JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
Page 1 of 8
JOB SPECIFICATION
FOR
HOT TAPPING
PROJECT : BS-VI PROJECT
OWNER : MANGALORE REFINERY &
PETROCHEMICALS LIMITED
JOB NO. : B038
0 17.04.18 ISSUED AS JOB SPECIFICATION UK PPS NA
A 04.04.18 ISSUED FOR COMMENTS UK PPS NA
Rev. Checked Approved
Date Purpose Prepared by
No by by
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JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
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Abbreviations:
API American Petroleum Institute
ASME American Society of Mechanical Engineers
NDT Non Destructive Testing
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JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
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CONTENTS
1.0 SCOPE ........................................................................................................................................ 4
2.0 REFERENCE CODE .................................................................................................................. 4
3.0 MATERIALS .............................................................................................................................. 5
4.0 PROCEDURE ............................................................................................................................. 5
5.0 WELDING .................................................................................................................................. 6
6.0 INSPECTION AND TESTING .................................................................................................. 7
7.0 CUTTING OPERATION ............................................................................................................ 7
8.0 COMPLETION ........................................................................................................................... 8
9.0 DOCUMENTATION .................................................................................................................. 8
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JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
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1.0 SCOPE
This specification covers the minimum requirements of safety, procedure and equipment for
hot-tapping work to be carried out on in-service carbon steel piping systems handling non–
sour hydrocarbons in liquid or gaseous phase, and utility service fluids, for BS-VI Project of
Mangalore Refinery and Petrochemicals Limited, Mangaluru, India.
This specification is not intended to be all inclusive, and the use of guidelines set forth herein
does not relieve the Contractor of his responsibility of performing the WORK safely and
completing the WORK capable of performing the intended service.
This specification shall be read in conjunction with the conditions of all specifications and
documents included in the CONTRACT between MRPL (Hereafter referred to as “Client”)
and Contractor.
2.0 REFERENCE CODE
2.1 The hot-tapping works shall be carried out in accordance with the latest edition of API RP-
2201 - “Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries” and this
specification. All requirements given in API RP-2201 as “recommendatory” shall be
considered as mandatory requirements.
2.2 Reference has also been made in this specification to the latest edition (edition enforce at the
time of issue of enquiry) of the following Codes, Standards and Specifications.
ASME B31.3 : ASME Code for Process Piping
ASME Section II : Specifications for Welding rods , Electrodes and filler metals
Part C
ASME Section VIII : Boiler and Pressure Vessel Code – Rules for Construction of
Pressure Vessels
MSS -SP-44 : Steel Pipeline Flanges
MSS-SP-75 : High Strength , Wrought, Butt – Welding Fittings
MSS-SP-97 : Integrally Reinforced Forged Branch outlet Fittings – Socket
Welding, Threaded and Butt Welding Ends.
API 510 : Pressure Vessel Inspection Code: Maintenance Inspection, Rating,
Repair, and Alteration
6-44-0051 : Technical Notes for| Pipes
6-44-0054 : Technical notes for butt welded, socket welded and screwed
fittings.
6-77-0001 : Welding specification for fabrication of piping
B038-6-44-0005 : Job Piping Material Specification
In case of conflict between the requirements of API RP-2201 or other Codes / Standards listed
above and this specification, the requirements of this specification shall govern.
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JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
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3.0 MATERIALS
3.1 All materials shall meet the requirements of specification for piping materials, included
elsewhere in the CONTRACT between Client and the Contractor and shall be suitable for the
service and applicable Class Rating for which they are to be used. In case, the Contractor
proposes to modify certain requirements of these specifications specifically to suit the hot
tapping procedure to be adopted, he may do so, after obtaining the Client’s/EIL’s approval in
writing. In any case, prior Client/EIL approval is required for all materials supplied by the
Contractor.
3.2 Material of fitting (split tee, welded outlet fittings) shall be compatible with the material of the
Run-pipe to be hot-tapped in terms of metallurgy and weldability. Statutory requirements, if
applicable, are to be complied with.
3.3 Hot-tap welding should not normally be performed on materials, which requires post weld
heat treatment. Therefore, material of split tee shall be selected in such a way, that there is no
requirement of post weld heat treatment.
3.4 Manufacturer shall submit all the test certificates in respect of the materials supplied as
required by the Client/EIL specifications and statutory requirements.
4.0 PROCEDURE
4.1 The Contractor shall obtain necessary permissions from the concerned authorities for all hot-
works. For lines requiring statutory approval, Contractor shall obtain approval from the
Competent Authority. The Contractor shall ensure that he has requisite permissions from the
Competent Authority as well as valid hot work permit before initiating any work whatsoever.
4.2 All taps shall be made using a full-encirclement fitting having a design suitable for
Contractor’s proposed procedure.
4.3 Prior to starting of work, the Contractor shall submit for Client’s/EIL’s approval, a detailed
procedure proposed to be adopted for hot tapping. Such procedure shall contain, but not
limited to, the following details:
- Preparation for hot works, viz., selection of location on pipe for hot tap, ultrasonic
testing to check the adequacy of available wall thickness and absence of laminations,
imperfections and out of roundness to ensure that pipe at the hot tap location is
suitable for welding, pre-heating (if required) and cutting operations, etc.
- Method of ensuring and monitoring recommended minimum and maximum velocity
of fluid in the piping.
- Connection details.
- Detailed welding procedure
- Procedure for non-destructive testing of weld and hydrostatic test of assembly
including test pressures, etc.
- Details of all materials and equipment
- Hot-tapping procedure.
- Safety instructions, and safety measures viz., gas detection tests, tests for presence of
toxic environment, etc., and safety measures for installations, equipment, personnel,
etc.
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JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
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- Approval from Statutory Authority as applicable.
Any additional requirements deemed necessary by Client/EIL or by Authorities having
jurisdiction for execution of any or all phases of the work shall be binding on the Contractor.
Contractor shall proceed with construction only after obtaining approval of the procedure from
Client/EIL in writing.
4.4 Contractor shall carry out all checks as recommended by Hot tapping equipment
manufacturer, before hot-tapping work is attempted.
4.5 The exact location of the hot tap on the pipe shall be carefully identified and marked in the
field and Client’s/EIL’s approval shall be obtained.
4.6 All necessary gas detection tests shall be conducted by the Contractor to ensure safe
environment.
4.7 Adequate safety arrangements shall be made for the protection of adjacent installations,
exposed personnel and equipment.
4.8 Contractor shall supply and erect the scaffolding required for the performance of hot tapping.
The scaffolding has to be erected in such a way that two separate and independent access will
be available for the temporary platforms erected for hot tapping.
4.9 No hot-tapping work shall be performed in adverse conditions of weather, such as rain, fog,
high dusty winds, etc., which may be detrimental to the quality of the work performed.
4.10 Contractor shall provide supports wherever required for existing pipe as per site condition to
take care of extra load of hot tapping stub, valve, blinds etc.
4.11 Contractor shall prepare safe approaches by filling soil/sand/sand bags/sleepers/wooden
blocks etc., for cranes, machineries, personnel to various hot tapping locations as required.
5.0 WELDING
5.1 Methods for welding procedure qualification and qualification of welders shall be prepared
and submitted by the Contractor for Client’s/EIL’s review and approval in accordance with
EIL Standard Specification No. 6-77-0001. Upon receipt of approval from Client/EIL, the
Contractor shall prepare for the tests and conduct them in the presence of Client’s
representative. Separate qualification tests shall be carried out for each grade of steel and each
size of weld. All welding shall be carried out by qualified welders and qualified welding
procedures. For welding of piping, falling under the purview of Statutory Regulations, only
those welders certified by/acceptable to the concerned regulatory authority shall be employed.
5.2 The manual arc process of welding using shallow penetration low hydrogen electrodes shall be
used.
5.3 Test certificates for each batch of electrodes and other welding materials obtained from the
Manufacturer(s) shall be submitted for the approval of Client/EIL. Client/EIL reserves the
right to reject such material at any time, in the event these materials do not perform to the
requirements of this specification.
5.4 The weld attaching the fitting to the pipe shall be circumferential to the pipe.
5.5 Welds shall be made in the following sequence - longitudinal welds first, then one end
circumferential weld, then the other.
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JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
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5.6 The heat input shall be controlled during welding operation to prevent undue overheating of
pressurized pipe or vessel.
5.7 The surface to be welded shall be smooth, uniform, free of fins, laminations, tears, scales, slag,
grease, paint and other deleterious materials, which might adversely affect the welding and its
quality.
5.8 All weld joints shall be cleaned of slag and other irregularities before the deposition of the
next pass. Defective welds shall be completely removed or repaired in accordance with the
qualified welding procedure before further welding and when instructed by Client/EIL.
5.9 Tack welds, if allowed, shall be executed as per qualified welding procedure. Defective tack
welds shall be completely removed prior to final welding.
5.10 Prior to commencement of final welding, Contractor shall obtain approval from Client/EIL for
proper joint fit-up and alignment.
6.0 INSPECTION AND TESTING
6.1 Magnetic particle inspection shall be performed for the first pass and after completion of all
welds. In addition, radiographic and/or ultrasonic tests of the welds shall be carried out. For
piping requiring statutory approval, testing/examination required as per statute also shall also
be complied with.
6.2 Before start of the cutting operation, assembly including full bore ball valve/ sandwich valve
kept in open position shall be hydrostatically tested to a pressure equal to or greater than the
operating pressure and not exceeding the internal design pressure of the run pipe. The test
pressure shall be maintained for a minimum period of one hour. Client’s representative shall
witness and grant approval on satisfactory completion of the hydrostatic test.
6.3 Before using valves in the hot tapping, stub testing is to done at site to check for any leakage
as per valve spec.
6.4 Pneumatic test of reinforcement pads to be done wherever pads are required as per piping
specification.
6.5 All welds, which, in the opinion of Client, are found to be defective by hydrostatic testing,
pneumatic testing or by NDT, shall be repaired or cut and re-welded, as directed by Client,
and re-tested. Repair of a repaired weld is not permitted.
7.0 CUTTING OPERATION
7.1 Instructions given by the Manufacturer of the hot-tapping machine shall be strictly followed
while installing the machine and during the cutting operation.
7.2 Cutting operation shall begin only after all welds have been tested and approved by
Client/EIL.
7.3 Contractor shall ensure that the full bore ball valve or the sandwich valve is precisely centered
on the tee-connection and is cleaned of all dirt, etc.
7.4 Boring bar of the hot tap equipment shall be run several times through the valve to ensure that
the cutter does not jam or drag.
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JOB SPECIFICATION No.
JOB SPECIFICATION FOR HOT B038-999-16-43-0062
TAPPING Rev. 0
Page 8 of 8
7.5 All bolted joints shall be checked for possible leakage. Packing of hot-tap machine, bleed
valve, bolts of cutter, pilot bit and blank catcher shall be checked before starting the cutting
operation.
7.6 After the cutting operation is complete, the boring bar shall be extracted, the valve closed and
the machine shall be depressurized by opening the bleed valve. Machine shall be dismantled
after these operations have been completed and when authorized by Client.
7.7 A blind flange shall be provided on the valve after removal of hot tap equipment. In the event
sandwich valve is utilized, the end shall be made with a Lock-O-Ring flange.
8.0 COMPLETION
8.1 The hot-tap work shall be considered complete when it has been certified in writing by
Client/EIL that all the works have been satisfactorily completed.
8.2 The Contractor shall clear-off the area removing all equipment and left over material, etc.
from the job site after completion of the work.
9.0 DOCUMENTATION
9.1 Documentation to be submitted by Vendor/Contractor to Client is summarized below.
Number of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT
document.
9.2 Following documents shall be submitted:
Hot Tapping Procedure.
Approved WPS and PQR.
General Arrangement Drawings (dimensional drawings)
Sketches of the location (Pipeline KP Point) where hot tapping is performed.
Details/data sheet of components including tees, valves etc. including size, rating and
material details.
Welding Records.
Line pipe material thickness records.
Weld inspection and NDT records.
Hydrostatic test Reports.
Statutory Approvals
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