Hot Tapping Procedure - International Paper

Department: Maintenance Area: Millwide 

Equipment: 

Not Applicable 

Maintenance Procedure Name: HOT TAPPING PROCEDURE 

Hot Tapping Procedure 

Procedure # 

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Equip.# 


1.0) Purpose: When Maintenance and Contractor Employees perform „Hot Tap‟ jobs there 

is a potential for injury from process materials contained in „live‟ piping 

systems unless strict guidelines are followed. This procedure provides 

specific guidance for doing „Hot Tap‟ work to ensure the safety of those 

involved. 

2.0) Scope: This procedure applies to Maintenance and Contractor personnel performing 

„Hot Tap‟ work at this site. 

2.1 Approved systems/processes: Mill water, seal water, white water, 

mill air, and stock provided operating pressure is less than 150 psi 

and temperature is less than 120 o F. 

2.2 Consideration for other systems/processes will be evaluated on a 

case-by-case basis and will be addressed at that time by addendum 

to this procedure or a separate procedure. 

2.3 Hot tap operations may be performed on approved systems provided 

continuity of service is essential and shutdown of the system is 

impractical. 

2.4 Contractors may utilize their own procedure provided the procedure, 

at a minimum, meets the requirements of this procedure and the 

need for the hot tap operation has been verified and documented. 

Page Rev. No. Print Date Page Revision Date Page Number 

0 March 5, 2012 ISSUED 3/7/02 JTW 1 of 6 

NOTE! The date shown represents the date the procedure was printed. 

This date should be current within 7 days.


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3.0) Responsibility; 


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All personnel assigned to performing the activities identified in this 

procedure and their management are responsible for ensuring the activity is 

executed and documented as described in the procedure. 

3.1 Maintenance or Contractor Management: 

3.1.1 Train employees on the use of the equipment and this 

procedure. 

3.1.2 Review this procedure with mechanics prior to commencing 

work. 

3.2 Maintenance Planner/ Contractor Manager is to ensure Contractor 

personnel performing “Hot Tap” jobs, review this S.O.P. prior to the 

start of the task and follow/ understand all the steps within. 

3.3 Employees performing a „Hot Tap‟ will review this procedure and 

adhere to it when performing this task. 

3.4 Production Managers 

� Will assess the need for the hot tap operation and sign on the line 

provided in Step 1 of the procedure (paragraph 6.0). 

� Will review the procedure and follow all steps when performing 

this task. 

� Will identify “shut off” of process line being tapped for purposes 

of securing it during an emergency. 

� Will assign a Production Operator at the control area of each 

“Hot Tap” task to expediently shut the system down in the case 

of an emergency. 






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4.0) Definitions: 


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4.1 „Hot Tap’ Process is a mechanical procedure for tapping a charged 

process line using special equipment without shutting the line down. 

4.2 Emergency is a rupture or sudden unexpected release of a product 

from a line being “Hot Tapped”, which could result in injury, equipment 

damage or an environmental problem. 

4.3 Hot Tap Equipment is special tooling for performing pipe taps on 

charged lines. (3 types in Tool Room.) 

4.4 Control Area is the actual location of the devices for securing the 

piping being “Hot Tapped”. (Ex: Pump switches, Control panel, Valves 

and etc.) 

5.0) References: 5.1 Franklin Mill “Hot Work Permit Procedure” 

5.2 Franklin Mill “Lock, Tag and Try Procedure” 

5.3 Franklin Mill “Procedure for Opening Dangerous Systems” 

5.4 29CFR1910.147 – OSHA Regulation for “The Control of Hazardous 

Energy (Lockout/Tagout) 






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6.0) Procedure: 

1 

2 

3 

4 



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PROCEDURE STEPS � 

Meet with operations and confirm need to “Hot Tap” versus securing the system for 

the tie-in. (See criteria in paragraphs 2.1 and 2.3) 

Operations ______________________________________ 

Maintenance _____________________________________ 

Contact appropriate operating department personnel and: 

� Make them aware of the „Hot Tapping‟ activity. 

� Review procedure with them and mechanics. 

� Identify the securing device for emergency shutdown of the process line. 

� Identify the Production Operator who will standby and manage the securing 

device in case of an emergency. 

� Identify the nearest safety shower and eyewashScope the job area for access, 

and hazards. 

� Determine if Lock, Tag and Try is indicated and implement if required. 

Review this procedure with employees performing the work. 

Obtain “hot tap” tool from the tool room and inspect for proper assembly and 

condition. 

4 Fill out the „Hot Work‟ permit and post fire watch personnel as required. Make sure 

all personnel in the area of the hot tap have on the proper PPE for the product 

in the process line. 

5 Barricade work area as required to protect personnel transiting the area. 

6 Weld a pipe coupling sized to the tapping equipment onto the process line. Use 

caution when setting the welding machine heat to prevent burning through the 

line during the welding part of the procedure. 

7 Attach the proper size valve to the coupling that was welded on the process line. 






Equipment: 




8 Mount the „Hot Tap‟ tool on the valve. 


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PROCEDURE STEPS � 

9 Operate the „Hot Tap‟ to drill through the open valve and pipe coupling and one side of 

the process line. 

10 Retract the „Hot Tap‟ saw, close the valve and remove the tapping equipment from the 

valve. Exercise extreme caution at this time, it is possible that metal shavings 

may wedge under the valve gate and cause leaking or spraying from the valve at 

this time. 

11 Notify production personnel of job completion. 

12 Complete the follow up fire watch and the „Hot Work‟ permit. See that this permit is 

sent to Loss Prevention Department when job is done. Remove any locks and tags that 

were required for job. 

13 Clean up tools and job site and return „Hot Tap‟ equipment to the toolroom. 

14 Sign off procedure and return with work order. 

END OF PROCEDURE 

All of the aforementioned repair steps have been completed. 

Signature______________________ Clock #______________ 






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7.0) Documentation: The signed off procedure and any additional documentation identified is 

8.0) Approval, Issue 

and Review: 

9.0) Safety and 

Environmental: 

to be returned with the completed workorder to the team leader. The 

Hot Work permit is to be sent to Loss Prevention Department. 

Any changes to this procedure are to be reviewed and approved by the 

Maintenance Superintendent or his designee on an as needed basis. 

Procedure to be reviewed every three years. 

IF required - equipment must be isolated and made safe in compliance with 

Reference 5.2, prior to starting any repair activity. 

Personal Protective Equipment: 

� Hearing Protection 

� Safety Glasses 

� Hard Hat 

� Safety Shoes 

� Gloves 

� *In addition to standard PPE for the task, a rain suit, face shield 

and rubber gloves should be worn. 

*Refer to Reference 5.3; section 6.2 Protective Clothing 

Requirements for additional PPE requirements.

Hot Tapping Procedure - International Paper

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