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Hot Tapping (Pressure Tapping) and Freezing 437

pressures as low as 15 psig can be sufficient for decomposition. Vinyl

acetylene has been shown to decompose at 10 psig pressure at moderate
temperature.
Butadiene is normally more stable than ethylene; applying the same
restrictions for ethylene to butadiene can avoid explosive decomposition.
Butadiene in the presence of oxygen reacts to form a peroxide polymer that
can decompose explosively. One must prevent the forming of butadiene
peroxide, even in small quantities, because of its highly unstable nature.
During hot tapping, the cutting machine must be purged of all air to pre-
vent the formation of butadiene peroxide in the hot tapping equipment.
Any line that contains butadiene peroxide should not be hot tapped.
When hot tapping piping contains hydrogen, hydrogen attack can occur.
Hydrogen attack is a function of the hydrogen partial pressure, temperature,
time, and material of construction. It can take the form of internal decarbur-
ization and fissuring, hydrogen blistering, and dissolved hydrogen leading to
embrittlement. Allowable hydrogen partial pressures are based on the API
RP 941, Steels for Hydrogen Service at Elevated Temperatures and Pressures
in Petroleum Refineries and Petrochemical Plants [Reference 2]. For hot
tapping, the piping should be operating at at least 100 psi (0.7 MPag) below
the appropriate Nelson curve. Typically, low hydrogen welding electrodes
are used for hydrogen service. The area hot tapped should be inspected
by magnetic particle or liquid penetrant approximately 2 days after welding.
To help distribute the residual stress in the weld connection, full encirclement
fittings are recommended for hydrogen service.
Shown in Table 7-1 are typical problematic processes for hot tapping.
This table is a general guideline for hot tapping piping where one should
use caution.

Table 7-1
Hot Tapping Selected Process Fluids
Service Comments

MEA or DEA No welded hot taps should be made for ferritic

steel containing these services. Use a bolt-on
hot tap saddle for hot taps. Ferrite steel cracks
under weld heat in amine service.
Caustic Under conditions requiring PWHT, use caution.
The hot tap package should be reviewed by a
materials and welding engineer, unless a
bolt-on hot tap saddle is used.
Combustible or flammable mixture Hot tapping is not recommended
at any pressure

(Table continued on next page)

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438 Escoe: Piping and Pipeline Assessment Guide

Table 7-1—cont’d
Hot Tapping Selected Process Fluids
Service Comments

Acids, chlorides, peroxides, or other Hot tapping is not recommended.

chemicals likely to decompose or Examples are sulfuric acid, acetylene,
become hazardous from weld heat high purity ethylene if air content is above
1000 ppm or the pressure is over
300 psig (2 MPag), butadiene, or elemental
sulfur.
Ethylene1 The flow should be as high as practical, but not
less than 10 ft/sec (3 m/sec). Weld procedures
should minimize heat input to the extent
practical by using low hydrogen weld
electrodes and low current settings. Special
precautions are required on ethylene lines at
any pressure if the stream contains 10%
inerts such as CO2, N2, or steam. If the
ethylene content in a hydrocarbon stream
is greater than 50%, special precautions
are required.
Air where absence of hydrocarbons Hot tapping is not recommended
cannot be assured
Pure oxygen, or air containing more Hot tapping is not recommended
than 50% oxygen, chlorine, or
liquefied gases
Catacarb solution Hot tapping is not recommended if line is
austenitic stainless steel.
Sulfur compounds Hot tapping is not recommended if line is monel.
Hydrogen Hot tapping is permissible provided the
equipment has not operated above the Nelson
curve limits.
Sour service Hot tapping is permitted.
Chilled water2 This service is difficult because the
water condensate can cause weld
porosity. However, hot tapping lines in
this service are done successfully on a
routine basis.

Notes:
1. If piping containing ethylene, butadiene, or acetylene is to be hot tapped, special precautions
must be taken to maintain circulation and prevent overheating and thermal decomposition
(with possible explosion) of the contents.
2. In general, hot tapping is not allowed on piping that is cold enough to be below the ambient
dew point temperature. This is because the moisture formed on the outside of the pipe will
make the welding impractical, as already mentioned.