Document Number: HSP - 201 Current Rev: 1/2019

Revised By: T. McLaurin Review Cycle: 3 years

Manager Approval: H. Garner Revision No. 8
Page 1 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

1.0 PURPOSE

1.1. Westlake, Plaquemine Operations, has developed this Hot Tap Permit
Program to eliminate potential accidents, injuries, and to enhance employee
protection.

1.2. To provide for the maximum personnel safety and to prevent the loss of
productivity all hot tap operations must have prior approval of Department
Manager or his designee in charge of the area involved and be conducted in
strict accordance with this Procedure. This procedure begins with any hot
work associated with the hot tap to the line.

2.0 SCOPE

2.1. This program applies to the entire Westlake, Plaquemine Operations.

2.2. This procedure also includes fillet welds (e.g., overlays, saddle welds,
reinforcing pads, etc.)

Note: A Management of Change is required for all Hot Taps.

3.0 DEFINITIONS

3.1. Hot Tap--The technique of attaching a welded branch fitting to piping or

equipment as it remains in service, and then creating an opening in that
piping or equipment by drilling or cutting a portion of the piping or equipment
within the attached fitting. Hot Tapping by definition involves Hot Work on
equipment “in service.”

3.2. Hot Work--For the purpose of this program, "Hot Work" means welding,
grinding, flame cutting, and flame producing and spark producing operations.

3.3. Regular Work--Any servicing, opening, or maintenance of process

equipment and machinery. Regular work does not involve any hot work, hot
taps, excavations, and/or confined space entry.

3.4. Engineer--An employee through education and experience qualified to

properly evaluate the hot tap, perform the required calculations and
implement the requirements of this procedure.

3.5. Spark Producing Operations--Operations such as using jackhammers and

sandblasting are considered hot work. Department Supervision should
consider the possibility of sparks resulting from scraping, hammering, and
other operations, and the advisability of obtaining a hot work permit to cover
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 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 2 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

such work.

4.0 RESPONSIBILITIES

4.1. Health and Safety (H&S)

4.1.1. Train employees on the proper implementation of this program.

4.1.2. Notify contractors of Westlake's Hot Work Permit Program during initial
Safety Orientation.

4.1.3. Ensure that safe work permit procedures are reviewed at least every
three years.

4.1.4. Maintain review records.

4.2. Department Supervision

4.2.1. Learn, understand, and follow this program.

4.2.2. Issue appropriate safe work permits (e.g., hot work, hot tap,
excavation, confined space).

4.2.3. Provide specific safe work details, unique to the job or area, to
production employees or the Maintenance Crew Leader involved with
the covered work.

4.2.4. Gives authorization for hot tap operations within the department.

4.2.5. List required personal protective equipment necessary for the work on
all permits.

4.2.6. Ensures all calculations

4.3. Area Technician

4.3.1. Learn, understand, and follow this program.

4.3.2. Perform atmospheric monitoring.

4.3.3. Review work area prior to issuing permit.

4.3.4. Complete applicable portions of Safe Work Permit.

Printed controlled copy expires 24 hours after 12:52 PM on 3/14/2019.
 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 3 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

4.3.5. Consult with Department Supervision to identify proper safe work

procedures.

4.3.6. Review the hot work permit with Maintenance Crew Leaders and verify
that all permit specifications have been met.

4.4. Maintenance Supervisor

4.4.1. Learn, understand, and follow this program.

4.4.2. Consult with operations to identify proper safe work procedures.

4.4.3. Review and provide a copy of all permits to maintenance crew before
work commences.

4.4.4. Ensure that maintenance crews follow plant requirements, including

specifications outlined HSP-201.

4.5. Contractors Involved in Hot Taps

4.5.1. Learn, understand, and follow this program.

4.5.2. Provide all pertinent information to Operations regarding the hot tap
work to be performed.

4.5.3. Review and comply with all permit requirements.

4.5.4. Provide coupon to Stationary Equipment Inspection Group once the

Hot Tap procedure is complete.

5.0 PROCEDURE

5.1. It should be emphasized that a hot tap is always a calculated risk; and, this
risk must be weighed against the problems and hazards involved in making
the connection in some other manner.

5.2. Any hot top outside of the scope of this procedure will require site manager
approval.

5.3. It is better to isolate, purge, and clean the equipment before making
connections. Where this is impractical, the following Hot Tap Permit
Procedure will be used to enhance job safety.

Printed controlled copy expires 24 hours after 12:52 PM on 3/14/2019.

 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 4 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

5.4. Determination of Safe Hot Tap

5.4.1. The Hot Tap table (see Appendix B - Hot Tap Table) lists three classes
of product lines:

5.4.1.1. Those that can be hot tapped with routine safety precautions;

5.4.1.2. Those that can be hot tapped with special permission from
the Department Manager; and

5.4.1.3. Those that cannot be hot tapped under any conditions.

5.4.2. Additions or modifications to this table will require written permission

from the Department Manager involved and with appropriate
consultation with the Engineering Manager and Health and Safety.

5.4.3. The line operating pressure and temperature must not exceed that of the
hot tap machine.

5.4.4. The line thickness must be sufficient to permit a safe weld without
danger of burning through the line. (See Appendix C - Calculation for a
Hot Tap Connection.)

5.4.5. Non-destructive thickness tests will be made on the area surrounding

the proposed welding connection. Line pressure must be considered
before a minimum wall thickness requirement can be determined.

5.5. Investigation Prior to the Hot Tap

5.5.1. Investigation prior to a hot tapping operation will include, but not be
limited to the following:

5.5.1.1. Safety requirements;

5.5.1.2. Metal thickness;

5.5.1.3. Physical material characteristics of the line or equipment;

5.5.1.4. Compatible metallurgy of welding material and material

welded:

Printed controlled copy expires 24 hours after 12:52 PM on 3/14/2019.

 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 5 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

5.5.1.5. Pressure-temperature conditions;

5.5.1.6. Material flow through the line or equipment;

5.5.1.7. Liquid level of at least 3 feet established if on a tank;

5.5.1.8. Hot tap equipment pressure-temperature limitations;

5.5.1.9. The exact plant site location of the hot tap must be positively
identified (such as marking with felt marker, paint, tag, etc.,
with initials and date) by the operating department;

5.5.1.10. The location must be communicated to the personnel doing

the work, not only to supervision, but also to the person who
will be welding;

5.5.1.11. Welding requirements;

5.5.1.12. Design requirements;

5.5.1.13. A qualified engineer is required to perform the hot tap

investigation and provide calculations.

5.5.1.14. Stationary Equipment Inspection Group (SEI) is required to

assist in the metal thickness and welding requirements of the
hot tap investigation.

5.6. Necessary Precautions Prior to Hot Tap

5.6.1. Required Approvals

5.6.1.1. Operations Supervisor shall notify the Incident Commander

on duty of all Hot Taps to be made on lines with flammable
contents.

5.6.1.2. Before any hot work begins, a safe work, hot work, and hot
tap permit will be issued to the Maintenance Supervisor who
will oversee the hot tap job. (See Appendix A - Hot Tap
Permit.)

5.6.1.3. The hot tap must be approved by the Operating Unit

Superintendent and Department Manager or designees,
having ownership responsibility for the line.

5.6.2. The equipment used must be designed for the pressure and
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 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 6 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

temperature involved.

5.6.3. The material's corrosive, toxic, or flammable characteristics may

require suitable protective clothing be worn by personnel making the
hot tap.

5.6.4. Consideration should be given to tying down or taping of sleeves at the

wrist to prevent accumulation of flammable or toxic gases under
employee clothing.

5.6.5. Shut-off valve locations, both upstream and downstream from the
welding location, will be determined so that the valves may be closed
quickly in an emergency.

5.6.6. Operating personnel must be stationed near shut-off valves during

welding on lines carrying flammables or steam.

5.6.7. Operating personnel will have adequate communications with the job
site, and have authority to close off the line in the event of a burn
through.

5.6.8. Pressure in the line to be tapped should be reduced to the lowest

possible pressure that will allow continued operation.

5.6.9. Pressure-temperature requirements must be established for each job.

5.6.10. On jobs where a fire hazard exists during welding or tapping,

adequate fire protection equipment must be available for immediate
use at the jobsite.

5.6.11. Where the connection is to be made below ground level, the ditch or
trench must be large enough to permit the welder to move out of a
direct line with the welding arc or leak in the event of a burn through.

5.6.12. Ample space should be available for the employee and hot tap
machine.

5.7. Safe Procedure for the Hot Tap

5.7.1. Only qualified and experienced craftsmen will be used for the welding
and tapping operation.

5.7.2. The Maintenance Department’s Stationary Equipment Inspection

Printed controlled copy expires 24 hours after 12:52 PM on 3/14/2019.
 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 7 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

Group will provide welding procedures and qualification of welders.

5.7.3. When welding the nozzle or connection to the main line, the initial pass
will be made with a 3/32" welding rod using the lowest possible
amperage.

5.7.4. Time will be allowed between each pass for the line to cool to prevent
line or product overheating.

5.7.5. Material flow through the equipment or line must be maintained during
the welding operation.

5.7.6. Before line tapping, the valve will be opened, the cutter run down to
the main trunk line then backed up into the machine, and the valve
closed. This is to check machine operation before cutting into the line.

5.7.7. Proper PPE must be worn by the person drilling and welding into lines.

5.7.8. An Operating Department designated representative must be present

during the entire hot tap operation, both welding and tapping.

5.7.9. All hot taps on lines under pressure should have some form of nozzle
reinforcement. This may be weld-o-let, repad, or full encirclement hot
tapping tee. (Refer to Westlake Engineering Standard 3004 -
Appendix 6, Westlake Engineering Standard 3006 - Page 4, and
Standard Details 3005-256, 257, 258, and 259.)

5.7.10. The hot tap permit must be completed and signed by the Maintenance
Supervisor or designee before the welding or hot tapping operations
have begun.

5.8. Materials Not on Hot Tap Table (Appendix B)

5.8.1. To perform hot taps on equipment containing materials not listed on

material chart (hot tap with Site Manager approval), the following is
required:

5.8.1.1. Research available data from sources such as Engineering

Department, knowledgeable contacts, and material
suppliers;

5.8.1.2. Prepare written procedure listing special precautions; and

Printed controlled copy expires 24 hours after 12:52 PM on 3/14/2019.

 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 8 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

5.8.1.3. Acquire Site Manager approval

6.0 TRAINING

6.1. All employees who are involved in hot tap procedures will receive appropriate
hot tap permit training prior to performance of any hot tap-related tasks.

6.2. Employees will be re-trained in the hot tap permit program for any updated
procedures or whenever changes in job assignment or process equipment
and machinery occur.

6.3. Retraining will be conducted whenever a periodic inspection reveals that

employees are not fully aware of, or are not following established procedures,
or if regulatory requirements change.

7.0 RECORDKEEPING

7.1. Hot Tap Permits will be kept for one year along with the accompanying Safe
Work Permit following work completion by each department.

8.0 PROGRAM REVIEW

8.1. This Hot Tap Permit program will be reviewed in conjunction with the Safe
Work Permit Program at least every three years. Health and Safety will
ensure this review is performed.

Printed controlled copy expires 24 hours after 12:52 PM on 3/14/2019.

 Document Number: HSP - 201 Current Rev: 1/2019
Revised By: T. McLaurin Review Cycle: 3 years
Manager Approval: H. Garner Revision No. 8
Page 9 of 16

HEALTH AND SAFETY PROCEDURE 201 – HOT TAP PERMIT

9.0 REFERENCES

9.1. American Petroleum Institute (February, 1983). "Safe Maintenance Practices

in Refineries," API Publication No. 2007, Washington, D.C.

9.2. American Petroleum Institute (August, 1988). "Safe Welding and Cutting
Practices in Refineries, Gasoline Plants, and Petrochemical Plants," API
Publication No. 2009, Washington, D.C.

9.3. Occupational Health and Safety Administration's 29 CFR 1910.119 (August

26, 1992). "Process Safety Management of Highly Hazardous Chemicals."

9.4. API PR2201

10.0 APPENDICES

10.1. Appendix A - Hot Tap Permit

10.2. Appendix B - Hot Tap Table

10.3. Appendix C - Calculation for Hot Tap Connection

Printed controlled copy expires 24 hours after 12:52 PM on 3/14/2019.

 Revision History

Rev Changes Approved Date

Westlake Branding. Review Cycle. Added revision history.
Clarification of HOTWORK Requirements, differentiate
8 between natural gas above and below 100psig, HSE audit H. Garner 1/2019
frequency removed, qualified engineer, removed liquid ammonia,
added definition for engineer

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 APPENDIX A

HOT TAP PERMIT

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 Hot Tap Permit
General Information
1. Equipment to be Hot Tapped
2. Equipment Location
3. Equipment Contents

Description of Work
1. Weld procedure to be used:

Thickness
2. Line thickness as indicated by thickness check:
(original)
3. Pressure limit established for this job:
4. Temperature limit established for this job:
5. Minimum flow requirement established for this
job:

YES N/A
6. Do mechanical requirements meet Engineering Specs?
7. Are operating personnel stationed at shut-off valves?
8. Has adequate communications been established between the job and
department supervision?
9. Is the exact point of the Hot Tap identified and visibly marked?
10. Has a Management of Change been completed?

Personnel and Production Facilities Protection

Specify any special personnel protection, fire equipment, protective devices, precautions, and/or any other
comments:

Signature Date
Person who Engineered the Hot Tap
Department Superintendent (Line Owner)
Maintenance Supervisor
Department Manager
Site Manager (or designee)
Safety Professional

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 APPENDIX B

HOT TAP TABLE

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 Hot Tap Table

HOT TAP WITH HOT TAP WITH

TOP SITE MANAGER DEPARTMENT REMARKS
APPROVAL MANAGER APPROVAL
Steam (>150 psi)
Ethylene All of these materials will react with steel
Hydrogen at welding temperatures or some may
Chlorine detonate.
Oxygen
Any Oxide Can cause weld embrittlement or
Liquid Ammonia cracking
Acetylene
Carbon Steel Below 32Deg F
Caustic
VCM

Methane Natural Gas < 100psig

Natural Gas > 100psig. Maintenance and Operations must
Propylene check and agree on procedure. Plant
Propane Supt. must sign and approve Safe Work
Butane Permit. Engineering and Plant
Supervision must approve type of
NOTE: This list is not all- nozzle reinforcement to be used.
inclusive.
Check with Westlake Consider metal embrittlement or
Engineering for products not cracking
on this list.

Potable Water These products require Safe Work

Process Water Permit signed by Plant Supt. Operations
Brine (Not Containing representative and Maint. Supervisor
Caustic) must both check line and agree that the
Nitrogen proper line is being tapped and that the
Steam (<150 psi) procedure is safe.
Air & Condensate

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 APPENDIX C
CALCULATION FOR HOT TAP CONECTION

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 HOT TAP PROCEDURE

Calculation for a Hot Tap Connection

Material: _______________________________________

Nominal Wall Thickness: Minimum inch; Maximum inch

Ultrasonic thickness measurement equipment accuracy +-10% inch

Presume Minimum Case

Calculate useful wall thickness:

Thickness measurement = x inch

Less .010 accuracy of meter -.010 inch
Less diameter of weld rod -.094 inch
(for depth of weld puddle (3/32 rod))

Usable wall thickness = X - .010 - .094 = (X - .104 inch)

Allowable pressure for hot tap with a minimum safety factor of 1.5:

2(S) (X - .104 in)

P-1 =
D (1.5)

P-1 = Maximum allowable pressure during hot tap operations

S = Specified minimum yield strength of header pipe
D = Outside diameter of header pipe

If the pressure cannot be lowered to = P-1, a hot tap is not recommended.

Actual Case:

The above calculations should be made using actual field measurements.

Engineer Date

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