PROCEDURE NO:

PROJECT SPECIFIC PROCEDURE

PSP-KOTI-19

ONSHORE CONSTRUCTION REVISION NO.: 0

HOT TAPPING PROCEDURE

FOR

PETRONAS CARIGALI SDN BHD

KUALA LUMPUR

PETRA RESOURCES SDN BHD PCSB

RE DAT PREPARED BY REVIEWED BY APPROVED BY REVIEWED BY APPROVED BY

V E NAME SIGN DATE NAME SIG DATE NAME SIG DATE NAM SIGN DATE NAME SIG DATE
NO
0 7/5/1 KC HYW AI
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TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 2

2.0 SCOPE 2

3.0 REFERENCE 2

4.0 DEFINITION 2

5.0 PROCEDURE
5.1 Preliminary Site Study/ Inspection 2
5.2 Site Preparation 3
5.3 Welding Work 3
5.4 Non-Destructive Testing 3
5.5 Pressure Testing 3
5.6 Drilling 4
5.7 Reinstatement 4

6.0 SPECIAL REQUIREMENT/ REFFERENCES 4

7.0 RECORDS 4

APPENDICES
Appendix I – Hot Tapping Checklist
Appendix II – Hot Tapping Equipment Datasheet
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1.0 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.

2.0 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.

3.0 REFERENCE
3.1 ASME B31.3 - Process piping
3.2 PTS 31.38.01.11 - Piping General Requirements
3.3 PTS 20.112 - Shop and Field Fabrication of Steel Piping
3.4 PTS 31.38.01.31 - Shop and Field Fabrication of Piping
3.5 PTS 31.38.60.10 - Hot Tapping on Pipeline, Piping and Equipment

4.0 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, and creating an opening in that piping or equipment by drilling
or cutting a portion of the piping or equipment within the attached fitting.

5.0 GENERAL REQUIREMENTS

5.1 Hot tap connections shall be designed and installed to meet all requirements as stated in Para
(3) of this procedure

5.2 The hot tapping operations are initiated, designed, and controlled by Project Manager with the
approval of the Area Operations Superintendent (PCSB & MLNG) and Operations Supervisor/
Superintendent (PCSB & MLNG) for tying in new installations to existing facilities.

5.3 PRSB shall appoint an Initiating Engineer, who shall be made responsible for the overall
coordination of the hot tapping activities. This is to ensure that designers,
construction/maintenance installation unit, hot tap, split tee (stopple) and valve crew,
operations and/or project management, engineering staff, and inspection staff cooperate
closely during all phases of the hot tapping operations.
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5.4 The Initiating Engineer shall identify the equipment in terms of service, location, pipe diameter,
header and branch pressure rating, and material type and notify the Hot Tap, stopple and valve
unit of this information.

5.5 The construction units are responsible for ensuring that approved welding procedures and
qualified welders are employed. QA/QC from both PRSB and PCSB shall verify this.

5.6 Compressed air piping and equipment shall not be hot tapped nor welded while in service.

5.7 Hot tapping lines upstream of rotating equipment shall be avoided unless such equipment is
protected from the cuttings by means of filters or traps. The normal in-line suction screens are
not considered adequate for this purpose.

5.8 Hot tap connections are not allowed for certain cases, unless a detailed design and installation
procedure has received prior approval from the both MLNG .

5.9 All hot tap connections, valves, and hot tap machines shall be pressure tested in accordance to
Para (3) codes

5.10 Precautions against electric shock, due to induced voltage, shall be taken into consideration
when installing hot tap connections on above ground pipelines near high voltage power lines.

5.11 Adequate support of the hot tap machine shall be provided to prevent overstressing of the pipe
and/or fitting, particularly in cases where the hot tap sticker is not installed in a vertical position.

5.12 Hot tapping shall not be permitted if:

5.12.1 within 18 inches of a flange (or threaded connection) as measured from the toe of
the reinforcement sleeve, 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,
operation and removal of the hot tap machine, and the removal of the piping or
pipeline flange bolts.

5.12.2 within 0.75 inches of a circumferential girth weld seam as measured from the toe
of the sticker weld or split tee circumferential fillet weld, to the toe of the nearest
girth weld.

5.13 Existing welds under the hot tap shall be ground smooth prior to fit up of the sticker and
reinforcing sleeve. Care should be taken when cutting across existing welds since the cutter
can be damaged.
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5.14 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.

5.15 Compact steel gate valves with extended body ends shall not be used for hot tap connections.

6.0 Precautions against H2S and other Toxic/Hazardous Materials

6.1 If a potential exists for a Hydrogen Sulfide (or other Toxic material) release at a work site, all
personnel involved shall be provided with an appropriate breathing apparatus with additional of
gas detector.

6.2 The standby person or fire watch, or other person certified as a gas tester, shall continuously
monitor the work site for the presence of hazardous materials during the work activity using
established gas testing procedures.

6.3 The chamber of the hot tap machine and valve shall be purged with nitrogen after cutting the
coupon, retracting the cutter and closing the tapping valve when any of the following exist:

5.13.1 H2S concentration is greater than 10 ppm.

5.13.2 Gas release may affect others in the area.
5.13.3 Hot tap equipment is larger than 36 inches.
5.13.4 The work is in a confined area.

6.4 In enclosed or confined areas, air horns/industrial fans shall be provided to improve air
circulation. However, the air velocity shall not interfere with the welding arc shielding gases.
Fans shall meet the electrical area classification requirements.

6.5 The Operations from PCSB and PRSB should provide written and verbal emergency
instructions (including evacuation procedure) to the hot tapping crew, fire watch personnel, and
other workers who may be in the work area.

6.6 When welding sour gas or sour crude lines, the fire watch personnel shall be clearly instructed
that should a burn-thru occur, the fire of the gas jetting from the pipe should not be
extinguished. If a burn-thru should occur, the Operation Superintendent should immediately be
notified to advise further action.

6.7 Firewater and extinguishers should be applied as required to workers, clothing, equipment,
etc., exposed to the burn-thru flame.
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7.0 Preparation of Hot Tap Specification and Test Calculations

7.1 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.

8.0 Locate and Inspect Hot Tap Position

8.1 The Initiating Engineer shall make all necessary arrangements for the preparation of hot
tapping(i.e. location, excavation, pipe inspection, surface preparation, etc.)

8.2 The Initiating Engineer shall arrange for a team, consisting of himself, operations, the
responsible inspector, and a representative of the Hot Tap and Stoppling crew, to survey the
general hot tap location in order to specify and mark the hot tap locations in detail.

8.3 The Initiating Engineer shall mark of the exact hot tap locations, and mark the hot tap number
alongside each hot tap location, ensuring the hot tap locations are at a position where the pipe
out-of-roundness does not exceed 3 mm. (Out of roundness criteria only applies to split tee or full
encirclement sleeves)

8.5 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.

8.6 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. The area to be scanned shall include the weld zone and 50 mm each side of it. The
minimum remaining wall thickness at the weld connection area shall not be below minimum
thickness , Tm, and in all cases, no less than 5 mm. The inspected area shall be permanently
marked for future reference and identification.

8.7 If ultrasonic readings indicate a lamination or evidence of hydrogen induced cracking (HIC)
damage, the hot tap position shall be relocated after consultation with the Initiating Engineer
and the responsible Operations from PCSB and MLNG

8.8 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.

9.0 Safety Requirements

9.1 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.
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9.2 Written approval of the detailed hot tap installation shall be obtained from the Operations
Superintendent, or higher, and a copy sent to the Area Loss Prevention Office and responsible
QA/QC for their review and concurrence prior to starting the installation. The installation
package shall be on-site during the entire installation process and verified, by the QA/QC, that
it is understood by the person(s) carrying out the work.

9.3 All work shall be in strict compliance with MLNG Work Permit System. The Work Permit shall
be approved by the MLNG and PCSB Operations Superintendent, prior to each of the
following:
9.3.1 Vehicle entry
9.3.2 Welding
9.3.3 Grinding
9.3.4 Hot Tapping

9.4 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.

9.6 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.

10 Pressure Test Requirements

10.1 The Initiating Engineer shall be responsible for ensuring that the pressure tests are performed
in accordance with PTS 31.38.60.10 on the hot tapping equipment, including the hot tap valve
and branch connection prior to and after installation. The initial pressure testing of the hot tap
machine, will take place in the shop after the machine has been checked and worn parts
replaced.

10.2 The hot tap machine shall have an overhaul of its renewable pressure sealing components and
be subjected to a shop rated pressure test, in accordance with the following criteria:
10.2.1 Pressure test once every four months and overhaul once every 12 months.
10.2.2 After it has been used on lines with operating temperatures in excess of 150 deg
C, even if the elapsed time is less than four months. For a series of consecutive
hot taps on a single type of service (i.e., steam, process stream, etc.) the hot tap
machine shall be shop tested at the end of the series of hot taps.
10.2.3 A stamped brass tag shall be affixed to the hot tap machine indicating the test
pressure, overhaul date, and the name of the testing organization.

10.3 Pneumatic testing of hot tap connections on hot lines over 93 deg C is not permitted
unless approved by the Manager, Inspection Department.

10.5 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, as follows:
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Line Temperature Hydrotest Fluid Stock No.

93 deg C to 290 deg C Turbine Oil 26-001-330

26-001-340
Over 290 deg C Silicone Fluid 200 26-010-037

Commentary Note:
Check to ensure compatibility of fluids used in hot tapping with that of the
line being hot tapped.
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10.6 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. Resilient (soft) seat valves shall have zero leakage,
Valves with metal to metal seats shall meet the leakage criteria of API 598. A back seat test
and low pressure seat test is not required. A tag shall be attached to the valve indicating test
date, test pressure and Inspector's name.

10.7 After installation of the branch connection, but prior to installing the reinforcing pad or full
encirclement ring, a full hydrostatic pressure test shall be applied to the branch connection.
This test pressure shall be the lower value shown in 4.4c or 4.4e on Saudi Aramco Form SA-
7627-ENG. During the test, the branch connection shall have a blind flange installed and
pressure applied through the branch connection boss as shown on Std. Dwg. AB-036719.

10.8 A pneumatic test of 173 kPa (ga) shall be applied to the reinforcing pad or ring after
installation. This pressure will then be reduced to 21 - 35 kPa (ga) for a tightness test using a
soap solution.

10.9 Install the hot tap valve and apply another high pressure closure test (seat test) per para.
3.8.6 above, with the valve in the closed position. The test pressure shall be the lower value
shown in 4.4c or 4.4d on Saudi Aramco Form SA-7627-ENG, and applied through the branch
connection boss.

10.10 Return the valve to the open position, mount the hot tap machine and apply another full
pressure test per paragraph 3.8.7 above, however, the MAOP of the line need not be
exceeded.

10.11 Ensure that the connection is opened, drained and vented upon completion of hydrostatic
testing to prevent possible build up of pressure from any source of heat. (Refer to paragraph
3.8.5)

10.12 After completion of the above tests, install a bar stock plug in the branch connection boss and
seal weld. At the option of the Inspector, an MT or PT may be applied to the branch
connection seal weld.

10.13 The appropriate Inspection Representative shall witness and approve all hydrostatic testing
required for completion of the hot tap connection.

11 Operating Conditions Requirements

11.1 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, hot tapping, and testing operations.

11.2 Maximum internal pressure of the piping/equipment during welding shall be in accordance with
SAES-L-052 paragraph 5.3 on welding of pipelines under pressure. A positive pressure and
flow shall be maintained at all times while welding and hot tapping is in progress.
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11.3 The minimum flow rates per para. 3.9.4 or the maximum attainable flow under normal working
pressure, whichever is less, shall be maintained during all welding operations.
11.3.1 Flow in a line shall be maintained while welding is being performed, unless
approved otherwise by the Operations Superintendent. In certain cases, such as
flare lines with insufficient or intermittent flow, the line shall be purged with steam,
inert gas, or hydrocarbon gas. This steam or gas shall be kept flowing through the
line during the entire welding operation.
11.3.2 In systems where hydrocarbon and oxygen mixtures are definitely not a possibility,
flow is not required.(e.g., sea water injection lines). However, to weld with "NO-
FLOW" conditions, the following must be satisfied:
11.3.2.1 For new construction tie-ins to existing lines,
approval shall be obtained from the responsible Project Manager,
General Supervisor / Superintendent Operations Engineering,
and the Operations Superintendent.
11.3.2.2 For normal maintenance tie-ins to existing systems
not involving new construction, approval shall be obtained from
the General Supervisor / Superintendent Operations Engineering,
and the Operations Superintendent.
11.3.2.3 Prior to and during any welding, Operations shall
verify a non-combustible mixture in the line. This shall be stated
in the remarks section of the Work Permit.

11.4 Maximum and minimum flow rates during hot tapping shall be 0.40 m/sec minimum and 9.10
m/sec maximum. However, if the branch connection size is less than 50% of the size of the line
being hot tapped, then the minimum values do not apply but a positive flow shall be
maintained. While hot tap work and pressure testing is in progress, the operator shall remain in
a location where he can control operating conditions such as flow, pressure, and liquid level
within the limits specified in the hot tap design information. An additional operator shall
standby at the job site while the work is in progress, if deemed necessary by the Operations
Superintendent. Continuous radio communications between the job site operator and the
Control Room is required.

11.5 Work shall be immediately stopped when constant flow and pressure as noted in paragraphs
3.9.2 and 3.9.3 cannot be maintained during the welding and hot tapping operations. Pressure
testing shall also stop if pressure in the header/ equipment is lost.
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12 Hot Tap Fittings/Sandwich Valve Installation Requirements

12.1 The Initiating Engineer shall coordinate all activities.

12.2 The Operations Superintendent shall ensure compliance with the safety precautions arranged
under paragraph 3.9 of this SAEP, including acceptance of the work permit.

12.3 The Inspector shall perform the following:

12.3.1 Verify a CSD approved welding procedure specification is utilized for installation of the
connection. (Refer Para. 3.5.9).
12.3.2 Verify that 3.2 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.
12.3.3 Inspect the branch connection/split tee, before and during the installation, for compliance with
the approved drawings and welding procedures.
12.3.4 Verify that a calibrated pressure gauge and relief valve are properly installed for testing.
12.3.5 Confirm that the hydrostatic test pressure for the branch connection is correct at the time of the
test, as prescribed in Section 4 of Form SA-7627-ENG.
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1 Responsibilities

13.1 Hot Tapping Operation Procedure

Procedure Responsibilities
Review the design drawings and requirements for the branch Init. Eng/Insp
connection, including an approved welding procedure in
accordance with the applicable SAES-W-XXX.
Ensure all the requirements of paragraph 3.2 General Init. Eng/Maint/Constr
Requirements" are met.
Check that the location of the installation is that location Opers/Maint/ Constr
specified by the initiating Engineer with the concurrence of the
Operations Supt.
Obtain an approved Hot Work Permit, Saudi Aramco Form SA- Init. Eng/Maint/Constr
924-2 (Para. 3.7.3) from the Operations Superintendent, or his
designee, prior to starting with work.
If long seam is under hot tap fitting, grind seam weld flush with Maint/Insp/Constr
the surface of the pipe taking care not to reduce the pipe wall
thickness. Check pipe wall thickness ensuring it does not
violate para. 3.5.6.
Ensure the pressure and flow requirements as identified in Init.
section 4 of Form SA-7627-ENG have been established prior Eng/Insp/Maint/Constr/Opers
to any welding.
Power wire brush the area for attachment welds to remove all Maint/Insp/Constr
traces of paint, rust and scale. The fit-up of the connection to
the header shall provide for a standard pipe bevel and 1/16
inch minimum root gap.
Install the nozzle or boss connection using full penetration
welds in the exact location shown on the approved drawing,
using a qualified welder and a CSD approved welding
procedure. The Inspection Unit will verify proper weld joint fit-
up.
Ensure that the nozzle connections are not welded on the Insp/Init Eng/Maint/Constr
inside unless the hot tap cutter is at least one pipe size smaller
than the nozzle. The cutters sometimes break if the cut is
made through a weld.
Precheck the tapping valve and the hot tap machine to assure Hot Tap Unit
good operable condition, including the cutter and coupon
retaining device.
Confirm that the shop rating test of the hot tap machine is Insp/Hot Tap Unit
current per para. 3.8.2
Mount the valve on the fitting ensuring that its alignment is Insp/Hot Tap Unit
within the manufacturer's tolerance
Close the valve and perform the hydrostatic test according to Maint/Constr/Hot Tap/Insp
this instruction.
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Procedure Responsibilities
Review the design drawings and requirements for the Init. Eng/Insp
branch connection, including an approved welding
procedure in accordance with the applicable SAES-W-XXX.

4.11.13 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.

4.11.14 Mount the hot tap machine on the valve. Hot Tap Unit/Maint/
Constr

4.11.15 Ensure that the tapping valve is tested in accordance Hot Tap Unit/Insp
with paragraph 3.8.9 and will easily pass the hot tap
cutter. 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.

4.11.16 Apply hydrostatic and pneumatic pressure tests to the Hot Tap Unit/Insp/
hot tap machine, valve, and welded connection in Maint/Constr
with the testing procedure specified in this SAEP and
SAES-L-052, paragraph 5.

4.11.17 Install and seal weld a threaded plug in the weld boss Maint/Constr
on the connection after all testing has been completed.
Refer to paragraph 3.8.12

4.11.18 After assembly of the hot tap machine on the tapping

valve and before the tapping operation is started:

4.11.18.1 Completely close and then completely open Hot Tap Unit
valve to ensure that it Is operable, and that
the cutter can be withdrawn a sufficient
distance to permit closure of the valve.

4.11.18.2 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.

4.11.19 Drill and cut coupon. Hot Tap Unit

4.11.20 Retract the hot tap machine boring bar. Hot Tap Unit
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4.11.21 Close the valve, purge with nitrogen, if required, and Hot Tap Unit
depressurize the hot tap machine adaptor.

4.11.22 Remove the hot tap machine from the line. Hot Tap Unit/
Maint/Constr

4.11.23 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.

4.11.24 The coupon shall be removed only by the Operations Opers

Supervisor and forwarded to the responsible Operations
Inspection Unit.

4.11.25 Ensure that the completed connection is blinded or Hot Tap Unit/Insp/
plugged before leaving the job site. Maint/Constr