Method Statement - Hot Tap-IOC Paradip
Method Statement - Hot Tap-IOC Paradip
PROJECT
VARIOUS HOT TAPPING @ IOCL PARADIP
PROCEDURE FOR
HOT TAPPING
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Project: Various Hot Tapping @ IOCL PARADIP
CONTENTS
Sr.
FEATURES Page Number
No.
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Project: Various Hot Tapping @ IOCL PARADIP
Hot Tapping
Hot Tapping or pressure Tapping is the method of making a branch connection to
existing pipelines or vessels or any process equipment while the existing system is
under pressure with appropriate hot tap machine.
Measuring Rod
Valve
Existing Pipeline
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Project: Various Hot Tapping @ IOCL PARADIP
Angle hot tap require special preparation & equipment to complete the job.
Manufacturing of angle hot tap fitting, In-service welding procedure, hot tapping
operation sequence is different than the standard
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Qty Nos. 44
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Project: Various Hot Tapping @ IOCL PARADIP
In-Service Welding
2) Consumables
Electrodes shall confirm to AWS A 5.5 / AWS CLASS EXX16 and / or EXX18 basic
coated low Hydrogen electrodes shall be specified in the Welding Procedure
Specification.
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3) Pipeline Inspection
Surface Preparation
Clean the mark location to bare metal by mechanical and/or
chemical means to remove all coatings, dirt, and other contaminates.
2 Proper precautions needs to take for not to remove the parent metal
during cleaning process.
Visual Inspection
Visual inspection has to be done for non existence of pitting and
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corrosion on the mark area for in service welding.
Defect Check
Ultrasonic test need to be carried out to determine the actual wall
thickness & the soundness of the pipe at the exact tap location. If
4 result from visual or ultrasonic inspection shows any defect or
excessive thinning or any unsatisfactory factor then new location
need to be determined.
Internal Consideration
Pipeline parameter need to cross check with hot tap datasheet before
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start of welding as calculation & analysis are according to it.
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Project: Various Hot Tapping @ IOCL PARADIP
4) Fit-Up Procedure
1 Safety
√ All lifting equipments like Crane, Chains, ropes and lifting tackles
shall be maintained in good operating condition & certified.
2 Fit-up Procedure
√ Verify that the axial centerline of the tapping path intersects the
axial centerline of the pipeline at right angles.
5) Welding Procedure
√ Weld both longitudinal seams first. Start the welds at mid length
and weld in opposite directions. Repeat this step, staggering the
starts/stops, until the seams are half full.
Allow the hot tapping fitting and Line to cool to ambient prior to
any Non-Destructive examination.
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Project: Various Hot Tapping @ IOCL PARADIP
BEFORE WELDING
DURING WELDING
AFTER WELDING
NDT Personnel shall be qualified to ASNT recommended practice for non destructive
testing. Only Level II or Level III personnel shall be used for interpretation of the
test result.
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Project: Various Hot Tapping @ IOCL PARADIP
1 Customer Co-ordination
3 Installation of Valve
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Project: Various Hot Tapping @ IOCL PARADIP
5 Tapping Measurements
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Project: Various Hot Tapping @ IOCL PARADIP
The welded hot tap fitting & hot tap machine should be tested to
assure they are leak proof and in accordance with applicable codes
before the actual hot tap is started.
The test pressure should be at equal to the operating pressure of line
to be hot tapped. It should not be increased than the 1.1 times of
pipeline operating pressure.
Excess test pressure than the present internal pressure may cause
possible internal collapse of the pipe.
Nitrogen to be used as testing media. Soap solution can be used on
the weld & flange joint to check leakage.
Start power unit & adjust the throttle for desired engine speed to get
required cutter RPM.
Once cutter reaches to tapping distances, stop power unit.
Retract cutter fully after tap is completed by moving lower in crank
anticlockwise.
Close the valve & bleed off the pressure through bleeder valve.
Remove bleeder valve from tapping machine.
If using hydraulic power unit, switch off the engine.
Remove tapping machine.
Install & tighten the Blind flange on the top of tapping valve.
Remove coupon & handover to customer.
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Responsibility Remark
Sr. No. Inspection Activity
PTS / TAUMAN IOCL
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Risk Assessment
1. Inform the Control A. Relevant authority not informed. 1. Inform the Control
Operator and other operator and relevant
departments of the proposed authority/ departments of
job and expected duration. proposed works, location,
and expected completion
time.
2. Obtain clearance from
the relevant authority
before commencing w/
job.
3. Ensure suitable
working communication
equipment is provided and
available on the job site.
(intrinsically safe)
4. Obtain approved
work permits (Hot
work, confined space,
as necessary)
B. Lack of communication link 1. Outline work schedule
relating to work, in case of to all Utilities stating
emergency expected duration.
2. Communicate w/
Utilities before excavation
commences.
3. Ensure utility rep is on
site during work.
4. Use signs to warn,
inform, direct public.
2. Review all procedures A. Ineffective/ incomplete 1. All individuals who may
with all individuals who may communication of task to be potentially be affected
potentially be affected by performed, steps involved, hazards have been identified and
operation. involved, steps to mitigate hazards, actively participate in the
recommended actions, and JSA.
understanding of individual
responsibilities.
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8. Evacuate personnel to a
safe zone in case of an
emergency
9. Enforce PPE
requirement at site
10. Eliminate or minimize
other Hot work in the area
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Project: Various Hot Tapping @ IOCL PARADIP
Hot Tapping
9. Close Hot Tap valve. A. Inability to completely seat valve Close the valve,
gate. monitoring the stem travel
distance to ensure the
valve is fully closed.
10. Remove Hot Tap A. Damage to equipment/personnel 1. Ensure that trapped
Machine and accessories. pressure from the Adapter
is bleeder off to a safe
area.
2. The bleed valve on the
hot tap machine will be
opened slowly.
B. Overhead lifting hazard Maintain a clear working
area.
Ensure proper lifting
procedure, use tagline and
trained personnel. Ensure
adequate size and support
for Crane
C. Public Safety 1. Establish a safe
perimeter and restricted
access to work area.
2. Observe all traffic,
vehicular regulatory and
safety regulations.
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Project: Various Hot Tapping @ IOCL PARADIP
Our primary objective is to provide and maintain safe working conditions, equipment
and systems of work for our employees. It is also our objective to ensure that all of
our employees understand clearly their own responsibilities with regard to Health,
Safety and the Environment and that they are actively involved in the implementation
of this Policy. To achieve these objectives, we will:
Carry out Risk Assessments ensuring that all hazards are identified, that adequate
controls are implemented and that these are communicated to our employees and
other persons as appropriate.
Monitor Health and Safety Performance by carrying out safety audits and general
inspections of the workplace.
Communicate the arrangements in this Policy to all employees and other persons
as appropriate and consult with them on matters affecting their health and safety.
Arrange for sufficient funds and resources to meet the requirements of the policy.
Provide information, instruction and supervision for our employees and other
persons as appropriate.
Provide adequate induction and on-going training to ensure that employees are
competent to carry out all work assigned to them, to ensure their own safety and
the safety of others.
Review and revise this Policy annually or more frequently as required, ensuring it remains in
compliance with current safety legislation and any changes made are brought to the
attention of our employees and other persons as appropriate.
Somesh Wani
Managing Director
Date: 21-Jan-2019
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ANNEXURE V
Wall If Sour Design Design Orientation Header Branch Above/Below Orientation of Valve
S.NO TP NO Line Material Product MAT ANSI # Valve Type
Thickness Service, advise Pressure Operatin Temperat Operating of Pipe Line Size Size Ground Level Tap Length
1 TP-016-901 STD A106 Gr.B CS H2SNA ppm 27.9 g
4 ure
180 Temperat
80 HOR 6 6 300 AG VERTICAL GATE 403
2 TP-016-904 NOT IN PMS Lean Amine CS NA 37.2 23 128 55 HOR 18 3 300 AG VERTICAL GATE 282
3 TP-016-905 NOT IN PMS Rich Amine CS NACE SOUR SERVICE 10 8 90 62 HOR 26 6 150 AG VERTICAL GATE 267
4 TP-016-906 NOT IN PMS CS NACE SOUR SERVICE 33 6.5 90 40 HOR 8 4 300 AG VERTICAL GATE 305
5 TP-016-907 STD A106 Gr.B(NACE) (Wild Naphtha) CS NACE SOUR SERVICE 22.5 13.6 65 40 VER 3 2 300 AG HORIZONTAL GATE 216
6 TP-016-911A SCH 40 A672 Gr.B60 CL.32 HSD CS NA 18 8 95 40 HOR 18 6 300 AG VERTICAL GATE 403
7 TP-016-911B STD A106 Gr.B ATF CS NA 18 8 95 40 VER 8 6 150 AG HORIZONTAL GATE 267
8 TP-016-915 XS A106 Gr.B (NACE) Stripped Water CS NACE SOUR SERVICE 21.7 8 90 65 HOR 8 4 300 AG VERTICAL GATE 305
9 TP-057-901 STD A106 Gr.B DCU NAPHTHA CS NA 17.2 4 65 45 HOR 4 4 150 AG VERTICAL GATE 229
10 TP-057-902 STD A106 Gr.B HTL NAPHTHA CS NA 17.2 4 65 45 HOR 6 6 150 AG VERTICAL GATE 267
11 TP-057-905 NOT IN PMS FUEL GAS CS NA 6 3.9 65 40 HOR 36 6 150 AG VERTICAL BALL 267
12 TP-057-910 STD A106 Gr.B NITROGEN CS NA 10.5 8 65 Amb. HOR 6 4 150 AG VERTICAL GATE 229
13 TP-057-911 STD A106 Gr.B INSTRUMENT AIR CS NA 10.5 7 65 40 HOR 6 4 150 AG VERTICAL GATE 229
14 TP-057-912 STD A106 Gr.B PLANT AIR CS NA 10.5 7 65 40 HOR 3 3 150 AG VERTICAL GATE 203
15 TP-057-923 STD A106 Gr.B (NACE) SOUR FLARE B.L. CS NACE SOUR SERVICE 7 6 150 38 HOR 6 6 150 AG VERTICAL GATE 267
16 TP-057-926 XS A671 Gr.CC60 CL.32(NACE) LP FLARE CS NACE SOUR SERVICE 3.5 0.87 250 230 HOR 42 24 150 AG LATERAL GATE 508
17 TP-057-927 STD A671 Gr.CC60 CL.32(NACE) HP FLARE CS NACE SOUR SERVICE 7 2.82 250 69 HOR 30 24 150 AG LATERAL GATE 508
18 TP-057-932 STD A106 Gr.B DSN Naphtha CS NA 0 0 0 0 HOR 6 6 150 AG VERTICAL GATE 267
19 TP-058-905 XS A106 Gr.B-IBR MP BFW CS IBR NA 40 28 150 105 HOR 12 6 300 AG VERTICAL GATE 403
20 TP-058-907 STD API 5L Gr.B (PSL-1) LP Nitrogen CS NA 10.5 8 65 Amb. HOR 16 4 150 AG VERTICAL GATE 229
21 TP-058-908 STD API 5L Gr.B (PSL-1) Instrument Air CS NA 10.5 7 65 40 HOR 16 4 150 AG VERTICAL GATE 229
22 TP-058-914 STD A672 Gr.B60 CL.32 Fuel Gas Supply CS NA 6 3.9 65 40 HOR 30 2 150 AG VERTICAL BALL 178
23 TP-058-921 STD A672 Gr.B60 CL.32 Fuel gas Return CS NA 10 5 65 45 HOR 30 8 150 AG VERTICAL BALL 292
24 TP-058-924 NOT IN PMS LP flare CS NACE SOUR SERVICE 3.5 0.87 250 230 HOR 60 16 150 AG LATERAL GATE 406
25 TP-058-925 NOT IN PMS HP flare CS NACE SOUR SERVICE 7 2.82 250 230 HOR 80 12 150 AG LATERAL GATE 356
26 TP-058-930 STD A106 Gr.B CCR PSA TAIL GAS CS NA 10 5 65 50 HOR 14 14 150 AG VERTICAL GATE 381
27 TP-205-902A STD A106 Gr.B CS NA ATM ATM 65 AMB HOR 14 14 150 AG VERTICAL GATE 381
28 TP-205-902B STD A672 Gr.B60 CL.32 CS NA ATM ATM 65 AMB HOR 16 16 150 AG VERTICAL GATE 406
29 TP-205-903A STD A106 Gr.B CS NA ATM ATM 65 AMB HOR 6 6 150 AG VERTICAL GATE 267
30 TP-205-903B STD A106 Gr.B CS NA ATM ATM 65 AMB HOR 6 6 300 AG VERTICAL GATE 403
31 TP-203-904 STD A106 Gr.B Nitrogen CS NA 10.5 8 65 Amb. HOR 6 4 150 AG VERTICAL GATE 229
32 TP-203-908 XS A106 Gr.B CS NA 18 8 95 40 HOR 2 2 150 AG VERTICAL GATE 178
33 TP-205-906 STD A106 Gr.B CS NA 19.2 0 65 40 HOR 8 8 150 AG VERTICAL GATE 292
34 TP-205-907 STD A672 Gr.B60 CL.32 CS NA 19.2 0.9 65 40 HOR 24 8 150 AG VERTICAL GATE 292
35 TP-205-908 STD A106 Gr.B CS NA 19.2 0.9 65 40 HOR 6 3 150 AG VERTICAL GATE 203
36 TP-203-924 STD A106 Gr.B Instrument air CS NA 10.5 7 65 40 HOR 3 2 150 AG VERTICAL GATE 178
37 TP-205-922 XS A106 Gr.B Plant Air CS NA 10.5 7 65 40 HOR 2 2 150 AG VERTICAL GATE 178
38 TP-122-902 STD A672 Gr.B60 CL.32 Plant Air CS NA 11.2 9.5 65 40 HOR 16 10 150 AG VERTICAL GATE 330
39 TP-122-903 STD A672 Gr.B60 CL.32 Instrument air CS NA 11.2 8.8 65 40 HOR 16 10 150 AG VERTICAL GATE 330
40 TP-122-905 XS A672 Gr.B60 CL.32 Instrument air CS NA 33 30 65 40 HOR 16 16 300 AG VERTICAL GATE 838
41 TP-058-906 STD API 5L Gr.B (PSL-1) Cooling Water Supply CS NA 8 5.5 65 35 HOR 80 16 150 UG VERTICAL GATE 406
42 TP-058-927 STD API 5L Gr.B (PSL-1) Cooling water Return CS NA 8 3.5 65 44 HOR 80 16 150 UG VERTICAL GATE 406
43 TP-104-906 STD API 5L Gr.B (PSL-1) Cooling Water Supply CS NA 8 6.18 65 35 HOR 80 48 150 UG VERTICAL GATE 1142
44 TP-205-923 XS A106 Gr.B Nitrogen CS NA 10.5 8 65 Amb. HOR 2 2 150 AG VERTICAL GATE 178