HOT TAP WELDING

HOT TAP WELDING

A CONSULTANTS
A CONSULTANTS
PERSPECTIVE
PERSPECTIVE
ENGINEERING RISK
ENGINEERING RISK
ASSESSMENT
ASSESSMENT
! must be conducted by the owners
engineering department and should include:
- hot tap welding pressures and flow rates
- potential for hydrogen cracking
- potential for burn-through
- mainline pipe condition (i.e. corrosion,
laminations, segregation)
- identification of mainline C.E.
CLARIFICATIONS
CLARIFICATIONS
! companies hired to prepare Hot Tap Welding
procedures typically do not perform
engineering risk assessment or reinforcement
calculations
! the application of the qualified welding
procedure is the sole responsibility of the
owner!!
! mainline & branch size, thickness & grade
! C.E. of mainline and branch
! mainline pressure during welding
! product type (i.e. oil, gas etc.)
! product flow rate during welding
! sweet or sour product
! cooling rate from 250 100C
INFORMATION REQUIRED
INFORMATION REQUIRED
TO START PROCEDURE
TO START PROCEDURE
QUALIFICATION
QUALIFICATION
! can be determined by using one of the
following methods:
1.) portable spark spectrograph
2.) obtaining chip samples from the location
where the branch is to be welded.
! portable spark spectrography has the
advantage of providing immediate results but
is much more costly
MAINLINE C.E.
MAINLINE C.E.
DETERMINATION
DETERMINATION
- identify some pipe in the bone yard with
potential for use in the procedure qualification
and have it analyzed at the same time.
! chip samples must be removed from the area
of branch connection attachment and sent to
a laboratory for analysis.
- pipe must be cleaned to bare metal to avoid
sample contamination.
! chemical analysis must include all of the
elements required by the CSA Z662 CE
formula.
! will not be required for all hot tap applications
! is mainly applicable to the following
conditions:
- mainline pipe with thickness less than
0.188
- liquid product lines
- mainline pipe with elevated C.E.
! can be determined using the Edison Welding
Institute 2 spot test method.
COOLING RATE
COOLING RATE
DETERMINATION
DETERMINATION
! The Edison Welding Institute spot test is
conducted by cleaning a 3 diameter circle to
bare metal. A 2 diameter circle within the
cleaned area is heated to approximately
300C with a rose bud heating torch. Using a
calibrated thermocouple or infrared
thermometer, measure the time of cooling
from 250-100C. Repeat the procedure two
or three times to ensure repeatability.
EWI SPOT TEST
EWI SPOT TEST
! Is divided into four unique stages as follows:
1.) Feasibility Study
2.) Test Material Selection & Procurement
3.) Laboratory Modeling and Welding
4.) Mechanical Testing & Write Up
! Feasibility Study
- the information provided will be assessed
using computer modeling and accumulated
experience to evaluate the potential for
success
PROCEDURE
PROCEDURE
QUALIFICATION
QUALIFICATION
! Test Material Selection & Procurement
- materials which have chemical and
mechanical properties which closely match
that of the mainline and branch materials will
be acquired
! Laboratory Modeling and Welding
- test coupons will be assembled to simulate
the pressures and cooling rates used for the
actual hot tap
- welding will commence using techniques
which will maximize the chance of success
- it is recommended that the owner and
contractor maximize their involvement during
this phase. The knowledge obtained during
the welding of the procedure test coupons will
be beneficial during the actual hot tap
operation
! Mechanical Testing and Write Up
- test results will provide conclusive data
regarding the success of the procedure
qualification
- includes both technical and workmanship
acceptance criteria making the welder skill
level significant
! welder training is essential for successful
procedure qualification and the actual Hot
Tap welding
! training should include the proper application
of weld passes using the welding variables
selected for procedure qualification.
! it is also a requirement of the CSA Z662
Code that the welder be instructed on the
avoidance of hydrogen induced cracking.
WELDER TRAINING
WELDER TRAINING
! Engineering Assessment
each Hot Tap situation should be considered
unique.
grouping of different pipeline systems is possible
providing that the essential variables of the
welding procedure and engineering critical
assessment remain valid.
! Carbon Equivalent
the C.E. of the mainline, branch or reinforcing
saddle must be determined and verified to comply
with the WPS prior to welding.
HOT TAP PREWELD
HOT TAP PREWELD
REQUIREMENTS
REQUIREMENTS
! Nondestructive Testing
full scan Ultrasonic Testing will verify the wall
thickness of the mainline pipe and identify any
subsurface indications such as corrosion pits,
cracks and laminations. Magnetic Particle
inspection will identify surface indications.
Nondestructive Testing procedures must be
developed by the NDT subcontractor and should
be reviewed and approved by the project engineer
! Welder Training
practice welds of similar configuration should be
conducted while ensuring adherence to the
welding variables listed on the procedure
! CSA Z662 requires that fillet welds including
branch connections are magnetic particle
tested for defects, and where practicable
ultrasonic tested.
! a time delay of not less than 48 hours should
be included between the completion of the
fillet weld and the commencement of it
nondestructive inspection
HOT TAP POSTWELD
HOT TAP POSTWELD
REQUIREMENTS
REQUIREMENTS
! the minimum wall thickness qualified will be
the wall thickness used for the procedure
qualification
! welding electrode diameter will be restricted
to the diameter used during procedure
qualification
! welding amperage and voltage are set point
values rather than qualified values +/- 20%
Restrictions not covered by
Restrictions not covered by
the Z662 Code
the Z662 Code
! involvement of the owners engineering department is
necessary
! participation of the welding and supervisory
personnel is essential
! the limitations placed on the hot tap welding
procedure make it very restrictive and should be re-
evaluated for each project
! welder and supervisory personnel training is critical if
a good chance of success is to be maintained
! it is more beneficial for the owner to develop their
own hot tap procedures.
SUMMARY
SUMMARY