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 involves drilling and welding fittings onto pressurised live process pipework without shutdown. Line-stopping isolates flow for downstream work. WHS Regulation 2025 Chapter 6 (hazardous chemicals) and Chapter 7 (plant pressure equipment) apply, requiring documented controls before work commences on energised process systems.
Hazards identified
3 hazards covered, sorted by priority.
Burns, chemical exposure, projectile injury
Explosion, fire, multiple fatalities
Catastrophic line rupture, personnel injury
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Verify pipe wall thickness via UT and confirm welding procedure qualified to AS 4458 before tapping.
- 2Conduct gas test and purge; maintain continuous flow to prevent localised overheating during hot work.
- 3Pressure test fitting to 1.5x operating pressure post-weld; isolate and permit-control all hot work.
Applicable Codes of Practice
Welding and fabrication standard for pressurised pipework fittings
Hot tapping procedures on live hydrocarbon pipelines
What you receive
- ✓Editable DOCX SWMS template with project-specific fields
- ✓State-specific WHS legislation schedule (all Australian jurisdictions)
- ✓Hazard register aligned to hierarchy of controls
- ✓Worker sign-on register for site induction records
Related legislation
- WHS Regulation 2025 Chapter 7 — Plant and pressure equipment
- WHS Regulation 2025 Chapter 6 — Hazardous chemicals
- WHS Act 2011 sections 19–20 — Primary duty of care