Procedure No.: PA-020-0014 Page: 1 of 19 Port Arthur, TX. Reviewed: 4/14 Effective: 4/14 (Rev.06) Supersedes: 8/13 (Rev.05) Preparer: Owner: Approver: EHS Team Member EHS Team Member EHS Manager Document Revision Change Table Revision Number Revision Description Revised By Revision Date 01 Changed Header and Footer VB 05/08 02 Added Freeze Plug Procedure DLS 04/09 03 Changes in Scope - Section 3 and Section 4.3.8 DLS 10/10 04 Attachment B for additional review and approvals due to DLS 3/13 Incident 0126 UTIL 12-0016 05 Responsibility changes on Attachment A DLS 08/13 06 Responsibility and Requirements Changes 4.4.1 Requires a meeting of Hot Tap approvers to approve and sign off DLS 04/14
Procedure No.: PA-020-0014 Page: 2 of 19 Port Arthur, TX. Reviewed: 4/14 Effective: 4/14 (Rev.06) Supersedes: 8/13 (Rev.05) 1. PURPOSE To establish a clear set of guidelines to be followed when performing Hot Tap and Stopple installations in piping systems that cannot be safely cleared and isolated to make an out-of-service tie-in. 2. DEFINITIONS 2.1. Coupon The part of the pipe that is removed during the Hot Tap operation. 2.2. Hot Tap The method of making a mechanical tie-in by welding an attachment to the pipe that is in service; then installing a valve and cutting a hole in the existing pipe through the new valve using a tapping machine specifically designed for such a purpose. 2.3. Stopple The installation of a flow-blocking device in a piping system that cannot otherwise be isolated depressurized or cleared. 2.4. Contractor the Company that supplies the Hot Tap and/or Stopple machine and its operating personnel. 2.5. Hot Tap/Stopple Document Package A collection of documentation required to obtain Hot Tap approval. All documentation should be attached within the appropriate sections of the MOC. The Stationary Equipment engineer is responsible for ensuring all documentation is correct and maintaining the appropriate files. Weldment Calculation (if applicable) Hot Tap Penetration Calculation Hot Tap Checklist Form A (Sections 1 Hot Work & 2 Owner Approval) Hot Tap Checklist Form B Stopple Checklist Form C (If applicable) Piping and/or Structural Stress Analysis (if applicable) Welding Procedure Thickness Testing Report Dye Penetrant Testing Report (Stainless Steel tie-ins only) Deviation Approval(s) (if applicable) Piping Iso of tie-in (Hand sketch is acceptable) TSA (Provided by Operations) Approved MOC
Procedure No.: PA-020-0014 Page: 3 of 19 Port Arthur, TX. Reviewed: 4/14 Effective: 4/14 (Rev.06) Supersedes: 8/13 (Rev.05) 2. DEFINITIONS cont d 2.6. Completion Plug - A metal plug sometimes installed in the tie-in piping after a stopple is completed, in order to isolate the process from the tie-in entry point without the use of a valve. 2.7. Weldment A welded-in pipe fitting that connects the new tie-in piping spool to the existing piping system (e.g. a split tee or a weld-o-let) 2.8. Job Coordinator Person assigned by the Operations Manager to coordinate a job. This is typically the Operations or Maintenance Coordinator. 2.9. Maintenance/Construction Representative Person assigned by either the Maintenance or Project Manager to follow a job, depending on whether the job is part of maintenance or a capital project. This is typically a Maintenance Planner for maintenance jobs, or the Construction Coordinator for capital jobs. 2.10. Freeze Plug/Line Freeze Use of cryogenic fluid to create a flow blockage of process fluid that cannot otherwise be isolated depressurized or cleared. 3. SCOPE Hot Taps, Stopples, and Freeze Plugs shall only be installed on piping that cannot be safely cleared and/or isolated due to operational and/or system design constraints, Hot Taps and Stopples represent a potential danger to personnel and to plant operations. Any Hot Tap and/or Stopple must be part of an approved MOC. All Hot Taps shall require a PSSR prior to being put into service. This procedure shall apply to all facilities located at the Port Arthur Site. All Hot Tap/Stopple installation work requests must be reviewed for potential risk. This review is required even for nonhazardous fluid service. Hot Taps that are part of a defined project must indicate and reference Hot Tap documentation within the project MOC. The project hot taps must be in a separate MOC and approved by the Operations Manager as required.
Procedure No.: PA-020-0014 Page: 4 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE 4.1. General 4.1.1. Hot Taps are NOT to be performed on piping containing: A. Combustible vapor/air/oxygen mixtures with-in flammable and/or explosive ranges. B. Hydrogen, if the equipment has operated above the Nelson Curve Limits C. Any chemicals likely to violently decompose or become hazardous from the heat generated by welding. D. Strong Caustics or Acids E. Oxygen or Ammonia F. Any process stream containing ethylene or acetylene Streams with low concentrations of ethylene/acetylene can be considered for Hot Tapping contingent on concurrence from Corporate Process Safety 4.1.2. Hot Tapping shall not be performed on piping under vacuum unless approved by the Operations Manager. 4.1.3. Hot Taps shall not be performed on piping that is lined, clad, or where stress relieving is required. 4.1.4. Hot Taps made upstream of equipment and/or in-line instrumentation that are not adequately protected by filters and cannot be isolated, shall be carefully evaluated for safety and operational risks that could arise from a coupon or metal shavings being left behind in the piping system. A risk analysis shall be completed and added to the Document Package if this paragraph is applicable. 4.1.5. Hot Tap and Stopple machinery shall be operated by authorized Contractor personnel only. Procurement maintains a list of approved Contractors. Potential new Contractor must go through the Site s procedure for qualifying new vendors through the PICS system. New vendors for this work should provide at least two references for his type work. It is the responsibility of the Contractor to ensure such equipment is properly maintained and in good working condition, and that their personnel are adequately trained.
Procedure No.: PA-020-0014 Page: 5 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE cont d 4.1 General cont d 4.1.6. When feasible, Hot Taps should be made on the top of the pipe vs. the bottom, in horizontal pipe runs. This makes it easier and safer to install/remove the Hot Tap Machine. 4.2. Design Considerations 4.2.1. All piping components used in a Hot Tap, Stopple or Line Freeze installation shall be in accordance with the relevant Port Arthur Site Piping Standards, with the exception of weldments will shall be in accordance with the Table 1 of this procedure Any proposed piping component deviation will require approval from the Technical Services Director or designee. 4.2.2. All welding on piping components used in a Hot Tap installation shall be in accordance with approved welding procedures. 4.2.3. Full port ball or gate valves are recommended for Hot Tap and Stopple installations, the Hot Tap Contractor will be consulted when a normal trim valve is the only/best option. These valves shall comply with the appropriate Port Arthur Site Piping Standard. 4.2.4. If a completion plug is to be used in the case of a Stopple, the elastomer components shall be reviewed and approved by Site Engineering to ensure compatibility with the process. 4.2.5. Due to the weight of Hot Tap and Stopple machines, the force exerted on the piping and supporting structure must have an engineering review of the stress loading. This review can be simply good engineering judgment, or if good engineering judgment dictates, a formal stress analysis shall be completed and included in the Hot Tap/Stopple Document Package. 4.2.6. Table 1 has been attached as a guideline for selecting the appropriate weldment. If this table is not used, an Engineering Standards Deviation Request must be approved.
Procedure No.: PA-020-0014 Page: 6 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE cont d 4.2 Design Considerations cont d 4.2.7. The location of the Hot Tap should be more that 18 away from all flanges or threaded connections, plus more than three inches from any existing weld seam. Deviations from these requirements must have the approval of the Technical Services Director or designee. 4.2.8. To minimize burn through, the first weld pass to equipment or piping less than ¼ (6.4 mm) thick should be made with a 3/32 (2.4 mm) or smaller diameter welding electrode to limit heat input. 4.2.9. When performing a line freeze, the piping service Minimum Design Metal Temperature should be noted and discussed. 4.3. Preparation 4.3.1. In consideration of the significance of the effort and expense involved in the preparation for a Stopple, Line Freeze, and/or Hot Tap, Operations should be appraised of any requests prior to proceeding with the preparations for the work. It is recommended a minimum two weeks advanced notice be provided in order for Operations to have adequate time to prepare a risk evaluation and emergency plan associated with completing the TSA, while the Contractor performs mechanical checks in the field. 4.3.2. The location of the Hot Tap shall allow for: A. Adequate clearance for the machine B. Adequate support for the machine C. Availability of air or electric power for the machine D. Easy and safe egress for personnel making the Hot Tap or Stopple, and easy access for emergency personnel.
Procedure No.: PA-020-0014 Page: 7 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE cont d 4.3 Preparation cont d 4.3.3. Drilling through the opposite side of the piping is a serious concern. The appointed Contractor shall perform measurements and calculations to verify that the cutter or the pilot drill shall not penetrate through the opposite wall of the line being Hot Tapped. Preferably the drill should not penetrate beyond the center of the pipe. For size-on-size or one size smaller connections, where the drill tip will have to move further into the pipe, measurements must ensure that the drill will not contact the inner surface of the other side of the pipe. The Maintenance/Construction representative shall review these measurements. 4.3.4. Thickness measurements and all associated piping inspections shall be made by the facility QA group in the location of the Hot Tap, extending out to either side, a minimum of 12 inches, or the diameter of the branch pipe, whichever is greater. If any of the following conditions exist, a engineering evaluation shall be performed by a qualified engineer and approved by the facility Fixed Equipment Engineer, to determine if a Hot Tap can be safely performed: A. Actual thickness < 3/16 B. Actual thickness > 1 C. Actual thickness < Nominal thickness corrosion allowance 4.3.5. Dye penetrant examination of the surface of a stainless steel pipe is required to ensure there is no stress cracking at the surface. If stress cracking exists, a qualified engineer/technician shall perform ultrasonic thickness testing to determine the suitability of the existing pipe for the Hot Tap.
Procedure No.: PA-020-0014 Page: 8 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE cont d 4.3 Preparation cont d 4.3.6. The attainable flow velocity in the line being Hot Tapped shall be verified by the Stationary Equipment Engineer. If the flow in a line being hot tapped is within the following velocity ranges: Liquid: 1.5 15.0 feet per second, Gas or vapor: 25.0 200.0 feet per second, then no engineering review is required. For liquid or gas velocities outside these ranges, Site Engineering will review the hot tap as per API Recommended Practice 2201 Procedures for Welding or Hot Tapping on Equipment in Service, Latest Edition. Site Engineering shall evaluate required flow in vapor lines on a case-by-case basis. 4.3.7. The WPS (Weld Procedure Specification) must be selected by the contractor s QA/QC department and attached to the checklist Form A. This procedure must be reviewed by the contractors QA/QC Representative and the Certified Welder prior to performing the work. 4.3.8. For Line Freezes on piping with wall thickness greater than ½ inch, special precautionary measures must be taken. 4.4. Hot Tap and Stopple Approval 4.4.1. Section 1 and 2 of the Hot Tap Checklist Form A shall be completely filled and approved as noted on the form, prior to the issuance of a hot work permit for the Hot Tap weldment. Approvers of the Hot Tap (Hot Tap Checklist Form A) must meet to discuss all aspects of the procedure and sign their approval at that time. 4.4.2. In some cases several days or even weeks may elapse between the completion of the hot work step and the actual hot tap line cutting. At least 1 day prior to issuing a Safe Work Permit for the Hot Tap, the Shift Coordinator and the Maintenance/Construction Representative shall meet and discuss all aspects of the proposed hot tap and sign off on the Hot Tap Checklist Form B, denoting the Hot Tap can safely commence.
Procedure No.: PA-020-0014 Page: 9 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE cont d 4.4. Hot Tap and Stopple Approval cont d 4.4.3. The Hot Tap Checklist Form B shall be completed as the job progresses in the field. It is the responsibility of the Maintenance/Construction Representative to ensure the Contractor provides all required information and signs off in the sequential order noted. 4.4.4. Prior to issuing a Safe Work Permit for a Stopple or Line Freeze, the Shift Coordinator, Contractor Representative and the Maintenance/Construction Representative shall sign off on the Stopple/Line Freeze Checklist Form C, denoting the work can safely commence. NOTE: If a section of this form does not apply, please mark NA in the appropriate space 4.5. Hot Tap and Stopple Field Work 4.5.1. The Job Coordinator together with the Maintenance/Construction Representative shall ensure the planned location of a Hot Tap as being correct and clearly marked in the field by a tie-point tag as specified in Port Arthur Safety Procedure PA-020-0002. The Hot Tap location shall have been cleaned as necessary to bare metal. This includes removal of paint, insulation, and any other debris that could interfere with potential Hot Tap operations. 4.5.2. The Job Coordinator together with the Maintenance/Construction Representative shall ensure the planned location of the Line Freeze as being correct and clearly marked in the field. 4.5.3. The Maintenance Manager or Project Manager, together with the Operations Manager, are responsible for ensuring that an emergency plan has been identified and communicated appropriately. This is a part of the Hot Tap/Stopple package presented during permitting and is reviewed as part of the 4 eyes system walk-through. The emergency plan must cover potential risks such as burn through during welding. Radio communication with the control room is required while installing a Hot Tap and while installing a Stopple or Freeze Plug.
Procedure No.: PA-020-0014 Page: 10 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE cont d 4.5. Hot Tap and Stopple Field Work cont d 4.5.4. All required documentation should be presented to the person issuing the hot work permit. 4.5.5. The person issuing the hot work permit shall confirm that no unusual process conditions exist, and the flow rate, temperature, and pressure ranges specified on the Hot Tap Hot Work Checklist A form exist in the field. 4.5.6. During line freeze operations temperature measurements shall be documented on an interval of 5 minute intervals. This record will accompany the work order and permit to job completion. 4.5.7. A pressure test of the installation shall be witnessed by the Maintenance/Construction representative upon completion of the Hot Tap welding. Valves utilized in conjunction with the Hot Tap shall be pressure tested prior to installation. 4.5.8. After completion of the Hot Tap/Stopple, the Maintenance/Construction Representative shall witness flow from the leak off valve on the Hot Tap/Stopple machine. 4.5.9. Before removing the Hot Tap/Stopple machine, the Maintenance/Construction Representative shall have the Hot Tap/Stopple technician verify that the requirements of the Hot Tap/Stopple have been completed and have the technician sign the hot work permit prior to the removal of the Hot Tap/Stopple machine. 4.5.10. For maintenance jobs, the Maintenance Department will retain the complete Hot Tap Stopple documentation package on file for one year. For projects, the Project Manager will provide a copy of the documentation package to the site Fixed Equipment engineer and upon completion put a copy in the project job book.
Procedure No.: PA-020-0014 Page: 11 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 4. PROCEDURE cont d 4.5. Hot Tap and Stopple Field Work cont d 5. RESPONSIBILITIES 4.5.11. The Maintenance/Construction Representative shall witness removal of the coupon. If the coupon is lost, he/she shall immediately notify the shift coordinator and initiate an Incident Report. The coupon shall be inspected by the Job Coordinator and properly disposed of, if there is nothing unusual about its condition. Upon completion of the Hot Tap, the PSSR section of the MOC (required for all hot taps and listed in section 2.5 as part of the job book) must be completed before the equipment is put back into service. 5.1. Maintenance/Construction Representative Ensure Section 1 of the Hot Tap Checklist Form A is accurate and closely monitor Contractor activities in the field. 5.2. Job Coordinator Ensure process conditions needed to perform the job safely exist, and ensure adequate communication occurs between the Contractor, Maintenance/Project, and Operations. Ensure Section 2 of the Hot Tap Checklist Form B is accurate. 5.3. Contractor Provide equipment in good working order and properly trained personnel, in additional to strictly following all safety and operations rules and procedures. Complete Checklist Forms B and/or C if applicable. 5.4. Operations Manager Ensure there are no other alternative to performing the Hot Tap and/or Stopple work. Evaluate potential risks associated with the job and establish an emergency plan to cope with these risks. 5.5. Maintenance/Project Manager Ensure the job has been properly engineered and that all required preparations have been carried out. 5.6. Environmental, Health, and Safety Manager Review the job scope and set-up in the field from a safety perspective to help ensure all identifiable precautions have been taken.
Procedure No.: PA-020-0014 Page: 12 of 19 Port Arthur, TX. Reviewed: 3/13 Effective: 3/15/13 (Rev.04) Supersedes: 10/01/10 (Rev.03) 6. RELATED DOCUMENTS ANSI B31.3 Chemical Plant and Petroleum Refinery Piping API Recommended Practice 2201 Procedures for Welding or Hot Tapping on Equipment in Service OSHA 1910.119 Process Safety Management of Highly Hazardous Chemicals Port Arthur Facility Procedure PA-020-0029 Management of Change Port Arthur Facility Procedure PA-020-0028 Pre-Startup Safety Reviews Port Arthur Facility Procedure PA-020-0002 Hot Work Table 1- Fitting Selection Table Attachment A-Hot Tap Checklist Attachment B-Hot Tap Checklist Attachment C-Stopple Checklist Attachment D- Hot Tap Machine Dimension
PA-020-0014 TABLE 1 - FITTING SELECTION TABLE This table is to be used to select hot tap fittings for pipelines only. A selection from this table does not require engineering review or mechanical calculations. NOTE: Incase of conflict with Pipe Spec, Hot Tap Procedure will govern. HEADER PIPE SIZE BRANCH SIZE 1" 1-1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 1" T or W 1-1/2" T or W T or W 2" W T or W T or W 3" W W T or W T 4" W W W T T 6" W W W T T T 8" W W W P T T T 10" W W W P P T T T 12" W W W P P T T T T 14" W W W P P T T T T T 16" W W W P P P T T T T T 18" W W W P P P T T T T T T 20" W W W P P P P T T T T T T 24" W W W P P P P T T T T T T T SYMBOLS W - Integrally reinforced fitting (weld-o-let). T - Full encirclement split tee. P - Reinforcement pad is required. Pad width shall equal half of branch nominal size, and thickness shall be no less than the header pipe wall thickness. NOTES 1. For branch diameters greater than 2", reinforcement is required - either reinforcement pad or split tee as shown in Table 1. 1/8" NPT tapped holes shall be provided in pad or tee and shall be sealed with RTV sealer. Reinforcement pads will be pneumatically tested at 15 psig. Where pneumatic testing is not practical (hot services), the use of integrally reinforced fittings (O-lets) will be considered, use of these fittings must be approved in advance by the engineer.2. All branch fittings must meet or exceed main pipe schedule.
Attachment A PA-020-0014 SECTION 1 (Hot Work) Hot Tap Checklist Form A To be completed by the Maintenance/Construction Representative Prior to Welding Plant Section MOC No. Existing Line To Be Hot Tapped: Line Number: Pipe Specification: Design Pipe sch./thickness: Pipe Material: Corrosion Allowance: Actual Pipe sch./thickness: Process Fluid: Fluid Flow velocity: ft/s Liquid ( ) Gas/vapor ( ) Mass Fluid Flow lbs/h Operating Pressure: psig Temperature: deg F Test Requirements for Weldment: NDE required ( )Root pass dye check ( )Final pass dye check ( ) Radiography ( ) Ultrasonic ( )Hydrostatic test @ psig ( )Pneumatic test @ psig ( ) Test Medium ( ) Y ( ) N ( ) n/a Does this job fully comply with the Site Hot Tap/Stopple Procedure? ( ) Y ( ) N ( ) n/a Are approved welding procedures included with the Hot Tap/Stopple Document Package? ( ) Y ( ) N ( ) n/a Does the new installation fully comply with Site Piping Standards and/or approved deviations? ( ) Y ( ) N ( ) n/a Has the Hot Tap location been clearly marked in the field and the pipe cleaned to bare metal? ( ) Y ( ) N ( ) n/a Has the added stress loading on the existing pipe and support structure been addressed? ( ) Y ( ) N ( ) n/a Does the Hot Tap/Stopple location allow for sufficient clearance and easy access/egress? ( ) Y ( ) N ( ) n/a Have thickness and dye penetrant (per Section 4.3.3) results been reviewed and determined to be satisfactory? ( ) Y ( ) N ( ) n/a Has the weldment been either selected from Table 1 or approved by Site Engineering? ( ) Y ( ) N ( ) n/a Has Site Engineering confirmed the required flow, and is it available for the Hot Work? Signatures: Maintenance/Construction Representative Mechanical QA Department Maintenance/Project Manager Job Coordinator A hot work permit CANNOT be issued if Sections 1 & 2 are not signed and/or there are any No answers. Effective: 3/13 Approved by: EHS Manager
Attachment A SECTION 2 (Owner Approval) To be completed by the Job Coordinator Prior to Welding PA-020-0014 Hot Tap Checklist Form A ( ) Y ( ) N ( ) n/a Has a TSA been completed and attached to this form? ( ) Y ( ) N ( ) n/a Does the TSA address the risks associated with losing a coupon or introducing metal shavings? ( ) Y ( ) N ( ) n/a Does the TSA denote measures taken to reduce the risk of burn through, and provide a contingency plan in the event of burn through? ( ) Y ( ) N ( ) n/a Will radio communication with the Control Room be available during the execution of this work? ( ) Y ( ) N ( ) n/a Has a complete Hot Tap/Stopple Document Package been provided to the Operations Manager or designee? ( ) Y ( ) N ( ) n/a If a stopple is going to be used, does the JSA address measures to be taken if the stopple fails? ( ) Y ( ) N ( ) n/a Welder is Code Certified?; Welder's Name: To ensure compliance with OSHA's Lockout/Tag-out Standard under 1910.147, the hot tap must be justified. The OSHA standard, as proposed, stipulated that hot tap operations would be exempt from the requirements of the standard if the employer could demonstrate that: (1) Continuity of service is essential; (2) shutdown of the system is impractical; and (3) documented procedures and special equipment are utilized which will provide effective protection for employees. Details of Requirement for continuity of service and/or impracticality of system shutdown: Continuity of service is essential - shutdown of the system is impractical documented procedures and special equipment are utilized which will provide effective protection for employees NOTE: Operation Signatures signify that the Hop Tap location and size are correctly identified, that the risks of performing a hot tap and the alternatives to a hot tap have been reviewed, and that performing a hot tap is necessary. Signatures Operations Manager or Designee EHS Manager or Designee A hot work permit CANNOT be issued if Sections 1 & 2 are not signed and/or there are any No answers. Effective: 3/13 Approved by: EHS Manager
Attachment B Hot Tap Checklist Form B To be completed by the Hot Tap Contractor Prior to Drilling the Coupon PA-020-0014 Valve Tested Before Installation? Y ( ) Name of Shop performing Test Hot Tap Operator # of Years Experience Pressure Test of branch weld: ( ) Hydro ( ) Pneumatic Test Pressure psig ( ) Passed ( ) Failed ( ) Radiography ( ) Other ( ) Passed ( ) Failed ( ) n/a Fluid Flow velocity: ft/s Liquid ( ) Gas/vapor ( ) Mass Fluid Flow lbs/h Machine support arrangement approved by the Job Coordinator? ( ) Y Machine bit rated for the maximum flow velocity of the process? ( ) Y Dimensional Checks Completed (see machine dimension sheet)? ( ) Y If conditions (including equipment performance level) All work must stop and contact the Shift Coordinator Shift Coordinator Maintenance/Construction Representative TES Director Prior to proceeding with the Hot Tap, the above information shall be completed and confirmation of successful test results provided, and radio communication established with the Control Room Contractor Hot Tap Checklist: Hot Tap Machine Used Wt lb Max Working pr psig Test date Boring bar travel set at " Do-not-exceed dimension " to prevent drill through Coupon holding pins on cutter ( ) Y ( ) N Number Machine bleed off verified: ( ) Y ( ) N Coupon Retrieved: ( ) Y ( ) N Hot Tap Contractor Representative Maintenance/Construction Representative Effective: 3/13 Approved by: EHS Manager
Attachment C PA-020-0014 Stopple/Line Freeze Checklist Form C To be completed by the Contractor Prior to Installation Machine support arrangement approved by the Job Coordinator? ( ) Y ( ) N Stopple o-ring material acceptable for service? ( ) Y ( ) N Expected o-ring life at process conditions: Stopple Machine Used Wt lb Max Working Pressure psig Test date Machine support arrangement approved by the Job Coordinator? ( ) Y ( ) N Completion Plug to be used ( ) Y ( ) N; If yes, elastomer material: If an existing completion plug is to be removed, the integrity of the o-rings must be verified before starting the job. Signatures Shift Coordinator Maintenance/Construction Representative Stopple Contractor Representative Prior to proceeding with the Stopple the above information shall and signed off, and radio communication established with the Control Room Effective: 3/13 Approved by: EHS Manager
Attachment D HOT TAP MACHINE DIMENSION & CALCULATION SHEET PA-020-0014 BRANCH SIZE " TAP SIZE " FLANGE RATING lb DIMENSION 'A' MAX " DIMENSION 'B' MIN " DIMENSION 'C' MIN " TOPAZ MODEL WEIGHT lbs 1 All 15 67 28 T-101 50 1-1/4 1-1/2 All 15 67 28 T-101 50 2 1-7/16 All 16 53 28 T-101 50 3 2-7/16 19 20 20 54 29 360 250 4 3-7/16 18 19 37 (61) 54 54 78 (102) 29 29 31 360 360 660 (760) 250 250 700 (900) 6 5-15/32 35 (59) 34 (58) 32 (56) 80 (104) 80 (104) 82 (106) 31 660 (760) 700 (900) 8 7-5/16 32 (56) 33 (57) 33 (57) 82 (106) 31 660 (760) 700 (900) 10 9-1/2 30 (54) 36 (60) 29 (53) 84 (108) 79 (103) 85 (109) 31 660 (760) 700 (900) 12 11-1/2 33 (57) 34 (58) 32 (56) 82 (106) 31 660 (760) 700 (900) 14 12-3/4 35 (59) 60 80 (104) 132 126 31 56 56 660 (760) 1200 1200 700 (900) 0 0 16 14-9/16 59 56 60 132 135 131 56 1200 0 18 15-1/16 56 60 133 133 130 56 1200 0 20 17 57 56 133 130 133 56 1200 0 24 21 53 136 132 132 56 1200 0 NOTES: - These are dimensions/weights for a typical (Topaz or T D Williams) machine for planning purposes only. These parameters may vary for a different machine. - Values given in parentheses are for a heavier and larger machine. Effective: 3/13 Approved by: EHS Manager
Attachment D PA-020-0014 HOT TAP MACHINE B A T R Adaptor C F Tapping Machine E D Hot Tap Machine Used Pipe OD to face of valve flange (A) " Machine end to adapter flange (B) " Machine width (C) ". Check Clearance to operate machine ( )Y Valve flange to plug/gate (D) " Header pipe inside radius (R) " Header pipe nominal thickness (T) " Retract boring bar: adapter flange to drill tip (E) " E < D to allow valve to close ( ) Y Drill tip projection from cutter (F) ". F<R to prevent contact with back of pipe ( )Y. Boring bar travel - Drill to touch pipe OD (A-E) - = " Cutter to touch pipe OD (A-E+F) - + = " To prevent drill from going through other side of pipe: Do not exceed (A-E+R+T) - + + = " Only for size-on-size and one size smaller: Do not exceed (A-E+T+2R) - + + 2 X = " Boring bar travel stops set to limit travel to " Boring bar travel is less than Do-not-exceed dimension? ( ) Y Effective: 3/13 Approved by: EHS Manager