1、Safe Hot Tapping Practices in thePetroleum and PetrochemicalIndustriesAPI RECOMMENDED PRACTICE 2201FIFTH EDITION, JULY 2003REAFFIRMED, OCTOBER 2010Safe Hot Tapping Practices in thePetroleum and PetrochemicalIndustriesDownstream SegmentAPI RECOMMENDED PRACTICE 2201FIFTH EDITION, JULY 2003REAFFIRMED,
2、OCTOBER 2010SPECIAL NOTESAPI publications necessarily address problems of a general nature. With respect to partic-ular circumstances, local, state, and federal laws and regulations should be reviewed.API is not undertaking to meet the duties of employers, manufacturers, or suppliers towarn and prop
3、erly train and equip their employees, and others exposed, concerning healthand safety risks and precautions, nor undertaking their obligations under local, state, or fed-eral laws.Information concerning safety and health risks and proper precautions with respect to par-ticular materials and conditio
4、ns should be obtained from the employer, the manufacturer orsupplier of that material, or the material safety data sheet.Nothing contained in any API publication is to be construed as granting any right, byimplication or otherwise, for the manufacture, sale, or use of any method, apparatus, or prod-
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7、rtment telephone (202)682-8000. A catalog of API publications and materials is published annually and updatedquarterly by API, 1220 L Street, N.W., Washington, D.C. 20005, www.api.org.This document was produced under API standardization procedures that ensure appropri-ate notification and participat
8、ion in the developmental process and is designated as an APIstandard. Questions concerning the interpretation of the content of this standard or com-ments and questions concerning the procedures under which this standard was developedshould be directed in writing to the Director, Standardization, Am
9、erican Petroleum Institute,1220 L Street, N.W., Washington, D.C. 20005, standardsapi.org. Requests for permissionto reproduce or translate all or any part of the material published herein should also beaddressed to the director.API standards are published to facilitate the broad availability of prov
10、en, sound engineer-ing and operating practices. These standards are not intended to obviate the need for apply-ing sound engineering judgment regarding when and where these standards should beutilized. The formulation and publication of API standards is not intended in any way toinhibit anyone from
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12、act conform to the applicable API standard.All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher
13、, API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005.Copyright 2003 American Petroleum InstituteFOREWORDThis publication is designed to provide a better understanding of the problems and haz-ards encountered when installing hot tap connections on piping, vessels or tanks containing
14、flammable or combustible liquids or gases. The essential elements of this publication arebased on accumulated knowledge and experience of the petroleum industry, current industrysafe operating practices, and existing consensus standards. The practices described in thispublication are designed to pro
15、tect the safety of personnel and the facilities for the workinvolved. It shall be noted, however, that special problems beyond the scope of this publica-tion are possible. Also, federal, state and local regulations or laws may contain additionalrequirements that must be taken into account when a hot
16、 tap program is developed for a spe-cific facility.API publications may be used by anyone desiring to do so. Every effort has been made bythe Institute to assure the accuracy and reliability of the data contained in them; however, theInstitute makes no representation, warranty, or guarantee in conne
17、ction with this publicationand hereby expressly disclaims any liability or responsibility for loss or damage resultingfrom its use or for the violation of any federal, state, or municipal regulation with which thispublication may conflict.Suggested revisions are invited and should be submitted to th
18、e Director, Standardization,American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.INFORMATION CONCERNING SAFETY AND HEALTH HAZARDS AND PROPER PRE-CAUTIONS WITH RESPECT TO PARTICULAR MATERIALS AND CONDITIONS SHOULDBE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER OR SUPPLIER OF THAT
19、MATERIAL, OR THE MATERIAL SAFETY DATA SHEET.iiiCONTENTSPage1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20、. . . . . . . . 11.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Retroactivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 Concept of Hazard vs. Ri
21、sk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Concept of Competent and Qualified Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REFERENCED PUBLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
22、DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 JOB ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.1 Job Analysis . . . . . . . . . . . . . . . . .
23、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.2 Reviewing Whether Hot Tapping is Appropriate . . . . . . . . . . . . . . . . . . . . . . . . . 54.3 Job-specific Hot Tapping Review for Work Authorization . . . . . . . . . . . . . . . . . . 55 HAZARD EVALUATION AND RISK
24、 REDUCTION FOR HOT TAPPING ON IN-SERVICE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.2 Hot Tapping Overview. . . . . . . . . . . . . . . . . . . .
25、 . . . . . . . . . . . . . . . . . . . . . . . . . . 95.3 Physical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.4 Thermal Burn Hazards to Personnel and Risk Reduction . . . . . . . . . . . . . . . . . . 95.5 Potential Acute Health Haz
26、ards and Risk Reduction . . . . . . . . . . . . . . . . . . . . . 105.6 Potential Chronic Health Hazards and Risk Reduction . . . . . . . . . . . . . . . . . . . 105.7 Flammable Liquids, Vapors, Solids, or Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.8 Combustible Materials and Ri
27、sk Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116WELDING AND HOT TAP METALLURGY CONSIDERATIONS. . . . . . . . . . . . 116.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.2 Burn-through Prevention .
28、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.3 Flow in Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.4 Metal Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29、 . . . . . . . . . . . . . . . 126.5 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.6 Post Weld Heat Treatment (PWHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.7 Metal Temperature . . . . .
30、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.8 Welding and Hot Tap Connection Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.9 Hot Tapping Equipment under Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136.10 P
31、iping and Equipment Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 HOT TAPPING MACHINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32、 . . . . . . . . . . . . . . . . . . . . . 137.2 Hot Tapping Machine Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158.1 Written Plans . . . .
33、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158.2 Management of Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158.3 Personnel Competency and Qualifications . . . . . . . . . . . . . . . . . . . . . .
34、. . . . . . . 15vPage9 SPECIAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159.1 Hot Tapping and Welding on Tanks or Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . 159.2 Welding or Hot Tapping on the Decks of Floating Roof Tan
35、ks is Prohibited . . 169.3 Welding or Hot Tapping Above or Below Grade . . . . . . . . . . . . . . . . . . . . . . . . 169.4 Welding or Hot Tapping on Lined Piping, Lined Equipment or Cased Lines . . 169.5 Hot Tapping on Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36、 . . . . . . . . 169.6 Hot Tapping Upstream of Equipment and Valves . . . . . . . . . . . . . . . . . . . . . . . . 1610 HOT TAP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610.1 Preliminary Requirements . . . . . . . . . . . . . . . . . .
37、. . . . . . . . . . . . . . . . . . . . . . . . 1610.2 Welding in Preparation for Hot Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1710.3 Inspecting the Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1710.4 Installing the H
38、ot Tapping Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1710.5 Testing the Weld and Hot Tapping Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1710.6 Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39、. . . . . . . . 18APPENDIX A EXAMPLE HOT TAP CHECKLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . 19APPENDIX B EXAMPLE HOT TAPPING REQUEST FORMS . . . . . . . . . . . . . . . . . 23APPENDIX C EXAMPLE OF WELDERS INSTRUCTIONS PRIOR TO HOT TAPPING . . . . . . . . . . . . . . . . . . . . . . .
40、 . . . . . . . . . . . . . . . . . . 25APPENDIX D EXAMPLE IN-SERVICE HOT TAP EMERGENCYACTION PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Figures1Typical Hot Tap Activity Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41、. . . . 62 Example Process to Review Whether Hot Tapping is Appropriate . . . . . . . . . . . . . 73 Example Decision Process for Authorizing Hot Tapping . . . . . . . . . . . . . . . . . . . . 84 Hot Tapping Machine and Typical Hot Tap Connection . . . . . . . . . . . . . . . . . . . . 14Tables1 Be
42、fore Starting the Hot Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Example of Fire Watch Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Before Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43、. . . . . . . . . . . . . . . . . . . . . . . 204 Before Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Before Removing the Hot Tapping Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 After Removing the Hot
44、Tapping Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21vi1Safe Hot Tapping Practices in the Petroleum a review of potential hot tapping concerns based onindustry experience; guidance on planning hot taps; application of “hazard versus risk” concepts applied tohot tapping; elem
45、ents to consider during the hot tap process fromjob analysis through completion; suggestions on “what to do if things go wrong.”This publication is not:a substitute for job-specific planning;a set of work procedures.Virtually every hot tapping job is different. A detailed,written, job-specific hot t
46、ap procedure should be availablebefore starting each job to help ensure that appropriate mea-sures are addressed. If there are standing procedures for hottapping they should be reviewed for applicability to the spe-cific job to be done. These procedures may need revision inresponse to unique job spe
47、cific problems or situations thatmay arise concerning the safety of personnel and facilities.The hot tap approach described in this publication appliesto piping and equipment fabricated from ferritic and austen-itic steel. Other materials, such as aluminum, copper, plastic,and cast iron may be unsui
48、table for hot tapping or welding ormay require special procedures.Hot tapping is a “change” subject to review based on facil-ity “management of change” processes or procedures.1.3 RETROACTIVITY Any provisions in this publication related to design areintended for reference when designing new faciliti
49、es or whenconsidering major revisions or expansions, or establishingnew programs. It is not intended that any recommendations inthis publication be applied retroactively to work performed atexisting facilities. This recommended practice should provideuseful guidance when there is a desire or need to review pro-cedures, programs or facilities.1.4 CONCEPT OF HAZARD VS. RISK Hazards are properties of materials with the inherent abil-ity to cause harm. Flammability, toxicity, corrosivity, storedchemical or mechanical energy all are hazards associatedwith various industrial materials. R
