01 hot tapping
TRANSCRIPT
-
7/31/2019 01 Hot Tapping
1/45
Pipeline Integrity, Hot Tapping &
Plugging Seminar
Sol Elite Marbella, Anyer
10 May 2007
Gunavel Rathinam
Regional Sales Manager
-
7/31/2019 01 Hot Tapping
2/45
AGENDAAGENDA
Objective
Basic Concept
Associated equipment
Fitting Specification
Large Diameter stopple
MTM Hitemp stopple
Strength / Q & A
-
7/31/2019 01 Hot Tapping
3/45
What is HOT TAPPING?
-
7/31/2019 01 Hot Tapping
4/45
-
7/31/2019 01 Hot Tapping
5/45
The Hot Tapping Process
Tapping-Maintaining the Coupon:
-
7/31/2019 01 Hot Tapping
6/45
Hot Tapping Applications
What are the Typical Setups?
-
7/31/2019 01 Hot Tapping
7/45
Hottap OperationHottap Operation
-
7/31/2019 01 Hot Tapping
8/45
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.
-
7/31/2019 01 Hot Tapping
9/45
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
-
7/31/2019 01 Hot Tapping
10/45
Temporary plugging to isolate section of
a pipeline without interruption of flow orwithout pipeline shutdown
What is STOPPLE?
-
7/31/2019 01 Hot Tapping
11/45
-
7/31/2019 01 Hot Tapping
12/45
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.
-
7/31/2019 01 Hot Tapping
13/45
STOPPLE OPERATIONSTOPPLE OPERATION
-
7/31/2019 01 Hot Tapping
14/45
Stopple Plugging
How Does the Plug Work?Folding Plugging Head
Plugging Head
-
7/31/2019 01 Hot Tapping
15/45
-
7/31/2019 01 Hot Tapping
16/45
Bypass/Stay On-stream
Why Tap and Plug?
Pipeline Repair
Valve Installation/Replacements Tie-ins
-
7/31/2019 01 Hot Tapping
17/45
Pipeline Plugging
How is the Completion Plug Set?
LOCK-O-RING Plug
-
7/31/2019 01 Hot Tapping
18/45
COMPLETION OPERATIONCOMPLETION OPERATION
-
7/31/2019 01 Hot Tapping
19/45
HT&P Equipment
Quality Service Requires Quality Equipment:
St l E i t & iSt l E i t & i
-
7/31/2019 01 Hot Tapping
20/45
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
-
7/31/2019 01 Hot Tapping
21/45
Hottap Machine & Sandwich ValveHottap Machine & Sandwich Valve
Tapping machine
Sandwich Valves
T i M hiTapping Machine
-
7/31/2019 01 Hot Tapping
22/45
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
-
7/31/2019 01 Hot Tapping
23/45
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
-
7/31/2019 01 Hot Tapping
24/45
Stopple Plugging EquipmentStopple Plugging Equipment
Hydraulic Cylinder &
Housing
Plugging Head &
Sealing element
Stopple Fitting
Stopple FittingStopple Fitting
-
7/31/2019 01 Hot Tapping
25/45
Stopple FittingStopple Fitting
HIGH PRESSURE FITTINGS
-
7/31/2019 01 Hot Tapping
26/45
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
-
7/31/2019 01 Hot Tapping
27/45
HOT TAP FITTING
VARIATIONS
Subsea Mechanical fittingSubsea Mechanical fitting
& Spherical fitting& Spherical fitting
33-- Way fittingWay fitting
TT--OO--RR
FittingFitting
AssemblyAssembly
Stopple FittingStopple Fitting
LockLock--OO--RingRingFlange & PlugFlange & Plug
-
7/31/2019 01 Hot Tapping
28/45
T f fi i
-
7/31/2019 01 Hot Tapping
29/45
Type of fitting
-
7/31/2019 01 Hot Tapping
30/45
-
7/31/2019 01 Hot Tapping
31/45
-
7/31/2019 01 Hot Tapping
32/45
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
-
7/31/2019 01 Hot Tapping
33/45
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
-
7/31/2019 01 Hot Tapping
34/45
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
-
7/31/2019 01 Hot Tapping
35/45
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
-
7/31/2019 01 Hot Tapping
36/45
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)
-
7/31/2019 01 Hot Tapping
37/45
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
-
7/31/2019 01 Hot Tapping
38/45
DF - CHART
DESIGN FACTOR 0.72 0.60 0.50 0.40
MAWP (PSI) 1480 1230 1025 820
-
7/31/2019 01 Hot Tapping
39/45
Method of Pipeline Expansion and modification
-
7/31/2019 01 Hot Tapping
40/45
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
-
7/31/2019 01 Hot Tapping
41/45
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
-
7/31/2019 01 Hot Tapping
42/45
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 = $1,000,000
2) Loss of Product ( NG)
3) Contractual penalty from customer
4) Environment & Safety issue
5) Increase in Operation cost
EXAMPLE : 10 Natural Gas Tie-in into
-
7/31/2019 01 Hot Tapping
43/45
Location : Gas Separation plant
Plant Capacity : 230 mmscfd
Duration of work : 7-10 days
Production : US$ 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
-
7/31/2019 01 Hot Tapping
44/45
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.
-
7/31/2019 01 Hot Tapping
45/45
Thank YouThank You
Global Pipeline SolutionsYour Source for