01 Hot Tapping

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Pipeline Integrity, Hot Tapping &

Plugging Seminar

Sol Elite Marbella, Anyer

10 May 2007

Gunavel Rathinam

Regional Sales Manager


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AGENDAAGENDA

Objective

Basic Concept

Associated equipment

Fitting Specification

Large Diameter stopple

MTM Hitemp stopple

Strength / Q & A


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What is HOT TAPPING?


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The Hot Tapping Process

Tapping-Maintaining the Coupon:


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Hot Tapping Applications

What are the Typical Setups?


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Hottap OperationHottap Operation


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HOT TAPPING DATA SHEETS

Why is a Tapping data Sheetrequired?

Ensure Correct Equipment is used.

The Pipeline conditions areconsidered for Hot Tapping &

STOPPLE

Applications

Flow conditions are considered for

Pilot drill Selection.

The correct Cutters & Pilot drills areused for Pipe O.D & Valve I.D.


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Valve Size (Inches) - Size of hottap

Flange Series ( # ) - Pressure rating of equipment

Line Size - Type of cutter & Pilot Drill

Pipe Material - Type of cutter

Wall Thickness (inches) - Type of cutter and model of machine

Product - Packing of machine

Pressure ( Psig ) - Pressure rating of machine

Temperature (Deg C) - Temp rating of machine Velocity (m/s) - Coupon retention

Wall Thickness-Branch - Size of cutter

Orientation of line : - Horizontal / Vertical

A & B Dimension - Travel of machine

Hot Tap Data SheetHot Tap Data Sheet


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Temporary plugging to isolate section of

a pipeline without interruption of flow orwithout pipeline shutdown

What is STOPPLE?


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Hottap & Stopple PluggingHottap & Stopple Plugging

STOPPLESTOPPLEPlugging is the process ofPlugging is the process of

inserting a plugging head into a pipeline toinserting a plugging head into a pipeline totemporarily isolating a section of pipe whiletemporarily isolating a section of pipe whilediverting the product flow using a bypassdiverting the product flow using a bypassinstalled around an isolated section. So thatinstalled around an isolated section. So thatrepairs,repairs, modifications,modifications, installation orinstallation orrelocation of essential piping systems can berelocation of essential piping systems can beaccomplished,accomplished, on stream WITHOUTon stream WITHOUT

SHUTDOWN.SHUTDOWN.


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STOPPLE OPERATIONSTOPPLE OPERATION


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Stopple Plugging

How Does the Plug Work?Folding Plugging Head

Plugging Head


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Bypass/Stay On-stream

Why Tap and Plug?

Pipeline Repair

Valve Installation/Replacements Tie-ins


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Pipeline Plugging

How is the Completion Plug Set?

LOCK-O-RING Plug


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COMPLETION OPERATIONCOMPLETION OPERATION


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HT&P Equipment

Quality Service Requires Quality Equipment:

St l E i t & iSt l E i t & i


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Stopple Equipment & accessoriesStopple Equipment & accessories

Consist 5 major Components :

Hottap Machine

Sandwich Valves

Hydraulic Cylinder & Housing

Plugging Head & Sealing element

Stopple Fitting

H tt M hi & S d i h V lH tt M hi & S d i h V l


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Hottap Machine & Sandwich ValveHottap Machine & Sandwich Valve

Tapping machine

Sandwich Valves

T i M hiTapping Machine


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Tapping MachineTapping MachineSpecifications

Maximum Operat ing Pressure1480 psi @ 100F

Maximum OperatingTemperature 700 F at 700 psi

Boring Bar Travel

T101 = 18 ( ~ 4 ) 660 = 42 ( 3 ~ 12 )

760 = 66 ( 3 ~ 16 )

1200 = 72 ( 12 ~ 30 )

1200XL= 102 ( 12 ~ 48 )

Rate of aut omat ic feed

T101 Manual Feed

660/760

Standard .005"/rev.

Slow Feed .003"/Rev

1200 0.4 / Rev

Pow er Sources = Air motor orHydraulic Power

AccessoriesAccessories


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Cutter

Type of cutter Standard cutter

Stopple cutter

Tank cutter

Special angled cutter

AccessoriesAccessories

Pilot Drill

Centering pin for cutter Coupon retention devices

Multi U-wire Pilot drill

Stopple Plugging EquipmentStopple Plugging Equipment


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Stopple Plugging EquipmentStopple Plugging Equipment

Hydraulic Cylinder &

Housing

Plugging Head &

Sealing element

Stopple Fitting

Stopple FittingStopple Fitting


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HIGH PRESSURE FITTINGS


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HIGH PRESSURE FITTINGS

Well designed, engineered andmanufactured

Wide variety of fittings available

Designed, tested and manufactured to beused on pipelines operating under various

codes ASME B31.8, ASME B31.4,

ASME B31.3, DOT Part 192 and 195 and

comparable international codesMaterial certificates available

Weldability assured

Installation instructions with each fitting


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HOT TAP FITTING

VARIATIONS

Subsea Mechanical fittingSubsea Mechanical fitting

& Spherical fitting& Spherical fitting

33-- Way fittingWay fitting

TT--OO--RR

FittingFitting

AssemblyAssembly


LockLock--OO--RingRingFlange & PlugFlange & Plug


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T f fi i


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Type of fitting


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DESIGN CODES

ANSI B 31.3 Chemical plant & Petroleum Refinery piping

ANSI B 31.8 Gas Transmission and Distribution piping System

ANSI B 31.4 Liquid Petroleum Transportation piping System

ANSI B 31.1 Power Piping

CONSTRUCTION CODE


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CONSTRUCTION CODE

INFORMATIONASME B31.1 ( POWER PLANT )

1) Power Piping

2) Allowable SMYS based on temperature

3) Temperature Range minus 20 degrees F to the plus

limits of listed materials

4) PWHT is required when the Governing Thicknessexceeds 3/4 inch, or 1 inch if a 200 oF preheat is used.

(Table 132)

CONSTRUCTION CODE


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CONSTRUCTION CODE

INFORMATIONASME B31.3 ( REFINERY, TOPSIDE, HPI )

1) Process Piping

2) Allowable SYMS based on temperature

3) Temperature Range plus and minus limits of listed

materials

4) PWHT is required when the Governing Thicknessexceeds 3/4 of an inch. (Paragraph 331.1.3)

CONSTRUCTION CODE


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CONSTRUCTION CODE

INFORMATIONASME B31.4

1) Pipeline Transmission Systems for liquid Hydrocarbons and

other Liquids2) Design factor .72

3) Temperature Range -20 to +250 degrees F.

4) PWHT is required when the Governing Thickness exceeds 1-

1/4 inches, or 1-1/2 inches if a 200 oF preheat is used. Joints

qualified at as-welded thickness may be exempt.

(Paragraph 434.8.9(a))

CONSTRUCTION CODE


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CONSTRUCTION CODE

INFORMATIONASME B31.8

1) Gas Transmission and Distribution Piping Systems

2) Design factors based on locations classes, .72, .6, .5 and .4

3) Temperature Range -20 to +450 degrees F with temperature

derrating factors above 250 degrees F.

4) PWHT required when the Governing Thickness exceeds 1-1/4 inches. (Paragraph 825.2)


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DESIGN FACTOR

Design Factor is a way of discounting material strength for Safety

Consideration.The smaller the Design Factor value the more conservative the

design.

Thickness = Pressure x Diameter / 2 X Mat. Strength X DF


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DF - CHART

DESIGN FACTOR 0.72 0.60 0.50 0.40

MAWP (PSI) 1480 1230 1025 820


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Method of Pipeline Expansion and modification


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Conventional Method = Shutdown

1) High cost of throughput loss

2) Contractual requirements to pipeline

customer

3) Loss of expensive product

4) Environmental issues

5) Wait till next shutdown period

Best Way = Hot Tap

1) Solve maintenance problems at

minimal cost with no shutdown or

spillage

2) Reduce Environmental impact/

hazardous with very little drain

down or refill3) No loss of expensive product

4) Well proven, safe and common

technique

Method of Pipeline Expansion and modification


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Benefits of Hot Tapping & PluggingBenefits of Hot Tapping & Plugging

No Shut down to plants or

Piping Systems

Time Saving

Minimum Personnel

Required

Money Saving

EXAMPLE : 10 Natural Gas Tie-in into


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Location : Gas Separation plant

Plant Capacity : 230 mmscfdDuration of work : 7-10 days

Production : US$ 100,000.00/day

existing system in Gas Separation Plant

Conventional Method

1) Loss of production = $100,000/day *10days = $1,000,000

2) Loss of Product ( NG)

3) Contractual penalty from customer

4) Environment & Safety issue

5) Increase in Operation cost

EXAMPLE : 10 Natural Gas Tie-in into


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Location : Gas Separation plant

Plant Capacity : 230 mmscfd

Duration of work : 7-10 days

Production : US$ 100,000.00/day

existing system in Gas Separation Plant

TDW Way(on stream w/o shutdown)

1) No loss of production / product

= Save $1,000,0002) No contractual penalty from customer =

$$$

3) No Environment & Safety issue

Well proven technology

4) Overall project cost at less than

anticipated


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Mitigate Your Risk Stay Online

The greatest percentage of accidents in plant and refineries

happen when bringing the system back online.

This risk associated with igniting the burners after shutdown is

costly in three ways :

- Cost of being offline

- The cost to human life

- Cost of rebuilding, both the facilityand reputation for safety.


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Thank YouThank You

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