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SAEP-311 Installation of Hot Tapped and Stopple Connections Piping Standards Committee Members
Nasri, Nadhir Ibrahim, Chairman Dib, Tony Georges, Vice Chairman Balhareth, Nasser Mohammad Bannai, Nabeel Saad Holland, Brad John Khashab, Jaafar M. Lewis, Trevor Mahmoud, Khalid Ahmed Phan, Howard Cong Rafie, Nader Yusof Rao, Sanyasi Rasheed, Mahmood Ayish Sharif, Talal Mahmoud Shiha, Saad Mohammed Swar, Ahmad Hamad
13 September 2009
Saudi Aramco DeskTop Standards
Table of Contents 1 2 3 4 5 6 7 8 9 Scope............................................................. 2 Conflicts and Deviations................................ 2 References..................................................... 3 Definitions...................................................... 4 Responsibilities.............................................. 5 Limitations on Hot Tap and Stopple Applications............................... 8 Safety Requirements.................................... 10 Technician Certification:............................... 11 General Design Requirements..................... 11
Previous Issue: 3 June 2008 Next Planned Update: 3 June 2013 Revised paragraphs are indicated in the right margin Primary contact: Nasri, Nadhir Ibrahim on 966-3-8760162
Copyright©Saudi Aramco 2009. All rights reserved.
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Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013
SAEP-311 Installation of Hot Tapped and Stopple Connections
Table of Contents (Cont'd.) 10 Limitations on Materials................................ 13 11 Limitations on Flow and Pressure during Hot Tapping....................... 13 12 Documentation............................................. 13 13 Installation and Welding of Hot Tap and Stopple Connections............... 15 14 Pressure Testing and Inspection................. 17 15 Stoppling...................................................... 21 Appendix A – Applicable Forms......................... 25
Scope 1.1 1.2 1.3 This SAEP provides procedures for the installation of hot tap connections to piping and tanks while in service. Also included is procedure for plugging pipes through hot tapped connections (stoppling). Hot tapping and stoppling are complex operations to be performed by trained technicians with the support of experienced engineers. This SAEP is not intended to detail all aspects of the operations and does not include adequate information to enable it to be used as an instruction manual. The equipment manufacturer's instruction manuals and data sheets will also need to be referenced and utilized. The work to be performed after the hot tap and stopple operation is not within the scope of this document.
Conflicts and Deviations 2.1 Any conflicts between this Procedure and other applicable Saudi Aramco Engineering Procedures (SAEPs), Engineering Standards (SAESs), Materials System Specifications (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this standard in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran.
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Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013
SAEP-311 Installation of Hot Tapped and Stopple Connections
References 3.1 Saudi Aramco References Saudi Aramco Engineering Procedures SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement Pipeline Repair and Maintenance
Saudi Aramco Engineering Standards SAES-A-004 SAES-D-008 SAES-D-108 SAES-L-101 SAES-L-110 SAES-L-150 SAES-W-010 SAES-W-011 SAES-W-012 General requirements for Pressure Testing Repairs, Alterations, and Re-rating of Pressured Equipment Repair, Alteration, and Reconstruction of Storage Tanks Regulated Vendor List for Pipes, Fittings and Gaskets Limitations on Pipe Joints and Components Pressure Testing of Plant Piping and Pipelines Welding Requirements for Pressure Vessels Welding Requirements for On-Plot Piping Welding Requirements for Pipelines
Saudi Aramco Materials System Specification 02-SAMSS-006 Hot Tap and Stopple Fittings
Saudi Aramco Standard Drawings AE-036175 AD-036643 AB-036719 Detail of Heavy Welding Boss for Threaded Connections to Vessels and Lines Detail of Heavy Welding Boss for Socket Weld Connections Reinforcement of Welded Branch Connections
Saudi Aramco Forms and Data Sheets Form SA 7235-ENG Hot Tap Data and Checklist
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Lock-o-Ring Flange and Plug: This is a special flange and plug assembly designed to allow the recovery of the hot tap valve while the pipeline is under pressure. performed using specialized equipment for cutting a hole in a pipe or tank through a welded or bolted branch connection while they are under pressure. The L-o-R plug has an o-ring seal on its circumference and can be lowered into the bore of the L-o-R flange.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Form SA 7627-ENG Hot Tap/Stopple & Reinforcement Calculation Request Saudi Aramco General Instructions GI-0002.001 3. Criteria for Hot-Tap Welding (catalogue # L51548) Review of procedures for Welding unto Pressurize Pipelines (catalogue # L51601) Proof Testing of the Pre-Hot-Tap Branch Connection (catalogue # L51561e) 4 Definitions Hot Tap: Hot tapping is technique. The L-o-R flange has retractable segments that Page 4 of 30 . using a hot tap machine.100 GI-0002.2 Industry Codes and Standards American Petroleum Institute API STD 598 API RP 2201 Valve Inspections and Test Procedures for Welding or Hot Tapping on Equipment Containing Flammables Work Permits Safety Precautions for Pressure Testing Atmosphere-Supplying Respirators American Society of Mechanical Engineers/Boiler and Pressure Vessel Code ASME SEC VIII D1 Pressure Vessels Pipelines Research Council International (PRCI) PR-185-617 PR-185-816 NG-18 Report # 175 Commentary Note: Referencing to PRCI reports is intended for expanding knowledge and to locate sources of many of the technical basis for the requirements of this procedure.102 GI-1780. It is not intended to be a mandatory document.
The responsibilities and involvement of relevant organizations are detailed below. design drawings and installation procedures is responsible for the hot tap design. The initiating organization shall appoint a Responsible Engineer to carryout the following duties and responsibilities: 5. normally inserted through a stopple split tee with a full line size hot tapped opening. The detailed hot tap installation design package shall be approved in writing by the facility Operations or Engineering Superintendents. Saudi Aramco has stoppling equipment for pipe sizes from 1" to 60". Initiating Organization 5. Stopple Split Tee: A stopple split tee is a fitting designed with dimensional requirements to suit the stopple plugging head. These valves cannot be operated unless the pressure is equalized across the gate.2. 5. Project Management with the approval of the Area Operations Superintendent and Operations Engineering General Supervisor / Superintendent in the case of tying in new installations. while the line is pressurized. a materials list. These fittings shall be purchased in accordance with 02-SAMSS-006.3 .2.2 The initiating organization shall prepare a design package for each hot tap that will include fully dimensioned drawings. or higher.1 The initiating organization will be either one of the following: The Operations Engineering Organization when the work is being undertaken by the Operations Organization. They are also used for hot tapping when the connection will only be used temporarily or when the reach of the hot tap machine is insufficient to complete a hot tap through a conventional valve. Sandwich Valve: This is a gate valve designed to have a short face to face dimension used as a temporary valve for stoppling. constructed by Project Management to existing facilities. These segments retain the plug in position so that the valve can be depressurized and removed and replaced with a blind flange or permanent valve. Direct Charge Requisitions and welding procedures.1 The engineering group that prepares the calculations.2 5. Stopple: A stopple is an articulated pipe plugging device.1 Be responsible for the overall coordination of the hot Page 5 of 30 5. 5 Responsibilities 5.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections can be advanced into a groove in the circumference of the plug above the o-ring.2.3.2.
This is to ensure that designers. Page 6 of 30 . P&IDs.4 5.A. "Hot Tap/Stopple and Reinforcement Calculation Request" and complete form 7235-ENG. scaffolding. "Hot Tap Data & Checklist" in accordance with appendix A. Ensure that stopple or hot tap split tees with the L-O-Ring plug to be delivered to the Hot Tap Unit shop in Dhahran to be checked prior installation.3.3. Installation. Pipelines Department The Hot Tap and Stopple Unit is responsible for the following: 5.6 5.3.2. Revise existing Saudi Aramco drawings.3 Hot Tap and Stopple Unit/N. excavation. 5.2.7 5.. For stopple installation.2.3.8 5. make sure that the Hot Tap Unit conducts pipe roundness check to ensure that it meets the requirements stipulated in Table-1 of section 9. constructors. Welding & Testing). location.2.3. facility operations and/or engineering.2 Initiate form 7627-ENG. because of the hot tap installation. Make all necessary arrangements for the preparation of the new connection.7 and mark the exact location of the stopple. as may be required. Operations.2.1 Review and initial the design package. hot tap unit. Arrange for a team.e. (i.3. project management and operation/project inspection staff cooperate closely during all phases of the hot tapping operations.3.2.3. the responsible inspector and a representative of the Hot Tap and Stoppling Unit. 5. or preparing new drawings.3. consisting of himself.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections tapping activities.5 5. pipe inspection. Make available at the site a copy of the latest version of this procedure and the installation design package during the entire installation process.2 and A.2. surface preparation. to survey the general hot tap location in order to specify and mark the hot tap locations and number (obtained from Form SA 7627-ENG) alongside each hot tap location.3 5.
4.4. hot tap tees.8 5.3. for compliance with the approved drawings and welding procedures.1 of this procedure.2 5.9 5.4 Review form 7235-ENG and ensure that the hot tap equipment required to perform the hot tap is available and validated. before and during the installation. Approve the fit up of the branch connection/split tee to the pipe prior to welding. 5.4.10 . Perform the hot tapping and/or stoppling operation in accordance with this procedure and an approved detailed design package.7 5. Verify that calibrated pressure gauges and relief valve are properly installed for hydrotesting.4. Review and approve any Direct Charge Requisitions prepared as part of the design package for stopple sealing elements. Page 7 of 30 5. or Lock-O-Ring flanges prior to issuing for purchase.3 Review and concur with the design package prior to the start of the installation.1 5. stopple split tees. Scan the weld zone and 50 mm (2 inches) each side of it.4 5.6 5. Inspect the branch connection/split tee. Review the welding procedure specification (WPS) and ensure that it has been approved by Consulting Services Department.3 5.4.2 5.4.4 Inspection Organization The responsible Inspection Unit shall be responsible for the following: 5.4. 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 applicable form in Appendix A. Confirm that the hydrostatic test pressure for the branch connection is correct at the time of the test.4. Inform the Responsible Engineer if the seam weld or any other projection needs to be ground flush with the pipe surface to permit proper UT scanning or fit-up of the split tee or reinforcing sleeve. as prescribed in Section 4 of Form SA 7627-ENG.4. Ensure that the connection is installed in accordance with the design package.4.3.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 5.3.5 5.
7 Loss Prevention Department In the case of stoppling activities. 5.4. 5.5 Construction or Maintenance Unit The construction or maintenance units are responsible for ensuring that approved welding procedures and qualified welders are employed. CSD and the proponent group shall be notified of this condition.6 Consulting Services Department Approve the welding procedure specification (WPS).3 The pipe contains flammable materials below atmospheric pressure.1 Welding and hot tapping shall not be allowed in the following cases.11 5.8 OSPAS OSPAS shall ensure operation stability prior and during pipeline hot tap and stopple operation.1.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 5.12 Mark the inspected area permanently for future reference and identification.4. OSPAS shall inform upstream and downstream facilities with ongoing work activities. 6.1.2 6. 5. 6 Limitations on Hot Tap and Stopple Applications 6. 5. Commentary Note: All hot tap and stopple equipment must be stamped with its maximum operating pressure and revalidated according to this procedure.1 The operating pressure of the pipeline or tank may exceed the maximum operating pressure of any of the hot tap or stopple equipment and their components while it is installed. 6. Consult with the Responsible Engineer and the responsible Operations Engineering Organization if ultrasonic readings indicate a lamination or evidence of hydrogen induced cracking (HIC) damage in order to relocate the hot tap position.1. The pipe contains a combustible mixture. the Loss Prevention office responsible for the area where the stopple activities will commence shall be notified and provided with procedures for review and be part of the site survey team. Page 8 of 30 .
The pipe has a corrosion or heat resistant lining such as metal lining or cladding.3 6.2. fired heater or boiler. manufactured in accordance with ASME Boiler and Pressure codes. This is dictated by SAES-D-008. unless the equipment being tapped is thoroughly cleaned and inerted prior to welding.1.2.5 The material to be welded may suffer metallurgical or physical deterioration from heating or requires post weld heat treatment. The pipe contains any of the following: a) b) c) d) e) f) g) Liquid acids Caustic Elemental Sulfur Oxygen Chlorine Ammonia Potential toxic material that would be injurious to personnel by contact. This restriction does not include internally coated piping but the damage that will result to the coating by hot tapping should be considered by the Operating Department.2. 6. Page 9 of 30 . 6. heat exchanger. Welding and hot tapping shall not be performed in the following cases unless a detailed design and installation procedure has been approved by the Chairman of the Piping Standards Committee. Commentary Note: Most industrial compressed air systems will have hydrocarbon contamination from compressor lubricating oil and will therefore required being inert.2.2 Any pressure vessel.2. 6.3 Welding and hot tapping shall not be performed in the following cases unless a detailed design and installation procedure has been approved by the Piping Standards Committee Chairman with endorsement of the Proponent.4 6. 6.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 6.4 6.1 Hot taps on air lines with compressed air if there is any possibility of hydrocarbon contamination.2 Hot tapping on the roofs of cone or floating roof tanks in hydrocarbon service.
100. all personnel involved shall be provided with an appropriate breathing apparatus.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections The pipe or surface temperature is at or below zero degrees centigrade (0°C).3. the fire jetting from the pipe shall not be extinguished.3 c) Page 10 of 30 . 6.2 All work shall be in strict compliance with GI-0002.4 Hot taps shall not be made directly upstream of sensitive equipments such as pump suction piping or control valves unless facilities exist to prevent chips and shavings from entering the equipment. "AtmosphereSupplying Respirators"). The work is in a confined area. 7.2 When welding on hydrocarbon lines. Precautions against H2S and other hydrocarbon or hazardous releases. 7. (Refer to GI-1780. Low wind conditions exist and a gas or liquid hydrocarbon release may create a hazard in the area or activate plant gas alarms. This is particularly important if the hydrocarbon contains H2S. The responsible operation representative or the work permit issuer shall make sure that a person certified as a gas tester shall continuously monitor the work site for the presence of hydrocarbons and hazardous gases during the work activity using calibrated instruments and established gas testing procedures. the Operations Superintendent should immediately be notified to advise further action.3 7. 7 Safety Requirements 7.3.1 If a potential exists for a Hydrogen Sulfide release (or other toxic gas) at a work site.001. The chamber of the hot tap machine and valve shall be purged with nitrogen and discharged to a safe location after cutting the coupon.3.1 7. Work Permit System. retracting the cutter and closing the tapping valve when any of the following exist: a) b) H2S concentration is greater than 10 ppm. the fire watch personnel shall be clearly instructed that should a burn-thru occur. The Operations Superintendent will assure that both Operations and the Installation Organization 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. If a burn-thru should occur. 7.
8 Technician Certification Hot Tap/Stopple technician shall be certified by.3.5 7. Loss prevention. 7. During each activity. Operation and Loss Prevention shall determine the size of the area to be barricaded based on the size of the pipeline.6 The initiating organization shall conduct an onsite safety meeting with all involved parties to review the stopple procedure prior to starting the work. 7. the hot tap and stopple equipment manufacturers or Saudi Aramco approved certifier. and the operating pressure.5. Page 11 of 30 .4 The work activities shall be planned such that the inserted stopple or plugging heads shall remain in the pipeline for shortest period. This is to minimize the possibility of deterioration of the sealing element and hydrogen damage to the stopple equipment. PMT. Additional Safety Requirements for Stopple Operation 7. Hot Tap Unit and Construction Contractor prior to start of any work activities.1 Initiating organization shall prepare a Jobsite Safety Analysis (JSA) plan review with all concerned parties including the Operation Organization.4 above.5.2 7.4 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.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 7. Commentary Note: The work to be performed after the hot tap and stopple operation is not within the scope of this document. all personnel and equipment not directly involved with such activity shall be kept at a safe distance outside the barricaded area established under Section 7. Fire protection. A jobsite visit shall be conducted by responsible representatives from all concerned parties to review and evaluate the JSA plan. Facility Operations and Loss prevention representative at work site shall ensure that the sequences of activities are carried out in accordance with a written procedure per the engineering design package in a safe manner. the fluid being transported. An engineering design package detailing the scope of work and all required safety measures shall be prepared.
The dimensions of the connection.1 For atmospheric or low pressure hydrocarbon storage tanks. 9. and the clearances shall be within the limits specified for the hot tapping equipment to be used. The minimum bore of the valve shall be large enough to pass the cutter. hot tap connections shall be located at least 1 m (39 inches) below the liquid level while welding or hot tapping is in progress.3 9.7 Adequate support of the hot tap machine shall be provided to prevent overstressing of the pipe and/or fitting.5 9. The valve seat lugs shall not restrict the opening. the hot tap valve.8 Page 12 of 30 .4 9. Storage Tanks 9. A tap equal to the nominal size of the header (such as required for stoppling of a pipeline) shall be made only when the accurate positioning of the cutter can be guaranteed. In hot tap cases other than those for stoppling purposes. Hot-Tap and Stopple Unit should be contacted to provide this data prior to purchase of any fitting with an extended branch nipple. the hot tap crew shall take measurements and mark the tapping location prior to welding of split tee to ensure that the pipe out of roundness meets the tolerances in the following table: Table 1 – Acceptable Header Diameter Out of Roundness for Stopple Installation Header Size (Stopple Size) Up to 32" 34" & Greater Maximum Acceptable out of Roundness Tolerance 0. If the hot tap is to be used for stoppling the pipe. particularly in cases where the hot tap sticker is not installed in a vertical position.6 9.8. the cutter should be at least one pipe size smaller than the pipe to be tapped.2 9.125" 0.4% of Header Diameter 9.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 9 General Design Requirements 9.1 Permanent hot tap connections shall be designed for the Maximum Allowable Operating Pressure for the equipment being tapped in accordance with the applicable ASME code.
1 The Maximum flow velocities during hot tapping shall be as follows: a) b) Liquid and two-phase 3. Commentary Notes: 1) Hot tap and stipple machine manufacturers have established the above maximum flow velocity in lines during the hot tapping operation.e.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 9. flow in the pipeline Page 13 of 30 .2 If the tank is in service during the welding or hot tapping process. However. the air must be removed from the pipeline by either putting the line in service with an adequate flow rate to sweep out or by other means such purging and venting to ensure that the air is displaced from the pipeline. 2 inch and less) are normally performed with a drill which does not cut a coupon.3 11 Limitations on Flow and Pressure during Hot Tapping 11.05 m/sec (10 ft/s) maximum Gas 9. or Lock-o-Ring flanges Stopple sealing elements shall be reviewed and approved by the Hot Tap and Stopple Unit prior to issuing for purchase.8.1 10. stopple split tees.2 Minimum flow is not mandatory during hot tapping operation. 9. therefore no velocity restrictions apply. Connections on tanks shall meet the requirements SAES-D-108.8. Small diameter hot taps (i. the Hot Tap & Stopple Unit should be consulted as steps can be taken to ensure that the coupon does not become detached even at higher velocities.2 Hot tap and stopple fittings shall be procured from an approved manufacturer per SAES-L-101. If higher velocities cannot be avoided. Higher velocities may cause spinning of the coupon on the pilot drill and subsequent loss of the coupon. Any Direct Charge Requisitions prepared as part of the design package for hot tap tees. Hot tap and stopple fittings shall comply with Saudi Aramco Materials System Specification 02-SAMSS-006. 10. 2) 11.3 10 Limitations on Materials 10..10 m/sec (30 ft/s) maximum. Commentary Note: When performing the coupon cutting operation for a stopple. in cases where a pipeline has been cut or ingress of air has otherwise been allowed. the operating organization shall ensure that the liquid level above the level of the weld or cut shall not be less than 1 meter.
1 Form 7627-ENG. 12. 2.1. AB-036719). diameter.1. flange rating and material of the new connection plus the type and dimensions of the connection reinforcement. The Project Engineer or the responsible Operations Engineering Supervisor shall perform the required calculations in accordance with Section 13 of this procedure and shall complete Section 4 of Form SA 7627-ENG.1. wall thickness.1. "Hot Tap/Stopple & Reinforcement Calculation" 12. and 3 are complete.1.7 Page 14 of 30 .1. distributed and documented as detailed in the section follows.1. Welding Procedure Specifications shall be approved by the Consulting Services Department/Welding Unit.5 12.2 The Responsible Engineer shall prepare a separate Form SA 7627-ENG for each hot tap operation. Drawings and specifications prepared by the responsible engineering shall include the length.6 12. to the Project Engineer or responsible Operations Engineering Supervisor.1 of this SAEP). if required (Refer to Std. Dwg. 12. together with ultrasonic thickness measurements (Appendix A. 12 Documentation The appropriate forms shall be completed. Each Form SA 7627-ENG shall be completed in sequence and by the organization identified: Form Section # 1 2 3 4 5 Person/Organization Initiating Engineer Operations Engineer Responsible Inspection Unit Operation or Project Engineer Operation or Project Engineer 12.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections to disperse the cuttings away from the stopple sealing area is advantageous but not essential.1 12.4 12. The responsible engineering shall obtain the appropriate approvals and endorsement on Form SA 7627-ENG. when Sections 1.3 The Responsible Engineer shall forward the form.
Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 12. as specified on the Safety Instruction Sheet (SIS). no less than 5 mm (0.2 inch). The data entered in this form must be obtained from a site inspection of the hot tap connection. 12. Tm.9 12.1. and in all cases.1 The Responsible Engineer shall prepare and forward Form SA 7235-ENG "Hot Tap Data & Check List" to the Hot Tap and Stopple Unit.2. Other Drawing Revisions The Responsible Engineer is responsible for revising and updating existing Saudi Aramco drawings.2 Form SA 7235-ENG "Hot Tap Data and Checklist": 12. P&IDs and any other drawing affected as a result of the hot tap installation.2 12.4 Form Hot Tap & Stopple measurement (Appendix A. the Responsible engineer shall distribute copies of each Form SA 7627-ENG to the following personnel: 1) 2) 3) 4) 5) 7) Operations Superintendent Hot Tap and Stopple Unit Operations Engineering Supervisor Construction/Maintenance Installation Crew Responsible Inspection Supervisor Project Manager (if appropriate) 12. and the design package forwarded to the Responsible Engineer for construction.1 The minimum remaining wall thickness at the weld connection area shall not be below minimum thickness.4) is to be filled by Hot Tap Unit Supervisor and approved by the Hot Tap Foreman.1.2 inch) may be undertaken provided the possibility of burn-through is Page 15 of 30 . a record copy shall be retained in a permanent central file. Once approval is obtained.2. 13 Installation and Welding of Hot Tap and Stopple Connections 13.8 After the responsible engineering group has obtained the appropriate approvals. Commentary Note: Welding of hot tap connections on pipe containing non-hazardous material such as water at less than 150 psig and below 65°C when the wall thickness is below 5 mm (0.3 12.
a continuous UT scan shall be conducted around the circumference of the pipe weld areas. 2S(t 0.3 13.3.3.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections recognized and the consequences accepted by the construction agent and proponent (this condition still requires a waiver to be processed thru CSD). the Consulting Services Department shall be contacted for welding procedure approval. For in-plant piping designed to ASME B31. replace S and F in the formula with the allowable stress in Table A-1 of ASME B31.1 The form SA 7627-ENG shall specify the maximum internal pressure in the pipeline.4 (1) Commentary Notes: 1. 13. The minus 0. For hardenable or high strength steels and for piping where pipe or fitting wall thickness requires preheat per the applicable ASME code. inches. the hot tap location should be selected such that no welds are located under the area to be cut by the hot tap cutter. inches. Page 16 of 30 .2 Existing welds under hot tap fittings or reinforcing pads (or sleeves) shall be ground smooth as required to ensure acceptable fit up. Welding on Pipelines under Pressure 13. The pressure in the pipe during welding shall not exceed that calculated by the following formula: Pmax = Where: Pmax = Maximum operating pressure of the pipeline during welding.10) 0.72 OD 13. This is particularly important for stopple fittings where the outlet flange must be accurately centered on the pipe and a projecting weld would prevent this. psig S t OD = Specified minimum yield strength of the pipe.10 inch wall thickness takes into account the molten and heat affected portion of the base metal which does not contribute to pressure containment. psi = Minimum measured wall thickness of the pipe at the weld area.4. 2. = Outside diameter of the pipe. If possible. To ensure the wall thickness is thoroughly measured.
the air must be removed from the pipeline before welding can be performed. Pneumatic testing of hot tap connections is not permitted. Pressure Test Fluid Turbine Oil Silicone Fluid 200 Stock No. One method of removing the air is by putting the line in service with an adequate flow rate to sweep out or by other means such as purging and venting to ensure that the air is displaced from the pipeline. Hot Tap Machine 14. welding can proceed with or without flow.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 13. the hot tap valve and branch connection have been pressure tested in accordance with this SAEP prior to commencing the actual hot tap operation.3.2 14.4.2 In cases where a pipeline has been cut or ingress of air has otherwise been allowed. For example. The appropriate Inspection Representative shall witness and approve all hydrostatic testing required for completion of the hot tap connection.1 The Responsible Engineer shall ensure that the hot tapping equipment.2 14. 14 Pressure Testing and Inspection 14. as follows: Line Temperature 93°C to 290°C 290°C to 310°C Commentary Note: Check that the hydrotest fluids used will not damage the soft seals in the hot tap valve. Once this has been achieved.1 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.4. Pressure Testing Media 14.3. EPDM seals used for steam and water service can be damaged by exposure to mineral oils.4 Hot tap shall not be conducted for piping system operating at more than 310°C.3 14.3 14.1 Shop pressure test every 6 months. Page 17 of 30 . 26-001-330 26-001-340 26-010-037 14.3. hot tap machine or other seals exposed to the test fluid such as the o-rings in Lock-o-ring flanges.
The pressure testing of the hot tap machine.6. Page 18 of 30 .3 14.6. A stamped brass tag/stencil shall be affixed to the hot tap and stopple equipments machine indicating the test pressure.6.1 14.4. the hot tap valve will be seat tested on site immediately prior to installation. 14.6 Hot Tap Valve 14. In this case. Commentary Note: This valve seat test cannot be performed when hot tapping a weld boss because there is no room for the test connection.5 14.6. Resilient (soft) seat valves shall have zero leakage.4 A body and high pressure seat test (on both sides) shall be performed in the shop on all hot tap valves prior to installation.3 14.2 14.4.6. maximum operating pressure and overhaul date. 14. Valve Inspection and Testing.2 14. The test pressure shall be the expected line pressure during hot tapping plus 10%. Valves with metal to metal seats shall meet the leakage criteria of API STD 598. A tag shall be attached to the valve indicating test date and test pressure.5 Hot Tap and Stopple Adaptors All adaptors shall be marked with their maximum operating pressure and test pressure.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 14. 14.5 The seat of the hot tap valve shall be leak tested after installation by applying pressure through the branch connection boss. Commentary Note: Sandwich valves only require the body test and a test of the seat on the hot tap machine side of the valve.4 Replace the boring bar and retaining rod main seals and hydrotest after the machine has been used on sour or highly corrosive fluids.4. Replace the boring bar and retaining rod main seals and hydrotest after it has been used on lines with operating temperatures in excess of 150°C. They must be visually inspected for corrosion or mechanical damage before use and shall be inspected by MPI or hydrotested every five years. will take place in the shop after the machine has been checked and worn parts replaced.4.
7 Stopple Equipment 14.2 Page 19 of 30 . "Proof Testing of the Pre-Hot-Tap Branch Connection".4 14. The nose piece bolts shall be tested by magnetic particle inspection or dye penetrant subsequent to the pressure test.7.8 Hot Tap Connections 14. The length of each of the nose piece bolts must be measured with a micrometer before and after the pressure test to ensure that yielding has not occurred. longitudinal and circumferential welds. 14.7. the branch connection shall be pressure tested prior to installing the reinforcing pad or full encirclement reinforcement.2 The lip seal on the back of the sealing element shall be cut to ensure that the test pressure is exerted over the full area of the nose piece which will be the worst case scenario during actual usage. When the nose piece screws and/or the pin yoke is replaced. 14.8. must be inspected 14.6 14.1 For field fabricated branch connections (non-factory made split tees). An increase in bolt length will indicate that the test pressure and hence design pressure is incorrect or the bolt tightening torque is too high.7. Stopple cylinders shall be pressure tested once a year. Table-2 utilizes with modification the results of PRCI Report # 175.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections 14.8. When the stopple head is modified. Stopple heads shall be pressure tested for the following conditions: a) b) c) 14. all welds of the pressure containing branch connection.5 14.7.3 In case that the calculated branch test pressure is less than the piping system test pressure.7.7.1 Stopple heads shall be disassembled and all components including bolts inspected by magnetic particle or dye penetrant for cracks subsequent to any use in sour service.3 Every five years.7 14.7. The test pressure of the branch connection shall comply with SAES-L-150 requirements and shall not exceed the maximum pressure per Table-2 below "Hot Connection Pressure Test Formulas". 14.8.
14.75 x P f Pb = Ph + 1. Db / D h All 0.25 P Pb = 0. For this calculation. & 8 Welded Stub-in Type 1. 2. the test pressure is considered as an external pressure to the header and the value of L shall be the total length of the split tee or db the inside diameter of the welded stub-in connection. The formula is P f = (16/3)(th/db)² Sy which considers the header section subject to pressure test as a flat plate.8. 14. the split tee (Types 3 and9 of Standard Drawing # AB-036719) shall have a blind flange installed and pressure applied through the welding boss as shown on the Standard Drawing. the actual line pressure at the time of the test shall be confirmed from a calibrated pressure gauge on the pipeline close to the hot tap connection or by any other acceptable means to comply with SA 7627-ENG. During testing of split tee connections. 6. 14.5 Table 2 – Formulas for Maximum Hot Connection Pressure Test Branch Connection Type Split Tee Type-3 & 9 Welded Stub-in Type 1. 2.8. 2. Commentary Note: The weep hole in the pad or sleeve is required to prevent build up of pressure under the reinforcement and to indicate leakage of the branch connection attachment weld. 5. P is the calculated differential pressure across the pipe header per the ASME SEC VIII D1. This is very critical for split tee case and for stub-in connection Db/Dh larger than 0.8. The weep hole must not be threaded. which would defeat its purpose.30 or less More than 0. Also.25 P Pb = 0. 4. 6. 4. Branch connection types are per Standard Drawing # AB-036719.3 All Formulae for Maximum Test Pressure Pb = Ph + 1.75 x P f Applicable Notes 3 2 3 3. Page 20 of 30 .Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections by magnetic particle inspection. & 8 Welding Boss 2 inches & smaller Notes on Table 2: 1.5.4 For testing purposes. paragraph UG-28. the flange to branch weld must be inspected by100% radiograph. as this would encourage the installation of a plug.6 The reinforcing pad and reinforcing sleeve should not be subject to pressure testing as they are required to provide mechanical reinforcement and not to contain internal pressure. 5.
UG-28 : Header outside diameter : Branch outside diameter : Branch inside diameter : Header pipe wall thickness : Branch pipe wall thickness : Header pipe pressure : Branch pipe test pressure : Pressure for flat plate = (16/3)(th/db)² Sy : SMYS of header pipe material Commentary Notes on Table 2: PRC Report # 175 "Proof Testing of the Pre-Hot-Tap Branch Connection".1. a final leak test of the entire assembly shall be made with the hot tap valve in the open position by applying pressure through the branch connection boss. If any significant differential pressure develops before full insertion is achieved. The formula gives very high pressure for testing compared to others for small branch connections.1 After installation of the hot tap machine. 14. The no flow condition is normally achieved on pipelines in Page 21 of 30 . After completion of the above tests.75 factor has been introduce to insure that section will not be subject to yield. 1989 contains detailed analysis of stress level in the hot tap joints under pressure testing. Commentary Note: Stopple plugging heads can only withstand a differential pressure once they are fully inserted in the pipeline.1 Stopples should be inserted in pipelines with no flow at the stopple location.2 15 Stoppling 15.9 Final Hot Tap Assembly Testing 14. a bar stock plug shall be installed in the branch connection boss and seal welded. 4.1 General Notes 15.9.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 Commentary Note: SAEP-311 Installation of Hot Tapped and Stopple Connections A 0. Nomenclatures used in the table: P Dh Db db th tb Ph Pb Pf Sy : The calculated differential pressure across the pipe header per the ASME SEC VIII D1.9. The test pressure shall be the expected line pressure during hot tapping plus 10%. 14. the stopple insertion equipment will be damaged and it may be impossible to retract the stopple head.
STOPPLE equalizing connection.1 – Typical Example of Inserting the Stopple with no Flow Condition 15. When retracting the stopple heads after pressure equalization. open during insertion.2 – Sequence of Pipeline Isolation with Two Stopples 15. equalization line size and negative differential pressure allowed to remain within the design limits of the stopple fittings. the upstream stopple shall be retracted first. Stopple heads can withstand a small differential pressure when inserted in the reverse direction of flow. the downstream stopple shall be inserted first to divert flow through the bypass before inserting the upstream stopple.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections service by diverting flow through a full flow bypass. Table 3 provides recommended bypass. VALVE Close valve before stopple insertion Figure 15.1 shows a typical example of inserting the stopple with no flow condition. Page 22 of 30 . Inserting the downstream stopple first uses this feature to create the small differential pressure required to divert flow to the bypass. Figure 15.2 When a section of pipeline is isolated with two stopples and a bypass. which must be large enough and short enough to carry the full flow with minimal pressure differential. Commentary Note: Inserting the downstream stopple first will divert the flow from the pipeline to the bypass. BYPASS FLOW INSERT DOWNSTRAM STOPPLE FIRST Figure 22.214.171.124 The bypass line size should be calculated.
PIPE SEAM INTERFERENCE PIPE STOPPLE NOSE PIECE Figure 15.5 The stopple head should be fully inserted prior to depressurizing.3.3 – Stopple Nose Location 15.1.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Table 3 – Recommended Bypass. Page 23 of 30 . Equalization Line Size andNegative Differential Pressure 15. Commentary Note: The straight or spiral seam of the pipe can interface with the correct positioning of the stopple nose piece when the seam is at the top of the pipe at the location of the nose piece as shown Figure 15.4 The stopple fitting should be installed in location where the longitudinal seam weld is not at 12 o'clock position.1.
3 15.2 It is mandatory to measure the amount of leakage in the isolated section. Without this differential pressure. it is mandatory to install second isolation or barrier with a bleed connection for combustible or hazardous product. The second isolation could be a balloon. Minor revision.6. For the bleed size.1 15. 3 June 2008 13 September 2009 Revision Summary Major revision. Before conducting any hot work.1. The design package detailing the activities preceding the stopple isolation shall detail all safety measures. mud pack. mechanical plug. Commentary Note: A new OIM "Isolate a Section of a Live Hydrocarbon Pipeline for Section Removal" being developed.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 Commentary Note: SAEP-311 Installation of Hot Tapped and Stopple Connections Stopple is locked in position when a differential pressure is applied across the sealing element.1.2 The maintenance/modification work shall be completed immediately as the pipelines shall not be left on operation against the stopple with an open end or to weld flange and blinded till work is ready for the final tie in. or similar device.6. 15. sealing scraper. the line pressure can exert sufficient force on the insertion equipment to cause the stopple head to retract. 15. A small amount of leakage should be expected. A second isolation with a bleed may be needed based on the leakage rate.6.6 Stopples cannot be guaranteed to seal 100%. Page 24 of 30 .1. The following requirements shall be addressed as a minimum in the design package: 15. SAEP-310 can be used as guideline.1. It is mandatory to continuously purge the isolated section with nitrogen during the cold cut.
Location. Sleeve Ends Line E-E----------Reinf.1 – Ultrasonic Thickness Measurements Hot Tap #_________________ J.O. Sleeve Ends C FLO W A B D E RESPONSIBLE INSPECTION UNIT: INSPECTOR: Page 25 of 30 . A Min:__________ Max. # ________________ Description (Job. from Pt. Line D-D----------Reinf./W. Pad Dia. ______________PLANT #_______________ DWG. etc.) ___________________________________________ Diameter HEADER: _____________ STICKER _____________ Grade ______________ ______________ Schedule _____________ _____________ Flange Rating ____________ ____________ HEADER MEASUREMENTS (CONTINUOUS SCANNING) Point A Min:__________ Circle B Min:__________ Circle C Min:__________ Line D-D Min:__________ Line E-E Min:__________ 180 deg.:_________ Max:__________ Max:__________ Max:__________ Max:__________ Max:__________ STICKER MEASUREMENT Min:__________ Max.:__________ D E LOCATION-------DESCRIPTION Point A------------Branch Center Circle B-----------Branch Diameter Circle C-----------Reinfr.Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Appendix A – Applicable Forms Appendix-A.O.
2 – Form 7627-ENG: Hot Tap/Reinforcement Data and Calculation Sheet Page 26 of 30 .Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Appendix A.
Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Page 27 of 30 .
3 – Form 7235-ENG: Hot Tap Data and Checklist Page 28 of 30 .Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Appendix A.
4 – Hot Tap and Stopple Measurements Form 1/ 2 Page 29 of 30 .Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Appendix A.
4 – Hot Tap and Stopple Measurements Form 2/ 2 Page 30 of 30 .Document Responsibility: Piping Standards Committee Issue Date: 13 September 2009 Next Planned Update: 3 June 2013 SAEP-311 Installation of Hot Tapped and Stopple Connections Appendix A.
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