BASF Corporation

Title: HOT TAP PROCEDURE

Individual Unit
Procedure

Function: Safety
No.: BCF 020.029

Page: 1 of 5

Freeport Site
Reviewed: New
Effective: 11/07/00 Supersedes: SS #29
Preparer:
Owner:
Approver:
Site Safety Representative
Manager, Environ, Health & Safety
VP and Gen. Mgr.,
Freeport

1.

PURPOSE
This procedure and attached work instructions provide guidelines and requirements for
the use of hot tap procedures. The use of hot tap procedures is to be limited to jobs that
cannot be accomplished using standard procedures without incurring a major safety,
economic or production impact. API 2201 serves as the basis for this procedure.

2.

DEFINITIONS
2.1.
*Hot Tap
The method of attaching connections or accessories onto a vessel or process line
that is in service. This includes not only the attachment of any external device
made by welding but also all penetrations into the process.
2.2.

Hot Tap Permit

A stepped checklist for the request, approval and procedures for performing
welding and hot tap operations. See BCF020.029 WI.

2.3.

*Post Weld Heat Treatment (PWHT)

Heating a vessel, pipe or structure to a sufficient temperature to relieve the
residual stresses which are the result of mechanical treatment or welding.

3.

SCOPE
This procedure and attached work instructions apply to BASF Corporations Freeport Site
(BCF).

4.

PROCEDURE
4.1.
General
Hot taps shall not be performed on vessels containing flammable liquids while
the liquid is being pumped out of the vessel. Pumps/valving must be
shutdown/closed and red tagged.
Hot taps upstream of rotating/reciprocating equipment, or control/isolation
valves, must be protected from cuttings by filters, screens or traps.
A thickness test and visual inspection must be conducted in the immediate
area and extending out a minimum of 12 inches, or the diameter of the line,
whichever is larger.
Note: If the thickness is less than the original thickness, or is less than 3/16
inches, an engineering evaluation must be done to determine if it is safe to
make a hot tap.

BASF Corporation

Title: HOT TAP PROCEDURE

Individual Unit
Procedure

Function: Safety
No.: BCF 020.029

Freeport Site

Reviewed: 11/99

Page: 2 of 5
Effective: 11/07/00 Supersedes:

SS #29

The TES Pressure Vessels Group shall evaluate and determine if a reinforcing
pad is required. The PV Group will provide a sketch showing fabrication
details for the attachment.
The hot tap location must be:
More than 18 inches from all flanges or threaded connections,
More than 3 inches from a welded seam.

Note: Proposed hot taps which do not meet these requirements may be
approved by the TES PV Group if an engineering analysis of the vessel,
piping design, operating conditions and the taps location is performed.

When welding the hot tap nozzle onto a line that contains flammable materials,
the flow in the line for a liquid or gas process must be at least 1.3 feet per
second, as a minimum.

Note: Excessive flow rates will increase the cooling rate at the weld site and
could increase the risk of weld cracking.

4.2.

When welding on a vessel containing liquid, the level must be at least 3 feet
above the location of the hot tap.
The oxygen content within the vessel or equipment must be less than 1%.

Prohibited Hot Taps

Hot taps on equipment in the below services shall not be done:

Vapor/air or vapor/oxygen mixtures near or within their flammable explosive

range.
Peroxides, chlorine, or other chemicals likely to violently decompose or
become hazardous from the heat of welding.
Unsaturated hydrocarbons (such as ethylene) that may experience exothermic
decomposition due to the high temperatures created by welding.
Caustics, amines, and acids (such as H. F. acid) if the concentrations and
operating temperatures are such that the fabrication specifications require post
weld heat treatment (stress relieving).
Oxygen
Oxygen enriched atmospheres.
Note: The amount of oxygen needed for an enriched atmosphere varies with
each products flammable limits.
Compressed air, unless known to be free of flammables and combustibles,
such as lubricating oil residues.

BASF Corporation

Title: HOT TAP PROCEDURE

Individual Unit
Procedure

Function: Safety
No.: BCF 020.029

Freeport Site

Reviewed: 11/99

5.

Page: 3 of 5
Effective: 11/07/00 Supersedes:

SS #29

Lines or equipment in any service where post weld heat treatment is required.
Lines or equipment that are clad or lined.

4.3.

Restricted Hot Taps

Welding or hot tapping on piping or equipment in vacuum service
(< atmospheric pressure) must have an engineering evaluation, and approval,
from the TES Pressure Vessels Group.
Welding or hot tapping on piping or equipment in hydrogen service must have
an engineering review, and approval, by a competent person (as determined
by the TES Group).

4.4.

*Training
Safe Work Permit and Hot Tap Permit writers shall be trained in the
requirements of this procedure and attached work instructions.
Training shall be done upon eligibility to write said permits, when changes to
the procedure(s) are made, or every three years as a minimum.

4.5

*Documentation
A record of training shall be kept in the employees training file.
The record should reflect the following:

Date of training

Instructor

RESPONSIBILITIES
5.1.

Managers
Review/approve hot tap requests.
Designate, in writing, qualified BASF personnel who are trained/authorized to
write and issue hot tap permits.
Audit hot tap permit system for compliance to requirements.
*Ensure unit/department personnel are trained in the requirements of this
procedure and attached work instructions.

5.2.

TES Mechanical Group, a.k.a., Pressure Vessel Group (TES MG)

Review hot tap permit requests.
Provide guidance/assistance to BASF Requestor and/or Representative in
acquiring thickness tests and performing visual inspections of the hot tap site.

BASF Corporation

Title: HOT TAP PROCEDURE

Individual Unit
Procedure

Function: Safety
No.: BCF 020.029

Freeport Site

Reviewed: 11/99

Page: 4 of 5
Effective: 11/07/00 Supersedes:

SS #29

Provide welding procedures/drawings and/or additional requirements i.e.,

reinforcement pads, flow and pressure requirements, etc.
Provide/assign restricted hot tap permit evaluations.
Approve hot tap permit requests.

5.3.

BASF Requestor
Fill in section "A" of the permit and submit to owning manager.

5.4.

BASF Representative
Coordinate hot tap job assignment and ensure that all necessary signatures
are obtained as the job progresses from step to step.
Verify procedural calculations and monitor job to ensure all required
procedures are followed.
Issue the Hot Tap Permit to the Hot Tap Technician (HTT).
Maintain original hot tap permit until the work is complete.
*Ensure that the control room is notified at the beginning of the welding step
and at the beginning of the hot tap step.
*Advise DOT of pending hot tap procedures for scheduling/preparation
purposes.
*Train in the requirements of this procedure and attached work instructions.

5.5.

DOT Leader
Coordinate with BASF Representative and Team to prepare necessary
procedures, emergency plans and address requirements for hot tap work, i.e.,
flows, temperatures, levels, communications, stand-by personnel, etc.
Review and sign section "B" and "C" when required to, ascertain that
requirements of hot tap permit have been met and that approval is given.
Notify team when hot tap welding and drilling activities are in progress.
*Train designated personnel in the requirements of this procedure and
attached work instructions.

5.6.

Hot Tap Technician (HTT)

Provide copy of hot tap rigs depth measurements, cutting distance calculations
to BASF Representative.
Verify with BASF Representative that there is sufficient room at the hot tap site
to safely operate the hot tap rig.
Adhere to the requirements of this procedure, work instructions, permit and
API's recommended practice 2201 (Hot Taps).
Verify applicable questions in section "C" and sign the hot tap permit before
beginning the tapping procedure.

BASF Corporation

Title: HOT TAP PROCEDURE

Individual Unit
Procedure

Function: Safety
No.: BCF 020.029

Freeport Site

Reviewed: 11/99

6.

Page: 5 of 5
Effective: 11/07/00 Supersedes:

SS #29

Verify applicable questions in section "D" and sign the hot tap permit before
removing the hot tap rig.

*RELATED DOCUMENTS
API Recommended Practice 2201
BCF020.023 Hot Work
BCF020.029WI Hot Tap Permit
BCF020.001 Safe Work Procedure

BCF020.029WI
Hot Tap Permit