Hot Tapping Procedure

(TIMAS-PR-PI-001)

Contract No :
Project Title :
Location :
Client :

Issued for Approval

Rev’d Client
Rev. Date Description Prp’d Chk’d Rev’d
(QA) App’d
 Doc.No.: TIMAS-PR-PI-001
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Table of Contents

1. Scope

2. References

3. Responsibility

4. Procedure

5. Inspection Records

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1.0 Scope
This procedure covers the essential for preparation, welding, cutting and
removing the Hot-Tapping. It also outlines the safety aspects of the process
and lists the necessary conditions and steps .

2.0 References

2.1 API 2201

2.2 Tie-in Procedure

2.3 ASME B.31.3

2.4 SEP STD 167

3.0 Responsibility

3.1 Field QA/QC Manager shall be responsible for Quality Control all phases of
implementation. It shall approve WPQ and Welders Tests, perform all NDE
required , and implement all the quality control steps stated in this procedure
and any other additional requirements deemed necessary.

3.2 Construction Superintendent and fire and safety Dept. shall ensure a safe and
trouble free operation and provide guide lines and necessary assistance during
the Hot – Tapping implementation. Safety of personnel facilities are
paramount.

3.3 Construction shall perform the work within the context of this procedure and
shall abide the limitations of this procedure. Hot Tap machine should be
operated by qualified personnel

3.4 Field Supervisor shall deliver the cut out metal coupon to inspection for the

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purpose of
- Establishing the positive record that the coupon has not been left
accidentally in the process system.
- Establish the internal condition of the coupon.

4.0 Procedure

4.1 Preparation :

4.1.1 Field Supervisor ensures that Hot-Tapping will be performed under safe
conditions. Both QA/QC and Safety Div. should be informed well in advance
about the job and activity involved.

4.1.2 Field Supervisor shall provide evidence of the adequacy of the Hot-Tapping
machine for the temp. and pressure of the medium inside the line or vessel.
Moreover the Hot-Tapping machines shall be proven for safe and trouble free
application.

4.1.3 Field Supervisor shall employ proven operators of Hot-Tapping machine for
this job.

4.1.4 Preparation shall be made for safe shutdown of facility in case of emergency.
This includes physical access to remote block valve etc and deployment of
operators and fire and safety personnel to meet sudden emergencies in the
plant.

4.1.5 The area on the carrier pipe to which a connection is to be made has been
identified and physically marked and verified by the nominated QC Inspector
and Owner.

4.1.6 A Hot Work Permit shall be acquired . The work shall be agreed upon the
acceptable range of operation pressure and temperature required to monitor
continuously during welding and drilling

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4.1.7 All necessary Gas and Toxicity tests shall be made to ensure safe environment
by Owner.

4.1.8 Personnel protective clothing and equipment shall be used where necessary

4.1.9 A “ Fire Watch “ has been established and equipped with a suitable fire
extinguisher or preferably dry chemical and pressurized fire hose.

4.1.10 Signs and barriers shall be provided where warranted.

4.1.11 Field Supervisor shall confirm that the weight of Tapping Valve , Hot
Tap Machine and Hot Tap Fitting will not overstress the pipe.

4.2 Inspection Before Hot-Tapping Welding.

4.2.1 Welding on too thin material could result in over heating and burn through. No
Hot-Tapping shall be done on piping and equipment with thickness less than
4.8 mm. ultrasonic Flaw Detection Survey for minimum thickness and
lamination should be carried out to ensure soundness of base metal, where
Hot-Tapping to be done.

4.2.2 Some equipment are unsuitable for Hot-Tapping because of metallurgy or

thickness of metal requires stress relieving, which normally cannot be done
while the equipment is pressurized. Special treatment is required for high
tensile strength alloy steels and special welding alloys must be used. Hot-Tap
fittings and weld electrode metallurgy must be compatible with equipment &
piping

4.3 Location Marking

4.3.1 The section of pipe to which the fitting is to be welded shall be thoroughly
cleaned with a wire brush or a distance extending 100 mm on either side of the
location of the fitting. After cleaning the pipe shall be visually examined for
lamination , pitting and any sign of mechanical damage.

4.3.2 NDE inspection, and ultrasonic examination shall be carried out to ensure that

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the examined areas are free from harmful defects.

4.3.3 The area of pipe beneath the fitting location ( base metal ) shall be examined
by ultrasonic to ensure freedom from laminations, which may result in harmful
defects, like hydrogen attack stress corrosion cracking, being propagated
during and after the Hot Tap operations. The area shall be scanned on a 75
mm square grid using the flow echo ratio.

4.3.4 Wall thickness measurements are to be taken by ultrasonic using a normal

probe and the results tabulated with Owner Inspection verifying such
measurements. Prior to any welding operations commencing these results are
to be reviewed and accepted by Owner.

4.3.5 The areas where attachment welds are to be made shall be 100%
ultrasonically examined to check for laminations and confirm adequate wall
thickness.

4.4 Qualification of Welding Procedure.

4.4.1 Qualification test shall be made on the piping sections for Welding Procedure
Specification (WPS)

4.4.2 The welding technique shall be accordance with the WPS and this procedure.

4.4.3 Parameters, operating techniques, type and size of electrodes, shall be stated
in detail in the WPS and shall be strictly adhered to in the course of works.

4.5 Qualification Of Welders.

4.5.1 The welders employed shall be qualified for butt welding on pipes and shall
have long and proven experience for piping welding.
4.6 Welding of Fitting.

4.6.1 Before beginning the welding, carefully clean the zone concerned by hand or
power brushing, and check for absence of out of roundness in the zone where

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the tie-ins is to be inserted.

4.6.2 It is necessary to check for wall thickness of the zone concerned with the
welding, by Ultrasonic examination or any NDT method deemed necessary for
determining the soundness of the pipe at the weld area. Grease, Oil Powder or
any other contaminant shall be thoroughly cleaned.

4.6.3 Moisture or condensate shall be removed by heating if necessary. Electrodes

shall be dried and well preserved in suitable containers to avoid moisture
absorption.

4.6.4 During the entire period of welding flow shall be maintained in the line. For the
similar operation carried out on tanks, minimum level of liquid to be maintained.

4.7 Preparation Of Carrier Pipe

4.7.1 Paint and or wrapping material shall be carefully removed from the carrier pipe
from the proposed area of attachment for a length extending to 400 mm either
side of the proposed location of the fitting.

4.7.2 The exposed pipe should be checked with calipers to ensure that any ovality is
within acceptable limits related to the fitting to be used at that particular
location.

4.7.3 The section of pipe which the fitting is to be attached shall be thoroughly
cleaned with the wire brush for a distance extending 150 mm either side of the
location of the fitting. After cleaning the pipe shall be visually examined for
lamination , pitting and any signs of mechanical damage.

4.7.4 The area of pipe beneath the fitting location shall be examined ultrasonically, to
ensure freedom from lamination which might prejudice welding operations,
refer to para 4.3.3.

4.7.5 Welding shall be carried out using an approved WPS supported by a Qualified

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PQR for the type of materials to be welded. All welding operations will be
carried out by the suitable Qualified welders. All welding operations will be
conducted in a continuous operation.

4.7.6 Attention is drawn to the rapid cooling effect of the gas flow. Heat dissipation
from the Weld area will be dependent on flow conditions at the time of
attachment and may vary during the Welding cycle.

4.8 Welding

4.8.1 Once again the attention is drawn to the rapid cooling effect of product flow.
Heat dissipation from the weld area will be dependent on the flow conditions at
the time of attachments and may vary during the welding cycle. Operating
pressure and product velocities must be monitored continuously during
welding. Acceptable ranges to be agreed with the Company operations prior to
the issue of work permits.

4.8.2 Tacking may proceed with the ends with the tacks being dressed by grinding to
a taper to full fusion with the root pass.

4.8.3 After completion of the root pass a buttering layer shall be applied to the pipe
according to the applicable WPS shall be deposited as close as possible to the
extremity of pass 3 without impinging on to the pipe wall . For welds in the
horizontal vertical position , fitting on top or bottom of the pipe , a stringer bead
technique shall be adopted, so avoiding the next for excessive weaving of the
electrode during deposition. The weld shall be completed in one cycle.

4.9 Inspection And Testing of welds :

4.9.1 The weld should be inspected during and after welding and before the Hot-Tap
machine is installed. Examination of Radiograph, Dye penetrant, Ultrasonic or
MPI is recommended particularly on final weld where practically possible.

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4.10 Checking Of Tapping Valve.

- The Hot Tap valve shall be tested for seat leakage.
- The valve shall be centered on the Nozzle flange.
- Measure valve bore for sufficient cutter clearance.
- Measure valve for sufficient hot tap adapters space for cutter and pilot face
of valves to seat rings. Record this dimension.

4.11 Assembly Tapping Machine

- Check boring bar drive ring for tightness and damage
- Check boring bar packing nut for adjustment. Bottom out and back off 1/4
turn.
- Checking retainer shaft packing for adjustment, tighten as much as possible
and still allow retainer shaft to be turned easily with measuring rod.
Packing nut must not extend out into taper or boring bar.
- Clean ring joints and steel gaskets.
- Install adapter on tapping machine, and snug top two bolts, leaving other
loose.
- Extend boring bar beyond face of adapter.
- Install cutter holder in boring bar. Tighten retainer shaft with measuring rod
by hand. Install safety pin with cutter pins on either ends.
- Check cutter teeth and OD of cutter. Install cutter on holder and tighten
socket head bolts first, then tighten lock nuts Acceptable alternative is to
assemble cutter and cutter holder before installing cutter holder in boring
bar.
- Check U-rods, insert tip drill, and nylon pin in pilot. Then install in cutter
holder and tighten.

4.12 Installation of Tapping Machine

- Clean flange faces
- Install gasket
- Install Tapping Machine on valve, taking care not to bump pilot or cutter on
valve.
- Align bolt holes on flange
- Install bleeder valve and leave open.

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- Install pipe work or hose to bleed connection to vessel, or to a suitable

distance if line product is hazardous or inflammable.
- Remove trapped pressure through bleeder valve.
- Remove bleeder valve, hydraulic hoses, and measuring rod.

4.13 Calculation of Tapping Distance

- Measure distance from pilot to face of adapter ( Ref. Dimension ‘ A ‘ on
Tapping Distance Measurement )
- Measure Distance from Top of Value to top of Pipe ( ref. Dimension ‘B’ on
Tapping Distance Measurement )
- Refer to Manual to approximate distance pilot and cutter must travel to
complete tap after pilot contacts pipe. ( Ref. Dimension ‘C’ on Tapping
Distance Measurement )
- If Pilot Tip is inside the adapter, total of A and B equals distance pilot must
travel to contact pipe.
- If pilot tip extends beyond face of adapter, total of B-A equals distance pilot
must travel to contact pipe.
- Ensure pilot drill coupon catcher is operating properly.
- Measure distance pilot tip extends beyond cutter teeth ( Ref. Dimension on
Tapping Distance Measurement )
- A+B+C or ( B-A+C ) equals total travel distance.
- Record all dimensions on Tapping Distance Measurement.

4.14 Tapping work

- Start power unit and engage hydraulic pump.
- Open control valve on tapping machine and rotate cutter slowly for first few
turns.
- When pilot penetrates pipe and air is purged from valve and adapter, close
bleeder valve.
- If machine should stall, close control valve and disengage clutch.
- When tap is complete the measuring valve will read exact tapping
distance.

4.15 Complete Tap

- When tap is complete, close control valve and disengage clutch

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- Extend boring bar two or three turns with lower in crank to ensure tap is
complete
- Retract cutter until measuring rod reads from step 3.
- Stop power unit.
- Close tapping Valve.

4.16 Removal of Tapping Machine from Tapping Valve

- Remove coupon from cutter and give it to the customer where possible.
- Steam, clean / wash where necessary to remove contaminants ( H2S traces
etc. )
- Close Hot Tap valve.
- Remove Hot Tap equipment.
- Install blind flange on hot tap valve immediately after removing machine till
tie in made with new line.

5.0 Inspection Records

All inspection and test results shall be submitted to QC and Owner if required.

PT. TIMAS SUPLINDO