_Engineering Procedure

Document Responsibility: PipingSAEP-311

Issue Date: 29 January, 2003

Next Planned Update: 1 March, 2003Installation of Hot Tapped Connections

Engineering ProcedureSAEP-31129 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.

Saudi Aramco DeskTop Standards

Table of Contents

1Scope.............................................................2

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

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

4Responsibilities.............................................14

Appendix I - Ultrasonic Thickness

Measurements 17

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

1Scope

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.

2Applicable Documents

2.1Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-310Pipeline Repair and Maintenance

Saudi Aramco Engineering Standards

SAES-A-004Pressure Testing

SAES-L-052Hot Tap Connections

SAES-L-056Pressure Testing of Plant Piping and Pipelines

SAES-W-010Welding Requirements for Pressure Vessels

SAES-W-011Welding Requirements for On-Plot Piping

SAES-W-012Welding Requirements for Pipelines

Saudi Aramco Standard Drawings

AB-036719Reinforcement of Welded Branch Connections

AB-036715Detail of Heavy Welding Boss for Threaded Connections

AB-036643Detail of Heavy Welding Boss for Socket Weld Connections

Saudi Aramco Forms and Data Sheets

Form SA 7235-ENGHot Tap Data and Checklist

Form SA 7627-ENGHot Tap/Stopple & Reinforcement Calculation Sheet

Saudi Aramco General Instructions

GI-0002.100Work Permits

GI-0002.102Safety Precautions for Pressure Testing

GI-0002.711Fire and Safety Watch

GI-1780.001Atmosphere-Supplying Respirators

2.2Industry Codes and Standards

American Petroleum Institute

API STD 598Valve Inspection and Test

API RP 2201Procedures for Welding or Hot Tapping on Equipment Containing Flammables

American Society of Mechanical Engineers/Boiler and Pressure Vessel Code

ASME SEC VIII D1Pressure Vessels

ASME B31.3Process Piping

ASME B31.4Liquid Transportation Systems for Hydrocarbons

ASME B31.8Gas Transmission and Distribution Piping Systems

3Instructions

3.1Definitions

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.

3.2General Requirements

3.2.1Hot tap connections shall be designed and installed to meet all requirements of this SAEP, and SAES-L-052, "Hot Tap Connections".

3.2.2The hot tapping operations are initiated, designed, and controlled by:

3.2.2.1Operations Engineering Organization in the case of existing facilities.

3.2.2.2Project 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.

3.2.3The 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.

3.2.4The 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.

3.2.5The 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.

3.2.6For carbon steels with minimum specified yield stresses less than or equal to 60 ksi, pre-approved welding procedures may be used.

3.2.7For carbon steels with minimum specified yield stresses greater than 60 ksi, the Consulting Services Department shall be contacted for welding procedure approval.

3.2.8For 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.

3.2.9Compressed air piping and equipment shall not be hot tapped nor welded while in service. Refer to SAES-L-052, paragraph 4.3.

3.2.10Hot 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.

3.2.11Hot 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.

3.2.12All hot tap connections, valves, and hot tap machines shall be pressure tested in accordance with this SAEP. (Refer to Para. 3.8)

3.2.13Precautions 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".

3.2.14Adequate 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.

3.2.15Hot 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.

3.2.16Storage Tanks

3.2.16.1For 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.

3.2.16.2The 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.

3.2.16.3Hot tapping is not permitted on cone or floating roofs of in-service tanks.

3.2.16.4On tanks, connections larger than 2 inch NPS require written approval of the Manager, CSD.

3.2.17When 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.

3.2.18Hot 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)

3.2.18.1Wall thickness above the lamination must be greater than 5 mm (0.2 inch).

3.2.18.2Reinforcement of the nozzle shall be based on the wall thickness above the lamination. (Does not apply to split-tee installation)

3.2.19Appropriate 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.

3.2.20Compact steel gate valves with extended body ends shall not be used for hot tap connections.

3.3Precautions against H2S and other Toxic/Hazardous Materials

3.3.1If 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 GI-1780.001, "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.

3.3.2When 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.

3.3.3The 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.

3.3.4In 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.

3.3.5The 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.

3.4Preparation of Hot Tap Specification and Test Calculations

3.4.1The Initiating Engineer shall provide Form SA 7627-ENG for each hot tap operation.

3.4.2Each Form SA 7627-ENG shall be completed in sequence and by the organization identified:

Form Section #Person/Organization

SummaryInitiating Engineer

(includes; Hot Tap Location,

Header Info, and Branch Info)

1Initiating Engineer

2Operations Engineer

3Responsible I.e.,. Unit

4Operations Eng. Div.

SummaryInitiating Engineer

(includes: Test & Process Info)(To be completed with actual conditions just prior to welding or cutting)

3.5Locate and Inspect Hot Tap Position

3.5.1The Initiating Engineer shall make all necessary arrangements for the preparation of hot tapping (i.e., location, excavation, pipe inspection, surface preparation, etc.)

3.5.2The 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.

3.5.3The 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 out-of-roundness does not exceed 3 mm. (Out of roundness criteria only applies to split tee or full encirclement sleeves).

3.5.4The hot tap number is obtained from Form SA 7627-ENG developed for each location.

3.5.5The 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.

3.5.6The 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:

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 burn-through are taken. (THIS CONDITION STILL REQUIRES A WAIVER TO BE PROCESSED THRU CSD).

3.5.7If 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.

3.5.8The Piping & Valves Unit/M&CED/CSD shall complete Section 3 of form SA 7627-ENG and return it to the Initiating Engineer.

3.5.9The 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.

3.6Approval and Distribution of Form SA 7627-ENG

3.6.1The 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.

3.6.2The 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.

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.

3.6.3After 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.

3.6.4Once approval is obtained, the Initiating engineer shall distribute copies of each Form SA 7627-ENG to the following personnel:

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)

3.6.5The Initiating Engineer shall prepare and forward Form SA 7235-ENG "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

3.6.6The 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.

3.7Safety Requirements

3.7.1The 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.

3.7.2Written 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.

3.7.3All 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:

1)Vehicle entry

2)Welding

3)Grinding

4)Hot Tapping

3.7.4The 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.

3.7.5The 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.

3.7.6The 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".

3.8Pressure Test Requirements

3.8.1The 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.

3.8.2The 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:

3.8.2.1Pressure test once every four months and overhaul once every 12 months.

3.8.2.2After 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.

3.8.2.3A stamped brass tag shall be affixed to the hot tap machine indicating the test pressure, overhaul date, and the name of the testing organization.

3.8.3Maximum hydrostatic test pressure applied to the branch (or hot tap) connection shall be in accordance with SAES-L-052, paragraph 7.3.b).

3.8.4Pneumatic testing of hot tap connections on hot lines over 93C is not permitted unless approved by the Manager, Consulting Services Department.

3.8.5Hot 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 TemperatureHydrotest FluidStock No.

93C to 290CTurbine Oil26-001-330

26-001-340

Over 290CSilicone Fluid 20026-010-037

Commentary Note:

Check to ensure compatibility of fluids used in hot tapping with that of the line being hot tapped.

3.8.6A 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.

3.8.7After 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. AB-036719.

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.

3.8.8A 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.

3.8.9Install 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.

3.8.10Return 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.

3.8.11Ensure 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)

3.8.12After 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.

3.8.13The appropriate CSD Representative shall witness and approve all hydrostatic testing required for completion of the hot tap connection.

3.9Operating Conditions Requirements

3.9.1The 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).

3.9.2Maximum 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.

3.9.3The 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.

3.9.3.1Flow 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.

3.9.3.2In 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:

3.9.3.2.1For 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.

3.9.3.2.2For 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.

3.9.3.2.3Prior 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.

3.9.4Maximum and minimum flow rates during hot tapping shall be as follows:

a)Liquid &0.40 m/sec minimum

Two-Phase4.50 m/sec maximum

b)Gas0.40 m/sec minimum

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.

Commentary Notes:

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.

3.9.5While 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.

3.9.6Work 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.

3.10Hot Tap Fittings/Sandwich Valve Installation Requirements

3.10.1The Initiating Engineer shall coordinate all activities.

3.10.2The Operations Superintendent shall ensure compliance with the safety precautions arranged under paragraph 3.9 of this SAEP, including acceptance of the work permit.

3.10.3The Inspector shall perform the following:

3.10.3.1Verify a CSD approved welding procedure specification is utilized for installation of the connection (Refer para. 3.5.9).

3.10.3.2Verify 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.

3.10.3.3Inspect the branch connection/split tee, before and during the installation, for compliance with the approved drawings and welding procedures.

3.10.3.4Verify that a calibrated pressure gauge and relief valve are properly installed for testing.

3.10.3.5Confirm 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.

4Responsibilities

4.11Hot Tapping Operation Procedure

ProcedureResponsibilities

4.11.1Review the design drawings and requirements for theInit. Eng/CSD

branch connection, including an approved welding

procedure in accordance with the applicable

SAES-W-XXX.

4.11.2Ensure all the requirements of paragraph 3.2Init. Eng/Maint/

"General Requirements" are met.Constr

4.11.3Check that the location of the installation is thatOpers/Maint/

location specified by the initiating Engineer with theConstr

concurrence of the Operations Supt.

4.11.4Obtain an approved Hot Work Permit, Saudi AramcoInit. Eng/Maint/

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

Superintendent, or his designee, prior to starting with

work.

4.11.5If long seam is under hot tap fitting, grind seam weldMaint/CSD/

flush with the surface of the pipe taking care not toConstr

reduce the pipe wall thickness. Check pipe wall

thickness ensuring it does not violate para. 3.5.6.

4.11.6Ensure the pressure and flow requirements as identifiedInit Eng/CSD/

in section 4 of Form SA 7627-ENG have been establishedMaint/Constr

prior to any welding.Opers

4.11.7Power wire brush the area for attachment welds toMaint/Constr/

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

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

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.

4.11.8Ensure that the nozzle connections are not welded onCSD/Init Eng/

the inside unless the hot tap cutter is at least one pipeMaint/Constr

size smaller than the nozzle. The cutters sometimes

break if the cut is made through a weld.

4.11.9Precheck the tapping valve and the hot tap machine Hot Tap Unit

to assure good operable condition, including the cutter

and coupon retaining device.

4.11.10Confirm that the shop rating test of the hot tap machineCSD/Hot Tap Unit

is current per para. 3.8.2.

4.11.11Mount the valve on the fitting ensuring that its alignmentCSD/Hot Tap Unit

is within the manufacturer's tolerance

4.11.12Close the valve and perform the hydrostatic testMaint/Constr/Hot

according to this instruction.Tap/CSD

4.11.13Check the valve by opening and the hot tap machineHot Tap Unit/Maint/

for operability and examine the condition of the cutterConstr

and coupon retaining device.

4.11.14Mount the hot tap machine on the valve.Hot Tap Unit/Maint/

Constr

4.11.15Ensure that the tapping valve is tested in accordanceHot 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.

4.11.16Apply hydrostatic and pneumatic pressure tests to theHot Tap Unit/ICSD/

hot tap machine, valve, and welded connection inMaint/Constr

with the testing procedure specified in this SAEP and

SAES-L-052, paragraph 5.

4.11.17Install and seal weld a threaded plug in the weld bossMaint/Constr

on the connection after all testing has been completed.

Refer to paragraph 3.8.12

4.11.18After assembly of the hot tap machine on the tapping

valve and before the tapping operation is started:

4.11.18.1Completely close and then completely openHot 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.

4.11.18.2Set the cutter travel indicator to prevent overHot Tap Unit

travel and consequent damage to the opposite

side of the header being hot tapped.

4.11.19Drill and cut coupon.Hot Tap Unit

4.11.20Retract the hot tap machine boring bar.Hot Tap Unit

4.11.21Close the valve, purge with nitrogen, if required, andHot Tap Unit

depressurize the hot tap machine adaptor.

4.11.22Remove the hot tap machine from the line.Hot Tap Unit/

Maint/Constr

4.11.23Remove the coupon from the pilot drill and tag andHot Tap Unit/

wire the coupon to the tapping valve on the connectionMaint/Constr

after hot tap is completed.

4.11.24The coupon shall be removed only by the OperationsOpers

Supervisor and forwarded to the responsible Operations

Piping & Valves Unit/M&CED/CSD.

4.11.25Ensure that the completed connection is blinded orHot Tap Unit/CSD/

plugged before leaving the job site.Maint/Constr

Revision Summary

1 Decenver, 1996Editorial revision to convert document to new format.

30 September, 1997Minor 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 April, 1998Added GI-1780.001 in the reference.

29 February, 2000Added 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, 2003Editorial revision to change the Document Responsibility from Inspection Department to Piping Standards Committee, CSD.

Appendix I Ultrasonic Thickness Measurements

Hot Tap #_________________

J.O./W.O. ______________PLANT #_______________ DWG. # ________________

Description (Job, Location, etc.) ___________________________________________

Diameter Grade Schedule Flange RatingHEADER: _____________ ______________ _____________ ____________

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:__________

STICKER MEASUREMENTMin:__________ Max.:__________

LOCATION-------DESCRIPTION

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

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

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

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

Line E-E----------Reinf. Sleeve Ends

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

ENGINEER:

REFERENCE: SAES-L-052, STD. DWG. AB-036719NOTE:For connection reinforcement requirements refer to ASME B31.3, ASME B31.4, ASME B31.8, ASME SEC VIII, and STD. DWG. AB-036719.

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 Tap1.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?

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 Cutting1.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

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.

Previous Issue: 29 February, 2000 Next Planned Update: 1 March, 2003

Revised paragraphs are indicated in the right marginPage 1 of 1Primary contact: Muhsen S. Al-Sannaa on phone 874-6679

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