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Method Statement: Taping and Chilled Water Installation 1 of 20

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QC 29-06-2023 EM00043-CGD-0002 Date:29/6/2023

Method Statement for Taping and Chilled Water

Installation for Senior Mess Hall at Al Maha Camp

Agreement Number: 4700018376

Joy Thomas Electromechanical & Engineering LLC.

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INDEX

1 PURPOSE
2 SCOPE
3 REFERENCES
4 RESOURCES
5 METHODOLOGY
6 SAFETY
7 RISK ASSESSMENT
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1.PURPOSE
The purpose of this method statement is to specify the detailed requirements and
procedures for Taping and Chilled Water Pipe Installation to achieve a good quality in
accordance with contract requirement.

2. SCOPE
This method statement specifies the sequence and methodology for Taping and Chilled
Water Pipe Installation at Al Maha Camp , Abu Dhabi, UAE.

3. REFERENCES
 AGES-SP-14-001- HVAC Design Basis
 AGES – SP – 14 – 002 - HVAC Equipment
 AGES – SP- 14 – 003 - HVAC Ductwork, Pipework & Accessories
 AGES-SP-14-004 HVAC Control Specific
 AGES – SP – 14 – 005 - Testing, adjusting and balancing of HVAC

4. RESOURCES
4.1 TOOLS AND EQUIPMENTS

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4.2 MATERIALS
Materials are to be selected as per approved material submittal.

4.3 SITE TEAM

The following list is provisional and may be adapted to suit site requirements and
needs:
1. Project Manager
2. Site Engineer Mechanical
3. Supervisors
4. Safety Officer
5. Foremen
6. Helpers

5.METHODOLOGY
5.1 GENERAL REQUIREMENTS
 Hot tap connections shall be designed and installed to meet all requirements.
 The hot tapping operations are initiated, designed, and controlled by Project
Manager with the approval of the Area Operations Manager. And Operations
Supervisor for tying in new installations to existing facilities.
 Company shall appoint an Site Engineer, who shall be made responsible for the
overall coordination of the hot tapping activities. This is to ensure that
designers, construction/maintenance installation unit, hot tap, split tee (stopple)
and valve crew, operations and/or project management, engineering staff, and
inspection staff cooperate closely during all phases of the hot tapping operations.
 The Site Engineer shall identify the equipment in terms of service, location, pipe
diameter, header and branch pressure rating, and material type and notify the
Hot Tap, stopple and valve unit of this information.
 The construction units are responsible for ensuring that approved welding
procedures and qualified welders are employed. QA/QC department shall verify
this.
 Compressed air piping and equipment shall not be hot tapped nor welded while
in service.
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 Hot tapping lines upstream of rotating equipment shall be avoided unless such
equipment is protected from the cuttings by means of filters or traps. The normal
in-line suction screens are not considered adequate for this purpose.
 All hot tap connections, valves, and hot tap machines shall be pressure tested.
 Precautions against electric shock, due to induced voltage, shall be taken into
consideration when installing hot tap connections o above ground pipelines near
high voltage power lines.
 Adequate support of the hot tap machine shall be provided to prevent
overstressing of the pipe and/or fitting, particularly in cases where the hot tap
sticker is not installed in a vertical position.
 Hot tapping shall not be permitted if:
1. Within 0.75 inches of a circumferential girth weld seam as measured from
the toe of the sticker weld or split tee circumferential fillet weld, to the
toe of the nearest girth weld.
2. Within 18 inches of a flange (or threaded connection) as measured from
the toe of the reinforcement sleeve, or split tee circumferential fillet weld
to the toe of the flange circumferential butt weld (or the closest edge of
the threaded connection). If this requirement cannot be met the
placement of the hot tap may be positioned closer than 18 inches
provided there is enough room to allow for the installation, operation and
removal of the hot tap machine, and the removal of the piping or pipeline
flange bolts.
 Existing welds under the hot tap shall be ground smooth prior to fit up of the
sticker and reinforcing sleeve. Care should be taken when cutting across existing
welds since the cutter can be damaged.
 Appropriate barricades and warning signs shall be posted around the worksite to
minimize the number of personnel in the work area while performing the hot
tapping operation.
 Compact steel gate valves with extended body ends shall not be used for hot tap
connections.

5.2 PRECAUTIONS AGAINST H2S AND OTHER TOXIC/HAZARDOUS MATERIALS

 If a potential exists for a Hydrogen Sulfide (or other Toxic material) release at a
work site, all personnel involved shall be provided with an appropriate breathing
apparatus with additional of gas detector.
 Firewater and extinguishers should be applied as required to workers, clothing,
equipment, etc., exposed to the burn-thru flame.
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 The standby person or fire watch, or other person certified as a gas tester,
shall continuously monitor the work site for the presence of hazardous
materials during the work activity using established gas testing procedures.
 The chamber of the hot tap machine and valve shall be purged with nitrogen
after cutting the coupon, retracting the cutter and closing the tapping valve when
any of the following exist:
1. H2S concentration is greater than 10 ppm.
2. Gas release may affect others in the area.
3. Hot tap equipment is larger than 36 inches.
4. The work is in a confined area.
 In enclosed or confined areas, air horns/industrial fans shall be provided to
improve air circulation. However, the air velocity shall not interfere with the
welding arc shielding gases. Fans shall meet the electrical area classification
requirements.
 When welding sour gas or sour crude lines, the fire watch personnel shall be
clearly instructed that should a burn-thru occur, the fire of the gas jetting from
the pipe should not be extinguished.

5.3 PREPARATIONS OF HOT TAP SPECIFICATIONS AND TEST CALCULATIONS

 The Site Engineer and contractor shall provide engineering calculation for each
hot tap operation and shall be reviewed by Client for approval.

5.4 LOCATE AND INSPECT HOT TAPE POSITION

 The Site Engineer shall make all necessary arrangements for the preparation of
hot tapping (i.e, location, excavation, pipe inspection, surface preparation, etc.)
 The Site Engineer shall mark of the exact hot tap locations, and mark the hot tap
number alongside each hot tap location, ensuring the hot tap locations are at a
position where the pipe out-of roundness does not exceed 3mm. (Out of
roundness criteria only applies to split tee or full encirclement sleeves).
 The QA/QC shall inform the Site Engineer if the seam weld or any other
projection needs to be ground flush with the pipe surface for proper UT scanning
and fit-up and if the out of roundness criteria is met for split tees/full
encirclement sleeves.
 If ultrasonic readings indicate a lamination or evidence of hydrogen induced
cracking (HIC) damage, the hot tap position shall be relocated after consultation
with the Site Engineer and the responsible client team.
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 The QA/QC shall review the welding procedure specification (WPS) for the
installation of the hot tap fittings and assure an approved WPS is employed.

5.5 SEQUENCE OF WORK – HOT TAPPING

 Check the valve by opening and the hot tap machine for operability and examine
the condition of the cutter and coupon retaining device.
 Mount the hot tap machine on the valve.
 Ensure that the tapping valve is tested and will easily pass the hot tap cutter.
This may require grinding of the lugs on the valve seat rings to provide adequate
clearance. Ensure that the dimension from the face of the valve flange to the
surface to be hot tapped will permit enough cutter travel to completely cut out
the coupon and not travel to the opposite side of the header.
 Apply hydrostatic and pneumatic pressure tests to the hot tap machine, valve,
and welded connection.
 Install and seal weld a threaded plug in the weld boss on the connection after all
testing has been completed.
 After assembly of the hot tap machine on the tapping valve and before the
tapping operation is started:
1. Completely close and then completely open valve to ensure that it is
operable, and that the cutter can be withdrawn a sufficient distance to
permit closure of the valve.
2. Set the cutter travel indicator to prevent over travel and consequent
damage to the opposite side of the header being hot tapped.
 Drill and cut coupon.
 Retract the hot tap machine boring bar.
 Close the valve, purge with nitrogen, if required, and depressurize the hot tap
machine adaptor.
 Remove the hot tap machine from the line.
 Remove the coupon from the pilot drill and tag and wire the coupon to the
tapping valve on the connection after hot tap is completed.
 The coupon shall be removed only by the Operations Supervisor and forwarded
to the responsible Operations Inspection Unit.
 Ensure that the completed connection is blinded or plugged before proceeding to
next Job.

5.6 Pressure Test Requirements

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Method Statement: Taping and Chilled Water Installation 8 of 20

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QC 29-06-2023 EM00043-CGD-0002 Date:29/6/2023
 The Site Engineer shall be responsible for ensuring that the pressure tests are
performed in accordance with API RP 2201 on the hot tapping equipment,
including the hot tap valve and branch connection prior to and after installation.

 The initial pressure testing of the hot tap machine, will take place in the shop
after the machine has been checked and worn parts replaced.
 The hot tap machine shall have an overhaul of its renewable pressure sealing
components and be subjected to a shop rated pressure test, in accordance with
the following criteria:
1. Pressure test once every four months and overhaul once every 12
months.
2. After it has been used on lines with operating temperatures in
excess of 150 deg C, even if the elapsed time is less than four
months. For a series of consecutive hot taps on a single type of
service (i.e., steam, process stream, etc.) the hot tap machine shall
be shop tested at the end of the series of hot taps.
3. A stamped brass tag shall be affixed to the hot tap machine
indicating the test pressure, overhaul date, and the name of
the testing organization.
 Pneumatic testing of hot tap connections on hot lines over 93 deg C is not
permitted unless approved by the Manager, Inspection Department.
 Hot tap connections installed on hot lines where hydrostatic testing with water is
not practical shall be hydrostatically tested using high temperature turbine oil or
silicone fluid, as follows:
 A body and high pressure seat test (on both sides of the seat) shall be performed
in the shop on all hot tap valves prior to installation. Resilient (soft) seat valves
shall have zero leakage, Valves with metal to metal seats shall meet the leakage
criteria of API 598. A back seat test and low pressure seat test is not required. A
tag shall be attached to the valve indicating test date, test pressure and
Inspector's name.
 A pneumatic test of 173 kPa (ga) shall be applied to the reinforcing pad or ring
after installation. This pressure will then be reduced to 21 - 35 kPa (ga) for a
tightness test using a soap solution.
 Install the hot tap valve and apply another high pressure closure test (seat test).
 Return the valve to the open position, mount the hot tap machine and apply
another full pressure test .
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 Ensure that the connection is opened, drained and vented upon completion of
hydrostatic testing to prevent possible build up of pressure from any source of
heat.

 After completion of the above tests, install a bar stock plug in the branch
connection boss and seal weld. At the option of the Inspector, an MT or PT may
be applied to the branch connection seal weld.
 The appropriate Inspection Representative shall witness and approve all
hydrostatic testing required for completion of the hot tap connection.

6. SAFETY
 The Site Engineer shall ensure that the safety of work crews involved in the hot tapping
operation is shared jointly by the Operator and the Hot Tap Supervisor/Maintenance
Foreman.
 All work shall be in strict compliance with client approved Work Permit System.
 The Site Engineer shall make available to the site a copy of the permit and ensure the
area has been sufficiently roped off to prevent unauthorized personnel from entering
the work area.
 Written approval of the detailed hot tap installation shall be obtained from the
Operations Superintendent, or higher, and a copy sent to the Area Loss Prevention Office
and responsible QA/QC for their review and concurrence prior to starting the
installation.
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