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PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0
HOT TAPPING PROCEDURE
FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR
PETRA RESOURCES SDN BHD R E 0 V DAT E PREPARED BY REVIEWED APPROVED
PCSB REVIEWED BY NA APPROVED
BY BY NAMESIGN DATE NAM SIG DAT NAM SIG DAT 7/5/ KC HY AI
BY SIG DAT NAME SIG DATE
4 Non-Destructive Testing 5.2 Site Preparation 5.0 SPECIAL REQUIREMENT/ REFFERENCES 4 RECORDS APPENDICES Appendix I Appendix II Datasheet 4 2 3 3 3 3 4 4 PAGE 2 – – Hot Tapping Checklist Hot Tapping Equipment .: 0 Page 2 of 4 TABLE OF CONTENTS SECTION 1.0 3.0 DESCRIPTION PURPOSE SCOPE 2 REFERENCE 2 DEFINITION 2 PROCEDURE 5.0 7.0 4.0 2.7 Reinstatement 6.3 Welding Work 5.5 Pressure Testing 5.0 5.6 Drilling 5.1 Preliminary Site Study/ Inspection 5.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.
112 PTS 31.0 SCOPE This procedure describes the suitable method for the hot tapping work (TP-15) at the existing 20” flare line in line with PETRONAS standard and other applicable international code/ standard for KUMANG CLUSTER ONSHORE TIE-IN at MLNG-2 project. designed.2 3.38.01.0 GENERAL REQUIREMENTS 5.11 PTS 20.3 PTS 31. and creating an opening in that piping or equipment by drilling or cutting a portion of the piping or equipment within the attached fitting.60.0 PURPOSE This procedure is intended to provide basic guidelines for the execution of hot tapping work for KUMANG CLUSTER ONSHORE TIE-IN at MLNG-2 project.0 DEFINITION COMPANY Petronas Carigali Sdn Bhd PRSB Petra Resources Sdn Bhd NDT Non-destructive Testing ITP Inspection Test Plan GA General Arrangement P&ID Process and Instrumentation Diagram Hot Tap The technique of attaching a welded branch fitting to piping or equipment in service.31 PTS 31. 5.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.2 The hot tapping operations are initiated.4 3.5 ASME B31.38.1 Hot tap connections shall be designed and installed to meet all requirements as stated in Para (3) of this procedure 5.38. 2. 3.01. Piping and 4.0 REFERENCE 3. and controlled by Project Manager with the approval of the Area Operations .10 Equipment Process piping Piping General Requirements Shop and Field Fabrication of Steel Piping Shop and Field Fabrication of Piping Hot Tapping on Pipeline.3 3.1 3.: 0 Page 3 of 4 1.
5. The construction units are responsible for ensuring that approved welding procedures and qualified welders are employed. and hot tap machines shall be pressure tested in accordance to Para (3) codes 5.3 PRSB shall appoint an Initiating Engineer.8 Hot tap connections are not allowed for certain cases. The normal in-line suction screens are not considered adequate for this purpose. This is to ensure that designers. due to induced voltage. QA/QC from both PRSB and PCSB shall verify this. The Initiating Engineer shall identify the equipment in terms of service. 5.5 5. 5.11 Adequate support of the hot tap machine shall be provided to prevent overstressing of the pipe and/or fitting. location. valves. particularly in cases where the hot tap sticker is not installed in a vertical position.: 0 Page 4 of 4 Superintendent (PCSB & MLNG) and Operations Supervisor/ Superintendent (PCSB & MLNG) for tying in new installations to existing facilities. engineering staff. unless a detailed design and installation procedure has received prior approval from the both MLNG .9 All hot tap connections.10 Precautions against electric shock. and material type and notify the Hot Tap. hot tap. 5. split tee (stopple) and valve crew. who shall be made responsible for the overall coordination of the hot tapping activities.6 Compressed air piping and equipment shall not be hot tapped nor welded while in service.12 Hot tapping shall not be permitted if: .4 5. and inspection staff cooperate closely during all phases of the hot tapping operations. operations and/or project management. 5. 5. stopple and valve unit of this information. pipe diameter. 5. construction/maintenance installation unit.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. header and branch pressure rating. shall be taken into consideration when installing hot tap connections on above ground pipelines near high voltage power lines.7 Hot tapping lines upstream of rotating equipment shall be avoided unless such equipment is protected from the cuttings by means of filters or traps.
6.0 Precautions Materials against H2S and other Toxic/Hazardous 6. shall continuously monitor the work site for the presence of hazardous materials during the work activity using established gas testing procedures. Care should be taken when cutting across existing welds since the cutter can be damaged. all personnel involved shall be provided with an appropriate breathing apparatus with additional of gas detector.12.: 0 Page 5 of 4 5.13 Existing welds under the hot tap shall be ground smooth prior to fit up of the sticker and reinforcing sleeve.2 within 0. 5. 5.15 Compact steel gate valves with extended body ends shall not be used for hot tap connections. 6. or split tee circumferential fillet weld to the toe of the flange circumferential butt weld (or the closest edge of the threaded connection). If this requirement cannot be met the placement of the hot tap may be positioned closer than 18 inches provided there is enough room to allow for the installation.12. retracting the cutter and closing the tapping valve when any of the following exist: . 5.1 within 18 inches of a flange (or threaded connection) as measured from the toe of the reinforcement sleeve. 6. or other person certified as a gas tester. and the removal of the piping or pipeline flange bolts. operation and removal of the hot tap machine.2 The standby person or fire watch. 5.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.14 Appropriate barricades and warning signs shall be posted around the worksite to minimize the number of personnel in the work area while performing the hot tapping operation.75 inches of a circumferential girth weld seam as measured from the toe of the sticker weld or split tee circumferential fillet weld.1 If a potential exists for a Hydrogen Sulfide (or other Toxic material) release at a work site. to the toe of the nearest girth weld.3 The chamber of the hot tap machine and valve shall be purged with nitrogen after cutting the coupon.
13. 6.4 H2S concentration is greater than 10 ppm. 6.13. 6. the Operation Superintendent should immediately be notified to advise further action. clothing. Hot tap equipment is larger than 36 inches. and other workers who may be in the work area. the fire of the gas jetting from the pipe should not be extinguished. Fans shall meet the electrical area classification requirements. If a burn-thru should occur.5 The Operations from PCSB and PRSB should provide written and verbal emergency instructions (including evacuation procedure) to the hot tapping crew.2 5. the air velocity shall not interfere with the welding arc shielding gases. 6.: 0 Page 6 of 4 5.13. . the fire watch personnel shall be clearly instructed that should a burn-thru occur.1 5.6 When welding sour gas or sour crude lines. exposed to the burn-thru flame. air horns/industrial fans shall be provided to improve air circulation. Gas release may affect others in the area. However. fire watch personnel.7 Firewater and extinguishers should be applied as required to workers. equipment.4 In enclosed or confined areas..3 5.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. The work is in a confined area. etc.13.
The minimum remaining wall thickness at the weld connection area shall not be below minimum thickness . and mark the hot tap number alongside each hot tap location.8 The QA/QCt shall review the welding procedure specification (WPS) for the installation of the hot tap fittings and assure a CSD approved WPS is employed.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. etc. 8. Tm.1 The Initiating Engineer and contractor shall provide engineering calculation for each hot tap operation and shall be reviewed by both PCSB and MLNG for approval.2 The Initiating Engineer shall arrange for a team. The inspected area shall be permanently marked for future reference and identification. to survey the general hot tap location in order to specify and mark the hot tap locations in detail.0 Preparation of Hot Tap Specification and Test Calculations 7.0 Locate and Inspect Hot Tap Position 8.3 The Initiating Engineer shall mark of the exact hot tap locations. and a representative of the Hot Tap and Stoppling crew. ensuring the hot tap locations are at a position where the pipe out-ofroundness does not exceed 3 mm. 8. the hot tap position shall be relocated after consultation with the Initiating Engineer and the responsible Operations from PCSB and MLNG 8. The area to be scanned shall include the weld zone and 50 mm each side of it. .5 The QA/QC shall inform the Initiating Engineer if the seam weld or any other projection needs to be ground flush with the pipe surface for proper UT scanning and fit-up and if the out of roundness criteria is met for split tees/full encirclement sleeves.7 If ultrasonic readings indicate a lamination or evidence of hydrogen induced cracking (HIC) damage.1 The Initiating Engineer shall make all necessary arrangements for the preparation of hot tapping(i. (Out of roundness criteria only applies to split tee or full encirclement sleeves) 8. excavation. surface preparation. location. operations. consisting of himself. 8.e. and in all cases.: 0 Page 7 of 4 7. pipe inspection.6 The QA/QC shall inspect and determine the minimum pipe wall thickness at the tie-in weld areas by a continuous UT scan along the lines to be welded and record this on the Appendix I form. 8.) 8. the responsible inspector. no less than 5 mm.
3.3. 9. or higher. 9.4 Hot Tapping 9.2 Written approval of the detailed hot tap installation shall be obtained from the Operations Superintendent. and a copy sent to the Area Loss Prevention Office and responsible QA/QC for their review and concurrence prior to starting the installation. 9.3 All work shall be in strict compliance with MLNG Work Permit System.1 The Initiating Engineer shall ensure that the safety of work crews involved in the hot tapping operation is shared jointly by the Operator and the Hot Tap Supervisor/Maintenance Foreman.2 Welding 9.0 Safety Requirements 9. that it is understood by the person(s) carrying out the work.: 0 Page 8 of 4 9.1 Vehicle entry 9.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.3.4 The Initiating Engineer shall make available to the site a copy of the permit and ensure the area has been sufficiently roped off to prevent unauthorized personnel from entering the work area. The Work Permit shall be approved by the MLNG and PCSB Operations Superintendent. The installation package shall be on-site during the entire installation process and verified.3 Grinding 9.3.6 The Operations Superintendent will assure that both Operations and the Installation team have the proper safety and fire protection equipment on site and in workable condition prior to the start of the job and that all relevant personnel are notified of the scheduled hot work. . prior to each of the following: 9. by the QA/QC.
For a series of consecutive hot taps on a single type of service (i.2.1 The Initiating Engineer shall be responsible for ensuring that the pressure tests are performed in accordance with PTS 31.e. will take place in the shop after the machine has been checked and worn parts replaced.38. and the name of the testing organization.5 Hot tap connections installed on hot lines where hydrostatic testing with water is not practical shall be hydrostatically tested using high temperature turbine oil or silicone fluid.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. The initial pressure testing of the hot tap machine.2 The hot tap machine shall have an overhaul of its renewable pressure sealing components and be subjected to a shop rated pressure test.60. overhaul date.: 0 Page 9 of 4 10 Pressure Test Requirements 10.2. even if the elapsed time is less than four months. 10. as follows: Line Temperature 93 deg C to 290 deg C 330 340 Over 290 deg C 037 Commentary Note: Hydrotest Fluid Turbine Oil Stock No.2 After it has been used on lines with operating temperatures in excess of 150 deg C. process stream.1 Pressure test once every four months and overhaul once every 12 months. in accordance with the following criteria: 10. 10. steam.3 Pneumatic testing of hot tap connections on hot lines over 93 deg C is not permitted unless approved by the Manager.. including the hot tap valve and branch connection prior to and after installation.) the hot tap machine shall be shop tested at the end of the series of hot taps. 10.3 A stamped brass tag shall be affixed to the hot tap machine indicating the test pressure. 26-00126-001- Silicone Fluid 200 26-010- .2. etc. 10. Inspection Department.10 on the hot tapping equipment. 10.
HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 10 of 4 Check to ensure compatibility of fluids used in hot tapping with that of the line being hot tapped. .
This test pressure shall be the lower value shown in 4.4c or 4. 10.8. 3.4c or 4. At the option of the Inspector. a full hydrostatic pressure test shall be applied to the branch connection.7 above. Dwg.4d on Saudi Aramco Form SA-7627-ENG.8. This pressure will then be reduced to 21 .10 Return the valve to the open position. (Refer to paragraph 3. 10. A back seat test and low pressure seat test is not required. the branch connection shall have a blind flange installed and pressure applied through the branch connection boss as shown on Std. A tag shall be attached to the valve indicating test date.9 Install the hot tap valve and apply another high pressure closure test (seat test) per para. .7 After installation of the branch connection. but prior to installing the reinforcing pad or full encirclement ring. 10. install a bar stock plug in the branch connection boss and seal weld.4e on Saudi Aramco Form SA-7627-ENG. During the test. AB036719.6 A body and high pressure seat test (on both sides of the seat) shall be performed in the shop on all hot tap valves prior to installation. drained and vented upon completion of hydrostatic testing to prevent possible build up of pressure from any source of heat.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.6 above. test pressure and Inspector's name.8.5) 10. mount the hot tap machine and apply another full pressure test per paragraph 3. The test pressure shall be the lower value shown in 4. 10.8 A pneumatic test of 173 kPa (ga) shall be applied to the reinforcing pad or ring after installation. the MAOP of the line need not be exceeded.11 Ensure that the connection is opened.: 0 Page 11 of 4 10.12 After completion of the above tests. and applied through the branch connection boss. however. an MT or PT may be applied to the branch connection seal weld.13 The appropriate Inspection Representative shall witness and approve all hydrostatic testing required for completion of the hot tap connection.35 kPa (ga) for a tightness test using a soap solution. Valves with metal to metal seats shall meet the leakage criteria of API 598. Resilient (soft) seat valves shall have zero leakage. 10. with the valve in the closed position. 10.
. A positive pressure and flow shall be maintained at all times while welding and hot tapping is in progress.2 For normal maintenance tie-ins to existing systems not involving new construction. sea water injection lines). 3. the following must be satisfied: 11.2 Maximum internal pressure of the piping/equipment during welding shall be in accordance with SAES-L-052 paragraph 5. approval shall be obtained from the General Supervisor / Superintendent Operations Engineering. 11.2 In systems where hydrocarbon and oxygen mixtures are definitely not a possibility. whichever is less. However. or hydrocarbon gas. This steam or gas shall be kept flowing through the line during the entire welding operation. to weld with "NO-FLOW" conditions. hot tapping.3 Prior to and during any welding.1 Flow in a line shall be maintained while welding is being performed.3.4 or the maximum attainable flow under normal working pressure. 11. unless approved otherwise by the Operations Superintendent. In certain cases. Operations shall verify a non-combustible mixture in the line.g. approval shall be obtained from the responsible Project Manager.3. 11. such as flare lines with insufficient or intermittent flow. flow is not required. and testing operations.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.2..3 The minimum flow rates per para.: 0 Page 12 of 4 11 Operating Conditions Requirements 11.2.(e. inert gas.3.2.3. shall be maintained during all welding operations. This shall be stated in the remarks section of the Work Permit. the line shall be purged with steam.3 on welding of pipelines under pressure. 11. and the Operations Superintendent. and the Operations Superintendent.3. 11. General Supervisor / Superintendent Operations Engineering.1 The Operations Superintendent shall ensure that pipeline pressure and flow are correct as specified on Form SA-7627-ENG and shall arrange for these conditions to be maintained prior to and during welding.1 For new construction tie-ins to existing lines. 11.9.
5 Confirm that the hydrostatic test pressure for the branch connection is correct at the time of the test.10 m/sec maximum. 11.40 m/sec minimum and 9. pressure. 12.9.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.1 Verify a CSD approved welding procedure specification is utilized for installation of the connection. before and during the installation. 12 Hot Tap Fittings/Sandwich Valve Installation Requirements 12. if the branch connection size is less than 50% of the size of the line being hot tapped. 12. (Refer Para.2 The Operations Superintendent shall ensure compliance with the safety precautions arranged under paragraph 3. the operator shall remain in a location where he can control operating conditions such as flow. However.9). Continuous radio communications between the job site operator and the Control Room is required. 12.3. including acceptance of the work permit. 12.2 and 3. An additional operator shall standby at the job site while the work is in progress. Pressure testing shall also stop if pressure in the header/ equipment is lost.3.4 Verify that a calibrated pressure gauge and relief valve are properly installed for testing. .2 Verify that 3.5.1 The Initiating Engineer shall coordinate all activities. as prescribed in Section 4 of Form SA-7627-ENG. if deemed necessary by the Operations Superintendent.18.104.22.168 cannot be maintained during the welding and hot tapping operations. 12.2 mm diameter cellulose weld electrodes are utilized only for the root pass and low hydrogen electrodes are used for all other passes for carbon steel branch connection welds. for compliance with the approved drawings and welding procedures.9 of this SAEP. and liquid level within the limits specified in the hot tap design information.3 Inspect the branch connection/split tee.5 Work shall be immediately stopped when constant flow and pressure as noted in paragraphs 3. then the minimum values do not apply but a positive flow shall be maintained. While hot tap work and pressure testing is in progress. 3.3.4 Maximum and minimum flow rates during hot tapping shall be 0.: 0 Page 13 of 4 11.3 The Inspector shall perform the following: 12. 12.
HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 14 of 4 .
HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.1 Hot Tapping Operation Procedure .: 0 Page 15 of 4 13 Responsibilities 13.
prior to starting with work. including an approved welding procedure in accordance with the applicable SAES-W-XXX. Install the nozzle or boss connection using full penetration welds in the exact location shown on the approved drawing. Check pipe wall thickness ensuring it does not violate para.8. including the cutter and coupon retaining device.7. Power wire brush the area for attachment welds to remove all traces of paint. Ensure that the nozzle connections are not welded on the inside unless the hot tap cutter is at least one pipe size smaller than the nozzle. using a qualified welder and a CSD approved welding procedure. The Inspection Unit will verify proper weld joint fit-up.3) from the Operations Superintendent. Obtain an approved Hot Work Permit. Check that the location of the installation is that location specified by the initiating Engineer with the concurrence of the Operations Supt. Saudi Aramco Form SA-924-2 (Para.2 Mount the valve on the fitting ensuring that its alignment is within the manufacturer's tolerance Responsibilities Init. 3. The cutters sometimes break if the cut is made through a weld. Precheck the tapping valve and the hot tap machine to assure good operable condition. Confirm that the shop rating test of the hot tap machine is current per para. Eng/Insp/Maint/Constr/ Opers Maint/Insp/Constr Insp/Init Eng/Maint/Constr Hot Tap Unit Insp/Hot Tap Unit Insp/Hot Tap Unit .HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. Ensure all the requirements of paragraph 3. Eng/Insp Init. Eng/Maint/Constr Opers/Maint/ Constr Init.5. If long seam is under hot tap fitting. Ensure the pressure and flow requirements as identified in section 4 of Form SA-7627ENG have been established prior to any welding. 3.6. The fit-up of the connection to the header shall provide for a standard pipe bevel and 1/16 inch minimum root gap.: 0 Page 16 of 4 Procedure Review the design drawings and requirements for the branch connection. Eng/Maint/Constr Maint/Insp/Constr Init. rust and scale.2 General Requirements" are met. grind seam weld flush with the surface of the pipe taking care not to reduce the pipe wall thickness. 3. or his designee.
9 and will easily pass the hot tap cutter. 4.16 Apply hydrostatic and pneumatic pressure tests to the Hot Tap Unit/Insp/ hot tap machine. paragraph 5.15 Ensure that the tapping valve is tested in accordance Hot Tap Unit/Insp with paragraph 3.12 4.11. Maint/Constr/Hot Tap/Insp Procedure Review the design drawings and requirements for the branch connection. including an approved welding procedure in accordance with the applicable SAES-WXXX.13 Check the valve by opening and the hot tap machine Hot Tap Unit/Maint/ for operability and examine the condition of the cutter Constr and coupon retaining device. Refer to paragraph 3.11.8.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.18 the hot tap machine on the tapping After assembly of . valve. and welded connection in Maint/Constr with the testing procedure specified in this SAEP and SAES-L-052.11. Eng/Insp 4.11.11. 4. This may require grinding of the lugs on the valve seat rings to provide adequate clearance. Ensure that the dimension from the face of the valve flange to the surface to be hot tapped will permit enough cutter travel to completely cut out the coupon and not travel to the opposite side of the header.11. Responsibilities Init.14 machine on the valve.8.: 0 Page 17 of 4 Close the valve and perform the hydrostatic test according to this instruction.17 Install and seal weld a threaded plug in the weld boss Maint/Constr on the connection after all testing has been completed. 4. Unit/Maint/ Mount the hot tap Hot Tap Constr 4.
4. 4.22 tap machine from the line.11. 22.214.171.124 Close the valve.25 completed connection is blinded or plugged before leaving the job site. if required. purge with nitrogen.19 Hot Tap Unit Drill and cut Retract the hot Hot Tap Unit 4.: 0 Page 18 of 4 valve and before the tapping operation is started: 4.11.1 Completely close and then completely open Hot Tap Unit valve to ensure that it Is operable. Ensure that the Hot Tap Unit/Insp/ Maint/Constr .18.2 Set the cutter travel indicator to prevent over Hot Tap Unit travel and consequent damage to the opposite side of the header being hot tapped.20 tap machine boring bar.23 Remove the coupon from the pilot drill and tag and Hot Tap Unit/ wire the coupon to the tapping valve on the connection Maint/Constr after hot tap is completed. 4.11. and that the cutter can be withdrawn a sufficient distance to permit closure of the valve. coupon.11.11. and Hot Tap Unit depressurize the hot tap machine adaptor.24 The coupon shall be removed only by the Operations Opers Supervisor and forwarded to the responsible Operations Inspection Unit.11.11. Remove the hot Hot Tap Unit/ Maint/Constr 4. 4. 4.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.11.