Msog-M1402-P-Rp-006 Rev 1

MISI SETIA OIL & GAS SDN BHD
ENGINEERING, PROCUREMENT, CONSTRUCTION AND

COMMISSIONING (EPCC) OF TGAST-OSC-GPP (TOG) MODIFICATION
AT GAS PROCESSING PLANT (GPP), KERTEH
(M1402)
DOCUMENT TITLE
HOT TAPPING ASSESSMENT REPORT
DOC. NO.:
MSOG-M1402-P-RP-006
Rev Date Status MSOG PGB

Prepared Checked By Approved By Checked Endorsed By
By By
1 27/05/14 Re-Issued for Construction NAV PB HWL
0 09/05/14 Issued for Construction NAV PB HWL
B 15/04/14 Issued for Owner Review NAV PB HWL
A 11/04/14 Issued for Internal Review NAV PB HWL

ENGINEERING, PROCUREMENT, CONSTRUCTION AND MSOG-M1402-P-
Doc. No.
COMMISSIONING (EPCC) OF TGAST-OSC-GPP (TOG) RP-006
MODIFICATION AT GAS PROCESSING PLANT (GPP),
KERTEH Rev. 1
DOCUMENT TITLE
HOT TAPPING ASSESSMENT REPORT Date 27 May 14
Page 2 of 17
Table Of Contents
1.0 INTRODUCTION 3
2.0 OBJECTIVE 4
3.0 DEFINITION AND ABBREVIATION 5
3.1 Definition 5
3.2 Abbreviation 5
4.0 CODE STANDARD REFERENCE 5
4.1 Petronas Technical Standard 5
4.2 International Codes and Standards 6
5.0 SCOPE 6
6.0 PROJECT CONSTRAINTS 6
6.1 General 6
6.2 Numbers of hot tapping 6
6.3 Assessment of hot tapping feasibility 6
7.0 HOT TAPPING APPLICATION ASSESSMENT 8
7.1 Hot tapping Philosophy 8
7.2 Hot tapping methodology 8
7.3 Hot tapping tie-in joint methodology 9
7.4 Hot tapping application & operation restriction 10
7.5 Hot tapping equipment 11
7.6 Procedure for hot tapping 11
7.7 Hot tapping vendor requirement 14
7.8 Hot tapping cost estimation 15
8.0 ASSESSMENT 15
8.1 Pressure 15
8.2 Process Medium 15
8.3 Fluid Velocity 16
8.4 PWHT 16
9.0 ATTACHMENT 16
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1.0 INTRODUCTION
PETRONAS is undertaking the TGAST-OSC-GPPA (TOG) Modification Project to

evacuate gas from 28” Terengganu Gas Terminal (TGAST) line to Gas Processing Plant
(GPP) and to ensure quality of gas evacuated to GPP meets the requirement of GSA
by blending OSC line with OGT-TGAST line. The objective of the project is to ensure
successfulness of flow from Block B-17 JDA Muda Processing Platform (MDPP) and
North Malay Basin (NMB) to GPP to meet Gas Sales Agreement (GSA).
TGAST will receive gas from Block B-17 JDA-MDPP in April 2015 and treated gas from
NMB Bergading Central Processing Platform in December 2016. However, TGAST
facilities are expected to be ready only in 1st June 2016.
In order to evacuate gas from MDPP and to meet the GSA and the NMB gas as per
Main Principal Agreement (MPA), this project needs to be executed and completed prior
to the readiness of the TGAST. Mechanical Completion Date (MCD) for the project is on
1st December 2014 and the First Gas is on 1st April 2015.
The project development scope for piping as listed below:
i) Installation of New Pipe 24”(600-P-29017-91440XX), Tie-in point at 42”(1050-P-

29017-91440XX) Pipe from Onshore Gas Terminal (OGT) to Tie-In point at
24”(P-24-1093-D7104)(N40A)(GPP-A Header).
OSC and OGT are existing facilities that operated by Peninsular Malaysia Operation
(PMO), PETRONAS Carigali; GPP-A is also an existing facilities operated by
PETRONAS Gas; On the other hand, TGAST is a new facilities to be operated by
PETRONAS Carigali.
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Details of the project development are shown in the schematic below:
Figure 1: Overall Project Development
2.0 OBJECTIVE
The objective of this document is to define the basis of hot tapping assessment for
TGAST-OSC-GPPA (TOG) Modification Project.
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3.0 DEFINITION AND ABBREVIATION

3.1 Definition
COMPANY / OWNER Shall mean PETRONAS Carigali Sdn Bhd /
Petronas Gas Berhad
CONSULTANT Shall mean MMC Oil and Gas Engineering Sdn.
Bhd.
VENDOR/ SUPPLIER The company on which the order or contract for

supply of the goods or services is placed
Shall Indicates requirement
Should Indicates a recommendation
Coupon Section of pipe cut out during the hot tap cutting
operation
3.2 Abbreviation
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
CAPEX Capital Expenditure
M Meters
mm millimeters
MMSCFD Metric Million Standard Cubic Feet per Day
Ppm Part per Million
PTS PETRONAS Technical Standard
4.0 CODE STANDARD REFERENCE

4.1 Petronas Technical Standard
PTS 31.38.60.10 Hot-Tapping On Pipelines, Piping & Equipment
PTS 31.10.60.30 Welding on Pressurized Pipes

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4.2 International Codes and Standards

API 2201 Safe Hot Tapping Practices in the Petroleum and
Petrochemical Industries
API 2009 Safe Welding, Cutting and Hot Practices in the
Petroleum and Petrochemical Industries
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B31.3 Process Piping: Ring-Joint, Spiral-Wound and

Jacketed
5.0 SCOPE
This document covers the Hot Tapping application onto carbon steel piping containing
hydrocarbons gas for TGAST-OSC-GPPA (TOG) Modification Project.
6.0 PROJECT CONSTRAINTS

6.1 General
GPPA plants are having continuous operation and shutdown for any piping
modification shall be minimized. Due to this constrain Hot Tapping shall be
executed in order to install New Piping 24”.
6.2 Numbers of hot tapping
The numbers of hot tapping works have been identified as below;
(i) GPPA Plant, 2 numbers of hot tapping as detail as below
 1 number of hot tapping at 42” pipe, line numbers 1050-P-29013-

91440X (refer to P&ID 0070, Attachment 2).
- Hot tapping work will be executed at TP02.
 1 number of hot tapping at 24” pipe, line numbers P-24”-1093-D7104-

(N40A) (refer to P&ID E7373-82-06, Attachment 2).
- Hot tapping work will be executed at TP03.
6.3 Assessment of hot tapping feasibility

Feasibility of hot tapping is based on API 2201 and PTS 31.38.60.10. Refer
Table 1 below the summary assessment of hot tapping feasibility;
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Thickness (4)
Fluid Fluid
Diamater Pipe Operating Operating Process
Requirement
Minimum Material PWHT Velocity Velocity
(NS) required, Nominal Current Class Temperature Pressure Fluid Tapping
-Cutting- -Welding-
tm point Technically
Item Run Pipe Identification Nos elevation
min: 0.4 Feasible
> 370 (2) Max: Stable Fluid: 5
- (4)(8)(9) - - No (16)
< -20 (3) 7000 Sour Gas: 10
max: 1.75
Unit mm mm mm mm - - ⁰C kPa - - m/s m/s mm
1. GPPA Plant
42” pipe, With
A672- 7334
1A. line no. 1050-P-29013- 1 1050 30.89 (14) 59.3 (5)(14) (11) 91440X 23 8000 Sour Yes Accessible Accessible Conditions
C60 (10)
91440X (TP-02) (6)(7)(8)
24” pipe, With
API 5L 605
1B. line no.P-24”-1093-D7104- 1 600 35.41 (15) 34.93 (5)(15) (11) D7104 28 7100 Sour Yes Accessible Accessible Conditions
Gr. B (10)
(N40A) (TP-03) (6)(7)
Note:
1. Vendor shall compliance all step that indicated in appendix 1 PTS 31.38.60.10
2. Maximum allowable operating temperature.
3. Minimum allowable operating temperature.
4. Shall be confirmed and justified with conducting ultrasonic examination specifically at each hot-tapping point before work execution.
5. Pipe >20mm thickness is required PWHT, as ASME B31.3.
6. When PWHT is required, the work should be reviewed to identify potential ignition source. A specialist shall be consulted to assess whether it is feasible.
7. The pressure is above than limit in PTS 31.38.60.10, clause 3.3.3. The hot tapping work may execute if Company confirm that run pipe pressure can be reduced to meet the requirement.
8. When the process fluid is sour / unstable, hot tapping shall not be performed unless positive evidence has been obtained that shown it can be applied safely.
9. Based on 2013 corrosion inspection result.
10. Pipe centerline elevation from ground level.
11. Current thickness of the pipe detailed on attachment 7.
14. Based on pipe class of 91440X
15. Based on pipe class of D7104
16. Based on MPDS 03-01-04, minimum gas velocity during welding is 0.4 m/s. No maximum velocity for gas.
Table 1: Assessment of Hot Tapping Feasibility

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7.0 HOT TAPPING APPLICATION ASSESSMENT

7.1 Hot tapping Philosophy
Hot tapping is an alternative method that makes new pipeline connection while
the pipeline remains in service. The hot tap method involves attaching a branch
connection, valve or any additional equipment on the outside of an operating
pipeline, and then cutting out the pipeline wall within the branch and removing
the wall section through the special valve.
Hot tapping avoids product loss, emissions and disruption service to company,
while maintain process operation and profitability.
7.2 Hot tapping methodology
Hot tapping is the method of making a connection to existing pipeline without the
interruption of emptying or stop the section of pipe or operation. This means that
pipe can continue to be in operation whilst maintenance or modifications are
being done. The process is also used to drain off pressurized casing fluid.
Hot tapping is also the first procedure in line stopping, where a hole saw is used
to make an opening in the pipe, so a line plugging head can be inserted. Line
stopping or line plugging is a means of isolating a piping system to provide a
shut off where none exists. This process serves as a control, or temporary valve,
that can be removed after alterations or valve replacements have been made.
With a hot tap previously made on a line, a line stopper is attached to a
temporary valve, and the valve is opened. The line stopper is hydraulically or
mechanically pushed into the line to seal the pipe. There are various types of line
stopping heads.
A single line stop can be used to stop off and abandon a shutdown. Two or more
line stops can be used in tandem to isolate and bypass many intersecting lines
at once. Fluid in the line is bypassed, leaving a workable dead section to alter,
repair or add a valve while service provided by this line is continued.
The basic steps to perform a hot tap are;
(i) Connect the fitting on the existing pipeline by welding
(ii) Install the hot tap machine through the permanent valve
(iii) Perform the hot tap by cutting the pipeline wall through the open valve. A
special devise retains the pieces of cutting pipeline wall for removal after
the hot tap operation. Withdraw the pieces of cutting pipeline wall through
the valve and close the valve.
(iv) Remove the tapping machine and add the branch pipeline. Purge oxygen,
open the valve and the new connection is put into services.
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7.3 Hot tapping tie-in joint methodology
Two (3) methodology of tie-in joint between existing pipe and new pipe as
follows;
i) Tee fitting with valve (standard tap fitting)

This requires COMPANY to supply a full bore gate valve or a ball valve in
order to remove sandwich valve upon completion of installing permanent
line. The tie in piping is then bolted to the permanent gate or ball valve
after the hot-tap is completed. That means COMPANY will need to supply
two gate or ball valves as there will be two hot-tap tie in points in GPPA
case.
Figure 7.3(i): Tee Fitting
ii) 3-Way fitting into two parts

Detailed in Hot Tapping Procedure Report (TMM Engineering)
iii) 3-way fitting with valve

To allow one ball valve to be used on the new tie in piping.
Figure 7.3(ii): 3-Way fitting

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7.4 Hot tapping application & operation restriction

Hot-tapping is potentially hazardous, and therefore shall only be undertaken
when shown to be technically feasible and to offer a clear advantage over other
alternatives.
Hot tapping may be performed only if all these criteria are met:
 Continuity of service is essential
 Shutdown of the system is impractical documented
 Procedure are available and followed
Refer Attachment 3 for Process to Review Whether Hot Tapping is Appropriate
extracted from Figure 2 of API RP 2201.
Welding and hot tapping should not be performed on piping or equipment or
material under certain conditions. Refer section 3 of PTS 31.38.60.10 for details
of Restriction on Applications and Operational Conditions for i.e.
 Material
 Process fluid
 Process conditions
 Hot tap locations
And section 6 of API 2201 for details of the Welding and Hot Tap Metallurgy
Considerations i.e.
 Burn through prevention
 Flow in lines
 Metal thickness
 Fittings
 Post weld heat treatment
 Metal temperature
 Welding and hot tap connection design
 Hot tapping equipment under vacuum
 Piping and equipment content
Also refer relevant section of the applicable codes, standards, or specification
(i.e. API RP 570, API RP 510, API RP 653 etc.) for details of the restrictions and
operational conditions when performing on-line welding or hot tapping.
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7.5 Hot tapping equipment

Hot tapping equipment is available for almost any pipeline size, pipe material
and pressure rating. The primary equipment for a typical hot tap application
includes;
7.5.1 Drilling machine

The drilling machine generally consists of boring bar, valve adapter, cutting
holder, saw cutter and pilot drill. The cutting tool is used to bore a pilot hole
into the pipeline wall in order to centered hole saw cutter that cut out the
curved section of the pipeline wall.
7.5.2 Fitting
Connection to the existing pipe is made within a fitting which can be
welded. Three type of fitting as follows (refer to Attachment 4);
 Reduced Branch fitting
 Reinforced set-on branch
 Preformed split tee
7.5.3 Valve
The Valve on a hot tap connection can be either block valve or a control
valve for the new connection, and must allow that cut out the curved
section of the pipeline wall to be removed after the cutting operation.
Suitable valves include a ball, gate valve or sandwich valve but not a plug
or butterfly valve.
7.6 Procedure for hot tapping
The following are the general steps in performing hot tapping operation, based
on Typical Hot Tap Activity Flow extract from Figure 1 of API 2201 and PTS
31.38.60.10.
7.6.1 Job analysis

An analysis shall be executed prior of hot tapping work execution. This
analysis will determine whether hot tapping is appropriate to carry out. All
data shall be compiled, study, verify and certified by project engineering
section.
Two (2) points of view data are;
(i) Feasibility and design (As Appendix 1 in PTS 31.86.60.10)

 Justification
- Justify the need for performing hot tapping instead of other
alternatives.
 Pipe data
- Compile data for the run and branch pipe.
 Inspection
- Perform inspection and check integrity of run pipe
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 Process and design condition inclusive restriction on application

and operational conditions, and special conditions applications.
- Max. pipe wall temperature, max. pressure, chemical stability,
fluid velocity and etc.
(ii) Operational feasibility

Process engineering section and Company shall confirm that the
fluid data and operating conditions as specified in (i) are correct and
that the proposed hot tap is acceptable from process and
operations viewpoint.
7.6.2 Hazard evaluation and risk reduction
(i) The hazards and risks shall be evaluated for each of the hot tapping
by performing risk analysis or job safety analysis.
(ii) Refer to Attachment 5 for decision process for authorizing hot

tapping (Evaluate Job Hazards & Risks) extracted from figure 3 of
API 2201.
(iii) Safety plan shall be prepared for each hot tapping operation. Topic
to be addressed shall include;
 Access to and around hot-tap location for personnel and the
welding and hot tapping equipment, including requirements for
scaffolding.
 Roles of dedicated personnel and their responsibilities
 Monitoring of operating condition
 Foreseeable hazards and contingency action
 Communication on site
 Warning system and emergency shut down
 Means of escape
 Firefighting equipment and personnel
 Safety equipment and services
 First aid facilities
7.6.3 Pre-execution checks and preparation
(i) Hot tapping machine shall be suitable for the application and
operating properly. Hot tapping requirement shall be as per section
7 of API 2201.
(ii) Checks & preparation prior to execution of hot tapping

 Written plan must be prepared before conducting welding (for
fitting) or hot tapping.
 Checks that must be carried out are as follows;
- Confirm welding procedure
- Check availability of safety plan
- Check equipment / pipework
- Check hot tapping machine
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- Check and confirm site conditions
7.6.4 Execution of hot tap operation
(i) Perform final check

 Preliminary requirement or conditions that must be satisfied
before proceed with hot tapping or welding shall refer to section
10.1 of API 2201.
(ii) Welding
 Ensure that welding is performed according to approved welding
procedure and using qualified welder.
 Refer to section 10.2 welding in preparation for hot tapping of API
2201.
(iii) Welding inspection

 Inspect weld before attaching the hot tap machine.
 Refer section 6 Welding and Inspection, of PTS 31.38.60.10 and
section 10.3 Inspection the Weld, of API 2201
 Refer applicable code or specification of the piping, pipeline, or
equipment for details of the requirements or criteria for weld
inspection.
(iv) Install hot tapping machine

 Install hot tapping machine and ensure that the manufacturer’s
instructions are followed.
 Refer section 10.4 Installing the Hot Tapping Machine, of API RP
2201
(v) Pressure testing

 Test weld attachment, valve, and hot tap machines to ensure
integrity, tightness, and compliance with codes, standards or
specification requirement before the cutting (perforation) is
started.
 Refer section 8 Pressure Testing, of PTS 31.38.60.10 and section
10.5 Testing the Weld and Hot Tapping Machine, of API 2201.
(vi) Perforation and completion

 Ensure that the operating parameters and risk reduction
mitigations that were identified are monitored and controlled.
 Refer section 9 Perforation and Completion, of PTS 31.38.60.10
and section 10.6 Completion, of API 2201.
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7.7 Hot tapping vendor requirement

In selection of potential hot tapping Vendor, Vendor shall have minimum
requirement as follows;
 The hot tapping machines shall provide proven effective protection for
employees as accordance with U.S. Federal OSHA requirement in
1910.147.
 Hot tap vendor must be qualified in accordance with applicable code and
standard.
 Hot tap machine must be in good operating condition and meet to criteria of
project requirement, such as pressure, temperature, material, fluid content
and etc.
 Vendor to ensure during the hot tapping process the self weight of the
machine is not transferable to the existing pipe. Therefore temporary self
support for the hot tapping machine shall be provided. Alternatively Vendor
to advise detail of support / service platform (with specific dimension
required).
 Any lifting equipment for execution of hot tapping work shall be provided by
Vendor and ensure it is compliance with any Company and Local
requirement.
 Have competent personnel to execute the hot tapping work.
 Have experience on execution of hot tapping in oil & gas fields.
 Pipe thickness (at the location of hot tapping to be executed) shall be
justified and confirmed by Vendor with performing Ultrasonic Testing (UT)
before execute Hot Tapping work.
 Three way tee fitting or tee fitting shall be supplied complete with flanges by
Vendor. Refer to below figure for example.
3 Way Tee 450 Angle

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Split Tee
7.8 Hot tapping cost estimation

Project team shall need to obtain hot tapping Vendor proposal of the work based
on confirm detail engineering. Cost estimation of Hot Tapping work can be
referred to PCSB-A-2045U/REP/PM0003.
8.0 ASSESSMENT
8.1 Pressure
As per clause 3.3.3 in PTS 31.38.60.10, the pressure of fluid inside the run pipe
that need to hot tap shall not exceed 7000kPa.
Based on Table 1 in this assessment, all hot tapping run pipe pressure is
exceeding than PTS requirement. However Petronas Gas Berhad provide
Deviation Standard Doc No PRIM-WP-22-F03-TOG-1 attachment 6 to proceed
with Hot Tapping for this project.
8.2 Process Medium
Process medium for item 1A in Table 1 categorized as sour. Hot tapping work
shall not be performed unless positive evidence has been obtained that shown it
can be applied safely. Company or Hot Tapping Vendor shall come out with
study and develop safety precaution procedure that shall be followed during
performing hot tapping.
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8.3 Fluid Velocity

During cutting, maximum flow velocity in run pipe shall be 5 m/s for fluid and
10m/s for gas.
During welding, minimum and maximum flow velocity in run pipe shall be 0.4 m/s
to 1.75 m/s.
Company shall make sure obtain the necessary velocity by controlling the flow.
8.4 PWHT
As per clause 3.1 in PTS 31.38.60.10 and clause 6.6 in API 2201, hot tapping
should not be performed if piping requires PWHT. Based on Table 1 in this
assessment, all hot tapping run pipe is required PWHT, according to code and
standard.
However for this project Temper Bead Welding method will be used as an
alternative to post weld heat treatment as refer to standard ASME B31.3 Section
IX and API 1104.
However, if no other alternative for modification work, the work of hot tapping
shall be consulted with a specialist to identify potential ignition source and
provide procedure and report to confirm feasibility.
9.0 ATTACHMENT
Attachment 1 - Plant Layout
Attachment 2 - P&ID
Attachment 3 - Example Process To Review Whether Hot Tapping is Appropriate
Attachment 4 - Type of Hot Tap Connection
Attachment 5 - Example Decision Process for Authorizing Hot Tapping
Attachment 6 - Deviation Specification of Hot Tapping
Attachment 7 - UT Result of Current Pipe Thickness

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HOT TAPPING ASSESMENT REPORT Date 27 May 14
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ATTACHMENT 1
Plant Layout
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ATTACHMENT 2
PIPING & INSTRUMENTATION DIAGRAM
DETAIL "F"
DETAIL"D" DETAIL"E"
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ATTACHMENT 3
Example Process to Review Whether Hot Tapping Appropriate
MSOG-M1402-P-
ENGINEERING, PROCUREMENT, CONSTRUCTION AND Doc. No.
RP-006
COMMISSIONING (EPCC) OF TGAST-OSC-GPP (TOG)
MODIFICATION AT GAS PROCESSING PLANT (GPP), Rev. 1
KERTEH
DOCUMENT TITLE Date 27 May 14

HOT TAPPING ASSESMENT REPORT
Page
ATTACHMENT 4
Type of Hot Tap Connection
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ATTACHMENT 5
Example Decision Process for Authorizing Hot Tapping
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ATTACHMENT 6
Deviation Form Hot Tapping
PLANT Deviation Form
OPERATIONS (PRIM-WP-22-F03) PRIM-WP-22-F03-TOG-1
DIVISION
SECTION A: Deviation Details
To: From:
Hot tapping on 7 400 kPa(ga) line. Hot tapping on maximum of 7 000 kPa(ga) line.
Note: Please attach the relevant Risk Assessment Study & any relevant references
PTS No./Index:
PTS 31.38.60.10 Feb 2010
PTS Title:
Hot-Tapping on Pipelines, Piping and Equipment
Description of Deviation Proposal:
Clause 3.3.3 Para.1 states that “For general safety reasons, at any time during the hot-tap operation
the pressure of fluid inside the run-pipe shall not exceed 7 000 kPa(ga) nor shall it exceed the
maximum working pressure of the hot-tap equipment if this is lower.”
TOG Modification Project requires for the hot tapping to be performed at operating pressure of 7 400
kPa(ga) to ensure no production loss to PGB.
Justification of Deviation Proposal:
TOG Modification Project is executing a blending facility project at Onshore Slug Catcher (OSC) and
Gas Processing Plant A (GPPA) and executing tie-in of export line from new TGAST to GPPA.
Several studies were done by MMC and PGB/PCSB to find the best way to blend the gas in order to
have one quality of gas before entering GPPA. Based on the studies, the best location to blend the gas
is at export line of OSC and the upstream of GPPA plant which are as per tie-in below:
1) Tie-in of 24” line to existing 24” line at OSC
For blending facility
2) Tie-in of 26” line to existing 26” line at OSC
3) Tie-in of 24” line to existing 42” line at GPPA
For tie-in of export line
4) Tie-in of 28” line to existing 42” line at GPPA
The hot tapping is the conclusion for blending facility and tie-in of export line since the shutdown for
both plants is not allowed due to unavailability of shutdown window.
Study was done on the existing line for tie-ins, and found that the pressure of fluid inside the run pipe
is 74 barg, which exceeds limit of 70 barg as per PTS.
Project Risk Assessment (PRA) was done on the Hot Tapping activities with input from stakeholders
GPPA and PMO, together with discipline TPCPs, with the result being medium risk with 28 critical risks
identified together with their mitigations.
Among the agreed action items from the PRA to mitigate this PTS deviation are as follows:
1. To establish specific plant operating procedure during hot tapping activities.
2. To acquire hot tapping principal's track record for pressure more than 70 bar.
3. To include continuous monitoring of flow using the existing flow meter at the metering skid
in hot tapping procedure.
4. TP to review and endorse Hot Tapping procedure.
5. To include endorsement requirement from PE (contractor) for non-routine activities in ITB.
6. Establish of communication protocol with operation personnel.
Note: Please attach relevant references

Reference used:
Status of Proposal:
Currently TOG Modification Project is in tendering phase.
SECTION B: Endorsement & Approval

Requester: Endorsed by Technical Authority:
___________________ ___________________
Name & Designation: Name & Designation:
Abang Ashaari Abdul Rahman
Asrul Hazimin Mohamad
Static Fired Engineer Principal Engineer - Piping
CE/GPU/PGB Petronas GTS
Date: 17/12/2013 Date: 19/12/2013
Remarks:
Approved by LOA/Asset Owner: Remarks:
___________________
Name & Designation:
Date:
SECTION C: Closure
Closed by: Remarks:
___________________
Name & Designation:
Date:
-. I.
Project Risk Assessment (PRA) Report
PETRONAS
Project Title: TGAST-OSC- GPP A (TOG) Modification
PRA No: 1
PRA Scope: Hot Tapping works
Assessment Date: 2/10/2013 & 10/10/2013
Facilitator: Sy M Hafiz b Sy Shahrul Zaman
Prepared by: Reviewed by: Approved by:
'. .
Sy M Hafiz b Sy Shahrul Zaman M ::2ahsari Mahzul B Saiman
PRA TOG Modification 2 of 11
(Hot Tapping Work)
Summary of Risks Rating

No Risk Elements Low Medium High Very High Total ORR
1 Project Management Team 1 1 1 3 M
2 Timing 0 0 3 0 3 H
3 Quality 0 1 0 0 1 M
4 Stakeholder Approval 0 1 0 0 1 M
5 Location 0 0 1 0 1 H
6 Contract 0 1 1 0 2 M
7 Contractor 0 0 3 0 3 H
8 HSE 1 4 5 0 10 M
9 Financing / Economic 0 0 0 0 0 -
10 Market & Commercial 0 0 0 0 0 -
11 Technical & Technology 1 2 3 0 6 M
12 Partner 0 0 1 0 1 H
Overall Project Risks 3 10 18 0 31 M
Summary of Risks Rating

12
10
8
Quantity
4
Very High
2 High
Medium
0
Low
Stakeholder Approval
Project Management Team
Market & Commercial

Quality
Contractor
Timing
Location
HSE
Partner
Contract
Financing / Economic
Technical & Technology
Risk Elements
(Hot Tapping Work)
Summary of Critical Risk:

No Risk Elements Summary
1. Lack of manpower to manage hot tapping contractor and EPCC
1 Project Management Team contractor (ie Inspector)
2. Incompetent PMT in Hot Tapping work
1. Unable to enter construction site
2. Late award of EPCC contract to contractor (Insufficient project
2 Timing
execution time)
3. Late material delivery
3 Quality 1. Poor online welding quality at Split Tee
4 Stakeholder 1. Plant management does not approve hot tapping activity
5 Location 1. Congestion at work site
1. Cancellation of Hot Tapping scope from EPCC scope
6 Contract
2. Late issuance of Hot Tapping contract
1. Poor execution communication and contractor managing sub con
7 Contractor 2. Incompetent hot tapping vendor
3. Insufficient Hot Tapping machine
1. Unable to achieve minimum flow during hot tapping activity
2. Gas leak during the hot tapping activity
3. Sudden pressure build up during hot tapping activity
4. Non-compliance to HSEMS requirement, eg PTW, OGSP, CIDB,
Competency card
5. Hot tapping machine/equipment malfunction
8 HSE 6. Burn through during fillet welding generating high heat contact to
pipe
7. Heat introduce higher than auto-ignition temperature of medium
8. Incomprehensive JHA documents
9. Trapped pressure prior to cold cutting activities and installation of
bypass line
10. Unable to proceed with stople installation work
9 Financing / Economic N/A
10 Market & Commercial N/A
1. Unable to operate at normal operating pressure of 72 - 74 barg
2. Cuopon falling off the holder during cutting
3. Material procured not meeting pipe specification
11 Technical & Technology 4. Stopple stuck during hot tapping work
5. Existing pipe and structure failure
6. Higher velocity on branch connection
1. HESS not agree to perform hot-tapping activities at TGAST-GPP
12 Partner
tie-in
(Hot Tapping Work)
Attendees
No Name Designation 2/10/13 10/10/13
1 Abang Ashaari b Abd Rahman PGB/TES / /
2 Md Ruzaidi Zaim b Md Razali PCSB/DD /
3 M Ali b Maidin PGB/HSE /
4 Asmawi b Rashid PCSB/PMO /
5 Adam b Ahmad PCSB/PMO /
6 M Sazli b Ismail PCSB/ME / /
7 M Haniff b Zamahsari PCSB/PE / /
8 Ammar Imran b Ghazali PGB/POD /
9 Narayanan Chidambaram PCSB/DD / /
10 M Fairuz b M Nasir PCSB/PMO /
11 Masriani Bt Mohamed - M Ghazali PGB/POD /
12 Zaidi B Mat Dom PGB/POD /
13 Mahzul B Saiman PCSB/DD /
14 Ahmad Yuhan B M Ayub PGB/POD /
15 Intan Shakira Bt Ahmad Farok PCSB/PMO /
16 M Azmeer Rozman PGB/POD /
17 Krishnan Venkatarama PCSB/PMO /
18 Syed M Hafiz b Syed Shahrul Zaman PGB/RMD / /
(Hot Tapping Work)
Risk Action Status

No Risk issues Causes Consequences Mitigation Action person Action due
Likelihood Impact Rating /Remarks
Project Team Risk
Lack of manpower to manage hot 1. Simulataneous 1. Quality Affected 1. To request additional inspectors 1. Project Engineer 1. 1/02/2014
tapping contractor and EPCC works perform at both 2. Schedule delay from TGAST, POD and PMO for 2. Piping Engineer 2. 30/06/2014
contractor (ie Inspector) OSC and GPP under 3. Cost impact hot tapping work 3. HSE Engineer 3. 1/11/2013 (ITB)
the same project team 4. HSE (Safety issues - 2. To include inspector at site 4. Project Engineer 4. If required
2. May work 24 hours Lack of supervision) requirement in the Inspection Test
1 Likely M H
5. HSE (fatigue) Plan (ITP)
3. To include fatigue management
plan in ITB
4. To establish 24 hours working
schedule
Incompetent PMT in Hot Tapping work 1. Non of the team 1. Schedule Delay 1. To consult principal's guideline 1. Piping Engineer 1. Done
have experience in hot 2. Quality Affected 2. Sharing session with experience 2. Piping Engineer 2. Done
tapping activities 3. Cost Impact personnel 3. Piping Engineer 3. 1/06/2014
2. Lack of knowledge 3. TP to review and endorse Hot 4. Piping Engineer 4. 1/11/2013
on the use of double Tapping procedure 5. Project Engineer 5. Done
2 stopple Possible M M 4. To include endorsement
requirement from PE (contractor)
for non-routine activities in ITB
5. To include teambuilding
requirement in ITB
Extension of contractors work days 1. OGT/OSC 1. Schedule delay

duration (Hot tapping contractors) unplanned shutdown 2. Cost Impact
3 Unlikely M L
prior to hot tapping
work
Timing Risk
Unable to enter construction site 1. Monsoon season 1. Schedule delay 1. To consider monsoon season in 1. Project planner 1. 1/02/2014
2. Bad weather 2. Cost overrun planning package 2. Project Engineer 2. 1/02/2014
1 Likely M H
2. To consider execution prior to
monsoon season
Late award of EPCC contract to 1. Late issuance of 1. Unable to meet MC date 1. To consider separate hot 1. Project leader/ 1. 30/10/2013
contractor (Insufficient project ITB (Delay of start of execution tapping contract Head of Facility
2 execution time) 2. Late completion of work) Possible H H
detailed design or 2. Increase cost
feed
Late material delivery 1. Late issuance of 1. Work Delay 1. To consider dedicated 1. Head of Facilities 1. 1/02/2014
contract to hot tapping 2. Cost increase expediator to close monitor the
contractor procurement package progress
2. Delay in
3 engineering of hot Possible H H
tapping
3. Delay in
procurement by hot
tapping vendor
(Hot Tapping Work)
Risk Action Status

Quality Risk
Poor online welding quality at Split 1. Lack of local 1. Progress delay 1. To include the requirement to 1. Project Engineer 1. 1/11/2013
Tee experienced welders 2. Rework priotize sourcing Malaysian
for online welding and welders, however, upon
temper bead method unavailability, contractor to
2. High demand of consider sourcing out to foreign
welders due to welders with following minimum
1 Possible M M
concurrent major criteria it ITB:
project at site (PRR4) i. Experienced in performing
welding on live pipe and temper
bead method
ii. Meet Welder Qualification Test
(WQT) requirement
Stakeholder Approval Risk
Plant management does not approve 1. Stakeholder 1. Scope deviate 1. To get PGB and PCSB 1. Head Of Facility 1. Done
hot tapping activity unconvinced of 2. Project delay management approval for contract 2. Piping Engineer 2. 1/06/2014
successfulness of hot 3. Cost incurred award 3. Piping Engineer 3. 1/10/2014
tapping since no 2. To perform risk assessments
1 experience tapping at Possible H H (PHA)
72 barg 3. To get approval from asset
2. Bad past owner as per PTS checklist
experiences (Coupon
drop)
Location Risk
Congestion at work site 1. Many near-by asset 1. HSE Incident (Property 1. To provide sufficient barracades 1. Project Engineer 1. 1/10/2014
equipment damage, Equipment and protection for existing assets 2. Project Engineer 2. 1/10/2014
2. Limited space for damage) 2. To perform site assessment and 3. Project Engineer 3. 1/10/2014
lifting/installation at 2. Schedule Delay execution review specifically hot
1 Likely H H
high elevation tapping scope
3. Concurrent project 3. To perform coordination
execution at site meeting with other project at site
Contract Risk
Cancellation of Hot Tapping scope 1. Availability of 1. Unprepared for 1. To include provision of 1. Project Engineer 1. 1/11/2013 (ITB)
from EPCC scope shutdown window shutdown scope - Schedule cancellation of scope in ITB
1 2. Management Delay Possible H H (Shutdown as optional for GPP
direction 2. Cost and Hot Tapping as optional for
3. Scope changes OSC)
Late issuance of Hot Tapping contract 1. Late award of 1. Schedule Delay 1. To consider single source award 1. Head Of Facility 1. 1/12/2013
EPCC contract 2. Cost to hot tapping vendor 2. Head Of Facility 2. 1/12/2013
2. Re-evaluate of 2. To consider having hot tapping 3. SCM Executive 3. 1/12/2013
other vendors due scope as a novation to EPCC
2 Unlikely H M
VDP graduated in contractor
November 2013 3. To perform pre-screening on
available hot tap vendors based on
SWEC
(Hot Tapping Work)
Risk Action Status

Contractor Risk
Poor execution communication and 1. Too many layers of 1. Schedule delay 1. To establish interfacing meeting 1. Piping Engineer 1. 1/11/2013 (ITB)
contractor managing sub con sub-con in the hot 2. Cost impact (to include the requirement of 2. Project Engineer 2. 1/11/2013 (ITB)
tapping work representative from each party to
2. Lack of coordination attend interfacing meeting)
1 Likely M H
3. Poor direction from 2. To include Liquidated Damage
PMT managers (LD) requirement in hot tapping
contract
Incompetent hot tapping vendor 1. VDP graduate in 1. Quality affected 1. To prepare and review the 1. Piping Engineer 1. 1/11/2013
November 2013 2. HSE Incidents technical criteria in ITB with TA 2. Head Of Facility 2. 1/11/2013
2 Possible H H
2. Weak technical 3. Schedule Delay 2. Tp consider of single sourcing to
criteria in ITB existing vendor (TMM)
Insufficient Hot Tapping machine 1. Lack of Hot 1. Schedule delay 1. To include requirement of 1. Piping Engineer 1. 1/11/2013 (ITB)
Tapping machine providing one additional hot
3 Possible H H
available tapping machine in Hot Tapping
spec
HSE Risk
Unable to achieve minimum flow 1. Plant trip 1. Schedule delay 1. Establish of communication 1. Project 1. 1/06/2014
during hot tapping activity 2. Inadvertant closure 2. HSE Incident (Explosion) protocol with operation personnel Engineer/Operation (Procedure)
of valve 2. To include continous monitoring Rep from PGB & 2. 1/06/2014
of flow using the existing flow PMO (procedure)
meter at the metering skid in hot 2. Piping Engineer 3. 1/06/2014
tapping procedure 3. Piping Engineer
1 Possible VH H 3. To include temperature
monitoring at weldment area in hot
tapping procedure
4. To consider alternative cooling
method
Gas leak during the hot tapping 1. Flange leakage 1. LOPC 1. Portable gas detector at site 1. HSE officer 1. 1/10/2014 (before
activity 2. Sandwich valve available 2. QA/QC site execution)
passing 2. To perform leak test 3. Piping Engineer 2. 1/10/2014 (before
2 Likely H H
3. To practice flange management site execution)
system 3. 1/10/2014 (before
site execution)
Sudden pressure build up during hot 1. Hot tap equipment 1. LOPC 1. To perform risk assessment 1. Process Engineer 1. 1/06/2014
tapping activity pressure rating lower (PHA) 2. Process Engineer/ 2. 1/06/2014
3 than systems pressure Possible H H 2. To establish specific plant Operation Rep
rating operating procedure during hot
tapping activities
Non-compliance to HSEMS 1. Lack 1. Unsafe act (HSE 1. Contractor to submit copy of 1. HSE officer 1. 1/06/2014
requirement, eg PTW, OGSP, CIDB, supervision/audit Incidents) competency matrix 2. HSE officer 2. 1/06/2014 (1
4 Possible H H
Competency card 2. High turnover of 2. Enforcement of plant entry month prior of
workers execution)
Hot tapping machine/equipment 1. Equipment not 1. Schedule delay 1. To consider stand-by 1. Project Engineer 1. 1/05/2014
malfunction inspected prior to site equipments for identified critical 2. Piping Engineer 2. 1/05/2014
5 mobilization Likely H H items (hydraulic pack)
2. To include pre-inspection in
workpack by contractor
(Hot Tapping Work)
Risk Action Status

Burn through during fillet welding 1. High heat input 1. Loss of containment 1. To follow approved Welding 1. QA/QC 1. 1/06/2014
generating high heat contact to pipe 2. slow travel speed 2. HSE Incident (Flash Procedure Specification (WPS) 2. QA/QC 2. 1/06/2014
3. Wall thickness less Fire) 2. To hire competent welder 3. QA/QC 3. 1/10/2014
6 Unlikely H M
than minimum 3. To perform wall thickness
requirement from PTS measurement
Heat introduce higher than auto- 1. Unaware of 1. Explosion 1. To perform chemical stability 1. Process Engineer 1. 1/10/2014 (prior
ignition temperature of medium chemical substances check (auto-ignition test) on the 2. Project Engineer to execution)
7 in medium Unlikely H M feed gas 2. 1/10/2014 (prior
2. To ensure no nearby flange to execution)
breaking during welding activities
Incomprehensive JHA documents 1. Incompetent work 1. HSE Incident 1. To conduct specific JHA review 1. Project Engineer 1. 1/10/2014 (prior
leader 2. Progress delay session to execution)
2. Time constraint
3. Improper planner
8 Unlikely H M
4. JHA is not
thoroughly discuss
with operation
personnel
Trapped pressure prior to cold cutting 1. No provision for 1. Uncontrol release of 1. To provide the bleed point 1. Piping Engineer 1. 1/06/2014
activities and installation of bypass line bleeding at the pressure 2. To consider purging 2. Piping Engineer 2. 1/06/2014
9 isolated location 2. LOPC Possible M M (During Engineering
Design)
Unable to proceed with stople 1. Flow exceed PTS 1. Schedule delay

10 installation work Unlikely M L
requirement
Financing/Economics
N/A
Market/Commercial Risk
N/A
(Hot Tapping Work)
Risk Action Status

Technical/Technology Risk
Unable to operate at normal operating 1. Line pressure need 1. Production slowdown 1. To apply MOC for PTS deviation 1. Piping Engineer 1. 31/12/2013
pressure of 72 - 74 barg to be at 70 barg at (GPP), production cutback of maximum pressure 2. Piping Engineer 2. Done
1 maximum (PTS (OSC, OGT) Possible H H 2. To acquire hot tapping
requirement) principal's track record for
pressure more than 70 bar
Cuopon falling off the holder during 1. Velocity during 1. Asset damage 1. To include continous monitoring 1. Piping Engineer 1. 1/06/2014
cutting perforation higher than (downstream equipments, of flow using the existing flow 2. Piping Engineer 2. 1/11/2013
allowable OSC - shutdown valve, meter at the metering skid in hot
GPP - Orifice plates) tapping procedure
2. Cost Incurred to recover 2. To include EPCC to bear the
2 Possible H H
coupon cost of recovering fallen coupon
3. Progress delay and the damages to asset if they
4. Production loss are at fault in ITB
5. Additional scope of work
Material procured not meeting pipe 1. Material wrongly/not 1. Progress delay 1. To verify the spec meeting the 1. Piping Engineer 1. Done
specification specified in hot 2. Cost Impact SOUR service/low temp 2. Piping Engineer 2. 30/06/2014
tapping specification requirement
2. Material supplied 2. To include in ITP:
not as per i. To obtain raw material spec from
specification manifacturer
3 Possible H H ii. To verify the material during
drawing and document reviews
iii. To do inspection of material at
manifacturing site
iv. To ensure contractor verify the
material during receiving at site
Stopple stuck during hot tapping work 1. Accumulated debris 1. Progress delay 1. To specify the requirement to 1. Piping Engineer 1. 1/11/2013
at internal pipe wall 2. Cost Impact conduct necessary Non- 2. Piping Engineer 2. 1/06/2014
2. Uneven internal Destructive Testing (NDT) in ITB 3. Piping Engineer 3. 1/11/2014
pipe surface 2. To perform functional test of
4 Unlikely H M
3. Mechanical failure stopple machine at vendor yard
of stopple 3. To inspect the machanical
machine prior to hot tapping
activities
Existing pipe and structure failure 1. Overloaded by Hot 1. Integrity Issue 1. To include stress analysis and 1. Piping 1. Done
tapping machine 2. Cost Incurred support design for piping and Engineer/Civil 2. 1/11/2013
2. Spring effect of 3. Progress Delay structure in ITB 2. Piping Engineer
5 coupon 4. HSE Incident (LOPC) Unlikely H M 2. To include requirement for hot
tapping contractor to provide
equalizing line in equipment setup
in ITB
Higher velocity on branch connection 1. Bore core smaller 1. Rework
6 Possible L L
than the piping ID 2. Cost
Partner Risk
HESS not agree to perform hot- 1. No written 1. Change of scope 1. To get approval via Evacuation 1. Head Of Facility 1. 1/12/2013
tapping activities at TGAST-GPP tie-in agreement with HESS of North Malay Basin Gas Delivery
1 Possible H H
on execution strategy System (ENGDS) Steering
Committee
Doc. No.
KERTEH Rev. 1
DOCUMENT TITLE
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ATTACHMENT 7
UT Result of Current Pipe Thickness

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MISI SETIA OIL & GAS SDN BHD

ENGINEERING, PROCUREMENT, CONSTRUCTION AND

Rev Date Status MSOG PGB

1 27/05/14 Re-Issued for Construction NAV PB HWL

0 09/05/14 Issued for Construction NAV PB HWL

B 15/04/14 Issued for Owner Review NAV PB HWL

A 11/04/14 Issued for Internal Review NAV PB HWL

PETRONAS is undertaking the TGAST-OSC-GPPA (TOG) Modification Project to

The project development scope for piping as listed below:

i) Installation of New Pipe 24”(600-P-29017-91440XX), Tie-in point at 42”(1050-P-

Details of the project development are shown in the schematic below:

Figure 1: Overall Project Development

3.0 DEFINITION AND ABBREVIATION

VENDOR/ SUPPLIER The company on which the order or contract for

4.0 CODE STANDARD REFERENCE

PTS 31.10.60.30 Welding on Pressurized Pipes

4.2 International Codes and Standards

ASME B31.3 Process Piping: Ring-Joint, Spiral-Wound and

6.0 PROJECT CONSTRAINTS

 1 number of hot tapping at 42” pipe, line numbers 1050-P-29013-

 1 number of hot tapping at 24” pipe, line numbers P-24”-1093-D7104-

6.3 Assessment of hot tapping feasibility

Table 1: Assessment of Hot Tapping Feasibility

7.0 HOT TAPPING APPLICATION ASSESSMENT

7.3 Hot tapping tie-in joint methodology

i) Tee fitting with valve (standard tap fitting)

Figure 7.3(i): Tee Fitting

ii) 3-Way fitting into two parts

iii) 3-way fitting with valve

Figure 7.3(ii): 3-Way fitting

7.4 Hot tapping application & operation restriction

7.5 Hot tapping equipment

7.5.1 Drilling machine

7.6.1 Job analysis

Two (2) points of view data are;

(i) Feasibility and design (As Appendix 1 in PTS 31.86.60.10)

 Process and design condition inclusive restriction on application

(ii) Operational feasibility

7.6.2 Hazard evaluation and risk reduction

(ii) Refer to Attachment 5 for decision process for authorizing hot

7.6.3 Pre-execution checks and preparation

(ii) Checks & preparation prior to execution of hot tapping

- Check and confirm site conditions

7.6.4 Execution of hot tap operation

(i) Perform final check

(iii) Welding inspection

(iv) Install hot tapping machine

(v) Pressure testing

(vi) Perforation and completion

7.7 Hot tapping vendor requirement

3 Way Tee 450 Angle

7.8 Hot tapping cost estimation

8.3 Fluid Velocity

Attachment 1 - Plant Layout

Attachment 3 - Example Process To Review Whether Hot Tapping is Appropriate

Attachment 4 - Type of Hot Tap Connection

Attachment 5 - Example Decision Process for Authorizing Hot Tapping