PROJECT SPECIFIC PROCEDURE ONSHORE CONSTRUCTIONPROCEDURE 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 0 3.4 Non-Destructive Testing 5.0 2.5 Pressure Testing 5.0 7.3 Welding Work 5.0 DESCRIPTION PURPOSE SCOPE 2 REFERENCE 2 DEFINITION 2 PROCEDURE 5.2 Site Preparation 5.0 4.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.0 SPECIAL REQUIREMENT/ REFFERENCES 4 RECORDS APPENDICES Appendix I Appendix II Datasheet 4 2 3 3 3 3 4 4 PAGE 2 – – Hot Tapping Checklist Hot Tapping Equipment .6 Drilling 5.1 Preliminary Site Study/ Inspection 5.: 0 Page 2 of 4 TABLE OF CONTENTS SECTION 1.7 Reinstatement 6.0 5. : 0 Page 3 of 4 1.2 The hot tapping operations are initiated.60.38. and creating an opening in that piping or equipment by drilling or cutting a portion of the piping or equipment within the attached fitting.38.1 3.01.10 Equipment Process piping Piping General Requirements Shop and Field Fabrication of Steel Piping Shop and Field Fabrication of Piping Hot Tapping on Pipeline. designed.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.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.01.38.2 3.3 PTS 31.5 ASME B31.0 GENERAL REQUIREMENTS 5. 3.4 3. Piping and 4.3 3.112 PTS 31.11 PTS 20.1 Hot tap connections shall be designed and installed to meet all requirements as stated in Para (3) of this procedure 5.31 PTS 31. 5. 2.0 REFERENCE 3.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. and controlled by Project Manager with the approval of the Area Operations .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. stopple and valve unit of this information.6 Compressed air piping and equipment shall not be hot tapped nor welded while in service. This is to ensure that designers. location. The construction units are responsible for ensuring that approved welding procedures and qualified welders are employed. The normal in-line suction screens are not considered adequate for this purpose. construction/maintenance installation unit. unless a detailed design and installation procedure has received prior approval from the both MLNG . engineering staff. particularly in cases where the hot tap sticker is not installed in a vertical position.: 0 Page 4 of 4 Superintendent (PCSB & MLNG) and Operations Supervisor/ Superintendent (PCSB & MLNG) for tying in new installations to existing facilities.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. 5.11 Adequate support of the hot tap machine shall be provided to prevent overstressing of the pipe and/or fitting. operations and/or project management. The Initiating Engineer shall identify the equipment in terms of service. who shall be made responsible for the overall coordination of the hot tapping activities. split tee (stopple) and valve crew. 5. and hot tap machines shall be pressure tested in accordance to Para (3) codes 5.5 5. and material type and notify the Hot Tap. 5.8 Hot tap connections are not allowed for certain cases.9 All hot tap connections. 5.12 Hot tapping shall not be permitted if: .4 5. due to induced voltage. and inspection staff cooperate closely during all phases of the hot tapping operations. QA/QC from both PRSB and PCSB shall verify this. pipe diameter.10 Precautions against electric shock. 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.3 PRSB shall appoint an Initiating Engineer. valves. 5. header and branch pressure rating. 5. hot tap. shall be taken into consideration when installing hot tap connections on above ground pipelines near high voltage power lines. 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. Care should be taken when cutting across existing welds since the cutter can be damaged.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. retracting the cutter and closing the tapping valve when any of the following exist: .3 The chamber of the hot tap machine and valve shall be purged with nitrogen after cutting the coupon.12. 6. 6. 5. and the removal of the piping or pipeline flange bolts. shall continuously monitor the work site for the presence of hazardous materials during the work activity using established gas testing procedures.75 inches of a circumferential girth weld seam as measured from the toe of the sticker weld or split tee circumferential fillet weld. 5. or other person certified as a gas tester.13 Existing welds under the hot tap shall be ground smooth prior to fit up of the sticker and reinforcing sleeve. all personnel involved shall be provided with an appropriate breathing apparatus with additional of gas detector. or split tee circumferential fillet weld to the toe of the flange circumferential butt weld (or the closest edge of the threaded connection).12.2 The standby person or fire watch.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. operation and removal of the hot tap machine. 5.2 within 0. 6. 5.: 0 Page 5 of 4 5. to the toe of the nearest girth weld.15 Compact steel gate valves with extended body ends shall not be used for hot tap connections.1 If a potential exists for a Hydrogen Sulfide (or other Toxic material) release at a work site.1 within 18 inches of a flange (or threaded connection) as measured from the toe of the reinforcement sleeve.0 Precautions Materials against H2S and other Toxic/Hazardous 6. 1 5.13.6 When welding sour gas or sour crude lines. .2 5.5 The Operations from PCSB and PRSB should provide written and verbal emergency instructions (including evacuation procedure) to the hot tapping crew. However. 6. air horns/industrial fans shall be provided to improve air circulation.3 5. equipment. the fire watch personnel shall be clearly instructed that should a burn-thru occur. 6.: 0 Page 6 of 4 5. clothing.13. fire watch personnel. the Operation Superintendent should immediately be notified to advise further action. exposed to the burn-thru flame. Hot tap equipment is larger than 36 inches.4 H2S concentration is greater than 10 ppm. 6.7 Firewater and extinguishers should be applied as required to workers..4 In enclosed or confined areas. 6. Gas release may affect others in the area. The work is in a confined area. If a burn-thru should occur. etc.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.13.13. Fans shall meet the electrical area classification requirements. the fire of the gas jetting from the pipe should not be extinguished. the air velocity shall not interfere with the welding arc shielding gases. and other workers who may be in the work area. 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. operations. surface preparation.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. 8. . etc.0 Preparation of Hot Tap Specification and Test Calculations 7.2 The Initiating Engineer shall arrange for a team.3 The Initiating Engineer shall mark of the exact hot tap locations. 8.) 8. and in all cases.7 If ultrasonic readings indicate a lamination or evidence of hydrogen induced cracking (HIC) damage. location.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.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. and a representative of the Hot Tap and Stoppling crew. The area to be scanned shall include the weld zone and 50 mm each side of it. the responsible inspector. The inspected area shall be permanently marked for future reference and identification. 8. ensuring the hot tap locations are at a position where the pipe out-ofroundness does not exceed 3 mm.: 0 Page 7 of 4 7. (Out of roundness criteria only applies to split tee or full encirclement sleeves) 8. consisting of himself. The minimum remaining wall thickness at the weld connection area shall not be below minimum thickness . no less than 5 mm. pipe inspection. to survey the general hot tap location in order to specify and mark the hot tap locations in detail. 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. Tm.e.0 Locate and Inspect Hot Tap Position 8.1 The Initiating Engineer shall make all necessary arrangements for the preparation of hot tapping(i. the hot tap position shall be relocated after consultation with the Initiating Engineer and the responsible Operations from PCSB and MLNG 8. and mark the hot tap number alongside each hot tap location. excavation. prior to each of the following: 9. The installation package shall be on-site during the entire installation process and verified.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.2 Written approval of the detailed hot tap installation shall be obtained from the Operations Superintendent. and a copy sent to the Area Loss Prevention Office and responsible QA/QC for their review and concurrence prior to starting the installation. that it is understood by the person(s) carrying out the work.3 All work shall be in strict compliance with MLNG Work Permit System.1 Vehicle entry 9.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. The Work Permit shall be approved by the MLNG and PCSB Operations Superintendent.4 Hot Tapping 9. by the QA/QC. 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. 9. .2 Welding 9.3.3.4 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. or higher.: 0 Page 8 of 4 9.3.0 Safety Requirements 9.3.3 Grinding 9. 9. 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. The initial pressure testing of the hot tap machine. etc. process stream. will take place in the shop after the machine has been checked and worn parts replaced. even if the elapsed time is less than four months.1 The Initiating Engineer shall be responsible for ensuring that the pressure tests are performed in accordance with PTS 31. in accordance with the following criteria: 10.2. 10. and the name of the testing organization. 10.38. Inspection Department.2. For a series of consecutive hot taps on a single type of service (i. 10.3 Pneumatic testing of hot tap connections on hot lines over 93 deg C is not permitted unless approved by the Manager.60.e.2 The hot tap machine shall have an overhaul of its renewable pressure sealing components and be subjected to a shop rated pressure test. 10.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.2.) the hot tap machine shall be shop tested at the end of the series of hot taps.: 0 Page 9 of 4 10 Pressure Test Requirements 10. including the hot tap valve and branch connection prior to and after installation.10 on the hot tapping equipment.. 26-00126-001- Silicone Fluid 200 26-010- . steam. 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.1 Pressure test once every four months and overhaul once every 12 months. overhaul date.3 A stamped brass tag shall be affixed to the hot tap machine indicating the test pressure.2 After it has been used on lines with operating temperatures in excess of 150 deg C. : 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. 4c or 4.7 above.9 Install the hot tap valve and apply another high pressure closure test (seat test) per para.4d on Saudi Aramco Form SA-7627-ENG. . AB036719. 10.4e on Saudi Aramco Form SA-7627-ENG. however. A back seat test and low pressure seat test is not required. the branch connection shall have a blind flange installed and pressure applied through the branch connection boss as shown on Std. with the valve in the closed position.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. 10. This test pressure shall be the lower value shown in 4. During the test.8. The test pressure shall be the lower value shown in 4. a full hydrostatic pressure test shall be applied to the branch connection. Valves with metal to metal seats shall meet the leakage criteria of API 598. an MT or PT may be applied to the branch connection seal weld. mount the hot tap machine and apply another full pressure test per paragraph 3. At the option of the Inspector. 10. drained and vented upon completion of hydrostatic testing to prevent possible build up of pressure from any source of heat. Dwg.8. but prior to installing the reinforcing pad or full encirclement ring. 10. 10.35 kPa (ga) for a tightness test using a soap solution.: 0 Page 11 of 4 10. 10. the MAOP of the line need not be exceeded.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.7 After installation of the branch connection. A tag shall be attached to the valve indicating test date.4c or 4. and applied through the branch connection boss. test pressure and Inspector's name.5) 10.8.11 Ensure that the connection is opened. install a bar stock plug in the branch connection boss and seal weld. Resilient (soft) seat valves shall have zero leakage. This pressure will then be reduced to 21 .6 above.8 A pneumatic test of 173 kPa (ga) shall be applied to the reinforcing pad or ring after installation.12 After completion of the above tests. (Refer to paragraph 3. 3.13 The appropriate Inspection Representative shall witness and approve all hydrostatic testing required for completion of the hot tap connection.10 Return the valve to the open position. 11.3.: 0 Page 12 of 4 11 Operating Conditions Requirements 11. This steam or gas shall be kept flowing through the line during the entire welding operation.3 The minimum flow rates per para. 11.2 In systems where hydrocarbon and oxygen mixtures are definitely not a possibility.1 For new construction tie-ins to existing lines.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. In certain cases. or hydrocarbon gas.(e. 11. approval shall be obtained from the responsible Project Manager. 11. This shall be stated in the remarks section of the Work Permit.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. A positive pressure and flow shall be maintained at all times while welding and hot tapping is in progress.2. hot tapping. whichever is less. 11.4 or the maximum attainable flow under normal working pressure. sea water injection lines). shall be maintained during all welding operations.g..9. .3 Prior to and during any welding.2.3.2. such as flare lines with insufficient or intermittent flow.1 Flow in a line shall be maintained while welding is being performed.3. However. and testing operations. Operations shall verify a non-combustible mixture in the line. and the Operations Superintendent. 3. the line shall be purged with steam.3. inert gas. unless approved otherwise by the Operations Superintendent. 11.2 For normal maintenance tie-ins to existing systems not involving new construction. approval shall be obtained from the General Supervisor / Superintendent Operations Engineering. General Supervisor / Superintendent Operations Engineering. and the Operations Superintendent.3 on welding of pipelines under pressure.3. to weld with "NO-FLOW" conditions. flow is not required.2 Maximum internal pressure of the piping/equipment during welding shall be in accordance with SAES-L-052 paragraph 5. the following must be satisfied: 11. While hot tap work and pressure testing is in progress.1 The Initiating Engineer shall coordinate all activities.9). 12. 12. (Refer Para. pressure.3. the operator shall remain in a location where he can control operating conditions such as flow.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. An additional operator shall standby at the job site while the work is in progress. before and during the installation.3 The Inspector shall perform the following: 12. However.2 and 3. 12.9. 3.2 The Operations Superintendent shall ensure compliance with the safety precautions arranged under paragraph 3.9 of this SAEP. Continuous radio communications between the job site operator and the Control Room is required.1 Verify a CSD approved welding procedure specification is utilized for installation of the connection. for compliance with the approved drawings and welding procedures. if deemed necessary by the Operations Superintendent. .3. if the branch connection size is less than 50% of the size of the line being hot tapped.10 m/sec maximum.3.5.5 Work shall be immediately stopped when constant flow and pressure as noted in paragraphs 3.: 0 Page 13 of 4 11.3.4 Maximum and minimum flow rates during hot tapping shall be 0. then the minimum values do not apply but a positive flow shall be maintained.3.4 Verify that a calibrated pressure gauge and relief valve are properly installed for testing.5 Confirm that the hydrostatic test pressure for the branch connection is correct at the time of the test. including acceptance of the work permit. 12.3 Inspect the branch connection/split tee.2 Verify that 3.40 m/sec minimum and 9. as prescribed in Section 4 of Form SA-7627-ENG. 12 Hot Tap Fittings/Sandwich Valve Installation Requirements 12. 11. 12.2 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. Pressure testing shall also stop if pressure in the header/ equipment is lost.9.3 cannot be maintained during the welding and hot tapping operations. 12. and liquid level within the limits specified in the hot tap design information. : 0 Page 14 of 4 .HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. 1 Hot Tapping Operation Procedure .: 0 Page 15 of 4 13 Responsibilities 13.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. 6. using a qualified welder and a CSD approved welding procedure. Ensure all the requirements of paragraph 3. Install the nozzle or boss connection using full penetration welds in the exact location shown on the approved drawing. Eng/Maint/Constr Opers/Maint/ Constr Init.3) from the Operations Superintendent.8. rust and scale. The Inspection Unit will verify proper weld joint fit-up.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. Obtain an approved Hot Work Permit. 3. or his designee. grind seam weld flush with the surface of the pipe taking care not to reduce the pipe wall thickness. The cutters sometimes break if the cut is made through a weld. If long seam is under hot tap fitting. Ensure that the nozzle connections are not welded on the inside unless the hot tap cutter is at least one pipe size smaller than the nozzle. Eng/Maint/Constr Maint/Insp/Constr Init.2 Mount the valve on the fitting ensuring that its alignment is within the manufacturer's tolerance Responsibilities Init. Check that the location of the installation is that location specified by the initiating Engineer with the concurrence of the Operations Supt. Confirm that the shop rating test of the hot tap machine is current per para.5. 3. Power wire brush the area for attachment welds to remove all traces of paint. including the cutter and coupon retaining device. Ensure the pressure and flow requirements as identified in section 4 of Form SA-7627ENG have been established prior to any welding. Eng/Insp Init. prior to starting with work. The fit-up of the connection to the header shall provide for a standard pipe bevel and 1/16 inch minimum root gap.7. Saudi Aramco Form SA-924-2 (Para. including an approved welding procedure in accordance with the applicable SAES-W-XXX. Check pipe wall thickness ensuring it does not violate para. 3.: 0 Page 16 of 4 Procedure Review the design drawings and requirements for the branch connection.2 General Requirements" are met. Precheck the tapping valve and the hot tap machine to assure good operable condition. Eng/Insp/Maint/Constr/ Opers Maint/Insp/Constr Insp/Init Eng/Maint/Constr Hot Tap Unit Insp/Hot Tap Unit Insp/Hot Tap Unit . including an approved welding procedure in accordance with the applicable SAES-WXXX.14 machine on the valve. Maint/Constr/Hot Tap/Insp Procedure Review the design drawings and requirements for the branch connection. 4.13 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. Responsibilities Init.18 the hot tap machine on the tapping After assembly of .: 0 Page 17 of 4 Close the valve and perform the hydrostatic test according to this instruction.9 and will easily pass the hot tap cutter. 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. valve.17 Install and seal weld a threaded plug in the weld boss Maint/Constr on the connection after all testing has been completed.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO. paragraph 5.12 4. Refer to paragraph 3.8.8. and welded connection in Maint/Constr with the testing procedure specified in this SAEP and SAES-L-052. 4.15 Ensure that the tapping valve is tested in accordance Hot Tap Unit/Insp with paragraph 3.16 Apply hydrostatic and pneumatic pressure tests to the Hot Tap Unit/Insp/ hot tap machine. Eng/Insp 4.11. 4.11.11. Unit/Maint/ Mount the hot tap Hot Tap Constr 4.11. This may require grinding of the lugs on the valve seat rings to provide adequate clearance.11.11. 4.20 tap machine boring bar.19 Hot Tap Unit Drill and cut Retract the hot Hot Tap Unit 4. 4.22 tap machine from the line.11.1 Completely close and then completely open Hot Tap Unit valve to ensure that it Is operable.21 Close the valve.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.18.11. Ensure that the Hot Tap Unit/Insp/ Maint/Constr .11.11.11. and Hot Tap Unit depressurize the hot tap machine adaptor. 4.HOT TAPPING PROCEDURE ONSHORE CONSTRUCTION PROCEDURE NO: PSP-KOTI-19 REVISION NO.18.24 The coupon shall be removed only by the Operations Opers Supervisor and forwarded to the responsible Operations Inspection Unit.11.11.11. purge with nitrogen. and that the cutter can be withdrawn a sufficient distance to permit closure of the valve. 4.2 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. Remove the hot Hot Tap Unit/ Maint/Constr 4. 4. if required.11. 4.: 0 Page 18 of 4 valve and before the tapping operation is started: 4.25 completed connection is blinded or plugged before leaving the job site.