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4 Non-Destructive Testing 5.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.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 7.2 Site Preparation 5.3 Welding Work 5.0 DESCRIPTION PURPOSE SCOPE 2 REFERENCE 2 DEFINITION 2 PROCEDURE 5.5 Pressure Testing 5.7 Reinstatement 6.6 Drilling 5.0 3.: 0 Page 2 of 4 TABLE OF CONTENTS SECTION 1.0 4.0 5.0 2.1 Preliminary Site Study/ Inspection 5.

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.1 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.1 Hot tap connections shall be designed and installed to meet all requirements as stated in Para (3) of this procedure 5. 5.3 PTS 31. 2.0 GENERAL REQUIREMENTS 5.01.31 PTS 31.38. Piping and 4.5 ASME B31.2 3.0 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. designed.38.11 PTS 20.0 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.3 3.2 The hot tapping operations are initiated.0 REFERENCE 3.38. 3.4 3.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.01.: 0 Page 3 of 4 1.112 PTS 31.60. and creating an opening in that piping or equipment by drilling or cutting a portion of the piping or equipment within the attached fitting.

5.10 Precautions against electric shock. The Initiating Engineer shall identify the equipment in terms of service.3 PRSB shall appoint an Initiating Engineer. split tee (stopple) and valve crew. 5. QA/QC from both PRSB and PCSB shall verify this. construction/maintenance installation unit. and hot tap machines shall be pressure tested in accordance to Para (3) codes 5. pipe diameter. particularly in cases where the hot tap sticker is not installed in a vertical position.5 5. 5. 5.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. header and branch pressure rating. 5. and material type and notify the Hot Tap. hot tap. due to induced voltage. who shall be made responsible for the overall coordination of the hot tapping activities. 5.8 Hot tap connections are not allowed for certain cases.11 Adequate support of the hot tap machine shall be provided to prevent overstressing of the pipe and/or fitting. and inspection staff cooperate closely during all phases of the hot tapping operations.4 5. This is to ensure that designers.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. unless a detailed design and installation procedure has received prior approval from the both MLNG . The construction units are responsible for ensuring that approved welding procedures and qualified welders are employed. engineering staff.: 0 Page 4 of 4 Superintendent (PCSB & MLNG) and Operations Supervisor/ Superintendent (PCSB & MLNG) for tying in new installations to existing facilities. stopple and valve unit of this information. location. The normal in-line suction screens are not considered adequate for this purpose. operations and/or project management.12 Hot tapping shall not be permitted if: .6 Compressed air piping and equipment shall not be hot tapped nor welded while in service. 5. valves. shall be taken into consideration when installing hot tap connections on above ground pipelines near high voltage power lines.9 All hot tap connections.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.12. or split tee circumferential fillet weld to the toe of the flange circumferential butt weld (or the closest edge of the threaded connection). or other person certified as a gas tester.12. operation and removal of the hot tap machine. 5. to the toe of the nearest girth weld.0 Precautions Materials against H2S and other Toxic/Hazardous 6. 5.2 The standby person or fire watch. 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. 5. and the removal of the piping or pipeline flange bolts. 6. 6.1 within 18 inches of a flange (or threaded connection) as measured from the toe of the reinforcement sleeve.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. 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.1 If a potential exists for a Hydrogen Sulfide (or other Toxic material) release at a work site. shall continuously monitor the work site for the presence of hazardous materials during the work activity using established gas testing procedures.75 inches of a circumferential girth weld seam as measured from the toe of the sticker weld or split tee circumferential fillet weld. 6.2 within 0.13 Existing welds under the hot tap shall be ground smooth prior to fit up of the sticker and reinforcing sleeve.: 0 Page 5 of 4 5.15 Compact steel gate valves with extended body ends shall not be used for hot tap connections. 5. retracting the cutter and closing the tapping valve when any of the following exist: .3 The chamber of the hot tap machine and valve shall be purged with nitrogen after cutting the coupon.

exposed to the burn-thru flame. 6. . Hot tap equipment is larger than 36 inches. the Operation Superintendent should immediately be notified to advise further action.3 5. and other workers who may be in the work area.5 The Operations from PCSB and PRSB should provide written and verbal emergency instructions (including evacuation procedure) to the hot tapping crew. the fire watch personnel shall be clearly instructed that should a burn-thru occur. clothing.13. equipment.1 5. 6. the fire of the gas jetting from the pipe should not be extinguished.13. Fans shall meet the electrical area classification requirements.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.4 H2S concentration is greater than 10 ppm.13. fire watch personnel.. If a burn-thru should occur. However. etc.7 Firewater and extinguishers should be applied as required to workers. Gas release may affect others in the area.6 When welding sour gas or sour crude lines. the air velocity shall not interfere with the welding arc shielding gases. The work is in a confined area. 6. air horns/industrial fans shall be provided to improve air circulation.4 In enclosed or confined areas.13.: 0 Page 6 of 4 5.2 5. 6.

3 The Initiating Engineer shall mark of the exact hot tap locations. to survey the general hot tap location in order to specify and mark the hot tap locations in detail.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.) 8. 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. operations. Tm.e. excavation. ensuring the hot tap locations are at a position where the pipe out-ofroundness does not exceed 3 mm. .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. etc.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.0 Locate and Inspect Hot Tap Position 8. The minimum remaining wall thickness at the weld connection area shall not be below minimum thickness . consisting of himself. and mark the hot tap number alongside each hot tap location.0 Preparation of Hot Tap Specification and Test Calculations 7. and a representative of the Hot Tap and Stoppling crew. and in all cases. 8. the hot tap position shall be relocated after consultation with the Initiating Engineer and the responsible Operations from PCSB and MLNG 8.1 The Initiating Engineer shall make all necessary arrangements for the preparation of hot tapping(i.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. the responsible inspector. pipe inspection. The inspected area shall be permanently marked for future reference and identification.7 If ultrasonic readings indicate a lamination or evidence of hydrogen induced cracking (HIC) damage. location. surface preparation. no less than 5 mm. (Out of roundness criteria only applies to split tee or full encirclement sleeves) 8. 8. The area to be scanned shall include the weld zone and 50 mm each side of it.: 0 Page 7 of 4 7. 8.

3.0 Safety Requirements 9. by the QA/QC.3. and a copy sent to the Area Loss Prevention Office and responsible QA/QC for their review and concurrence prior to starting the installation. 9.1 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. .HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 8 of 4 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.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.2 Written approval of the detailed hot tap installation shall be obtained from the Operations Superintendent. 9.3 All work shall be in strict compliance with MLNG Work Permit System.3.4 Hot Tapping 9.3 Grinding 9.2 Welding 9. prior to each of the following: 9. that it is understood by the person(s) carrying out the work. or higher. The installation package shall be on-site during the entire installation process and verified. The Work Permit shall be approved by the MLNG and PCSB Operations Superintendent. 9.1 Vehicle entry 9.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.1 Pressure test once every four months and overhaul once every 12 months.3 A stamped brass tag shall be affixed to the hot tap machine indicating the test pressure. 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. For a series of consecutive hot taps on a single type of service (i.2. Inspection Department. in accordance with the following criteria: 10. 10. steam. including the hot tap valve and branch connection prior to and after installation.2. 10. The initial pressure testing of the hot tap machine. process stream.1 The Initiating Engineer shall be responsible for ensuring that the pressure tests are performed in accordance with PTS 31.38.2 The hot tap machine shall have an overhaul of its renewable pressure sealing components and be subjected to a shop rated pressure test. 26-00126-001- Silicone Fluid 200 26-010- .e.: 0 Page 9 of 4 10 Pressure Test Requirements 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.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. 10.) the hot tap machine shall be shop tested at the end of the series of hot taps.. overhaul date.10 on the hot tapping equipment. etc. will take place in the shop after the machine has been checked and worn parts replaced. and the name of the testing organization.3 Pneumatic testing of hot tap connections on hot lines over 93 deg C is not permitted unless approved by the Manager. 10.60. 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.

8.: 0 Page 11 of 4 10. During the test.12 After completion of the above tests. 10. 10. test pressure and Inspector's name. a full hydrostatic pressure test shall be applied to the branch connection.8. This pressure will then be reduced to 21 .8 A pneumatic test of 173 kPa (ga) shall be applied to the reinforcing pad or ring after installation. The test pressure shall be the lower value shown in 4.7 After installation of the branch connection.13 The appropriate Inspection Representative shall witness and approve all hydrostatic testing required for completion of the hot tap connection. AB036719. 10.9 Install the hot tap valve and apply another high pressure closure test (seat test) per para. 10.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. install a bar stock plug in the branch connection boss and seal weld. with the valve in the closed position.11 Ensure that the connection is opened.4e on Saudi Aramco Form SA-7627-ENG. A tag shall be attached to the valve indicating test date. At the option of the Inspector.4c or 4. Valves with metal to metal seats shall meet the leakage criteria of API 598. however.8. but prior to installing the reinforcing pad or full encirclement ring.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. A back seat test and low pressure seat test is not required.35 kPa (ga) for a tightness test using a soap solution.6 above.4c or 4. 10. This test pressure shall be the lower value shown in 4.5) 10. mount the hot tap machine and apply another full pressure test per paragraph 3. 3. and applied through the branch connection boss. the MAOP of the line need not be exceeded. 10.4d on Saudi Aramco Form SA-7627-ENG. Dwg.7 above. drained and vented upon completion of hydrostatic testing to prevent possible build up of pressure from any source of heat. the branch connection shall have a blind flange installed and pressure applied through the branch connection boss as shown on Std. Resilient (soft) seat valves shall have zero leakage. (Refer to paragraph 3.10 Return the valve to the open position. . an MT or PT may be applied to the branch connection seal weld.

1 Flow in a line shall be maintained while welding is being performed.2 In systems where hydrocarbon and oxygen mixtures are definitely not a possibility.(e. the following must be satisfied: 11. hot tapping.9.2 Maximum internal pressure of the piping/equipment during welding shall be in accordance with SAES-L-052 paragraph 5. such as flare lines with insufficient or intermittent flow. approval shall be obtained from the General Supervisor / Superintendent Operations Engineering.3. .3. A positive pressure and flow shall be maintained at all times while welding and hot tapping is in progress. 11.2. approval shall be obtained from the responsible Project Manager. Operations shall verify a non-combustible mixture in the line. In certain cases. whichever is less. However.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.3. 11. and testing operations. This steam or gas shall be kept flowing through the line during the entire welding operation.2. 11. 11. the line shall be purged with steam. inert gas. and the Operations Superintendent. unless approved otherwise by the Operations Superintendent. 11.1 For new construction tie-ins to existing lines..3 The minimum flow rates per para. 3.2. shall be maintained during all welding operations. or hydrocarbon gas.g. General Supervisor / Superintendent Operations Engineering. and the Operations Superintendent.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.4 or the maximum attainable flow under normal working pressure. sea water injection lines).3. 11.3.2 For normal maintenance tie-ins to existing systems not involving new construction.3 Prior to and during any welding.: 0 Page 12 of 4 11 Operating Conditions Requirements 11. This shall be stated in the remarks section of the Work Permit.3 on welding of pipelines under pressure. to weld with "NO-FLOW" conditions. flow is not required.

if deemed necessary by the Operations Superintendent. 12.1 Verify a CSD approved welding procedure specification is utilized for installation of the connection. (Refer Para.3. .10 m/sec maximum. 12.: 0 Page 13 of 4 11.3 The Inspector shall perform the following: 12.3. 12. However. 3.2 The Operations Superintendent shall ensure compliance with the safety precautions arranged under paragraph 3.2 and 3.3. then the minimum values do not apply but a positive flow shall be maintained.5 Work shall be immediately stopped when constant flow and pressure as noted in paragraphs 3.40 m/sec minimum and 9. before and during the installation. pressure.9. While hot tap work and pressure testing is in progress. including acceptance of the work permit. Pressure testing shall also stop if pressure in the header/ equipment is lost. the operator shall remain in a location where he can control operating conditions such as flow.9.4 Verify that a calibrated pressure gauge and relief valve are properly installed for testing.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. 11. 12. for compliance with the approved drawings and welding procedures.3. An additional operator shall standby at the job site while the work is in progress.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. Continuous radio communications between the job site operator and the Control Room is required.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.3.3 Inspect the branch connection/split tee. and liquid level within the limits specified in the hot tap design information.3 cannot be maintained during the welding and hot tapping operations. if the branch connection size is less than 50% of the size of the line being hot tapped. 12.4 Maximum and minimum flow rates during hot tapping shall be 0.5.1 The Initiating Engineer shall coordinate all activities.9). 12.2 Verify that 3.9 of this SAEP. 12 Hot Tap Fittings/Sandwich Valve Installation Requirements 12.


1 Hot Tapping Operation Procedure .: 0 Page 15 of 4 13 Responsibilities 13.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.

7. Power wire brush the area for attachment welds to remove all traces of paint.6. Ensure all the requirements of paragraph 3. The Inspection Unit will verify proper weld joint fit-up.: 0 Page 16 of 4 Procedure Review the design drawings and requirements for the branch connection. Eng/Insp Init. including the cutter and coupon retaining device. Eng/Insp/Maint/Constr/ Opers Maint/Insp/Constr Insp/Init Eng/Maint/Constr Hot Tap Unit Insp/Hot Tap Unit Insp/Hot Tap Unit . or his designee. Confirm that the shop rating test of the hot tap machine is current per para. Obtain an approved Hot Work Permit. prior to starting with work.5. The cutters sometimes break if the cut is made through a weld.2 Mount the valve on the fitting ensuring that its alignment is within the manufacturer's tolerance Responsibilities Init. 3. rust and scale. Ensure the pressure and flow requirements as identified in section 4 of Form SA-7627ENG have been established prior to any welding.3) from the Operations Superintendent. 3. Precheck the tapping valve and the hot tap machine to assure good operable condition.8. using a qualified welder and a CSD approved welding procedure.2 General Requirements" are met. Check pipe wall thickness ensuring it does not violate para. 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. 3. 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. Eng/Maint/Constr Opers/Maint/ Constr Init. including an approved welding procedure in accordance with the applicable SAES-W-XXX. grind seam weld flush with the surface of the pipe taking care not to reduce the pipe wall thickness. If long seam is under hot tap fitting. 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. Eng/Maint/Constr Maint/Insp/Constr Init.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.

11.14 machine on the valve. Unit/Maint/ Mount the hot tap Hot Tap Constr 4. and welded connection in Maint/Constr with the testing procedure specified in this SAEP and SAES-L-052.16 Apply hydrostatic and pneumatic pressure tests to the Hot Tap Unit/Insp/ hot tap machine. This may require grinding of the lugs on the valve seat rings to provide adequate clearance.11.11. including an approved welding procedure in accordance with the applicable SAES-WXXX. Eng/Insp 4. 4. Responsibilities Init. Refer to paragraph 3.17 Install and seal weld a threaded plug in the weld boss Maint/Constr on the connection after all testing has been completed. 4.15 Ensure that the tapping valve is tested in accordance Hot Tap Unit/Insp with paragraph 3. 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. and will easily pass the hot tap cutter. Maint/Constr/Hot Tap/Insp Procedure Review the design drawings and requirements for the branch connection. valve.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. paragraph 5. 4.8.18 the hot tap machine on the tapping After assembly of .: 0 Page 17 of 4 Close the valve and perform the hydrostatic test according to this instruction.11.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.12 4.

18.: 0 Page 18 of 4 valve and before the tapping operation is started: 4.11. 4.20 tap machine boring bar.11.25 completed connection is blinded or plugged before leaving the job site.11. 4. 4. coupon.11. if required.11.22 tap machine from the line. and Hot Tap Unit depressurize the hot tap machine adaptor. and that the cutter can be withdrawn a sufficient distance to permit closure of the valve. 4. Ensure that the Hot Tap Unit/Insp/ Maint/Constr .11.21 Close the valve. 4.24 The coupon shall be removed only by the Operations Opers Supervisor and forwarded to the responsible Operations Inspection Unit. 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.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. purge with nitrogen.18.19 Hot Tap Unit Drill and cut Retract the hot Hot Tap Unit 4. Remove the hot Hot Tap Unit/ Maint/Constr 4. 4.23 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.1 Completely close and then completely open Hot Tap Unit valve to ensure that it Is operable.