Académique Documents
Professionnel Documents
Culture Documents
COMPANY
This page is a record of all revisions of this document . All previous issues are hereby superseded and are
to be destroyed .
Rev
Date
Prepared by
Checked by
Approved by
04-04-2011
GDE
SSS
PVP
Notes :
1. Revisions are denoted as follows:
(a) By a vertical line in the left-hand margin against the revised text .
(b) By a triangle symbol for graphics, the revision number being denoted within the symbol.
Revision symbols are positioned adjacent to the revision.
Para No.
Para No.
Table of Contents
1. INTRODUCTION
2. SCOPE
3. DEFINITION AND ABBERVIATIONS
3.1 Definitions
4. REFERENCE DOCUMENTS
4.1 Codes and standarads
4.2 Project Specific Document
4.3 Company DGS
5. HOT TAP LIMITATION
5.1 Process Fluid
5.2 Pipe Material
ANNEXURE-A : 6 X 1/2" HOT-TAP (WT-6.8MM)
6. INTRODUCTION
7. MAXIMUM TEMPERATURE OF THE PIPE WALL
8. TEMPERATURE DERATING METHOD
9. VELOCITY CONSIDERATIONS
10. LOADING
11. CONFIGURATION REQUIREMENTS
11.1 General
11.2 Area Replacement
12. STRENGTH TEST PRESSURE
13. CONCLUSION AND RECOMMENDATION
ATTACHMENT-1 : PIPING LAYOUT
ATTACHMENT-2 : UT REPORT
23
24
25
1.
INTRODUCTION
Abu Dhabi Gas Industries Ltd. (GASCO) owns and operates Habshan Plant Located in the
In the western region of the emirate of Abu Dhabi which is situated 150 Kms south of Abu
Dhabi city. The plant elevation is 64 meters of jebel Dhanna Datum and approx. 25
kilometers from the coast. Habshan cooling water system is divided into three units,
Namely Habshan-0; 1 & 2.
GASCO- Habshan has been facing the problem of brass tube failure in lube oil coolers &
carbon steel tube failures in water chillers and in order out the problem , a study was
carried out by GE.
As a recommendation from GE study, GASCO intends three chemical injection packages for
each cooling water expansion drum 66-V-501 located in Habshan-0, and 66-V-701 located in
Habshan II . These packages are corrosion inhibitor injection package, Biocide injection
package and Oil dispersant injection package .
GASCO awarded the project to M/s Babcock Borsig Service on EPC basis to meet the
objective of this project.
M/s. Babcock Borsig Service has awarded detail engineering part of the project to Tebodin
middle east Ltd.(TME) as a subcontractor to Babcock.
2. SCOPE
Under this project six (6) hot tapping connections are required as tabulated below. The hot
tap shall be carried out based on approved document Method Statement for Hot Tapping
(HBT/E-040449-MS-1300-009). The calculation enclosed in appendix-A is applicable to
TP-03, TP-04 & TP-05, Where the actual wall thickness of the run pipe (6 NPS) is 6.8mm as
measured by UT.
For TP-09,TP-10 & TP-11 same calculations are applicable , since the wall thickness is 6.9mm
as measured by UT and all other parameters are identical.
Tie-in
TP-03
TP-04
TP-05
Hot Tap
6X1/2
6X1/2
6X1/2
Service
Cooling water
Cooling water
Cooling water
Table-1
Header(Existing)Line no
66-3501-L-6
66-3501-L-6
66-3501-L-6
TP-09
TP-10
TP-11
6X1/2
6X1/2
6X1/2
Cooling water
Cooling water
Cooling water
66-0709-CWS-6
66-0709-CWS-6
66-0709-CWS-6
66-xxxx-CH-1/2-13450-N
66-xxxx-CH-1/2-13450-N
66-xxxx-CH-1/2-13450-N
This report gives the outline for hot tap design calculations to arrive the maximum
operating pressure and other design guidelines to be considered while carrying out hot
tapping works on the operating cooling water lines.
The Design calculation for hot tapping shall be include the following considerations:
Pipe
Pressure, Temperature
Loading
3.
3.1
Definitions
COMPANY
PURCHASER/EPC/
CONTRACTOR
ENGINEERING
CONSULTANT
VENDOR
4. REFERENCE DOCUMENTS
4.1 Codes and Standards
ASME B31.3
- Process piping
ASME Sec VIII
- Boiler and pressure Vessel Code
DEP 31.38.60.10-Gen - Hot-Tapping on pipelines, Piping and equipment
4.2 Project Specific Document
HBT/E-0400449-MS-1300-009 - Method Statement for Hot Tapping
02-A0-xxxx
- Utility Flow Diagram UNIT-66 cooling water System
02-A0-xxxx
- Piping Plan Area 60-22
HBT/E-SP-XXX
contained process fluids shall remain stable when subjected to the high metal
Temperature during welding
The
process fluids remain stable when it comes in contact with air during drilling and
Perforation operations
There
There
shall be no chemical reaction between the fluid and the hot contained wall
(Burning, stress, corrosion, embrittlement).
These requirements lead to a number of situations in which welding operations are prohibited on
equipment which contains:
Mixtures of gases or vapours within their flammable range or which may become flammable as a
result of heat input in welding operations
Substances which may undergo reaction or decomposition leading to dangerous increase in
pressure. Explosion or attack on metal. In this context, attention is drawn to the possibility that
under certain conditions of concentration, temperature and pressure, acetylene and other
unsaturated hydrocarbons may decompose explosively, initiated by a welding hot spot
Oxygen-enriched atmospheres in the presence of hydrocarbons which may be present either in the
atmosphere or deposited on the interior surface of equipment or pipe
Compressed air in the presence of hydrocarbons which may be present either in the air or
deposited on interior surfaces of equipment or pipe
Gaseous mixtures in which the partial pressure of hydrogen exceeds 700kPa(g), except where
evidence from tests has demonstrated that this can be done safely .
In addition, welding operation is prohibited on piping which contains hazardous subs conditions,
as listed below. If any of these substances are known to be present within the piping , even in small
quantities, investigations should be made on the stability of the fluid at the pipe wall temperature.
The relevant substances/conditions included:
Acetylene
Acetonitrile
Butadiene
Caustic soda
Chlorine
Compressed air (Pressure is excess of 3000 kPa(g))
Ethylene
Ethylene oxide
Rich/lean DEAIMEA
6. INTRODUCTION
The following design data of the existing 6" cooling water line (66-3501-L-6") has been considered
for hot tap design calculation at TP-03. The tie- in location is at the area 60-22(Refer attachment-1) .
Pipe Material
API 5L Gr.B
Service
Cooling Water
- 6 bar g
- 87 C
- 45 C
For a specific hot-tap. the permitted ranges of voltages. current and welding speed are defined in
the Welding Procedure Specification (WPSl or method statement. The actual or mid-range valves can
be considered.
The heat input during the Root pass, 1 st butterin9 and 2nd buttering are calculated using the
current , voltage and travel speed values derived from the WPS parameter provided by
CONTRACTOR (Refer attachment-3) and are tabulaled below in Table-A1 :
HI = K V*A
S
HI = 0.57 22.5*90
1.76
HI = 659.57 J/mm
Current
Voltage(V)
90
90
90
22.5
22.5
22.5
Travel
speed(mm/s)
1.75
1.75
1.75
RA heat input
(j/mm)
659.57
659.57
659.57
From the heat input vs wall thickness graph. The welding temperature of the pipe wall (i.e. The
maximum temperature of the inside of the pipe wall attained during welding) is determined for the
preheat case with initial pipe wall temperature of 25 C. (Refer Attachment-4 of this document which is
a copy of Appendix-12 of OGS-1300-OO1).
The actual run pipe (ON 6' existing header) wall thickness is 6.8 mm. As confirmed by UT (Refer
attachment-2). From the graph in attachment-4, the inner pipe wall temperatures, the penetration
depths, reduced wall thicknesses during the critical welding passes are calculated and tabulated
below in Table-A2 :
Table-A2
Pass
1) Root Pass
2) Buttering
3) Buttering
Max.inner wall
temperature(oc)
Reduced wall
thickness `t (mm)
420
350
272
1.61
1.30
1.08
5.19
5.50
5.72
Post pass
thickness *
(mm)
8.8
10.8
12.8
P = 2t SEWT
(D-2tY)
Where
w = Weld joint strength reduction factor = 1.00 (at temp. 510 D C and below)
y = Coefficient from table 304.1.1 of ASME 831 .3 = 0.4
t = Reduced wall thickness, (H-u) = 5.19 mm
E = Quality Factor from Table A-1A or A-l 8 of ASME 831 .3 = 1.00
T = Temperature Derating Factor is 0.634 (Refer DGS-1300-100, Sec 8.3.3.3, Table-l)
p = 2 x 5.1 9 x 137.89 x 1.00 x 1.00 x 0.634
168.28 - (2 x 5.1 9 x 0.4)
= 5.53 N/mm2
= 55.3 bar (9) > 6 bar (g)
Hence calculated maximum allowable operating pressure is 55.3 bar (g) whereas the expected
arrival pressure at the hot tap point is 6 bar (g)
"THE OPERATING PRESSURE OF THE EXISTING MAIN PIPE IS ACCEPT A8LE FOR HOT TAPPING
OPERATION".
9. VELOCITY CONSIDERATIONS
The suggested maximum and minimum velocity for liquid flow is 1.75 m/sec and 0.5 m/s
respectively.
Max. Flow Rate, Q = AV
Q= x (d1)2 x V
4
3.14x(0.1547)2 x1 .75
4
For General Safety Precaution for hot lap the CONTRACTOR shall refer to Section 7.4 of DGS-1300100
The document includes only one set of calculation for the HOT -TAP operation and shall be
applicable for all six (6) connections (Refer Table-1). Since the calculation parameters are
identical.