Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 1 of 10

Wyandotte Preparer: EHS Specialist

Reviewed: 09/09 Effective: 10/09 Owner: EHS Specialist

Supersedes: NEW Approver: EHS Hub Manager

Revision History Revision Date

Revision Number

10/2009

1

Details of Change New document.

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 2 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

1.

Effective: 10/09

NEW

PURPOSE To set forth additional site requirements at the BASF Corporation (“BASF”) Wyandotte, Michigan (“Wyandotte”) site to ensure compliance with BC032.016 Hot Work and to establish minimum standards for installing Hot Taps and Stopples in plant piping systems or vessels. The use of Hot Taps is to be limited to jobs that cannot be accomplished using standard procedures without incurring a major safety, economic or production impact. This procedure is based on API Recommended Practice 2201 “Procedures for Welding or Hot Tapping on Equipment in Service”.

2.

3.

DEFINITIONS 2.1.

Coupon Part of the original pipe that is removed by the hot tap machine after cutting.

2.2.

Engineer An individual who is knowledgeable in the applicable design, inspection, and repair codes for pressure vessels, tanks, and/or piping.

2.3.

Hot Tap The method of attaching connections or accessories onto a vessel or process line that is in service or that has been drained and de-pressurized, but not cleaned. This includes not only the attachment of any external device made by welding but also all penetrations into the process.

2.4.

Hot Tap Contractor A specialty company contracted by BASF to perform Hot Taps and install and remove Stopples.

2.5.

Owning/Operating Department The department that operates or is responsible for the daily operation of the process lines or equipment where work is being conducted.

2.6.

Stopple A flow-stopping device that is installed via a Hot Tap in a piping system that can not be isolated, depressurized, or cleared.

SCOPE 3.1.

This procedure applies to hot taps and stopples performed on piping systems and vessels owned by BASF at the Wyandotte site.

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 3 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

3.2.

4.

Effective: 10/09

NEW

All piping systems and vessels that are not owned by BASF but reside within the Wyandotte site fence line are not subject to this procedure (e.g. DTE Energy, Wyandotte Water Department, etc.)

PROCEDURE 4.1.

General Requirements 4.1.1. To ensure compliance with MIOSHA's Control of Hazardous Energy Sources (Part 85) Rules and WYN032.010, Lock, Tag and TryAdditional Requirements, the hot tap must be justified. Hot Taps shall not be installed on piping that can be shut down for sufficient time to allow other methods of making tie-ins or where the Hot Tap can be delayed until an upcoming shutdown. 4.1.2. Hot tap operations will be exempt from the requirements of MIOSHA's Control of Hazardous Energy Sources (Part 85) Rules and WYN032.010, Lock, Tag and Try- Additional Requirements, if it can be demonstrated that all of the following conditions are met: · · ·

4.2.

Continuity of service is essential Shutdown of the system is impractical Documented procedures and special equipment are utilized which will provide effective protection for employees

Prohibited Hot Taps 4.2.1. Welding or Hot Tapping shall not be performed on piping or equipment containing the following materials or having the following conditions: · · · · · ·

Vapor/air or vapor/oxygen mixtures near or within their flammable explosive range. Acetylene or cracked gas containing acetylene above 0.5% by weight. 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 or oxygen enriched atmospheres (oxygen content within the vessel or equipment must be less than 1%). The amount of oxygen

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 4 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

· · · 4.3.

Effective: 10/09

NEW

needed for an enriched atmosphere varies with each product’s flammable limits. Compressed air, unless known to be free of flammables and combustibles, such as lubricating oil residues. Lines or equipment in any service where post weld heat treatment is required. Lines or equipment that are clad or lined.

Restricted Hot Taps 4.3.1. Welding or Hot Tapping performed on piping or equipment containing the following materials or having the following conditions may be conducted pending a thorough engineering evaluation that is approved by a Site Engineer: · ·

4.4.

Hydrogen (if the equipment is operating above the Nelson Curve Limits per API Publication 941) Welding or hot tapping on piping or equipment in vacuum service (< atmospheric pressure).

Special Considerations 4.4.1. It must be recognized that no hot tap is trivial. Even if the fluid is not hazardous, a hot tap represents a potential danger to personnel and to plant operations. 4.4.2. Hot taps shall not be performed on vessels containing flammable liquids while the liquid is being pumped out of the vessel. Pumps/valves must be shutdown/closed and red tagged. 4.4.3.

Hot taps made upstream of machinery that is not adequately protected by filters and cannot be isolated, should be carefully considered and "loss of coupon" procedures must be developed since metal shavings or the coupon can enter the line.

4.4.4. When welding on a vessel containing liquid, the level must be at least 3 feet above the location of the hot tap. 4.4.5. Hot taps made upstream of instrumentation should be carefully considered as shavings or the coupon entering the line may damage the instrumentation.

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 5 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

Effective: 10/09

NEW

4.4.6. Hot taps made on breathing air or potable water lines must be reviewed to ensure that downstream users will not be affected by metal shavings that may enter the line. 4.4.7. 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. 4.4.8. Hot Taps on ASME coded pressure vessels are excluded from the scope of this procedure. 4.5.

Hot Tap Location and Design Considerations 4.5.1. The Hot Tap shall be located: · ·

At least 18 inches from all flanges and/or threaded connections At least 3 inches from any weld seams

4.5.2. Other Hot Tap placement considerations include: · · · · ·

Clearance & support for the Hot Tap machine (including weldment) Safe egress for personnel making the Hot Tap and easy access for emergency personnel Bending moments applied to the piping by the machine Support requirements for the pipe being hot tapped due to the additional loads from the new fittings and branch line Availability of utilities for the Hot Tap machine

4.5.3. Thickness measurements shall be taken in the location of the hot tap. The number of examination points may vary according to pipe size, but shall have no less than five (5) readings. This shall include the center of the Hot Tap location and all four (4) quadrants as a minimum. The readings before and after the Hot Tap location should be conducted at 12 inches or two pipe diameters (whichever is larger). Results of the thickness examinations shall be attached to the Hot Tap Permit (See Section 6. Related Documents) and maintained on file. 4.5.4. If the Hot Tap is to be made on stainless steel, a dye penetrant examination is to be made at the location of the tap and the surrounding location to ensure that no stress cracking is present in the area. If cracking

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 6 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

Effective: 10/09

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is present, an ultra-sonic determination of the suitability of the hot tap location is to be conducted. 4.5.5. Calculations shall be made to determine suitability for hot tapping if any of the following conditions exist: · · ·

Thickness is less than 3/16" Thickness is greater than 1.0" Thickness is less than nominal thickness minus corrosion allowance

4.5.6. Engineering review or mechanical calculations are not required if the weldment design can be selected from the Hot Tap Fitting Selection Table (See Section 6. Related Documents). 4.5.7. Full port gate or ball valves shall be used for all hot taps. 4.6.

Hot Tap Requests and Approval 4.6.1. The Hot Tap requestor completes in section "A" of the Hot Tap Permit and submits it to the Facilities Manager, or designee, for approval. 4.6.2. The Facilities Manager, or designee, indicates approval by signing off on Section “A” and forwards the permit to the appropriate Maintenance Facilitator who will coordinate the work. 4.6.3. The Maintenance Facilitator forwards the Hot Tap Permit to the appropriate Engineer along with the following information: · ·

Thickness reports of the line(s)/equipment. Design calculations for the hot tap rig to be used for the job.

Note: The Maintenance Facilitator can obtain this information from the Hot Tap Contractor. 4.6.4. The Maintenance Facilitator should also alert the Engineer of any extenuating circumstances or conditions that may necessitate additional evaluations. 4.6.5. The Engineer will evaluate the procedure(s) and complete the applicable questions in section "B" of the Hot Tap Permit. If approval is granted, the Engineer must sign off on the permit.

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 7 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

Effective: 10/09

NEW

4.6.6. The Engineer shall attach the following items to the Hot Tap Permit and return it to the Maintenance Facilitator: · · ·

Welding procedure(s) Pressure/flow/temp requirements Additional equipment requirements, if applicable

4.6.7. Site EHS should be given a courtesy notification, if possible, prior to work commencing. Contact the Ecology On Call phone at 734-558-1072. 4.7.

Welding Pre-work 4.7.1. The Maintenance Facilitator arranges for the welding of the branch connection (nozzle) onto the line in preparation for the hot tap (drilling) procedure. 4.7.2. The Maintenance Facilitator arranges the following: · · · · · ·

Safe work permits Area barricading (as needed) Adherence to the Engineer’s instructions/procedures Development of an Emergency Plan that evaluates potential hazards and formulates response plan in case of an emergency Hot work permit(s) Inspection and installation of the valve(s), connections, or other accessories to the nozzle

4.7.3. The Owning/Operating Department verifies and completes assigned items in section "B" of the Hot Tap Permit Form and signs where noted. 4.7.4. The Maintenance Facilitator, while at the weld/hot tap site, shall test emergency communications with an emergency response team. 4.7.5. The Maintenance Facilitator completes section "B" of the Hot Tap Permit verifying the information and ensures that all required signatures are obtained. 4.8.

Welding 4.8.1. A Hot Work permit is issued as per site Safe Work and Hot Work procedures. It shall reference the Hot Tap Permit.

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 8 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

Effective: 10/09

NEW

4.8.2. The Owning/Operating Department monitors process conditions, as applicable, in regards to flow/pressure/temperature requirements from welding procedures. 4.9.

Hot Tap Pre-work 4.9.1. The Maintenance Facilitator arranges for the tapping (drilling) of the line. This includes permitting for the set-up and bolt-on of the hot tap rig. 4.9.2. The Maintenance Facilitator and the Hot Tap Technician complete section "C" of the Hot Tap Permit verifying that all items are complete and that all required signatures are in place.

4.10.

Hot Tapping 4.10.1. Hot tapping can now begin per the requirements of these work instructions.

4.11.

Hot Tap Machine Removal 4.11.1. Once the Hot Tap is complete, the Maintenance Facilitator and the Hot Tap Technician will complete section "D" of the Hot Tap Permit verifying that all questions have been adequately addressed. 4.11.2. The Hot Tap rig can now be removed and the valve closed. If the valve is not to be used in the immediate future, a blind flange should be installed on the valve. 4.11.3. If a coupon is available, a Maintenance Facilitator is to witness its removal.

4.12.

Inspections 4.12.1. Inspection of the welds and the weldment shall consist of the following: · ·

·

Where conditions permit, for all hot taps, 100% of the root pass and 100% of the final pass of all welds shall be dye penetrant examined. If dye penetrant examination is not possible, a pneumatic test at 110% of design pressure shall be performed. The pressure shall be raised in discrete steps, and held for a suitable period of time to relieve stress at each step. After the test pressure is achieved, the pressure will be reduced to design pressure prior to examination of the weldment. Valves used for the Hot Tap or Stopple shall be tested and certified leak-free by an approved valve inspection facility.

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 9 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

Effective: 10/09

NEW

4.12.2. All pressure tests are to be witnessed by the Maintenance Facilitator. 4.12.3. Pneumatic testing of the re-pad or split tee is not required. 4.12.4. The Maintenance Facilitator will complete section "E" of the Hot Tap Permit verifying that the welds or weldment passed inspection. 4.13.

Recordkeeping 4.13.1. The Maintenance Facilitator will retain copies of the completed permit, calculations and welding procedures with the project or maintenance files.

5.

RESPONSIBILITIES 5.1.

Facilities Manager · ·

5.2.

Engineer · · · · ·

5.3.

Review and approve hot tap requests. Responsible for implementation of this procedure.

Review Hot Tap Permit requests from a technical engineering stand point. Provide guidance/assistance to Maintenance Facilitator in acquiring thickness tests and performing visual inspections of the Hot Tap site. 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.

Maintenance Facilitator (Ex: Construction Supervisor) · · · · ·

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. Advise Operating/ Owning Department of pending hot tap installation for scheduling and safe work permit preparation purposes.

Title: Hot Taps and Stopples

Site Procedure

Function: Ecology, Health & Safety No.: WYN032.057

Page: 10 of 10

Wyandotte

Reviewed: 09/09

Supersedes:

5.4.

·

Review and sign Hot Tap Permit section "B" and ascertain that requirements have been met and that approval is given. Coordinate with Maintenance Facilitator to prepare necessary procedures, emergency plans and address requirements for hot tap work, i.e., flows, temperatures, levels, communications, stand-by personnel, etc.

Hot Tap Technician (HTT) · · · ·

5.6.

Provide copy of hot tap rigs depth measurements, cutting distance calculations to Maintenance Facilitator. Verify with Maintenance Facilitator that there is sufficient room at the hot tap site to safely operate the hot tap rig. Adhere to the requirements of this procedure and permit. Verify applicable questions in sections “B”, "C" & “D” and sign the Hot Tap Permit.

EHS Specialist · ·

6.

NEW

Owning/Operating Department ·

5.5.

Effective: 10/09

Responsibility for administration and interpretation of this procedure. Provide a governance roll to ensure that procedure is being implemented and in compliance as intended.

REFERENCED DOCUMENTS 6.1.

BC032.016 Hot Work

6.2.

API Recommended Practice 2201

6.3.

Hot Tap Fitting Selection Table

6.4.

Hot Tap Permit

6.5.

WYN032.011 Hot Work

6.6.

WYN032.054 Safe Work

6.7.

MIOSHA Part 85 Rule Control of Hazardous Energy Sources Rule

6.8.

WYN032.010 Lock, Tag and Try