Professional Documents
Culture Documents
SAEP-311
29 January, 2003
Page 1 of 25
SAEP-311
Scope.............................................................
Applicable Documents...................................
Instructions.....................................................
Responsibilities.............................................
14
17
18
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
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SAEP-311
Pressure Testing
SAES-L-052
SAES-L-056
SAES-W-010
SAES-W-011
SAES-W-012
AB-036715
AB-036643
Form SA 7627-ENG
2.2
GI-0002.100
Work Permits
GI-0002.102
GI-0002.711
GI-1780.001
Atmosphere-Supplying Respirators
Page 3 of 25
SAEP-311
API RP 2201
Pressure Vessels
ASME B31.3
Process Piping
ASME B31.4
ASME B31.8
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:
3.2.3
3.2.2.1
3.2.2.2
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SAEP-311
3.2.4
3.2.5
3.2.6
For carbon steels with minimum specified yield stresses less than or equal to
60 ksi, pre-approved welding procedures may be used.
3.2.7
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
3.2.11
Hot tap connections are not allowed for certain cases (refer to SAES-L-052
paragraph 4.1), unless a detailed design and installation procedure has
received prior approval from the Manager of CSD and concurrence from the
Loss Prevention Department.
3.2.12
All hot tap connections, valves, and hot tap machines shall be pressure tested
in accordance with this SAEP. (Refer to Para. 3.8)
3.2.13
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SAEP-311
3.2.14
3.2.15
b)
Existing welds under the hot tap shall be ground smooth prior to fit up of the
sticker and reinforcing sleeve. Care should be taken when cutting across
existing welds since the cutter can be damaged.
3.2.16
Storage Tanks
3.2.16.1
3.2.16.2
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.
3.2.16.3
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SAEP-311
3.2.16.4
3.3
3.2.17
When hot taps are being made to obtain coupons for HIC determination, the
Saudi Aramco Form SA 7627-ENG and the ultrasonic scan data shall be
evaluated by M&CED of the Consulting Services Department. The
Consulting Services Department shall designate the location of the hot tap,
type of reinforcement, and other special requirements.
3.2.18
3.2.18.2
3.2.19
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.
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 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.
3.3.2
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
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SAEP-311
3.4
The chamber of the hot tap machine and valve shall be purged with nitrogen
after cutting the coupon, retracting the cutter and closing the tapping valve
when any of the following exist:
1.
2.
3.
4.
3.3.4
3.3.5
The Initiating Engineer shall provide Form SA 7627-ENG for each hot tap
operation.
3.4.2
Person/Organization
Summary
(includes; Hot Tap Location,
Header Info, and Branch Info)
Initiating Engineer
Initiating Engineer
Operations Engineer
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SAEP-311
3.5
Summary
(includes: Test & Process Info)
Initiating Engineer
(To be completed with actual
conditions just prior to welding or
cutting)
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
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 out-of-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.
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SAEP-311
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).
3.6
3.5.7
3.5.8
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.
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
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SAEP-311
3.6.4
3.6.5
1)
Operations Superintendent
2)
3)
4)
5)
6)
The Initiating Engineer shall prepare and forward Form SA 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
3.6.6
3.7
Safety Requirements
3.7.1
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SAEP-311
3.8
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
Vehicle entry
2)
Welding
3)
Grinding
4)
Hot Tapping
3.7.4
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.
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 GI0002.711, "Fire and Safety Watch".
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
Page 12 of 25
SAEP-311
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
3.8.2.3
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
Over 290C
26-001-330
26-001-340
26-010-037
Commentary Note:
Check to ensure compatibility of fluids used in hot tapping with that of
the line being hot tapped.
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SAEP-311
3.8.6
A body and high pressure seat test (on both sides of the seat) shall be
performed in the shop on all hot tap valves prior to installation. Resilient
(soft) seat valves shall have zero leakage. Valves with metal to metal seats
shall meet the leakage criteria of API STD 598. A back seat test and low
pressure seat test is not required. A tag shall be attached to the valve
indicating test date, test pressure and Inspector's name.
Commentary Note:
This seat test does not apply to sandwich valves.
3.8.7
3.8.8
A pneumatic test of 173 kPa (ga) (25 psi) shall be applied to the reinforcing
pad or ring after installation. This pressure will then be reduced to 21 - 35
kPa (ga) (3 - 5 psi) for a tightness test using a soap solution.
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)
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SAEP-311
3.9
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.
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).
3.9.2
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
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SAEP-311
3.9.3.2
3.9.4
3.9.3.2.2
3.9.3.2.3
Maximum and minimum flow rates during hot tapping shall be as follows:
a)
b)
Liquid &
Two-Phase
Gas
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)
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SAEP-311
2)
3.10
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.
3.10.2
3.10.3
3.10.3.2
3.10.3.3
3.10.3.4
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SAEP-311
3.10.3.5
Responsibilities
4.11
Responsibilities
4.11.1
Init. Eng/CSD
4.11.2
Init. Eng/Maint/
Constr
4.11.3
Opers/Maint/
Constr
4.11.4
Init. Eng/Maint/
Constr
4.11.5
Maint/CSD/
Constr
4.11.6
Init Eng/CSD/
Maint/Constr
Opers
4.11.7
Maint/Constr/
CSD
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SAEP-311
CSD/Init Eng/
Maint/Constr
4.11.9
4.11.10 Confirm that the shop rating test of the hot tap machine
is current per para. 3.8.2.
4.11.11 Mount the valve on the fitting ensuring that its alignment
is within the manufacturer's tolerance
Maint/Constr/Hot
Tap/CSD
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.
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
Maint/Constr
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SAEP-311
4.11.23 Remove the coupon from the pilot drill and tag and
wire the coupon to the tapping valve on the connection
after hot tap is completed.
Opers
1 Decenver, 1996
30 September, 1997
29 April, 1998
29 February, 2000
29 January, 2003
Revision Summary
Editorial revision to convert document to new format.
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.
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.
Editorial revision to change the Document Responsibility from Inspection Department to
Piping Standards Committee, CSD.
Page 20 of 25
SAEP-311
Diameter
Grade
Schedule
Flange Rating
HEADER: _____________
______________
_____________
____________
STICKER _____________
______________
_____________
____________
HEADER MEASUREMENTS
(CONTINUOUS SCANNING)
Point A
Min:__________
Max.:_________
Circle B
Min:__________
Max:__________
Circle C
Min:__________
Max:__________
Line D-D
Min:__________
Max:__________
Line E-E
Min:__________
Max:__________
Min:__________
Max:__________
STICKER MEASUREMENT
Min:__________
Max.:__________
Page 21 of 25
SAEP-311
C
FLOW
LOCATION-------DESCRIPTION
For connection reinforcement requirements refer to ASME B31.3, ASME B31.4, ASME B31.8, ASME SEC VIII, and
STD. DWG. AB-036719.
Page 22 of 25
SAEP-311
2.
Does the tapping machine have a suitable pressure and temperature rating for the job?
3.
Has the exact location of the hot tap on the line or vessel been identified or marked?
4.
Has the area to be welded been inspected for thickness and freedom from lamination or
HIC?
5.
Has the need for stress relieving the weld area been considered?
6.
Do the flanges, bolts, gaskets, pipe, and valve to be installed meet the piping code for the
line or vessel to be hot tapped?
7.
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.
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SAEP-311
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?
2.
Is the fitting properly positioned so misalignment of the hot tap machine will not occur?
2.
Have the hot tap valve, gaskets, and bolts been checked for possible leakage?
3.
4.
Has the bleed off valve been checked to be sure it will hold and is not stopped up?
5.
Are all bolts on the cutter and pilot bit tight and is the coupon catcher on the pilot bit?
6.
7.
Has the cutting depth been calculated to avoid cutting the opposite side of the pipe?
8.
Has the boring bar been run through the valve several times to ensure free passage?
9.
Has the pressure and temperature of the contained material been reduced as much as the
process operations will allow?
10.
Is there liquid or flowing gas in contact with the area to be hot tapped?
Follow the manufacturer's instructions to be sure the boring bar is fully retracted before
closing the valve.
2.
Page 24 of 25
SAEP-311
3.
4.
Open the bleeder valve and be sure all pressure is off the hot tap machine before
removing bolts from the flange. If flow or pressure persists, the main valve is probably
leaking.
5.
6.
Remove the coupon and from the pilot drill and wire to the tapping valve.
7.
Ensure the completed hot tap is blinded or plugged before leaving the jobsite.
8.
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