API RP 2201:2003(2010) pdf download
API RP 2201:2003(2010) pdf download.Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries.
5.1 GENERAL
Hazards are inherent properties that relate to specific materials, activities or situations. While these properties cannot he changed. with knowledge of the hazards a hazardous material might be removed, activities restructured or an alternate work approach substituted. Thus an exposure-dependent risk can be reduced or eliminated. A careful job analysis (see 4.1) and determination of whether hot tapping should be used should be made of potential hazards and the operations to he pertormed prior to starting work. This will help determine the appropriate procedures, safeguards, required engineering controls and/or personal protective equipment necessary to perform the work (see 4.3). This safety analysis includes elements of a normal hot work permit procedure. The following sections discuss hazards (including employee physical safety and health concerns as well as fire safety) that could he associated with welding and subsequent hot tap activities. Section 6 discusses additional risk reduction techniques.
5.2 HOT TAPPING OVERVIEW
Hot tapping involves both welding oii equipment in service and cutting through the containment material. Both of these introduce significant elements which are diflèrent from normal ‘hot work”. Welding on equipment in service is addressed as a special case in API RP 2009, along with general welding safe work practices. Hot tapping is an even bmore special” case of working on equipment in service. Hot tapping should never be considered ‘routine”,
Knowledge, experience and planning along with good procedures, competent personnel with appropriate skills who perform their work in conformance to procedures, and proper equipment are keys to safe and successful hot tapping. Hot tapping should not be emergency work—if precautions cannot he established in advance and accommodated then the unit or equipment should he taken out of service or shut down. This is because:
a. there is typically a significant inventory of flammable material in vessels or equipment and thus containment is very important.
b. the welding associated with the hot tap can stress metal and heat fluids in vessels and piping.
5.3 PHYSICAL HAZARDS
Many of the hazards present in the normal workplace exist in the welding and hot tapping environment. Normal precautions not specifically addressed here include:
a. protection against slip-trip-fall hazards in work areas with cables, hoses and lines;
h. use of normal workplace PPE (head, foot, eye, respiratory and thermal protection in accordance with facility requirements for the work environment);
c. fall protection procedures and equipment:
d. protection from electric hazards associated with welding machines or electric lighting in the area (use of bonding, grounding, low voltage or GFI are the same as for other maintenance);
e. protection against eye and face injuries caused by flying particles, molten metal, liquid chemicals, acids or caustic liquids, or irritating chemical gases or vapors.
5.4 THERMAL BURN HAZARDS TO PERSONNEL AND RISK REDUCTION
High temperature contact exposure can cause serious bums. This hazard is familiar to those who do welding work. Risk reduction is provided through avoidance of contact by using good work practices and protective clothing, injuries have occurred due to sparks or hot metal falling into pockets. folds of rolled up sleeves, pants-cuffs or work boots. And, frayed clothing is more easily ignited.
Because hot tapping often involves cutting into contained flammable or combustible materials, the potential for a release is greater than in normal welding. The use of fire resistant clothing is especially prudent for personnel working in the hot tap area.
