MEGA-STEAM ENGRG PTE LTD Prepared By : Johan

Rev. : 01
Method Of Statement
Effective Date : 01- Apr -17

Title : Hot Tapping at Plant Condensate Line

1 Permit Application:

1.1. Prior to start of work a Permit to Work shall be applied.

1.2. Work can only start upon the permit approval.
1.3. A layout indicating the location of Hot Tapping shall be submitted with
the permit application.

2 Prior to start work preparation:

2.1 All workers involved are to attend the daily toolbox meeting prior to
start of work.

2.2 When there is a need for scaffold, ensure the scaffold used is clean,
certified and endorsed by scaffold supervisor.

2.3 Make sure all ladders, electrical tools, PPE are certified and checked
by Safety supervisor prior to start work

2.4 Site inspection to be carried out prior to work starts to ensure the
other trade that around us and ensure safety for others

2.5 Barricades and signage to be put up at working area.

2.6 Materials brought to site shall be properly placed and barricaded.

3 Hot Tapping Procedure

3.1. Verify, with the Client, conditions are accurate and as stated on the
approved layout piping drawing and machine position drawing. (Refer
to the attached drawing for pipe and machine position).

3.2. The existing condensate line (about 80C) is covered properly to

prevent scalding.

3.3. The hydrostatic test is to be done for hot tapping nozzle before do hot
tapping and witnessed by the Lonza host.

3.4. Ensure there is no drop of pressure for the hot tapping nozzle.

Page 1 of 6
MEGA-STEAM ENGRG PTE LTD Prepared By : Johan

Rev. : 01
Method Of Statement
Effective Date : 01- Apr -17

Title : Hot Tapping at Plant Condensate Line

3.5. The full port gate valve is installed at the nozzle and prepares the
tapping machine to drill the line.

3.6. The Lonza incharge person monitor and present at all time during hot
tapping process.

3.7. All pre-assembled joints must be checked and ensure for integrity.
Note : The Technician is required to inspect the hot tap
machine, cutter size, pilot length and verify all measurements before
beginning the hot tap.
Note : Verify all equipment checklists pertaining to the hot
tap are complete. Place your initials in the column marked "Field" to
indicate verification the item is completed satisfactorily. Occasionally,
the Technician will initial both locations.

3.1. Confirm the customer has pressure tested valves and fitting.

3.2. Verify operation of the service valve.

3.3. Verify the valve is aligned to the I.D. of the fitting and the gate clears
the bore of the valve.

3.4. Inspect the valve and fitting for foreign materials, proper operation
and bore size

3.5. Verify the gasket does not protrude into the bore.

3.6. Verify the fitting is not back welded.

3.7. If working through any fitting other than a split tee, verify the fitting
centerline is in line with the run pipe centerline and the fitting is
square to pipe.

3.8. Verify the tapping machine has sufficient travel to complete the tap.

3.9. Install the hot tap machine and gasket, centering it to the valve.

3.10. Tighten the flanges following the appropriate torque sequence.

3.11. Tighten all studs in the proper sequence. Torqueing is recommended

for studs 11/4" and larger.
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MEGA-STEAM ENGRG PTE LTD Prepared By : Johan

Rev. : 01
Method Of Statement
Effective Date : 01- Apr -17

Title : Hot Tapping at Plant Condensate Line

3.12. Mark the Lower In (LI) on the hot tap machine.

3.13. Lower the boring bar into position. Verify the Lower In (LI) distance.

3.14. Mark the Pilot To Cutter (PTC), Book Cut Out (BCO) and Maximum
Cut Out (MCO) on the measuring rod.

3.15. Perform a joint integrity test on the final makeup.

Note: If the joint integrity test is greater than 1.10 times the
operating pressure, the boring bar must be retracted and the hot tap
valve shall be in the closed position. Lower the boring bar to the
Lower In (LI) position.

3.16. If tapping into a flammable service, verify the hot tap machine is air
free.

3.17. A purge medium may be required to perform the hot tap.Remove the
crank handle, if applicable.
Note: Using an air operated machine verify a minimum air
pressure of 90 psig, 90105 cfm, for the hot tap machine.
Start the hot tap.

3.18. When the pilot completely penetrates the pipe, stop the hot tap
machine and lower the cutter to the pipe (COP).

3.19. Remove the crank handle, if applicable. 5.27. Restart the hot tap.
Note: Occasionally stop the hot tap machine and use the
measuring rod to verify the cutter is tight.

3.20. When the cutter reaches the Book Cut Out (BCO) mark, the hot tap
machine can be stopped and the cut out verified by extending the
cutter to 1, by hand.
Note: If the hot tap is not complete, continue with the hot tap.

3.21. Complete the hot tap.

Note: Size on size hot taps may require traveling to the Maximum
Cut Out (MCO) to complete the hot tap.
Warning: Do not exceed the Maximum Cut Out (MCO) distance.

3.22. Retract the boring bar.

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MEGA-STEAM ENGRG PTE LTD Prepared By : Johan

Rev. : 01
Method Of Statement
Effective Date : 01- Apr -17

Title : Hot Tapping at Plant Condensate Line

3.23. Close the service valve and verifying the number of turns or the
length of the stem.
Note: Venting fluid may require collecting or piping the fluid to
disposal facilities.

3.25 De-pressure and remove the hot tap machine.

3.24. Decontaminate and clean all equipment.

3.25. ALL equipment must be drained, thoroughly flushed, cleaned and

neutralized of chemicals / processes. Equipment that has not been
decontaminated WILL NOT be forwarded or returned to any
equipment center.

3.26. The hot tap valve is to be LOTO by the Lonza host after finish the hot
tapping

4. House Keeping

4.1 Ensure house keeping is carried out after the work has been done.

Page 4 of 6
MEGA-STEAM ENGRG PTE LTD Prepared By : Johan

Rev. : 01
Method Of Statement
Effective Date : 01- Apr -17

Title : Hot Tapping at Plant Condensate Line

18"T-101 Tapping Machine 1"150# Hot Tap

T-101 Tap Mcahine

50# 47

71 1/16

Cutter/Housing 18"
10#

1" 150#
Gate Valve 5"
15#

1 1/16"
Page 5 of 6
MEGA-STEAM ENGRG PTE LTD Prepared By : Johan

Rev. : 01
Method Of Statement
Effective Date : 01- Apr -17

Title : Hot Tapping at Plant Condensate Line

18"T-101 Tapping Machine 1"150# Hot Tap

28" T-101 Tapping Machine 1" 150# Hot Tap

T-101 Tap Machine

60# 57"

81 1/16"

Cutter/Housing
10" 18"

1" 150# 5"

Gate Valve
15# 1 1/16"
Page 6 of 6