Hot Tapping

Checklist

Date:

Supervisor:

Client:

Machine
Serial No:

Location:
Introduction
Mirage portable machine tools optimise the performance of on-site
assets by achieving operational excellence, maximising uptime and
improving productivity.

Our proprietary technology drives the development of the most reliable,

durable, efficient and precise portable machine tools on the market, that
are capable of delivering the most exacting standards of tolerance with
the highest quality output.

Our portfolio of portable machine tools are suitable for a diverse range
of on-site machining applications. Mirage have been granted ISO
9001:2008 certification for our design and manufacturing systems
and we are able to provide full CE certification for our products.

Site checks
Initial here

Is lifting and support equipment available for the hot tapping machine and
additional piping?

Can the work area be easily accesses for emergency/operational

purposes?

Can the work area be isolated if required?

Has testing for dangerous and harmful gases been completed and
confirmation received of zero or safe levels?

Is there enough external clearance for operation of the hot tapping

machine?

Has approval to carry out the works at the site been provided?

Is fire-fighting equipment available?

Has appropriate protective equipment been issued to everyone in the hot

tapping work area?
Line/vessel checks Initial here

What are the contents? Can they be hot tapped safely? Are any special
measures required?

Does the wall thickness of the line/vessel create any risks? For example,
burning through or cracking the weld?

What is the temperature of the line? Will any special measures or

equipment be required during hot tapping?

Does the wall thickness and operating environment demand that the flow
be maintained, reduced or stopped?

When hydrotesting the branch line, is there any risk of collapsing the
parent line?

What is the metallurgy of the line/vessel? Are special welding measures

required? Is post-weld treating of the hot-tap welds required?

Pre hot tapping checks

Has a hot tap plan been both completed and signed off?

Has the exact location for hot tapping been marked on the line/vessel?
For tanks and vessels this must be a minimum of one metre below the
liquid level

Has the welding area on the line/vessel been checked for thickness?

Is the welding area free from any forms of metal degradation

or imperfections?

Have the appropriate branch connection and welding electrode

been selected for the metallurgy of the line/vessel?

What is the pipeline/piping/tank/pressure vessel code for the line/vessel

to be hot tapped? Do the bolts/flanges/gaskets/pipe and valves to be
installed meet the code?
 Initial here

Is stress relieving of the welding area required?

Does the hot tapping machine to be used have suitable pressure and
temperature ratings?

Does the hot tap fitting meet the required length for operation of the hot
tapping machine?

Does the hot tapping machine have adequate cutter travel?

Can the cutter be comfortably retracted through the valve?

Pre welding checks

Does the welding area need preheating?

Is an approved welding procedure in place that meets the required

code and uses low hydrogen electrodes and the temper bead weld
pass sequence?

Are the welders carrying out the work qualified as per the required
code? Are they experienced in welding on pressurised flowing lines?
Do they understand that the line is under pressure? Are they aware
of the associated risks?

Is the hot tap fitting positioned such that the hot tapping machine
will be accurately aligned?

Has the flow rate been reduced or stopped to minimise scope

for weld cracking?

For hot tapping on tanks, have all valves been closed, locked and tagged?
Pre cutting checks Initial here

Has non-destructive testing been carried out on the welds?

Have checks for leakage been carried out on the hot tap valve, packing,
gasket and bolts?

If the hot tap connection needs to be hydro tested, has the system been
checked for the correct hydro test pressure? This should not exceed:
• The flange rating
• The collapse pressure of the main run
• The rupture pressure of the reinforcement sleeve

Have the packing or seals on the hot tapping machine been checked and
confirmed as appropriate for the line/vessel contents and temperature?

Has the bleed off valve been checked?

• Is it in working order?
• Does it have the correct pressure rating?
• Is it free from obstruction?

Have the cutter and pilot bit bolts been tightened?

Is the coupon catcher attached to the pilot bit?

Is the valve centred on the flange?

Has the cutting depth been calculated and set accurately to cut only
one side of the line/vessel?

Has the cutter stem been marked to show where the cut will be
completed and where the cutter should be retracted past the valve seats?

Has the boring bar been run through the valve to check it can
do so without any obstruction?

Can the cutter be retracted and the hot tap valve closed?
Checks prior to removal of
the hot tapping machine Initial here

Have the machine’s instructions been followed closely to ensure that

the boring bar is fully retracted prior to closure of the hot tap valve?

Has the hot tap valve been closed?

Has the bleeder tap been opened?

Is the hot tap valve holding?

Before removing bolts from the flange, has all pressure been
bled off the hot tapping machine?

Checks prior to returning the line to service

Have all closed, locked and tagged valves been returned
to service, and locks and tags removed?

Have the pressure and flow rate returned to normal,

pre hot tapping levels?

Disclaimer
Mirage Machines Ltd has made every effort to ensure that the Information given in this leaflet machine is correct and understandable.
However it is acknowledged that there may be errors or omissions in this publication.

The company also reserves the right not to provide updates, corrections or amendments to this publication but will endeavour to keep
its customers up to date with all changes that may affect machine operation or safety.

Mirage Machines Ltd makes no claim that this safety checklist is exhaustive or complies with the necessary health and safety standards
in every locality. This document is intended to offer guidance only and, as such, it is the responsibility of the hot tapping machine operators
to ensure they have complied with all regional, international and internal company safety standards.