HOT TAPPING FOR 42 FLARE HEADER:Introduction:

A Hot tapping of running refinery Flare header at HPCL, Mumbai refinery was conducted on 14th May2013 and was successfully completed on 15th May2013 to connect the DHT project flare header to the existing refinery flare. As the 42 DHT flare header to be connected to existing 48 refinery flare header, the hot tapping was done for 42 size, the Indias biggest Hydro carbon line hot tapping conducted so far.Client

: Hindustan Petroleum Corporation Limited, Mumbai

PMC

: Jacobs Engineering India Private Limited

Contractor: Conmat Systems Private Limited

Hot Tapping is the technique of attaching a mechanical welded branch fitting to piping or equipment in service and cutting a hole in the operating pipeline or piping system, operating heat exchangers, vessels, columns, tanks without shutting down the system with appropriate tapping machine.

Hot Tapping:

Initially, 48 x 42 tapping fitting was installed in the 48 existing flare header and welded by passing Nitrogen continuously through the running flare line.

After it was allowed to cool, the 42 valve was installed on the tapping fitting and then the Hot tapping machine was installed above the valve. The tapping machine is having a 42 size cutter along with a pilot drilling bit attached, which is having locking arrangements to hold the cut piece of pipe after completion of hole cutting.Once the Hot tapping machine was installed, the cutting was started on 14th May2013 with all adequate safety requirements by revolving the pilot drill and cutter and finally the cutting was completed on the same day. Then the cut piece has been brought above the valve and then the valve was kept in closed position. The next day, the tapping machine was brought di=to the ground and the cut piece coupon plate was taken out and removed from the hot tapping machine to attach a specially fabricated Sealtite Plug to the tapping machine. Tapping Machine

With Cut PieceThe Sealtite Plug was assembled to the hot tapping machine and the machine was installed on top of the 42 valve. The valve was opened and the Sealtite Plug was fitting with the Sealtite flange of the tapping fitting installed earlier. The tapping machine was disengaged with the Sealtite Plug holder and machine was removed. Then the valve and plug holder also removed and finally Blind flange was installed on the tapping fitting. Cut Piece

Sealtite PlugResults:Finally the 42 size hot tapping, a biggest hydro carbon line hot tapping in India was conducted and completed successfully on 15th May, 2013, in a very safe and proper manner due to proper planning and execution by HPCL/Jacobs/ Conmat.Hot Tapping Machine

Tapping Machine Adaptor

42 Gate valve

48 x 42 Tapping Fitting