Beruflich Dokumente
Kultur Dokumente
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Siti Hajar Binti Jaafar( 9710 )
Emi Zurima Binti Ismail( 9136 )
Nor Wani IdayuBinti Ab Wahid ( 10266)
Nurul Zahidah Binti Md Hasidin( 10809 )
Noor Azreen Binti Mohd Faizol( 10902 )
April 2011
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We started the case study by choosing the hot tapping project that had been
PMO). The main objective of hot tapping is to install new flare meter at Resak and
Duyong flare header line at Onshore Gas Terminal (OGT) to calculate the amount of
product being flared because the quality and performance of plant is based on the value
being calculated.The few metering systems are installed at the flare pipelines without
any hazards to determine quantity such as Mass, Volume and Energy and quality of
The project took about a month to be done for specific pipelines at the PCSB
PMO. As the project being conducted, it must follow schedule which will be discussed
in detail in Work Breakdown and it shows how important project management is in the
every aspect of life especially in industrial world. Besides, precaution, safety aspects,
The scope of study for the hot tapping project is basically on how to conduct hot
tapping project in specific operating conditions at specific pipelines locations for the
OGT at PCSB PMO with Trisystems Engineering Sdn Bhd as contractor and TMM
At the end of the project, the objective which is to install new flare meter at
Resak and Duyong flare header line at Onshore Gas Terminal (OGT) to calculate the
amount of product being flared because the quality and performance of plant is based on
the value being calculated, had been achieved successfully without any hazard occurred.
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Executive Summary 2
Table of Content 3
List of Figures and Tables 4
Introduction & Background of The Project 5-6
Organization Chart
c PCSB PMO 7
c Maintenance Engineering Department 8
c Hot-Tapping Project 9
Environmental Impact 10
Work Breakdown
c Project Life Cycle c
Activities Estimation
c Procedures 17
c Close-up procedures 18 - 26
Cost Estimation 27 - 35
Scheduling 36 - 39
Health & Safety Issues
c Compliance to authority standards and guidelines 40 - 41
c Hazard Observation 41 - 43
Discussions & Recommendations
c Discussion of the outcomes 44 - 45
c Recommendations 46
c Conclusions 46
Appendices 47
References 48
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Figure 1: Organization Chart of PCSB PMO 7
Figure 2: Organizational Chart of Maintenance Eng. Dept. 8
Figure 3: Organization Chart of Hot Tapping Project 9
Figure 4: Project Life Cycles Stages 11
Figure 5: Sequence of Activities vs. Time 12
Figure 6: Level of Work Breakdown Structure 12
Figure 7: Fit-up Work 18
Figure 8: Leak Test on Welding Joint 19
Figure 9: Tightening and Untightening in cross sequence 20
Figure 10: Gaskets 20
Figure 11: Valve Installation 20
Figure 12: Hot-Tapping Machine 21
Figure 13: Leak Test on Hot tapping Machine / Gate Valve 22
Figure 14: Fixing Pitot Drill and Boring Bit 23
Figure 15: Tightening Hot-Tapping Machine 23
Figure 16: Leak Test on Hot tapping Machine using Nitrogen gasc 24
Figure 17: Cutter pass check, cutting travel measurement, 24
alignment using manually c
Figure 18: Hot Tap Perforationc 25
Figure 19: Probe Installationc 26
Figure 20: Exhibit 5 and Exhibit 6c 34
Figure 21: Exhibit 7 and Exhibit 8c 34
Figure 22: Project Gantt Chartc 36
Figure 23: Fire Trianglec 41
Figure 24: Possible gas leak identified and coveredc 43
Figure 25: Gas detector and Fire waterc 43
Table 1: Description on Project Manager¶s Role 13
Table 2: Method of Magnetic Particle Inspection (MPI) 19
Table 3: Exhibit 3 29
Table 4: Exhibit 4 32
Table 5: Project Description based on Gantt Chart 37 - 39
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Hot Tapping is the method of making perforation on the online line without the
interruption of emptying the section of pipe safely. This means the pipe can continue to
be in operation while maintenance or modifications are being done to it. The hot tapping
also used to drain off pressurized casing fluids. In this hot tapping, the heat must be
Hot tapping can be done to most any type of pipe, ranging from carbon steel to
PVC that contain water, oil, gases, fuels, steam and other chemical substances with
specific temperature and pressure condition. Pressures up to 1440 Pascal at 100° can be
Typical Hot Tap installation consists of a tapping saddle, gate valve, and Hot
Taping Machine. The installation is tested, the valve is opened, and the cutter and pilot
drill advanced. When the cut is completed, the cutter and pilot drill are retracted, the
There are three types of hot tapping which is tapping on tangential of pipeline,
tapping not on tangential (offset tapping), twisted and not on tangential of pipeline. At
OGT, there are two types of pipelines used which is High Pressure (HP) and Low
For HP pipeline, the tapping types are flow transducers: offset tapping, pressure
transmitter: tangential tapping and temperature transmitter: tangential tapping where for
LP pipeline, the tapping types are flow transducers: twisted and offset tapping, pressure
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In this report, the scope of study is basically on Hot Tapping and perforation
(making holes) that were done to the existing pipelines at Onshore Gas Terminal (OGT)
in PETRONAS Carigali Sdn Bhd, Peninsular Malaysia Operation (PCSB PMO) to tie-in
and pressure transmitters are installed on the flare pipelines to measure the flared gas to
keep track on where the product goes and the percentage. The operating condition
during the entire hot tapping process must be monitored crucially as the pipelines
pressure must not exceed maximum gas pressure that will absolutely contributed to
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Figure 1: Organization Chartof PETRONAS CARIGALI SDN BHD, PENINSULAR MALAYSIA OPERATIONS
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Mr. M Fallah bin Mohamed
c c To lead the project
and supervise the
contractor involved.
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give an impact on environmental. Gas vented from the pipeline segment represents a
loss of product and an increase in methane emission. From the record, up to 6000 cubic
ii
feet natural gas vented to make a new connection or non-leaking repairs.[ ]The
quantity is depends on pipe diameter, length between isolation valves and operation
pressure. For example, a shutdown connection on a steel can require one to three or
more days if pipeline outage and possible interruption of natural gas shipments in
in bulk by pipeline in its natural gas form. It is a relatively potent a greenhouse gas.
Compared with carbon dioxide, it has a high global warming potential of 72 (calculated
over a period of 20 years) or 25 (for a time period of 100 years). It is also affects the
degradation of the ozone layer. Large amount of methane are produced anaerobically by
methanogenesis. [ iii ]
So, hot tapping is an alternative technique that allows the connection to be made
without shutting down the system and venting gas to the atmosphere. With that, the
quantity of methane gas at atmosphere will be reducing. Hot tapping will avoided
cutting, realignment and re-welding of pipeline sections. It will also avoid inserting or
gas-freeing pipeline section for hot work. In other side, hot tapping also can reduce
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^^
have to invest our time, money and resources in hope of a return. In the Hit Tapping
Project, four stages in sequence are done to follow the timeline. The four stages are:
2.PLANNING
1.DEFINING
!"#$!%
4.DELIVERING 3.EXECUTION
In Hot Tap Project, each stage of life cycles is done by different types of team
according to their area of works. In defining stage, there are 3 minor stage will be done
which is inception, definition of project and proposal preparation which done by the
project manager. Organization chart of the project is created which included the main
contractor, mechanical contractor and the client. The job scope has been defined to all
members.
(POLC) level is being used. The planning is satisfied by top management and completes
the strategies using the resources of time, money, team members, material of the
Leading is by directing each team to complete their jobs within time using motivating
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methods and good communication skills. Finally, manager has to control the project
flow with respect to time, cost, and quality of the flared gas.
Execution stage is important because this is where the construction begins. The
metering instrument is installed regarding to the sequence and the drilling, welding, and
perforation process is done in safe environment by following the HSE standard. After
construction is done, we reach the final stage, delivering. This is where we handing over
the process of plant. The project life cycle is simplified in the diagram below:
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Figure 5: Sequence of Activities vs. Time
Work breakdown is the schedule which guides all the teams to develop the project
according to the timeline. Work breakdown structure is divided into three main phases
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To make sure that the yield flared gas, installation and perforation process of Hot tap
Project is follows the requirement and standard given, several task need to be completed
This task is done by the project manager where he has to make sure that the
Project Initiation Initiation of project that fulfill client¶s need and
standard requirement.The client, PETRONAS
Carigali Sdn Bhd want the project is done without
shutting down the process of plant and the heat can be
measured from digital meter installed on the pipeline.
Project Directive Basic direction of the project flow which includes the
scope and procedure on how to complete the task.The
direction is given including the duration of the
drilling, welding, installation and perforation process.
Project Requirement Follow the standard and requirement highlighted by
Specification client or project director to be completed by
management, design, engineering and construction
teams.Project manager will manage the flow of
project, electrical and mechanical engineering teams
will do the installation of metering instrument and
construct the related equipment to the flare pipeline.
Project Management Plan Defines the objectives, scope for implementation,
installation and the task responsible for each team.
Construction Management Build and develop the project according to the
Plan requirements in a manner rules for electrical and
mechanical area.
Work Breakdown Structure Develop a structure for completing project according
each subordinate and working area.
Table 1: Description on Project Manager¶s Role
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2)c Development Phase
a)c Engineering
inspection of the parent wall for example, the radio graph and/or ultra-sonic
of test pressures, method of testing and the test media, appropriate drawings
and files up-dated. Special consideration must be given to testing media due
will assist other involved groups in the evaluation, planning, and execution.
The parent metal, at the immediate location of the hot tap, shall be inspected
prior to the welding of the nozzle onto the line, and vessel. The type, design
and temperature of the parent metal will determine the type of wall
contacted prior to performing a high risk tap and/ or line plug for example,
lethal services, pressures greater than 1000 psig and/or temperatures greater
o
than 600 F.
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b)c Inspection Group
The Inspection Group which consists of the project manager and supervisor¶s
the welding method and procedure to the engineer. The Engineer will make a
decision concerning x-raying of the hot tap valve and any other special
the planning, ordering, and execution of the job. In conjunction with the
for the proper inspection of the tapping and/or plugging machine, and
d)c Operations
completion of the hot tapping data list used for preplanning and submitting
these sheets with the permit request. With assistance from other groups, as
process conditions, justification and the safety review for a hot tap or plug is
also included in the client's responsibility. At the completion of the job, the
planner will send one copy of the completed data sheets to the responsible
The Procurement phase is where the Hot Tap is installed based on the request
from the client after the Development phase completed. The quality of Hot Tap
engineering team. Before Hot Tap is installed in real plant process pipeline, there
are several samples of Hot Tap being tested by the quality team during
experimentation. This is to ensure that the product does not have any issue in
must be within the estimated cost and time given before the deadline to avoid
any additional in cost and delay time to the client and plant process. If the
products are not settled at the agreed time between the company and the client,
there will be a penalty and bad reputation to the company. After the Procurement
phase and delivery of the products to the customer, the project comes to the
Manager issues the Project Closure report to the Corporate Engineering Team.
The details of the project are attached such as the documents related to the
project including the planning, designs, development and procurement. The list
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This project can be generally classified to two major parts, &&"(welding,
!*)'+
1.c Pre-works
7.c Leak test of hot tap machine set up using Nitrogen gas.
8.c Cutter pass check and cutting travel measurement, alignment using manually.
9.c Connecting high pressure air hoses between hot tap machine and power unit/air
compressor.
11.cBleeding off gas after first penetration and after perforation completion.
14.cProbe installation
15.cHousekeeping.
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i.c Fit-up: Fittings are measured and cut accurately to fitthe pipeline before
perforation. Pipeline is measured and marked to make sure the fittings are
ii.c Grinding: Pipeline is grinded before welding to remove paint and coating on
iii.c Welding: There are four phases of welding: Tark (welding points on the
pipeline just as markings of where should the nozzles will be welded), Root
Pass (welding around the nozzle circumference.), Hot Pass (several layers of
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Welds are tested to make sure its robustness. One of weld tests is by using the
Principle of MPI:
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attracted to the U-magnet. If there is discontinuity on the welding, the metal became lots
of magnets (poles formed magnets). The iron particles will not attracted to the U-magnet
but it will be attracted to the cracks. The tubing and fitting have to be check to make sure
they are properly fitted, control valve operational, ball valves and other venting outlets
are in close position and all bolts and nuts are in tight condition.
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Valve is installed on the branch fitting Nuts and bolts are put randomly.
Sphere wound gasket is inserted The bolts are tightened cross sequence.
Figure 9: Tightening and untightening bolts in cross sequence
ii.c Gasket
Gasket is chosen according to the pipeline size and type. In this project, we
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Visit TMM Engineering Sdn. Bhd. to check the operation of the hot-tap equipment.
4)"&()'*+
The pilot drill for the hot Coupon cutter 1 ½´ drilling bit
tap machine T-101
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ii.c Fixing of pitot drill and boring bit
Drilling bits are attached to the hot-tapping machine. We run the hot tap
machine and observe the movement of the drilling bit. The drilling bit
Hot tap machines are tightened to the valves before any perforation done on the
pipeline.
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Masking tape is wrapped around Nitrogen gas injected 2.5 bars. Pressure
the mounting between the hot injected must be higher than operating
tapping machine and the valve. pressure in the pipeline. . Pressure of the
gauge drop indicates leak of the hot tapping
machine.
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Figure 16: Leak Test of Hot Tap Machine Set Up Using Nitrogen Gas.
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Height of the valve and branch fitting is Alignment of the boring bit is
measured. Travel length is the length for adjusted according to the travel
the drilling bit being screwed up/down lengthto make sure that drilling bit is
during and after perforation. taken out without being stuck when
the isolation valve is closed after
perforation is done.
Figure 17: Cutter Pass check and Cutting Travel Measurement, Alignment
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Valve is in open position. Then, Nitrogen gas is injected to the hot tapping
Nitrogen gas is injected again for about 2 seconds to purge out the natural gas
inside the valve chamber that may contain oxygen which can cause explosion.
Bleed valve is closed, nitrogen gas supply stopped. Nitrogen gas inside the
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pressure.Drilling is complete when the hot tapping machine reached marked link.
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3.c Compare the options and determine the economics of hot tapping.
&-+("&5$'"!%!*""'#5:"'"%".
determine the maximum operating pressure (during the hot tap), type of pipe material
(steel, cast iron, plastic), condition of the parent pipeline (internal/external conditions
to evaluate include the location of nearby valves for emergency and corrosion, wall
thickness) to assure a safe project, location of nearby valves for emergency isolation in
the event of an accident, desired tap diameter depends on size of pipeline involve,
working space around the connection, location of other pipeline welds and
as many gas transmission companies avoid operational disruptions by shifting the load
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to a parallel line. It is advisable to develop and follow a written plan to assure full and
&u+%!)%!'#&#("'5)*/"!!.
To tap a new point on a pipeline, there are two options, either to shutdown
important to calculate the cost of both options. The cost of an actual project would
blow down and purge costs, labor, and scheduling expenses) and H"**!''1Cost
services, and excavating for stopples and purge connections). Operators would be
advised to reference historical data to determine these costs. For the purposes of this
scoping analysis, material and labor costs for cutting out the line section and welding
in a tee connection in the shutdown method are assumed to be comparable to the cost
of welding on the fitting and performing the hot tap when the branch connection is the
same size as the pipeline. However, the costs of the gas lost through venting and inert
gas purging are unique to the shutdown interconnect.The formulas used to determine
the cost of a shutdown interconnects are shown in Exhibit 3. For these calculations,
low pressure is defined as less than 2 psig.For comparative purposes, calculating the
cost analysis given the up-front capital costs of owning and operating a hot tap
machine and the need to perform several interconnections throughout a given year.
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Exhibit 4 illustrates how the cost calculations in Exhibit 3 can be applied in a
projects on pipelines of various sizes and pressures. Cost calculations, however, are
only provided for the 4-inch pipeline scenario and only cover direct costs.
:5"7"0+%!)%"5'#5)*/!!
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D = diameter of pipeline (inches)
T = tap hole diameter (inches) - for low pressure shutdown with tap holes for
stoppers
L = length of pipeline between tap holes (feet) - for high pressure shutdown
P = line pressure (psia for low pressure, psig for high pressure)
Ppgas = current purge gas market price ($/Mcf) - assumed $4/Mcf
Pg = current gas market price ($/Mcf) - assumed $3/Mcf
Ce = cost of extra excavation, use company records ($)
Cp = cost of purge connections and excavation
Cs = cost of hidden shutdown expenditures, see Appendix ($)
Cf = cost of fittings, see Appendix ($) Time Taphole is open = from prior
experience (minutes)
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Table 3: Exhibit 3
Additional factors that are company specific include gas leakage past the pipeline
valves on both ends of the shutdown, number of stoppers, tap holes for venting and
purging, and type of purge gas. Leakage is particularly important as large pipeline block
valves can leak significant volumes of gas because they are used infrequently and the
valve seat can accumulate debris that inhibits a tight seal. The volume of leakage is
highly variable, dependent on valve type, age, pipeline pressure and service (dry gas
causes much less corrosion and accumulation of debris than wet gas). If a partner¶s
&0+%!)%5!'#5&&!*).
When comparing the up-front costs of hot tapping with shutdown interconnects
the only significant difference is the cost of the hot tap equipment. The tee fitting or full
encirclement sleeve and the valve have nearly the same cost for either method when the
branch is essentially the same size as the pipeline. The cost of welding a full
encirclement sleeve is nearly the same as the cost of welding a tee fitting in a line.
Labor cost for cold cutting the pipeline and hot tap cutting out a coupon are
sufficiently close for this type of feasibility evaluation. Maintenance costs apply only to
hot tap equipment, such as drill sharpening and other equipment care and replacement.
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Tapping machines come in several sizes, and a single machine can perform hot taps
from 3 to 12 inches. Less expensive machines can be purchased to perform small taps. In
general, capital costs for purchasing the hot tap machines typically used by gas
companies for the most common sized connections range from $13,200 to $23,000.
depreciated over the life of the equipment, typically 15 to 20 years. Each company,
however, should calculate the depreciation in the same manner used for other equipment
purchases. This should be considered in conjunction with how often the machine will be
used in the future. To make this determination, operators should look at company
records to determine the number of times similar connections have been performed.
Typically, a company that performs several hot taps a year will find it economical to
own the equipment, especially in sizes up to 12 inches, and to maintain trained personnel
to perform the service. These jobs are usually simpler and require less specialized
training than larger hot tap jobs. For larger and less frequent hot taps a company might
consider it more cost effective to hire a contractor who will supply the equipment and
trained personnel. Most hot tap vendors will supply all necessary tapping equipment,
including the drilling machine, fittings, valves, cutters, and repair services. The majority
of vendors also offer contract services for larger or infrequent jobs, or will rent out the
tapping equipment. Supplying support services, such as excavation, welding, and cranes,
Other factors, such as the line material and thickness, system pressure, and
hot tapping equipment or hiring contractors. A company should evaluate how often the
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tapping equipment would be used and if they would realize savings by owning and
:5"7" Ô+ $&5"!% !" * :(&% %!)%" # ' ' *
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Cost = $74 for each of the 4 inch pipeline shutdown interconnects
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Table 4:Exhibit 4
The procedures described above are general guidelines for preliminary economic
assessment and can differ from company to company. Additional factors that are
company specific include gas leakage past the pipeline valves on both ends of the
shutdown, number of stoppers, tap holes for venting and purging, and type of purge gas.
significant volumes of gas because they are used infrequently and the valve seat can
accumulate debris that inhibits a tight seal. The volume of leakage is highly variable,
dependent on valve type, age, pipeline pressure and service (dry gas causes much less
corrosion and accumulation of debris than wet gas). If a partner¶s individual evaluation
following this lesson learned results in marginal economic justification, then company
Exhibit 5 presents ranges of hot tapping costs for both equipment purchase and
contracted services. The cost ranges shown include all materials; additional expenses
will result from labor and maintenance expenditures, as discussed above. Vendors state
that the operations and maintenance (O&M) costs can vary greatly, depending on the
Exhibit 6 shows the equipment, O&M, and contractor services cost to per-form
the 320 taps per year in the hypothetical scenario first described in Exhibit 4. The
assumption is made that the 4´, 8´, and 10´ taps (a total of 305 taps) would be
performed by the company. Because few taps equal to or larger than 18 inches are
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performed each year, these taps (a total of 15 taps) would be contracted to vendors. The
equipment cost includes the purchase cost of two small (<12´) tap machines. For the
purpose of this lessons learned, the average value of the purchase, O&M, and
contracting service costs listed in Exhibit 5 are used to complete the cost analysis for the
hypothetical scenario. Based on these assumptions the total equipment cost is calculated
at $36,200, the O&M cost at $5,500 and the contract services cost at $37,500.
&Ô+3%)5''3"'7#"'#5&&".
Exhibit 7 presents the natural gas and purge gas savings associated with hot
tapping on small and large diameter high-pressure pipelines in the hypothetical scenario
of 320 taps per year. The values are calculated using the equations in exhibit 3,
multiplied by the number of annual connections. Gas losses associated with shutdown
interconnects are the primary savings when these connections are made by hot tapping.
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The economic analysis shown in Exhibit 8 compares the significant cost and
benefit differences between hot tapping and shutdown interconnections for the
hypothetical scenario of 320 taps per year. The significant costs are the purchase,
operation and maintenance of hot tapping equipment and/or contracting for hot tapping
services. Here, both costs are included: the purchase of two hot tapping machines for
$36,200 for the smaller sizes and contracting the 15 large taps at $37,500 per year. The
purchased hot tap machines are operated and maintained at $5,500 per year. All these
costs are calculated in Exhibit 6. Many expenses, including the cost of fittings, valves
and basic labor, are assumed to be similar in both hot tap and shutdown procedures, and
can be excluded in the comparative analysis. A more complete analysis can be done by
evaluating and including the company specific ³hidden´ costs per Exhibit 3.The
significant benefit differences are the reduction in natural gas loss by eliminating
venting and the inert purge gas used in the shutdown interconnect procedure. As
summarized in Exhibit 7, annual natural gas savings total 24,440 Mcf for the
hypothetical hot tapping scenario, worth $73,320 per year at $3 per Mcf gas price. The
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annual inert gas savings of 1,710 Mcf is worth $6,840 per year at $4 per Mcf of
In conclusion, hot tapping has been found to be more cost effective than
shutdown interconnects. Even when the system must be taken out of service, hot tapping
presents opportunities for both time and cost savings. While hot tapping is a by
companies for reasons other than the gas savings, consideration of the methane reduction
benefits can often serve to justify hot tapping over the shutdown inter-connect procedure
in a variety of circumstances.
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A study is done; discussing the needs and problems faced by the operators of the plant. Identification of c Consultants
problems and the personnel involved will discuss on the solution. Personnel involved are experienced c IR engineers
multidiscipline engineers. c Multidiscipline
.c '"!"" engineers will be
Involves cost estimation, process flow diagram and specification sheets. involved in a
project study
.c "%*""
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i.c Complete specification
ii.c Construction drawing
P&ID k mechanical flow diagram (MFD), Equipment datasheet, Instrument index,
Instrument specification sheet, Block diagram, Junction box, Cable, Terminations,
Instrument Installation Standards, Functional logic diagram, Instrument loop sketch,
Instrument location drawing, Cable routing and Material Take-Off (MTO)
c
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Process, Mechanical, Pipeline, Electrical, Instrument and Civil/construction
.c !)( Engineer in charge
During this stage, project materials will be purchased. Purchase Order (PO) will be issued and all charges
on project materials will be under the PO.
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<500k >500k
cRegister in Quotation committee cRegister in MPP
cOpen bid cTender Plan: 2weeks issue out bids
cSOW cLayout for how to execute projects
cEngineering design package: send to PSM
with PR
cPrepare technical evaluation specifications.
i.c Proposals
Technical Commercial
A
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Projects which are chosen must be technically acceptable and commercially attractive.
Tender committee:
For PCSB, there are 3 levels of tender committee.
c TC1: 15 Million
c TC2: 2 Million k 15 Million
c TC3: 500k k 2 Million
For PETRONAS, there are 2 levels of tender committees (above 2 Million)
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After the purchase, Factory Acceptance Test (FAT) will be conducted to inspect/check the performance of the
equipment. Any fault or á will be settled during FAT or latest on Site Acceptance Test (SAT).
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Hot taps are permissible ³only´ as a last resort, i.e. when safety, the time required
preceding are less safe. If the facility is a ³covered process´ as defined by OSHA
A special permit is required for all hot taps according to Safety Procedures, Fire
There are several authority standard and guidelines to follow in completing this
project. A lot of safety precautions to be take into account. The standard and
guidelines are;
C.c Special Safety Requirements are Two (2) points of egression, Sewers in the
area covered, Trapping required to retain welding sparks , Two (2) fire
extinguishers at the Hot Tap site, Periodic Sniff Test, Area enclosed with
inter-institutional body with delegated authority for quality assurance, before they
can report credits from assessment against unit standards or deliver courses of study
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leading to that assessment.[iv]. All hot taps should be designed, fabricated, inspected
and tested in accordance with the applicable Codes and Standards. The applicable
standard for pressure vessels is usually the National Board Inspection Code (NBIC)
Vessels.´ These Codes or Standards require that the design of the hot tap should also
be in accordance with the original code of construction. In most cases in the US, this
is typically the ASME Code Section VIII Division 1. In addition, API Recommended
Hazard Observation
Hot tapping have an explosion hazard. Gas can ignite, causing explosion, death or
serious injury. Tapping into pipe under pressure can cause severe injury if safety
procedures are not followed. No person should make a hot tap unless that person has
been trained and qualified in the use of equipment. Welding is one of element in this
project, but it is the most crucial part of the project. This is because welding involves
heat, hydrocarbon element in the pipeline and also oxygen gas available in the
pipeline. Any carelessness may cause flame/explosion as all the elements in the fire
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To prevent explosion happen, consider the fire triangle. We must eliminate at least
one of the factors to prevent fire which are flammable materials in the equipment,
i.c Oxygen
possible
physical barrier
ii.c Blanketing
ii.c Fuel
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This last chapter will give the big picture for the hot tapping project¶s outcomes,
Each year pipelines typically undergo several transformations. Performing hot taps to
make these connections and installations can reduce methane emissions from
pipelines and increase savings and efficiency. The following are several lessons
1)c Hot tapping has been performed by transmission and distribution companies
for decades. By evaluating the gas savings associated with this practice, hot
tapping can be used in many situations where it would not ordinarily have
been used
2)c The site for the branch weld must be free of general corrosion, stress
3)c Hot tap should not be performed immediately upstream of rotating equipment
4)c For tapping on steel pipes, fitting generally consist of a welded branch
concrete, the fitting cannot be welded onto the existing header. Alternative
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5)c For plastic systems, the operator should ensure that the hot tapping fittings
are compatible with the type of plastic pipe in the system and appropriate
joining methods are used. Vendors can supply suitable fittings and tools for
6)c If hot tapping has not been performed in the past, hot tapping procedures
7)c All equipment must meet minimum industry and federal standards for
encountered that are unusual for your system, be sure to consult the
9)c Industry and federal codes and standards should be consulted for more
specific specifications
10)cRecord emissions reductions associated with using hot taps and submit them
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Recommendations
õc Safety
õc Code/statutory requirements
õc Operating conditions
õc Economic aspects
õc Environmental/pollution aspects
Conclusion
Hot tapping is potentially hazardous and therefore should only be undertaken when
The advantage may be economic and, in some situations, the safety and
environmental risk may be less than those associated with more conventional
methods.
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1.1.1Product Requirement
Specification 1.1.1.1ProductTraceability
Matrix
1.2.1Project Management Plan
Checklist 1.2.1.1Project Status Report
1.2.2Project Estimation 1.2.3.1Issues Tracker
1.1Project Directive
1.2Project Management Plan 1.2.3Issue Management Plan 1.2.3.2Minutes of Meeting
1.2.4Risk Management Plan 1.2.4.1Risk Assessment Tools
1. Initiation 1.3Configuration Management 1.3.1Document Master Checklist 1.3.2.1Formal Evaluation Report
Phase Plan
1.4Project Timeline 1.4.1Work Breakdown Structure 1.4.1.1Project Matrix Sheet
4. Closure 4.1Project Closure Report 4.1.1Compile All Related Document 4.1.1.1Handover Checklist
Phase
Appendix i: Hot Tap Metering Installation Work Breakdown Structure
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