Pipeline Integrity, Hot Tapping & Plugging Seminar Sol Elite Marbella, Anyer 10 May 2007 Hot Tapping & Plugging Gunavel Rathinam Regional Sales Manager AGENDA • • • • • • • Objective Basic Concept Associated equipment Fitting Specification Large Diameter stopple MTM Hitemp stopple Strength / Q & A What is HOT TAPPING? Hot Tapping Is an Operation to an opening into a pressurised pipe, tanks conveying a product without having to shut down the process. PURPOSE OF HOT TAPPING z TO GAIN SAFE ACCESS TO THE PIPELINE CONTENTS : ¾ FOR DELIVERY TO ANOTHER SOURCES z TO ACCEPT ADDITIONAL PRODUCT FROM A NEW OR UNTAPPED SOURCE z TO OBTAIN INFORMATION ON INTERNAL PIPELINE CONDITION z TO INSTALL : ¾ PIG SIGNAL ¾ CORROSION PROBE OR COUPON ¾ CHEMICAL INJECTION POINT ¾ SAMPLING POINT z TO CREATE A BYPASS z TO ALLOW INSERTION OF LINE PLUGGING EQUIPMENT (STOPPLE) The Hot Tapping Process Tapping-Maintaining the Coupon: Hot Tapping Applications What are the Typical Setups? Hottap Operation HOT TAPPING DATA SHEETS Why is a Tapping data Sheet required? Ensure Correct Equipment is used. The Pipeline conditions are considered for Hot Tapping & STOPPLE Applications ® Flow conditions are considered for Pilot drill Selection. The correct Cutters & Pilot drills are used for Pipe O.D & Valve I.D. Hot Tap Data Sheet Valve Size (Inches) Flange Series ( # ) Line Size Pipe Material Wall Thickness (inches) Product Pressure ( Psig ) Temperature (Deg C) Velocity (m/s) Wall Thickness-Branch Orientation of line : A & B Dimension - Size of hottap Pressure rating of equipment Type of cutter & Pilot Drill Type of cutter Type of cutter and model of machine Packing of machine Pressure rating of machine Temp rating of machine Coupon retention Size of cutter Horizontal / Vertical Travel of machine What is STOPPLE? Temporary plugging to isolate section of a pipeline without interruption of flow or without pipeline shutdown PURPOSE OF STOPPLING z TO REMOVE A SECTION OF THE PIPELINE TO INTRODUCE AN EQUIPMENT OR VALVE INTO AN EXISTING PIPELINE z z TO RE-LOCATE / REROUTE AN EXISTING PIPELINE SECTION z TO CREATE A BYPASS Hottap & Stopple Plugging STOPPLE® Plugging is the process of inserting a plugging head into a pipeline to temporarily isolating a section of pipe while diverting the product flow using a bypass installed around an isolated section. So that repairs, modifications, installation or relocation of essential piping systems can be accomplished, on stream WITHOUT SHUTDOWN. STOPPLE OPERATION Stopple Plugging How Does the Plug Work? Folding Plugging Head Plugging Head Bypass/Stay On-stream Why Tap and Plug? • • • Pipeline Repair Valve Installation/Replacements Tie-ins Pipeline Plugging How is the Completion Plug Set? LOCK-O-RING Plug COMPLETION OPERATION HT&P Equipment Quality Service Requires Quality Equipment: Stopple Equipment & accessories Consist 5 major Components : • Hottap Machine • Sandwich Valves • Hydraulic Cylinder & Housing • Plugging Head & Sealing element • Stopple Fitting Hottap Machine & Sandwich Valve • Tapping machine • Sandwich Valves Tapping Machine Specifications Maximum Operating Pressure 1480 psi @ 100° F Maximum Operating Temperature 700º F at 700 psi Boring Bar Travel 9 T101 = 18” ( ¾” ~ 4”) 9 660 = 42” ( 3” ~ 12”) 9 760 = 66” ( 3” ~ 16”) 9 1200 = 72” ( 12” ~ 30”) 9 1200XL=102”( 12” ~ 48”) Rate of automatic feed 9 T101 – Manual Feed 9 660/760 – Standard .005"/rev. – Slow Feed .003"/Rev 9 1200 – 0.4” / Rev Power Sources = Air motor or Hydraulic Power Accessories Cutter Type of cutter 9 Standard cutter 9 Stopple cutter 9 Tank cutter 9 Special angled cutter Pilot Drill Centering pin for cutter Coupon retention devices Multi U-wire Pilot drill Stopple Plugging Equipment • Hydraulic Cylinder & Housing • Plugging Head & Sealing element • Stopple Fitting Stopple Fitting HIGH PRESSURE FITTINGS Well designed, engineered and manufactured Wide variety of fittings available Designed, tested and manufactured to be used on pipelines operating under various codes – ASME B31.8, ASME B31.4, ASME B31.3, DOT Part 192 and 195 and comparable international codes Material certificates available Weldability assured Installation instructions with each fitting HOT TAP FITTING VARIATIONS Stopple Fitting Lock-O-Ring Flange & Plug T-O-R Fitting Assembly Subsea Mechanical fitting & Spherical fitting 3- Way fitting Type of fitting DESIGN CODES ANSI B 31.3 – Chemical plant & Petroleum Refinery piping ANSI B 31.8 – Gas Transmission and Distribution piping System ANSI B 31.4 – Liquid Petroleum Transportation piping System ANSI B 31.1 – Power Piping CONSTRUCTION CODE INFORMATION ASME B31.1 ( POWER PLANT ) 1) Power Piping 2) Allowable SMYS based on temperature 3) Temperature Range minus 20 degrees F to the plus limits of listed materials 4) PWHT is required when the Governing Thickness exceeds 3/4 inch, or 1 inch if a 200 oF preheat is used. (Table 132) CONSTRUCTION CODE INFORMATION ASME B31.3 ( REFINERY, TOPSIDE, HPI ) 1) Process Piping 2) Allowable SYMS based on temperature 3) Temperature Range plus and minus limits of listed materials 4) PWHT is required when the Governing Thickness exceeds 3/4 of an inch. (Paragraph 331.1.3) CONSTRUCTION CODE INFORMATION ASME B31.4 1) Pipeline Transmission Systems for liquid Hydrocarbons and other Liquids 2) Design factor .72 3) Temperature Range -20 to +250 degrees F. 4) PWHT is required when the Governing Thickness exceeds 11/4 inches, or 1-1/2 inches if a 200 oF preheat is used. Joints qualified at as-welded thickness may be exempt. (Paragraph 434.8.9(a)) CONSTRUCTION CODE INFORMATION ASME B31.8 1) Gas Transmission and Distribution Piping Systems 2) Design factors based on locations classes, .72, .6, .5 and .4 3) Temperature Range -20 to +450 degrees F with temperature derrating factors above 250 degrees F. 4) PWHT required when the Governing Thickness exceeds 11/4 inches. (Paragraph 825.2) DESIGN FACTOR Design Factor is a way of discounting material strength for Safety Consideration. The smaller the Design Factor value the more conservative the design. Thickness = Pressure x Diameter / 2 X Mat. Strength X DF DF - CHART DESIGN FACTOR 0.72 0.60 0.50 0.40 MAWP (PSI) 1480 1230 1025 820 Method of Pipeline Expansion and modification Conventional Method = Shutdown Best Way = Hot Tap 1) High cost of throughput loss 2) Contractual requirements to pipeline customer 3) Loss of expensive product 4) Environmental issues 5) Wait till next shutdown period 1) Solve maintenance problems at minimal cost with no shutdown or spillage 2) Reduce Environmental impact/ hazardous with very little drain down or refill 3) No loss of expensive product 4) Well proven, safe and common technique Benefits of Hot Tapping & Plugging ;No Shut down to plants or Piping Systems ;Time Saving ;Minimum Personnel Required ;Money Saving EXAMPLE : 10” Natural Gas Tie-in into existing system in Gas Separation Plant Location : Gas Separation plant Plant Capacity : 230 mmscfd Duration of work : 7-10 days Production : US$ 100,000.00/day Conventional Method 1) Loss of production = $100,000/day * 10days = $1,000,000 2) Loss of Product ( NG) 3) Contractual penalty from customer 4) Environment & Safety issue 5) Increase in Operation cost EXAMPLE : 10” Natural Gas Tie-in into existing system in Gas Separation Plant Location : Gas Separation plant Plant Capacity : 230 mmscfd Duration of work : 7-10 days Production : US$ 100,000.00/day TDW Way(on stream w/o shutdown) 1) No loss of production / product = Save $1,000,000 2) No contractual penalty from customer = $$$ 3) No Environment & Safety issue Well proven technology 4) Overall project cost at less than anticipated Mitigate Your Risk – Stay Online The greatest percentage of accidents in plant and refineries happen when bringing the system back online. This risk associated with igniting the burners after shutdown is costly in three ways : - Cost of being offline - The cost to human life - Cost of rebuilding, both the facility and reputation for safety. Thank You Your Source for… Global Pipeline Solutions
