PEC Ltd

21, Shipyard Road, Singapore 628 144. Tel: 6268 9788 Fax: 6268 9488

URL:http://www.peceng.com

Date Title Doc No.

27 Nov 2019 Method Statement PEC-
Hot Tap Procedure Job No.
Rev. No Page No.

HOT TAP PROCEDURE

GEORGE /
0 27/11/2019 Initial Release
BALAJI

Rev Date Description Prepared Checked Approved

Page 1 of 6
 PEC Ltd
21, Shipyard Road, Singapore 628 144. Tel: 6268 9788 Fax: 6268 9488

URL:http://www.peceng.com

Date Title Doc No.

27 Nov 2019 Method Statement PEC-
Hot Tap Procedure Job No.
Rev. No Page No.

Scope:

The Hot tapping procedure has been prepared to PEC in Singapore and CRISP Mechanical
Project.

REFERENCE CODES:

API653, API650, API 577, API 582, API 2201, ASME Sec V , ASME Sec IX & Client
procedure and specifications.

UT THICKNESS MEASUREMENT ON SHELL

 UT thickness survey / 100% lamination check has been carried out on hot tapping
location areas & 150mm beyond re pad areas and minimum thickness to be confirmed
respective locations as per API 653 Table 9.1.
 Hot taps shall not be installed on laminated or severely pitted shell plate.
 The minimum height of tank liquid above the hot tap location shall be at least 3 feet
as per 653 or 6feet as per MWP – ME802 during the hot tapping operation of welding
and cutting.
Connection Size , Pipe( in) Minimum Shell plate thickness in (mm)
≤6 5.0
≤8 6.4
≤ 14 9.5
≤ 18 12.7

PREPARATION FOR HOT TAPPING:

 Hot tap locations are marked and verified together as per project client requirements.
 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.
 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.
 Contact the Unit Operations Team / Technician to confirm and monitor the flow
before proceeding with the welding operation for the nozzle fit-up.

Page 2 of 6
 PEC Ltd
21, Shipyard Road, Singapore 628 144. Tel: 6268 9788 Fax: 6268 9488

URL:http://www.peceng.com

Date Title Doc No.

27 Nov 2019 Method Statement PEC-
Hot Tap Procedure Job No.
Rev. No Page No.

 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 tank surface should be provided.
 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 and using by GTAW process
for root.
 Use low hydrogen electrodes (E7018-1H4) 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).
 After the completion of nozzle root pass welding, the weld shall be visually inspected,
100% PT or MT inspected before proceeding with the cover pass welding
 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.
 Pressure test the nozzle with a blind flange installed.
 Test pressure should be at least equal to the operating pressure of the line.
 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.
 Painting shall be carried out on the hot tapping surface refer the drawing and client
requirements.

BUTTER (WELD OVER LAY)

 Butter (weld over lay) allows a balanced welding sequence to be used.

 Before welding preheat to 90 ºC - 100 ºC to remove the surface moisture.

 Low hydrogen electrode (E7018-1H4) shall be used for SMAW process and for butter
(weld overlay).
 Butter (Weld over Lay) 3 to 4mm thick with at least two layers at nozzle and
reinforcement pad weld areas.
 Grind the weld over layer area in smooth.
 The width of the buttering should be sufficient to overlap the nozzle attachment weld
by 1/4 in. (6.5 mm) on both the inside and outside diameters.
Page 3 of 6
 PEC Ltd
21, Shipyard Road, Singapore 628 144. Tel: 6268 9788 Fax: 6268 9488

URL:http://www.peceng.com

Date Title Doc No.

27 Nov 2019 Method Statement PEC-
Hot Tap Procedure Job No.
Rev. No Page No.

 The surface of the buttered layer should be ground smooth, the edges de-burred and
both the weld and the pipe local to the weld inspected by appropriate crack detection
and ultrasonic methods.
 100% MT on butter (Weld over Lay) after 48 Hours to check for delayed cracking, if
any indications found in MT examination perform PAUT Examination.
 100% UT on butter examination on butter (Weld over Lay) after the MT examination.
 Hardness tested on welds and acceptable hardness value shall be 200HB expect high
strength steel (SM 53C) 225HB.
TEMPER BEAD TECHNIQUE

 Approximately one- half of the thickness of this layer shall be removed by grinding
before depositing subsequent layers.
 A final temper bead weld shall be applied to a level above the surface being repaired
without contacting the base material. But close enough of the edge of the under laying
weld bead to assure tempering of the base material heat affected zone.
 The removal of top temper bead capping pass (removal of high hardness weld toe) in
the event of a break during welding process.
 To ensure welder is qualified for temper bead welding
 To check the preheat temperature control as per approved WPS and continuous
welding during temper bead process.

INSPECTION:

 Verifying adequate wall thickness along the lengths of the proposed welds typically
using UT or RT and reviewing the results are satisfactory conditions.
 Power brush and clean the shell with an organic solvent to remove paint, dirt, grease
and scale at the nozzle and reinforcing plate location.
 Verifying the welding procedure. Often, plants have welding procedures qualified
specifically for hot taps and in-service Welding.
 Verifying flow conditions and the minimum height of tank liquid above the hot tap
location shall be at 6feet.
 Specifying the sequence of welding full encirclement sleeves and fittings
(circumferential and longitudinal welds).
 Verifying fit-up of the hot tap fitting.

Page 4 of 6
 PEC Ltd
21, Shipyard Road, Singapore 628 144. Tel: 6268 9788 Fax: 6268 9488

URL:http://www.peceng.com

Date Title Doc No.

27 Nov 2019 Method Statement PEC-
Hot Tap Procedure Job No.
Rev. No Page No.

 Auditing welding to assure the welding procedure is being followed.

 Perform NDE of completed welds. Typically this includes VT, UT shear wave using
special procedures for the joint
 Configuration, MT or PT as applicable for material and temperature.
 Witness leak testing of fitting, if specified.
 Perform positive metal identification (PMI) testing on the hot tap component material.
 Jurisdictions the hot tap component may require to have a registered design in which
case this should be verified.

NOZZZLE:
 Prepare the weld area and fit up the nozzle. The nozzle centerline should accurately
intersect the pipe centre line longitudinally.
 A uniform gap of 1.5 to 3mm between the hot tap nozzle and tank surface should be
provided.
 Welding shall be carryout as per approved Hot tapping Procedure and followed by
visual and NDT.
 100%RT – Nozzle pipe to flange butt weld.
REINFORCEMENT PAD

 After the pipe is welded, the reinforcing plate shall be installed either in one piece or
two pieces with horizontal weld. The reinforcing plate to nozzle shall be installed with
a full penetration weld.
 Each Reinforcement pad plate 1/4 in. tell-tale hole, drill and tap for1/8-in. pipe
thread hole has to be maintained 1/8”or 4mm and as per project specifications.
 During the welding follow the approved Hot Tapping WPS parameters.
 After the reinforcing plate has been welded to the shell and NDE performed, the pad
shall be pneumatically tested by the procedure described in API 650.

REFER THE ATTACHMENT DOCUCMENTS WHICH ARE LISTED AS BELOW.

 Marked PID Flow Sketch

 Marked Isometric Drawing
 Welding Procedure Specification
Page 5 of 6
 PEC Ltd
21, Shipyard Road, Singapore 628 144. Tel: 6268 9788 Fax: 6268 9488

URL:http://www.peceng.com

Date Title Doc No.

27 Nov 2019 Method Statement PEC-
Hot Tap Procedure Job No.
Rev. No Page No.

 Welder Qualification Certification

 Manual UT Procedure
 PAUT Procedure
 Radiography Procedure
 NDT Technician Qualifications

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