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Hot Tap Execution Plan & Procedure

As per KN Scope
Document Title Execution Plan / Procedure for
6" N.B HOT TAP ONTO A PIPELINE STANDARD [perpindicular / square to pipeline]

[welded fittings on-shore location]

Document Ref. No. : HT-ExP 22487B - 1

GS Engineering & Construction (GS E&C)


Client : G.S. Engineering

Client Ref No : 1802-PI-2-B-024-15

Site / Installation : KNPC MAA CFP-MAA Project

Project Title : Hot tapping and Cold tapping works - CFP Project

Job Description : 6 X 10 150# Hot Tap As Per KN Scope


Tie-In No. : CF0-11-032 & CFP-011-033

select select select select select select


select select select select select select
select select select select select select
select select select select select select
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select select select select select select
select select select select select select
select select select select select select
select select select select select select
1 31-Aug-16 Issued for Approval SG select select
0 24-Aug-16 Issued for Approval SG SG select
Rev No Date Description Prepared Approved Approved
(HT) (HT) (Client)

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Table of Content

1.0 General ....................................................................................................................................................... 3


2.0 Work Scope Details ...................................................................................................................................... 4
2.1 Work Scope 1 CFP-011-032 ............................................................................................................................................. 4

2.2 Work Scope 2 CFP-011-033 ............................................................................................................................................. 5

3.0 Key Activities & Responsibilities .................................................................................................................... 6


4.0 Safety Check List ......................................................................................................................................... 9
5.0 Risk Assessment ........................................................................................................................................ 11
6.0 Hot Tapping & Welding Checklist ................................................................................................................ 22
7.0 Pre-Mobilisation Checks .............................................................................................................................. 27
8.0 Site Hot Tap Procedure .............................................................................................................................. 30
9.0 Site Dimension Data Sheet Drilling ........................................................................................................... 36
10.0 Job Completion Certificate .......................................................................................................................... 37
11.0 Site Notes ................................................................................................................................................. 38
APPENDIX 1 Equipment Data Sheet ................................................................................................................... 39

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1.0 General

1.1 Introduction
1.1.1 This document represent an execution plan to define a method to safely complete the work scope, identify
the hazards & identify the responsibility of each party(ies) involved in the operation detailed below

1.2 Applicable Codes & Specifications


1.2.1 API 2201 - Procedure for Welding or Hot Tapping on Equipment in Service
1.2.2 Shell DEP 31.38.60.10:2006 - Gen Hot-Tapping on Pipelines, Piping and Equipment
1.2.3 ASME B31.3 - Process Piping

1.3 Abbreviations
1.3.1 Client : Kuwait National Petroleum Company (KNPC)
1.3.2 Contractor : GS Engineering (GS) Kharafi National/Hydratight
1.3.3 Sub-Contractor : Hydratight (HT)
1.3.4 PPE Personal Protective Equipment
1.3.5 ITP : Inspection Test Plan
1.3.6 PTW : Permit to work
1.3.7 WPS : Welding Procedure Specification
1.3.8 NDT : Non-Destructive Testing
1.3.9 JSA : Job Safety Analysis

1.4 Definitions
1.4.1 Hot Tap Performer Hydratight
1.4.2 Drilling Machine A pressure retaining machine (sometimes known as a hot tap machine), used to
cut new access points in a live pressure system, without loss of integrity.
1.4.3 Tapping Valve A valve (typically Ball or Gate), fitted above the Hot Tap Fitting, used to
isolate the line medium.
1.4.4 Vent Valve A small valve fitted to the drilling machine to allow pressure to be introduced (for
pressure testing, etc) or vented (evacuation of residual pressure after drilling
operations).
1.4.5 Hot Tap Fitting A pressure vessel installed onto the existing pipeline (typically full encirclement or
weld-o-let design
1.4.6 Coupon The disk shaped section removed from the pipeline during drilling operations.
1.4.7 Power Source Compressor or Hydraulic Power Pack used to drive Drilling Machine.

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2.0 Work Scope Details To be modified As per KN Scope

2.1 Work Scope 1 CFP-011-032

Tie-In Number : CFP-011-032


W.O Ref No : TBA

Branch Details
Size : 6" N.B
Orientation : Vertical Up (see Fig 1)
Angle : Straight (see Fig 2)
Position : Square (see Fig 3)
Joint class : 150#
Joint type : R.F

Run Pipe Details


Size : 10"n.b
Material type : Carbon Steel
Material specification : A106-B
Orientation : Horizontal
Thickness / Sch : Sch. 20

Operating Parameters
Line medium : Cooling Water
Design pressure : 100 psig
Max. pressure during tap : 35 psig
Design temperature : 165 Fahrenheit (F)
Max. temperature during tap : 105 Fahrenheit (F)
H2S % inside line : 0%
Max Velocity during tap : 5 meters / second (liquid line)

Fitting
Fitting type : Full encirclement hot tap tee
Pigging bars required : No

Tapping Valve
Type : Gate

Tapping Equipment
Machine type : T660 (2" to 12" taps)
Cutter size / type : 6" n.b - 5.469" (138mm) o/d Hole Saw, with coupon catcher

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2.2 Work Scope 2 CFP-011-033

Tie-In Number : CFP-011-033


W.O Ref No : TBA

Branch Details
Size : 6" N.B
Orientation : Vertical Up (see Fig 1)
Angle : Straight (see Fig 2)
Position : Square (see Fig 3)
Joint class : 150#
Joint type : R.F

Run Pipe Details


Size : 10"n.b
Material type : Carbon Steel
Material specification : A106-B
Orientation : Horizontal
Thickness / Sch : Sch. 20

Operating Parameters
Line medium : Cooling Water
Design pressure : 100 psig
Max. pressure during tap : 55 psig
Design temperature : 165 Fahrenheit (F)
Max. temperature during tap : 95 Fahrenheit (F)
H2S % inside line : 0%
Max Velocity during tap : 5 meters / second (liquid line)

Fitting
Fitting type : Full encirclement hot tap tee
Pigging bars required : No

Tapping Valve
Type : Gate

Tapping Equipment
Machine type : T660 (2" to 12" taps)
Cutter size / type : 6" n.b - 5.469" (138mm) o/d Hole Saw, with coupon catcher

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3.0 Key Activities & Responsibilities

3.1 Pre-Start Operational Check List


Responsibility

3.1.1 Site Inductions


Site inductions and passes for personnel & equipment, as required. GS
3.1.2 Permits / End Client Approvals
Obtain all work permits, and any approvals which may be required. GS
3.1.3 Safety Equipment
All safety requirements, including fire extinguishers, BA sets, gas monitors, as required. GS
3.1.4 Compressed Air
Compressed air supply to within 2 meters of the workplace (90psi @ 105cfm). GS
3.1.5 Pressure Test Medium
Test medium to leak test fittings & service equipment during execution of the work GS
scope.
3.1.6 Hot Tap Fitting
Supply of hot tap fitting GS
3.1.7 Tapping Valve
Supply of tapping valve GS
3.1.8 Drilling Equipment
Supply of drilling (hot tap) equipment HT
3.1.9 New Pipe Work
All work and testing associated with the installation of any new piping equipment GS
separately required.
3.1.10 Welding Equipment
Supply of welding equipment & associated consumables GS
3.1.11 Cranage / Lifting
Supply of lifting equipment and qualified personnel as required. GS
3.1.12 Support Personnel
To provide a minimum of 2 suitably qualified personnel to assist with general fit up of GS
the hot tap equipment.
3.1.13 Pipeline Support
Adequate support for piping and equipment, commensurate with individual maximum GS
weights of combined fitting and service equipment.
3.1.14 Excavation / Civil Works
Excavation of the pipeline (where applicable). GS
3.1.15 Scaffolding
Provide safe access & egress to and from the work area for personnel (Scaffolding, GS
Ladders, safety harness, etc) based on the project safety policies /requirements
3.1.16 Run Pipe Coating Removal & Surface Cleaning
To remove the external coating of proposed pipeline (where applicable) extending up to GS
200 mm either side of the hot tap fitting location.
3.1.17 Run Pipe Defect Checks / Inspection

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To check for the presence of laps, cracks, pitting, laminations, and other defects signs GS
that may interfere with the welding and hot tap operations. Positive confirmation of wall
thickness shall be obtained over the complete circumference of the pipe at these
locations. If the thickness measure is less than 4.8 mm (or the minimum pipeline wall
thickness specified by the client), at any location over the pipe circumference covered by
the fittings; such locations shall not be used for the welded fittings.
3.1.18 Hot Tap Location Acceptance GS / KNPC
To accept the proposed location fit for installation of the hot tap fitting, and subsequent
hot tap operation.
3.1.19 Calculations prior to Welding
Provide all related calculations like burn through calculations, taking into account GS / KNPC
Maximum allowable internal pressure, flowrate, and temperature during welding.
3.1.20 Stimulation Test GS
To Conduct stimulation test (If applicable)in accordance with I &
C Proc No : IC-18 Rev 02
3.1.21 Create a Job Specific WPS/PQR GS
To prepare a job specific WPS/PQR and qualify welders in accordance with I & C Proc
No : IC-18 Rev 02 Maintain & monitor the preheat & inter-pass temperature as per
specification throughout the welding process
3.1.22 Pipe Support GS
To provide adequate support for piping and equipment during tapping operation,
commensurate with individual maximum weights of combined fitting and service
equipment.
3.1.23 Installation / Welding of Hot Tap Fitting GS
To provide all welding equipment, consumables & manpower to safely weld the fittings
to the run pipe, inclusive of NDE inspection.
3.1.24 Calculations prior to Pressure Testing GS
To prepare buckling calculations to determine the maximum allowable pressure on
pipeline, when pressure testing the hot tap fitting.
Prepare buckling calculations to determine the maximum allowable pressure on
pipeline, when pressure testing the hot tap fitting.
3.1.25 Pressure Test of Hot Tap Fitting GS
To provide conduct the pressure testing of the hot tap fitting, on completion of the
installation and subsequent NDE testing.
3.1.26 Controlled Bolt Tightening Equipment GS
To provide bolting equipment required for tightening of drilling machine, tapping valve,
etc.
3.1.27 Installation of Tapping Valve GS
To install tapping valve, tightening of the connections, and subsequent pressure testing
3.1.28 Installation of Drilling Machine GS / HT
To install drilling machine, tightening of the connections.
3.1.29 Medium for Leak Testing of Drilling Machine GS
To provide nitrogen for leak testing of the hot tap machine
3.1.30 Pressure Testing of Hot Tap Equipment GS
To conduct leak test of service equipment once it has been installed on the tapping valve

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before and during execution of the work scope


3.1.31 Operation of Tapping Valve HT
To open and close all tapping valves
3.1.32 Drainage, Venting & Purging GS
Safe drainage, venting and purging facilities, including capture of pipeline product and
storage of purging element, as required for all equipment during mounting and
dismantling.
3.1.33 Removal of Drilling Machine GS
To unbolt drilling machine, lift and remove to machine to safe area.
3.1.34 Post Tapping Tie-Ins. GS
Complete the installation of any tie-in pipe work, blind flanges, etc, on completion of the
tapping operation.

Note: Activities & responsibilities shall be discussed & confirmed with KNPC and GS, prior to the execution
of the work scope.

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4.0 Safety Check List

4.1 Pre-Start Safety Check List


Responsibility Review
Authorize

4.1.1 Consent from the client with respect to location & alignment. GS KNPC
4.1.2 Welding Procedure specification (WPS) and procedure qualification GS KNPC
(PQR) shall be prepared by contractor and approved by client.
4.1.3 Test Certificates of hot tap fitting to be approved. GS KNPC
4.1.4 Welders qualified for welding in according to approved WPS. GS KNPC
4.1.5 Overall method statement for the job. GS / HT KNPC
4.1.6 Location of hot tap fitting welding selected taking into consideration GS KNPC
possibilities of ovality, weld seams, lamination and wall thickness of
the run pipe (UT Survey).
4.1.7 Proper support for the section of the pipeline where welding / hot GS KNPC
tapping is to be executed, including necessary calculations.
4.1.8 Hot tap fitting installed and clamped, contour to match with run pipe. GS KNPC
Level of branch opening checked to ensure perfect square to run
pipe.
4.1.9 Pressure & flow calculations submitted and approved for safe welding GS KNPC
of the fitting.
Pressure and flow in pipe during welding shall be maintained
according to relevant standards.
Minimum flow required for gaseous services for safe welding is 0.5
m/s, No flow or intermittent flow lines should be purged with
nitrogen at 0.4 m/s during welding.
4.1.10 If run pipe is cathodic protected, the CP to be switched off a GS KNPC
minimum of 48 Hours prior to welding.
4.1.11 Pressure and flow in pipe shall be maintained according to approved GS KNPC
method statement.
4.1.12 Adequate safety and fire protection equipment to be available at site. GS KNPC
4.1.13 Pre-Start Risk assessment sheet (for welding) to be produced and GS KNPC
approved.
4.1.14 Pre-Start Risk assessment sheet (for hot tap) to be produced and GS / HT KNPC
approved.
4.1.15 PTW to be completed, signed and agreed on all requests before any GS KNPC
job commences.
4.1.16 No of personnel at site to be limited to the minimum required. GS / HT KNPC
4.1.17 Vehicle present during executing of the job, (equipped with first aid GS KNPC
kit, radio and its charger) (for remote locations only)
4.1.18 Qualified Fire-fighters shall be present and confirmed ahead of work. GS KNPC
4.1.19 All personnel should always stay upwind from the welding location. GS / HT KNPC
Wind socks to be available.
4.1.20 Gas test to be performed frequently or as required. GS KNPC
Portable gas monitors to be available to give immediate warning.

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4.1.21 Approval taken to work after day light, if work hours to be extended. GS KNPC
4.1.22 Written operation emergency action shall be provided in case of GS KNPC
emergency (drawing to be attached).
4.1.23 Communication shall be established between the site, operations, GS KNPC
safety, & the central control room.
4.1.24 Welding sequence followed as per approved PQR GS KNPC
(Approved PQR/WPS to be available at site).
4.1.25 NDT testing of the weld joints. GS KNPC
4.1.26 Hydrostatic testing of the tapping valve for its seat tightness and GS KNPC
body. After testing, a suitable dust cover should be installed to
prevent any ingress of dust or contaminants, until such times as the
tapping valve is installed at site.
4.1.27 Installation of tapping valve after approval. GS KNPC
4.1.28 Pressure testing of attachment welding up to the tapping valve. GS KNPC
4.1.29 Drilling machine tested before commencing drilling for the following: HT KNPC
- Valid Pre-dispatch [from Hydratight Service Centre] Pressure Test
Certificate for drilling machine and cutter housing
- Check assembly of all parts including cutter and pilot drill.
- Check Drive System of drilling machine and presence of coupon
catcher.
- Ensure all the accessories are available including handle, etc
4.1.30 Installation of drilling machine and leak test done on the drilling HT KNPC
machine.
4.1.31 Adjustment of cutter travel to cut only top wall thickness HT KNPC
4.1.32 Check final assembly of the tapping valve HT KNPC
4.1.33 Start drilling operations HT KNPC
4.1.34 Retrieving of cutter after drilling operations and then closing the HT KNPC
tapping valve.
4.1.35 Removal of drilling machine after decompressing the area above the GS / HT KNPC
tapping valve
4.1.36 Deliver coupon to clients representative to carry out any examination HT KNPC
(e.g, thickness checks) as required.
4.1.37 Re-instalment of Cathodic Protection (as required) GS KNPC
4.1.38 Recoating of exposed Pipe (as required) GS KNPC
4.1.39 Holiday detection of the coated area (as required) GS KNPC

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5.0 Risk Assessment

5.1 Scope
5.1.1 This risk assessment considers the typical activities associated with Hot Tap operations on a variety of
clients plants and construction sites.
5.1.2 In all operations conducted by Hydratight, a pre-start / job specific risk assessment will be carried out in
partnership with the client to identify site-specific risks and implement mitigating safety measures where
necessary.

5.2 Operations Personnel


5.2.1 Hot Tapping is a specialist skill. Only operatives trained and competent in the use of this equipment for
the specific project shall carry out these activities.
5.2.2 This Execution Plan applies to personnel who hold Hydratight level 1 competence status; personnel who
have S1 or S2 approval can only work under the supervision of personnel holding level 1 status.

5.3 Background to the Risk Assessment


5.3.1 Detailed Execution Plans / Procedures are prepared and issued to personnel covering all aspects of Hot
Tapping. The provisions identified in this risk assessment are detailed in these instructions.

5.4 Risk Assessments Summary


5.4.1 The risk assessment is contained in the attached schedule.
5.4.2 Pre-work risk assessment must be completed [at site] and in conjunction with the client.

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5.5 Risk Assessment

Location MMA MAB SHU LM OTHER Ref. No: SRA-2016-0078

Department / Division Projects/MAA/CFP/0054 Date:


Area/ Unit AREA: 1 UNIT : 11 (Tie-In Package CFP-U11-SOO9) Review Date (see note-4)

Description of Activity Hot Tapping of 6 line to existing 10 header line Estimated Number of Persons Likely to Operation
Existing Line: CWR-75-3361-L1-10 be exposed Maintenance
Tie-in job: CFP-011-032 Contractors
Process: COOLING WATER RETURN HSE
Others
No Hazard Likelihood Severity Risk Mitigation (Precautions taken) Consider KNPC Standards / Codes / Practices Likelihood Severity Residual Risk

Working on site a. Site induction course highlights the hazard and restates risks even for those
General hazards associated whist experienced in site work.
working on clients site. b. Personnel to wear standard PPE, including:-
Safety helmet approved to BS EN 397:1995
Eye protection approved to BS EN 166:2002
Fire retardant coveralls.
Non slip safety footwear, c/w internal steel toecap.
c. Cut resistant safety gloves to 3111 EN388
d. Site procedures shall ensure industry best-practice.
e. Toolbox talk prior to commencement of work in conjunction with client and
all personnel involved directly or indirectly with the operation.
f. Obtain appropriate work permit and authorization. Ensure related
documents are attached
g. Do the test for flammable and toxic gases expected from nearby unit and
allow people work only if the readings are well within limits.
h. Each individual shall be provided with valid H2S monitor.
i. Carry out gas test using multi-gas detector by authorized gas tester and
continue periodically as per site requirement and record it. Contractor key

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personnel shall carry a multi-gas monitor permanently on site.


j. All employees shall be aware of adjacent plant emergencies, wind socks,
transfer points and evacuation route.
k. Hazards and KNPC emergency numbers 23881111 and 888 shall be
discussed in Toolbox meeting and as per the activities performed.
l. Contractor supervisor shall be present with radio or intrinsically safe mobile
and stand by vehicle to manage site medical emergency.
m. Dont block emergency services such as fire hydrant, Fire alarm,
evacuations routes, transfer point etc.
n. Adequate protection of existing facilities must be provided by contractor.
Working on site a. Good housekeeping.
Slip, Trips & Falls
Poor housekeeping a. Site supervisor should ensure that the site is clean prior to start of job.
Proper housekeeping shall been done during and after the activity before
closing the work permit.
b. Unwanted materials shall be removed from site and the waste produced
from fabrication work shall be identified stacked and segregated before
disposal.
Working at height a. Adequate barriers in place around the work area to prevent falls.
Scaffolding Collapse b. all scaffolding structure must be inspected by a competent scaffold
Personnel Fall inspector approved by the company and he shall install GREEN TAG prior to
Material Fall approach and use of the scaffolding.
Tool Fall c. Full body harness with double lanyard shall be worn by all workers, 100%
Line of fire/Drop area tied off with anchoring point. All workforces shall be trained in Work at
Height.
d. Do not overload working platform and avoid stacking materials more than
the specified bearing capacity or general purpose mentioned in the GREEN
TAG.
e. A 3-point contact shall be maintained while ascending/ descending from a
ladder.
f. Use tool bag or bucket to secure hand tools at height. Do not leave or place
hand tools unsecured in an open side of the working platform.
Scaffolding/ a. Specialist personnel shall erect all temporary access/scaffolding etc.
Working Platforms / Ladders b. All temporary access/scaffolding to be properly inspected and maintained
Inadequate temporary platforms (e.g. Scaftag System)
c. Only Specialist personnel may make modifications.
d. Close off any opening on platform or scaffolding.
e. Fall arrester to be worn when working deemed necessary.
f. Check the platform, hand rails, scaffolding and access.

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g. Install sign below Men Working Above.


Scaffolding/ a. As Above
Working Platforms / Ladders
Restricted working access
Noise a. Ear protection approved to BS EN 352-2:2002 (minimum)
Noise greater than 80db. b. If noise is measured above 95 dB(A) ear plugs and ear muffs must be worn
Use of compressed air a. Hoses & fittings manufacture to international standard
Failure of hoses & fittings b. Pressure test of hoses & fittings prior to mobilisation.
c. Maximum air pressure is regulated at source
d. Safety relief device installed at source
e. Visual inspection of air hoses & fittings prior to use.
f. Whip checks on all air hose connections
g. Safety pins installed on all connections.
Use of hydraulic equipment a. Hoses & fittings manufactured to international standard.
Failure of hoses & fittings b. Pressure test of hoses & fittings prior to mobilisation.
c. Safety relief device installed at pressure source.
d. Maximum hydraulic pressure is regulated at source.
e. Whip checks on all hydraulic hose connections.
Lifting & handling a. Personnel to wear approved non slip safety footwear, c/w internal steel
Dropping equipment parts on feet toecap.

Lifting & handling a. Equipment in excess of 25kg has suitable lifting eyes fitted.
Muscular strain injury resulting b. Limit manual lifts up to 25kg or shared lifts.
from lifting and pulling during c. Where necessary specialised riggers must be provided.
loading/unloading and d. Use of approved lifting procedure
transportation to the work area e. Using certified lifting gear
f. Use of certified rigger
g. Soil & floor condition should be confirmed prior to setting of crane
Damage to property or personal h. The location where lifting activities are carried out should be properly
injury barricaded and appropriate sign board should be placed
i. No lifting activity should be carried out during high wind or low visibility
periods
j. Proper lifting plan should be prepared considering load charts, working
radius 75% of SWL etc.
k. All rigging tools should be with proper colour coding, crane operator should
be qualified and certified
l. The machine/ equipment should be secured with chain block during lifting
& operation
m. Limit manual lifts up to 25kg or shared lifts. If excessive, then use crane
age.

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Use of substances a. Refer MSD sheets for specific instructions


Exposure to Hydraulic Oil & b. Proper PPE to be used
lubricants c. Proper storing & handling practices to be followed

Discharge of process medium a. Products other than air, steam or water shall be subject to the Hydratight
Exposure to line medium Chem-Check procedure, to identify additional PPE requirements.
b. Refer MSD sheets for specific instructions
Discharge of process medium a. Establish Exclusion Zone with proper safety barrier and signage to keep
Venting of product from all unnecessary personnel out
equipment and lines:
Health Hazards a. Provide adequate shade over work area.
Adverse weather conditions. b. Provide fans and moving air
Heat Exhaustion c. Be aware of fatigue and allow sufficient rest period between works
d. Assess weather condition prior to commencement of work.
e. Provide sufficient cool drinking water
f. Work force engaged in heavy task shall be monitored and rotated if
required.
Preheating, welding & inter- a. Thickness check to be done prior to welding as per inspection procedure
pass temperature monitoring b. Welding should be stopped immediately in case of less flow rate informed
Burn through by KNPC operations.
Lack of fusion c. Utilities to ensure sufficient fire water pressure are available before the
Rapid cooling of weld start and during the tenure of job
d. Hot work permit procedure and requirement laid in to be complied
e. Feed isolation procedure (in case of pipe failure) should be available at site
and to be discussed with operators.
Pipe failure while welding a. Thickness check to be done prior to welding as per inspection procedure
Inadequate wall thickness may b. Welding should be stopped immediately in case of less flow rate informed
result in burning through the by KNPC operations.
line and tendency of fire and c. Utilities to ensure sufficient fire water pressure are available before the
explosion in probable start and during the tenure of job
d. Hot work permit procedure and requirement laid in to be complied
e. Feed isolation procedure (in case of pipe failure) should be available at site
and to be discussed with operators.
Hot Tap Process a. All product is contained within the Hot Tap equipment.
Exposure to product b. Controlled venting procedures are used.
c. Client to provide accurate product data.
Hot Tap Process a. All equipment is enclosed, no immediate danger to personnel regarding
Failure of the cutter cutter fragments.
b. Cutter assembly may be retracted past the isolation valve to allow
replacement of the cutter.

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Hot Tap Process a. Use of qualified and experienced hot tapping personnel only
Loss of Coupon b. A minimum of two keeper wires is fitted to the pilot drill.
Obstruction in pipeline c. Velocity rates to be maintained below agreed levels.
Stringing of coupon on larger d. Service engineer to be informed regarding actual flow rates/velocity
diameter hot taps e. Client to consider the possible loss of a coupon and the effect on the
process.
f. Use of qualified and experienced hot tapping personnel only
g. Technicians to be informed regarding actual flow rates/ velocity
h. It should be made sure that fluid velocity in the pipeline should not exceed
10m/s for gas service and 5m/s for liquid service.
i. Where necessary a coupon reinforcement ring to be welded to parent pipe
prior to fitting installation.
Hot Tap Equipment a. A site pressure test on machine to valved assembly is carried out.
Failure of components b. Equipment designed to recognised standards.
Hot Tap Equipment a. Ensure the mounting, assembling and operation of the hot tapping machine
Mounting, assembling and are performed by trained and competent person for this purpose only, with
operation of hot tapping full time supervision by highly qualified and certified person is available to
machine carry on the operation.
Incompetency in this b. Ensure that the selection of proper fitting and reinforcement for use in
operation may turn to tragedy, making the hot tap connection is based on the relevant codes.
machine may fails during c. Ensure that the overall fitting and valve assembly length do not exceed the
cutting process. Cutting may machine boring bar maximum travel.
rub through the opposite wall d. Measurement will be monitored and recorded.
of the pipe if depth
measurement is not done and
checked properly and the
result is massive gas leak
Hot Tap Equipment a. Pressure tests are carried out at several stages during the hot tap
Failure of component procedure.
Failure of gaskets or seals b. A site leak test on machine to valve assembly is carried out before hot
Hydrocarbon leak tapping
Personal injury c. Equipment is designed to recognized standard
d. Hot tap equipment with proper boring bar reach should be selected
e. Parent pipeline should be properly supported to with stand weight of
machine, fitting etc.
f. Equipment should be designed to with stand expected pressure inside the
line
g. Pressure/ Leak test are carried out at several stages during hot tap
procedure
h. Spare gaskets, seals, etc are located in technician tool boxes at the work
site. A site leak test on machine to valve assembly is carried out before hot

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tapping
i. Equipment is designed to recognized standard
j. Hot tap equipment with proper boring bar reach should be selected
k. Parent pipeline should be properly supported to with stand weight of
machine, fitting etc.
l. Equipment should be designed to with stand expected pressure inside the
line
m. Pressure/ Leak test are carried out at several stages during hot tap
procedure
n. Spare gaskets, seals, etc are located in technician tool boxes at the work
site.
Bolting and de-bolting of hot a. Ensure that appropriate air rating temporary hose connection to be used,
tap machine. connections are protected with anti-whip arrestors to prevent whipping
Failure of compressor and its motion. Maximum air pressure is regulated at source. Hydraulic machine to
accessories due to defects can be kept away from hot tap machine. All hoses and coupling meet safety
lead to severe injury standard and laid properly to avoid tripping.
b. Ensure that the compressor have valid third party certificate and KNPC
safety certificate and this are available at site for verification. The
compressor undergone routine and maintenance check before operation
and to be operated only by competent person.
c. Ensure that all pressure gauges have valid calibration test certificate.

Operating Hot Tap Valves a. If not at present, evaluate the possibility of hot tapping at the 12 clock
Ingress of swarf into valve position where there is minimum entry of swarf in to the valve.
Valve passing b. Sand bags or dampers may be used to prevent vibration during hot tapping
operation ( if necessary)
Cutting off coupon from a. Hydratight hot tap procedure shall be strictly followed
header pipe b. Condition of hot tap cutter should be confirmed prior to job execution
Failure of cutter c. All dimensions should be double checked with dimensions logged on hot
Personnel injury tap date sheet prior to pilot drill penetration
d. Use flow rates & temperature data sheet before operation.
e. All equipment is enclosed, no immediate danger to personnel regarding
cutter fragments.
f. Risk assess the effect of pilot wire ingress in to run pipe downstream of the
hot tap location.
g. All technicians to be informed regarding actual flow rates/ velocity
h. Cutter assembly will be retracted past the isolation
i. Valve to allow replacement of the cutter
Boring of header pipe a. Evaluate the entry of swarf in to equipment downstream of the hot tap
Ingress of swarf in to pipelines location
Damage to downstream b. Condition of pilot drill, coupon retainer wires should be confirmed

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equipment c. Cutting OD should be checked against valve bore and its retrieval through
valve bore should be confirmed.
Hot Tapping, closing of valve a. All products are contained within the hot tap equipment.
and removal of hot tap b. Controlled venting procedures as per site safety procedures should be
machine followed
Exposure to product c. Entire hot tap assembly should be purged with nitrogen
Contamination d. Nitrogen back pressure should be maintained inside the assembly to
Personnel injury prevent spilling of containment.
Explosive
3 Preheating, welding & inter- a. UT check of parent pipe to be conducted prior to welding
pass temperature monitoring b. All guidelines set forth by KNPC I & C Proc no :IC-18 Rev 2 should be
Burn through strictly adhered to Minimum /Maximum flow rates to be maintained for
Lack of fusion entire duration of welding activities
Rapid cooling of weld c. Welders to be qualified based on approved WPS/PQR shallow penetration
low hydrogen electrodes with minimum diameter to be used to limit heat
input
d. Preheating to be done as per WPS prior to commencement of welding
e. Welding supervisor/Engineer to closely monitor each parameter

4 Pipe failure while welding a. Thickness check to be done prior to welding as per inspection procedure
Inadequate wall thickness b. Welding should be stopped immediately in case of less flow rate informed
may result in burning by KNPC operations.
through the line and c. Utilities to ensure sufficient fire water pressure are available before the
start and during the tenure of job
tendency of fire and
d. Hot work permit procedure and requirement laid in to be complied
explosion in probable e. Feed isolation procedure (in case of pipe failure) should be available at site
and to be discussed with operators.
5 Use of Hydraulic Equipment a. All hoses & fittings are manufactured to specified standard
Failure of fittings & hoses b. Maximum hydraulic pressure is regulated at source
The use of power pack in a c. All hoses pressure tested before mobilization
hazardous area
6 Use of compressed air (if a. hoses & fittings manufacture to international standard
applicable) b. pressure test of hoses & fittings prior to mobilization
Failure of hoses & fittings c. safety relief device installed at source
Lead to personal injury d. air hoses should have whip lash arrestors
fire e. air compressor & safety relief valve should have valid test certificate
f. visual inspection of air hoses & fittings prior to use whip check on all air
hose connection
g. Safety pins installed on all connections
h. All diesel driven equipment must have certificate from third party certifying
that the equipment is suitable for zone 2 ( if applicable)

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7 Lifting & handling a. Use of approved lifting procedure


Dropping equipment parts on b. Using certified lifting gear
feet c. Use of certified rigger
Damage to property or d. Equipment in excess of 25kg must have suitable lifting eyes fitted
personal injury e. Soil & floor condition should be confirmed prior to setting of crane
f. The location where lifting activities are carried out should be properly
barricaded and appropriate sign board should be placed
g. No lifting activity should be carried out during high wind or low visibility
periods
h. Proper lifting plan should be prepared considering load charts, working
radius 75% of SWL etc.
i. All rigging tools should be with proper colour coding, crane operator should
be qualified and certified
j. The machine/ equipment should be secured with chain block during lifting
& operation
k. Limit manual lifts up to 25kg or shared lifts. If excessive, then use
craneage.

9 Use of Hot Tap Equipment a. A site leak test on machine to valve assembly is carried out before hot
Failure of component tapping
Failure of gaskets or seals b. Equipment is designed to recognized standard
Hydrocarbon leak c. Hot tap equipment with proper boring bar reach should be selected
Personal injury d. Parent pipeline should be properly supported to with stand weight of
machine, fitting etc.
e. Equipment should be designed to with stand expected pressure inside the
line
f. Pressure/ Leak test are carried out at several stages during hot tap
procedure
g. Spare gaskets, seals, etc are located in technician tool boxes at the work
site.
10 Retrieval of coupon a. A minimum of two keeper wires are fitted to the pilot drill
Loss of coupon b. Customer to consider the possible loss of a coupon and the effect on plant
Obstruction in pipeline c. Use of qualified and experienced hot tapping personnel only
Stringing of coupon on larger d. Technicians to be informed regarding actual flow rates/ velocity
diameter hot taps e. It should be made sure that fluid velocity in the pipeline should not exceed
10m/s for gas service and 5m/s for liquid service.
f. A coupon reinforcement ring to be welded to parent pipe prior to fitting
installation
11 Bolting and de-bolting of hot a. Ensure that appropriate air rating temporary hose connection to be used,
tap machine. connections are protected with anti-whip arrestors to prevent whipping
Failure of compressor and its motion. Maximum air pressure is regulated at source. Hydraulic machine to

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accessories due to defects can be kept away from hot tap machine. All hoses and coupling meet safety
lead to severe injury standard and laid properly to avoid tripping.
b. Ensure that the compressor have valid third party certificate and KNPC
safety certificate and this are available at site for verification. The
compressor undergone routine and maintenance check before operation
and to be operated only by competent person.
c. Ensure that all pressure gauges have valid calibration test certificate.
12 Operating Hot Tap Valves a. If not at present, evaluate the possibility of hot tapping at the 12 clock
Ingress of swarf into valve position where there is minimum entry of swarf in to the valve.
Valve passing b. Sand bags or dampers may be used to prevent vibration during hot tapping
operation ( if necessary)
13 Cutting off coupon from a. Hydratight hot tap procedure shall be strictly followed
header pipe b. Condition of hot tap cutter should be confirmed prior to job execution
Failure of cutter c. All dimensions should be double checked with dimensions logged on hot
Personnel injury tap date sheet prior to pilot drill penetration
d. Use flow rates & temperature data sheet before operation.
e. All equipment is enclosed, no immediate danger to personnel regarding
cutter fragments.
f. Risk assess the effect of pilot wire ingress in to run pipe downstream of the
hot tap location.
g. All technicians to be informed regarding actual flow rates/ velocity
h. Cutter assembly will be retracted past the isolation
i. Valve to allow replacement of the cutter

14 Boring of header pipe a. Evaluate the entry of swarf in to equipment downstream of the hot tap
Ingress of swarf in to pipelines location
Damage to downstream b. Condition of pilot drill, coupon retainer wires should be confirmed
equipment c. Cutting OD should be checked against valve bore and its retrieval through
valve bore should be confirmed.
15 Hot Tapping, closing of valve a. All products are contained within the hot tap equipment.
and removal of hot tap b. Controlled venting procedures as per site safety procedures should be
machine followed
Exposure to product c. Entire hot tap assembly should be purged with nitrogen
Contamination d. Nitrogen back pressure should be maintained inside the assembly to
Personnel injury prevent spilling of containment.
Explosive
Specific prevention and protection measures KNPC references: In additional all the precautions mentioned in KNPC SWP shall be follow where ever applicable

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Key: ALARM -Serious or major harm will probably occur, ALERT -Moderate harm probable, major harm unlikely to occur

CAUTION -Minor harm probable, major harm very unlikely to occur, CARE-Minor harm possible, major harm very unlikely to occur

BROWN FIELD

Section Head Operations Construction Engr. Construction Engr. Safety Engineer Safety Engineer Others
Contractor Contractor KNPC
Controller KNPC
CFP Refinery PMC Supt. PMC - HSE
Const.

Signature

Name

Emp no.

Note:
1. Master copy (original) shall be retained in file for record and future reference
2. Photo copy shall be attached with work permit
3. Ref. no. guidance: - Example LOCATION DEPT. /DIV. RISK ANALYSIS YEAR SERIAL NO. e.g. 1. MAA XXXXRA 05-1001, 2. PRJ XXXXRA 05-11
4. If same Risk assessment is being used again, it must be reviewed to check relevancy.
5. Approved WMS shall be followed by Contractor (JGSK)

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6.0 Hot Tapping & Welding Checklist


INSPECTION & CORROSION POLICY & PROCEDURE MANUAL
I&C. PROC. NO. : IC-18

INSPECTION OF HOT TAPPING & ON-LINE WELDING ON REV : : 02


EQUIPMENT AND PIPING DATE: : MAY,2010

KNPC PAGES: : 10 of 14
INSP & CORR. DIV
ATTACHMENT A1

KUWAIT NATIONAL PETROLEUM COMPANY (KSC)


REQUEST FOR HOT TAPPING (PIPING)
MAINTENANCE WORK ORDER NO. Date
Unit Line No

A. MAINTENANCE PLANNING DIVISION / PROJECT

1. Main Pipe inches NB Wall Thickness inches, Material


Type : Seamless / ERW / Spiral Welded
2. Branch: NB inches NB Wall Thickness inches Material
3. Valve: Rating lbs Clear bore inches Tested at Workshop
4. Flange Facing YES / NO
5. Stub Height
6. Orientation
7. Total Stub Height
Head room
8. available YES / NO
9. Approved Engg. Drg. attached YES/NO Drg. No

Name : Signature :

Designation : Emp. No. :

B. OPERATIONS
1. Line No 2. Service
3. Operating Temp Pressure psig
4. Design Temp Pressure psig
5. If pressure could be reduced Yes / No to to psig
6. Hot tap location marked at site Yes / No

Name : Signature :

Designation : Emp. No. :

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INSPECTION & CORROSION POLICY & PROCEDURE MANUAL


I&C. PROC. NO. : IC-18

INSPECTION OF HOT TAPPING & ON-LINE WELDING ON REV : : 02


EQUIPMENT AND PIPING DATE: : MAY,2010

KNPC PAGES: : 11 of 14
INSP & CORR. DIV
C. INSPECTION

(i) Before Welding


Minimum required thickness : 4.8 mm (3/16)
1. Measured thickness : mm / inches
2. Material : Dia. mm / inches
3. Checked : Stress Relieving not required.
4. Hot Tapping: Permitted/Not permitted because
5. Electrodes Preheat of
NOT Inspector Inspection Engineer

Name :

Designation :

Emp. No. :

Signature :

(ii) AFTER WELDING


1. Weld Examined Visually LP MP UT
2. Reinforcement pad pneumatically tested at psig
3. Stub Pressured Tested: Hydrostatic / Pneumatic psig
NOT Inspector Inspection Engineer

Name :

Designation :

Emp. No. :

Signature :

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INSPECTION & CORROSION POLICY & PROCEDURE MANUAL


I&C. PROC. NO. : IC-18

INSPECTION OF HOT TAPPING & ON-LINE WELDING ON REV : : 02


EQUIPMENT AND PIPING DATE: : MAY,2010

KNPC PAGES: : 12 of 14
INSP & CORR. DIV

D. ROTATING EQUIPMENT

Hot Tapping Carried out by on

Supervised by

Name : Signature :

Designation : Emp. No. :

E. AREA MAINTENACE

Hot Work Permit No Date


Valid upto
As built site measurement communicated to
for updating drawings

Name : Signature :

Designation : Emp. No. :

DISTRIBUTION : All Concerned

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INSPECTION & CORROSION POLICY & PROCEDURE MANUAL


I&C. PROC. NO. : IC-18

INSPECTION OF HOT TAPPING & ON-LINE WELDING ON REV : : 02


EQUIPMENT AND PIPING DATE: : MAY,2010

KNPC PAGES: : 10 of 14
INSP & CORR. DIV
ATTACHMENT A2

KUWAIT NATIONAL PETROLEUM COMPANY (KSC)


CHECK LIST FOR HOT TAP (PIPING)
Line No / Location Date

Delete this check


Before Starting Hot Tap list. KNPC
Work /Hot permit obtained approved checklist
Checking Suitability of hot tap machine shall be used
Location for Hot Tap marked
Welding area has been inspected for thickness & defects
Sufficient space available for the operation of Hot Tap machine
Fluid flow in the line has been established
Procedure to isolate the work area in the event of failure has been prepared

Before Welding
Joint fit up inspected to avoid misalignment of Hot Tap machine
Whether pressure and temperature of the fluid have been reduced to permissible level
Is there fluid in contact with the area to be Hot Tapped?

Before Cutting
Has the weld been inspected or tested?
Has the valve centred on the flange?
Has the cutting depth been calculated to avoid cutting of the opposite side.

Name : Signature :
Designation
(Rotating equipment) : Emp. No. :

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INSPECTION & CORROSION POLICY & PROCEDURE MANUAL


I&C. PROC. NO. : IC-18

INSPECTION OF HOT TAPPING & ON-LINE WELDING ON REV : : 02


EQUIPMENT AND PIPING DATE: : MAY,2010

KNPC PAGES: : 10 of 14
INSP & CORR. DIV
ATTACHMENT A2

KUWAIT NATIONAL PETROLEUM COMPANY (KSC)


CHECK LIST FOR ON-LINE WELDING Delete this
UNIT / AREA Date checklist. KNPC
EQUIPMENT / PIPING NO. approved checklist
IAT NO. shall be used

SR NO ITEM TO BE CHECKED REMARKS ACTION BY


1. Fluid in line/ equipment suitable for welding Yes/No Operations
2. Pressure & Temperature of fluid PSIG F
3. Flow in line/level in equipment Yes Operations
4. Exact location of welding identified & Yes/No Executor
marked
5. Thickness measurements at welding locations Yes/No Inspection
6. Fire fighting equipment available Yes/No Operations
7. Fire Section Informed Yes/No Operations
DESCRIPTION OF WORK TO BE DONE:

Name : Signature :
Designation
(Rotating equipment) : Emp. No. :

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7.0 Pre-Mobilisation Checks

7.1 Hot Tap Equipment


Operation Additional Information
7.1.1 Inspect the overall condition of the Hot Tap
Machine.
7.1.2 Lubricate the Gearbox and ensure that it is leak
tight.
7.1.3 Check the drive motor and ensure that it is well
lubricated.
7.1.4 Check all hose connection and ensure that they [Refer to Hyd. Hose and Fittings section below].
are free of any damages.
7.1.5 Open/Close the Valves and ensure that it is
working.
7.1.6 Advance and retract the Boring bar using the
ratchet drive to ensure that the boring bar is
functioning properly with- out any play.
7.1.7 Ensure that the Lifting slings are in good condition
and the certificates are valid.
7.1.8 Install the pressure Test dome onto the boring bar Test pressure : 1,450 Psig
side and pressurize the machine to ensure the Duration : 30 Minutes
packing seals are holding and in the good
condition.
7.1.9 Remove the Pressure Test Dome and install the
job Specific Hot Tap Adapter.
7.1.10 Blind the Hot Tap Adaptor with a suitable Blind Gaskets or RTJ Rings as applicable
flange and using CAF/Spiral Wound
7.1.11 Pressure test the machine complete with the hot Test pressure : 1450 Psig
tap adaptor Duration : 30 Minutes
7.1.12 Remove the Blind flange.

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7.2 Cutter & Pilot Drill


Operation Additional Information
7.2.1 Check Cutter and Pilot Drills to ensure that the
cutting teeth are in good condition.
7.2.2 Check condition of coupon retainer on the Pilot
Drills
7.2.3 Install the cutter and pilot on to the cutter holder
7.2.4 Extend the boring bar past the adaptor and install
the cutter holder on to the boring bar.
Ensure Bolts and nuts are tightly fastened.
7.2.5 Ensure the cutter is concentric to the machine
adaptor by measuring it in all 360 Degrees.
7.2.6 Insert the measuring rod into the top end of the
machine and lock/unlock the cutter holder.
7.2.7 Check Purge valve on the adaptor is functioning
properly.

7.3 Hydraulic Motor


Operation Additional Information
7.3.1 Connect the Hydraulic Power Pack to the motor on
the machine.
7.3.2 Start the Hot Tap machine, set it on auto feed and
ensure the boring bar is moving forward
7.3.3 Set the drive on reverse and ensure the boring bar
is moving back into the adaptor.
7.3.4 Leave the machine running in neutral for 15
minutes as a function test for both the machine
and the drive unit.
7.3.5 Disconnect the drive after the boring bar has been
completely retracted into the hot tap adaptor.
7.3.6 Reinstall the Blind flange on the Hot Tap Adaptor
to prevent any damage to the face of the hot tap
adaptor during transportation.

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7.4 Hose & Fittings


Operation Additional Information
Prior to assembly, a careful examination of the To avoid injury during system checks:
hose and fittings must be performed. All Do not touch any part of the system when
components must be checked to ensure that they checking for leaks
are the correct type, size, and length.
Stay out of potentially hazardous areas while
testing hose systems
Relieve system pressure before adjusting
connections.
7.4.1 The manufacturer ratings to be checked for Any of the following conditions require immediate
compatibility with the pressure rating of the shut down and replacement of the hose assembly:
system and the environment within which the Fitting slippage on hose.
system is to be used.
Damaged, cracked or charred hose. Crack, damage
or badly corroded fittings. Leaks at fitting or in
hose.
Kinked, crushed, flattened or twisted hoses.
Blistered, soft, degraded or loose covers
7.4.2 Particular attention must be given to prevent sharp
bends at the hose connection to the fitting. Any
bending during installation to less than the
minimum bend radius should also be avoided.
7.4.3 The hose must be examined for cleanliness,
obstructions, blisters, kinks, cracks, cuts or any
visible defects.
7.4.4 The fitting and sealing surfaces need to be
inspected for burns, nicks, corrosion or other
imperfections.
7.4.5 Ensure that the hose assembly is routed in such a
manner so that if a failure does occur, the
escaping media will not cause personal injury of
property damage.
7.4.6 Eliminate all air entrapment after completing the
installation. Follow manufacturers instructions to
test the system for possible malfunctions or leaks.
7.4.7 Operate the system at maximum operating
pressure and check for possible malfunctions
and leaks. Personnel must avoid potentially
hazardous areas while testing the system
7.4.8 Once tests are complete, Use protective tape to
protect fittings from corrosion.

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8.0 Site Hot Tap Procedure

8.1 Site Establishment


Operation Additional Information
8.1.1 On arrival at the worksite, complete all necessary The site specifications should be recorded and
site inductions, orientations, etc. cross-checked with the Service Questionnaire as
supplied by the client. All discrepancies should be
noted and discussed with the Clients
representative.
8.1.2 Conduct site survey with the clients representative
and confirm plant specifications.

8.1.3 Conduct pre-start risk assessment. Minutes of the risk assessment should be recorded
and attached to the worksite permit.
8.1.4 Conduct a toolbox talk with all personnel affected Minutes of the toolbox talk should be recorded and
by the operation. attached to the worksite permit.
8.1.5 Raise appropriate work permits. Confirm that all safety measures detailed in the job
specific risk assessment has been applied.
8.1.6 Establish continuous gas monitors at the worksite. Locate all tools required for the job, up wind of the
worksite.
8.1.7 Establish site
8.1.8 Erect a safety barrier around the worksite,
extending to a 5 meters radius around the tie-in
point.
8.1.9 Ensure the power source is located up wind of the Locate a fire extinguisher next to the power
worksite a minimum of 5 meters from the tie-in source.
point.
8.1.10 Confirm the power source has sufficient fuel for
the duration of the tap
8.1.11 Confirm the drilling machine & tapping adaptor
pressure test certificate [test completed before
dispatch from Hydratight Service Centre] is
available and valid.
8.1.12 Run the hoses from the power source to the tie-in Whip checks and safety pins shall be fitted to all
point. hoses connections.
8.1.13 Ensure the scaffolding has a valid inspection A minimum of 2 access and egress points should
certificate attached (Scafftag or similar) be available on the scaffolding.
8.1.14 Locate a fire extinguisher at the top of the
scaffolding
8.1.15 Take 5 minutes to check the work site for any trip,
slip or fall hazards.

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8.2 Hot Tap Fitting Inspection


Operation Additional Information
8.2.1 Confirm that the fitting has been pressure tested. A copy of the pressure test certificate should be
attached to the work permit.
8.2.2 Visually inspect the sealing face of the hot tap Any damage must be repaired prior to installation
fitting flange ensuring it is free of pits, scratches, of the tapping valve.
dust or any other damage, which may affect the
joint integrity.
8.2.3 A suitable dust cover should be installed to
prevent any ingress of dust or contaminants, until
such times as the tapping valve is installed.

8.3 Installation of the Tapping Valve (Client Responsibility Included for Guidance only)
Operation Additional Information
8.3.1 Visually inspect the sealing face of the tapping Any damage must be repaired prior to installation
valve flange ensuring it is free of pits, scratches, of the tapping valve
dust or any other damage, which may affect the
joint integrity.
8.3.2 Visually inspect the bolts & nuts to be used, Lightly coat the studs bolts with a suitable lubricant
ensuring they are in sound condition. (molycoat or similar).
8.3.3 Install the specified gasket on the hot tap fitting.
8.3.4 Carefully lower the tapping valve on to the hot tap Care should be taken not to damage the gasket.
fitting.
8.3.5 Install all bolts and hand tighten only
8.3.6 Centralize the tapping valve to the hot tap fitting.
8.3.7 Tighten the bolts to the specified loading.
8.3.8 Close the tapping valve. A suitable dust cover should be installed to prevent
any ingress of dust or contaminants, until such
times as the drilling machine is installed.

8.4 Site Dimension Checks


Operation Additional Information
8.4.1 Open the tapping valve to ensure it is operating Record the number of turns required to operate
correctly. the valve.
8.4.2 Measure the distance from the wall of the parent Record this distance
pipe (at the highest point of the pipe radius), to Note : All measuring equipment used must be
the upper sealing face of the tapping valve. calibrated (within the past 12 months).
8.4.3 Measure the distance from the seat face of the Record this distance
tapping valve to the uppermost face of the valve
flange / joint.
8.4.4 Measure the bore of the tapping valve. Record this size.

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8.4.5 Close the tapping valve. A suitable dust cover should be installed to prevent
any ingress of dust or contaminants, until such
times as the drilling machine is installed.

8.5 Drilling Machine Pre-Fit Up Checks


Operation Additional Information
8.5.1 Extend the boring bar of the drilling machine until
the pilot drill and cutter are extended past the
cutter housing.
8.5.2 Confirm the cutter is the correct dimension All discrepancies should be noted and discussed
with Hydratight Operations Department and, where
necessary, the customers representative.
8.5.3 Visually inspect the condition of the cutter
confirming the teeth are in good condition.
8.5.4 Visually inspect the condition of the pilot drill tip
confirming the cutting face is in good condition.
8.5.5 Visually inspect the catcher wires on the pilot A minimum of 2 catcher wires are required.
drill, confirming they are installed and in good
condition.
8.5.6 Retract the boring bar of the drilling machine until
the graduations marks on the drilling machine
8.5.7 With the drilling machine reading zero, record all Use Site Dimension Data Sheet to record and
relevant measurements calculate all distances.

8.6 Installation of the Drilling Machine


Operation Additional Information
8.6.1 Visually inspect the sealing face of the cutter Any damage must be repaired prior to installation
housing, ensuring it is free of pits, scratches, dust of the drilling machine.
or any other damage, which may affect the joint
integrity.
8.6.2 Visually inspect the bolts & nuts to be used, Lightly coat the studs bolts with a suitable lubricant
ensuring they are in sound condition. (molycoat or similar).
8.6.3 Install the specified gasket on the tapping valve.
8.6.4 Carefully lower the drilling machine on to the Care should be taken not to damage the gasket.
tapping valve.
8.6.5 Fit and secure the drilling machine to the tapping
valve.
8.6.6 Install all bolts and hand tighten only
8.6.7 Centralize the drilling machine to the tapping
valve.
8.6.8 Tighten the bolts to the specified loading.

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8.7 Pressure Test the Hot Tap Assembly.


Operation Additional Information
8.7.1 Fit the bleed valve and test gauge to the bleed Ensure that the bleed valve is open in readiness for
point on the drilling machine. the purging & pressure testing.
8.7.2 Open the tapping valve.
8.7.3 Re-confirm the operating pressure of the pipeline
to be tapped.
8.7.4 Leak test the complete assembly using Water Increase the test pressure in 25% increments until
the final test pressure of 1.1 times the line
pressure is achieved.
8.7.5 Keep the assembly under pressure for a minimum The pressure test is considered satisfactory only if
duration of 15 minutes. there is no leak or any pressure drop.
8.7.6 Close the tapping valve
8.7.7 Drop the pressure above the tapping valve to 1%
of the test pressure.
8.7.8 Monitor the test gauge for any pressure build up Any pressure build up will indicate a potential leak
for 5 minutes. on the tapping valve. The pressure test is
considered satisfactory only if there are no leak or
any pressure increase.
8.7.9 Balance the pressure between the tapping valve This is required to prevent any potential damage to
via the bleed valve. the tapping valve seat caused by opening the
tapping valve with a differential pressure.
8.7.10 Open the tapping valve.
8.7.11 Open the bleed valve and drop the pressure in the
hot tap assembly to zero.

8.8 Drilling Operation


Operation Additional Information
8.8.1 Confirm with the clients representative that the Reconfirm that all emergency procedures as per
hot tap can now start. the risk assessment are in place, and good
communications are established between the
worksite and relevant personnel.
8.8.2 Connect the hoses between the power source and Reconfirm whip checks and safety pins are fitted to
the drilling machine. all hoses.
8.8.3 Confirm the bleed valve is in the open position.
8.8.4 Connect a vent hose to the bleed valve and run to As specified in the risk assessment.
a safe area. All hoses should be fitted with whip checks and
properly secured to prevent any trip hazards.
8.8.5 Take 5 minutes to check the work site for any trip,
slip or fall hazards.
8.8.6 Ensure that the firewatcher is located next to the

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power source.
8.8.7 Reconfirm the wind direction has not changed.
8.8.8 Reconfirm the tapping valve is in the open
position.
8.8.9 Reconfirm the drilling machine is set at zero. Check the graduations marks on the drilling
machine
8.8.10 Manually advance the pilot / cutter assembly until Do not over feed. Check graduations on the drilling
it contacts the wall of the run pipe. machine against values calculated and cross-
reference to the dimensions previously recorded.
Record distance.
8.8.11 Retract the pilot drill / cutter assembly approx. 2
mm
8.8.12 Start the drilling machine drive motor.
8.8.13 Manually advance the pilot / cutter assembly cuts
into the wall of the parent pipe.
8.8.14 Monitor the progress of the pilot drill. As the pilot drill cuts into the wall of the parent
pipe the forward movement of the graduations on
the drilling machine indicate the distance of travel.
8.8.15 Monitor the purging process until all gases are
purged, then close the bleed valve.
8.8.16 Allow the pilot drill to fully penetrate the wall of It is important that the pilot drill is allowed to clear
the parent pipe. the inside of the pipe wall to ensure that any rags
or burrs created during the drilling are removed.
8.8.17 Stop the drilling machine drive motor.
8.8.18 Manually advance the pilot/cutter until the main
cutter touches the run pipe.
8.8.19 Check the measurement by the graduations on the
drilling machine
8.8.20 Retract the pilot/cutter approx. 2 mm,
8.8.21 Reconfirm the distance the cutter has to travel to As per the cutter travel calculation sheet
complete the tap.
8.8.22 Start the drilling machine drive motor. Set the machine cutting speed to the desired RPM,
refer to manufacturers tables if necessary.
8.8.23 Monitor the progress of the main cutter. The graduation marks on the drilling machine will
indicates the distance of travel.
8.8.24 When the cutter has completed the main cut, stop
the drilling machine drive motor.
8.8.25 Fit the manual cranking handle and advance the This will confirm the cutter has fully penetrated the
pilot/cutter approx. (12.5 mm) pipeline.
8.8.26 Retract the drilling machine to zero. The graduation marks on the drilling machine will
indicates the distance.

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8.8.27 Close the tapping valve. Count the number of turns as previously recorded.

8.9 Evacuating the hot tap assembly


Operation Additional Information
8.9.1 Reduce the pressure in the hot tap assembly
(above the tapping valve), to 1% of the pipe
operating pressure.
8.9.2 Monitor the pressure gauge for any pressure build Any pressure build up will indicate a potential leak
up for 5 minutes. on the tapping valve. The pressure test is
considered satisfactory only if there are no leaks or
any pressure increase.
8.9.3 Open the bleed valve and drop the pressure in the
hot tap assembly to zero.
8.9.4 Remove the drilling machine.

8.10 Install Blind Flange (Client Responsibility Included for Guidance only)
Operation Additional Information
8.10.1 Visually inspect the sealing face of the blind flange Any damage must be repaired prior to installation
and tapping valve, ensuring it is free of pits, of the blind flange.
scratches, dust or any other damage, which may
affect the joint integrity.
8.10.2 Visually inspect the bolts & nuts to be used, Lightly coat the studs bolts with a suitable
ensuring they are in sound condition. lubricant (molycoat or similar).
8.10.3 Install the specified gasket on the hot tap valve.
8.10.4 Carefully lower the blind flange on to the tapping Care should be taken not to damage the gasket.
valve.
8.10.5 Tighten the bolts to the specified loading.

8.11 Clear Site


Operation Additional Information
8.11.1 Clear the work site. Take 5 minutes to ensure all tools are recovered
and the site is left in a safe condition
8.11.2 Sign off all permits
8.11.3 Prepare and pack equipment for return to the
Hydratight Service Centre.
8.11.4 Sign off Service time sheets and job completion
certificate.

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9.0 Site Dimension Data Sheet Drilling


Item Description Dimensions
9.1.1 Top of branch flange to top of parent pipe Dim A

9.1.2 Top of tapping valve flange to top of branch flange Dim B

9.1.3 Top of branch flange to top of tapping valve seat Dim C

9.1.4 Clearance above tapping valve for service equipment Dim D

9.1.5 Bore of branch Dim E

9.1.6 Bore of tapping valve Dim F

9.1.7 Pipe wall thickness Dim G

9.1.8 Tip of pilot drill to the face of the cutter housing. Dim X
(With boring bar set a zero)

9.1.9 Tip of pilot drill to tip of cutter teeth Dim Y

9.1.10 Main cutter travel distance to complete tap Dim CTD

9.1.11 No of turns required to open the tapping valve


9.1.12 Total travel until pilot drill touches parent pipe (A + B + X)
9.1.13 Total travel until pilot drill penetrates parent pipe (A + B + G + X)
9.1.14 Total travel until cutter touches parent pipe (A + B + X + Y)
9.1.15 Maximum travel distance to complete tap (A + B + G + X + Y + CTD + (3mm))

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10.0 Job Completion Certificate

[This section must be completed by the Hydratight Field Service Engineer for each coupon delivered to the customer]

HT Project No :

Client Reference No. :

Customer Details
Name :
Contact :

Job Details
Completion Date :
Tie-In Point No :
Line Size :

P&ID No :

Coupon Hand Over Confirmation


The above job has been safely completed and the coupon has been handed over to the person detailed below.

Hot Tap Engineer Recipient

Name [print] Name [print]

Name [sign] Name [sign]

Company Company

Date select Date select

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11.0 Site Notes


[FSE to record any site observations]

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APPENDIX 1 Equipment Data Sheet

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