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Engineering Procedure

SAEP-311

29 January, 2003

Installation of Hot Tapped Connections


Piping Standards Committee Members
Al-Sannaa, M.S., Chairman
Al-Dossary, M.B.
Al-Nasri, N.I.
Al-Sabti, R.A.
Al-Sharif, T.M.
Al-Teraiki, A.M.
Balhareth, N.M.
Chen, J.T.
Fadley, G.L.
Ismail, A.A.
Khashab, J.M.
Kim, S.U.
Lewis, T.
Mahmoud, K.A.
Mullen, M.A.
Phan, H.C.
Solaiman, M.Z.
Stark, G.D.

Previous Issue: 29 February, 2000

Next Planned Update: 1 March, 2003

Revised paragraphs are indicated in the right margin


Primary contact: Muhsen S. Al-Sannaa on phone 874-6679

Page 1 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

Saudi Aramco DeskTop Standards


Table of Contents

Scope............................................................. 2

Applicable Documents................................... 2

Instructions..................................................... 3

Responsibilities............................................. 14

Appendix I - Ultrasonic Thickness


Measurements

17

Appendix II - Hot Tap Checklist.......................... 18

Page 2 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

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

Saudi Aramco References


Saudi Aramco Engineering Procedure
SAEP-310

Pipeline Repair and Maintenance

Saudi Aramco Engineering Standards


SAES-A-004

Pressure Testing

SAES-L-052

Hot Tap Connections

SAES-L-056

Pressure Testing of Plant Piping and Pipelines

SAES-W-010

Welding Requirements for Pressure Vessels

SAES-W-011

Welding Requirements for On-Plot Piping

SAES-W-012

Welding Requirements for Pipelines

Page 3 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

Saudi Aramco Standard Drawings


AB-036719

Reinforcement of Welded Branch Connections

AB-036715

Detail of Heavy Welding Boss for Threaded


Connections

AB-036643

Detail of Heavy Welding Boss for Socket Weld


Connections

Saudi Aramco Forms and Data Sheets


Form SA 7235-ENG

Hot Tap Data and Checklist

Form SA 7627-ENG

Hot Tap/Stopple & Reinforcement Calculation


Sheet

Saudi Aramco General Instructions

2.2

GI-0002.100

Work Permits

GI-0002.102

Safety Precautions for Pressure Testing

GI-0002.711

Fire and Safety Watch

GI-1780.001

Atmosphere-Supplying Respirators

Industry Codes and Standards


American Petroleum Institute
API STD 598

Valve Inspection and Test

API RP 2201

Procedures for Welding or Hot Tapping on


Equipment Containing Flammables

American Society of Mechanical Engineers/Boiler and Pressure Vessel Code


ASME SEC VIII D1

Pressure Vessels

ASME B31.3

Process Piping

ASME B31.4

Liquid Transportation Systems for


Hydrocarbons

ASME B31.8

Gas Transmission and Distribution Piping


Systems

Page 4 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003
3

Installation of Hot Tapped Connections

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

Hot tap connections shall be designed and installed to meet all


requirements of this SAEP, and SAES-L-052, "Hot Tap
Connections".

3.2.2

The hot tapping operations are initiated, designed, and controlled


by:
3.2.2.1 Operations Engineering Organization in the case of existing
facilities.
3.2.2.2 Project Manager with the approval of the Area Operations
Superintendent and Operations Engineering General
Supervisor/ Superintendent in the case of tying in new
installations to existing facilities.

3.2.3

The appropriate management shall appoint an Initiating Engineer.


The Initiating Engineer 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,
stopple and valve crew, operations and/or project management,
engineering staff, and inspection staff cooperate closely during all
phases of the hot tapping operations.

3.2.4

The Initiating 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.

Page 5 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

3.2.5

The construction or maintenance units are responsible for


ensuring that approved welding procedures and qualified welders
are employed. The Piping & Valves Unit/M&CED/CSD shall
verify this.

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

For carbon steels with minimum specified yield stresses greater


than 60 ksi, the Consulting Services Department shall be contacted
for welding procedure approval.

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

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.

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

Precautions against electric shock, due to induced voltage, shall be


taken when installing hot tap connections on above ground
pipelines near high voltage power lines. Refer to SAEP-310,"
Pipelines Repair and Maintenance".

Page 6 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

3.2.14

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.

3.2.15

Hot tapping shall not be permitted:


a)

within 457 mm (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);
Commentary Note:
If this requirement can not be met the placement of the hot
tap may be positioned closer than 457 mm (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.

b)

within 19 mm (0.75 inch) 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.

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

For atmospheric or low pressure hydrocarbon storage


tanks, hot tap connections shall be located at least 1 m
(39 inches) below the liquid level while welding or hot
tapping is in progress.

3.2.16.2

The liquid level in a tank shall remain constant at the


stated level and no flow into or out of the tank shall
occur while welding or hot tapping is in progress.

Page 7 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

3.3

Installation of Hot Tapped Connections

3.2.16.3

Hot tapping is not permitted on cone or floating roofs of


in-service tanks.

3.2.16.4

On tanks, connections larger than 2 inch NPS require


written approval of the Manager, CSD.

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

Hot tap connections made to obtain coupons for HIC


determination, according to paragraph 3.2.17 shall not be used for
future connections with process piping unless approved by CSD.
Such hot taps shall be marked "Do Not Use" with a non-corroding
metal tag permanently affixed to the hot tap connection.
(Reference para. 3.5.7)
3.2.18.1

Wall thickness above the lamination must be greater


than
5 mm (0.2 inch).

3.2.18.2

Reinforcement of the nozzle shall be based on the wall


thickness above the lamination. (Does not apply to splittee installation)

3.2.19

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.

3.2.20

Compact steel gate valves with extended body ends shall not be
used for hot tap connections.

Precautions against H2S and other Toxic/Hazardous Materials

Page 8 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

3.3.1

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. (Refer to GI1780.001, "Atmosphere-Supplying Respirators"). 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.

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.

H2S concentration is greater than 10 ppm.

2.

Gas release may affect others in the area.

3.

Hot tap equipment is larger than 36 inches.

4.

The work is in a confined area.

3.3.4

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.

3.3.5

The Operations Engineering Organization should provide written


and verbal emergency instructions (including evacuation
procedure) to the hot tapping crew, fire watch personnel, and other
workers who may be in the work area.

Page 9 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003
3.4

Installation of Hot Tapped Connections

Preparation of Hot Tap Specification and Test Calculations


3.4.1

The Initiating Engineer shall provide Form SA 7627-ENG for each


hot tap operation.

3.4.2

Each Form SA 7627-ENG shall be completed in sequence and by


the organization identified:

Form Section #

Person/Organization

Summary

Initiating Engineer

(includes; Hot Tap Location,


Header Info, and Branch Info)

Initiating Engineer

Operations Engineer

Responsible I.e.,. Unit

Operations Eng. Div.

Summary

Initiating Engineer

(includes: Test & Process Info)

(To be completed with actual


conditions just prior to welding or
cutting)

Page 10 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003
3.5

Installation of Hot Tapped Connections

Locate and Inspect Hot Tap Position


3.5.1

The Initiating Engineer shall make all necessary arrangements for


the preparation of hot tapping (i.e., location, excavation, pipe
inspection, surface preparation, etc.)

3.5.2

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.

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

The hot tap number is obtained from Form SA 7627-ENG


developed for each location.

3.5.5

The Piping & Valves Unit/M&CED/CSD 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.

3.5.6

The Piping & Valves Unit/M&CED/CSD 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. The area to be scanned shall
include the weld zone and 50 mm (2 inches) each side of it. The
minimum remaining wall thickness at the weld connection area
shall not be below minimum thickness, Tm, and in all cases, no
less than 5 mm (0.2 inch). The inspected area shall be
permanently marked for future reference and identification.
Commentary Note:

Page 11 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

When hot tapping components containing non-hazardous material


such as water at less than 1034 kPa (150 psi) and below 65C,
then the components with wall thicknesses less than 5 mm (0.2
inch) may be hot tapped provided precautions against burnthrough are taken. (THIS CONDITION STILL REQUIRES A WAIVER
TO BE PROCESSED THRU CSD).

3.6

3.5.7

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 Initiating Engineer
and the responsible Operations Engineering Organization. CSD
and the proponent group shall be notified of this condition.

3.5.8

The Piping & Valves Unit/M&CED/CSD shall complete Section 3


of form SA 7627-ENG and return it to the Initiating Engineer.

3.5.9

The Piping & Valves Unit/M&CED/CSD shall review the welding


procedure specification (WPS) for the installation of the hot tap
fittings and assure a CSD approved WPS is employed.

Approval and Distribution of Form SA 7627-ENG


3.6.1

The Initiating Engineer shall forward the form, when Sections 1, 2,


3 and the Summary section (excluding the test and process
information, are complete and signed), together with ultrasonic
thickness measurements (Appendix I of this SAEP), to the Project
Engineer or responsible Operations Engineering Supervisor.

3.6.2

The Project Engineer or the responsible Operations Engineering


Supervisor, shall complete Section 4 of Form SA 7627-ENG when
the design and calculations are complete. Full responsibility for
the hot tap design is to be assumed by the engineering group that
prepares the calculations, design drawings and installation
procedures. The responsible engineering group shall determine
and obtain the appropriate approvals on Form SA 7627-ENG.

Page 12 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

Drawings and specifications prepared by the responsible


engineering group shall include the length, diameter, wall
thickness, flange rating and material of the new connection plus
the type and dimensions of the connection reinforcement, if
required (Refer to Std. Dwg. AB-036719) and the Weld Procedure
Specifications approved by the Consulting Services Department.
3.6.3

After the responsible engineering group has obtained the


appropriate approvals, a record copy shall be retained in a
permanent central file, and the design package forwarded to the
Initiating Engineer for construction.

3.6.4

Once approval is obtained, the Initiating engineer shall distribute


copies of each Form SA 7627-ENG to the following personnel:

3.6.5

1)

Operations Superintendent

2)

Hot Tap and Stopple Crew or Operations Engineering


Supervisor

3)

Construction/Maintenance Installation Crew

4)

Responsible CSD/M&CED/Piping & Valves Unit Supervisor

5)

Area Loss Prevention Engineer

6)

Project Manager (if appropriate)

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

Page 13 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003
3.6.6

3.7

Installation of Hot Tapped Connections

The Initiating Engineer is responsible for revising existing Saudi


Aramco drawings, P&IDs, or preparing new drawings, as may be
required, as a result of the hot tap installation.

Safety Requirements
3.7.1

The Initiating Engineer shall ensure that the requirements of


SAES-L-052, "Hot Tap Connections" are followed. The
responsibility for the safety of work crews involved in the hot
tapping operation is shared jointly by the Operator and the Hot
Tap Supervisor/Maintenance Foreman.

3.7.2

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
Piping & Valves Unit/M&CED/CSD 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 Piping & Valves Unit/M&CED/CSD, that it is
understood by the person(s) carrying out the work.

3.7.3

All work shall be in strict compliance with GI-0002.100, Work


Permit System. The Work Permit shall be approved by the
Operations Superintendent, prior to each of the following:

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.

Page 14 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

3.8

Installation of Hot Tapped Connections

3.7.5

The Initiating Engineer shall make available to the site a copy of


this SAEP and ensure the area has been sufficiently roped off to
prevent unauthorized personnel from entering the work area.

3.7.6

The Operations Superintendent will assure that both Operations


and the Installation Organization 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. Refer to GI-0002.711, "Fire and Safety
Watch".

Pressure Test Requirements


3.8.1

The Initiating Engineer shall be responsible for ensuring that the


pressure tests are performed in accordance with this SAEP 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, per
paragraph 3.8.2.

3.8.2

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:
3.8.2.1 Pressure test once every four months and overhaul once
every 12 months.
3.8.2.2 After it has been used on lines with operating temperatures
in excess of 150C, 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.
3.8.2.3 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.

Page 15 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

3.8.3

Maximum hydrostatic test pressure applied to the branch (or hot


tap) connection shall be in accordance with SAES-L-052,
paragraph 7.3.b).

3.8.4

Pneumatic testing of hot tap connections on hot lines over


93C is not permitted unless approved by the Manager,
Consulting Services Department.

3.8.5

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:
Line Temperature

Hydrotest Fluid

Stock No.

93C to 290C

Turbine Oil

26-001-330
26-001-340

Over 290C

Silicone Fluid 200

Page 16 of 33

26-010-037

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

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

After installation of the branch connection, but prior to installing


the reinforcing pad or full encirclement ring, a full hydrostatic
pressure test shall be applied to the branch connection. This test
pressure shall be the lower value shown in 4.4c or 4.4e on Saudi
Aramco Form SA 7627-ENG. During the test, the branch
connection shall have a blind flange installed and pressure applied
through the branch connection boss as shown on Std. Dwg. AB036719.
CAUTION: Header walls can collapse during testing by applying
insufficient internal operating pressure or excessive external
hydrostatic test pressure. This is especially true when large
diameter connections are being tested.

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

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

3.9

Installation of Hot Tapped Connections

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

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)

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

The appropriate CSD Representative shall witness and approve


all hydrostatic testing required for completion of the hot tap
connection.

Operating Conditions Requirements


3.9.1

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, hot tapping, and testing operations.
Commentary Note:
Operations, Maintenance, and Construction are to ensure that the
hot tap machine operating pressure is higher than the actual
header pressure while cutting the coupon. Hot tap machine
operating pressure is to be provided by the Hot Tap machine
operating Supervisor before starting the job. (The allowable
operating pressure defined by the hot tap crew is different than
the test pressure).

Page 18 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

3.9.2

Maximum internal pressure of the piping/equipment during


welding shall be in accordance with SAES-L-052 paragraph 5.3 on
welding of pipelines under pressure. A positive pressure and flow
shall be maintained at all times while welding and hot tapping is in
progress.

3.9.3

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.
3.9.3.1 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.
3.9.3.2 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 "NOFLOW" conditions, the following must be satisfied:
3.9.3.2.1

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.

3.9.3.2.2

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.

Page 19 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

3.9.3.2.3

3.9.4

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.

Maximum and minimum flow rates during hot tapping shall be as


follows:
a)

Liquid & 0.40 m/sec minimum


Two-Phase

b)

Gas

4.50 m/sec maximum

0.40 m/sec minimum


9.10 m/sec maximum

Page 20 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

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)

T.D. Williamson has established the above maximum flow velocity


in lines during the hot tapping operation.

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

While hot tap work and pressure testing is in-progress, an 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.

3.9.6

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.

Hot Tap Fittings/Sandwich Valve Installation Requirements


3.10.1

The Initiating Engineer shall coordinate all activities.

3.10.2

The Operations Superintendent shall ensure compliance with the


safety precautions arranged under paragraph 3.9 of this SAEP,
including acceptance of the work permit.

3.10.3

The Inspector shall perform the following:


3.10.3.1

Verify a CSD approved welding procedure specification


is utilized for installation of the connection (Refer para.
3.5.9).

Page 21 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

3.10.3.2

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.

3.10.3.3

Inspect the branch connection/split tee, before and


during the installation, for compliance with the
approved drawings and welding procedures.

3.10.3.4

Verify that a calibrated pressure gauge and relief valve


are properly installed for testing.

3.10.3.5

Confirm that the hydrostatic test pressure for the


branch connection is correct at the time of the test, as
prescribed in Section 4 of Form SA 7627-ENG.
CAUTION: Pipe or pressure vessel walls can collapse
during testing by applying insufficient internal
operating pressure or excessive external hydrostatic test
pressure. This is especially true when large diameter
connections are being tested.

Responsibilities
4.11

Hot Tapping Operation Procedure

4.11.1

Procedure

Responsibilities

Review the design drawings and requirements for the

Init. Eng/CSD

branch connection, including an approved welding


procedure in accordance with the applicable
SAES-W-XXX.

4.11.2

Ensure all the requirements of paragraph 3.2

Init. Eng/Maint/

"General Requirements" are met.

Constr

Page 22 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

4.11.3

Installation of Hot Tapped Connections

Check that the location of the installation is that

Opers/Maint/

location specified by the initiating Engineer with the

Constr

concurrence of the Operations Supt.

4.11.4

Obtain an approved Hot Work Permit, Saudi Aramco

Init. Eng/Maint/

Form SA 924-2 (Para. 3.7.3) from the Operations

Constr

Superintendent, or his designee, prior to starting with


work.

4.11.5

If long seam is under hot tap fitting, grind seam weld

Maint/CSD/

flush with the surface of the pipe taking care not to

Constr

reduce the pipe wall thickness. Check pipe wall


thickness ensuring it does not violate para. 3.5.6.

4.11.6

4.11.7

Ensure the pressure and flow requirements as identified

Init Eng/CSD/

in section 4 of Form SA 7627-ENG have been established

Maint/Constr

prior to any welding.

Opers

Power wire brush the area for attachment welds to

Maint/Constr/

remove all traces of paint, rust and scale. The fit-up

CSD

of the connection to the header shall provide for a


standard pipe bevel and 1/16 inch minimum root gap.
Install the nozzle or boss connection using full
penetration welds in the exact location shown on the

Page 23 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

approved drawing, using a qualified welder and a CSD


approved welding procedure. The Piping & Valves Unit/
M&CED/CSD will verify proper weld joint fit-up.

4.11.8

Ensure that the nozzle connections are not welded on

CSD/Init Eng/

the inside unless the hot tap cutter is at least one pipe

Maint/Constr

size smaller than the nozzle. The cutters sometimes


break if the cut is made through a weld.

4.11.9

Precheck the tapping valve and the hot tap machine

Hot Tap Unit

to assure good operable condition, including the cutter


and coupon retaining device.

4.11.10 Confirm that the shop rating test of the hot tap machine

CSD/Hot Tap Unit

is current per para. 3.8.2.

4.11.11 Mount the valve on the fitting ensuring that its alignment

CSD/Hot Tap Unit

is within the manufacturer's tolerance

4.11.12 Close the valve and perform the hydrostatic test


according to this instruction.

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

Hot Tap Unit/Maint/


Constr

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

4.11.14 Mount the hot tap machine on the valve.

Hot Tap Unit/Maint/


Constr

4.11.15 Ensure that the tapping valve is tested in accordance

Hot Tap Unit/CSD

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.

4.11.16 Apply hydrostatic and pneumatic pressure tests to the


hot tap machine, valve, and welded connection in

Hot Tap Unit/ICSD/


Maint/Constr

with the testing procedure specified in this SAEP and


SAES-L-052, paragraph 5.

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

4.11.18 After assembly of the hot tap machine on the tapping


valve and before the tapping operation is started:

Page 25 of 33

Maint/Constr

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

4.11.18.1 Completely close and then completely open

Hot Tap Unit

valve to ensure that it Is operable, and that


the cutter can be withdrawn a sufficient
distance to permit closure of the valve.

4.11.18.2 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.

4.11.19 Drill and cut coupon.

Hot Tap Unit

4.11.20 Retract the hot tap machine boring bar.

Hot Tap Unit

4.11.21 Close the valve, purge with nitrogen, if required, and

Hot Tap Unit

depressurize the hot tap machine adaptor.

4.11.22 Remove the hot tap machine from the line.

Hot Tap Unit/


Maint/Constr

4.11.23 Remove the coupon from the pilot drill and tag and
wire the coupon to the tapping valve on the connection

Hot Tap Unit/


Maint/Constr

after hot tap is completed.

4.11.24 The coupon shall be removed only by the Operations


Supervisor and forwarded to the responsible Operations

Page 26 of 33

Opers

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

Piping & Valves Unit/M&CED/CSD.

4.11.25 Ensure that the completed connection is blinded or


plugged before leaving the job site.

Hot Tap Unit/CSD/


Maint/Constr

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

Added GI-1780.001 in the reference.

29 February, 2000

Added SAES-A-056 in the reference.

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

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

Appendix I Ultrasonic Thickness Measurements

Hot Tap #_________________


J.O./W.O. ______________PLANT #_______________ DWG. # ________________
Description (Job, Location, etc.) ___________________________________________

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:__________

180 deg. from Pt. A

Min:__________

Max:__________

Page 28 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

STICKER MEASUREMENT
Min:__________

Max.:__________

C
FLOW

LOCATION-------DESCRIPTION

Point A------------Branch Center

Circle B-----------Branch Diameter


Circle C-----------Reinfr. Pad Dia.

RESPONSIBLE PIPING & VALVES UNIT/M&CED/CSD:

Line D-D----------Reinf. Sleeve Ends


ENGINEER:

REFERENCE: SAES-L-052, STD. DWG. AB-036719

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

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

Page 30 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

Appendix II Hot Tap Checklist


This checklist should be used as a reminder to accomplish the steps in order, but
should not be considered as including all preparation steps which may be dictated
by the particular circumstances of the job. It should be kept as a part of the final
documentation package.
LOCATION:________________________________
DATE:____________________
Before Starting Hot Tap
1.

Has the properly approved work permit been obtained?

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.

Is there sufficient clearance to accommodate the operation of the hot tap


machine and sufficient clearance to retract the cutter through the valve?

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?

Page 31 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

12.

Has fire fighting equipment been provided?

13.

Has suitable protective equipment been provided to all exposed personnel in


the hot tap area?

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?

Before Starting Welding


1.

Is preheat of the weld area required?

2.

Is the fitting properly positioned so misalignment of the hot tap machine will
not occur?

Before Starting Cutting


1.

Has the weld been tested?

2.

Have the hot tap valve, gaskets, and bolts been checked for possible leakage?

3.

Has the packing on the hot tap machine been checked?

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.

Is the valve centered on the flange?

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?

Before Removing the Hot Tap Machine

Page 32 of 33

Document Responsibility: Piping

SAEP-311

Issue Date: 29 January, 2003


Next Planned Update: 1 March, 2003

Installation of Hot Tapped Connections

1.

Follow the manufacturer's instructions to be sure the boring bar is fully


retracted before closing the valve.

2.

Close the valve.

3.

Make sure any necessary nitrogen purging is completed.

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.

Remove the hot tap machine from the tapping valve.

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.

Operations Supervisor is to ensure that the coupon is forwarded to the


responsible Operations Piping & Valves Unit/M&CED/CSD to verify wall
thickness or corrosion patterns.

Page 33 of 33

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