Professional Documents
Culture Documents
G # 7
Page 1 of 4
Revised 12/13/99
1.0 PURPOSE
To establish safety guidelines for hot tapping or in-service welding at this facility.
2.0 SCOPE
This S.H.G. will be applied to all hot taps and/or in-service welding on vessels, lines, etc., which
have not been properly isolated, emptied and gas freed. This Safety and Health Guide applies to
anyone working at this facility.
3.0 DEFINITIONS
Hot Tap: The welding and mechanical procedure that enables a connection to be made to
a line or vessel while that line or vessel remains in service.
In Service Welding: The practice of welding on equipment (e.g., tank, pipe, vessel,
exchanger, etc.) which has not been purged (gas freed) and has not been removed from
service. This includes but is not limited to grinding, burning or welding.
Coupon: That piece of pipe or vessel cut away during the hot tap procedure.
4.0 RESPONSIBILITY
5.0 GUIDELINES
All Hot Work Guidelines will be followed when preparing the area for in-service welding or
hot tapping.
Hot taps will not be made on vessels or lines containing compressed air, oxygen or
oxygen rich air, amine, chlorine, ammonia, caustic soda, lines that contain oxidizing
agents or equipment operating below atmospheric pressure.
Minimum flow will be maintained in lines during welding or hot tapping. In general, for gas
and vapor service the minimum is 3ft/sec. For liquids, velocities between 1.3 ft/sec and
8ft/sec are required. In certain cases such as flare lines where there may be insufficient or
no flow, it is necessary to maintain flow in the line with steam or gas during the welding
operation.
Equipment that has contained or is suspected of containing hydrogen sulfide (H2S) above
the TLV (10-ppm) will require the availability and/or use of breathing air at the job site
depending on permit requirements.
Tanks to be hot tapped or welded on will contain a liquid level at least 3 feet above the
weld in order to cool the heat-affected area.
A tank will not be pumped into, pumped out, or agitated while welding or hot tapping is
being performed.
All nozzle and reinforcement pad welds for hot taps will be tested prior to cutting the hole
with valve and hot tap machine in place. The maintenance inspection group will
determine test medium and pressure.
Emergency Variance - Should a condition exist where needed Department Managers are
not available for immediate approval, the Plant Manager or his designee will be contacted
for authorizing the hot tap or the in-service welding to proceed. All procedures outlined in
Section 5.0 must be followed to assure a safe hot tap or in-service weld. The supervisor,
in charge at the time of the emergency, will assure that all requirements are followed.
Normal documentation will be completed as soon as it is feasible.
VALERO KROTZ SPRINGS S.H.G # 7
Page 4 of 4
Revised 12/13/99
Special Considerations: Hot taps will not generally be made on vessels or lines containing compressed air, oxygen or oxygen
rich air, amine, chlorine, ammonia, caustic soda, lines containing oxidizing agents or equipment operating below atmospheric
pressure.
Equipment Information:
A. Product in Equipment ___________________
B. Equipment pressure ________________ psi
C. Equipment temperature _________________ F
D. Line size to be tapped _____________ inches
E. New line size _____________ inches
F. Is the weld location properly marked? _______yes _______no
G. Metal thickness at the weld site ___________________
H. Requirements to meet minimum flow