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SAEP-311
29 January, 2003
Page 1 of 33
SAEP-311
Scope............................................................. 2
Applicable Documents................................... 2
Instructions..................................................... 3
Responsibilities............................................. 14
17
Page 2 of 33
SAEP-311
Scope
This SAEP provides the installation procedures for hot tapping pipe, pressure
vessels and tanks. It assigns responsibilities for the work required and the safety
precautions to be taken. Any deviation to this procedure requires the approval of
the Manager, Consulting Services Department, Dhahran.
Applicable Documents
2.1
Pressure Testing
SAES-L-052
SAES-L-056
SAES-W-010
SAES-W-011
SAES-W-012
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SAEP-311
AB-036715
AB-036643
Form SA 7627-ENG
2.2
GI-0002.100
Work Permits
GI-0002.102
GI-0002.711
GI-1780.001
Atmosphere-Supplying Respirators
API RP 2201
Pressure Vessels
ASME B31.3
Process Piping
ASME B31.4
ASME B31.8
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SAEP-311
Instructions
3.1
Definitions
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.
3.2
General Requirements
3.2.1
3.2.2
3.2.3
3.2.4
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SAEP-311
3.2.5
3.2.6
For carbon steels with minimum specified yield stresses less than
or equal to 60 ksi, pre-approved welding procedures may be used.
3.2.7
3.2.8
For hardenable or high strength steels and for piping where pipe
or fitting wall thickness requires preheat, the Consulting Services
Department shall be contacted for welding procedure approval.
3.2.9
Compressed air piping and equipment shall not be hot tapped nor
welded while in service. Refer to SAES-L-052, paragraph 4.3.
3.2.10
3.2.11
Hot tap connections are not allowed for certain cases (refer to
SAES-L-052 paragraph 4.1), unless a detailed design and
installation procedure has received prior approval from the
Manager of CSD and concurrence from the Loss Prevention
Department.
3.2.12
All hot tap connections, valves, and hot tap machines shall be
pressure tested in accordance with this SAEP. (Refer to Para. 3.8)
3.2.13
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SAEP-311
3.2.14
3.2.15
b)
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.
3.2.16
Storage Tanks
3.2.16.1
3.2.16.2
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SAEP-311
3.3
3.2.16.3
3.2.16.4
3.2.17
When hot taps are being made to obtain coupons for HIC
determination, the Saudi Aramco Form SA 7627-ENG and the
ultrasonic scan data shall be evaluated by M&CED of the
Consulting Services Department. The Consulting Services
Department shall designate the location of the hot tap, type of
reinforcement, and other special requirements.
3.2.18
3.2.18.2
3.2.19
3.2.20
Compact steel gate valves with extended body ends shall not be
used for hot tap connections.
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SAEP-311
3.3.1
3.3.2
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 extinquished.
If a burn-thru should occur, the Operations Superintendent should
immediately be notified to advise further action or be included in
the emergency instructions as required by para. 3.3.5. Firewater
and extinquishers should be applied as required to workers,
clothing, equipment, etc., exposed to the burn-thru flame.
3.3.3
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:
1.
2.
3.
4.
3.3.4
3.3.5
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SAEP-311
3.4.2
Form Section #
Person/Organization
Summary
Initiating Engineer
Initiating Engineer
Operations Engineer
Summary
Initiating Engineer
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SAEP-311
3.5.2
3.5.3
The Initiating 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 outof-roundness does not exceed 3 mm. (Out of roundness criteria
only applies to split tee or full encirclement sleeves).
3.5.4
3.5.5
3.5.6
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SAEP-311
3.6
3.5.7
3.5.8
3.5.9
3.6.2
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SAEP-311
3.6.4
3.6.5
1)
Operations Superintendent
2)
3)
4)
5)
6)
The Initiating Engineer shall prepare and forward Form SA 7235ENG "Hot Tap Data & Check List" to the appropriate
maintenance group performing the actual hot tap. For hot taps to
be made by Pipelines Maintenance Hot Tap, Stopple, and Valve
Unit, the SA 7235-ENG Form shall be sent to:
Superintendent
Pipelines Maint. Services Div.
Hot Tap, Stopple, and Valve Unit
Bldg. 3071, Old Abqaiq Rd., Dhahran
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SAEP-311
3.7
Safety Requirements
3.7.1
3.7.2
3.7.3
3.7.4
1)
Vehicle entry
2)
Welding
3)
Grinding
4)
Hot Tapping
The Hot Work Permit (Red Saudi Aramco Form SA 924-2) shall
have recorded under the "Other precaution" section the maximum
allowable line pressure, minimum and maximum flow rates, and
level limitations during welding/cutting plus the number of this
SAEP.
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SAEP-311
3.8
3.7.5
3.7.6
3.8.2
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SAEP-311
3.8.3
3.8.4
3.8.5
Hydrotest Fluid
Stock No.
93C to 290C
Turbine Oil
26-001-330
26-001-340
Over 290C
Page 16 of 33
26-010-037
SAEP-311
Commentary Note:
Check to ensure compatibility of fluids used in hot tapping with
that of the line being hot tapped.
3.8.6
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 STD 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.
Commentary Note:
This seat test does not apply to sandwich valves.
3.8.7
3.8.8
A pneumatic test of 173 kPa (ga) (25 psi) shall be applied to the
reinforcing pad or ring after installation. This pressure will then
be reduced to 21 - 35 kPa (ga) (3 - 5 psi) for a tightness test using a
soap solution.
Page 17 of 33
SAEP-311
3.9
3.8.9
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. The test pressure shall be the lower value shown in 4.4c
or 4.4d on Saudi Aramco Form SA 7627-ENG, and applied
through the branch connection boss.
3.8.10
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.
3.8.11
3.8.12
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.
3.8.13
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SAEP-311
3.9.2
3.9.3
3.9.3.2.2
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SAEP-311
3.9.3.2.3
3.9.4
b)
Gas
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SAEP-311
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.
Commentary Notes:
3.10
1)
2)
Small diameter hot taps (i.e., 2 inch and less) have no maximum
or minimum flow limitations. Pressure requirements still apply.
3.9.5
3.9.6
3.10.2
3.10.3
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SAEP-311
3.10.3.2
3.10.3.3
3.10.3.4
3.10.3.5
Responsibilities
4.11
4.11.1
Procedure
Responsibilities
Init. Eng/CSD
4.11.2
Init. Eng/Maint/
Constr
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SAEP-311
4.11.3
Opers/Maint/
Constr
4.11.4
Init. Eng/Maint/
Constr
4.11.5
Maint/CSD/
Constr
4.11.6
4.11.7
Init Eng/CSD/
Maint/Constr
Opers
Maint/Constr/
CSD
Page 23 of 33
SAEP-311
4.11.8
CSD/Init Eng/
the inside unless the hot tap cutter is at least one pipe
Maint/Constr
4.11.9
4.11.10 Confirm that the shop rating test of the hot tap machine
4.11.11 Mount the valve on the fitting ensuring that its alignment
4.11.13 Check the valve by opening and the hot tap machine
for operability and examine the condition of the cutter
and coupon retaining device.
Page 24 of 33
Maint/Constr/Hot
Tap/CSD
SAEP-311
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.
4.11.17 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
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Maint/Constr
SAEP-311
4.11.23 Remove the coupon from the pilot drill and tag and
wire the coupon to the tapping valve on the connection
Page 26 of 33
Opers
SAEP-311
Revision Summary
1 Decenver, 1996 Editorial revision to convert document to new format.
30 September, 1997
29 April, 1998
Minor revision to paragraphs 2, 3.1, 3.2.9, 3.2.11, 3.2.15, 3.6.1, 3.6.2, 3.8.3, 3.8.6 & 3.9.2
29 February, 2000
Editorial revision to paragraphs 3.2.15(a) (b), 3.2.16.1, 3.2.18.1, 3.5.6 and 3.8.8.
Added four new lines of statements to Appendix II.
29 January, 2003 Editorial revision to change the Document Responsibility from Inspection Department to Piping
Standards Committee, CSD.
Page 27 of 33
SAEP-311
Diameter
Grade
Schedule
Flange Rating
HEADER: _____________
______________
_____________
____________
STICKER _____________
______________
_____________
____________
HEADER MEASUREMENTS
(CONTINUOUS SCANNING)
Point A
Min:__________
Max.:_________
Circle B
Min:__________
Max:__________
Circle C
Min:__________
Max:__________
Line D-D
Min:__________
Max:__________
Line E-E
Min:__________
Max:__________
Min:__________
Max:__________
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SAEP-311
STICKER MEASUREMENT
Min:__________
Max.:__________
C
FLOW
LOCATION-------DESCRIPTION
NOTE:
For connection reinforcement requirements refer to ASME B31.3, ASME B31.4, ASME B31.8, ASME SEC VIII, and
STD. DWG. AB-036719.
Page 29 of 33
SAEP-311
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SAEP-311
2.
Does the tapping machine have a suitable pressure and temperature rating
for the job?
3.
Has the exact location of the hot tap on the line or vessel been identified or
marked?
4.
Has the area to be welded been inspected for thickness and freedom from
lamination or HIC?
5.
Has the need for stress relieving the weld area been considered?
6.
Do the flanges, bolts, gaskets, pipe, and valve to be installed meet the piping
code for the line or vessel to be hot tapped?
7.
8.
Is the hot tap fitting of the proper length to accommodate operation of the hot
tap machine?
9.
Have combustible and/or toxic gas tests been conducted in the area of hot
tapping?
10.
Has the chemical composition of the contents in the line or vessel been
considered to avoid welding or equipment containing flammable mixtures,
hydrogen or chemicals which could affect metal strength?
11.
Is the contents in the line stable under heated conditions and free of oxygen?
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SAEP-311
12.
13.
14.
Is the area to be hot tapped located below the liquid level of a tank or on a
line or piece of equipment in which fluid flow has been established?
2.
Is the fitting properly positioned so misalignment of the hot tap machine will
not occur?
2.
Have the hot tap valve, gaskets, and bolts been checked for possible leakage?
3.
4.
Has the bleed off valve been checked to be sure it will hold and is not stopped
up?
5.
Are all bolts on the cutter and pilot bit tight and is the coupon catcher on the
pilot bit?
6.
7.
Has the cutting depth been calculated to avoid cutting the opposite side of the
pipe?
8.
Has the boring bar been run through the valve several times to ensure free
passage?
9.
Has the pressure and temperature of the contained material been reduced as
much as the process operations will allow?
10.
Is there liquid or flowing gas in contact with the area to be hot tapped?
Page 32 of 33
SAEP-311
1.
2.
3.
4.
Open the bleeder valve and be sure all pressure is off the hot tap machine
before removing bolts from the flange. If flow or pressure persists, the main
valve is probably leaking.
5.
6.
Remove the coupon and from the pilot drill and wire to the tapping valve.
7.
Ensure the completed hot tap is blinded or plugged before leaving the jobsite.
8.
Page 33 of 33