Welding and Hot Tapping

Authored By: Blanchard Refining Company LLC Doc No.
: RSW-000055-GB
Adam Collier Galveston Bay Refinery Rev No: 1
Doc Custodian:
Safety Supervisor
Approved By:
PR-24 In-Service Welding and Hot Refinery Safe Work Procedure
Sean Levy Tapping
Date Approved: 5/8/2020 Next Review Date: 10/31/2025 Effective Date: 10/12/2020
TABLE OF CONTENTS
1.0 Purpose ............................................................................................................................................ 2
2.0 Scope ............................................................................................................................................... 2
3.0 Procedure ......................................................................................................................................... 2
3.1 Documentation & Form Requirements for In-service Welds and Hot Taps ................................ 2
3.1.1 Requesting an In-Service Weld or a Hot Tap 2
3.1.2 Obtaining Approval for an In-Service Weld or Hot Tap 3
3.1.3 Job Site Meeting and Completion of the In-Service Weld Site Review Checklist 4
3.1.4 Documentation Required for the Request and Approval of Hot Taps 4
3.1.5 Job Site Meeting and Completion of the Hot Tap Site Review Checklist 5
3.2 In-service Welding Requirements ................................................................................................ 6
3.2.1 In-Service Welding Considerations 6
3.2.2 Performing the In-Service Welding 10
3.2.3 In-Service Welding on Tanks 11
3.2.4 Weld Machine Requirements: 11
3.3 Hot Tap Requirements ............................................................................................................... 11
3.3.3 Work Above and Below Grade or in Congested Areas 12
3.3.4 Flow in Lines 12
3.3.5 Hot Tap Machine Suitable 12
3.3.6 Base Metal is Suitable 12
3.3.7 Line or Vessel Contents are Suitable 12
3.3.8 Personnel are Qualified 12
3.3.9 Hot Tap Connection is Suitable 12
3.3.10 Responsible Engineer Responsibilities 12
3.3.11 Operations/Products Control Responsibilities 13
3.3.12 Performing the Hot Tap 13
4.0 Definitions ...................................................................................................................................... 15
5.0 References ..................................................................................................................................... 15
6.0 Attachments ................................................................................................................................... 16
7.0 Revision History ............................................................................................................................. 16
Attachment A: In-service Weld/Hot Tap Request Form .............................................................................. 17
Attachment B: In-service Weld/Hot Tap Approval Form ............................................................................. 18
Attachment C: In-service Weld Site Review Checklist ................................................................................ 20
Attachment D: Hot Tap Site Review Checklist ............................................................................................ 22
Attachment E: In-service Weld/Hot Tap Location Tag ............................................................................... 24
Attachment F: In-service Weld/Hot Tap “Do Not Operate” Tag .................................................................. 24
Attachment G: Process Flow/Decision Logic for a Hot Tap/In-service Weld ............................................. 25
Attachment H: Tables for In-service Welding Flow Requirements ............................................................. 26
Attachment I: Diagram 1: Hot Tap Location & Travel Distance of Hot Tap Machine.................................. 27
Printed 10/21/2020 RSW-000055-GB.docx Page 1 of 27

Printed copies should be used with caution. The user of this document must ensure that the current approved
version of the document is used.
Blanchard Refining Company LLC Galveston Bay Refinery
Title: PR-24 In-Service Welding and Hot Tapping Doc Number: RSW-000055-GB Rev No: 1
1.0 Purpose
In-service welding and hot tapping are potentially hazardous activities because of the hazardous nature of
the materials present. Therefore, every reasonable effort must be made to minimize the use of in-service
welds and hot taps and to ensure that they are made safely. The purpose of this procedure is to establish
requirements for safely performing these activities. For detailed in-service weld and hot tap engineering
requirements, refer MPC Refining specification SP-50-24, “Procedures for In-Service Welding or Hot
Tapping on Piping and/or Equipment.
2.0 Scope
1.1 This procedure will allow evaluation of the need to perform an in-service weld and/or hot tap, as
well as establish a specific sequence of steps to be followed when performing the work.
1.2 This procedure identifies specifications, forms, and authorizations that must be utilized in order to
safely grind, burn, weld, and/or drill on piping or equipment (except drill and tap of valve packing
and seat, that is covered by RSP-1150-050, “Valve Drill, Tap, and Injection.” Management of Minor
Leaks and Clamp/Wrap Life Cycle Management is covered under RSP-1150-040.
1.3 This procedure applies to all work performed on equipment owned by Marathon Petroleum
Company’s (MPC) Galveston Bay Refinery (GBR) by contractors and/or employees.
3.0 Procedure
3.1 DOCUMENTATION AND FORM REQUIREMENTS FOR IN-SERVICE WELDS AND HOT TAPS
3.1.1 Requesting an In-Service Weld or a Hot Tap
In order to use the proper order of forms required for an in-service weld,
utilize the Process Flow/Decision Logic for an In-Service Weld/Hot Tap
located in Attachment G.
If required, a Management of Change (MOC) shall be initiated by the
requestor and progressed to the implementation stage prior to proceeding
with any paperwork. A copy of the MOC’s documentation shall be attached
to the In-Service Weld/ Hot Tap Request Form (Attachment A) prior to its
approval. All hot taps require an MOC.
A request for an in-service weld will be initiated by a Galveston Bay Refinery
(GBR) Asset Coordinator, Maintenance Coordinator, Responsible Engineer
or other originator using the In-Service Weld/Hot Tap Request Form.
A tie-in requiring both an in-service weld and a hot tap may
be formally requested through the use of one In-Service
Weld/Hot Tap Request Form if the hot tap will be performed
within 28 days of the in-service weld.
Hot taps that are performed later than 28 days from the
associated in-service weld require the completion of a
separate Hot Tap Request Form.
Once in-service welding is deemed necessary, the approved location will be
marked and tagged with an In-Service Weld/Hot Tap Location Tag found in
(Attachment E) or other project-specific tie-in tag containing the same
information on the pipe, tank, vessel, or other equipment. This location will
be approved by the Operations or Product Control Day Foreman or delegate
and then the location tag will be hung.

The Engineering portion of the In-Service Weld/Hot Tap Request Form will
be completed and verified by the Responsible Engineer and then forwarded
to the Engineering Manager for approval.
The appropriate Process Engineer and Owning Department Supervisor, will
complete and approve the Owning Department/Process Engineering portion
of the Request form. The Owning Department Manager or his designee
must give final approval of the In-Service Weld/Hot Tap Request Form.
Once completed and approved, a copy of the In-Service Weld/Hot Tap
Request Form will be returned to the Responsible Engineer and filed as
necessary. A copy of the In-Service Weld/Hot Tap Request Form will be
attached to the MOC for hot taps and the Inspection IWR for in-service welds
that do not involve a hot tap. Retain a copy of this form to attach to the In-
Service Weld/Hot Tap Approval Form.
3.1.2 Obtaining Approval for an In-Service Weld or Hot Tap
An in-service weld must be formally requested through the use of the In-
Service Weld/Hot Tap Request Form as described in Section 3.1.1 prior to
proceeding with the approval process.
The approved and processed In-Service Weld/Hot Tap Request Form will be
attached to the In-Service Weld/Hot Tap Approval Form (Attachment B) prior
to proceeding.
The originator will initiate a In-Service Weld/Hot Tap Approval Form then
ensure that the Responsible Engineer completes the appropriate portion of
the form and that the Engineering Manager approves the form.
One In-Service Weld/Hot Tap Approval Form may be used
to gain approval for both the in-service weld and the hot tap
associated with a tie-in if the hot tap is completed within 28
days of the associated in-service weld.
separate Hot Tap Approval Form.
The form is then forwarded to the Inspection Department to complete and
verify the requested information. The Inspection Department will inspect the
site, specify the weld procedure, and note any limitations or requirements for
additional testing on the In-Service Weld/Hot Tap Approval Form.
The appropriate Responsible Engineer (Reliability Engineer, Maintenance
Engineer, Area Engineer, Project Engineer), Inspection Coordinator,
Engineering SME, Engineering Supervisor, Engineering Manager,
Maintenance Manager, Area Team Leader, and Owning Department
Manager must give final approval of the In-Service Weld/Hot Tap Approval
Form.
Any variance from this procedure requires variance request and approval of
Maintenance Manager, Owning Department Manager, and Refinery
Manager.
Once completed and approved, a copy of the In-Service Weld/Hot Tap
Approval Form will be returned to the Responsible Engineer and filed as
necessary. If applicable, a copy of the In-Service Weld/Hot Tap Approval
Form will be attached to the MOC within the MOC database for hot taps and
the Inspection IWR for in-service welds that do not involve a hot tap. Retain

a copy of this form with any attachments to attach to the In-Service Weld
Checklist.
3.1.3 Job Site Meeting and Completion of the In-Service Weld Site Review Checklist
An in-service weld must be formally requested and approved through the use
of the In-Service Weld/Hot Tap Request Form and In-Service Weld/Hot Tap
Approval Form respectively prior to proceeding with the In-Service Weld Site
Review Checklist and job site review.
A copy each of the approved and processed In-Service Weld/Hot Tap
Request Form and In-Service Weld/Hot Tap Approval Form will be attached
to the In-Service Weld Site Review Checklist (Attachment C) prior to
proceeding. Copies of the Weld Procedure and completed Job Safety
Analysis are also required to be attached to this document prior to the job
occurring.
The Weld Procedure shall be provided by the MPC
Maintenance Coordinator and shall be approved by the
GBR’s Inspection Department prior to the in-service weld.
The originator will initiate a In-Service Weld Site Review Checklist then
ensure that the Owning Department completes and verifies the requested
information on the first page of the form. The Owning Department
Supervisor will give his or her initial approval for this portion of the form.
The form is then forwarded to the Responsible Engineer who completes and
verifies the requested information on the first page of the form prior to giving
his or her initial approval for this portion of the form.
A meeting will be held at the job site of the in-service weld and attended by
the appropriate Safety Representative, Responsible Engineer, Asset
Coordinator, Maintenance Coordinator, Owning Department Supervisor,
Contractor Foreman, and the welder performing the In-Service Weld in order
to go over the “AT THE SITE” portion and give their approval for the in-
service welding to occur.
Approval is required from the individuals listed on the In-Service Weld Site
Review Checklist as required by the nature of the job. Approvals cannot be
given if any of the In-Service Weld Site Review Checklist answers are
marked “NO.”
Once completed and approved at the site, this In-Service Weld Site Review
Checklist along with any attachments shall be attached to the Safe Work
Permit. It is at this time that a Safe Work Permit can be issued. This entire
packet of information is considered to be the “Additional Permit” required by
the Safe Work Permit for in-service welding. It is only once the completed
paperwork is attached to the completed Safe Work Permit that the in-service
welding can occur.
This packet will stay with the permit at the job site while the welding takes
place and then will be turned in with the permit for proper retention as
required through the Safe Work Permit retention process.
A copy of the completed In-Service Weld/Hot Tap Approval Form shall be
provided to the Inspection Department in order to be inserted into the piping’s
quality assurance/quality control (QA/QC) documentation.
3.1.4 Documentation Required for the Request and Approval of Hot Taps
The formal hot tap request process and hot tap approval process is the same

as is listed in Section 3.1.1 and Section 3.1.2 for an in-service weld. Refer to
the referenced sections for requirements and completion of these forms.
The following items must be completed before the Hot Tap Site Review
Checklist can be initiated:
Once a hot tap is deemed necessary, the Process Engineer
will verify the line or vessel contents are stable during
welding.
The Operations/Products Control Day Foreman or delegate
will have the location identified with the location tag
(Attachment E) and will approve the location.
The in-service welding requirements for the tie-in can only
be completed as described in Section 3.2 after the In-
Service Welding/Hot Tap Request Form, the In-Service
Welding/Hot Tap Approval Form, and the In-Service Weld
Site Review Checklist have been completed and approved
as described in Section 3.1 as well as attached to the Safe
Work Permit.
separate hot tap request and approval. Refer to sections
3.1.1.3 and 3.1.2.3 for more information.
3.1.5 Job Site Meeting and Completion of the Hot Tap Site Review Checklist
A Hot Tap Site Review Checklist (Attachment D) must be completed for all
hot taps. The Hot Tap Site Review Check List covers the mechanical and
safety requirements for making the hot tap. The following documentation
process applies to the Hot Tap Site Review Checklist:
A hot tap must be formally requested and approved through
the use of the In-Service Weld/Hot Tap Request Form and
In-Service Weld/Hot Tap Approval Form respectively prior to
proceeding with the Hot Tap Site Review Checklist and job
site review.
A copy each of the approved and processed In-Service
Weld/Hot Tap Request form and In-Service Weld/Hot Tap
Approval Form will be attached to the Hot Tap Site Review
Checklist prior to proceeding. Diagram 1: Hot Tap Location
and Travel Distance of Hot Tap Machine (Attachment I) must
be attached to the In-Service Weld/Hot Tap Approval Form.
Copies of the Weld Procedure and a completed Job Safety
Analysis are also required to be attached to this document
prior to the job occurring.
The originator will initiate a Hot Tap Site Review Checklist
then ensure that a meeting will be held at the job site of the
hot tap and attended by the appropriate Inspector, Safety
Representative, Responsible Engineer, Maintenance
Coordinator, Owning Department Supervisor, Contractor
Foreman, and GBR Asset Coordinator in order to go over
the “AT THE SITE” portion and give their approval for the hot
tap to occur.
Approval is required from the applicable individuals as

required by the nature of the job. Approvals cannot be given

if any of the Hot Tap Site Review Checklist answers are
marked “NO.”
Once completed and approved at the site, this Hot Tap Site
Review Checklist along with any attachments shall be
attached to the Safe Work Permit. It is at this time that a
Safe Work Permit can be issued. This entire packet of
information is considered to be the “Additional Permit”
required by the Safe Work Permit for hot tapping. It is only
once the completed paperwork is attached to the completed
Safe Work Permit that the hot tapping can occur.
This packet will stay with the permit at the job site while the
hot tapping takes place and then will be turned in with the
permit for proper retention as required through the Safe
Work Permit retention process.
3.2 IN-SERVICE WELDING REQUIREMENTS
3.2.1 In-Service Welding Considerations
It will be the responsibility of Operations/Products Control and Maintenance
Representative to properly assess the benefits versus risks of in-service
welds. The following alternatives must be considered.
Installation delay must be seriously considered, so that
connections can be made at a time when equipment or
piping is not in service.
Alternate locations for connections should be investigated to
prevent the need for in-service welding.
Every attempt possible must be made to isolate equipment
or process systems when it is decided to make connections
which would otherwise require in-service welding.
While making the necessary drawings, bills of materials, and
completing the required forms, the following items should be
carefully considered. Design details are outlined in
Engineering Specification SP-50-24 which proves to be a
very useful reference.
It will be the responsibility of the GBR person who is coordinating the in-
service weld to remain on site to oversee the in-service weld throughout its
duration.
Base Metal is Suitable for Welding and Hot Tapping- The following conditions
must be met prior to in-service welding:
The base metal thickness must be approved and be heavy
enough to support the new connection and the hot tap
machine or other equipment.
The Inspector will indicate the minimum metal thickness and
mark the thickness on the piping or equipment at the location
of the in-service weld or hot tap. This measurement must
have been taken no longer than 28 days prior to the in-
service weld/hot tap. The thickness must also be
documented on the In-Service Weld/Hot Tap Location Tag
(Attachment E).

3.2.1.3.2.1 The measurement shall be recorded on the

equipment after any paint has been
removed from the weld area.
Welding onto thin material could result in overheating and
burn-through. Depending on the service, it is sometimes
possible to temporarily reduce the pressure and/or
temperature within the equipment to provide an additional
safety factor while welding takes place.
If the piping thickness is greater than 0.75” (¾”), and/or the
equipment is greater than 1.25” (1-1/4”), the Inspection
Department must give their approval.
The base metal must be free of laminations and hydrogen or
caustic attack (fissuring). Consideration must be given to
the contained commodity where the weld connection is to be
made. Be sure there are no other defects that would
preclude making a sound weld.
Metal Temperature – The following items must be considered prior to
performing an in-service weld:
In-service welding shall not be performed on lines or
equipment when the metal temperature is less than 50°F
unless special consideration is given to the base metal
characteristics, electrodes, and method of metal preheating
and is approved by the Engineering Department.
If the metal temperature is less than 50°F, preheating of the
weld area prior to welding per the Welding Procedures in
Section IX of the ASME Boiler and Pressure Vessel Code of
ASME/ANSI B31.3, Part 330 shall be considered.
Similarly, no welding shall be done if the metal temperature
exceeds process temperature of 450°F prior to welding
unless approved by the Engineering Department.
When metal temperatures are below the atmospheric dew
point, preheating or other steps are desirable to reduce the
moisture content in the weld area. Moisture inclusion could
result in weld porosity and underbead cracking.
Risk of Burn-Through- the following items should be considered prior to in-
service welding:
The risk of burn-throughs can be minimized if:
3.2.1.5.1.1 The equipment is properly inspected for
adequate wall thickness and absence of
defects,
3.2.1.5.1.2 Controlled welding techniques are done by
experienced welders to prevent overheating,
and
3.2.1.5.1.3 Other appropriate safety procedures are
followed.
3.2.1.5.1.4 The metal thickness at the hot tap/in-service
welding location is Prohibited when less

than 3/16 inch (0.187 inches) thick for

pressures and temperatures given in the
chart located in Section 4.2 of SP-50-24.
A thorough and complete inspection of each connection area
must verify that the metal thickness is adequate for the
pressure and temperature involved and that there are no
laminations or other defects. Welding can only be made in
lamination-free areas.
To minimize the possibility of burn-through, the first weld
pass to the equipment shall be made with a 3/32-inch
diameter welding electrode and the remaining passes shall
be made with electrodes not to exceed 1/8 inch diameter if
actual metal thickness does not exceed 1/2 inch.
For heavier wall thickness (1/2”) where burn-through is not a
primary consideration, larger diameter electrodes may be
used to compensate for the larger mass. This will minimize
the potential for fusion defects.
Line or Vessel Contents are Suitable for Welding or Hot Tapping- The
following conditions must be met:
Contents of the line or vessel being hot tapped will not
preclude welding as per Section 3.2.1.7.
The oxygen level within the equipment will be controlled to
preclude the formation of a vapor/air mixture within the
flammable or explosive range.
Chemical Considerations - In-service welding cannot be performed if the
equipment contains:
Oxygen service
Plant or instrument air service (compressed air receivers,
etc.)
Hydrofluoric (HF) or Sulfuric acid service (hot tapping
restricted only; other in-service welding shall be managed
with Specification Waiver)
Hydrogen, unless the Responsible Engineer conducts a
review to ensure that the equipment has not operated above
the Nelson Curve Limits for the particular steel involved
because of the possibility of hydrogen embrittlement of the
metal (see API Publication 941 - Steels for Hydrogen
Service at Elevated Temperatures and Pressures in
Petroleum Refineries and Petrochemical Plants);
Services containing flammables below atmospheric pressure
or containing a mixture within the flammable range and
operating at any pressure, expect as approved by MPC
Engineering;
Caustic, amine, or chloride-containing service with austenitic
material as the carrier pipe;
Certain unsaturated hydrocarbons that may experience
exothermic decomposition reactions (acetylene, ethylene,

butadiene for example) if the metal temperature, resulting

from the heat of welding, could initiate such a reaction at the
maximum expected pressure. Such reactions could have
the potential for causing localized hot spots on pipe walls
that could lead to failure.
Compressed Air Line or Vessels - welding shall NOT be performed on
compressed air lines or air receivers under pressure. Such equipment may
contain a residue of lubricating oil or carbon, which may ignite. Even when
depressured, welding should be done on air lines only after thorough
cleaning. Steps shall be taken to ensure that combustible material is not
present inside the line or that oxygen has been excluded.
Flow in Lines - In certain cases where there may be insufficient or interrupted
flow, such as a flare line, it may be necessary to continually purge or flood
the line with steam or inert gas to ensure that the line or equipment does not
contain a flammable mixture during the welding operation. Suggested
product velocities during welding are:
Liquids - See Table 1: In-Service Welding Flow
Requirements - Liquids (Attachment H) for flow rates that are
based on the minimum velocity to achieve turbulent flow.
Velocity should not exceed 4 ft./sec. to prevent excess heat
removal, which could give a brittle weld.
Gas - See Table 2: In-Service Welding Flow Requirements -
Gases (Attachment H) for flow rates which are based on
minimum velocities depending on line size.
Consult the Process Engineer for the unit to determine the
meter units of flow required to meet these velocities.
Selecting the Weld Fitting - Care should be taken to select the proper fitting
for the connection. Many types of connecting fittings are available, such as
welded outlet fittings (weld-o-lets), weld-ends, split tees, saddles, and
nozzles. Connections shall be designed to the applicable code, i.e., ASME
Boiler and Pressure Vessel Code; API RP 2201, API 650, Welded Steel
Tanks for Oil Storage; or ASME B31-3, Pressure Piping Code. Be sure the
fittings are the proper size to accommodate the hot tapping requirements.
Full encirclement saddles are required for size to size hot
taps
Closeness to Other Connections - Weld seam location closer than 3 inches
to an existing weld seam or is closer than 18 inches to a flange or threaded
connection is Prohibited. Important:
The 3 inches minimum dimension should be observed
between the two closes points of adjacent weld seams.
Similarly, the 18-inch dimension shall be measured from the
flange face to the nearest hot tapped weld seam (not the
center of the hot tap)
Instances where these dimensional requirements may not be
met shall be evaluated by MPC Engineering and Inspection
Departments on a case-by-case basis.
The piping system shall be checked for expansion, loading,
support, etc.

Air Temperature - Welding should not be performed on lines or equipment

when the wind chill factor is -50°F or less. Hot tap machines should also be
checked for suitability at low temperatures (below 32°F).
Alloys and Stress Relieving - Some equipment is unsuitable for in-service
welding because the metallurgy or thickness of metal requires stress
relieving, which normally cannot be done while the equipment is pressurized.
Special treatment is required for high tensile strength alloy steels and special
welding electrodes must be used. Fitting and weld rod metallurgy must be
compatible with the equipment, piping, and vessels. These are managed on
a case-by-case basis and require MPC Engineering and Inspection
Department approval.
Lined Piping or Equipment - In-service welding should not be done on lines
or equipment with cladding or linings, such as lead, strip lining, glass, plastic
and so forth. Welding on refractory lined equipment requires approval of
Engineering and Inspection.
H2S or Toxins - Special safety precautions will be required when the
equipment contains H2S or toxins. (Refer to MSDS for toxic information.)
Means of Personnel Exit - For work above and below grade or in congested
areas, a means of personnel exit shall be provided.
Atmospheric Monitoring and Controls - To ensure that excavations are safe
for entry and hot work, tests for the presence of flammable and toxic material
should be made. If either of these are present, an air mover or some other
positive means of ventilation shall be provided. Air breathing equipment shall
be used if atmospheric monitoring indicates that it is necessary.
Personnel are Qualified
Qualified personnel will do the welding. Welders must be
qualified to the weld procedure to be used.
Welders must be approved by Marathon’s Inspection
Department.
Welders shall read and understand the welding procedure
prior to signing the In-Service Weld/Hot Tap Site Review
Checklist and Safe Work Permit.
He or she shall also be instructed on the requirements in this
In-Service Welding and Hot Tapping Procedure.
Any comments or special considerations must be indicated on the In-Service
Welding Approval Form.
3.2.2 Performing the In-Service Welding
Before proceeding with the welding, the following conditions must be satisfied:
The area to which a connection is to be made has been identified, physically
marked, and the metal thickness measured and marked on the equipment
and on the In-Service Weld/Hot Tap Location Tag (Attachment E).
The In-Service Weld/Hot Tap Request Form, In-Service Weld/Hot Tap
Approval Form, and the In-Service Weld Site Review Checklist must be
completed, approved, and attached to the Safe Work Permit along with other
required attachments as discussed in Section 3.1.
An Operations or Products Control Representative will be present until the

first pass of the welding operation is completed.

A suitable fire extinguisher (dry chemical or pressurized fire hose) has been
provided and a fire watch has been established.
A Safe Work Permit has been secured, and all necessary gas tests have
been made to ensure a safe environment.
The fitting must be properly positioned.
The base metal temperature must be in accordance with Section 3.2.1.4 of
this procedure.
The product must be moving at the desired velocity as specified in Tables 1
or 2 (see Attachment H).
3.2.3 In-Service Welding on Tanks
Liquid Level Changes - Never pump into or out of a tank while hot work is in
progress. Close and lock and tagout all valves on liquid lines at the tank and
all mechanical tank mixers. Install the In-Service Weld/Hot Tap Do Not
Operate Tag located in Attachment F to the valves and mixers.
Heating Coils - Turn off all heating coils during the in-service welding
procedure.
Liquid Level Above the Weld Area - Maintain at least three feet of liquid head
above the weld area. A hand tape gauge of the tank contents shall be made
immediately prior to the In-Service Weld Site Review Checklist is approved
since automatic or remote reading gauges may not be reliable enough for the
measurement. No attempt shall be made to weld on atmospheric pressure
petroleum storage tanks above the liquid level, i.e., in the vapor space or on
the roof, because of the danger of an explosive atmosphere inside the tank.
The liquid level shall be periodically monitored throughout the welding
process.
Pontoon Decks - Welding shall not be permitted on the deck of a floating-roof
tanks in service except under very carefully controlled conditions and
approval from MPC Engineering and Inspection Department. Each situation
could be unique to hazards that would be encountered, including exit from
the tank in the event of an emergency, flammability within the pontoon or
between the deck and liquid surface, and flammability in the seal area.
Extreme caution is advised.
3.2.4 Weld Machine Requirements:
Welding machines must have a proper ground connection at all times and
shall be connected as close as possible to the weld. Welding machines must
have a ground attached to the work when welding on pumps, turbines or
compressors to eliminate welding grounding through bearings or seals.
Ground attachment to the preceding equipment is prohibited when welding
elsewhere.
3.3 HOT TAP REQUIREMENTS
3.3.1 It will be the responsibility of Operations/Products Control and Maintenance to properly
assess the risks and benefits of Hot Taps. The following alternatives must be
considered:
Installation delay must be seriously considered so that connections can be
made at a time when equipment or piping is not in service.

Alternate locations for connections should be investigated to prevent the

need for hot tap.
Every attempt possible must be made to isolate equipment or process
systems when it is decided to make connections that would otherwise require
hot tapping.
3.3.2 It will be the responsibility of the GBR person who is coordinating the in-service weld to
remain on site to oversee the in-service weld throughout its duration.
3.3.3 Work Above and Below Grade or in Congested Areas - For work above and below grade
or in congested areas, provide an easy personnel exit. To ensure that excavations are
safe for entry and hot work, tests for the presence of flammable and toxic material should
be made. If either of these are present, an air mover or some other positive means of
ventilation should be provided. Air breathing equipment shall be used to protect
personnel from toxic atmospheres.
3.3.4 Flow in Lines - In certain cases where there may be insufficient or interrupted flow, such
as a flare line, it may be necessary to continually purge or flood the line with steam, inert
gas to ensure that the line or equipment does not contain a flammable mixture during the
hot tap operation. Suggested product velocities during welding are:
Liquids - (See Table 1 for Flow Rates) (attachment H)
Gas - (See Table 2 for Flow Rates) (attachment H)
3.3.5 Hot Tap Machine Suitable - The hot tap machine can be considered suitable if the
pressure and temperature of the material inside the line or vessels falls within the working
limits of the hot tap machine.
3.3.6 Base Metal is Suitable - The base metal thickness must be approved and be heavy
enough to support the new connection and the hot tap machine.
3.3.7 Line or Vessel Contents are Suitable - The oxygen level within the equipment will be
controlled to preclude the formation of a vapor/air mixture within the flammable or
explosive range.
3.3.8 Personnel are Qualified - Trained personnel will operate the tapping machine and can
provide training documentation if requested.
3.3.9 Hot Tap Connection is Suitable - The connection through which a hot tap will be made
must be designed in accordance with the appropriate code. The design shall cover the
specifications of gaskets, pipe, valve, and bolts. Hot tap fitting length must accommodate
the machine, but there must also be sufficient clearance for the cutter or drill. Clearance
to install and remove the hot tap machine shall be provided.
3.3.10 Responsible Engineer Responsibilities
Reviews the composition of the material in the line or vessel for stability while
welding. While making the drawings, bills of material, and completing the
forms, the following should be carefully considered. Design details are
outlined in Engineering Specification SP-50-24.
Selecting the Weld Fitting - Care should be taken to select the proper fitting
for the connection. Many types of connecting fittings are available such as
weld-o-lets, weld-ends, split tees, saddles, and nozzles. Connections should
be designed to the applicable code, i.e., ASME Boiler and Pressure Vessel
Code; API 650, Welded Steel Tanks for Oil Storage; or ANSI B31.3,
Pressure Piping Code. Be sure the fitting is the proper size to accommodate
the hot tap machine.
Full encirclement saddles are required for size to size hot taps. For example,

saddles are required for a 6” tap on a 6” line.

Ensure the correct equipment or line has been selected and tagged at in-
service weld or hot tap location (Attachment E)
The piping system should be checked for expansion, loading, support, etc.
Lined Piping or Equipment - Hot tapping on lines or equipment with cladding
or linings such as lead, strip lining or refractory lined equipment requires
approval of Engineering and Inspection.
Downstream Equipment - Avoid hot tapping upstream of rotating equipment,
control valves, and/or instrument orifices unless such equipment is protected
from the cutting by means of filters or traps.
Any comments or special considerations should be indicated on the “In-
Service/Hot Tap Approval Form”, “Hot Tap Connection Form” and drawing
and the Engineering Manager may then approve it.
3.3.11 Operations/Products Control Responsibilities
The Operations/ Products Control Manager shall make the final approval. No
hot tap shall be made without the required departmental signatures.
Operations/Products Control Day Foreman or delegate will verify the location
of the In-Service Weld or Hot Tap
Ensure that the specified flow rate is established or the tank is at adequate
level.
Operator / Product Control Operator will attach a hot tap tag (Attachment F)
to valves utilized to control flow. For tanks, ensure isolation using the Energy
Isolation procedure PR-14 during the hot tap or in-service weld. The hot tap
tag will read "Hot Tap or In-Service Weld in Progress - Do not Operate"
(Attachment F).
Notify other affected department or Areas.
3.3.12 Performing the Hot Tap: Before proceeding with the hot tap, the following conditions must
be satisfied:
The In-Service Weld/Hot Tap Request Form, In-Service Weld/Hot Tap
Approval Form, and the Hot Tap Site Review Checklist must be completed,
approved, and attached to the Safe Work Permit along with other required
attachments as discussed in Sections 3.1 and 3.3.
A hydrostatic test of the welded attachment will be conducted in accordance
with the applicable code before cutting. If the temperature of the metal is
50°F or below, the transition temperature of the metal should be considered
to preclude brittle fracture.
Hot tap connection valve body shall be tested at same
pressure as the hot tap connection
Nitrogen test at25 psig with “snoop” or soap solution on the
welds of reinforcement pads or split tees,
The valve seats shall be tested from both directions
Additional in-process non-destructive examination (NDE) is required prior to
any pneumatic testing being performed. The need for magnetic testing (MT),
penetrate testing (PT), and/or ultrasonic testing (UT) on root and/or final
welds should be identified by the GBR Inspection Department in the

Inspection comments section of the In-Service Weld Approval Form.

The position of the hot tap must be on Diagram 1 (ATTACHMENT I)
A Operations/Products Control Representative will be present during the final
cut through of the hot tap operation.
A Safe Work Permit has been secured, and all necessary gas tests have
been made to ensure a safe environment.
A suitable fire extinguisher (dry chemical or pressurized fire hose) has been
provided and a fire watch established.
The product must be moving at the desired velocity. See Attachment H for
the desired velocities.
Check tightness of bolts, packing, packing nuts, and bypass line, if required,
to avoid possible leakage.
On a non-vertical hot tap, a gate valve must be provided to be able to flush
the valve seat of any cuttings
Installing the Machine - Follow the instructions of the manufacturer and
check the following items:
Before installing the hot tap machine, the hot tap valve must
be closed, this is to ensure the valve can be closed following
the hot tap after the cutter is fully retracted
Be sure the valve on the connection nozzle is a full-opening
gate valve, centered on the flange, and clean.
Run the boring bar through the main valve opening several
times to be sure the cutter does not jam or drag.
Carefully calculate and log the travel of the cutter on diagram
1 to ensure that it can be retracted through the valve,
particularly in small size pipe, and to ensure that the
opposite side of the pipe will not be cut.
Check that the bleed-off valve will hold pressure and is not
plugged.
After Cutting - Besides the measurement, as determined by the machine stop
setting, it is possible to tell when the cut is complete by the reduced
resistance to the hand cranking or by the speed up of the air or hydraulic
motor. The manufacturer’s instructions should be followed when retracting
the bore and closing the valve.
Retract the boring bar and close the main valve.
Depressurize the hot tap machine and ensure the main valve
is not leaking before removing the hot tap machine.
If the blank or coupon is lost:
3.3.12.12.3.1 No attempt should be made to fish for it.
3.3.12.12.3.2 A notice shall be circulated to all Department
Managers
3.3.12.12.3.3 If feasible, the coupon shall be located and
removed at the first opportune time. In some
cases, it will be necessary to shut down the

equipment and depressure the line to

recover a lost blank.
4.0 Definitions
4.1 Hot Tapping – This refers to the procedure to be followed when a special tool called a “Hot Tap
Machine” is fastened to a valve attached to a new connection that was welded onto pipe or
equipment which is in service containing hydrocarbons or other materials. The “Hot Tap
Machine” is totally enclosed so that the cutter can drill through the connection and into the pipe or
equipment without allowing the contents of the pipe or equipment to escape to the atmosphere.
The cutter or drill can be retracted back into the “Hot Tap Machine”, the valve closed, and the
“Hot Tap Machine” removed.
4.2 Hydrostatic Test – A test of the piping, equipment or system under pressure to give proof the
welds and material will withstand expected stresses and that the system is leak-tight.
4.3 In-Service Welding – This refers to the procedure to be followed when welding on pipe or
equipment which is in service containing hydrocarbons or other materials. This includes grinding
(other than surface cleanup), burning, and welding for any purpose such as adding brackets,
shoes, backwelding, adding weld-o-lets, adding studs, etc., in addition to new connection or
revisions.
4.4 Owning Department – The term “owning department” refers to the department that owns and
operates process, process-related, and/or utility equipment, machinery, building, and/or systems.
This term is also applied for individuals that are assigned ownership of outlying areas per
Permitting Ownership Area Maps
4.5 Responsible Engineer – The Responsible Engineer can be the Reliability Engineer, Area
Engineer, or Project Engineer.
4.6 Stoppling – “Stoppling” is using a device called a “stopple” to isolate a section of pipe while the
line contains hydrocarbons or other materials.
4.7 Tightness Test – A test under pressure for leaks after system re-assembly.
4.8 Owner Supervisor – The Marathon owning department’s supervisor. This is typically, although
not always, a Shift or Unit Supervisor.
4.9 Maintenance Coordinator – The Maintenance Coordinator is a coordinator that works in the
maintenance department.
5.0 References
5.1 ASME Boiler and Pressure Vessel Code Section VIII: “Construction of Pressure Vessels”
5.2 ANSI ASME B31.3Process Piping Code
5.3 API RP 2201 “Procedures for Welding or Hot Tapping on Equipment Containing Flammables”
5.4 API 650, “Welded Steel Tanks for Oil Storage”
5.5 API 941 “Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum
Refineries and Petrochemical Plants”
5.6 MPC Refining specification SP-50-24, “Procedures for In-Service Welding or Hot Tapping on
Piping and/or Equipment.” – Revision 17
5.7 GBR PR-14 Energy Isolation
5.8 API 510 “Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair, and Alteration”

5.9 API 570 “Inspection Repair, Alteration, an Rerating of Inspection Piping Systems”
5.10 API 577 “Welding Inspection and Metallurgy”
5.11 API STD 653 “Tank Inspection, Repair, Alteration, and Reconstruction”
6.0 Attachments
6.1 Attachment A: Hot-Tap / In-service Weld Request Form
6.2 Attachment B: In-service Welding/Hot Tap Approval Form
6.3 Attachment C: In-service Weld Site Review Checklist Form
6.4 Attachment D: Hot-tap site Review Checklist Form
6.5 Attachment E: In-service Weld/Hot Tap Location Tag
6.6 Attachment F: Hot Tap / In-service Weld “Do Not Operate” Tag
6.7 Attachment G: Process Flow/Decision Logic for Hot Tap/In-service Weld
6.8 Attachment H: Table 1 – In-service Welding Flow Requirements – Liquids
6.9 Attachment I: Table 2 – In-service Welding Flow Requirements – Gases
7.0 Revision History
Revision Revision Effective

Description of Change Written by Approved by
Number Date Date
Original issue. New integrated site

0 procedure replaces GBR-HESS-PR-24 and A. Collier S. R. Levy 12/18/2019 1/16/2020
RSW-0029-TC under MOC 68003.
Added references to the “Do Not Operate”

1 A. Collier S. R. Levy 10/8/2020 10/12/2020
tags to Attachments C and D checklists.

ATTACHMENT A: IN-SERVICE WELD/HOT TAP REQUEST FORM (Page 1 of 1)

(Attach a copy of the Management of Change (MOC) documentation if applicable.)
Work Order No. MOC No. Date
Request for:
Size and Description of In-Service Weld/Hot Tap
Justification for this In-Service Weld/Hot Tap
Line/Tank and Product

* Select the In-Service Weld and Hot Tap Combination option if Originator:
a tie-in’s hot tap will be performed within 28 days of its in-service Mtce Coord./Asset Coord./ or Resp. Eng Date
weld. Otherwise, separate forms for each task are required.

ENGINEERING – Initial the appropriate YES or NO column YES NO
The chemical composition of the contents in the line or vessel has been considered to avoid
welding on equipment containing vapor/air flammable mixtures, hydrogen or chemicals, which
could affect metal strength?
Alternate locations for connections were investigated to prevent the need for a hot tap?
A review of design criteria has been made to ensure all conditions to proper mechanical design
will be met?
An In-Service Weld/Hot Tap Location Tag has been hung on the In-Service Weld / Hot Tap
location?
What is the design pressure of the line to be hot tapped? psig Intended (designed) thickness? in
Comments:
Originator: APPROVAL:
Resp. Engineer Date Engineering Manager Date

OWNING DEPARTMENT/PROCESS ENGINEERING – Initial the appropriate YES or NO column YES NO
Installation delay was seriously considered, so that connection could be made at a time when
equipment or piping is not in service?
Alternate locations for connections were investigated to prevent the need for an in-service weld or
hot tap?
Consideration was made to isolate equipment or process system?
Has the exact location been identified and marked with the tag found in Attachment E?
Process Temperature °F Pressure psig Flow Rate ft/sec Contents
Comments:
APPROVAL: APPROVAL:
Owning Department Supervisor Date Process Engineer Date

OWNING DEPARTMENT MANAGER – Initial the appropriate YES or NO column YES NO
This in-service weld and/or hot tap can be made after the In-Service Weld/Hot Tap Approval
Form(s) and appropriate In-Service Weld or Hot Tap Site Review Checklist has been signed and
approved.
Comments
APPROVAL:
Owning Department Manager Date
Return this form to the Responsible Engineer. The Responsible Engineer will file the original in the Hot Tap
Documentation file and return a copy to the originator. Attach a copy of this approved form to the In-Service Weld
Approval Form or the Hot Tap Approval Form.
Printed copies should be used with caution. The user of this document must ensure that the current approved version of the
document is used.
ATTACHMENT B: IN-SERVICE WELD/HOT TAP APPROVAL FORM (PAGE 1 OF 1)

(Attach a copy of the appropriate approved/processed In-Service Weld/Hot Tap Request Form, its
attachments, and the Weld Procedure. For Hot Tap Approval forms, also attach the completed Diagram 1:
Hot Tap Location and Travel Distance of Hot Tap Machine.)
Request for:
Size and Description of In-Service Weld/Hot Tap
Justification for this In-Service Weld/Hot Tap

* Select the In-Service Weld and Hot Tap Combination option if
a tie-in’s hot tap will be performed within 28 days of its in-service Originator
weld. Otherwise, separate forms for each task are required. Mtce Coord/Asset Coord/ or Resp. Eng Date

ENGINEERING – Initial the appropriate YES or NO column YES NO

Has a drawing been made?
Has a bill of material been made?
Do the flanges, bolts, gasket, pipe and valve to be installed meet the piping code for the line or
vessel for the in-service weld/hot tap?
Piping/equipment is strong enough to safely hold the weight of the hot tap machine?
Full encirclement saddles are required for size-to-size hot taps in accordance with the Core
Specification. Is proposed hot tap size-to-size, for example, 6” tap on a 6” line?
If the original Hot Tap scope has changed or if there exists any special considerations that
were evaluated, this document must be resubmitted for management and technical
approvals.
Comments:
APPROVAL: APPROVAL:
Engineering SME Date Engineering Supervisor Date
APPROVAL: APPROVAL:
Engineering Manager Date Resp. Eng (Reliability Eng, Area Eng, Project Eng) Date

INSPECTION – Initial the appropriate YES or NO column YES NO

Has the location of the in-service weld/hot tap on the line or vessel been identified, tagged, and
marked, and does it agree with the location identified by operations/engineering?
Has the area to be welded or tapped been inspected for thickness and freedom from lamination or
hydrogen embrittlement?
Has the need for stress relieving the welded area been considered and provided for, if required?
Can the base metal temperature be maintained above 50 °F for carbon steel or °F for
other base metals? (Refer to Section 3.2.1.4)
Has the weld procedure (attached) and type of welding rod to be used been approved?
NDE requirement has been addressed for final test (hydro, pneumatic, or MT/PT/UT root, final)?
The minimum thickness measurement taken within 6 months time of the weld at the in-service
weld/hot tap is inches. The intended thickness or designed thickness (from the
In-Service Weld/Hot Tap Request Form) is inches. Minimum required thickness is 3/16 “.
Thickness readings within 20% of 3/16” (.226” or below) shall require UT scanning 360°
and radiography.

document is used.
Comments:
APPROVAL: APPROVAL:
Inspector Date Inspection Coordinator Date
APPROVAL: APPROVAL:
Maintenance Manager Date Owning Department Manager Date
APPROVAL:
Area Team Leader Date
Forward form to the Originator for processing and retention.

document is used.
ATTACHMENT C: IN-SERVICE WELD SITE REVIEW CHECKLIST Page 1 of 2)
(Attach completed/processed In-Service Weld Request, In-Service Weld Approval Form, Weld Procedure, and
completed Job Safety Analysis to this document.)

Size and Description of In-Service Weld
Justification for this In-Service Weld

* Select the In-Service Weld and Hot Tap Combination option if
a tie-in’s hot tap will be performed within 28 days of its in-service Originator
weld. Otherwise, separate forms for each task are required. Mtce Coordinator/Asset or Resp. Engineer Date

OWNING DEPARTMENT/PROCESS ENGINEER – Initial the appropriate YES or NO column YES NO
Is the material in the line stable under heated conditions and free of oxygen?
Is the flow through the line of the required velocity as established by Engineering?
Is the area to be welded located below the liquid level (three feet minimum) of a tank or on a line
or piece of equipment in which flow has been established?
Has the exact location been identified and marked with the location tag in Attachment E?
Temperature °F Pressure psig Contents
Flow rate has been established at correct velocity in accordance with Tables 1&2 and control is in
place to maintain for in-service welding?
Flow Rate ft/sec
Has the “Do not Operate” tags, attached in Attachment F, been installed on the control device(s)?
APPROVAL:
GBR Owning Department Supervisor Date

RESPONSIBLE ENGINEER – Initial the appropriate YES or NO column YES NO
Has a chemical composition of the contents of the line or vessel been considered to avoid welding
on equipment containing flammable mixtures, hydrogen or chemicals, which could affect metal
strength? (Attach any associated data or studies conducted to ensure metal strength).
APPROVAL:
Responsible Engineer Date

AT THE SITE – Initial the appropriate YES or NO column YES NO
Has overhead clearance been reviewed/verified for applicable material, stopple or hot tap
machine installation?
Do the flanges, bolts, gasket, pipe, and valve to be installed meet the requirements of the
drawings or piping code for the line or vessel to be hot tapped?
Is the material on site?
Has the weld procedure (attached) been specified, and is the welder qualified for the procedure?
Is the correct diameter welding rod specified in the welding procedure being utilized?
Have the personnel doing the welding been qualified by the Inspection Department?
Has the welder been instructed on the In-Service Weld Procedure?
The Safe Work Permit explains all required activities by the Operations/Products Control
Department as well as the personnel doing the work.

document is used.
ATTACHMENT C: IN-SERVICE WELD SITE REVIEW CHECKLIST (Page 2 of 2) YES NO

Has consideration been given to the location of the weld to assure that there are personnel exits
and that the area will not trap flammable and/or toxic vapors?
The use of breathing equipment has been considered and provided for if required?
Are all the safety rules for working in this area being followed?
Are suitable fire extinguishers available?
Has the Inspection Department performed a thickness measurement within 6 months of the time
the weld is to take place?
Has a Job Safety Analysis (JSA) been reviewed and attached to this document?
IF ANY OF THE ABOVE ITEMS ARE MARKED “NO,” DO NOT SIGN THIS FORM!
APPROVALS: Obtain the Galveston Bay Refinery or Project Signatures below.
GBR Maintenance Coordinator Date

GBR Asset Coordinator Date
Welder Performing the Weld Date

GBR Responsible Engineer Date
GBR Safety Representative Date

Contractor Foreman Date
Once the above signatures are obtained, the Owning Department Supervisor has the final approval right.
Signed form to be kept at job site with the Safe Work Permit. At job completion, this form along with any other applicable
documents is to be attached to and turned in with the Safe Work Permit.

document is used.
ATTACHMENT D: HOT TAP SITE REVIEW CHECKLIST (Page 1 of 2)

Attach completed/processed Hot Tap Request Form, Hot Tap Approval Form, Diagram 1: Hot Tap Location
and Travel Distance of Hot Tap Machine, and Job Safety Analysis to this form.

Size and Description of Hot Tap

NOTE: Before the hot tap can be made, the nozzle is to be welded on under the authorization of an In-Service
Welding Site Review and associated Safe Work Permit.

AT THE SITE – Initial the appropriate YES or NO column YES NO
1. Has the In-Service Weld/Hot Tap Approval Form been signed by all parties?
2. Is the drawing and material on site? Drawing No.
NOTE: No hot taps are to be done without an Engineering drawing.
3. Has the exact location been identified and marked with the location tag in Att E?
Temperature °F Pressure psig Contents
4. A (type) hot tap machine will be used for this hot tap.
5. The hot tap machine and packing is suitable for the service.
6. The clearance for the hot tap machine is large enough.
7. Has overhead clearance been reviewed/verified for stopple or hot tap machine
installation?
8. Do the flanges, bolts, gaskets, pipe and valve to be installed meet the requirements of
the drawings or piping code for the line or vessel to be hot tapped and the piping and
equipment is strong enough to safely hold the weight of the hot tap machine?
9. The connection has been hydrostatically tested at psig.
Witnessed by:
Inspector’s Signature Date
10. The hot tap machine pressure vent will be tested to be sure it is clear and holds the
proper pressure.
11. The outside diameter of the drill bit has been checked and will clear the smallest
diameter of the connection (usually the inside valve diameter). A trial run has been
performed where the bit has been fitted through the smallest diameter of the connection.
12. The travel of the hot tap machine drill has been checked and marked on the hot tap
machine. It is long enough to completely penetrate the pipe but not go through the
other side or penetrate the equipment wall and will extract completely back through the
valve. Reference Diagram 1 for the exact travel distance.
13. When the hot tap machine is attached to the connection, the connection and machine
have been tested for tightness at psig with (material). If the hot tap
machine is tested with the connection, then both must conform to the hydrostatic testing
requirements (see question #7).
Witnessed by:
Contractor’s Signature Date
Witnessed by:
GBR Maintenance Coordinator’s Signature Date
14. Consideration has been given to the location of the hot tap to assure that there are
personnel exits and that the area will not trap flammable and/or toxic vapors.
15. The use of supplied air and other appropriate personal protective equipment has been
considered.
16. Is there sufficient flow in the line? (Refer to Tables 1 or 2) List flow: ft/sec

document is used.
ATTACHMENT D: HOT TAP SITE REVIEW CHECKLIST (Page 2 of 2) YES NO

17. Has the “Do not Operate” tags, attached in Attachment F, been installed on the control
device(s)?
18. If hot tapping a tank, is the liquid level three feet or more above the hot tap area, and has
the liquid level been checked by a hand gauge? NOTE: Do not pump into or out of the
tank while the hot tap is in progress.
19. Are all the safety rules for working in this area being followed?
20. Are suitable fire extinguishers available?
21. Personnel have been instructed on this Hot Tap Safety Procedure?
22. Have pressure and temperature been verified immediately prior to the actual hot tap?
23. Have all the comments been read and understood on the In-Service Weld/Hot Tap
Approval Form?
24. Consideration has been given to the possibility of safely back flushing the completed hot
tap to remove cuttings from the connection.
25. The Safe Work Permit explains all required activities by the Operations/Products Control
Department as well as the Mechanic doing the work.
26. Has a Job Safety Analysis (JSA) been reviewed and attached to this document?
27. Has the contingency plan been reviewed and a copy is available on site?
IF ANY OF THE ABOVE ITEMS ARE MARKED “NO,” DO NOT SIGN THIS FORM!
APPROVALS: Obtain the Galveston Bay Refinery or Project Signatures below.
GBR Asset Coordinator Date GBR Maintenance Coordinator Date
GBR Respoinsible Engineer Date Machinist Performing the Hot Tap Date
Contractor Foreman Date GBR Safety Representative Date
Once the above signatures are obtained, the Owning Department Supervisor has the final approval right.
Signed form to be kept at job site with the Safe Work Permit. At job completion, this form along with any other applicable
documents is to be attached to and turned in with the Safe Work Permit.

document is used.
ATTACHMENT E: IN-SERVICE WELD/HOT TAP LOCATION TAG
SAP# 90240132
HOT TAP NO.:__________________________

SIZE OF TAP: __________________________
IN –SERVICE WELD NO:__________________
IN-SERVICE WELD SIZE:_________________
DRAWING LOCATION NO.:_______________
OWNING DEPT REP:__________________
Print / Sign
RESPONSIBLE ENGR: ___________________________
Print / Sign
ATTACHMENT F: IN-SERVICE WELD/HOT TAP “DO NOT OPERATE” TAG
SAP# 90240131
Galveston Bay Refinery

document is used.
ATTACHMENT G: PROCESS FLOW/DECISION LOGIC FOR A HOT TAP/IN-SERVICE WELD
Required Forms/Tags
1. In-Service Weld/Hot Tap Request Form Step 3 (Location Tag)
2. In-Service Weld/Hot Tap Approval Form Step 2 (Request Form) Project Planner or Engineer
3. In-Service Weld Site Review Checklist Step 1 – (MOC) If needed
A hot tap/in-service weld is ensures In-Service Weld/Hot
A Management of Change (MOC) is
4. Hot Tap Site Review Checklist requested, and a Request Form Tap Location Tag at the site of
5. In-Service Weld/Hot Tap Location Tag initiated and progressed to Stage 6:
is initiated by the originator. weld or tap is hung
6. In-Service Weld/Hot Tap “Do Not Operate” Tag Implementation of Change.
7. Safe Work Permit
Step 4
Step 7 Step 6 Step 5 The Responsible Engineer
The request form will then be The Owning Department The request form will be will verify the line or vessel's
forwarded to either the Operations or Supervisor and Process forwarded to Engineering contents will be stable
Products Control Manager for final Engineer will complete and Manager for approval. during welding.
approval. approve the request form.
Step 8 Step 10 Step 11

The request form will be returned Step 9 (Approval Form) The approval form will be The approval form will be
to the Responsible Engineer and Originator will initiate a hot forwarded to the Resp. forwarded to the Maintenance
filed in Intelex under the MOC. A tap/in-service weld Engineering and Inspection and the Operations or Products
copy will be sent to the originator. Approval Form. Departments for requested Control Manager for approval.
information and approval.
Step 15 Step 14 Step 12

Step 13 (Checklist)
A meeting, attended by the Safety Rep., Operations/Products Control The completed approval form is
The Hot Tap/In-Service
Responsible Engineer, Maintenance Coordinator, places the In-Service Weld/Hot forwarded to the originator. The
Weld Site Review Checklist
Asset Coordinator, Welder or Machinist, Tap “Do Not Operate” Tag on the completed form is returned to the
is then initiated by the
Owning Department Supervision, and Contractor process valves that control the Resp. Engineer and filed in
Maintenance Coordinator.
Foreman will be held at the job site to complete the process flow for the weld or tap. Intelex under the MOC.
checklist but are not to sign yet.
Step 16 Step 17
The In-Service Weld or Hot Tap Site Step 19
The Safe Work Permit (Work Step 18 Send Safe Work Permit
Authorization as Hot Work) with an Review Checklist is then
Begin hot tap or and associated
Additional Permit (In-Service signed/completed, and all requested
in-service weld. attachments to Safety
Weld/Hot Tap) may then be issued documents are to be attached to the
Safe Work Permit and displayed with Department for retention.
and reviewed by all parties.
the permit at the job site.

Printed copies should be used with caution. The user of this document must ensure that the current approved version of the document is used.
ATTACHMENT H
TABLE 1
IN-SERVICE WELDING FLOW REQUIREMENTS - LIQUIDS
PIPE SIZE (IN) 0” 1” 1½” 2” 3” 4” 6” 8” 10” 12”

SCHEDULE 80 80 80 80 40 40 40 40 40” 40”
PIPE ID 0.74 0.96 1.50 1.94 3.07 4.03 7.98 10.02 12.00
6.07
8.0 MINIMUM VELOCITY
(FT/SEC) 0.90 0.70 0.50 0.40 0.30 0.20 0.20 0.10 0.10 0.10
9.0 MINIMUM FLOW
(FT3/MIN) 0.16 0.21 0.37 0.49 0.92 1.06 2.41 2.09 3.29 4.71
(GPM) 1.21 1.57 2.75 3.68 6.91 7.94 18.02 15.60 24.59 35.26
(BBL/DAY) 41.6 53.8 94.5 126.3 237.1 272.2 617.7 534.8 843.0 1209.0
10.0 MAXIMUM VELOCITY
(FT/SEC) 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0
NOTE: For lines larger than 12-inch Nominal Pipe Size, a liquid velocity should be specified between 0.1
fps and 4 fps. Minimum velocity based on the minimum velocity to achieve turbulent flow with kerosene
TABLE 2
IN-SERVICE WELDING FLOW REQUIREMENTS - GASES
PIPE SIZE (IN) 0.75” 1” 1½” 2” 3” 4” 6” 8” 10” 12”

SCHEDULE 80 80 80 80 40 40 40 40 40” 40”
PIPE ID 0.74 0.96 1.50 1.94 3.07 4.03 6.07 7.98 10.02 12.00
MINIMUM VELOCITY (FT/SEC)
1.30 1.30 1.00 1.00 0.50 0.50 0.50 0.50 0.50 0.50
MINIMUM FLOW (SCFM)
0.23 0.39 0.74 1.23 1.54 2.65 6.02 10.42 16.42 23.56
MINIMUM FLOW (SCFM)
@ 50 PSI 1.0. 1.71 3.24 5.41 6.78 11.67 26.48 45.85 72.27 103.65
@ 100 PSI 1.83 3.04 5.74 9.603 12.01 20.68 46.94 81.28 128.12 183.75
@ 150 PSI 2.62 4.36 8.25 13.78 17.25 29.70 67.40 116.71 183.97 263.86
@ 200 PSI 3.42 5.69 10.75 17.96 22.48 38.72 87.86 152.15 239.82 343.96
@ 300 PSI 5.01 8.34 15.76 26.33 32.95 56.75 128.79 223.01 351.51 504.16
@ 400 PSI 6.60 10.99 20.76 34.69 43..43 74.78 169.71 293.87 463.21 664.37
@ 500 PSI 8.20 13.64 25.77 43.06 53.90 92.81 210.63 364.74 574.91 824.57
NOTE: For lines larger than 12-inch Nominal Pipe Size, a vapor velocity should be specified no less than
0.5 fps with no limit on maximum velocity.

document is used.
ATTACHMENT I
DIAGRAM 1: HOT TAP LOCATION & TRAVEL DISTANCE OF HOT TAP MACHINE

document is used.

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Authored By: Blanchard Refining Company LLC Doc No.

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required by the nature of the job. Approvals cannot be given

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3.2.1.3.2.1 The measurement shall be recorded on the

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than 3/16 inch (0.187 inches) thick for

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butadiene for example) if the metal temperature, resulting

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Air Temperature - Welding should not be performed on lines or equipment

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first pass of the welding operation is completed.

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Alternate locations for connections should be investigated to prevent the

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saddles are required for a 6” tap on a 6” line.

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Inspection comments section of the In-Service Weld Approval Form.

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equipment and depressure the line to

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7.0 Revision History

Revision Revision Effective

Original issue. New integrated site

Added references to the “Do Not Operate”

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ATTACHMENT A: IN-SERVICE WELD/HOT TAP REQUEST FORM (Page 1 of 1)

Work Order No. MOC No. Date

Size and Description of In-Service Weld/Hot Tap

Justification for this In-Service Weld/Hot Tap

Line/Tank and Product

ATTACHMENT B: IN-SERVICE WELD/HOT TAP APPROVAL FORM (PAGE 1 OF 1)

Justification for this In-Service Weld/Hot Tap

Line/Tank and Product

ENGINEERING – Initial the appropriate YES or NO column YES NO

INSPECTION – Initial the appropriate YES or NO column YES NO

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ATTACHMENT C: IN-SERVICE WELD SITE REVIEW CHECKLIST Page 1 of 2)

Work Order No. MOC No. Date

Justification for this In-Service Weld

Line/Tank and Product

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ATTACHMENT C: IN-SERVICE WELD SITE REVIEW CHECKLIST (Page 2 of 2) YES NO

GBR Maintenance Coordinator Date

Welder Performing the Weld Date

GBR Safety Representative Date

GBR Owning Department Supervisor Date

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ATTACHMENT D: HOT TAP SITE REVIEW CHECKLIST (Page 1 of 2)

Work Order No. MOC No. Date

Line/Tank and Product

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ATTACHMENT D: HOT TAP SITE REVIEW CHECKLIST (Page 2 of 2) YES NO