Safe Work Procedure: Hot Tapping

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the necessary safety precautions and procedures for performing hot tapping operations on pressurized pipelines, vessels, or tanks. Hot tapping involves welding on a piece of equipment under pressure to install connections or appurtenances . This procedure applies when continuity of service is essential and shutdown of the system is impractical .

This SWP is applicable to all employees, contractors, and subcontractors involved in hot tapping activities. It covers work on transmission and distribution systems for substances such as gas, steam, water, or petroleum products .

This SWP should be used in conjunction with other relevant safety procedures, including but not limited to, confined space entry, lockout/tagout, welding, and fire prevention procedures.

2. Definitions

Hot Tap: A procedure used in repair, maintenance, and service activities involving welding on equipment (pipelines, vessels, or tanks) under pressure to install connections or appurtenances . It is commonly used to add or replace sections of pipeline without interrupting service .

Competent Person: An individual who, because of knowledge, training, and experience, is qualified to perform the assigned work safely and efficiently.

Flammable Substance: A substance that is easily ignited and capable of burning rapidly.

3. Responsibilities

3.1 Supervisors

Ensure that a site-specific hazard analysis is conducted before any hot tap work begins .
Ensure that a hot work permit is issued before hot work begins, indicating the nature of the hazard, required atmospheric testing, safe work procedures, precautionary measures, and required protective equipment .
Verify that all workers involved in the hot tap operation are competent and properly trained 2, 4.
Ensure that the hot tap machine and accessories are of adequate design and capability for the work to be performed 2, 4.
Ensure that all equipment is inspected before use to ensure it is in safe working condition .

3.2 Workers

Participate in pre-job briefings and hazard assessments .
Inspect all equipment and tools before use and report any defects to the supervisor .
Use the correct personal protective equipment (PPE) as required by this procedure and the site-specific hazard assessment 2, 4.
Follow all safe work procedures and instructions provided by the supervisor 2, 4.
Immediately report any incidents, near misses, or unsafe conditions to the supervisor 2, 4.

3.3 Health and Safety Representative

Provide guidance and support to supervisors and workers on health and safety matters related to hot tapping 2, 4.
Participate in incident investigations and recommend corrective actions 2, 4.
Monitor the effectiveness of the hot tapping program and recommend improvements as needed 2, 4.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Fire and Explosion	Burns, injuries, fatalities	Ensure the equipment does not contain a harmful substance, is not in hydrogen service, and does not contain an explosive mixture . Monitor the atmosphere for flammable substances and ensure the concentration does not exceed 20% of the lower explosive limit . Have fire suppression equipment readily available .
Release of Hazardous Materials	Exposure to toxic or corrosive substances, environmental contamination	Identify the contents of the pipeline or equipment being tapped. Ensure that workers wear appropriate PPE, including respiratory protection if necessary . Ensure that the material being supplied to the pipe or equipment being hot tapped can be shut off immediately in an emergency 2, 4.
Equipment Failure	Injury from flying debris, pressure release	Ensure that the hot tap machine and fittings are of adequate design and capability for the process, conditions, pressure, and temperature 2, 4. Inspect equipment before use .
Electric Shock	Electrocution, burns	Ensure that arc welding performed in wet conditions or under conditions of high humidity has special protection against electric shock .
Exposure to Toxic Coatings	Respiratory irritation, skin irritation	Strip all surfaces covered with toxic preservatives of all toxic coatings for a distance of at least 4 inches from the area of heat application, or protect employees by airline respirators .

5. Personal Protective Equipment (PPE)

Proper PPE must be worn at all times during hot tapping operations to minimize the risk of injury 2, 4.

Safety Glasses/Face Shield - Protects eyes and face from flying debris, sparks, and chemical splashes.
Welding Helmet - Provides eye and face protection during welding activities, protecting from arc radiation and sparks.
Gloves - Protect hands from cuts, burns, and chemical exposure. Use appropriate gloves for the specific hazards involved (e.g., welding gloves, chemical-resistant gloves).
Flame-Resistant Clothing - Protects the body from burns and heat exposure. Ensure clothing covers all exposed skin.
Steel-Toed Boots - Protect feet from impact and compression hazards.
Respiratory Protection - Use appropriate respirators (e.g., airline respirators) when working in enclosed spaces or when exposed to toxic substances .

Inspect all PPE before use for damage or defects. Replace damaged or worn PPE immediately. Clean and maintain PPE according to the manufacturer's instructions.

6. Equipment and Tools

Ensure that all equipment and tools are in good working condition and suitable for the task 2, 4.

Hot Tapping Machine - Used to drill into the pressurized pipeline or equipment. Ensure the machine is of adequate design and capability for the process, conditions, pressure, and temperature 2, 4.
Welding Machine - Used to weld the connection fitting to the pipeline or equipment. Ensure the welding machine is properly grounded and in good working condition .
Cutting Torch - Used for cutting and preparing the area for welding. Inspect torches and fittings before use to ensure they are in a safe working condition .
Grinder - Used for surface preparation and weld finishing. Ensure the grinder is equipped with a guard and is in good working condition.
Hand Tools - Wrenches, pliers, screwdrivers, etc. Use appropriate hand tools for the task and ensure they are in good working condition.

Inspect all equipment and tools before each use. Remove any defective equipment from service. Follow the manufacturer's instructions for the proper use and maintenance of all equipment and tools.

7. Pre-Job Requirements

7.1 Training and Competency

Workers must be trained and competent in hot tapping procedures, welding, and the use of relevant equipment 2, 4.
Training must include hazard identification, risk assessment, and control measures 2, 4.
Workers must be trained in the proper use and maintenance of PPE 2, 4.

7.2 Pre-Job Briefing

Conduct a pre-job briefing with all workers involved in the hot tapping operation 2, 4.
Review the scope of work, potential hazards, and control measures 2, 4.
Discuss the sequence of events and emergency response plan .
Ensure that all workers understand their roles and responsibilities 2, 4.

7.3 Work Area Preparation

Clear the work area of combustible materials .
Ensure adequate ventilation is provided, especially in enclosed spaces 6, 7.
Provide sufficient working space at the location of the hot tap 2, 4.
Ensure that exit routes are available and their locations are known by workers 2, 4.
Inspect the point in the pressure-containing barrier to be hot tapped to ensure it is strong enough for the hot tap to be done safely 2, 4.

8. Safe Work Procedure Steps

8.1 Preparation and Inspection

Verify that all pre-job requirements have been met, including training, permits, and work area preparation 2, 4, 8.
Inspect the pipeline or equipment to be hot tapped for any signs of damage or corrosion .
Ensure that the pressure in the pipeline or equipment is as low as practical during the hot tap operation 2, 4.
Check that the point in the pressure containing barrier to be hot tapped is strong enough for the hot tap to be done safely 2, 4.

Safety considerations: Ensure that all inspections are documented and that any issues are addressed before proceeding.

8.2 Welding the Connection Fitting

Prepare the surface of the pipeline or equipment for welding .
Position and secure the connection fitting to the pipeline or equipment 2, 4.
Weld the connection fitting to the pipeline or equipment, following approved welding procedures 6, 7.
Inspect the weld for any defects and repair as necessary .

Safety considerations: Use appropriate welding techniques and PPE to prevent burns, electric shock, and exposure to toxic fumes 6, 7. Ensure adequate ventilation to remove fumes .

8.3 Drilling the Hole

Attach the hot tapping machine to the connection fitting 2, 4.
Verify that the hot tapping machine is properly aligned and secured 2, 4.
Start the hot tapping machine and carefully drill through the pipeline or equipment wall 2, 4.
Retract the cutter and close the valve on the connection fitting 2, 4.
Remove the hot tapping machine 2, 4.

Safety considerations: Monitor the pressure during drilling and be prepared to stop if any issues arise. Ensure that the material being supplied to the pipe or equipment being hot tapped can be shut off immediately in an emergency 2, 4.

9. Precautions and Safety Measures

Hot Work Permit: Obtain a hot work permit before starting any hot tapping operation .
Atmospheric Testing: Regularly test the atmosphere for flammable substances and ensure the concentration does not exceed 20% of the lower explosive limit .
Fire Prevention: Keep fire suppression equipment readily available and ensure workers are trained in its use .
Emergency Shutdown: Ensure that the material being supplied to the pipe or equipment being hot tapped can be shut off immediately in an emergency 2, 4.
Equipment Inspection: Inspect all equipment and tools before use to ensure they are in safe working condition .

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, immediately stop work and evacuate the area 2, 4.
Activate the emergency alarm and notify the supervisor 2, 4.
Follow the site-specific emergency response plan .
Provide first aid to any injured workers .

10.2 Specific Emergency Scenarios

Fire or Explosion: Activate the fire alarm, evacuate the area, and use fire suppression equipment to extinguish the fire .
Release of Hazardous Materials: Evacuate the area, contain the release if possible, and notify the appropriate authorities 2, 4.
Equipment Failure: Stop work, assess the damage, and repair or replace the equipment before resuming work 2, 4.

10.3 Emergency Contact Information

[Emergency Contact 1] - [Phone Number]
[Emergency Contact 2] - [Phone Number]
[Emergency Contact 3] - [Phone Number]

11. Incident Reporting and Investigation

Report all incidents, near misses, and hazards to the supervisor immediately 2, 4.

Investigate all reported incidents to determine the root cause and implement corrective actions to prevent recurrence 2, 4.

12. References and Related Documents

Occupational Safety and Health Standards (OSHA 29 CFR 1910) 1, 14
General Regulation (N.B. Reg. 91-191) 2, 3, 5
Occupational Health and Safety Code 4, 8, 12, 13
Safety Standards for General Safety and Health Standards (Chapter 296-24 WAC) 6, 7, 9, 11, 18, 19, 20
Kobelco SK135SR-7, SK140SRLC-7, SK140SRL-7 Operation Manual (Excavators)
Kobelco SK500XSLC-10, SK520XDLC-10 Operation Manual

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]