GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
DOCUMENT TITLE: TIE-IN PROCEDURE DOCUMENT NO.: PR-D-1102.21-4012-005 REVISION: 0 REVIEW STAMP COMMENTS E. Work may proceed. F. Work may proceed. Submit for Construction Documents. G. Revise and Resubmit. Work may proceed Subject to incorporation of changes indicated. H. Revise and Resubmit. Work may not proceed. I. Review not required. Work may proceed. Acceptance in any of these categories shall be in no way relieve the Contractor/Supplier of its responsibility for the due and proper performance of the Work in accordance with the Contract/Purchase Order. Name: Sign: Date:
0 11/04/13 Issued for Construction WS JR NP A 25/03/13 Issued for Approval WS JR NP Rev. Date Description Prepared By Checked By Approved By CONTRACTOR: SIAM RAJATHANEE JOINT VENTURE CONSULTANT: UNITY ENGINEERING AND CONSULTANCY SERVICES CO.,LTD.
TIE-IN PROCEDURE GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-D-1102.21-4012-005 Rev. 0 Page 2 of 13
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DOCUMENT CHANGE RECORD
Rev Date Prepared/ Revised By Reviewed By Approved By Description A 25/03/13 WS JR NP Issued for Approval 0 11/04/13 WS JR NP Issued for Construction
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TIE-IN PROCEDURE GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-D-1102.21-4012-005 Rev. 0 Page 4 of 13
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1.0 SCOPE OF WORK
This document has been complied by Contractor to provide a set of detailed instruction to allow for efficient completion of piping tie-in for flange NPS 12 2 point & Hot trap 2 1 point for the Gas Pipeline and Gas Metering and Regulating Station Project.
2.0 DEFINITIONS
Owner means Ratchaburi World Cogeneration Company Limited. Advisor means PTT Public Company Limited. Project means Gas Pipeline and Gas Metering and Regulating Station Project. Consultant means Unity Engineering and Consultancy Services Co., Ltd. Contractor means Siam Rajathanee Joint Venture SHE means Safety, Health and Environment Subcontractor means The party which Contractor has assigned a portion of the Work under this contract, without any form of employment relationship to the works subject to the approval of the Owner or Consultant.
3.0 RESPONSIBILITY Project Manager will be in charge of defining the role and responsibilities of each team member. The main duties of the PM will be: Management and co-ordination of the efforts of the project team Assistance and liaison to PTT Overall supervision of the project work under consideration of the results of the controlling team and PTTs requirements Construction Manager is responsible for ensure that piping Tie-in activities shall always be performed by trained, experienced employees in a manner acceptable to Project Specification and Procedure requirements. Field Engineer shall be responsible for procedure for tie-in at Metering & Regulating Station area (By PTTs region 5) and ensure all operations are carried out in correct and safe manner and that all stages of the operation comply with laid down procedure and codes. SHE Manager shall ensure that all activities and specified Health, Safety, Security and Environment rules and regulations are enforced with regards to this project. Quality Control manager is responsible for ensuring that the owner agreed quality requirements are satisfied and that they are included in this method statement. He shall ensure the inspectors inspect and control in accordance with this method statement.
4.0 PREPARATION PROCEDURE All piping and shall complete with NDT, Hydrostatic test, Flushing and Leak Test. All valves shall complete leak test following Site Acceptance Test For Valve Procedure (PR-P-1102.21-4012-003)
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5.0 TIE-IN PROCEDURE
5.1 Tie-in Type; TP-01 is Flange Connection (Bolting Type) TP-02 is Flange Connection (Bolting Type) TP-03 is Hot tap
5.2 For exiting line gas NPS 12 Tie-in No.01 and No.02 (Bolting Type) Permission Work is required for all activity in Metering & Regulating Station area (By PTTs region 5) To ensure that exiting Ball Valve 12 HOV010, 12-V032-022 of line pipe G- 024-12-D60 shall be 100% closed position. Hydraulic hose, Pressure gauge, Coupling and all necessary fitting shall provide to connect for temporary line for gas ventilation from vent valve 1/2 of exiting Ball Valve 12 HOV010, 12-V032-022 to atmosphere at high point, slowly open valve for gas venting and continuously vent until gas percentage is not more than 5% (should not exceed 5 minute for venting if no gas passing) In case of gas passing from valve 12, repair ball valve shall commence to proceed with Sealant Injection process. Connect the Giant Button-Head Coupler to Sealant Injection Fittings for cleaning valve with using solvent cleaner, Lubricant No.2X, 3X, 4X is recommend to injection.
Start pumping for charging the lubricant through around seat valve (approximately 12 ounce.), both side of seat valve shall be inject solvent cleaner with same condition, during, inject the cleaner process, monitor and control pump pressure shall not exceed 5,000 psig. And then holding 30 minutes (min). Re-checking gas percentage at vent valve with Gas Detector. If still seat passing, sealant injection shall commence to proceed. The 5050 Sealant is recommended to injecting Attach the gun loaded with sealant on the sealant injector and charge the sealant. While charging, try rotation the ball through a small angle (10 deg.) And return it back to original position. Remove the gun. Check and ensure that there is no leakage across the seats. After completed, open the flange of existing pipe spool and replace new pipe spool proceed to tie-in flange 12. Commence to proceed torque bolt, leak test process. After the pipe spools have been completed, the nitrogen will be packed into piping at 10 psig.
5.3 For exiting vent line NPS 12 Tie-in No.03 (Hot tap)
5.3.1 Prerequisite Meeting between PTT, Siam Rajathanee Joint Venture . must be held to assure complete understanding of what is to be accomplished and how. Verify line contents, pressure, temperature, pipe wall thickness, flow rate and out of round conditions must be properly documented. Generally, gas flow rate and pressure shall conform to Hot tap manufacturer recommendation which mandatory to Hot tap conference. Review PRE-HOT TAP AND HOT TAP OPERATION CHECK LIST as attachments. Discuss what items will be provided for the operation such as ladder, excavation, shoring, de-watering equipment, safety equipment, gasoline, oil, grease, wrenches, lifting equipments, supervised labor, gaskets, bolts, scaffolds, support for pipe, valve and tapping machine.
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Record the memorandum of above meeting and attach into the Hot tap procedure to remind all concerned party requirements prior starting the work.
5.3.2 Branch Connection Welding
Permission Work is required for all activity in Metering & Regulating Station area (By PTTs region 5) Tie-in No.03 will locate at the existing pipe 12 Line No. V-005-12-D10, Tie-in will perform by weldolet 2 to existing 12 vent line. Tie-in point shall be checked for determining in advance the location, vertical elevations, alignment, pipe diameter, joints, materials, wall thickness and configuration of existing pipeline to which connections are to be made. The tie-in joint is nominated as a Golden Weld which this joint will not be hydrostatically tested following completion, and as such shall be subject to additional NDT. Pipe End Preparation The edges or surfaces of the parts to be welded shall be prepared to the shape and dimensions specified on the approved Weld Procedure Specification by beveling machine. The edges or surfaces of the parts to be welded shall be cleaned of all oil, grease or paint for a minimum distance of no less than 40 mm form the edges of the weld preparation internally and externally. After the edges have been dressed for welding, visual examination shall confirm that the preparations are smooth and uniform, free from tears, gouges and other discontinuities of any planar/lamellar type defects, if required magnetic particle or ultrasonic shall be used to assist further inspection.
Removal of Foreign Matter and Materials Each open pipe end shall be inspected before installation final alignment and welding for cleanliness and to ensure that grindings, weld rods, spoil, dirt and other foreign matter are removed. If necessary, the internals of pipe ends shall be adequately swabbed to remove dirt, debris and other foreign matter. The swabbing should preferably be carried out dry, unless dry swabbing proves ineffectual. In such cased, wet swabbing should be used followed up by dry swabbing. Shall be 100% closed position.
Alignment and Fit Up The edges of the parts to be joined by welding shall be held in proper alignment by an external pipe clamp, and shall have the correct root gap in accordance with the dimensions specified on the approved Weld Procedure Specification All fit up and alignment details shall be recorded as per the requirements of PR-P- 1102.21-4012-007 Inspection and Test Plan for Station Piping Work.
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Inspection & Testing The Welding Inspector shall carry out, visual examination, before, during and after welding operation. All layers of welds shall be examined by MT in accordance with ASME V, API 1104 and NDT Procedure provide by third party. Following visual inspection and NDT of the completed weld, the QC manager will complete the reports and submit them to the Document Controller Centre for Final Certification.
Painting Following completion and inspection acceptance and clearance of the weld, the weld joint margins shall be cleaned, prepared and painted. Any visible damage to the adjacent painting shall be repaired. Repair procedure shall be in according with PR-Q-1102.21-4012-001 Painting Procedure for above Ground Piping. The exposed pipe length and painted joint shall be subject to a Dry Film Thickness the full length and circumference. Following completion of the repair shall be repeated over the repair area to confirm satisfactory repair, witness by Owner / Consultant representative who shall provide signatory approval.
5.3.3 HOT TAP
Make Tapping
1. Install tapping machine on valve and gasket, and tighten flange bolts evenly. Note: If fitting has not been pressure tested, suggest to customer to test before starting tap. 2. Install bleeder valve on the tapping machine and leave open. 3. Connect hydraulic hoses from power unit to tapping machine. 4. Extend boring bar until pilot contacts pipe and verify the dimension noted on Check Sheet. Retract slightly and engage clutch. Remove crank. 5. Install measuring rod and mark tapping measurement.
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6. Check with customer for OK to begin tap. By verify the current line pressure 7. Introduce nitrogen gas to pressurize the hot tap branch connection from Hot tap machine purged connection to 50 Psig above the current line pressure 8. Communication between hot tap operator and inspector shall be maintains at all time during the tapping process. 9. Start power unit and engage hydraulic pump. 10. Open control valve on tapping machine; rotate cutter slowly for first few turns. 11. When pilot penetrates pipe and air is purged from valve and adapter, close bleeder valve. 12. If. Machine should stall, close control valve, disengage clutch and retract cutter slightly. Engage clutch and resume tapping. 13. When tap is complete the measuring rod should read calculated tapping distance as Check Sheet 14. Close control valve and disengage clutch. 15. Extend cutter two or three turns to ensure tap is complete. 16. Retract cutter all the way back. 17. Stop power unit. 18. Install the Sealant Inject gun to Hot tap grease injection port and inject the lubricant grease grade 911# to lubricate the valve seat before making any attempt to cycle the hot tap valve Lubricant usage should be approximately 1ounch for every 1 inch of ball valve size. 19. Close taping valve, counting turns, and close internal bypass (if applicable) 20. Relieve trapped pressure through bleeder valve. 21. Remove bleeder valve, hydraulic or pneumatic hoses and measuring rod. 22. Remove tapping machine from tapping valve, which is allowing client to proceed for tie-in. 23. Remove Coupon from tapping machine and give away to client. 6.0 SAFETY Contractor will take all necessary safety precautions related to or arising out of the performance of the contract in order to protect the work, Contractors personnel, property of Owner and all Third parties. JSEAs shall be conducted for tie in work. The contracted shall provided safety equipment as required for tie-in work to control and protect, any accident may be occurred.
Nitrogen purge Area barricade Warning sign Fire extinguisher Stand by Service Car Fire Fighting mobile
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Contractor will comply with all applicable safety laws, regulations (including permit to work systems) in accordance with Job Safety And Environment Analysis. ED-X-1102.21-4012-001 The Safety department will employ a dedicated trained fire watcher, who shall be on site while any tie in work is in progress. This will include cold cutting and welding. No tie in operations shall be permitted to commence until the fire watcher is satisfied that all safety precautions are in place. 7.0 QUALITY CONTROL The works shall be managed in accordance with PL-A-1102.21-4012-001 Project Execution Plan. Contractor shall provide all supervision and inspection of fabrication and installation to ensure compliance with the Project Specifications and AFC drawings.
THE HOT TAPPING STEP
7.1 PREREQUISITE
1. Meeting between PTT, TRC Construction Public Company Limited must be held to assure complete understanding of what is to be accomplished and how. 2. Verify line contents, pressure, temperature, pipe wall thickness, flow rate and out of round conditions must be properly documented. Generally, gas flow rate and pressure shall conform to Hot tap manufacturer recommendation which mandatory to Hot tap conference. Review PRE-HOT TAP AND HOT TAP OPERATION CHECK LIST as attachment 7 and 8. 3. Discuss what items will be provided for the operation such as ladder, excavation, shoring, de-watering equipment, safety equipment, gasoline, oil, grease, wrenches, lifting equipments, supervised labor, gaskets, bolts, scaffolds, support for pipe, valve and tapping machine. 4. Record the memorandum of above meeting and attach into the Hot tap procedure to remind all concerned party requirements prior starting the work.
7.2 CHECK AND INSTALLED TAPPING VALVE
1. Clean valves faces. 2. Install gaskets, lower valves onto fitting slowly. 3. Align bore with bore of fitting as near perfect as possible. 4. Check flange make up for bolts and gasket and be sure bolts have been tightened. 5. Check to make sure valve will open and close properly. 6. Measure valve bore for sufficient cutter clearance. Record this dimension. 7. Measure valve for sufficient housing space for cutter and pilot face of valve to seat rings. Record this dimension in hot tap check list (see attachment 8). 8. Install gasket on top of valve.
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7.3 ASSEMBLE TAPPING MACHINE
1. Check boring bar drive ring for tightness and damage. 2. Check ring joint and steel ring gasket. 3. Install tapping adapter on tapping machine and snug top two bolts leaving others loose. 4. Extend boring bar beyond face of adapter. 5. Install cutter holder in boring bar. Tighten retainer shaft with measuring rod by hand. Install safety pin with cotter pins on both ends. 6. Check cutter teeth and O.D. of cutter. Install cutter on cutter holder and tighten socket head bolts first, then tighten lock nuts. Acceptable alternate is to assemble cutter and cutter holder before installing cutter holder in boring bar. 7. Check U-rods, cutting edges and nylon lock pin in pilot. Then install pilot in cutter holder and tighten. 8. Align adapter with cutter and tighten adapter bolts. For alignment reference measuring from O.D. of cutter to O.D. of flange raised face. 9. Retract boring bar and cutter all the way back. Take measurement with measuring rod or tape.
7.4 CALCULATE TAPPING DISTANCE
Calculate measurements for carrying out hot taps. See check sheet no. 1; ensure cutter and pilot combination is correct for the job.
1. Measure Tapping Machine Adapter Face to Pilot Tip. 2. Measure face of top of valve. 3. Check tapping machine manual for correction of tapping distance.
When machine is bolted to valve, extend cutter and pilot to top of valve, and then the machine is ready for hot tap operation.
7.5 INSTALL TAPPING MACHINE ON TAPPING VALVE
1. Install tapping machine on valve, taking care not to bump pilot or cutter on valve. 2. Align bolt holes of flange. 3. Install bolts and tighten evenly. 4. Install bleeder valve and leave open. 5. Connect hydraulic hoses from power unit to tapping machine. 6. Extend boring bar until pilot contact pipe, retract slightly and engage clutch. Remove crank. 7. Install measuring rod and mark tapping measurements. 8. If fitting has not been pressure tested, suggest to customer to test before starting tap.
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7.6 COMPLETE TAP
1. Check with customer first if O.K. to begin tap. 2. Start power unit and engage hydraulic pump. 3. Open control valve on tapping machine and rotate cutter slowly for first few turns. 4. When pilot penetrates pipe and air is purged from valve and adapter, close bleeder valve. 5. If machine should stall, close control valve, disengage clutch and retract cutter slightly. Engage clutch and resume tapping. 6. When tap is complete, machine will run smoothly and measuring ring rod should read approximate tapping distance.
7.7 COMPLETE TAP
1. When tap is complete, close control valve and disengage clutch. 2. Extend boring bar two or three turns with lower in crank to insure tap is complete. Stop power unit. 3. Retract cutter until measuring rod reads measurement. 4. Close tapping valve. 5. Relive trapped pressure through bleeder valve. 6. Remove bleeder valve, hydraulic hoses and measuring rod. 7. Remove coupon from cutter and give to PTT, and/or representative. 8. Install temporary blind flange and can be removed anytime to provide Tie-in work. 8.0 VENDOR DOCUMENT (S) Material certificates Plant and Equipment dimensional drawings Operation Manual for isolated valves shall be made available by the Owner at the work site for reference during the construction Technical calculation certificated report by vendor
9.0 REFERENCE DOCUMENT(S) ASME Section IX - Qualification for Standard Welding And Brazing Procedures ASME B31.3 - Process Piping ASME B31.8 - Gas Transmission and Distribution Piping Systems API Std 5L - Specification for Line Pipe
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API Std 1104 - Standard for Welding of Pipelines and Related Facilities PL-A-1102.21-4012-002 - Project Execution Plan PR-P-1102.21-4012-007 - Inspection and Test Plan for Station Piping Work PR-P-1102.21-4012-005 - Material Receipt ,Storage and Issue Procedure PR-Z-1102.21-4012-001 - Non Destructive Testing Procedure PL-A-1102.21-4012-002 - Health, Safety & Environment (HS&E) Plan SP-A-1102.21-010-006 - Specification for Shop Inspection Item List SP-P-1102.21-010-011 - Specification for Piping Material Classes SP-W-1102.21-010-002 - Specification for Welding of Pipe for Station Construction PR-W-1102.21-4012-001 - PTT Welding Procedure Specification for Piping and Pipeline (WPS) PR-W-1102.21-4012-002 - Welding Procedure Specification for Steel Structure (WPS) PR-W-1102.21-4012-003 - PTT Welder Qualification Testing for Aboveground Piping and Underground Piping (WQT) PR-W-1102.21-4012-005 - PTT Procedure Qualification Record (PQR) PR-W-1102.21-4012-006 - Welding And Inspection Control Procedure
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ATTACHMENT(S)
Existing PTTs MR station Piping & Instrument Diagram No. A1-9704.20-4100-028
FIGURE 1 TIE-IN No. TI-01, TI-02 & No. TI-03
Hot Tapping Location Check List
Note: Surface preparation at Hot-Tap point
1. All surface to be welding and bored, shall be check thickness by ultrasonic test, thickness in existing pipeline not less then 95% of standard pipe 12 API 5L, GR.B, SCH STD (9.53 mm.) 2. Weld joint of existing pipe is not allowed in location of hot-tapping point. 3. Seam weld of pipe should not locate in the area of cutting hole except the area of hot-tap
Checked by:
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Witness by:
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Accepted by:
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HOT TAP CHECK LIST SHEET 1
Item Description Result 1 Field Condition Survey 1.1 Discuss job with maintenance, operation and safety personnel to assure complete understanding of what is to be accomplished and how.
1.2 Verify line contents, pressure, temperature, flow rate and pipe wall thickness. Discuss what items will be needed to complete job : gasoline, oil, grease, rages, wrenches, lifting equipment, supervised labor, gaskets, bolts, scaffolds, support for pipe, valve and tapping machine, etc
2 Check Tapping Valves 2.1 Check valve bore and nipple for alignment 2.2 Check flange makeup for bolts and gasket and be sure bolts have been tightened. 2.3 Check to make sure valve will open and close properly. 2.4 Measure valve bore for sufficient cutter clearance. Record this dimension. 2.5 Measure valve for sufficient housing space for cutter and pilot. Face of valve to seat rings. Record this dimension.
3 Assembly Tapping Machine 3.1 Check boring bar drive ring for tightness and damage. 3.2 Check boring bar packing nut for adjustment. Bottom out and back off turn. 3.3 Check retainer shaft packing nut for adjustment. Tighten as much as possible. 3.4 Still allow retainer shaft to be turned easily with measuring rod. Packing nut must not extent out into taper of boring bar.
3.5 Clean ring joints and steel ring gaskets. 3.6 Install adapter on tapping machine and snug top two bolts leaving others loose. 3.7 Extend boring bar beyond face of adapter. 3.8 Install cutter holder in boring bar. Tighten retainer shaft with measuring rod by hand. Install safety pin with cotter pins on both ends.
3.9 Check cutter teeth and O.D. of cutter. Install cutter on cutter holder and tighten socket head bolts first, then tighten lock nuts. Acceptable alternate is to assembly cutter and cutter holder before installing cutter holder in boring bar.
3.10 Check U-rod, Insert Drill, and nylon lock pin in pilot. Then install pilot in cutter holder and tighten.
3.11 Align adapter with cutter and tighten adapter bolts. For alignment reference, measure from O.D. of cutter to O.D. of flange raised face.
3.12 Retract boring bar and cutter all the way. Take measurement with measuring rod. Calculation Tapping Distance.
Checked by:
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Witness by:
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Accepted by:
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HOT TAP CHECK LIST SHEET 2
Item Description Result 4 Install Tapping Machine on Tapping Valve 4.1 Clean flange faces 4.2 Install gasket 4.3 Install tapping machine on valve, taking care not to bump pilot or cutter on valves. 4.4 Align bolt holes of flanges 4.5 Install beeder valve and leave open. 4.6 Connect hydraulic hoses from power unit to tapping machine. 4.7 Extend boring bar until pilot contacts pipe, retract slightly, and engage clutch. Remove Crank 4.8 Install measuring rod or measuring tap for tapping measurements. 4.9 Tightness test for equipment assembly with valve and fitting. 5 Begin Tap 5.1 Check with customer first if OK to begin tap. 5.2 Start power unit and engage hydraulic pump 5.3 Open control valve on tapping machine and rotate cutter slowly for first few turns. 5.4 When pilot penetrates pipe and air is purged from valve and adapter close bleeder valve.
5.5 If machine should stall, close control valve, disengage clutch, and retract cutter slightly. Engage clutch and resume tapping.
5.6 When tap is complete, machine will run smoothly, and measuring rod should read approximate tapping distance
6 Complete Tap 6.1 When tap is complete, close control valve, and disengage clutch. 6.2 Extend boring bar two or three turns with lower-in crank to insure tap is complete. 6.3 Retract cutter until cutter and drill return all in tapping adapter. 6.4 Stop power unit 6.5 Close tapping valve 6.6 Relief trapped pressure through bleeder valve 6.7 Remove bleeder valve, hydraulic hoses and measuring rod. 6.8 Remove tapping machine from tapping valve 6.9 Remove coupon from cutter and give to customer