ACR-AF-RR-MSRA-008

METHOD STATEMENT
OF
HOT TAPPING WORK
PROJECT: LONZA RR PROJECT

PREPARED BY APPROVED BY
(SIGNATURE /DATE) (SIGNATURE /DATE)

JACHIN LIM MOHAMMAD SUFYAN

(PROJECT ENGINEER) (PROJECT MANAGER)
 ACROMEC ENGINEERS LTD
Method of Statement ACR-AF-RR-MS-013
Hot Tapping Works

Date Issue: Rev:00 Page 2 of 2

26/04/2016

1.0 Scope of Work & Activity

Outline the Requirement of providing a safe working environment for the hot tapping
works.

2.0 Health & Safety

A Safety/ Site Supervisor shall be on site when there are site activities for the day
to supervise and ready to act on all safety issues.

Qualified scaffold erector(s), who have successfully undergone the mandatory

scaffold training course is authorized to erect the scaffold.

Only qualified scaffold supervisor can certified the erection and dismantle the
scaffolding.

Risk Assessment and Fall Prevention Plan Briefing shall be conducted and
recorded by Site foreman/ Supervisor in the presence of Safety Personnel and
Lifting Supervisor on site.

Daily Toolbox Meeting (TBM) shall be conducted and recorded every morning.

All personnel at site shall attend Safety Induction Course conducted by Acromec
Engineers Pte Ltd and the Main Contractor of the same project site before
commencing work.

Suitable and appropriate Personal Protective Equipment (PPE) shall be used

according to the job requirement. PPE shall include the following:-

Safety Helmet/ Hard Hat with Chin strap

Safety Glasses/ Goggles/ Face Shield
Ear Plugs/ Muffs
Reflective Vest
Hand Gloves (Rubber, Cotton, Leather, cut resistance )
Safety Harness with lanyards attached to shock absorbers/ Restraint Belt
Safety Boots/ Shoes ( Mid /High cut )

Working area as specified in the drawings shall be barricaded. Signage shall be

put up to prevent unauthorized personnel from entering the work area and to
caution passerby near the worksite.

Housekeeping shall be done after the completion of work daily.

Page 2 of 5
 ACROMEC ENGINEERS LTD
Method of Statement ACR-AF-RR-MS-013
Hot Tapping Works

Date Issue: Rev:00 Page 3 of 2

26/04/2016

3.0 Piping Handling & Installation

3.1 Equipment, Tools and Materials used

Equipment Tools Materials

Scissor Lift Electric Cutter Sheet Metal/ Rock
Mobile/ Tower Scaffold Rec Knife Screws
Welding set Battery drill Lead Lining Sheets
Extension boxes Galvanized Iron Sheet
Electric Drill Hollow Section Frame
Screw driver

3.2 Preliminary works before actual work commencement

Ensure no obstruction is observed on site.

To have Fall Prevention Plan readily available.
Ensure temporary storage area is clean and dry.
Ensure confirm layout plan is ready for verifying information and planning.
Affected work areas are to be barricaded.
Obtain relevant permits from the Main Contractor for the usage of scaffolds and
scissors lifts.

4.0 DUTIES AND RESPONSIBILITIES

4.1 Project Manager

Coordination for company inter-departmental.

Support for site project team.

Review the quality procedures and monitor overall quality system.

4.2 Site Supervisor

To get the approved permit to work (PTW) for all site activities from client
representative.

All necessary permits to be completed and approved by client representative before

commencement of the site activity.

Page 3 of 5
 ACROMEC ENGINEERS LTD
Method of Statement ACR-AF-RR-MS-013
Hot Tapping Works

Date Issue: Rev:00 Page 4 of 2

26/04/2016

The permit has to be closed and return back to client representative at the end of
each day of site activity.

To arrange all necessary materials and hand tools for the installation work.

To give instruction to workers in carrying out the installation work.

To supervise on site during the installation work

4.3 Safety Coordinator

Implementation and monitoring of workforce for safety on the job site and
administer the safety plan.

To conduct safety toolbox meetings.

To conduct site safety, walk and process all applications for inspection in relation to
safety.

To make sure the installation work is carried out safely.

4.4 Working at height Supervisor

To provide direct and close supervisions of the tasks performed by the workers.

To inspect regularly on the worksites, i.e. condition of the scaffold platforms, which
require workers to work at height

To communicate with the workers on the possible risk and control measures to be
taken while working at height.

To make sure workers who are assigned to work at height to have gone through the
Work at Heights training.

4.5 General Workers

To assist piping supervisor in preparing all the necessary material and hand tools for
pipe launching work.

To assist in guiding pipes to workplace trestle until all the pipes are launched
completely.

Page 4 of 5
 ACROMEC ENGINEERS LTD
Method of Statement ACR-AF-RR-MS-013
Hot Tapping Works

Date Issue: Rev:00 Page 5 of 2

26/04/2016

4.6 Work Methods

4.6.1 Method of Installation

Page 5 of 5
 1

INSTRUCTIONS OF
HOT TAPPING
 2

NAVAL HOT TAPPING TOOL / HOT TAPPING VALVES:

Operating instructions for NAVAL hot tapping tool when used together with NAVAL hot
tapping valves.

Locate the exact point for the joint on the main pipe line and prepare
the main pipe for welding of the valve.

Check the place of the joint on the main pipe (if main pipe is a weld seam tube, avoid welding the hot
tapping valve on the weld seam on the main pipe)

Prepare the weld end of the hot tapping valve to match with the radius of the main pipe and taper the
edges as required for the best welding result (see sketch 1).
The weld seam has to comply with the local requirements for size and strength. A support collar is to
be used when necessary.
Note! The threaded end of the valve may be prepared for welding or shortened only after the drilling
through the main pipe has been carried out.

Sketch 1

The valve may be welded to any angle 0-360 on

the main pipe (see sketch 2). The valve is to be at an angle of 90 with the longitudinal axis of the
main pipe line (see sketch 3).
 3

sketch 2 sketch 3

After welding the tightness of the weld seam can be tested e.g. by pressure testing the joint by
compressed air through the draining valve in the hot tapping tool.

Now select a hole saw in size that corresponds to the DN size of the valve. Also select a respective
size socket and adapter from the case. First install the adapter to the tool and after that install the
socket assembly (socket assembly = socket + center drill bit + hole saw) on the shaft of the tool.

Check that the edge of the Frame I is aligned with the groove on the Frame II (see sketch 4, the
groove is in the threaded area of the Frame II). This set up correcponds to the maximum feeding
distance. This position must not be exceeded under any circumstances when the tool is pressurized.
Make sure that the valve is fully OPEN. Attach the tool assemby complete to the threads on the valve.
Test that the hole saw can freely slide through the ball in the valve.
 4

Sketch 4

Attach draining valve + hose to Frame II and close the draining valve.

Before drilling through the main pipe test that the valve can be closed:
Release the shaft locking by pulling the spring loaded part # 400012 (see appendix 1) and
slide out the shaft until it mechanically stops at the outermost position. Close and open the
hot tapping valve for verifying a proper operation of the valve.

Select a locking position that corresponds to the size of the hot tapping valve and lock the shaft to the
selected position (three alternatives -> see appendix 1)
 5

Before drilling check the following details with the drilling machine:
- rotation direction to be clockwise
- the percussion function must not be on under any circumstances
- select the speed of rotation: area 1 or 2 (see sketch 5)
- set the rpm speed, scale A F (see sketch 6)

sketch 5 sketch 6

When starting the drilling, i.e. when drilling the center hole, use high rpm (460 rpm) area 2 and scale F.
Use steady and smooth feeding.
During the drilling it is recommended to keep the draining valve open for removing the cuttings.

Stop after drilling through with the center drill bit only. Adjust the speed of rotation area (1 or 2) and
scale (A-F) for the actual hole cutting and close the draining valve.

Carry out the feeding for the hole saw steady and smooth. During the cutting you may keep the
draining valve open. Close the draining valve after finishing the cutting.

Release the shaft locking and slide the shaft to the outermost position (due to pressure in the valve the
shaft slides out automatically). Then close the hot tapping valve.

Open the draing valve for releasing the pressure from the hot tapping valve.

NOTE! Before removing the drilling tool from the hot tapping valve make
sure that the hot tapping valve is in fully closed position.
Check the markings at the stem to make sure that the hot tapping valve is fully closed.
The tightness of the hot tapping valve must be verified by the draining valve. There must
be no water flow at all through the draining valve after the hot tapping valve is close

Disassemble the drilling tool. Remove first the draining valve and after that remove the tool complete
(incl. adapter) from the hot tapping valve. Then disassemble the tool.

Closing the stem by welding:

If so required the stem can be permanently closed by welding. Remove the PTFE sealing
underneath the cap. Take care of the proper cooling of the stem to avoid damaging the stem O-
rings.
 6

We recommend the following options for the drilling machine

AEG SB2E 1010 RS

BOSCH GSB20 2 RCE

WHEN USING OTHER DRILLING MACHINES ( brand , type ) MAKE SURE THAT THEY
FULFILL THE FOLLOWING CRITERIA:

- input power min 1000 W

- speed of rotation areas Area 1: 0 1000 rpm
Area 2: 0 3000 rpm
- required speed adjustments are available for different hole saw sizes
- the diameter of the neck of the drilling machine to be 43 mm
If you select other brand and models than above please check with the drilling machine
manufacturer that the criteria will be fulfilled.
 7
DN 25 -INSTALLATION DIMENSIONS AND SETTING OF RPM

LOCKING GROOVE Nr 1 HOLE SAW 24

MAIN PIPE LINE A B C

NOMINAL SIZE
+2
DN 32 99 -2 20 105

+0
DN40 100 -10 20 105

+0
DN 50 101 -10 20 105
SPEED OF
ROTATION:370 rpm
+0 AREA 2
DN 65 102 -10 20 105 SCALE D
+0
DN 80 102 -10 20 105

+0
DN 100 103 -10 20 105

+0
DN 125 103 -10 20 105

+0
DN 150 103 -10 20 105

+0
DN 200 105 -10 20 105

THE ABOVE GIVEN DIMENSION A MUST NOT BE EXCEEDED.

WITH MAINPIPE LINE SIZES DN32-40 THE FEEDING OF THE SAW MUST BE STOPPED
AT LEAST 10mm BEFORE THE MAXIMUM FEEDING DISTANCE.
DIMENSIONS A ARE VALID FOR HOLE SAWS MANUFACTURED BY LENOX AND
SANDVIK.
 8
DN32 INSTALLATION DIMENSIONS AND SETTING OF RPM

LOCKING GROOVE Nr 1 HOLE SAW 30

MAIN PIPE LINE A B C

NOMINAL SIZE

+2
DN 40 85 -0 20 93

+0
DN 50 87 -10 20 93

+0
DN 65 89 -10 20 93

+0
DN 80 90 -10 20 93

+0
DN 100 91 -10 20 93 SPEED
ROTATION:285 rpm
AREA 2
+0 SCALE D
DN 125 91 -10 20 93

+0
DN 150 92 -10 20 93

+0
DN 200 92 -10 20 93

+0
DN 300 92 -10 20 93

+0
DN 400 92 -10 20 93
+0
DN 500 93 -10 20 93

IF DIMENSION A FOR DN40 IS AFTER WELDING

SMALLER THAN THE GIVEN SETTING VALUE (85mm) THE FEEDING DISTANCE MUST
BE SHORTENED RESPECTIVELY IN ORDER TO AVOID DRILLING THROUGH THE
OTHER SIDE OF THE MAIN PIPE LINE WITH THE CENTER DRILL, WITH BIGGER SIZES
THER IS NO RISK OF DRILLING THROUGH.
DIMENSION A ARE VALID FOR HOLE SAWS MANUFACTURED BY LENOX AND
SANDVIK
 9
DN40-INSTALLATION DIMENSIONS AND SETTING OF RPM

LOCKING GROOVE Nr 1 HOLE SAW 38

MAIN PIPE LINE A B C

NOMINAL SIZE

+0
DN 50 90 -10 20 111

+0
DN 65 93 -10 20 111

+0
DN 80 94 -10 20 111

+0
DN 100 95 -10 20 111 SPEED OF
ROTATION:230 rpm
AREA 2
+0 SCALE B1
DN 125 96 -10 20 111

+0
DN 150 96 -10 20 111

+0
DN 200 97 -10 20 111

+0
DN 300 98 -10 20 111

FOR MAIN LINE SIZES DN100 WITH WALL THICKNESS

10mm
THE SETTING DIMENSIONS A ARE RECOMMENDED TO BE 10mm SMALLER THAN
THE VALVES GIVEN IN THE TABLE ABOVE THIS IS TO QUARANTEE THAT THE HOLE
SAW GOES FULLY THROUGH
THE WALL OF THE MAIN PIPE.DIMENSIONS A ABOVE ARE VALID FOR LENOX
HOLE SAW.
IF SANDVIK HOLE SAW ARE USED AN ADDITIONAL 10mm MUST BE DEDUCTED FROM
ALL THE DIMENSIONS A ABOVE (SANDVIK HOLE SAW WITH 38mm DIAM. IS 10mm
SHORTER THAN RESPECTIVE LENOX HOLE SAW).
E.G REDUCE 20mm (10+10mm) FROM DIMENSION A WHEN PIPELINE DN100 WITH
WALL THICKNESS 10mm IS USED.
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DN50-INSTALLATION DIMENSIONS AND SETTING OF RPM

LOCKING GROOVE Nr 2 HOLE SAW 48

MAIN PIPE LINE A B C

NOMINAL SIZE
+0
DN 65 120 -0 20 131

+0
DN 80 121 -10 20 131

+0
DN 100 124 -10 20 131

+0
DN 125 126 -10 20 131
SPEED OF
ROTATION:180 rpm
+0 AREA 1
DN 150 127 -10 20 131 SCALE E

+0
DN 200 128 -10 20 131

+0
DN 300 129 -10 20 131

+0
DN 400 129 -10 20 131

+0
DN 500 131 -10 20 131

THE ABOVE GIVEN DIMENSION A MUST NOT BE EXCEEDED.

WITH MAINPIPE LINE SIZES DN65-80 THE FEEDING OF THE THE SAW MUST BE
STOPPED AT LEAST 10mm BEFORE THE MAXIMUM FEEDING DISTANCE !
DIMENSION A ARE VALID FOR HOLE SAWS MANUFACTURED BY LENOX AND
SANDVIK.
 11
DN65-INSTALLATION DIMENSIONS AND SETTING OF RPM

LOCKING GROOVE Nr 3 HOLE SAW 64

MAIN PIPE LINE A B C

NOMINAL SIZE
+2
DN 80 123 -0 20 140

+0
DN 100 127 -10 20 140

+0
DN 125 130 -10 20 140

+0
DN 150 132 -10 20 140

+0
DN 200 134 -10 20 140

+0
DN 300 136 -10 20 140 SPEED OF
ROTATION: 135 rpm
AREA 1
+0 SCALE C
DN 400 137 -10 20 140

+0
DN 500 138 -10 20 140

+0
DN 600 139 -10 20 140

+0
DN 800 140 -10 20 140

DIMENSIONS A ARE VALID FOR HOLE SAWS MANUFACTURED BY LENOX AND

SANDVIK
 12
DN 80-INSTALLATION DIMENSIONS AND SETTING OF RPM

LOCKING GROOVE Nr 3 HOLE SAW 76

MAIN PIPE LINE A B C

NOMINAL SIZE

+0
DN 100 138-10 20 154

+0
DN 125 142-10 20 154

+0
DN 150 145-10 20 154

+0
DN 200 147-10 20 154

+0
DN 250 149-10 20 154

+0 SPEED OF
ROTATION: 115 rpm
DN 300 150-10 20 154 AREA 1
VALID B
+0
DN 400 151-10 20 154

+0
DN 500 152-10 20 154

+0
DN 600 153 -10 20 154

+0
DN 800 154 -10 20 154

DIMENSIONS A ARE VALID FOR HOLE SAWS

MANUFACTURED BY LENOX AND SANDVIK
 13

DN100- INSTALLATIN DIMENSIONS AND SETTING OF RPM

LOCKING GROOVE Nr 3 HOLE SAW 95

MAIN PIPE LINE A B C

NOMINAL SIZE

+0
DN 125 132-10 20 157

+0
DN 150 138-10 20 157

+0
DN 200 143-10 20 157

+0
DN 250 146-10 20 157

+0
DN 300 148-10 20 157 SPEED OF:
ROTATION 90 rpm
AREA 1
+0 SCALE A
DN 400 150-10 20 157

+0
DN 500 152-10 20 157

+0
DN 600 154-10 20 157

+0
DN 800 157-10 20 157

DIMENSIONS A ARE VALID FOR

HOLESAWSMANUFACTURED BY LENOX AND
SANDVIK
 14

DN 125/150 INSTALLATION DIMENSIONS AND SETTING RPM

LOCKING GROOVE Nr 3 HOLESAW 121

MAIN PIPE LINE A B C

NOMINAL SIZE

+0
DN 200 153-10 20 175

+0
DN 250 158-10 20 175

+0
DN 300 161-10 20 175

SPEED OF
+0 ROTATION: 90 rpm
DN 400 165-10 20 175 AREA 1
SCALE A
+0
DN 500 165-10 20 175

+0
DN 600 168-10 20 175

+0
DN 800 170-10 20 175

DIMENSIONS A ARE VALID FOR HOLESAWS

MANUFACTURED BY LENOX AND SANDVIK
15