Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries

API RECOMMENDED PRACTICE 2201 FIFTH EDITION, JULY 2003

REAFFIRMED, MARCH 2020

Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries

Downstream Segment

API RECOMMENDED PRACTICE 2201 FIFTH EDITION, JULY 2003

REAFFIRMED, MARCH 2020

SPECIAL NOTES

API publications necessarily address problems of a general nature. With respect to partic- ular circumstances, local, state, and federal laws and regulations should be reviewed.

API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or fed- eral laws.

Information concerning safety and health risks and proper precautions with respect to par- ticular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or prod- uct covered by letters patent. Neither should anything contained in the publication be con- strued as insuring anyone against liability for infringement of letters patent.

Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect five years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Standards Department [telephone (202) 682-8000]. A catalog of API publications and materials is published annually and updated quarterly by API, 1220 L Street, N.W., Washington, D.C. 20005, www.api.org.

This document was produced under API standardization procedures that ensure appropri- ate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or com- ments and questions concerning the procedures under which this standard was developed should be directed in writing to the Director, Standardization, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005, standards@api.org. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.

API standards are published to facilitate the broad availability of proven, sound engineer- ing and operating practices. These standards are not intended to obviate the need for apply- ing sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices.

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API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005.

Copyright © 2003 American Petroleum Institute

FOREWORD

This publication is designed to provide a better understanding of the problems and haz- ards encountered when installing hot tap connections on piping, vessels or tanks containing flammable or combustible liquids or gases. The essential elements of this publication are based on accumulated knowledge and experience of the petroleum industry, current industry safe operating practices, and existing consensus standards. The practices described in this publication are designed to protect the safety of personnel and the facilities for the work involved. It shall be noted, however, that special problems beyond the scope of this publica- tion are possible. Also, federal, state and local regulations or laws may contain additional requirements that must be taken into account when a hot tap program is developed for a spe- cific facility.

API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict.

Suggested revisions are invited and should be submitted to the Director, Standardization, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.

INFORMATION CONCERNING SAFETY AND HEALTH HAZARDS AND PROPER PRE- CAUTIONS WITH RESPECT TO PARTICULAR MATERIALS AND CONDITIONS SHOULD BE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER OR SUPPLIER OF THAT MATERIAL, OR THE MATERIAL SAFETY DATA SHEET.

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1. SPECIAL CONDITIONS 15

   1. Hot Tapping and Welding on Tanks or Vessels 15

   2. Welding or Hot Tapping on the Decks of Floating Roof Tanks is Prohibited . . 16

   3. Welding or Hot Tapping Above or Below Grade 16

   4. Welding or Hot Tapping on Lined Piping, Lined Equipment or Cased Lines . . 16 9.5 Hot Tapping on Piping 16

      9.6 Hot Tapping Upstream of Equipment and Valves 16

2. HOT TAP OPERATIONS 16

   1. Preliminary Requirements 16

   2. Welding in Preparation for Hot Tapping 17

   3. Inspecting the Weld 17

   4. Installing the Hot Tapping Machine 17

   5. Testing the Weld and Hot Tapping Machine 17

   6. Completion 18

APPENDIX A EXAMPLE HOT TAP CHECKLISTS 19

APPENDIX B EXAMPLE HOT TAPPING REQUEST FORMS 23

APPENDIX C EXAMPLE OF WELDERS INSTRUCTIONS PRIOR

TO HOT TAPPING 25

APPENDIX D EXAMPLE IN-SERVICE HOT TAP EMERGENCY

ACTION PLAN 27

Figures

1. Typical Hot Tap Activity Flow 6

2. Example Process to Review Whether Hot Tapping is Appropriate 7

3. Example Decision Process for Authorizing Hot Tapping 8

4. Hot Tapping Machine and Typical Hot Tap Connection 14

Tables

1. Before Starting the Hot Tap 19

2. Example of Fire Watch Duties 20

3. Before Welding 20

4. Before Cutting 20

5. Before Removing the Hot Tapping Machine 20

6. After Removing the Hot Tapping Machine 21

Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries

SECTION 1—GENERAL

1. PURPOSE

   This publication provides information to assist in safely conducting hot tapping operations on equipment in service in the petroleum and petrochemical industries. No document can address all situations nor answer all potential questions. However, the understanding of potential hazards, and applica- tion of this knowledge, can help reduce the probability and severity of incidents.

   
   

2. SCOPE

   Hot tapping is the technique of attaching a welded branch fitting to piping or equipment in service, and then creating an opening in that piping or equipment by drilling or cutting a portion of the piping or equipment within the attached fitting. (In certain specific situations a bolted or mechanical fitting may be used. This approach is not common practice in oil processing and petrochemical facilities and this document does not address any considerations unique to “hot tapping without welding”.) Hot tapping is usually performed when it is not feasible, or is impractical, to take the equipment or pip- ing out of service, or to purge or clean it by conventional methods. With proper review to determine that a hot tap is appropriate, and development and conformance to job-spe- cific procedures, many hot tap connections have been safely made without interfering with the process operation.

   This publication covers the safety aspects to be considered before and during hot tapping on in-service piping or equip- ment. It provides:

   • aids to recognize, review, and address safety concerns;

   • a review of potential hot tapping concerns based on industry experience;

   • guidance on planning hot taps;

   • application of “hazard versus risk” concepts applied to hot tapping;

   • elements to consider during the hot tap process from job analysis through completion;

   • suggestions on “what to do if things go wrong.”

     This publication is not:

   • a substitute for job-specific planning;

   • a set of work procedures.

   Virtually every hot tapping job is different. A detailed, written, job-specific hot tap procedure should be available before starting each job to help ensure that appropriate mea- sures are addressed. If there are standing procedures for hot tapping they should be reviewed for applicability to the spe- cific job to be done. These procedures may need revision in

   1

   
   

   response to unique job specific problems or situations that may arise concerning the safety of personnel and facilities.

   The hot tap approach described in this publication applies to piping and equipment fabricated from ferritic and austen- itic steel. Other materials, such as aluminum, copper, plastic, and cast iron may be unsuitable for hot tapping or welding or may require special procedures.

   Hot tapping is a “change” subject to review based on facil- ity “management of change” processes or procedures.

   
   

3. RETROACTIVITY

   Any provisions in this publication related to design are intended for reference when designing new facilities or when considering major revisions or expansions, or establishing new programs. It is not intended that any recommendations in this publication be applied retroactively to work performed at existing facilities. This recommended practice should provide useful guidance when there is a desire or need to review pro- cedures, programs or facilities.

   
   

4. CONCEPT OF HAZARD VS. RISK

   Hazards are properties of materials with the inherent abil- ity to cause harm. Flammability, toxicity, corrosivity, stored chemical or mechanical energy all are hazards associated with various industrial materials. Risk requires exposure. A hot surface or material can cause thermal skin burns or a cor- rosive acid can cause chemical skin burns, but these can occur only if there is contact exposure to skin. There is no risk when there is no potential for exposure.

   Determining the level of risk involves estimating the prob- ability and severity of exposure that could lead to harm. While the preceding examples relate hazards to the risk to people, the same principles are valid for evaluating property risk. For instance, hydrocarbon vapors in a flammable mix- ture with air can ignite if exposed to a source of ignition resulting in a fire which could damage property.

   
   

5. CONCEPT OF COMPETENT AND QUALIFIED PERSONS

OSHA uses the term “competent person” in dozens of standards for persons serving a variety of roles. In other stan- dards the term “qualified person” is used. Sometimes both terms are used in the same standard. This recommended prac- tice also uses these terms. The following sections explain this usage. In both cases it is the employer who has the responsi- bility for designating the person.