1.

TRABAJO MECANICO: Paso 1 Se realiza la fabricacin del spool en nuestros talleres de CONTA Santa Cruz, compuesto de un niple de 4 con una brida WN de 600 lista para ser montado a un cao de 4 u/o 8 pulg Traslado del material con Personal y equipos para realizar la intervencin en el campo bajo los siguientes actividades Soldado del niple a cao a intervenir dando la ubicacin exacta en la lnea, una vez soldado realizar la, verificacin de la soldadura con lquidos penetrantes o plaquetas de gammagrafa y dar el informe correspondiente una vez aprobado realizar el montaje de camisa de 4.

Montado de valvula de 4, Ubicacin de equipos y spool en el lugar demarcado para la intervencin, Armado del spool a lnea a ser intervenida Realizar el montaje de vlvula con sus respectivas empaquetaduras, posteriormente montar el cabezal de prueba para realizar la prueba hidrulica durante 4 hrs, para posteriormente recabar el informe correspondiente de aprobacin para luego montar el equipo centrado de hot tap descrito

2. TRABAJO INTERVENCIONDE HOT TAP: USO DE HOT TAPS PARA LAS CONEXIONES DE TUBERAS EN SERVICIO (Using Hot Taps for In Service Pipeline Connections) Resumen gerencial: Las compaas de transmisin y distribucin de gas natural necesitan hacer conexiones a las tuberas muchas veces al ao para expandir o modificar sus sistemas existentes. Histricamente, esto ha requerido sacar de servicio una porcin el sistema y purgar el gas a la atmsfera para garantizar la seguridad al momento de hacer la conexin. Este procedimiento, llamado interrupcin e interconexin, causa emisiones de metano, prdida de producto y ventas, molestias ocasionales a los consumidores y el costo de la evacuacin del sistema de la tubera existente. Existe un procedimiento alternativo llamado hot tapping el cual realiza la conexin nueva de tubera mientras la tubera permanece en servicio, con flujo de gas natural bajo presin. El procedimiento hot tapping consiste en adherir una conexin derivada y una vlvula a la parte externa de una tubera en funcionamiento, y despus se corta la pared de la tubera dentro de la derivacin y se quita la seccin de pared a travs de la vlvula. El uso de hot taps evita la prdida de producto, lasemisiones de metano y la interrupcin del servicio a los consumidores. Aunque esta tcnica no es una prctica nueva, el mejoramiento reciente de diseo ha reducido las complicaciones y la incertidumbre que los operadores experimentaban en el pasado. Varios participantes de transmisin y distribucin de Natural Gas STAR informan que usan los procedimientos de hot tapping rutinariamente, los trabajos pequeos se realizan casi diariamente mientras que los ms grandes (ms de 12 pulgadas) se realizan dos o tres veces al ao. Al realizar hot taps, los participantes de Natural Gas STAR han logrado reducciones de emisiones de metano y han aumentado los ingresos. Los ahorros de gas generalmente son suficiente razn para justificar el hacer todas las conexiones nuevas a las lneas en operacin mediante hot taps. El plazo de recuperacin de la inversin al usar hot taps con frecuencia es inmediato 2.1. Antecedentes tecnolgicos En los sistemas de transmisin y distribucin de gas natural, con frecuencia es necesario volver a colocar o expandir tuberas existentes, instalar vlvulas nuevas o reparar las viejas, instalar laterales nuevas, realizar el mantenimiento o tener acceso a lneas durante emergencias. Histricamente, ha sido una prctica comn sacar de servicio una porcin del sistema durante la reparacin, ventilar el gas que contiene el segmento aislado y purgar la tubera con gas inerte para garantizar la seguridad durante la conexin. Este procedimiento para realizar la interrupcin e interconexin difiere levemente dependiendo de la presin del sistema. En sistemas de alta presin, las vlvulas que los rodean se cierran para aislar el segmento de tubera y se colocan bloqueadores adicionales (tapones insertados) junto a las vlvulas para evitar las fugas de gas natural y mejorar las condiciones de seguridad en el lugar de la interconexin. En un sistema de baja presin, la longitud de la tubera que se sacar de servicio por lo general es mucho ms corta. En lugar de cerrar las vlvulas que se encuentran alrededor, los tapones se usan para aislar la porcin de la tubera que est directamente en el rea de la derivacin. En ambos casos, el gas en el segmento aislado de la tubera se ventila y la lnea se purga. Los efectos relacionados con la interrupcin de la interconexin son tanto econmicos como al medio ambiente. El gas ventilado del segmento de tubera representa una prdida de producto y un aumento de emisiones de metano. Adems, sacar de servicio un segmento de tubera puede en ocasiones causar interrupciones graves al servicio a

los consumidores. Por ejemplo, una conexin paralizada en una lnea de acero puede requerir de tres o ms das con la tubera fuera de servicio y la posible interrupcin de los embarques de gas natural adems de la liberacin de metano a la atmsfera. La tcnica de hot tapping es una alternativa que permite que se haga la conexin sin tener que sacar de servicio el sistema ni ventilar gas a la atmsfera. La tcnica de hot tapping tambin se conoce como intervencin de la lnea, intervencin de la presin, corte de presin y corte lateral. El proceso implica adherir conexiones derivadas y cortar agujeros en la tubera en funcionamiento sin interrumpir el flujo del gas, y sin liberar ni perder producto. Los hot taps permiten nuevas derivaciones en los sistemas existentes, la insercin de dispositivos en la corriente del flujo, desviaciones permanentes o temporales y es la fase preparatoria para el bloqueo de la lnea con tapones de globo temporales inflables (tapones). El equipo para realizar hot taps est disponible para casi cualquier tamao de tubera, materiales de tuberas y tasas de presin en los sistemas de transmisin y distribucin. El equipo principal para la aplicacin de hot taps tpicos incluye una mquina para taladrar, un accesorio de derivacin y una vlvula. El equipo de hot taps se describe ms adelante y se muestra en el Cuadro 1. Mquina para taladrar. La mquina para taladrar generalmente consiste en una barra giratoria o fija telescpica accionada mecnicamente que controla la herramienta de cortado. La herramienta de cortado se usa para producir un agujero piloto en la pared de la tubera para poder centrar una sierra perforadora que corta el cupn o la seccin curva de la pared de la tubera. Accesorio. La conexin a la tubera existente se hace dentro de un accesorio, el cual puede ser un simple tubo corto soldado para una conexin pequea (por ejemplo, una pulgada) a una tubera ms grande, o una T de manga dividida de envoltura completa para brindar apoyo adicional cuando la derivacin sea del mismo tamao que la tubera principal. La T se envuelve completamente alrededor de la tubera, y cuando se suelda, ofrece el refuerzo mecnico de la derivacin a la tubera portadora. Vlvula. La vlvula de la conexin hot tap puede ser una vlvula de bloqueo o una vlvula de control para una nueva conexin, y debe ser capaz de permitir que el cupn (la seccin de la pared de tubera cortada con una sierra perforadora) pueda quitarse despus de la operacin de cortado. Algunas vlvulas adecuadas incluyen las vlvulas de globo o compuerta, pero no los tapones ni las vlvulas de mariposa.

El Cuadro 2 ofrece un esquema general de un procedimiento de hot tap. Los pasos bsicos para realizar un hot tap son: Conectar el accesorio a la tubera existente con soldadura (acero), pernos (hierro fundido) o adhesiones (plsticas) e instalar la vlvula. Instalar la mquina de hot taps a travs de la vlvula permanente. Llevar a cabo el hot tap cortando el cupn de la tubera a travs de la vlvula abierta. Un dispositivo especial sostiene el cupn para quitarlo despus de la operacin del hot tap. Sacar el cupn a travs de la vlvula y cerrar la vlvula. Quitar la mquina de hot tap y aadir la tubera derivada. Purgar el oxgeno, abrir la vlvula y la conexin nueva estar en servicio.

VERIFICACION Y MONTADO DE EQUIPO DE HOT TAPS

VERIFICACION DE PRESION DE LINEA O EN SPOOL A INTERVENIR

INICION DE PERFORACION Y NIVELACION DE PRSERION EN PRUEBA: Se realiz la verificacin de presiones en lnea (con la subida de presin a 2500 psi), luego de perforado se ve la nivelacin en ambos manometros la subida de presin que se nivelan en ambos lados con una cada de presin muy pequea, luego se mantiene durante 2 horas para que no varen y no exista cada alguna por fugas.

Los hot taps pueden ser verticales, horizontales o en cualquier ngulo alrededor de la tubera siempre que exista espacio suficiente para instalar la vlvula, el accesorio y la mquina para hacer el hot tap. La tecnologa actual permite que las derivaciones se hagan en todo tipo de tubera, a todas las presiones, los dimetros y las composiciones, incluso en tuberas viejas que se fusionan a una nueva. Ahora se encuentran disponibles mquinas para realizar hot taps nuevas de peso ligero que permiten realizar el trabajo con un solo operador, sin bloqueo ni reforzamiento adicional. Los manuales de seguridad y las directrices de procedimiento estn disponibles a travs del American Petroleum Institute (API), American Society of Mechanical Engineers (ASME) y otras organizaciones para el soldado en tuberas en servicio de todos tamaos, tasas de flujo y ubicaciones. Esos manuales ofrecen informacin sobre qu considerar cuando se suelda, incluyendo la prevencin de aberturas por quemadura, el flujo en las lneas, el grosor del metal, los accesorios, el tratamiento de calor posterior al soldado, la temperatura del metal, la conexin hot tap y el diseo de la soldadura, y el contenido de la tubera y el equipo.

Los catlogos de equipo y los manuales del vendedor tambin son buenas fuentes para determinar qu tamao y tipo de equipo es el ms apropiado. Varios vendedores han publicado directrices globales y guas para realizar los procedimientos hot tap, incluyendo la informacin para la derivacin en varios materiales, la evaluacin y la preparacin del lugar de trabajo, la seleccin y la instalacin de accesorios y otro equipo, y las precauciones de seguridad. Lo ms importante, debido a que este procedimiento es peligroso, cada hot tap potencial debe evaluarse individualmente y debe prepararse o revisarse un procedimiento detallado y por escrito antes de comenzar cada trabajo para garantizar que se sigan todos los pasos correctamente y de manera segura. 2.2. Beneficios econmicos y para el medio ambiente Los beneficios clave econmicos y al medio ambiente al emplear los procedimientos de hot taps en lugar de conexiones con tubera fuera de servicio incluyen: La operacin continua del sistema se evita sacar de servicio la tubera y las interrupciones. No se libera gas a la atmsfera. Se evitan los cortes, la realineacin y volver a soldar las secciones de tubera. La reduccin del costo relacionado con la planificacin y la coordinacin, reuniones, programas, documentacin, produccin perdida y mano de obra directa. Seguridad mejorada para los trabajadores. Eliminacin de la obligacin de notificar a los consumidores de gas sobre las interrupciones de servicio. Al garantizar que se sigan las mejores prcticas cuando se realiza un hot tap, se reduce el tiempo necesario para realizar el procedimiento as como el potencial de que falle. Los operadores pueden evaluar los aspectos econmicos de realizar el hot tap como alternativa a la conexin con la suspensin del servicio siguiendo los cinco pasos siguientes: Paso 1: Determinar las condiciones fsicas de la lnea existente. En preparacin para realizar un proyecto de hot tap, los operadores necesitarn determinar la presin mxima de operacin (durante la realizacin del hot tap), el tipo de material de la tubera (acero, hierro fundido, plstico) y la condicin de la tubera principal (corrosin interna y externa, grosor de la pared) para garantizar la seguridad del proyecto. Una conexin de hot tap puede hacerse en una tubera solamente cuando el material de la tubera principal est en buenas condiciones. Otras condiciones que deben evaluarse incluyen la ubicacin de vlvulas cercanas de aislamiento de emergencia para casos en los que ocurra un accidente, el dimetro deseado de la derivacin, el espacio de trabajo alrededor de la conexin, la ubicacin de otras soldaduras de la tubera y las imperfecciones u obstrucciones. Los operadores tambin deben determinar si la lnea est en circuito, ya que muchas compaas de transmisin prefieren evitar perturbaciones de funcionamiento cambiando la carga a una lnea paralela. Se recomienda que se prepare y siga un plan por escrito para garantizar la evaluacin completa y adecuada de una conexin futura. Paso 2: Calcular el costo de realizar la interrupcin e interconexin. El costo de un proyecto real incluir los costos directos como los materiales y el equipo, los requisitos de soldadura, el control de calidad, los costos de purgado, la mano de obra y los gastos de programacin. Algunos gastos indirectos adicionales o costos ocultos pueden incluir el costo de las vlvulas de cerrado, la publicidad de qu servicio se interrumpir, reencendido del servicio de los consumidores, y las excavaciones y los tapones y las conexiones de purga. Se recomienda a los operadores que consulten los datos histricos para determinar estos costos. Para fines del alcance de este anlisis, los costos de materiales y mano de obra para cortar la seccin de la lnea y soldarla en una conexin en T con el mtodo de sacado de

servicio de la tubera se suponen que son comparables al costo de soldar el accesorio y realizar un hot tap cuando la conexin de derivacin sea del mismo tamao que la tubera. Sin embargo, el costo de la prdida de gas mediante la ventilacin y el purgado del gas inerte son nicos para el mtodo de interrupcin e interconexin. Las frmulas usadas para determinar el costo del mtodo de interrupcin e interconexin se muestran en el Cuadro 3. Para estos clculos, la presin baja se define como menor de 2 psig. Para fines comparativos, el clculo del costo del mtodo de interrupcin e interconexin debe tomar en cuenta un panorama con mltiples proyectos. Esta perspectiva de proyectos mltiples permite un anlisis comparativo ms completo dados los costos de capital iniciales de ser propietario y operar una mquina de hot taps y la necesidad de realizar varias interconexiones durante un ao dado. Cmo los clculos de costo pueden aplicarse a un panorama de conexiones mltiples. La situacin hipottica presentada incluye varios proyectos en tuberas de varios tamaos y presiones. Sin embargo, los clculos de costo, solamente se ofrecen en el caso de una tubera de 4 pulgadas y slo cubre los costos directos.

Hot Tap and Line Stops A guide for those who know very little, but who may have a need to know

By: Lindsey Lee PE, Principal Engineer, FLOWSERVE Industrial Services, 6330 Dixie Drive, Houston TX, 713-844-7656 Hot Taps and Line Stops are under pressure drilling operations , meaning that a pipe or other pressure vessel is drilled into, while the system remains in service, and under pressure. There are many reasons to do this, and by the same token, there are many good reasons to not do this, if a system can be shut down, in order to perform the drilling operation. A good example of a need to perform a hot tap, is to connect a service (for example a new homeowner needs water service connected to a system serving many others). Other people would be inconvenienced if the system were to be shut down, depressurized, connected, sanitized?, brought back online, all to connect one service. For this reason, it is very common to perform a hot tap. (A hot tap is commonly assumed to mean drilling into a pipe that is live, it may, or may not actually be hot). This paper was written as an aid, to those technical persons, who know little or nothing about hot taps and line stops. There are quite a few different publications, technical articles, manuals, and other printed matter that delve into the details of various aspects of hot taps and line stops, this short paper is intended to simply hit the high spots. Part I, Why go to all of this trouble? It is really a lot of trouble to perform a hot tap, or a line stop, but these operations provide us a tool to be used, to avoid shutting down a pipe system. In order to shut down a pipe system, it may be necessary to depressurize, purge, clean, inert etc. To bring the system back up, may take just as much work. For example, in an industrial process unit, shutting the unit down might take days, or longer, result in hundreds of thousands of dollars in lost production, and would impact other operations in the facility. For this reason, continuous operating systems, such as chemical process units, refineries, power plants, etc., shut down very rarely, for them, a hot tap, or line stop, is the only economical option. By the same token, if a city water system is shut down, as it loses pressure, contaminants could enter the system from groundwater, therefore, municipal water systems are also on and pressurized 24/7. In all of these cases, it is very desirable to remain in service, under pressure, and operating. Please note, Hot tapping and line stopping are both science, and art, the state of the industry is such, that there are as many unanswered questions, and items to still be determined, as there are hard fast answers. For example, at 1 ft/second, flow velocity, the coupon (section of pipe that is cut out), will generally not be pulled off of the pilot bit, with u-wires, to retain it. On the other hand, at 1000 ft/second, nothing that is currently available in the industry, would keep the coupon (or pilot bit for that matter), in place. For this reason, often the client will ask, is this flowrate too high, or can I go higher. There are also higher pressures, larger sizes, and many other areas to be developed in the art, sizes greater than 48 diameter for line stops, and 72 diameter for hot taps, become very rare, FLOWSERVE recently completed a line stop on a 60 water line in Columbia South America, at 150 psi, really stretched the limit on the available head, and the supporting equipment. Hot taps and line stops involve the use of specialized equipment and highly trained technicians, in order to cut a hole in a pipe, without taking the pipe out of service, or

lowering the pressure. This is most often done in Chemical Plants, Refineries, Power Plants, Manufacturing Plants, Nuclear Power Plants, or any other location, where loss of service, is not acceptable. This technical paper is intended to be a primer of the hot tap and line stop operation, primarily intended for those who have little if any prior knowledge of the process. This work is highly technical, requires years of training, highly specialized equipment, and should not be attempted without proper training and instruction. Part II, What is a hot tap. A hot tap in its simplest form, involves drilling or cutting a hole in an existing pipe, while the pipe is under pressure, and at operating temperature. For the reasons discussed above, someone wants to establish a new service to an existing pipe, it is not convenient or practical to take the system out of service, therefore a hot tap is required. For example, a process plant may use high temperature steam, as an integral part of its process. Shutting the steam line down might involve shutting one or more production units down, which could involve hours, days, or weeks of lost production, plus a considerable cost to bring the unit back up. The hot tap is performed, through the clients valve, the valve is closed, the hot tap machine is removed, then the client/owner hooks up to his new service connection. The Coupon, is the section of pipe that is removed, to establish service. It is very highly desirable to retain the coupon, and remove it from the pipe, and in the vast majority of hot taps, this is the case. Please note, short of not performing the hot tap, there is no way to absolutely guarantee that the coupon will not be dropped, but we can do a great deal to make this a very rare occurrence. Coupon retention is mostly the job of the u-wires, these are wires which run through the pilot bit, and are cut and bent, so that they can fold back against the bit, into a relief area milled into the bit, and then fold out, when the pilot bit has cut through the pipe, in almost all cases, multiple uwires are used, to act as insurance against losing the coupon, if the u-wires are in good condition, this normally works very well, the coupon is brought out, everything is fine. Here are some of the factors, which adversely affect coupon retention;

High Flowrate (can include both liquids and gases) Viscous fluids Bad U-wires Dirty pilot bit, such that the u-wires are not free to rotate out Pulling back out, after the pilot bit has passed through the cut (this has been done before, if a technician did not complete the cut, he pulls back, shearing off the u-wires, then runs the machine back down to complete the cut, with broken u-wires!).

Simply keep in mind, that no matter how hard we try, it is still possible to lose, or drop the coupon into the pipe, that is one of the inherent risks in hot tap and line stop operations. If it is not possible to risk losing a coupon, an alternative to hot tapping should be considered!

Part III, How do we perform a hot tap? A. Hot Tap Setup

For a simple hot tap, there are three major components necessary to safely tap into a pipe, the fitting, the valve, and the hot tap machine (which includes the cutter, and housing). The fitting is attached to the pipe, normally by welding. In many cases, the fitting is a full encirclement split tee, with a flanged outlet (See Figure 6). Onto this fitting, a valve is attached, and the hot tap machine is attached to the valve (see FIGURE 1). For hot taps, new studs, nuts, and a new valve should always be used, as the studs, nuts, and valve will become part of the permanent facilities and equipment. The fitting/valve combination, is attached to the pipe, and is normally pressure tested by the site owner. The pressure test is very important, so as to make sure that there are no structural problems with the fitting, and so that there are no leaks in the welds (it makes no sense to cut a hole in a perfectly good pipe, and to create a new leak in the system). The hot tap cutter, is a specialized type of hole saw, with a pilot bit in the middle, mounted inside of a hot tap adapter housing. The hot tap cutter is attached to a cutter holder, with the pilot bit, and is attached to the working end of the hot tap machine, so that it fits into the inside of the tapping adapter. The tapping adapter will contain the pressure of the pipe system, while the pipe is being cut, it houses the cutter, and cutter holder, and bolts to the valve. Key Points Hot Taps:

Client/Owner supplied valve Primarily to establish new service Can be size on size, or smaller hole cut into larger pipe New studs and nuts should be used to bolt on the valve, as it becomes part of the permanent installation

Figure 1, Hot Tap Stackup

B.

Hot Tap Operation

The Hot Tap is made in one continuous process, the machine is started, and the cut continues, until the cutter passes through the pipe wall, resulting in the removal of a section of pipe, known as the coupon. The coupon is normally retained on one or more u-wires, which are attached to the pilot bit. Once the cutter has cut through the pipe, the

hot tap machine is stopped, the cutter is retracted into the hot tap adapter, and the valve is closed. Pressure is bled off from the inside of the Tapping Adapter, so that the hot tap machine can be removed from the line. The machine is removed from the line, and the new service is established. (Figure 5 shows a detail of the cutter having cut through the pipe, on a size on size hot tap or line stop tap.) Part IV What is a Line Stop? Line Stops (sometimes called Stopples[1]) start with a hot tap, but are intended to stop the flow in the pipe. Line Stops are of necessity, somewhat more complicated than normal hot taps, but they start out in much the same way. A fitting is attached to the pipe, a hot tap is performed as previously detailed. Once the hot tap has been completed, the valve is closed, then another machine, known as a line stop actuator is installed on the pipe. The line stop actuator is used to insert a plugging head into the pipe, the most common type being a pivot head mechanism. Line stops are used to replace valves, fittings, and other equipment, once the job is done, pressure is equalized, and the line stop head is removed. The Line Stop Fitting has a specially modified flange, which includes a special plug, that allows for removal of the valve. There are several different designs for these flanges, but they all work pretty much the same, the plug is inserted into the flange through the valve, it is securely locked in place, with the result that the pressure can be bled off of the housing and valve, the valve can then be removed, and the flange blinded off. (See Figures 3 & 4, for more details) A. Line Stop Setup

The Line Stop Setup includes the hot tap machine, plus an additional piece of equipment, a line stop actuator. The Line Stop Actuator can be either mechanical (screw type), or hydraulic, it is used, to place the line stop head into the line, therefore stopping the flow in the line. The Line Stop Actuator is bolted to a Line Stop Housing, which has to be long enough to include the line stop head (pivot head, or folding head), so that the Line Stop Actuator, and Housing, can be bolted to the line stop valve. Line stops often utilize special valves, called Sandwich Valves. Line Stops are normally performed through rental valves, owned by the service company who performs the work, once the work is completed, the fitting will remain on the pipe, but the valve and all other equipment is removed.

FIGURE 2 - Valve, Pivot Head, Line Stop Housing and Line Stop Actuator Stackup

B.

Line Stop Operation

A Line Stop starts out the same way as does a Hot Tap, but a larger cutter is used,. The larger hole in the pipe, allows the line stop head to fit into the pipe. Once the cut is made, the valve is closed the hot tap machine is removed from the line, and a line stop actuator is bolted into place. New gaskets are always to be used for every setup, but used studs and nuts are often used, because this operation is a temporary operation, the valve, machine, and actuator are removed at the end of the job. New studs, nuts, and gaskets should be used on the final completion, when a blind flange is installed outside of the completion plug. The line stop actuator is operated, to push the plugging head (line stop head), down, into the pipe, the common pivot head, will pivot in the direction of the flow, and form a stop, thus stopping the flow in the pipe. C. Completion Plug

In order to remove the valve used for line stop operations, a completion plug is set into the line stop fitting flange (Completion Flange). There are several different types of completion flange/plug sets, but they all operate in basically the same manner, the completion plug and flange are manufactured, so as to allow the flange, to accept and lock into place, a completion plug. This completion plug is set below the valve, once set, pressure above the plug can be bled off, and the valve can then be removed.

Figure 3 Completion Plug, attached to boring bar, with ball check valve, and plug holder

Once the plug has been properly positioned, it is locked into place with the lock ring segments, this prevents plug movement, with the o-ring becoming the primary seal. Several different types of completion plugs have been developed with metal to metal seals, in addition to the o-ring seal.

Figure 4, completion plug in place , boring bar is released and retracted, the tapping machine can now be removed, as can the valve and holder, leaving a plug ready to be blinded to complete the job.

Key Points Line Stops:

Service Company supplied (rental) valve Primarily to stop flow in the pipe Higher pressure pivot head operations must be size on size, for lower pressure applications, a folding head may be used, subject to pressure and service limitations. Should use new studs and nuts to bolt on blind flange, may want bleeder on blind flange.

Part V Safety considerations Job Planning In almost all situations, basic hot tap and lines stop operations involve cutting a hole in a pipe, or other pressure vessel, which is at operating temperature and pressure.

There are two significant and quite different job planning operations, both must be completed prior to starting the hot tap. The first planning operation, is often part of a Job Safety Analysis (JSA), which should include the site owner, his technical personnel, and the service company selected to perform the work. This process must include all applicable safety considerations, including but not

limited to pressures, temperatures, pipe/tank contents, safety, and environmental issues (are special arrangements necessary for pressure bleed off, for example oil/gasoline verses steam or water). Once the JSA is completed (prior to putting the fitting on the line, or mobilizing equipment), the decision to go ahead with the job is made. When the job is definitely a go, a fitting is welded onto the pipe, equipment/personnel are mobilized to the site, then it is time for the second job planning operation, normally starting with a safety discussion. The job should then be planned out as to who will do what, and when. The job calculations are also completed at this time, for example, the travel necessary to complete the cutout of the coupon, and not drill through the backside of the pipe (drilling through the opposite side of the pipe, can result in a complete shutdown of the unit, explosions, fire, injuries, even including fatalities, so this possibility should never be discounted!).

Part VI. Hot Tap and Line Stop Cutters For small holes in pipes, a common drill bit is commonly used, (up to nominal two inch diameter holes). For sizes above one inch, hot tap and line stop cutters are essentially specialized hole saws. The hole saw is held in line for the cut, by a pilot bit (modified twist drill bit, or specialized pilot bit). The pilot bit also normally has one or more uwires, which are set in the bit, and go in, but do not come out, so as to retain the coupon on the cutter/pilot bit assembly. Figure 3 is a small cutter setup, Figure 4 is a larger cutter pilot setup for larger machines.

Figure 3, Cutter holder & pilot bit, & assy, small setup (FLOWSERVE/IPSCO IP-100)

Figure 4, cutter, holder, and pilot for a large machine, (FLOWSERVE/IPSCO IP 914), illustrating holder, cutter, pilot bit with u-wires, and socket head cap screw bolts and lock-nuts. Variations in cutters include carbide or tool steel cutter teeth, the design/profile of the teeth, pass-through holes in the cutter barrel, number of teeth, and the overall geometry of the cutter holder connection points. Cutters used to cut through tanks, or blind flanges have significantly less teeth, than cutters used for conventional hot taps/line stops. In order to understand how pipe cutters are designed, and to understand their sizes, it is important to review pipe sizes, what is referred to here, as nominal, and actual cutter dimensions. Nominal sizes refer to the approximate inside diameter of the pipe, for example, a 2 (nominal) pipe has an outside diameter of 2.375 (2 3/8), with the most common size or schedule (schedule 40), having a 0.154 wall thickness, with an ID of 2.067. Thinner pipe (lower schedule number) has a larger ID, thicker pipe (higher schedule number), has a smaller pipe ID. Since a line stop head must enter the pipe, and since the head must pivot and then seal, a line stop cutter is normally a larger OD cutter than is a hot tap cutter, on smaller sizes (up to nominal 16 inch), there are actually two different sizes of cutter, the smaller OD cutter is the hot tap cutter, the larger OD cutter is the line stop cutter. Line stop valves must also have a larger ID, and be full port, since the cutter has to be able to pass through the valve. For hot tapping, there should be a minimum of 1/8 diameter difference between the full port ID of the valve, and the OD of the cutter, so as to not jam a cutter as it advances through the valve.

Pipe OD

HT Cutter OD 3 1/2 4 1/2 6 5/8 8 5/8 10 3/4 12 3/4 14 16 18 20 22 24 26 28 30 32 34 36 2.438 3.438 5.469 7.312 9.500 11.500 12.750 14.688 15.062 17.000 19.000 21.000 23.000 25.000 27.000 29.000 31.000 33.000

Table 1, common sizes of hot tap, and line stop cutters LS Cutter OD

3.938 5.938 7.875 9.875 11.812 13.062 15.062 17.000 19.000 21.000 23.000 25.000 27.000 29.000 31.000 33.000 35.000

Figure 5, cutout detail of a hot-tap/linestop cutter going through the pipe

Part VII Fitting Selection and design considerations

There are many different considerations on selecting hot tap and line stop fittings, the simplest form of a hot tap fitting, is a simple flanged nozzle, which is welded to the pipe. Keep in mind that there are serious engineering considerations as to what should be put onto the pipe, for example, even a simple small hot tap on a large pipe (cutting a two (2) inch hole in a twelve (12) inch line for example), removes some of the run pipe, resulting in a loss of cross sectional area, plus adding stress concentrations to the equation. It is always necessary to perform an engineering evaluation of the system, so as to determine the correct type of fitting, so as to prevent pipe failure, during, or after the cut. As a minimum, an area replacement calculation should be run, in accordance with applicable code standards, so as to assure that the pipe is sufficiently reinforced by the fitting, prior to cutting a hole in the pipe. Common weld-o-lets, are sized, so as to provide enough material, so that allowable pipe stresses are not exceeded as a result of the hot tap. For many applications, it is necessary to use a full encirclement fitting, such as is illustrated in Figure 6.

Figure 6, Typical Full Encirclement Hot Tap Fitting, with flange. In most cases, the fitting is welded onto the pipe in the location desired for the new service. The ends of the fitting are welded to the pipe, the run seam is also welded together, the inside of the hot tap nozzle is never welded, as this would result in severe cutter damage, an unsuccessful cut, and a very dangerous situation. Weld material is usually stronger and harder than the base material, a cutter would be seriously damaged,

were the area to be backwelded, prior to making the tap (backwelding refers to welding a bead inside the nozzle part of the fitting, right where the cut is to be made, backwelding will often destroy a hot tap cutter!). A full encirclement fitting will do a couple of things that a simple nozzle will not, it will assist to re-round thin-walled pipe, that may not be round, it will handle the horizontal stresses that the line stop head will place on the pipe, it will also handle the bending stresses applied by the line stop head. For all of these reasons, it is generally much safer, to use a full encirclement fitting on hot tap and line stop operations. Hot Tap and Line Stop Fitting Design Codes for Hot Tap Fitting Designs ASME B 31.1 for Power Piping, is primarily for power plant design, fittings are tested to 1.5 times design pressure ASME B 31.3 for Process Piping, is primarily for chemical plants, refineries etc. ASME B 31.4 is for liquid pipelines, for transportation of fluids ASME B 31.8 is for gas transmission, and distribution systems. This paper will not go into a great deal of information about design code specifics, other than to mention that the design of the fitting(s) must comply with the applicable design code. Part VIII Odd Jobs The following are different types of jobs, all can be done, all have been done, but all require specialized equipment, procedures, and planning. Across the line stop is a method of cutting a hole in the pipe, and inserting a plugging head directly in the line, so as to stop the flow into a stub-out or nozzle directly below the hot tap cut. For example, to change out a valve on a drain on the bottom of the pipe, a nozzle or weld o let is installed on the top of the pipe, a hot tap is made through the valve, a special head is lowered and seals against the opposite pipe wall, allowing for removal of the drain valve Angle Taps, are hot taps made at an angle different from 90 degrees to the flow direction of the pipe. On all angle taps, the cutter is often much longer than on conventional taps, and an angle tap boss is normally used, to allow the pilot bit to drill directly into the pipe at 90 degrees, so as to prevent damage to the pilot bit, housings, valve, and pipe, resulting from the side loads placed on the bit, but the angled pipe. Bag Stop is a process, whereby a small hot tap is made into a pipe, and an inflatable pipe plug is inserted into the pipe, so as to allow the plug to stop the flow in the pipe. This system is a bit risky, and is limited to very low pressure applications, limited by the pressure limit of the inflatable plug, small diameter systems up to about 75 psi max, larger ones, are limited to single digit pressures (under 10 psi).

Elbow Taps and Stops are taps, and sometimes line stops, done through a pipe elbow. This is only done, if it is not possible to use a straight run of pipe, as it requires a special type of fitting, and a specially modified cutter. High Temperature and/or High Pressure Stops are any hot tap, or line stop with pressure temperature combinations that would exceed the standard ANSI Class 600 pipe systems, or any temperature of the system exceeding 400 degrees F. There are many different methods of stopping flow in high temperature and/or high pressure applications, but the normal pivot heads for line stops, and stock hot tap machines, are not rated to these pressures, so specialized equipment is used here. Permanent Stop is a process of using a modified line stop head, or FLOWSERVEs Perma-Stop system, to permanently seal off the end of the pipe, for example, if a client wants to abandon a section of pipe, a fitting is welded onto the pipe, and a permanent plug is placed in the line, allowing the pipe downstream of the plug to be cut off, and abandoned. Part IX Conclusions The purpose of this paper, is to offer an insight into the area of hot taps and line stops. This paper is not intended to address all possible engineering issues with hot taps and line stops, rather, it is intended to provide a basis for discussion of the most important considerations of hot taps and line stops. The paper should serve as a starting point in an engineers education as to the many facets of hot taps, line stops, and other similar and related under pressure operations. Service companies who routinely perform hot taps and line stops, are a good source of information about these operations, they should be brought in early, to discuss feasibility of a particular operation, estimated costs, and design considerations associated with the proposed operation. Bigraphical; Lindsey Lee PE

I am Operations Manager, and Principal Engineer for FLOWSERVE Online Services, Houston TX. This is an industrial Services Company, does hot taps, line stops, onstream leak repair, concrete repair, field machining, and other specialty service work. FLOWSERVE/IPSCO also manufactures and sells hot tap and line stop fittings, and a complete line of equipment. At this location, I oversee much of the project engineering, equipment modification, and fitting design, as well as supervise the crews locally who do the work. I started my professional career with Halliburton, worked for both Halliburton Services, and the Brown & Root side of the company, as well as several other service companies prior to joining FLOWSERVE two years ago. I have a couple of patents from my Halliburton days, several published articles, I write/edit operations manuals, job procedures, and technical documents dealing with this work. I am a licensed mechanical engineer, based in Houston TX

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0,24 0,22 0,20 0,18 0,15 0,13

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Services Services

ne Plugging

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Process Flows

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Vacuum Gauge installation

ne construction

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allations

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ps for flow meters

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ure indicators

Hot Stop Services

ration requires

A hot tap is made on thepipe through the valve

sealing

element

is

selected for compatibility based on the process, pressure and temperature The line stop machine is attached to the valve The line stop head seals and isolates the section of pipe

fitting the pipe

is

The coupon is retained byU-wires on the pilot drill The hot tap machine

g is pressure

andcoupon are removed The valve is closed

is installed

Pressure

is

line stop head

SealTite set and locked

bolts removed

is

t a future date

e is installed

Stops Elbow Stop Across-The-Header-Stop

alve-Stop

non-functioning

A special SealTite fitting is installed to the elbow permit

Applicable clearance limitation line does normal

when not stopping

d vessels machine is

An

angle

tap

is

ting valve

performed on the elbow through a temporary valve The line stop is set and the defective valve replaced SealTite completion plug is set and the temporary valve removed

methods A is installed A hot tap is made and the plug is set When the repairs are complete the SealTite completion SealTite fitting is

aged valve is new valve

welded to the header and a valve

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SealTite fitting

backside of the

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And Bleed

Tite fittings are welded to the line

y valves are installed and two line stop taps completed

ne stops are set and the pressure is vented downstream of both line stops

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downstream is completed

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Linestop

m Class 150# - 48, 66, 72, 78

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n plug offers greater sealing strength with its metal-tometal seal

g provides an additional safety for the completion plug

ands are located on the SealTite Flanges recessed jack bolts

SealTite completion plug eliminates potential check valve leaks

Flanges can be safely utilized to re-enter the line at high temperatures and pressures

Flanges can be rebuilt online

completion Flanges are available in stock for 150#, 300#, 600# and 900# flange ratings. 1500# and 2500#

available on request

nd fitting with metal plug

SealTite Completion Plug

SealTite Flange Completion Plug (Note recessed jack screws)

red 150# and mperature/high ite Completion vailable upon

Line Plugging / Line Stop

Line plugging / Line stop is a method of temporarily isolating and bleeding down part of a pressurized system, for purposes of alteration or maintenance within the isolated section. This is done without shut down of the entire system and without loss of product. If flow must be maintained, a temporary or permanent bypass can be installed around the isolated work section.

Topaz is currently equipped for the following: Low pressure Line plugging / Line stop: 1" through 48". 60 PSIG Maximum pressure @ 100F. 250F. Maximum temperature @ lower pressures High pressure Line plugging / Line stop: 2" through 16". 900 PSIG Maximum pressure @ 100F. 350F. Maximum temperature @ reduced pressures. In addition to extreme pressure and temperature conditions, Topaz is experienced with applications involving particularly volatile, corrosive, and toxic products.

Fittings and valves: Topaz maintains a large inventory of completion style fittings in common sizes and flange ratings for use in low and high-pressure line plugging services / line stop applications. These specialty fittings allow us to work through temporary valves, which Topaz provides, during the plugging operation. Once the repair or modification within the isolated work section is finished, we secure an o-ring sealed metal plug in the fitting below the temporary valve. Pressure is then bled off above the plug, the valve is removed, and a blind flange is installed on the fitting to complete the job. If necessary, line plugging / line stopping work can also be performed through permanent valves and standard hot tap fittings. When plugging through permanent valves, contact Topaz for required bore diameters and overall fitting and valve dimensions prior to welding.

Information we require for line plugging services / line stopping services: section. Size of bypass, if required. Scope of alteration or maintenance while line is plugged. Orientation of the line and required fitting orientation. Nominal size of the line. Will line be plugged on one end or both ends of isolated section? Material and wall thickness (schedule) of the line. Product in the line. Operating pressure and temperature. Maximum possible pressure and temperature while line is plugged. Blowdown and equalization provisions for depressuring and repressuring of work