Method Statement For Hot Tapping

Document Number:
METHOD STATEMENT OML34-GEN-PM-PCD-0001

FOR HOT TAPPING Classification Status: Restricted
Discipline : QUA Revision : 00 Page 0 of 13
METHOD STATEMENT FOR HOT TAPPING

Document Number:
1.0 Purpose…………………………………………………………………………… 2
2.0 Scope…………………………………………………………………………….. 2
3.0 Reference………………………………………………………………………… 2
4.0 Definition………………………………………………………………………… 2
5.0 General requirement……………………………………………………………... 2
6.0 Precautions Against H2S And Other Toxic/Hazardous Materials……………. 4
7.0 Preparation Of Hot Tap Specification And Test Calculations………………….. 4
8.0 Locate And Inspect Hot Tap Position…………………………………………… 4
9.0 Safety Requirements…………………………………………………………….. 5
10 Pressure Test Requirements…………………………………………………….. 6
11 Operating Conditions Requirements……………………………………………. 6
12 Hot Tap Fittings/Sandwich Valve Installation Requirements………………….. 7
13 Sequence Of Work – Hot Tapping……………………………………………... 8
APPENDICES
Appendix I – Hot Tapping Checklist
Appendix II – Hot Tapping Equipment Datasheet
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1.0 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.
2.0 SCOPE
This procedure describes the suitable method for the hot tapping work on a live pipe.
3.0 REFERENCE
3.1 ASME B31.3 - Process piping
API Rp 2201 - Safe Hot Tapping Practices in the Petroleum &
Petrochemical Industries
4.0 DEFINITION
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, and creating an opening in that piping or
equipment by drilling or cutting a portion of the piping or equipment
within the attached fitting.
5.0 GENERAL REQUIREMENTS
5.1 Hot tap connections shall be designed and installed to meet all requirements as stated
in Para (3) of this procedure
5.2 The hot tapping operations are initiated, designed, and controlled by Project Manager
with the approval of the Area Operations Manager. and Operations Supervisor/ Superintendent
for tying in new installations to existing facilities.
5.3 Company shall appoint an Site Engineer, who shall be made responsible for the overall
coordination of the hot tapping activities. This is to ensure that designers,
construction/maintenance installation unit, hot tap, split tee (stopple) and valve crew,
operations and/or project management, engineering staff, and inspection staff cooperate
closely during all phases of the hot tapping operations.
5.4 The Site Engineer shall identify the equipment in terms of service, location, pipe diameter,
header and branch pressure rating, and material type and notify the Hot Tap, stopple and
valve unit of this information.
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5.5 The construction units are responsible for ensuring that approved welding procedures and
qualified welders are employed. QA/QC department shall verify this.
5.6 Compressed air piping and equipment shall not be hot tapped nor welded while in service.
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. The normal in-line suction screens
are not considered adequate for this purpose.
5.8 All hot tap connections, valves, and hot tap machines shall be pressure tested in
accordance to Para (3) codes
5.9 Precautions against electric shock, due to induced voltage, shall be taken into
consideration when installing hot tap connections on above ground pipelines near high
voltage power lines.
5.10 Adequate support of the hot tap machine shall be provided to prevent overstressing of the
pipe and/or fitting, particularly in cases where the hot tap sticker is not installed in a vertical
position.
5.11 Hot tapping shall not be permitted if:
5.11.1 within 18 inches of a flange (or threaded connection) as measured from the toe of
the reinforcement sleeve, or split tee circumferential fillet weld to the toe of the
flange circumferential butt weld (or the closest edge of the threaded
connection). 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, operation and removal of the hot tap machine, and the removal of the
piping or pipeline flange bolts.
5.11.2 within 0.75 inches of a circumferential girth weld seam as measured from the
toe of the sticker weld or split tee circumferential fillet weld, to the toe of the
nearest girth weld.
5.12 Existing welds under the hot tap shall be ground smooth prior to fit up of the sticker and
reinforcing sleeve. Care should be taken when cutting across existing welds since the cutter
can be damaged.
5.13 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.
5.14 Compact steel gate valves with extended body ends shall not be used for hot tap connections.
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6.0 Precautions against H2S and other Toxic/Hazardous Materials
6.1 If a potential exists for a Hydrogen Sulfide (or other Toxic material) release at a
work site, all personnel involved shall be provided with an appropriate breathing
apparatus with additional of gas detector.
6.2 The standby person or fire watch, or other person certified as a gas tester, shall
continuously monitor the work site for the presence of hazardous materials during the
work activity using established gas testing procedures.
6.3 The chamber of the hot tap machine and valve shall be purged with nitrogen after cutting
the coupon, retracting the cutter and closing the tapping valve when any of the following
exist:
6.3.1 H2S concentration is greater than 10 ppm.
6.3.2 Gas release may affect others in the area.
6.3.3 Hot tap equipment is larger than 36 inches.
6.3.4 The work is in a confined area.
6.4 In enclosed or confined areas, air horns/industrial fans shall be provided to improve air
circulation. However, the air velocity shall not interfere with the welding arc shielding
gases. Fans shall meet the electrical area classification requirements.
6.5 When welding sour gas or sour crude lines, the fire watch personnel shall be clearly
instructed that should a burn-thru occur, the fire of the gas jetting from the pipe should not
be extinguished. If a burn-thru should occur, the Operation Superintendent should
immediately be notified to advise further action.
6.6 Firewater and extinguishers should be applied as required to workers, clothing, equipment,
etc., exposed to the burn-thru flame.
7.0 Preparation of Hot Tap Specification and Test Calculations

7.1 The Site Engineer and contractor shall provide engineering calculation for each hot tap
operation and shall be reviewed by Client for approval.
8.0 Locate and Inspect Hot Tap Position
8.1 The Site Engineer shall make all necessary arrangements for the preparation of hot
tapping(i.e. location, excavation, pipe inspection, surface preparation, etc.)
8.2 The Initiating Engineer shall arrange for a team, consisting of himself, operations, the
responsible inspector, and a representative of the Hot Tap and Stoppling crew, to survey the
general hot tap location in order to specify and mark the hot tap locations in detail.
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8.3 The Site Engineer shall mark of the exact hot tap locations, and mark the hot tap number
alongside each hot tap location, ensuring the hot tap locations are at a position where the
pipe out-of roundness does not exceed 3mm. (Out of roundness criteria only applies to split
tee or full encirclement sleeves)
8.5 The QA/QC shall inform the Site 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.
8.6 If ultrasonic readings indicate a lamination or evidence of hydrogen induced cracking (HIC)
damage, the hot tap position shall be relocated after consultation with the Site Engineer and
the responsible client team
8.7 The QA/QC shall review the welding procedure specification (WPS) for the installation of
the hot tap fittings and assure an approved WPS is employed.
9.0 Safety Requirements
9.1 The Site 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.
9.2 Written approval of the detailed hot tap installation shall be obtained from the Operations
Superintendent, or higher, and a copy sent to the Area Loss Prevention Office and
responsible QA/QC for their review and concurrence prior to starting the installation. The
installation package shall be on-site during the entire installation process and verified, by
the QA/QC, that it is understood by the person(s) carrying out the work.
9.3 All work shall be in strict compliance with client approved Work Permit System. The
client responsible team shall approve the Work Permit, prior to each of the following:
9.3.1 Vehicle entry
9.3.2 Welding
9.3.3 Grinding
9.3.4 Hot Tapping
9.4 The Site 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.
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.
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10 Pressure Test Requirements
10.1 The Site Engineer shall be responsible for ensuring that the pressure tests are performed
in accordance with API RP 2201 on the hot tapping equipment, including the hot tap valve
and branch connection prior to and after installation. The initial pressure testing of the hot
tap machine, will take place in the shop after the machine has been checked and worn parts
replaced.
10.2 The hot tap machine shall have an overhaul of its renewable pressure sealing components
and be subjected to a shop rated pressure test, in accordance with the following criteria:
10.2.1 Pressure test once every four months and overhaul once every 12 months.
10.2.2 After it has been used on lines with operating temperatures in excess of 150 deg C,
even if the elapsed time is less than four months. For a series of consecutive hot
taps on a single type of service (i.e., steam, process stream, etc.) the hot tap machine
shall be shop tested at the end of the series of hot taps.
10.2.3 A stamped brass tag shall be affixed to the hot tap machine indicating the test
pressure, overhaul date, and the name of the testing organization.
10.3 Pneumatic testing of hot tap connections on hot lines over 93 deg C is not permitted unless
approved by the Manager, Inspection Department.
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,
as follows:
10.6 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. Resilient (soft) seat valves shall have zero leakage,
Valves with metal to metal seats shall meet the leakage criteria of API 598. A back seat test
and low pressure seat test is not required. A tag shall be attached to the valve indicating test
date, test pressure and Inspector's name.
10.8 A pneumatic test of 173 kPa (ga) shall be applied to the reinforcing pad or ring after
installation. This pressure will then be reduced to 21 - 35 kPa (ga) for a tightness test using
a soap solution.
10.9 Install the hot tap valve and apply another high pressure closure test (seat test) per para.
3.8.6 above, with the valve in the closed position.
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10.10 Return the valve to the open position, mount the hot tap machine and apply another full
pressure test per paragraph 3.8.7 above, however, the MAOP of the line need not be
exceeded.
10.11 Ensure that the connection is opened, drained and vented upon completion of hydrostatic
testing to prevent possible build up of pressure from any source of heat. (Refer to paragraph
3.8.5)
10.12 After completion of the above tests, install a bar stock plug in the branch connection boss
and seal weld. At the option of the Inspector, an MT or PT may be applied to the branch
connection seal weld.
10.13 The appropriate Inspection Representative shall witness and approve all hydrostatic testing
required for completion of the hot tap connection.
11 Operating Conditions Requirements
11.1 The minimum flow rates per para. 3.9.4 or the maximum attainable flow under normal
working pressure, whichever is less, shall be maintained during all welding operations.
11.1.1 Flow in a line shall be maintained while welding is being performed, unless
approved otherwise by the Operations Superintendent. In certain cases, such as
flare lines with insufficient or intermittent flow, the line shall be purged with steam,
inert gas, or hydrocarbon gas. This steam or gas shall be kept flowing through the
line during the entire welding operation.
11.1.2 In systems where hydrocarbon and oxygen mixtures are definitely not a
possibility, flow is not required.(e.g., sea,water injection lines). However, to
weld with "NO-FLOW" conditions, the following must be satisfied:
11.1.2.1 For new construction tie-ins to existing lines, approval shall be obtained
from the responsible Project Manager, General Supervisor /
Superintendent Operations Engineering, and the Operations
Superintendent.
11.1.2.2 For normal maintenance tie-ins to existing systems not involving new
construction, approval shall be obtained from the General Supervisor /
Superintendent Operations Engineering, and the Operations
Superintendent.
11.1.2.3 Prior to and during any welding, Operations shall verify a non-combustible
mixture in the line. This shall be stated in the remarks section of the Work
Permit.
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11.4 Maximum and minimum flow rates during hot tapping shall be 0.40 m/sec minimum and
9.10 m/sec maximum. However, if the branch connection size is less than 50% of the size
of the line being hot tapped, then the minimum values do not apply but a positive flow shall
be maintained. While hot tap work and pressure testing is in progress, the operator shall
remain in a location where he can control operating conditions such as flow, pressure, and
liquid level within the limits specified in the hot tap design information. An additional
operator shall standby at the job site while the work is in progress, if deemed necessary by
the Operations Superintendent. Continuous radio communications between the job site
operator and the Control Room is required.
11.5 Work shall be immediately stopped when constant flow and pressure as noted in paragraphs
3.9.2 and 3.9.3 cannot be maintained during the welding and hot tapping operations.
Pressure testing shall also stop if pressure in the header/ equipment is lost.
12 Hot Tap Fittings/Sandwich Valve Installation Requirements
12.1 The Site Engineer shall coordinate all activities.
12.2 The Operations Superintendent shall ensure compliance with the safety precautions
arranged under paragraph 3.9 of this method statement, including acceptance of the work
permit.
12.3 The Inspector shall perform the following:
12.3.1 Verify a Client approved welding procedure specification is utilized for installation
of the connection. (Refer Para. 3.5.9).
12.3.2 Verify that 3.2 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.
12.3.3 Inspect the branch connection/split tee, before and during the installation, for
compliance with the approved drawings and welding procedures.
12.3.4 Verify that a calibrated pressure gauge and relief valve are properly installed for
testing.
13.1 SEQUENCE OF WORK – HOT TAPPING

1. Check the valve by opening and the hot tap machine for operability and examine the
condition of the cutter and coupon retaining device.
2. Mount the hot tap machine on the valve.
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3. Ensure that the tapping valve is tested in accordance with paragraph 3.8.9 and will easily
pass the hot tap cutter. This may require grinding of the lugs on the valve seat rings to
provide adequate clearance. 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.
4. Apply hydrostatic and pneumatic pressure tests to the hot tap machine, valve, and welded
connection in with the testing procedure specified in this method statement.
5. Install and seal weld a threaded plug in the weld boss on the connection after all testing has
been completed. Refer to paragraph 3.8.12
6. After assembly of the hot tap machine on the tapping valve and before the tapping operation
is started:
i. Completely close and then completely open valve to ensure that it is operable, and
that the cutter can be withdrawn a sufficient distance to permit closure of the valve.
ii. Set the cutter travel indicator to prevent over travel and consequent damage to the
opposite side of the header being hot tapped.
7. Drill and cut coupon.
8. Retract the hot tap machine boring bar.
9. Close the valve, purge with nitrogen, if required, and depressurize the hot tap machine
adaptor.
10. Remove the hot tap machine from the line.
11. Remove the coupon from the pilot drill and tag and wire the coupon to the tapping valve
on the connection after hot tap is completed.
12. The coupon shall be removed only by the Operations Supervisor and forwarded to the
responsible Operations Inspection Unit.
13. Ensure that the completed connection is blinded or plugged before proceeding to next Job.
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APPENDIX A
INSPECTION CHECK SHEET
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Method Statement For Hot Tapping

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Document Number:

METHOD STATEMENT OML34-GEN-PM-PCD-0001

METHOD STATEMENT FOR HOT TAPPING

5.0 GENERAL REQUIREMENTS

5.11 Hot tapping shall not be permitted if:

6.0 Precautions against H2S and other Toxic/Hazardous Materials

7.0 Preparation of Hot Tap Specification and Test Calculations

8.0 Locate and Inspect Hot Tap Position

9.0 Safety Requirements

10 Pressure Test Requirements

pressure, overhaul date, and the name of the testing organization.

11 Operating Conditions Requirements

12 Hot Tap Fittings/Sandwich Valve Installation Requirements

12.1 The Site Engineer shall coordinate all activities.

12.3 The Inspector shall perform the following:

13.1 SEQUENCE OF WORK – HOT TAPPING

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