Hot Tapping on Live Process Lines SWMS
Safe work method statement for hot tapping and line-stopping on pressurised live process pipework including pressure containment, leak testing, and management of process fluids under pressure.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Hot tapping of live process pipework covers the connection of a new branch or fitting into a live, pressurised process pipe or main without shutting it down — drilling into the live pipe under controlled conditions to make a connection while the system remains in service. It is high-consequence work used to avoid shutting down a process or supply, and it carries severe hazards: the release of the pressurised, often hazardous, process contents; the integrity of the hot-tap fitting and equipment under pressure; the potential for fire, explosion or toxic release depending on the contents; and, where the contents are flammable, the hot-work ignition risk. This document is written on the basis that hot tapping is carried out by specifically competent personnel under a rigorous procedure, with the pressure, contents, fitting-integrity and ignition hazards controlled.
Hot tapping of live process pipework is specialised work carried out under engineered procedures and the requirements for the specific process and contents, in connection with the relevant pressure equipment and pipework standards. The defining hazards are the live, pressurised contents — which may be flammable, toxic or hazardous — and the integrity of the hot-tap fitting, valve and machine under pressure. The work is hazardous and is carried out under a permit and a detailed procedure. This document coordinates the pressure, contents, fitting-integrity, ignition and procedure controls so the hot tap is made without a loss of containment or ignition.
Hazards identified
9 hazards covered, sorted by priority.
Loss of containment of the pressurised, possibly hazardous, contents
Fire or explosion from the release or ignition of flammable contents
Toxic exposure from the release of toxic process contents
Loss of containment from failure of the hot-tap equipment under pressure
Ignition of flammable contents from the hot work of the tap
Loss of containment from incorrect procedure, fitting or equipment
Pressure release and stored-energy hazard from the live pipe
Loss of the cut coupon or swarf into the live system
Crush and musculoskeletal injury from the heavy hot-tap equipment
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Administrative: carry out the hot tap under an engineered procedure and a permit specific to the process, the contents and the pressure, with the procedure and equipment assessed for the specific application by competent personnel.
- 2Engineering: confirm the integrity of the hot-tap fitting, valve and machine for the pressure and contents, with the fitting welded or fixed and tested before the tap is cut, so the equipment contains the pressure.
- 3Administrative: where the contents are flammable, control the hot-work ignition hazard — assessing the contents, the hot work and the ignition control — and where toxic, control the toxic-release hazard.
- 4Engineering: manage the stored pressure and energy of the live system throughout, and control the release of the contents so containment is maintained.
- 5Engineering: retrieve the cut coupon and control swarf so it is not lost into the live system, using the hot-tap machine's coupon retention.
- 6Administrative: assess the specific process and contents, and apply the requirements and controls for that process — flammable, toxic or hazardous — including the emergency arrangements.
- 7Engineering: use mechanical aids for the heavy hot-tap machine and equipment, and confirm the connection and integrity after the tap.
- 8Administrative: ensure the work is carried out and certified by an appropriately licensed plumber or drainer under the relevant state or territory plumbing licensing scheme, with the relevant competencies and a compliance certificate issued where required.
- 9Administrative: all workers must hold a valid White Card (General Construction Induction Training, CPCCWHS1001) before entering any construction workplace, with the plumbing, excavation, confined space and any other competencies and licences required for the work.
- 10Administrative: conduct a daily pre-start toolbox talk covering the day's work, identified hazards, isolations, required PPE and emergency procedures, and record attendance in the consultation section.
- 11Administrative: consult workers and any health and safety representatives on the work and its risks, record the consultation, and keep this document available at the workplace.
- 12PPE: eye protection to AS/NZS 1337.1, hearing protection where required, gloves appropriate to the task, high-visibility clothing, and Class I or Class II safety footwear with protective toecap to AS/NZS 2210.3.
- 13Administrative: review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or health and safety representative raises a concern, when new hazards are identified, or at minimum every 12 months.
Applicable Codes of Practice
The pressure equipment and pipework standards for the live pressurised pipe and the hot-tap fitting.
Management of the process contents where flammable, toxic or hazardous, and the ignition and release controls.
Fire precautions for the hot work of the tap where the contents are flammable.
Confined space controls where the hot tap is carried out in a confined location.
The risk management process and hierarchy of controls applied to the hazards of the work.
High-Risk Construction Work triggered
Hot tapping a live pressurised process pipe or main is work on or near pressurised piping, which is high risk construction work requiring a SWMS before the work commences.
This is licensed plumbing, drainage or specialist work that, in the circumstances described, is high risk construction work — pressurised gas or fuel pipelines or process piping — so a SWMS must be prepared before the work commences, kept readily accessible, reviewed as necessary, and given to the principal contractor if one is appointed. The work is carried out to the relevant AS/NZS 3500 plumbing and drainage standards, the excavation, confined space and pressure-equipment requirements, and the relevant utility requirements, which are called up by the relevant legislation, with the excavation, confined-space, electrical, pressurised-pipe or work-at-height controls applied as relevant. A failure in this work can cause burial, an atmospheric incident, a service strike, a loss of containment or serious injury, and breaches of the relevant legislation and the primary duty of care under the model WHS Act are actively enforced, with offence categories running from failure-to-comply through to reckless conduct, and the most serious breaches carrying imprisonment for individuals. Body-corporate maxima are substantial and indexed; the current maximum follows the prevailing schedule of the responsible regulator.
Who this is for
- →Specifically competent personnel carrying out hot tapping of live pipework.
- →Hot-tapping and live-connection specialists.
- →Process, pipeline and industrial contractors making live connections.
- →Process operators and PCBUs requiring a live hot tap.
- →PCBU safety managers and supervisors coordinating the pressure, contents and procedure controls.
What you receive
- ✓Editable Microsoft Word document (.docx) fully compatible with Microsoft Word 2016 and newer, Google Docs, and LibreOffice Writer.
- ✓Title page with editable fields for PCBU name, ABN, site address, project name, principal contractor details, and document revision date.
- ✓Hazard register with the hot tapping of live process pipework hazards — each with a documented consequence, inherent risk rating on a 5x5 likelihood-consequence matrix, hierarchy-of-control measures, and residual risk rating.
- ✓Hot-tapping prompts referencing the pressure equipment standards and the engineered procedure, a contents-and-pressure assessment section, a fitting-integrity and coupon-retrieval section, and an ignition and emergency-arrangements section.
- ✓Licensing, competency and permit prompts for the relevant plumbing, excavation, confined space and specialist work, and a respiratory protection selection and fit-test record per AS/NZS 1715 where relevant.
- ✓Worker consultation record per the model WHS Act consultation duty and a worker sign-on register (blank, expandable).
- ✓Applicable legislation and Codes of Practice schedule pre-populated for the model WHS jurisdiction with a state-variance reference table covering the harmonised states, plus Victoria.
- ✓Emergency procedure template and a revision log.
Worked example
A hot-tapping specialist is engaged to make a live connection into a pressurised process pipe without shutting it down. The hot tap is carried out under an engineered procedure and a permit specific to the process, the contents and the pressure, with the procedure and equipment assessed for the specific application by competent personnel. The integrity of the hot-tap fitting, valve and machine is confirmed for the pressure and contents, with the fitting welded and tested before the tap is cut, so the equipment contains the pressure. The contents are assessed; because they are flammable, the hot-work ignition hazard is controlled with assessment of the contents, the hot work and the ignition control. The stored pressure and energy of the live system are managed throughout, and the release of the contents controlled so containment is maintained. The cut coupon and swarf are retained by the hot-tap machine so they are not lost into the live system. The emergency arrangements for the contents are in place. Mechanical aids are used for the heavy equipment. The connection and integrity are confirmed after the tap, and the records retained.
Related legislation
- Model Work Health and Safety Act — primary duty of care; the duty to consult workers; the reckless-conduct offence; and notifiable-incident provisions, as enacted in each jurisdiction.
- Model Work Health and Safety Regulations — Section 291 high risk construction work and the SWMS preparation and review duties, and the excavation, confined space and pressurised-pipe provisions where applicable, as enacted in each jurisdiction.
- The relevant plumbing and drainage standards AS/NZS 3500 (Parts 0–5), the excavation and confined space Codes of Practice, the pressure equipment and pipework standards, and the silica Code of Practice where cutting concrete, are called up by the relevant legislation, together with the Before You Dig Australia information and the relevant utility requirements.
- Plumbing and drainage work is licensed under each state and territory's plumbing licensing scheme, with the relevant competencies for excavation, confined space and specialist work, and compliance certification required for notifiable work; electrical work is carried out by a licensed electrician.
- Victoria operates under the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2017, with the high risk construction work, excavation and confined space provisions applying in place of the model instruments.
Frequently asked questions
What is hot tapping?
Hot tapping is the connection of a new branch or fitting into a live, pressurised process pipe or main without shutting it down — drilling into the live pipe under controlled conditions to make a connection while the system remains in service. It is high-consequence work used to avoid shutting down a process or supply, carried out under a rigorous engineered procedure.
Why is hot tapping so hazardous?
Hot tapping is hazardous because it involves drilling into a live, pressurised pipe whose contents may be flammable, toxic or hazardous, with the risk of a loss of containment, fire, explosion or toxic release, and the integrity of the hot-tap fitting and equipment under pressure is critical. The work is carried out under a permit and a detailed procedure with the pressure, contents and ignition hazards controlled.
How is the hot-tap equipment integrity assured?
The integrity of the hot-tap fitting, valve and machine is confirmed for the pressure and contents, with the fitting welded or fixed and tested before the tap is cut, so the equipment contains the pressure throughout. Confirming the equipment integrity before cutting the tap ensures the live, pressurised contents are contained during the connection.
What if the process contents are flammable or toxic?
Where the contents are flammable, the hot-work ignition hazard is controlled by assessing the contents, the hot work and the ignition control, and where toxic, the toxic-release hazard is controlled. The specific process and contents are assessed, and the requirements and controls for that process — flammable, toxic or hazardous — applied, including the emergency arrangements.
What happens to the cut coupon?
The coupon cut from the pipe and any swarf are retained by the hot-tap machine's coupon retention so they are not lost into the live system, where they could cause problems downstream. Retrieving the coupon and controlling swarf is part of carrying out the hot tap correctly, alongside maintaining containment of the pressurised contents.