Non-routine work increases process risk and can directly lead to conditions that make a catastrophic accident much more likely.
Safe work practices are critical elements in the management of non-routine work.
Safe work practices include an integrated management system of policies, procedures and permits that help protect workers from hazards and prevent the sudden release of process materials or energy during non-routine work activities.
The Person in Charge is responsible for the Operation of the Plant or unit within a plant. This is typically a Site or Area Manager whose responsibilities include:
Site specific written down procedure for hot tapping
Even though there are API codes and guidelines available for conducting welding/drilling on live systems, each facility is unique. It is recommended that each site develop an exhaustive procedure for carrying out hot tapping on live equipment at their premises.
Incidents during hot tapping are sparsely reported or available.
The worst-case scenario during hot tapping is a burn-through during welding of the nozzle on a live piece of pipeline or equipment. If the leaking fluid is flammable, it could immediately lead to fire and/or explosion with potentially catastrophic consequences.
Other fluids like steam and/or condensate, etc., at high temperature can cause serious injuries to personnel close to the hot tap location.
To identify and manage risks associated with welding, cutting drilling and other process boundary-penetration on live equipment and pipelines, so that fires or explosions that could result in personal injuries, property damage, community impacts, environmental impacts, or business impacts are prevented.
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