Hot Tap Form Proposed Signatories

Welding On Live Equipment, Hot Tap Procedure & Checklist
ZFSC0002
MWP-ME-802
Singapore Chemical Plant

and Refinery
Mechanical Work Practices
Section-8 Metals (Fixed Equipment) Work Practice
MWP-ME-802
Welding On Live Equipment, Hot Tap Procedure &

Checklist
SME:
Subject Matter Expert

________________________
(Kee Ah Chye)
Approved By
Document Owner:
Metals Maintenance Manager

________________________
(Quey Joo Hiong)
Endorsed By:
Combined Operations Procedure Committee

________________________
(Chairman)
Purpose:
Hot tap applies to a connection made to a pipeline or vessel that is under

pressure or has been depressurized but has not been cleared for conventional
construction methods. Before any hot tap operation is carried out, it must be
thoroughly reviewed and approved. This procedure outlines the control,
responsibilities and safety requirements pertaining to Welding on Live Equipment
(WOLE), hot tap operations at SCP and Singapore Refinery.
Precautions:
Safety, Health,
Environmental
Quality
Hot taps are carried out only when it is impractical to take equipment out of
service.
The wall thicknesses must be adequate to allow welding without causing a
burn through on the pipe.
5mm or the calculated minimum thickness, whichever is higher, for piping
in service.
6.5mm or the calculated minimum thickness, whichever is higher, for
vessels (excluding tank) in service.
For tank refer to API 653 Table 9.1. The hot tap connection sizes and
minimum shell thickness are :
Connection Size, NPS (in.) Minimum Shell Plate Thickness (mm)
6
5.0
6.4
14
9.5
18
12.7
Flow must be established in the line to be hot tapped to ensure that the heat
from welding and cutting is properly dissipated. In the case of hot tapping on
a tank, there shall be at least 6ft liquid level above the selected hot tap
location and maintained throughout the welding and cutting operation.
References:
IH-11 Welding and thermal cutting guideline.
Rev. 1, 14/07/11
Any printed copy is uncontrolled
Last printed: 27/11/2015 14:56:06
Page 1 of 43
Note:
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MWP-ME-802
Vendor Hot Tap Machine Instruction Manual

API 653 Tank Inspection, Repair, Alteration& Reconstruction 4 th edition, 2009
API 598 Valve Inspection & Testing, 9th edition, 2009
ExxonMobil Piping Maintenance Guide
ExxonMobil Tank Maintenance Guide
ExxonMobil Global Practice - Hot Taps (GP-03-01-04)
Deviation from any procedure step(s) require approval from the FLS
PROPOSED
SIGNATORIES
Prerequisites:
Materials
Required:
The OS/FLS or job lead shall hold a discussion before

starting this procedure to address any Safety concerns
Work job package.
Pressure test the full bore hot tap valve according to API
598. Test shall be done for closure (both sides) and back
seat with zero leakage. Date of test shall not be more than
7 days prior to hot taps.
The required forms filled out and approved (Refer to
Appendix III for copies) :
WOLE/Hot Tap Design Form (Appendix IIIA)
WOLE/Hot Tap Mechanical Form (Appendix IIIB)
WOLE/Hot Tap Inspection Form (Appendix IIIC)
Vendor Hot Tap Data Form ( Appendix IIID )
EM inspector has been consulted for any Ministry of
Manpower (MOM) requirements and documents approved
by MOM as required.
Inspection to take ultrasonic thickness measurement,
lamination checks and performed any other required NDT
at the Hot Tap location.
The welding procedure must be reviewed and approved by
EM inspector.
Hot tap machine has been checked as per the guidelines
(Appendix IV). Hot tap operation must be done by qualified
persons. Qualified persons can be specialist technicians
from company providing hot tapping services.
This procedure shall be made available in the field and the
EM Execution FLS on the job must complete the procedure
steps in this procedure and return to his/her supervisor
upon job completion.
Welding equipment.
A hot tap machine.
Hand/pneumatic operated hot tap machine for 2 inch
NPS and below.
Pneumatic/hydraulic operated hot tap machines for
larger size.
Crane is required to help handle the larger machine.
For underground hot taps, forced-air fans are required
to dissipate vapors released when the machine is
removed. Also, bleeders used to depressurize the
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EMR
S3 Operations
WEC+FW
QA/QC
EMR
EM Inspector
WEC+FW
QA/QC
WEC+FW
QA/QC
WEC+FW
QA/QC
EMR
WEC+FW
QA/QC
TDW
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MWP-ME-802
machine for removal should have tubing attached so

vapors and pressure can be vented away from the job
site.
NOTE: Check to ensure that the operating pressure and temperature of the
pipe/equipment to be hot tapped are within the range specified in the hot tap machine
data sheet.
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Procedure Steps:
Initial/Date
A) Preparation For Welding

1. Hot tap locations are marked and verified together with EM
Execution FLS, EM inspector and Operation Technician.
EMR
2. The nozzle stub shall be a pre-fabricated piece done in the

workshop environment. The welded assembly shall be inspected
for compliance with flange alignment tolerances and clearances.
WEC+FW
QA/QC
3. The nozzle stub shall be accurately aligned with the flange face
such that the face is parallel to the pipe longitudinal axis across the
diameter.
WEC+FW
QA/QC
4. Contact the Unit Operations Console and/or responsible Operation

Technician to confirm and monitor the flow before proceeding with
the welding operation for the nozzle fit-up.
EMR
WARNING
ALL WORK TO STOP IF CONDITIONS CHANGE (I.E.
HYDROCARBON LEAKS IN THE AREA, PERSONNEL
INJURIES, ETC.). THE OPERATION TECHNICIAN IS
TO BE NOTIFIED IMMEDIATELY.
5. Prepare the weld area and fit-up the nozzle. The nozzle centerline
should accurately intersect the pipe centerline longitudinally. A
uniform gap of 1.5 to 3mm between the hot tap nozzle and pipe
surface should be provided. (See Attachment 2)
EMR
NOTE: Unless determined by an engineering review to be otherwise acceptable, welding

or hot tapping closer than 18 inches to a flange or threaded connection, or closer than
the greater of 2 inches (50mm) or 4 times the wall thickness of the header pipe to a
welded seam (including the longitudinal seam of welded piping) should be avoided.
6. Do not weld on the inside of nozzles 6 inch NPS (150mm) and
smaller. Ensure the excess weld metal from the root pass does not
extend past the inside diameter for nozzles 6 inch and below to
avoid damaging the cutter. (See detail A in Attachment 1)
EMR
7. Nozzles 8 inch NPS (200mm) and larger should have a 45 deg

bevel on the inside, and one weld pass made on the inside. Weld
metal should not project more than 1/8inch (3mm) from the nozzle
wall. After back welding/grinding from the outside to sound metal,
the weld should be completed from the outside.
EMR
8. Use low hydrogen electrodes and no more than 1/8 inch (3mm)
electrode diameter. Larger diameter electrodes may be considered
for fill passes if the wall thickness is greater than or equal to 1/2
inch (13mm).
EMR
9. After the completion of nozzle root pass welding, the weld shall be
visually inspected, 100% PT or MT inspected before proceeding
WEC+FW
QA/QC
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Initial/Date
with the cover pass welding.

10.After the completion of nozzle welding and before applying any
specified reinforcement pad, the completed weld shall be visually
inspected, 100% PT or MT inspected.
11. Pressure test the nozzle with a blind flange installed.
WEC+FW
QA/QC
WEC+FW
QA/QC
12.Test pressure should be at least equal to the operating pressure of

the line or vessel to be tapped, but it should not exceed the present
internal (operating) pressure by more than 10% in order to avoid
possible internal collapse of the pipe wall. If higher test pressure is
required by local codes or standards, Fixed Equipment Engineer
shall be consulted.
WEC+FW
QA/QC
13.The reinforcement pad welds should be visually, and PT or MT

inspected, and the reinforcement pad leak test (25psig) carried out.
The tapped hole should not be plugged after the test is completed.
However, the hole may be filled with grease/sealant or to prevent
corrosion due to moisture accumulation. After the hot tap is done,
the tapped hole shall then be plugged with a steel plug.
WEC+FW
QA/QC
NOTE: For non -perpendicular branch connections.

Angled branch connections shall only be used when a 90deg connection is not possible.
When used, they shall be at least one size smaller than the header size
An internal guide shall be attached to the angled surface perpendicular to the pilot drill
and centered on the angled surface. A 4.5 mm guide plate (for size 2" and below) shall
also be welded to the end of the straight section of the nozzle to keep the nozzle
accurately aligned.
NOTE: For large lines
Consideration should be given to reinforcing the coupon to prevent it from becoming flat
and causing the cutter to bind up. For spiral weld seams, reinforcing is required for 16
inch and above. For other pipings, reinforcing is required for 24 inch and above.
Centering device shall also be installed.
B) Hot Tapping
NOTE: EM Execution FLS and Operation Technician must be at site throughout duration
of Hot Tapping.
1. Mobilize hot tap equipment to site and EM Execution FLS to
inspect the hot tap equipment.
EMR
NOTE: EM Execution FLS to check and ensure that the coupon catcher (retainer pins)
are in place and properly installed, cutters are in good condition.(Use Appendix IV)
Typically for size 2" and below, hot tap is done via drilling. Do not use Holesaw cutter.
2. Apply a hot work permit for the hot tap operation.
EMR
3. Install the hot tap machine and adapter on the tapping valve and
leak test the machine to adapter and adapter to valve flange joints
by pressuring the assembly with air, steam, nitrogen or inert gas to
at least 50psig, but not exceeding line operating pressure, and test
for leak at all flange connection using soap and water solution. Air
should only be used for services where a combustible mixture
cannot be formed in the event of a leak.
EMR
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Initial/Date
NOTE: Hot tap valve should be closed prior to installation of hot tap machine to ensure
that the pilot do not extend beyond the valve disc.
4. If the tap is in horizontal plane, the bleeder connection on adapter
should be positioned on the bottom of adapter to facilitate draining
the fluid from the adapter when the cut is completed. The hot tap
machine set up should also be properly supported.
EMR
5. Contact the Unit Operations Console to notify them that the work is
going to start and verify/monitor the flow.
EMR
WARNING
ALL WORK TO STOP IF CONDITIONS CHANGE (I.E.
HYDROCARBON LEAKS IN THE AREA, PERSONNEL
INJURIES, ETC.). THE OPERATION TECHNICIAN IS
TO BE NOTIFIED IMMEDIATELY.
6. Ensure the hot tap valve is fully open.
EMR
7. Extend and retract the cutter ensuring there are no restrictions.
EMR
NOTE: The EM Execution FLS and Hot Tap Specialist Technician equipment will verify
that the measurement of travel is correct as indicated in the Vendor Hot Tap Data SheetAppendix IIID.
8. Advance the cutter through the opened valve until the pilot bit
touches the wall of the pipe or vessel.
EMR
9. Set the cutter feed indicator to zero and mark the position of the
predetermined depth on the indicator.
EMR
10.Proceed to cut through the wall of the pipe or vessel to the

predetermined depth.
EMR
11. Manually extend the travel forward slightly to confirm that the
cutting is completed.
EMR
12.Retract the cutter and close the block valve.
EMR
13.Open the bleeder to depressurize and drain the hot tap machine to
a safe location. Verify that the block valve is not passing. For toxic
product e.g. H2S, benzene, use N2 to purge the content in the
adaptor to a safe location.
EMR
14.If block valve is passing and the pressure does not drop, stop all
work and notify the unit Operations FLS.
EMR
15.If block valve is holding, apply an OPE permit for removal of hot
tap machine. Since this is Vendor equipment, all draining shall be
done by Hot Tap Specialist Technician in the presence of Operation
Technician. Once Operation Technician has verified that the
machine is drained, he will put on his LOTO tag on the hot tap
valve.
EMR + S3 Ops
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MWP-ME-802
Initial/Date
16.Remove the hot tap machine and remove all metals chips from
inside the valve. Contain any spillage when removing the machine.
EMR + S3 Ops
17.Ensure that the coupon is retrieved and verified by Operation

Technician. If not, notify the Operation Technician and EM
Execution FLS.
EMR + S3 Ops
18.Install a blind flange or make a permanent tie-in. Use proper

gaskets and bolts.
EMR
C) Housekeeping
1. Clean up and housekeep the area and return all the work permits.
EMR
2. Arrange for scaffolds removal.
EMR
3. Fill out and turn in the validation sheet to your supervisor if there is
improvement needed.
** END OF PROCEDURE **
EMR
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MWP-ME-802
VALIDATION
*Employee Name: __EMR_________________*Team: _______
*Date of Use: ______________
Check the applicable boxes below.

This procedure was followed / performed as written, and is accepted as valid and correct.
(This includes satisfying any identified resource requirements.)
Some resource, steps, sequencing or conditions were adjusted during the performance of the
procedure. A copy of the marked up procedure is attached including applicable authorization
signatures.
This procedure as currently written requires the following revisions to be correct:
Page
Step
*Employee Signature:
Comment
_______________________________________
*Date: _____________
Supervisor Responsibility
Validation that checklists submitted are complete as required.

Follow-up steps identified are being progressed in consideration of the comments
above.
*Supervisor Name & Signature:
______EM PE_________________________________
______________________________________________________________________
US / MC/ Craft Planner Responsibility
For permanent changes to procedure, MOC (procedure change form) for procedure
changes must be approved before the next use.
The revision(s) in this procedure is(are) to be made permanent and uploaded into
procedure database.
*US / MC/ Craft Planner Name & Signature:

NOTE: 1) *Denotes must fill column
____S3 Operations__________
Procedure user and his supervisor must sign on the validation sheet even if no change
to the procedure is recommended.
Completed procedure with validation form must be forwarded to Procedure
Administrator / Procedure Coordinator for action and close out.
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Appendix I
HOT TAP GUIDELINES
1. PROHIBITED HOT TAPS - No Hot Tap Allowed
Hot taps are Prohibited under the following conditions/services:
A. Combustible or flammable mixture (Hydrocarbon & Air within flammable range or with potential to
enter flammable range) at any pressure.
B. Acids, chlorides, ammonia, peroxides, or other chemicals likely to decompose or become
hazardous from the heat of welding. Examples include sulphuric acid, butadiene peroxide, hydrofluoric
acid and acetylene
C. Air content in high purity ethylene or butadiene lines exceeds 1000ppm, or the pressure exceeds
2000 Kpag (290 Psig)
D. Hydrogen above 100C (212F).
E. Hydrogen partial pressure exceeds 700 Kpag in carbon steel lines or is within 690 Kpag (100 psig) of
the limit set by Nelson Curve.
F. Caustic service where PWHT is required or steam-out of caustic lines is performed during
shutdowns/start-ups
G. Pure Oxygen, TEAL or Chlorine service
H. Air lines where the absence of hydrocarbon cannot be assured, e.g. instrument air lines with
possibility of lube oil
I. Jacketed Piping or Jacketed Storage Tanks - Potential of cutting through the internal vessel/pipe or
support rods
J. Monel piping handling sulphur compounds
K. Stainless steel piping containing Catacarb solution
L. The pipe is made of an air hardened alloy, as there is a risk of metallurgical changes in heat affected
zone
2. HOT TAPS that requires special precautions.

Special Precautions are required for the following conditions/services:
A. Hydrogen service below 100C - It should be confirmed that the pipe has not experienced hydrogen
attack. Confirmed operation within the Nelson Curve limits of API-941 is sufficient to satisfy this
requirement in lieu of inspection
B. H2S or other toxic materials. Special safety precautions should be specified and followed
C. Wet H2S - The key to hot tapping equipment in wet H 2S service is maintaining an acceptably low
hardness in the HAZ of the attachment weld.
D. Elemental Sulfur, Caustic and Hydrogen can cause metallurgical changes in carbon, alloy and
stainless steels at elevated temperatures.
E. Ethylene - Hot tapping is permitted at any line pressure if ethylene contains at least 10% inerts such
as CO2, N2, or if ethylene content in the hydrocarbon stream is less than 50%. Decomposition
pressures and temperatures should be considered. The minimum flow rate should typically be 10 ft.
/sec (3 m/sec), with the maximum kept as close to this value as possible.
F. Butadiene - Butadiene, in the presence of oxygen, can decompose explosively. Decomposition
pressures and temperatures should be considered. If butadiene peroxide is present in the line, hot
tapping is prohibited. In addition, during permitted hot tapping of butadiene lines the cutting machine
should be purged of all air to prevent formation of butadiene peroxide polymer in the hot tapping
equipment. Inspect the area to be hot tapped for Butadiene peroxide polymer. Butadiene peroxide can
exothermically react.
G. Acetylene - Due to thermal decomposition, hot taps on acetylene is prohibited when:
a) The line contains 5% or greater acetylene in ethylene or butadiene (liquid or vapor)
b) The line contains 20% or greater acetylene with other hydrocarbons
H. Air lines that are free of hydrocarbon with greater than 23.5% oxygen. Nitrogen purging may be
required during hot tapping
I. Di-methyl Formanide (DMF)
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

J. Flammable or Combustible Liquid Below Atmospheric Pressure - Provisions should be made to
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

K. Gases Under Vacuum - Ensure the system stays air-free by maintaining a continuous purge with inert
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

L. Pipe wall thickness is less than 5 mm.
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

M. Line ANSI temperature/pressure rating exceeds 600# Flange Rating
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

N. Deviation from Required Velocities - For welding on liquid service, flow is within 0.4m/sec Rev. 1, 14/07/11
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

P. High Temperatures - Piping operating at a process temperature above 750F (400C) is more
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

Q. Low Temperatures - Hot taps that will be made at low temperatures [e.g., carbon steel below 40F
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

R. PWHT - Piping & storage tanks that require PWHT according to applicable codes, standards, and/or
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

S. Brittle Fracture - Equipment that meets a level 3 brittle fracture assessment (grand-fathered) requires
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

T. Stress Corrosion Cracking - Stainless steel subject to chloride stress corrosion cracking should be
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

U. Embrittlement - Special evaluation of the welding procedure with respect to process side metal
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

V. Hydrogen Fissuring - For services in which aqueous or room temperature hydrogen fissuring may
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

W. Lining, Cladding, Overlay - For piping & tanks with internal linings, cladding or weld overlay, the
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

X. Concrete and Refractory Lined Pipe - For piping with concrete or refractory linings, the potential for
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

Y. Cast Iron Lines - Using a welded fitting is prohibited on cast iron lines, a commercial bolt-on fitting
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

Z. Underground Pipe - For underground lines that run through a casing, be sure that the work is done
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

AA. Vessel & Exchangers - Restricted regardless of temperature, pressure and contents
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

BB.The location of hot tap is within 600mm of flanged or threaded connections, as the heat from welding
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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

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Appendix I
HOT TAP GUIDELINES
acid and acetylene
shutdowns/start-ups
support rods
zone

Notes:
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Appendix II
WELDING ON LIVE EQUIPMENT/HOT TAP FLOW SHEET
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Hot tap request

by BU
Contact / FE Engrs &

Mech Planner prepare
SOC package & review
Contact Engr/Process
Designer fill up WOLE
Design Form
(Appendix III A)
No
Final
SOC
Approval
obtained
Contact Engr / Opn

MC & FE review
design form & sign
Mech Planner arrange

final review with Contact,
FE Engrs & Opn MC/Unit
Supervisor to confirm
conditions not changed &
sign on Appendix IIIB
Yes
Contact Engr submit
request to DDO for
design package
Contact Engr seek BTM /

Process Heads approval
Mech Planner furnish field

info in vendor hot tap data
form & obtain vendor
response for Appendix IIID
DDO handover package to

Mech Planner & arrange
plant walk through
No
Mech Planner notify

inspector for NDE &
thickness checks & fill up
Mech Form (Appendix IIIB)
Approval
by BTM/
Process
Heads
Mech Planner provide field

execution person all the
signed forms & design
package & prepare for field
execution
Inspector fill up Inspection

Form (Appendix IIIC)
Yes
No
Is full SOC
required
Mech Planner handover

thickness readings (Form
IIIC) to FE for verification
and signature
Yes
End
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Appendix III A (Page 1 of 2)

DESIGN FORM
WELDING ON LIVE EQUIPMENT (WOLE) & HOT TAP
Part I : General Information
This form is to be completed by the BU contact engineer/process
designer to initiate the hot tap process, on-stream welding for line
padding and detailed engineering, as part of the PDS or MOC.
MOC / Job No.

Existing Line Size
1-PD-0376
1-1/2
Date
08 April 2013
W.O.L.E
P&ID No.
ESPL-A-500-AXXX-3C
Tie-in No.
Pipe Spec
PAC Pip Spec BG-3
Tie-in Size
Stopple
TP20-01
1-1/2
2069
65.5
26 - 38
Op. Press/Temp
Design Press/Temp
828
If hot tap is size on size, summarize justification for size on size.
kpag
By
Hot Tap
kpag
The required new line size is 1-1/2 due to consumption and pressure drop consideration across
approx 800m to Sulfur Pelletizer Unit from S3 near GO MEA.
Nearest N2 header identified for tie-in is near GO MEA area on No. 1 N-S piperack with header
size of 1-1/2, as identified by S3 Operations.
Reasons For WOLE/Hot Tap:
No isolation available on this N2 header.
Part II: WOLE/Hot Tap Detail & Flow Establishment

WOLE/Hot Tap Flow Sketch
See attached isometric.
Tag ID or other method for flow measurement:
SSDP Process Design Follow-up
Post responsible for monitoring flow:
SSDP Process Design Follow-up
SSDP Process Design Follow-up :

For Welding
If flow / velocity
outside this range,
FE to be consulted
- Liquid
0.4 - 1.3 m/sec
- Vapor
0.4 - 3 m/sec
Expected Composition, wt%
(List all components > 5%)
Allowed Flow
Range in
Units (
/hr)
Normal Flow
(
)
Normal Velocity
(m/sec)
Nitrogen
Operating Density
Reasons for Deviating from Flow Requirements & Why is it Acceptable? (Consult Fixed Equipment Engineer)
Rev. 1, 14/07/11
Last printed: 27/11/2015 14:56:08
Page 33 of 43
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MWP-ME-802
Appendix III A (Page 2 of 2)

DESIGN FORM - WELDING ON LIVE EQUIPMENT (WOLE) & HOT TAP
Part III: Other Precautions
A) Is the hot tap tie-in upstream of equipment that can be damaged by hot tap shavings? E.g. pump, compressor,
PD flow meters or Desalter?
Yes
No *S3 Ops to determine
If Yes, Review by relevant Espec Engineer for strainer size
(Name/Signature of Espec Engineer/Date)
B) Special Welding Precautions (Supplied by Fixed Equipment Engr)
E.g. PWHT, Stress corrosion cracking

impact, etc
Nil
C) Contingency Strategy for Loss of Coupon :
N/A (No coupon)
D) Emergency Isolation Strategy
Special Procedure Required?

*S3 Ops to determine
Yes
No
E) Fire Fighting Strategy

*EM FSSD to determine
Yes
No
F) Emergency Egress Strategy

*EM FSSD to determine
Yes
No
G) Process Upset Response Strategy

*S3 Ops to determine
Yes
No
PART IV : WOLE/HOT TAP SOC APPROVAL
For Hot Taps that require special precautions, the BTM/ Process Heads have the authority to
approve/reject the hot after review of the request with special precautions and procedures
proposed. BTM/ Process Heads may also escalate to full SOC review as appropriate.
Any other deviation from the procedure shall require SOC approval.
Approvals
Process Designer /
Contact Engineer
Manufacturing
Coordinator(MC) / Operations
Unit Supervisor
Fixed Equipment
Engineer(FE)
BTM / Process Head
Name/Signature
Date
Name/Signature
Date
Name/Signature
Date
Name/Signature
Date
SOC ( only if required)
Rev. 1, 14/07/11
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Page 34 of 43
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Instructions/Guidelines for Design Form for WOLE & Hot Tap

IS THE WOLE/HOT TAP YOU ARE PROPOSING REALLY NEEDED?
This question should be asked every time there is an urge to make connections by hot tapping into existing facilities. Anytime we propose a
hot tap or WOLE we are exposing personnel and equipment to conditions, which if not evaluated thoroughly, can be unsafe. Hot taps have
been and can be performed safely, but should be minimized. They should only be used where:
It is impractical to employ conventional methods.
It is impractical to take the equipment out of service.
A huge cost incentive exists.
Taking equipment out of service may pose more risks than hot tapping.
Each hot tap must be evaluated individually by using sound engineering judgment and by considering all potentially adverse conditions.
General guidelines to follow at the design stage:
1.
Check to see if process fluid is suitable for a safe hot tap. Equipment handling ethylene, butadiene, acetylene or where the heat of
welding may induce explosion or other hazardous reactions within system shall be approved by Full SOC.
2.
Specify the min and max flow required at the hot tap/WOLE location to dissipate the heat. Max flow is specified to prevent
excessively rapid cooling of the welded area and to avoid the coupon from dislodging.
3.
Hot tapping of air lines or lines containing explosive mixtures are not permitted.
4.
Check for the min wall thickness that is required for the hot tap.
5.
Hot taps are not permitted for equipment in amines or caustic service if operating condition would require stress relieving.
6.
For hot taps that will be made at low temperature, (< 4C) consult with the Fixed Equipment Specialist (sweating & icing service
requires special procedures).
7.
Hot taps/WOLE shall not be specified for piping or pressure vessels at locations where fluid flow does not exist.
8.
Hot taps upstream of rotating machinery should be avoided unless facilities exist to prevent chips and shavings from reaching the
machinery.
9.
Is there adequate clearance to install the hot tap machine to carry out the hot tap in the orientation suggested?
Those are only the general guidelines for the person to follow when he/she proposes a hot tap/WOLE. Detailed information is included in
Appendix I.
FILLING OUT THIS FORM

This form is required to be filled out by the process designer or contact engineer for each hot tap or WOLE during the PDS development.
Part I: General Information

Provide general information about the WOLE, Hot tap or Stopple; MOC/Job no.; P&ID; size; piping specs; operating and design conditions.
If the hot tap required is a size on size, furnish a justification for size on size. Size on size should be avoided if possible, consider hot
tapping a size smaller and expanding line size after the hot tap valve.
Part II: Hot Tap / WOLE Detail & Flow Establishment

A flow schematic is required for the hot tap / WOLE. The schematic should clearly indicate:
a)
Line number and location of hot tap.
b)
Equipment, valve or instrument used to measure or establish the required flow.
c)
All valves to be tagged for welding and cutting activities.
d)
All relevant branches for the system.
e)
Location of any temporary connections used to establish the required flow.
It is necessary to maintain a min flow in the pipe during welding in order to dissipate welding heat. Conversely, it is sometimes necessary
to impose a limit of max flow rate in order not to quench the weld & contribute to hard weld cracking or fusion problems (Higher velocities
may be used with special coupon retainers.):
a)
In gas services, a min flow rate should be typically 0.4 m/s (1.3ft/s) for welding. For cutting, the max flow rate should generally be
limited to 3 m/s (10ft/s) to minimize the likelihood of spinning the cut coupon and having it dislodged. Max flow is not critical for vapor
service welding.
b)
In liquid services, the flow rate for welding should typically be kept in the range of 0.4 to 1.3 m/s (1.3 to 4 ft/s). For cutting, wet steam
should be considered as liquid.
The flow rates to be established must be endorsed by the manufacturing coordinator/operation supervisor and responsibility for monitoring
this rate must be indicated. Flow rates specified should be consistent with the monitoring flow meter reading.
Specify the composition of the stream to be hot tapped. Refer to SCP Safety Procedure Manual for a list of compounds that require special
attention while carrying out hot taps or WOLE.
Part III: Other Precautions

A.
If the hot tap is at the suction of machinery, such as compressors or gear pumps, etc. then a machinery expert should be consultant.
Ensure facilities, such as strainers, are available upstream of the machine to prevent chips and shavings from reaching the machine.
Alternatively, there may be a possibility to carry out the hot tap while bypassing the equipment with minor adjustments to the process.
B.
Fixed equipment engineer should review this form and indicate if any further precautions are required, such as PWHT, piping liners &
Stress Corrosion Cracking impacts, etc.
C.
Incase the coupon is dislodged, prior evaluation and planning should be carried to see where it is most likely to settle. Its long/ short
term impact to process and equipment should be high-lighted here.
D-G highlights the strategies for the given situations, if different of usual emergency response. If a special procedure is required for any of
these, this should be indicated and procedures should be developed by Operations Supervisor prior to executing the hot tap.
Part IV: SOC Review & Approval
Provide reason for carrying out the Hot Tap, and acceptable deviations.
The Process Designer/Contact Engineer (or other author of this form) should sign here along with MC/Ops Supervisor and Fixed
equipment Engineer and obtain the final approval from Process Heads (SCP) or BTM (Refinery)
Rev. 1, 14/07/11
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Page 35 of 43
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MWP-ME-802
Appendix III B
MECHANICAL FORM
WELDING ON LIVE EQUIPMENT AND HOT TAP
PROJECT
TITLE:
Singapore Sulphur Disposition Project
The Equipment to be welded on has been appropriately identified with the Mechanical Planner / FLS
and clearly marked.
Unit Supervisor/Manufacturing
S3 Ops
Signature:
Date:
Coordinator(MC) Name:
All required NDE has been completed and the location found to be acceptable for welding.
Unit Inspector Name
FW QAQC
Signature:
Date:
PROCESS CONDITIONS PRIOR TO WELDING S3 Operations

Are process conditions on the W.O.L.E. / Hot Tap Form still valid?
YES / NO
Is the velocity specified in Design Form correct?
YES / NO
If No, Contact Engineer shall have the Process Designer/MOC Author revise the WOLE/Hot Tap Design
Form and attach it after reviewing it with Manufacturing Coordinator/Ops Supervisor.
If Yes, Contact Engineer shall Sign and return to Mechanical Planner
Unit Process Contact Engineer S3 Ops
Signature:
Date:
Name:
Unit Supervisor/Manufacturing
Coordinator Name:
S3 Ops
Signature:
Is there special welding or testing procedures (See Attached)

Fixed Equipment (FE)/
FW QAQC
Signature:
Inspection Engineer Name:
Date:
YES / NO
Date:
Additional Requirements
SOC Variances Form Attached, if Required
A Copy of NDE Reports Attached (Furnished by Unit Inspector)
Special Procedures Required as identified in the Hot Tap Design From Appendix IIIA
Mechanical Planner/Project Engr/ EMR
Signature:
Date:
EM Execution FLS Name:
Rev. 1, 14/07/11
Last printed: 27/11/2015 14:56:08
YES / NO
YES / NO
YES / NO
Page 36 of 43
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MWP-ME-802
Appendix III C
INSPECTION FORM
WELDING ON LIVE EQUIPMENT AND HOT TAP
1) Field Thickness Measurements (3rd Party Inspector)
Reinforcement Pad,
Box or Pad edge
rd
1a)
Thickness Measurement Equipment (3 Party Inspector)
UT Meter
Probe
36DL
D790SM
1
8
*Hot Tap
Couplant Used:
Sound safe
Copper Slip
High Temp. Couplant
3
B
A
6
Please tick () the appropriate box
4
5
rd
1b) Thickness Data (3 Party Inspector)

IMPORTANT NOTE ON THICKNESS MEASUREMENTS:
THICKNESS MEASUREMENT POINTS MUST BE BASED ON MARKED-OUT PROFILE OF THE ACTUAL WELDING LOCATION.
Recorded Thickness (mm)

Location
tmin (min. recorded)
A
B
Verified by Inspector : ________FW QAQC__________
Name/Signature/Date Inspected
FOR INSPECTION REFERENCE ONLY
New Piping Wall Thickness in mm to Sch No.
UT EQUIPMENT GUIDELINES
(EE.68E.84)
TEMPERATURE
RANGE
UT
METER
PROBE
COUPLANT
Below 200F
(Below 93C)
36DL
D790SM
SOUNDSAFE
200 - 350F (93 177C)
36DL
D790SM
SOUNDSAFE OR
COPPER SLIP
350 - 750F
(177 - 399C)
36DL
D790SM
HIGH
TEMPERATURE
COUPLANT
Nozzle
Size
1
1.5
2
3
4
6
8
10
12
OD 14
OD 16
OD 18
OD 20
OD 24
O.D.
33.4
48.3
60.3
88.9
114.3
168.3
219.1
273.1
323.9
355.6
406.4
457.2
508.0
609.6
S10
6.4
6.4
6.4
6.4
6.4
S20
S40
S80
S160
6.4
6.4
6.4
7.9
7.0
7.9
9.5
9.5
3.4
3.7
3.9
5.5
6.0
7.1
8.2
9.3
10.3
11.1
12.7
14.3
15.1
17.5
4.6
5.1
5.5
7.6
8.6
11.0
12.7
15.1
17.5
19.1
21.4
23.8
26.2
31.0
6.4
7.1
8.7
11.1
13.5
18.3
23.0
28.6
33.3
35.7
40.5
45.2
50.0
59.5
2) Verification of Minimum Thickness FW QAQC

2a) Minimum required line/equipment thickness, t r, as specified by Engineering Design Section is: __________ mm 1
(1based on Design Pressure: _____ KPag; Design Temperature: _____ oC, and includes 3mm for HAZ)
2b) is the minimum line/equipment thickness, t min (as verified by Inspection Section), adequate for onstream welding?
(i.e. min. recorded thickness, tmin > tr)
*YES/NO
Fixed Equipment Engineer: __EMRE NPQC__________________

Name/Signature/Date
3) Inspection requirement (others) FW QAQC

3a) UT scans for lamination.
Completed on: ____________
3b) UT scans on affected longitudinal seam of existing pipe.
3c) Hot-tap valves tested as per Piping Maintenance Guide
3d) MOM / MOM third party survey
Reviewed and released for Hot-tap by Area Inspector: ___Ooi Soo Ken_________________________
Rev. 1, 14/07/11
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Page 37 of 43
ZFSC0002
MWP-ME-802
Name/Signature/Date
Appendix III D
VENDOR HOT TAP DATA FORM (After WOLE done) TDW
Project Title:
Singapore Sulfur Disposition Project
JOB PLANNER
Business Unit:
Work Order No.:
Flange/stub alignment check within tolerance : Yes / No
Field Verification Information (fill in information, attach copy of isometric and send to vendor):
Overhead clearance from flange to nearest obstacle:
Orientation of line to be hot tapped:
Horizontal
Vertical
Orientation of hot tap nozzle on line:

Average wall thickness determined by ultrasonic measurement:
Minimum I.D. of nozzle connection and valve:
(Must field verify this measurement)
Travel dimension (O.D. of header to face of connecting flange):
VENDOR REPRESENTATIVE
Name /
Signature:
Phone /
Fax:
Date:
HOT TAP VENDOR RESPONSE: (fill in information and return to Job Planner)
A. ________________________
CUTTER
B. ________________________
C. ________________________
C
PILOT
Cutter tooth material: _________________________

B
Number of teeth on cutter: _____________________

Model no. of hot tapping equipment: _____________
Power requirements: _________________________
Vendor Name: ___________________
Special requirements: ________________________
Signature/Date: __________________
Rev. 1, 14/07/11
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Page 38 of 43
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MWP-ME-802
Appendix IV
GUIDELINE FOR HOT TAP MACHINE CHECKS PRIOR TO
INSTALLATION
If any of the following points are unsatisfactory, rectify before installation. TDW
PILOT
Is the pilot the correct size and length?

Number of wires conform to document
Ensure cutting edge in not pitted or blunt (dull)
Wires should fall freely during rotation of pilot
Wire protruding out 2-3 mm circumferentially for holesaw and 3-5mm for
standard pilot / cutter
Visual check for defects e.g. hairline cracks
CUTTER
Ensure cutting edge in not pitted or blunt (dull)

Check cutter size conforms to Vendor Data form and compare with stub
ID
Visual check for any defects e.g. hairline cracks
HOT TAP MACHINE
Check Machine model conform to Vendor Data form

Ensure hydraulic hoses/fittings are in good condition
Correct seals and packing used?
Machine must be serviced and pressure tested. Vendor to produce
certification
Flanges are of correct rating?
TIGHTNESS TESTS REQUIREMENTS TDW
To Check the Integrity of the Flanges and Hot Tap / Stopple Machine Assembly
Testing Medium
Air
Nitrogen
Others
Leak Test Pressure to be at least 50psig but not exceeding the operating pressure of the line or
vessel to be hot tapped
Test Pressure:
Kpag/Psig
Checked by:
Hot tap Specialist Technician Name: ___TDW__________Signature: __________Date: ______
EM Execution FLS
Rev. 1, 14/07/11
Name: _____EMR________Signature: __________Date: ______
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Page 39 of 43
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MWP-ME-802
Attachment 1 - Tapping valve, Adapter and Cutting machine set-up
Bleeder - For releasing

pressure on tapping machine
Tapping Machine
Vent as required
Bleeder connection to drain adapter. When hot

tap is in horizontal position, essentially all liquid
can be removed. When hot tap is in vertical
position, liquid from top disc to bleeder cannot
be drained.
Adapter
Use this connection for inert

gas purge as required.
Tapping Valve
Tapping Nozzle
1/4" NPT telltale hole each
section of reinforcement; after
pressure test, install steel plug
"SET ON NOZZLE INSTALLATION
WITH SEPARATE REINFORCEMENT"
Full encirclement saddle - use
1/8" max. electrode to weld
nozzle to pipe; electrodes larger
than 1/8" may be used to joint
sections of reinforcement
NOTE:
Reinforcement Pad
Pressurized Line
or
Vessel
"INTEGRALLY
FORGED FITTING"
Longitudinal seams shall not be tied to

wall of header. Use backing material
or appropriate welding procedure.
* For size on size hot taps, use single-piece, full encirclement saddle
(i.e. nozzle shall be one-piece with saddle) with full fillet welds.
Detail A - Weld details
For weld joining reinforcing pad

to tapping nozzle, electrodes
larger than 1/8" may be used.
Rev. 1, 14/07/11
For nozzles NPS 6 and smaller, no inside weld

is permitted. For nozzles NPS 8 and larger, use
3/32" electrode and grind smooth, leaving 1/16"
maximum projection inside nozzle.
Use maximum 1/8" dia. electrode

for welds onto pressurized pipe.
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Page 40 of 43
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MWP-ME-802
Attachment 2 - Measuring nozzle centerline and stub alignment check

NOTE: Determine centre of main pipe & ensure hot tap stub is on centerline
Check flange levelness after installing stub
Hot tap stub

Centre of main pipe
Main pipe
NOTE: Measure dimensions "a" and "b" as shown during fit up check.
Centerline of branch pipe
measure dimension "a"
measure dimension "b"
Centerline of main pipe
Rev. 1, 14/07/11
Last printed: 27/11/2015 14:56:08
Page 41 of 43
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MWP-ME-802
Attachment 3 Additional Requirement for Stoppling

Stopples are used to perform repairs or to remove a section of line without interrupting service.
Hot tapping is a prerequisite for installing stopples and all the requirements for hot taps apply to
the installation of stopples.
The stopple must provide a tight seal. Stopples have definite limitations and it must be
determined that the stopple is adequate for the line size, temperature and pressure. The material
chosen for the stopple cups must also be resistant to the line environment. When a vendor is
used, they must have demonstrated experience in stoppling lines of similar size, temperature,
pressure and service.
For size-on size hot taps for stoppling, a full encirclement reinforcing pad must be installed to
provide additional wall thickness in case the cutter cuts into the pipe wall. The diameter of the
stoppling cutter is almost the same as the inside diameter of the pipe. A straight hot tap cutter has
a smaller diameter and provides some clearance between the cutter and the pipe wall.
For stopple works the detailed work sequence and checks shall be developed by specialist
contractor and reviewed with the owner. The sequence shall include the installation of the stopple
machine to the removal of the stopple machines.
The max flow rate for insertion of stopple is 2.1 m/s (7 ft/sec) for liquid service and 5 m/s for gas.
For single stopple (i.e. there is a upstream or downstream isolation valve available), the line
should be static.
After the stopple is installed, it should be tested for leaks by bleeding the isolated section of the
line. If a leak is found, the stopple should be repositioned and rechecked for leaks. If the leak still
persists, the stopple should be removed, reinserted and retested. The operation must be
repeated until a tight seal is obtained.
Rev. 1, 14/07/11
Last printed: 27/11/2015 14:56:08
Page 42 of 43
ZFSC0002
MWP-ME-802
REVISION LOG:
Para Title
Rev. 1, 14/07/11
Rev #
Rev Date
Last printed: 27/11/2015 14:56:08
Description
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Welding On Live Equipment, Hot Tap Procedure & Checklist

Singapore Chemical Plant

Section-8 Metals (Fixed Equipment) Work Practice

Welding On Live Equipment, Hot Tap Procedure &

Subject Matter Expert

Metals Maintenance Manager

Combined Operations Procedure Committee

Hot tap applies to a connection made to a pipeline or vessel that is under

IH-11 Welding and thermal cutting guideline.

Last printed: 27/11/2015 14:56:06

Welding On Live Equipment, Hot Tap Procedure & Checklist

Vendor Hot Tap Machine Instruction Manual

The OS/FLS or job lead shall hold a discussion before

Last printed: 27/11/2015 14:56:06

Welding On Live Equipment, Hot Tap Procedure & Checklist

machine for removal should have tubing attached so

Last printed: 27/11/2015 14:56:06

Welding On Live Equipment, Hot Tap Procedure & Checklist

A) Preparation For Welding

2. The nozzle stub shall be a pre-fabricated piece done in the

4. Contact the Unit Operations Console and/or responsible Operation

NOTE: Unless determined by an engineering review to be otherwise acceptable, welding

7. Nozzles 8 inch NPS (200mm) and larger should have a 45 deg

Last printed: 27/11/2015 14:56:06

Welding On Live Equipment, Hot Tap Procedure & Checklist

with the cover pass welding.

12.Test pressure should be at least equal to the operating pressure of

13.The reinforcement pad welds should be visually, and PT or MT

NOTE: For non -perpendicular branch connections.

Last printed: 27/11/2015 14:56:06

Welding On Live Equipment, Hot Tap Procedure & Checklist

6. Ensure the hot tap valve is fully open.

7. Extend and retract the cutter ensuring there are no restrictions.

10.Proceed to cut through the wall of the pipe or vessel to the

12.Retract the cutter and close the block valve.

Last printed: 27/11/2015 14:56:06

Welding On Live Equipment, Hot Tap Procedure & Checklist

17.Ensure that the coupon is retrieved and verified by Operation

18.Install a blind flange or make a permanent tie-in. Use proper

2. Arrange for scaffolds removal.

Last printed: 27/11/2015 14:56:06

Welding On Live Equipment, Hot Tap Procedure & Checklist

*Date of Use: ______________

Check the applicable boxes below.

Validation that checklists submitted are complete as required.

*Supervisor Name & Signature:

*US / MC/ Craft Planner Name & Signature:

Last printed: 27/11/2015 14:56:07

Welding On Live Equipment, Hot Tap Procedure & Checklist

2. HOT TAPS that requires special precautions.

Last printed: 27/11/2015 14:56:07

Welding On Live Equipment, Hot Tap Procedure & Checklist

2. HOT TAPS that requires special precautions.

Last printed: 27/11/2015 14:56:07

Welding On Live Equipment, Hot Tap Procedure & Checklist

2. HOT TAPS that requires special precautions.

Last printed: 27/11/2015 14:56:07

Welding On Live Equipment, Hot Tap Procedure & Checklist

2. HOT TAPS that requires special precautions.

Last printed: 27/11/2015 14:56:07

Welding On Live Equipment, Hot Tap Procedure & Checklist

2. HOT TAPS that requires special precautions.

Last printed: 27/11/2015 14:56:07

Welding On Live Equipment, Hot Tap Procedure & Checklist