury to
personnel from hot oil if a leak or failLlre of the newly welded connection should occur. Oil should
not be used when its flash point is below the operating temperature of the piping/storage tanks
being tested. Oil shall never be used above its autoignition temperature.

When air is used and consequently heated, the pressure shall not be permitted to exceed the test
.f!:ressurie req~ired by the governing cclde or standard. A NPS 3/4 (NPS = nominal pipesize, inches) relief
'l)alve, that IS set at the test pressure may be used to prevent overpressure. Connections on
low-pressure lines operating at or below 100 kPa gage (15 psig) and on nozzle reinforcing pads
should be given a soap-suds and low-pressure air test at 100 kPa gage (1 5 psig).

(c) Hot tap connections on abovE~ground storage tanks shall be pressure tested in accordance
with EGS 266.

5.5 Hot Tap Assembly Testing

The operability of the tapping machine shall be checked prior to use.

After installation of the tapping machine,. check the tightness of bolts, packing, and packing nuts and
pressure test the assembly. The test medium should be the same as in Paragraph 5.5. The test
pressure should be at least equal to the operating pressure of the hot tapped piping.

5.6 Coupon Cutting

5;.6.1 The tapping machine shall be installed on the gate valve, as shown in Figure 1. The cutter
~-j be extended through the valve op4~ning several times to be sure that it will clear. The operator
shall ensurl~ that there is sufficient clearance between the tip of the pilot drill and the trim of the closed
valve to permit retraction of the cutter after the coupon is cut. When tapping a line, the operator shall
determine the cutter travel required for cl~tting through the pipe wall without scoring the opposite side.
The positions of the cutter, when full',! retracted and after cutting through the pipe wall, shall be
marked on the measurement rod of the tapping machine before drilling and documented for records.

5.6.2 The cutter body may be filled with oil. This will lubricate the cutter, absorb heat, and
eliminate the air space. Where contamination of product is a problem, the tapping machine body may
be filled with the product if it is a Clas~; II or Class III liquid, as classified in NFPA 321 .

Oil should never be used when tapping air lines. The cutter should be operated dry and at a slow
speed to minimize heat generation, or water should be used for cooling -provided the water will not
contaminate the product. When the temlperature of the fluid contained in the piping/storage tank being
tapped is above its autoignition temperature, it is preferable that the tapping machine assembly be
purged with an inert gas. A pressure galge should be installed to avoid an excessive pressure buildup
in the tapping machine.
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OCTOBER 1993 PAGE 9 OF 16 EGS 1150 -1993

NOTE: If the valve i~;to be removed after the coupon is cut, a Lock-Q-Ring
fitting must be welcied to the header (see Paragraph5.71.

FIGURE 1
ARRANGEMENT FOR MAKING HOT TAP
SHO~'ING TAPPING MACHlrllE IN POSITION
 MOBIL ENGINEERING GUIDE

EGS 1150 -1993 PAGE100F16 OCTOBER 1993

5.6.3 Except for products that are health hazardous or highly volatile, when the pilot drill penetrates
the piping/storage tanks, allow the prodlJct to fill the cutter housing and to bleed out through the vent
valve on the tapping machine, then closl9 the vent valve. When the cutter penetrates the wall, run the
machine a few turns to remove burrs.

5.6.4 The cutter and coupon shall be retracted, the valve closed, and the vent on the tapping
machine opened. Retention and identifi(~ation of the coupon for information purposes is recommended
for a period of at least one month.

With removal of the tapping machine, the connection is ready for use.

5.7 Blinding a Hot Tap

When it is desirable to remove the hot tap valve and to blind the hot tapped connection, the following
Oedure shall be used:

(a) Weld a fitting complete with a T.D. Williamson Lock-O-Ring flange or an approved equivalent
(see Figure 2) on the piping or storage tank being hot tapped. For small connections (NPS 2 and 3),
a threaded plug and internally threaded flange should be used. These flanges are available in ANSI
Classes 150, 300, and 600.

LOCKlt-IG RING
SEGME,NT
C~RINGS~1l

SCREW

LOCK-o-RING "
-LJ
FlANGE LOCK-Q-RING PLUG

:>J~~~~ '"'"'"/\

FIGURE ~~
ME"rHOD OF REMOVING THE GATE VALVE
USED FOR THE HOT TAP
OCTOBER 1993 PAGE 11 OF 16

{bl Install the steel gate valve, adapter, and tapping machine. After cutting the coupon, remove
the tapping machine, then remove the cutter from the tapping machine boring bar and attach a
Lock-O-Ring plug or approved equivalent.

(c) Re-install the tapping machine on the gate valve flange. Open the gate valve and insert the
Lock-O-Ring plug into the lock ring flange by extending the boring bar. Seal the plug by tightening
the lock ring segments. Open the vent valve on the tapping machine to test the seal. The Buna-N
O-ring seal material limits the use of standard seal plugs to temperatures that do not exceed 82°C
(180°F). The local plant engineering department or MRDC should be consulted prior to hot tap
operations for services above 82°C (180°F).

(d) Release the tapping machine from the plug and retract the cutter, leaving the plug holding the
line pressure.

(e) Remove the tapping machine and gate valve, and attach a blind flange with proper gasket and
blDlting to the Lock-O-Ring flange. A NPS 3/4 valved connection should be mounted on the blind
flange to check for leakage of the plug if there is any possibility of re-using the connection.

5.8 Replacing a Pipe Section

5.8.1 When replacing or removing a pipe section, the procedures in Paragraphs 5.1 through 5.7
should be followed in installing a temporary bypass to permit work on the pipe section without
interrupting flow (see Figure 3). The bypass may be smaller than line size, and a flow calculation can
be made to determine the minimum permissible size. This method is usually limited to lines operating
at temperatures not exceeding 82°C (180°F) because of the elastomeric sealing element of the stopple.
The local plant engineering department or MRDC should be consulted prior to hot tap operations for
services above 82°C (180°F).

The following is the typical hot tap procedure for the replacement of a pipe section:

(a) A stopple fitting with a Lock-O-Ring or approved equivalent flange is welded on each end of
the section to be isolated.

(b) Bypass fittings with Lock-Q-Ring or approved equivalent flanges and equalization connections
are welded to the line. (The equalization connections will also be used for venting, purging, and
testing purposes.)

(c) At each fitting, an isolating valve and a tapping machine are installed, and a tap is made
through the valve into the line.

(d) The cutter is withdrawn after each tap, the valve closed, and the tapping machine removed

(e) The bypass line is installed and the bypass valves opened.

(f) The seals of the stopple plugging machines shall be inspected for defects before installing the
machines; the outside diameter of the sealing element must be correct for the inside diameter of
the line to be hot tapped.
 MCIBIL ENI31NEERING GUIDE

EGS 1150 -1993 PAGE120F16 OCTOBER 1993

~ 1. Remove the bypass and install the Lock-O-Ring plug.

C)Remove~e bypass and install tt1e Lod<-O-Ringpllug.
2. Remove the valve and install the blind. 2. Remove the valve and install the blind.

~VALVESTOBEPWGGED
~ I
t~ ~=~ONOF
PIPE -!p

-~a= ~
1. Removethe stopple plugging machine and install ~ 1. Remove the stopple plugging machine and ins1all
the u)ck-o-Ring plug.
the Loo,.o-Ring plug.
2. Remove!the valve and install the blind. 2. Remove the valve and install the blind.

FIGURE 3
HOT TAP APPLICATION "~VOLVING THE REMOVAL OF A SECTION OF PIPE

::::r=:2-
 MOBIL ENGINEERING GUIDE

OCTOBER 1993 PAGE 13 OF 16 EGS 11 50 -1993

(g) Stopple plugging machines are mounted on stopple fittings, and the plugging heads are
loV1/ered into sealing position.

(h) The isolated section is vented, drained, and purged with an inert gas during cutting operations
to remove this section.

(i) The new pipe section is then welded to the line under continuous purge, the pressure
equalized, the plugging heads are retracted, the valves at the stopple connections closed, and the
plugging machines removed.

(j) The bypass valves are closed, and the bypass line is removed.

(k) Lock-a-Ring or approved equivalent plugs are installed in the stopple and bypass fittings with
a tapping machine.

(I) All equipment is then removed, the valves recovered, and blind flanges installed at stopple
and bypass fittings.

5.8.2 In liquid service, lines to be removed should be drained by drilling a drain hole on the bottom
at one end that is to be cut and a vent hole on the top at the opposite end after the stopple is in place.

When it is difficult to drill the bottom drain hole on an underground line, the pipe section to be
removed may be vacuum drained by installing a NPS 2 hot tapped connection with a gate valve and
a packing gland on the top side at one end of the pipe. A NPS 3/4 pipe, beveled or slotted on the end,
is inserted through the packing gland and valve to the bottom of the line. One end of a hose is
connected to the NPS 3/4 pipe and the other end is connected to a vacuum tank which is used to drain
the line.

Before drain holes are drilled, the content of the line should be evaluated to ensure proper disposal.

5.8.3 Hot work can proceed only if the readings of flammable gases are below safe limits;
otherwise, the purge shall be continuous. If the pipes contain flammable gas or liquid, the unwanted
C~ctions of pipe should be purged with inert gas or steam and a flammable gas check shall be done
~efore cutting. Cold cutting methods shall be used. Line crews should be prepared to handle
pyrophoric deposits found in sections of the pipe that will be exposed to the atmosphere. When a
section of pipe is to be removed, it should be electrically bonded with a conducting cable before it is
cut. This precaution prevents a static discharge in case a stray current exists.

.
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EGS 1150 -1993 PAGE140F1S OCTOBER 1993

APPENDIX
HOT TAP CHECKLIST

PERMIT ISSUER:
CONTRACTOR:

This checklist shall be attached to the Safety Permit prior to the start of hot
tap work. Initial each item to indicate consideration has been given.
Particular circumstances of the job may dictate additional checklist items.

BEFORE STARTING A HOT TAP:

1. Is hot tapping the most appropriate option? Have other alternatives

(for example, next turnaround, piping/storage tank shutdown or
isolation) been considered?

2. Has the hot work permit been obtained?

Has the coordination meeting between all involved departments been

held?

4. Has the equipment or line been checked to ensure that the materials
and the services p.~rmit hot tapping? (Do not weld/braze on cast iron
lines, except pos~;ibly for low-pressure water lines. Use mechanical
fittings instead.)

Has the exact location of the hot tap on the piping/storage tank been
identified and marked?

6. Has the area to be welded been irlspected and the absence of

laminations or other metallurgical imperfections verified? Are the
thickness readings above the minimum recommended thickness?

Is the selected welding procedure suitable for the intended hot tap
application?

8. Has the metallurgy of the line or storage tank been established, and is
it compatible with the connecting fitting?

9. Have combustible and toxic gas tests been conducted in the area of
hot tapping and is there provision for continuous testing during the
entire hot tap operation?

10. Have engineering drawing(s) been prepared that detail the hot tap
operation?

11. Do the connections, reinforcing pads (if required), flanges, bolts,

gaskets, and valve to be installed meet the piping code for the line or
storage tank to be hot tapped?

5.
7.
3.
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OCTOBER 1993 PAGE 15 OF 16 EGS 1150 -1993

12. Is the gate valve full port? Has it been pressure tested?

13. Does the tapping machine have suitable pressure and temperature
rating and adequate cutter travel for this job?

14. Is there sufficient external clearance to accommodate the operation of

the tapping machine? Is there adequate access and clearance to rotate
the isolating valve if a threaded valve is used (e.g., for a corrosion
probe fitting installation).

15. Is there sufficient internal clearance to retract the cutter through the
valve?

16 Is the hot tap fitting of the proper length to accommodate operation

of the tapping machine?
8
17. Is the material in the line stable under heated conditions and free of

oxygen?

18. Has suitable protective equipment been provided for all personnel
involved in the hot tap operation?

19. Is a fire watch provided?

20. Has adequate fire fighting equipment been provided?

21. Is the area to be hot tapped located 1 m (3 ft) below the liquid level
of a tank or on a line in which fluid flow has been established?

22. Is there adequate hoisting and support equipment for the tapping
machine and room for operational and emergency access? .

23. Is the work area protected from unauthorized entry during the hot tap
8 operation?

24. Has a procedure to isolate the work area in the event of an emergency
been prepared and are the personnel involved trained to implement this
procedure?
Are there at least two egress/access areas provided if work is from a
25.
permanent or temporary platform?

BEFORE WELDING:

Each of the following considerations should be satisfied before welding:

1. Is a preheat of the weld area required?

2. Is the fitting properly positioned so misalignment of the tapping

machine will not occur?
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EGS 1150 -1993 PAGE160F16 OCTOBER 1993

Have the flowrate, pressure, and temperature of the contained material

been reduced as much as the process operations will allow?

4. Is there liquid or flowing gas in contact with the area to be hot

tapped?

BEFORE CUTTING:

Each of the following considerations should be satisfied before cutting:

1. Has the nozzle weld been pressure tested? Has the nozzle reinforcing
pad, if required, been pressure tested?

Has the tapping machine assembly been pressure tested?

Has the bleedoff valve been checked to be sure it will hold pressure,
is operable, and is not obstructed?

4. Are all bolts tight on the cutter and pilot bit?

Is the coupon catcher on the pilot bit?

Is the valve centered on the flange?

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

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

9. Have precautions been taken for safe disposal of material collected

above the gate varve?

BEFORE REMOVING THE TAPPING MACHINE:

Each of the following considerations should be satisfied before removing the

tapping machine:

1. Have the manufacturer's instructions been followed to be sure the

boring bar is fully retracted before closing the isolating valve?

2. Has the isolating valve been closed?

3. Has the bleedoff valve been opened?

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

3.
5.
6.
8.
4.
3.