You are on page 1of 18

PROJECT SPECIFIC PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0

HOT TAPPING PROCEDURE

FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR

PETRA RESOURCES SDN BHD R E 0 V DAT E PREPARED BY REVIEWED APPROVED

PCSB REVIEWED BY NA APPROVED

BY DAT NAM SIG BY DAT NAMESIGN DATE NAM SIG 7/5/ KC HY AI

BY DATE SIG DAT NAME SIG

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 2 of 4

TABLE OF CONTENTS SECTION 1.0 2.0 3.0 4.0 5.0 DESCRIPTION PURPOSE SCOPE 2 REFERENCE 2 DEFINITION 2 PROCEDURE 5.1 Preliminary Site Study/ Inspection 5.2 Site Preparation 5.3 Welding Work 5.4 Non-Destructive Testing 5.5 Pressure Testing 5.6 Drilling 5.7 Reinstatement 6.0 7.0 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

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 3 of 4

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

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

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 4 of 4

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. 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. 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.

5.4

5.5

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:

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 5 of 4

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. 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 Materials against H2S and other Toxic/Hazardous

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:

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 6 of 4

5.13.1 5.13.2 5.13.3 5.13.4

H2S concentration is greater than 10 ppm. Gas release may affect others in the area. Hot tap equipment is larger than 36 inches. 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.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 7 of 4

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-ofroundness 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.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 8 of 4

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.

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.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 9 of 4

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:

Line Temperature 93 deg C to 290 deg C 330 340 Over 290 deg C 037 Commentary Note:

Hydrotest Fluid Turbine Oil

Stock No. 26-00126-001-

Silicone Fluid 200

26-010-

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.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 11 of 4

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. AB036719. 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.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 12 of 4

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.

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.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 13 of 4

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. 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.

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 14 of 4

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 15 of 4

13 Responsibilities 13.1 Hot Tapping Operation Procedure

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 16 of 4

Procedure Review the design drawings and requirements for the branch connection, including an approved welding procedure in accordance with the applicable SAES-W-XXX. Ensure all the requirements of paragraph 3.2 General Requirements" are met. Check that the location of the installation is that location specified by the initiating Engineer with the concurrence of the Operations Supt. Obtain an approved Hot Work Permit, Saudi Aramco Form SA-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 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 section 4 of Form SA-7627ENG have been established prior to any welding. Power wire brush the area for attachment welds to remove all 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 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 good operable condition, including the cutter and coupon retaining device. Confirm that the shop rating test of the hot tap machine is current per para. 3.8.2 Mount the valve on the fitting ensuring that its alignment is within the manufacturer's tolerance

Responsibilities Init. Eng/Insp

Init. Eng/Maint/Constr Opers/Maint/ Constr

Init. Eng/Maint/Constr

Maint/Insp/Constr

Init. Eng/Insp/Maint/Constr/ Opers Maint/Insp/Constr

Insp/Init Eng/Maint/Constr

Hot Tap Unit

Insp/Hot Tap Unit Insp/Hot Tap Unit

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 17 of 4

Close the valve and perform the hydrostatic test according to this instruction.

Maint/Constr/Hot Tap/Insp

Procedure Review the design drawings and requirements for the branch connection, including an approved welding procedure in accordance with the applicable SAES-WXXX.

Responsibilities Init. Eng/Insp

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 machine on the valve. Unit/Maint/ Mount the hot tap Hot Tap 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 the hot tap machine on the tapping After assembly of

HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION

PROCEDURE NO: PSP-KOTI-19 REVISION NO.: 0 Page 18 of 4

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. coupon. 4.11.19 Hot Tap Unit Drill and cut Retract the hot Hot Tap Unit

4.11.20 tap machine boring bar.

4.11.21 Close the valve, purge with nitrogen, if required, and Hot Tap Unit depressurize the hot tap machine adaptor. 4.11.22 tap machine from the line. Remove the hot 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 completed connection is blinded or plugged before leaving the job site. Ensure that the Hot Tap Unit/Insp/ Maint/Constr