ukcssop024_iss1am01

Hot Tapping Manual UKCS-SOP-024
Contents
Authorisation for Issue

Amendment Record
Amendment Summary
Distribution List
Preface
Paragraph Page
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1 General 1
1.1 Introduction 1
1.2 Approval of Hot Tap Procedures 1
2 Safety Consideration and Contingency Plan 1
3 Stages of Installation 2
4 Control of Header Flow Conditions 3
5 Fabrication, Welding and Installation 3

5.1 General 3
5.2 Header Pipe Preparation 3
5.3 Hot Tap Branch Installation 5
5.4 Installation of Hot Tap Valve 7
6 Inspection and Non-destructive Testing (NDT)

Requirements 7
6.1 Pre-installation 7
6.2 Post-installation 9
7 Pressure Testing 9
8 Hot Tap Operation 9
9 Documentation 10
August 2001 Issue 1 i

UKCS-SOP-024 Hot Tapping Manual
Contents (cont’d)
Figure Page
1 Weldolet Assembly 4
2 Split Tee Assembly 6
3 Example of Weldolet Assembly 6
4 Example of Split Tee 7
5 Weldolet Assembly 8
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Addendum 1 References
Addendum 2 GFU Hot Tap Proposal Approval Sheet
Addendum 3 GFU Hot Site Preparation Sheet
Addendum 4 GFU Tap Data Sheet 1
Addendum 5 Sullom Voe Terminal – Hot Tap Data Sheet 2
Addendum 6 Method of Calculating Maximum Test Pressure
Addendum 7 Proforma Examples
ii August 2001 Issue 1

Authorisation for Issue
Issue Authority
Name: John Watson
Signature: ________________________________________________
Date: ________________________________________________
Position: Operations Delivery Team Leader, GFU

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Technical Authority
Name: Bill Logan
Signature: ________________________________________________
Date: ________________________________________________
Position: OIM/Development Engineer, GFU
August 2001 Issue 1 iii/iv

Amendment Record
For Audit Use

Amendment Incorporated By
Checked
Number
Name Signature Date Signature Date
Uncontrolled
AMOSAF.171
August 2001 Issue 1 v/vi

Amendment Summary
Issue No Date Description

Issue 1 August 2001 First issue.
Issue 1/AM01 March 2002 Details of required flow conditions added to
Paragraph 4. The use of the correct type of pilot
drills will ensure that the header flowrates are not
exceeded.
Further details, if required, are available from the
Uncontrolled
hot tap contractor.

Reference to Detail A in Figure 4 deleted as not
applicable.
Distribution list updated.
March 2002 Issue 1/AM01 vii/viii

Distribution List
Holders of Controlled Hard Copy
Copy Copyholder Location
01 Data Control Centre (DCC) ODL, Aberdeen
Virtual Copyholders
Copy Copyholder
Uncontrolled
01 Document Issue Authority (John Watson)

02 Document Technical Authority (Bill Logan)
03 EoS Document Controller (Dave Taylor)
04 EoS Operations Excellence HSE Consultant (David Egan)
05 OOE, Magnus
06 OTL, North West Hutton
07 OTL, Thistle
08 Thistle/NWH Field Support Team Leader (Colin Browning)
09 BSG SMS Co-ordinator (Peter Malcolm)
10 MNS SMS Co-ordinator (Peter Faulkner)
11 MNS SMS Co-ordinator (Peter Thompson)
12 MNS SMS Co-ordinator (Carl Thomessen)
13 MNS SMS Co-ordinator (Justin Haigh)
14 CNS SMS Co-ordinator (Jim Blacklaws)
15 NBU SMS Co-ordinator (David Robertson)
16 NBU EPU SMS Co-ordinator (David Egan)
17 NBU SMS Co-ordinator (John Beaumont)
18 NSI SMS Co-ordinator (Ann Rosbrook)
19 SBU SMS Co-ordinator (Malcolm Watson)
20 SBU SMS Co-ordinator (Simon Robinson)
21 MNS SMS Co-ordinator (Bruce Morrison)
March 2002 Issue 1/AM01 ix/x

Preface
Purpose
The hot tap operation is carried out by a specialist contractor. Therefore it is the purpose of this
document to provide a standardised method for the auxiliary work required to enable the hot
tap to be done, whilst providing a brief description of the hot tap operation.
A copy of this document must be issued to the hot tap contractor at the initial enquiry stage as
it refers to design and fabrication parameters.
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Review and Update

This document will be subject to 12-monthly review and update, when document holders will
have the opportunity to express opinions and suggest improvements.
However, the document control system allows for continuous update of this document. As
such, any user may at any time identify an error or suggest an improvement using an
Amendment Proposal proforma which is available electronically on the UK Upstream SMS
website, from the Data Control Centre (DCC) Supervisor or from the Technical Authority.
All holders of this document are registered so that they can be sent updates and be kept
informed of changes or reviews.
Responsibility of Copyholders
It is the responsibility of the registered copyholder of controlled hard copy versions to
maintain the accuracy of the document by ensuring that all updates are promptly
incorporated and acknowledged.
Furthermore, the registered copyholder of controlled hard copy versions must at all times
maintain custody of this document unless prior approval is given by the relevant
Technical Authority.
The roles and responsibilities of copyholders and ‘virtual’ copyholders are detailed in Section 1
of the Document Control Procedure (UKCS-DCM-001).
August 2001 Issue 1 xi/xii

1 General
1.1 Introduction
A ‘hot tap’ is a method of cutting a hole in a piping system which is under pressure,
without loss of containment of the contents, using a valve, pipe fittings and a
tapping machine.
1.2 Approval of Hot Tap Procedures

The hot tap and associated activities shall be carried out in accordance with the Permit to
Work (PTW) system.
Before a hot tap can be carried out, details of the proposal have to be submitted for
approval by:
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• Delivery Area Team Leader

• Senior Mechanical and Integrity Engineer
• Senior Integrity Engineer
• Shift Team Leader
The Job Officer shall nominate a responsible person to prepare a proposal for approval
which shall include the following:
• Hot Tap Data Sheet 1 – all sections completed
• Hot Tap Data Sheet 2 – section indicated* to be completed
• Hot Tap Activity Sheet – job reference to be completed
• Calculation of maximum test pressure
The proposal should also include (where applicable):
• Isometric(s)
• Pressure test procedure
• Engineering Line Diagram (ELD)
• General arrangement
• Location drawing
2 Safety Consideration and Contingency Plan

Prior to commencing welding and hot tapping, a copy of the approved procedure shall be
issued to the following:
• Relevant operations branch
• Safety branch
• Emergency services branch
August 2001 Issue 1 1

A contingency plan shall be developed to cover all eventualities which could arise during
the work and subsequent corrective action, including fire protection, evacuation etc,
and identify the responsibilities and authority to proceed.
The location of the hot tap shall be cordoned off and only essential personnel allowed to
enter the area.
Radio contact between the work area, the relevant operations control room and
emergency services control room shall be maintained throughout the duration of
the work.
3 Stages of Installation
The following stages are required to install a hot tap connection onto a piping system.
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Item Stage Ref Paragraph
1 Header Pipe Preparatory Work 5.2
2 Pre-installation Inspection 6.1
3 Pre-fabrication of Hot Tap Branch 5.1
4 Installation of Hot Tap Branch 5.3
5 Establish Header Flow Conditions 4.0
6 Weld Hot Tap Branch to Header 5.3
7 Normalise Header Flow Conditions –
8 Hot Tap Branch Inspection 6.2
9 Install Valve on Hot Tap Branch 5.4
10 Pressure Test Valve and Branch 7.0
11 Remove Temporary Attachments –
12 Inspect Area of Temporary Attachments 6.2
13 Install Hot Tap Machine on to Valve 8.0
14 Check Cutter Through Valve 8.0
15 Pressure Test Branch Valve and Machine 7.0
16 Hot Tap Header Pipe 8.0
17 Close Valve and Lock 8.0
18 De-pressurise Hot Tap Machine 8.0
19 Remove Hot Tap Machine from Valve 8.0
20 Install Blank Flange on to Valve 8.0
2 August 2001 Issue 1

4 Control of Header Flow Conditions

The product flow in the piping system shall be controlled during the hot tap branch
welding, so that:
• The welds do not crack due to excessive cooling caused by high flowrates in the
piping system
• Overheating of the product does not occur due to no flow or low flow in the
piping system
• ‘Blow through’ does not occur due to elevated metal temperature caused by no flow
or low flow in the piping system
It is recommended that a minimum velocity of 0.4m/s is maintained for liquids or gas and
a maximum of 1.2m/s for liquids.
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During the drilling of the hot tap, the header flow conditions may require to be controlled
to a maximum of 10mls gas, 5mls liquid for a standard pilot drill. Positive retention pilot
drills will allow these figures to be exceeded; consult the hot tap contractor for details.
5 Fabrication, Welding and Installation

5.1 General
The pre-fabrication, welding, installation and inspection of hot tap fittings shall be in
accordance with BP Engineering Standards.
A copy of the appropriate specification must be issued to both the hot tap contractor at
initial enquiry stage and, if relevant, to the third-party representative prior to the
commencement of inspection.
All fittings associated with the hot tap assembly shall be in accordance with the Header
and Branch Material Specification. Where material specifications differ, the higher class
material specification shall be used.
All welding shall be in accordance with the relevant BP approved weld procedure(s).
5.2 Header Pipe Preparation

The location of the hot tap branch shall be marked off on the header pipe and checked.
The location of the branch shall be a minimum of 75mm clear of any pipe circumferential
weld and shall not be over a longitudinal seam weld except by agreement of the
Job Officer.
The header pipe shall be cleaned to bright shiny metal over the area of the fitting,
extending 150mm beyond any proposed weld locations (refer to Figure 1).
When a hot tap split tee is to be installed on a header pipe with a longitudinal seam
weld, the seam weld shall be ground flush for a length of 150mm out from the ends of
the tee (refer to Figure 2).
The cleaned areas shall be inspected in accordance with Paragraph 6.
March 2002 Issue 1/AM01 3

WELDOLET
Uncontrolled
ELEVATION
WELDOLET WELD LINE
PLAN
CLEAN AREA WITHIN CIRCLE
UKCSSOP024_001.ai
Figure 1 Weldolet Assembly

5.3 Hot Tap Branch Installation

After successful inspection of the header pipe (refer to Paragraph 6), the installation of
the hot tap branch can commence.
5.3.1 Weldolet Assembly

The weldolet and flange may be welded together and inspected prior to being installed
onto the header pipe.
The assembly shall be positioned on the header, ensuring that the flange is set square
with the root gap in accordance with the weld procedure and between the weldolet and
header pipe (refer to Figure 3).
The flange shall be checked for squareness after tacking and on completion of welding.
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5.3.2 Split Tee Assembly

The split tee is a proprietary item which is supplied with bands painted on matching
ends. The ends are also identified by a number stamped on the upper and lower halves
of the fittings at the band end. To ensure correct alignment of the fitting, the bands must
match and the numbers correspond.
A gap of 2mm maximum, 1mm minimum shall be allowed between the fitting and the
header pipe.
The longitudinal weld shall not fuse to the header pipe. To ensure this, the weld gap
between the fittings shall be 3.0mm maximum, 1.5mm minimum. In addition, backing
tape or a mild steel backing strip shall also be fitted (refer to Figure 4). The split tee
fitting may require special preparation to accommodate the backing strip and this should
be specified when purchasing the fitting.
The top half of the fitting, including the strip, shall be installed so that the flange is set
square, after which the bottom half of the fitting shall be installed and the alignment of
the two halves checked before being tack-welded together.
The welding of the split tee shall be continuous using two Welders positioned
diametrically opposite each other.
The weld sequence of the fitting is as follows:
(1) Weld longitudinal seams.
(2) Fillet weld one end of fitting.
(3) Fillet weld remaining end of fitting.
All welds shall be inspected in accordance with Paragraph 6 and Part 1 of the Hot Tap
Data Sheet (refer to Addendum 5).

SPLIT TEE
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150 150
AREA TO BE CLEANED
UKCSSOP024_002.ai
Figure 2 Split Tee Assembly
WELDOLET
ROOT GAP HEADER PIPE
UKCSSOP024_003.ai
Figure 3 Example of Weldolet Assembly

SPLIT TEE
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UKCSSOP024_018.ai
Figure 4 Example of Split Tee
5.4 Installation of Hot Tap Valve

Following a successful hot tap branch inspection, the hot tap valve can be installed.
The valve shall be fully open so that the bore of the valve and branch can be centralised,
after which the valve to branch joint can be bolted up.
The hot tap assembly shall be pressure tested in accordance with Paragraph 7.
6 Inspection and Non-destructive Testing (NDT)

Requirements
All inspection shall be in accordance with BP Guidance for Specifications GS 118-5 plus
Section 1 of Hot Tap Data Sheet 2 (refer to Addendum 5).
6.1 Pre-installation
Prior to the installation of the hot tap branch the header pipe shall be checked as follows:
• For cracks, laminations and wall thickness using Magnetic Particle Inspection (MPI)
and ultrasonics
- 150mm either side of fillet weld locations
- Hot tap area (refer to Figure 5)
• For cracks only using MPI
- Header pipe longitudinal seam welds for 150mm from end of fitting
• Roundness of header pipe (by hot tap contractor)
March 2002 Issue 1/AM01 7

WELDOLET
Uncontrolled
ELEVATION
HOT TAP AREA
PLAN
MPI AND UT AREA WITHIN CIRCLE
150
UKCSSOP024_004.ai
Figure 5 Weldolet Assembly

6.2 Post-installation
All welds and locations where temporary attachments (ie thermocouples, earthing
lugs etc) have been removed shall be subject to visual examination and MPI.
All results shall be recorded and Section 1 of Hot Tap Data Sheet 2 (refer to Addendum 5)
signed off.
7 Pressure Testing
All pressure testing shall be in accordance with Safe Isolation and Reinstatement of Plant
(UKCS-SSW-001).
The pressure test shall be in two stages:
(1) Hot tap branch and valve assembly.
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(2) Hot tap branch, valve and hot tap machine.

The test pressure shall be in accordance with BP specification and be to a maximum
of 5% less than system Pressure Safety Valve (PSV) settings.
The header pipe shall be checked by calculation to determine that the pipe wall is not
over stressed by the applied test pressure.
8 Hot Tap Operation

As stated earlier, the hot tap operation is carried out by a specialist contractor.
This paragraph provides a brief description of the operation and is not intended to be
used as a procedure.
The hot tap contractor shall submit detailed procedures for BP to review prior to the
commencement of site work.
Consideration should be given to provision of a secondary hot tap branch to provide
vent/purge facilities downstream of the primary hot tap.
Once the hot tap branch has been completed and accepted, the hot tap machine and
certification shall be examined and approved, before the machine can be installed on to
the hot tap valve and the flange joint bolted up.
The hot tap valve shall be fully open and the boring bar run through the valve several
times to ensure that the clearance between the cutter and valve is adequate. The hot tap
branch can now be pressure tested in accordance with Paragraph 7.
Before drilling commences, the travel of the cutter shall be calculated to ensure that it
does not come into contact with the opposite wall of the header.

The hot tap valve and bleed valve on the hot tap machine shall be open, at which point
the hot tap machine can be started and the boring bar passed through the valve to make
contact with the header. As the header is being drilled, the pilot bit will penetrate the
header wall; at this stage the boring bar shall not be lowered further. The hole made in
the header by the pilot will allow the product to flow into the hot tap branch and
machine, forcing the air out through the bleed valve which shall be closed once the
product is detected at the valve. The boring bar can now be lowered until the cutter
completes cutting the hole in the header. When the boring bar is withdrawn the coupon
should be retained by the cutter, if the coupon should be lost no attempt should be
made to recover it.
The boring bar and cutter shall be withdrawn into the hot tap machine housing and the
hot tap valve closed and locked. The hot tap machine shall be depressurised to
atmospheric pressure by opening the bleed valve.
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The hot tap machine shall be removed from the hot tap valve and a blank flange fitted to
the valve.
9 Documentation
On completion of hot tapping, a Guidance of Certification (GOC) System Handover
Document (SH-1) shall be compiled and authorised by the Offshore Installation Manager
(OIM). This SH-1 pack shall contain the following completed documentation:
• Hot Tap Proposal Approval Sheet
• Hot Tap Data Sheet No 1
• Hot Tap Data Sheet No 2
• Hot Tap Activity
• Hot Tap Machine Certificate
• Calculations of maximum test pressure
• Fabrication Approval Sheet (FAS)
• Weld procedure(s)
• Pressure test procedure
• Proposal for pressure test
• Pressure Test Certificate
• Calibration Certificate(s)
• Punch list proforma
• Leak Test Certificates
• Mechanical Completion Certificate
• System Handover Certificate

Addendum 1
References
(1) Furmanite Hot Tapping Pipe Procedures – FIP.

(2) Sullom Voe Terminal Procedure n EDPO-01-02.
(3) BP XEU HSE Practices 26.
(4) Forties HSE practices.
(5) Safe Isolation and Reinstatement of Plant (UKCS-SSW-001).
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References
August 2001 Issue 1 Add 1-1/2
Addendum 2
GFU Hot Tap Proposal Approval Sheet
Greater Forties Unit
HOT TAP PROPOSAL APPROVAL SHEET
Proposed Hot Tap of:
Job Reference:
Uncontrolled
Prepared by: Date:
This hot tap proposal consisting of: Hot Tap Data Sheet 1 Isometric(s)*
Hot Tap Data Sheet 2 Pressure Test Procedure*
Hot Tap Activity Sheet ELD*
Calculation of Maximum Test Pressure General Arrangement*
Location Drawing*
*Delete if not applicable
Has been reviewed and approved by the undersigned:
Approved by:
Originator Delivery Area Team Leader: Date:
Senior Technical Integrity Engineer: Date:
Offshore Integrity Engineer: Date:
Offshore Installation Manager: Date:
Copies of Approved Proposal to:
HSE Team Leader
UKCSSOP024_005.doc
GFU Hot Tap Proposal Approval Sheet

Addendum 3
GFU Hot Site Preparation Sheet
HOT TAP SITE PREPARATION SHEET
JOB REFERENCE:......................................................................................................................................................
AREA: ........................................................................................................................................................................
TITLE: ........................................................................................................................................................................
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LINE NO: ....................................................................................................................................................................
ACCESS:
JOB ENGINEER: ...................................................................
PRE-WORK INSPECTION REPORT:
DATE: ....................................................................... PIB:..................................................................................
TASK RISK ASSESSMENT:
A STAGE 2 TASK RISK ASSESSMENT SHALL BE CARRIED OUT AND A COPY OF THIS REPORT INCLUDED IN
THIS DOSSIER. REFER TO HSE PRACTICE NO 09.
DATE: ....................................................................... JOB ENGINEER: .............................................................
UKCSSOP024_006.doc
GFU Hot Site Preparation Sheet

Addendum 4
GFU Hot Tap Data Sheet 1
GREATER FORTIES UNIT – HOT TAP DATA SHEET 1
JOB REFERENCE: DRAWINGS
AREA: LOCATION:
TITLE:
KEY DATES: ISOMETRIC:
DATA HEADER BRANCH
Line number
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Pipe material specification
Pipe size
Wall thickness (mm)
Pipe manufacture
Flange class (lb)
Product
Design pressure (barg)
Normal working pressure (barg)
Design temperature (°C)
Normal working temperature (°C)
Insulation
Branch connection: weldolet/split tee

0
Valve type: gate/ball (full bore)
Branch orientation:
Design code:
Fabrication code:
Inspection code:
270 90 Weld procedure No:
Maximum cutting depth (mm):
Hot tap machine mode/type:
180
RESPONSIBLE PERSONNEL
Delivery Area Manager:
Notified Shift Team Leader:
Job Officer:
Job Engineer:
Fabrication Contractor:
Installation Contractor:
Hot Tap Contractor:
UKCSSOP024_007.doc
GFU Hot Tap Data Sheet 1

Addendum 5
Sullom Voe Terminal – Hot Tap Data Sheet 2
SULLOM VOE TERMINAL – HOT TAP DATA SHEET 2
*JOB REFERENCE: .......................................................................................
(1) NON-DESTRUCTIVE TESTING *Sections to be completed for Proposal

(a) Pre-installation
Weld Area +150mm either side MPI and ultrasonics
Hot Tap Area MPI ultrasonics
Longitudinal MPI
(b) Post-installation
Longitudinal Welds Visual and MPI
Circumferential Welds Visual and MPI
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Weldolet Weld Visual and MPI

Location of Temporary Fittings Visual and MPI
(2) CHECK ROUNDNESS OF HEADER PIPE

Header pipe roundness within specification.
The above examinations have been carried out and found to be acceptable.
JOB ENGINEER:..................................................................................... FOR PIB:..................................................................
DATE: .................................................................................................... DATE: ......................................................................
(3) PRESSURE TESTING
COMPONENT(S) TESTED PRESSURE (barg)* MEDIUM DURATION
Branch and Valve
Branch, Valve and Machine
For calculation of test pressure effect on header refer to attached spreadsheet.

The above pressure tests have been carried out and found to be acceptable.
JOB ENGINEER:...................................................................................... DATE: ......................................................................
PIB: ......................................................................................................... DATE: ......................................................................
(4) HOT TAP MACHINE

(a) Certification: valid and correct pressure rating (d) Cutter and Pilot Bit: is secure
(b) Gland Packing: in good condition (e) Coupon Catcher: is suitable
(c) Bleed Valve: free from blockage (f) Machine Support: Is adequate
(5) CONTROL OF HEADER PARAMETERS
PARAMETER MONITOR BY DURING WELDING DURING TAPPING
Contents
Pressure (barg)
Temperature
Velocity (m/s) Min Normal Max
Flowrate (m/hr)
The header parameters have been maintained in accordance with the above data.
JOB ENGINEER: .................................................................................... FOR OPERATIONS:.................................................
DATE: ..................................................................................................... DATE: ......................................................................
UKCSSOP024_008.doc

August 2001 Issue 1 Add 5-1
SULLOM VOE TERMINAL – HOT TAP DATA SHEET 2
# To be completed for Proposal

JOB REFERENCE: #
ITEM ACTIVITY INITIAL DATE
1 Clean header pipe and mark off hot tap location
2 MPI and ultrasonic weld areas
3 MPI and ultrasonic hot tap area
4* MPI longitudinal seam weld
5* Check ovality of header
6 Establish header
Uncontrolled
7* (a) Set and tack upper half of split tee
(b) Set and tack lower half of split tee
(c) Weld longitudinal seams
(d) Weld circumferential fillet welds
8* (a) Set and tack weldolet
(b) Weld weldolet
9 Inspect welds visually and MPI
10 Install valve and check centralisation
11 Pressure test hot tap assembly (refer to Pressure Test Procedure Sheet)
12 Remove temporary fittings and connections (ie thermocouples, etc)
13 MPI location of temporary fittings
14 Check hot tap machine certification and condition
15 Install hot tap machine onto assembly
16 Open valve and check clearance between cutter and valve
17 Pressure test assembly and hot tap machine (refer to Test Procedures)
18 Hot tap header
19 Retract boring bar and coupon into machine
20 Close valve and lock
21 Depressure hot tap machine to atmospheric pressure
22 Remove hot tap machine
23 Fit blind flange into valve
* Delete if not applicable
The hot tap operation has been completed in accordance with the above.
JOB ENGINEER: Date:
UKCSSOP024_009.ai

Add 5-2 August 2001 Issue 1
Addendum 6
Method of Calculating Maximum Test Pressure
Paragraph Page
1 Weldolet Branch 1
2 Split Tee Branch 1

Uncontrolled

August 2001 Issue 1 Add 6-i/ii
When the hot tap assembly is pressure tested the header pipe could be overstressed by the
applied pressure, therefore it is necessary to determine the maximum pressure which can be
applied externally to the header.
1 Weldolet Branch
To simplify the calculation, the section of the header pipe to which the hot tap branch
assembly is attached shall be considered to be an unstayed head and the following
formula from ASME VIII, Division 1, Section UG34 shall be used:
t = d √ CP/SE
Where:
t = thickness of header pipe (mm)
Uncontrolled
P = maximum external pressure (N/mm2)

d = internal diameter of branch (mm)
S = allowable stress (N/mm2) ASME/ANSI B31.3 allowable
C = co-efficient = 0.2 (ASME VIII)
E = joint efficiently = 1.0
Re-arranging the formula to give pressure:
P = [(t/d)2 x SE]/C
Also the branch wall thickness shall be checked to ensure the hoop stress does not
exceed the allowable stress in accordance with ANSI B31.3.
Using the equation for hoop stress:
Sh = Ph x D/2t
Where:
Sh = hoop stress (N/mm2) ASME/ANSI B31.3 allowable
Ph = hoop stress pressure (N/mm2)
D = outside diameter of branch (mm)
t = branch wall thickness (mm)
Re-arranging to give pressure:
Ph = Sh x 2t/D
The test pressure shall not exceed the maximum pressure (P) or stress pressure (Ph).
2 Split Tee Branch

The maximum pressure which can be applied on the header pipe shall be in accordance
with ASME VIII Division 1 Section UG28.

DIMENSION L (mm) FOR EQUAL TEE
Size (inches) Class 150 Class 300 Class 600
1 107 107 107 (Use 11/2 x 11/2 Tee)
11/2 119 119 119 (Use 2 x 2 Tee)
2 272 272 272 (Use 3 x 3 Tee)
3 175 175 175
4 273 273 273
6 356 356 356
8 420 420 420
10 508 508 508
Uncontrolled
12 559 559 559
14 660 660 660
16 762 762 762
18 838 838 838
20 914 914 914
22 1016 1016 1016
24 1092 1092 1092
26 1194 1194 1194
28 1245 1245 1245
30 1295 1295 1295
34 1448 1448 1448
36 1524 1524 1524
DIMENSION L (mm) FOR REDUCING TEE
Size (inches) Class 150 Class 300 Class 600
6x4 273 273 273
8x4 356 356 356
10 x 6 420 420 420
12 x 6 508 508 508
14 x 8 559 559 559
16 x 12 660 660 660
20 x 16 762 762 762
UKCSSOP024_010.ai
Figure 1 Dimensions of Split Tees

CALCULATION OF MAXIMUM TEST PRESSURE
PMP NO:
DESCRIPTION:
PREPARED BY: DATE:
This calculation is for a weldolet branch assembly.
BASE:
Outside diameter of header pipe: mm

Wall thickness of header pipe: mm
Outside diameter of branch pipe: mm (D)
Wall thickness of branch pipe: mm
BP material specification:
°C
Uncontrolled
Design temperature:
Test pressure: barg
Material specification:
2
Allowable stress at design temperature: N/mm (S)
Corrosion Allowance: mm
CALCULATION VALUES:
(1) Header pipe wall thickness 12.5% under tolerance and corroded mm (t)
(2) Branch pipe wall thickness 12.5% under tolerance mm (x)
(3) Inside diameter of branch pipe: (D-x) mm (d)
Assuming that the section of header to which the branch is connected is an unstayed head and using the rearranged
equation from ASME VIII Division 1 Section UG34.
2
PM = (t/d) x S x E
C
Where:
2
Pm = Maximum external pressure (N/mm )
t = Wall thickness of header (mm) – worst case, minimised
d = Inside diameter of branch (mm) – maximised
2
S = Allowable stress per ASME/ANSI B31.3 (N/mm )
E = Joint efficiency = 1.0
C = Coefficient from ASME VIII – 0.2
2
Using Input date PM = N/mm
UKCSSOP024_011.doc
Figure 2 Calculation of Maximum Test Pressure

CALCULATION OF MAXIMUM TEST PRESSURE
PMP NO:
Also to determine the maximum pressure which can be applied to the branch pipe so that the hoop
stress does not exceed the allowable stress.
Hoop stress on branch pipe: Sh = Ph x D

2t
Where:
Sh = Allowable stress (N/mm2) – refer to value for S, page 21
Ph = Applied pressure (N/mm2)
Uncontrolled
D = Outside diameter of branch (mm)
t = Wall thickness of branch (mm) – refer to value for x, page 23
Re-arranging to give maximum pressure without exceeding the allowable hoop stress.
Ph = Sh x 2t
D
Conversion: 1 N/mm2 = 10bar
SUMMARY:
Test pressure (Pt) barg

Maximum allowable external pressure on header pipe (Pm) barg
Maximum allowable pressure on branch pipe (Ph) barg
The proposed pressure test does not exceed the header maximum allowable external pressure or the
branch hoop stress pressure and is therefore acceptable.
Prepared by: Date:
Approved by: Date:
UKCSSOP024_012.ai
Figure 2 Calculation of Maximum Test Pressure (cont’d)

Addendum 7
Proforma Examples
Paragraph Page
1 Greater Forties Unit Terminal –

Hot Tap Proposal Approval Sheet 1
2 Greater Forties Unit – Hot Tap Data Sheet 1 2
3 Greater Forties Unit – Hot Tap Data Sheet 2 3

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Proforma Examples
August 2001 Issue 1 Add 7-i/ii
1 Greater Forties Unit Terminal –

Hot Tap Proposal Approval Sheet
HOT TAP PROPOSAL APPROVAL SHEET
Proposed Hot Tap of:
Job Reference:
Prepared by: Date:

Uncontrolled
This hot tap proposal consisting of: Hot Tap Data Sheet 1 Isometric(s)*
Hot Tap Data Sheet 2 Pressure Test Procedure*
Hot Tap Activity Sheet ELD*
Calculation of Maximum Test Pressure General Arrangement*
Location Drawing*
*Delete if not applicable
Has been reviewed and approved by the undersigned:
Approved by:
Ops Availability Team Leader: Date:
Integrity Co-ordinator: Date:
Offshore Installation Manager: Date:
Operations Team Leader: Date:
Copies of Approved Proposal to:
GFU HSE (TL)
UKCSSOP024_014.doc
Proforma Examples
2 Greater Forties Unit – Hot Tap Data Sheet 1
JOB REFERENCE: DRAWINGS
AREA: LOCATION:
TITLE:
KEY DATES: ISOMETRIC:
DATA HEADER BRANCH
Line number
Pipe material specification
Pipe size
Wall thickness (mm)
Uncontrolled
Pipe manufacture
Flange class (lbs)
Product
Design pressure (barg)
Normal working pressure (barg)
Design temperature (°C)
Normal work temperature (°C)
Insulation
Branch connection:
0
Valve type:
Branch orientation:
Design code:
Fabrication code:
Inspection code:
Weld procedure No:

270 90
Maximum cutting depth (mm):
Hot tap machine mode/type:
180
RESPONSIBLE PERSONNEL
Superintendent:
Notified Shift Supervisor:
Job Officer:
Engineer:
Site Supervisor:
Fabrication Contractor:
Installation Contractor:
Hot Tap Contractor:
UKCSSOP024_015.doc
Proforma Examples
3 Greater Forties Unit – Hot Tap Data Sheet 2

*JOB REFERENCE: .....................................................................................................
(1) NON-DESTRUCTIVE TESTING *Sections to be completed for Proposal

(a) Pre-installation
Weld Area +150mm either side MPI and ultrasonics
Hot tap area MPI ultrasonics By OIS
Longitudinal MPI
(b) Post-installation
Longitudinal welds Visual and MPI
Circumferential welds Visual and MPI
Weldolet weld Visual and MPI
Location of temporary fittings Visual and MPI
(2) CHECK ROUNDNESS OF HEADER PIPE

Header pipe roundness within specification. yes/no
Uncontrolled
The above examinations have been carried out and found to be acceptable.
JOB ENGINEER:..................................................................................... FOR PIB:..................................................................
DATE: .................................................................................................... DATE: ......................................................................
(3) PRESSURE TESTING
COMPONENT(S) TESTED PRESSURE (barg)* MEDIUM* DURATION
Branch and Valve
Branch, Valve and Machine
For calculation of test pressure effect on header refer to attached spreadsheet.

The above pressure tests have been carried out and found to be acceptable.
PIB: ......................................................................................................... DATE: ......................................................................
(4) HOT TAP MACHINE

(a) Certification: valid and correct pressure rating (d) Cutter and pilot bit: is secure
(b) Gland packing: in good condition (e) Coupon catcher: is suitable
(c) Bleed valve: from blockage (f) Machine support: Is adequate
(5) CONTROL OF HEADER PARAMETERS
PARAMETER MONITOR BY DURING WELDING DURING TAPPING
Contents
Pressure (barg)
Temperature
Velocity (m/s) Min Normal Max
Flowrate (m/hr)
The header parameters have been maintained in accordance with the above data.
JOB ENGINEER: ....................................................................................... FOR OPERATIONS:.................................................
DATE: ........................................................................................................ DATE: ......................................................................
UKCSSOP024_016.doc
Proforma Examples
# To be completed for Proposal

JOB REFERENCE: #
ITEM ACTIVITY INITIAL DATE
1 Clean header pipe and mark off hot tap location
2 MPI and ultrasonic weld areas
3 MPI and ultrasonic hot tap area
4* MPI longitudinal seam weld
5* Check ovality of header
6 Establish header
Uncontrolled
7* (a) Set and tack upper half of split tee
(b) Set and tack lower half of split tee
(c) Weld longitudinal seams
(d) Weld circumferential fillet welds
8* (a) Set and tack weldolet
(b) Weld weldolet
9 Inspect welds visually and MPI
10 Install valve and check centralisation
11 Pressure test hot tap assembly (refer to Pressure Test Procedure Sheet)
12 Remove temporary fittings and connections (ie thermocouples, etc)
13 MPI location of temporary fittings
14 Check hot tap machine certification and condition
15 Install hot tap machine onto assembly
16 Open valve and check clearance between cutter and valve
17 Pressure test assembly and hot tap machine (refer to Test Procedures)
18 Hot tap header
19 Retract boring bar and coupon into machine
20 Close valve and lock
21 Depressure hot tap machine to atmospheric pressure
22 Remove hot tap machine
23 Fit blind flange into valve
* Delete if not applicable
The hot tap operation has been completed in accordance with the above.
JOB ENGINEER: Date:
UKCSSOP024_017.ai
Proforma Examples

ukcssop024_iss1am01

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Hot Tapping Manual UKCS-SOP-024

Authorisation for Issue

2 Safety Consideration and Contingency Plan 1

4 Control of Header Flow Conditions 3

5 Fabrication, Welding and Installation 3

6 Inspection and Non-destructive Testing (NDT)

8 Hot Tap Operation 9

August 2001 Issue 1 i

Addendum 2 GFU Hot Tap Proposal Approval Sheet

Addendum 3 GFU Hot Site Preparation Sheet

Addendum 4 GFU Tap Data Sheet 1

Addendum 5 Sullom Voe Terminal – Hot Tap Data Sheet 2

Addendum 6 Method of Calculating Maximum Test Pressure

Addendum 7 Proforma Examples

ii August 2001 Issue 1

Authorisation for Issue

Position: Operations Delivery Team Leader, GFU

Position: OIM/Development Engineer, GFU

August 2001 Issue 1 iii/iv

For Audit Use

August 2001 Issue 1 v/vi

Issue No Date Description

hot tap contractor.

March 2002 Issue 1/AM01 vii/viii

Holders of Controlled Hard Copy

Copy Copyholder Location

01 Data Control Centre (DCC) ODL, Aberdeen

01 Document Issue Authority (John Watson)

March 2002 Issue 1/AM01 ix/x

Review and Update

August 2001 Issue 1 xi/xii

1.2 Approval of Hot Tap Procedures

• Delivery Area Team Leader

2 Safety Consideration and Contingency Plan

August 2001 Issue 1 1

2 August 2001 Issue 1

4 Control of Header Flow Conditions

5 Fabrication, Welding and Installation

5.2 Header Pipe Preparation

March 2002 Issue 1/AM01 3

WELDOLET WELD LINE

CLEAN AREA WITHIN CIRCLE

Figure 1 Weldolet Assembly

4 August 2001 Issue 1

5.3 Hot Tap Branch Installation

5.3.1 Weldolet Assembly

5.3.2 Split Tee Assembly

August 2001 Issue 1 5

Figure 2 Split Tee Assembly

ROOT GAP HEADER PIPE

Figure 3 Example of Weldolet Assembly

6 August 2001 Issue 1

Figure 4 Example of Split Tee

5.4 Installation of Hot Tap Valve

6 Inspection and Non-destructive Testing (NDT)

March 2002 Issue 1/AM01 7

HOT TAP AREA

MPI AND UT AREA WITHIN CIRCLE

Figure 5 Weldolet Assembly

8 August 2001 Issue 1

(2) Hot tap branch, valve and hot tap machine.

8 Hot Tap Operation

August 2001 Issue 1 9

10 August 2001 Issue 1