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T.D.

WILLIAMSON ASIA PACIFIC







METHODOLOGY / SEQUENCE OF OPERATION
FOR

12 HOTTAP



0 16 Aug
2010
Issued for information Rakhesh Shetty Lee Boon Hau Lee Boon Hau -
REV DATE REASON FOR ISSUE PREPARED CHECKED APPROVED APPROVED

DISCIPLINE
COORDINATOR
DISCIPLINE
MANAGER
DISCIPLINE
MANAGER
QA
CLIENT APPROVAL:

PROJECT NUMBER: SYSTEM NO: FILE REF:
THIS DOCUMENT IS THE PROPERTY OF TDW
PIPELINE CLEANING SERVICES.
PROJECT
No.
PLANT
IDENTIFIER
DOC TYPE
CODE
DISC
CODE
SEQUENCE
NUMBER
REVISION
IT IS NOT TO BE COPIED NOR SHOWN TO A THIRD
PARTY WITHOUT THE PRIOR CONSENT.

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METHODOLOGY / METHOD STATEMENT
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TDW HOT TAPPING PROCEDURES


Only certified, experienced HT&P Specialists from TDW or TDWAP, certified by
TDW are allowed to do hottaps jobs for TDWAP/TDW, using TDW made tapping
equipment.
These procedures apply to use of TDW manufactured tapping equipment and
accessories, recommended to be used for hottap on live lines. TDW does not
guarantee the applicability of these procedures with non TDW tapping equipment.
Use by non HT&P specialist, or personnel who have no knowledge of hottapping
do it at own risk and own responsibility. TDW /TDWAP disclaim all liabilities from
the improper use of these procedures by unauthorised personnel, non TDW
personnel and HT &P specialists.


Pre-Mobilisation Preparation of TDW hottap equipment @ TDWAP Spore
prior to any job:

a. Checking, confirmation & selection of all necessary Hottap equipment &
accessories required for the job, taking into the consideration of the
Space allowance for Machine set-up clearance, machine travel and
machine capability in accordance to the Hottap Data Sheet(S) to be
furnished by Customer .

b. Pressure testing of Hottapping machine.

c. Meet with Customer
i. Obtain and review hottap data sheet filled up by customer.
Discuss job with maintenance, operation and safety personnel to
assure complete understanding of what is to be accomplished and
how.
ii. Obtain Pipeline condition:

A. Product
B. Pressure
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METHODOLOGY / METHOD STATEMENT
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c. Temperature
D. Pipe Material
E. Pipe Schedule
F. Flow Rate in M/s
G. Main Line Size in inches
H. Tap Size in inches
I. Flange Rating

iii. Verify line contents, pressure, temperature, flow rate and pipe wall
thickness.
iv. Discuss what items will be needed to complete job: gasoline, oil,
grease, rags, wrenches, lifting equipment, supervised labor,
gaskets, bolts, scaffolds, support for pipe, valve and tapping
machine, etc
v. Fitting furnish by customer are to be welded onto the main line
and tested to the approval of all parties according to customer's
welding specification and all welding must undergo 100% X -ray /
NDT according to customer requirement , if applicable , prior to
commencement of Hottap. (Perform by customer).
vi. Pre-tested full bore ANSI RF isolation valve must be installed onto
branch fitting and pressure tested on both ends according to
customer requirement prior to mobilization of equipment and
arrival of technician (perform by customer)



EQUIPMENT
Company to supply
- All equipment and tools, labor, cranes, gaskets, permits, etc, required for installation
of fittings and WIC (TDW) service equipment.
- All equipment and tools required for providing dry work environment.
- Support for fittings and equipment.
- All fuel, hyd oils, air supply for HOT TAP operations.



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METHODOLOGY / METHOD STATEMENT
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FITTINGS & OTHER SITE EQUIPMENT
To be furnished by Customer:
1. 1 pieces of 12X12 Hottap fitting-150# RF

Site Equipment and Others briefly are but not limited to the following:
1. Heavy duty hydraulic cranes, lifting gears, with certified operator
2. Excavation shall be provided with proper & adequate shoring,
sandbags, and working pumps to keep the pit dry
3. Welding equipment and accessories
4. Qualified and experienced welders and NDT personnel.
5. Nitrogen supply, Air compressor, c/w hoses , connections
6. Supervised labor , c/w pipe wrenches, tools,
7. Blind flanges, studs, nuts, gaskets
8. Safety personnel, safety equipment, fire extinguisher.
9. Scaffolding & working platform
10. Support for the machine.


TDWAP
- All necessary HOT TAPPING equipment.
- On-site coordination from one (1) technician in installing, mounting, dismounting,
and loading of TDWAP services equipment.
- On-site operation of all TDW Services equipment.

Equipment List for Hottap Operations Furnished by TDWAP:
- 1 ea 760 Tapping machine
- 1 ea Hydraulic Power Unit
- 1 ea 12- RF Tapping machine Adapter
- 2 ea 12 Cutter (11-1/2 OD) c/w cutter holder
- 2 ea bleeder valves
- Spare parts for tapping machine




TD Williamson Asia Pacific


METHODOLOGY / METHOD STATEMENT
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1. Equipment arrived on site on the day of job commencement (all transfer within
the job site location, lifting, loading/unloading, docs, etc to be handled by
CUSTOMER) prior to job start.

2. Check 12 Tapping Valve ( Full bore isolation Valve)
A. Check valve bore and nipple for alignment.
B. Check flange makeup for bolts and tightened bolts.
C. Check to make sure valve will open and close properly.
D. Measure valve bore for sufficient cutter clearance. Check nesting space in
valve. Face of valve to seat rings.

3. Assemble TDW Tapping Machine
A. Install the correct TDW TM adapter on tapping machine.
B. Install the correct TDW cutter holder in boring bar
C. Check cutter & install correct cutter on cutter holder.
D. Check the appropriate u-rods, insertip drill, in pilot.
E. Retract boring bar and TDW cutter all the way.
F. Take required tapping measurements and enter in the appropriate blanks
(refer to Figure 1 below)















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METHODOLOGY / METHOD STATEMENT
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4. Install TDW Tapping Machine on Tapping Valve
A. Clean Flange faces.
B. Install spiral wound gasket.
C. Install the appropriate TDW tapping machine on valve.
D. Align bolt holes of flange and Install bolts and tighten.
E. Extend boring bar until pilot contacts pipe and retract.
F. Install TDW measuring rod and mark measurements.
G. If fitting has not been pressure-tested, suggest to customer to test before
starting tap.






5. Perform leak test of machine assembly & Operational check
A. Pack Nitrogen into machine set-up to displace any possible pressure of air
in between tapping machine, adapter, valve and fitting and pressure test
(Leak test) assembly to customer specification to ensure bubble tight seal
on all bolted connections prior to any hottapping. ( Leak Test pressure As
per customer suggestion, hoses & fitting provided by customer)
B. Use soap solution to determine bubble tight seal on all flange connection.
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METHODOLOGY / METHOD STATEMENT
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C. Extend and retract boring bar with cutter to obtain smooth passage through
isolation valve and fitting until touches pipe surface.

6. Begin Hottapping
A. Secure/check for proper permits and approvals from customer prior to hot
tap work.
B. Start TDW power unit
C. Open valve on TDW tapping machine and rotate TDW cutter slowly.
D. When pilot penetrates pipe and air is purged from valve and adapter, close
bleeder valve.
E. Continue tapping till complete and coupon (where apply) is free.
















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METHODOLOGY / METHOD STATEMENT
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7. Complete Tap
A. Upon completion, cutter retrieve into the housing adapter and stop TDW
power unit
B. Close isolation valve.
C. Bleed off pressure from tapping machine until atmospheric pressure.

Note: Customer is to ensure the availability of all necessary facilities/method for
product disposal and responsible for the proper disposal of such.


























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METHODOLOGY / METHOD STATEMENT
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8. Remove TDW Tapping Machine from Tapping Valve
A. Remove coupon from cutter and give to customer.
B. Repackage all TDW equipment properly and securely for return shipment.


















9. Customer to always ensure and provide a safe, secured storage, warehouse, for
the equipment to prevent misuse, accidental damage, etc.

NB; Customer is to provide the necessary supervised labor with hand
tools/wrenches, crane, mounting /dismounting, handling equipment, testing
equipment, N2 bottles, site access, scaffolding, shoring, transport, heli-transfers ( for
offshore site),barges, supply/work boats, work permits, safety equipment, safety
personnel, product disposal facilities, etc.

***** END *****