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1、MANUAL HOT-TAPPING ON PIPELINES, PIPING AND EQUIPMENT DEP 31.38.60.10-Gen. December 1998 DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell International Oil Pro
2、ducts B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any fo
3、rm or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) and
4、Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and maintenance of processing u
5、nits and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good design and engineering
6、practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications i
7、s provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt t
8、he information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not spe
9、cifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principa
10、l or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of user
11、s of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized to
12、 use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply w
13、ith the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or i
14、n connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs. Without prejudi
15、ce to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have bee
16、n provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at any
17、time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDD
18、s generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be rep
19、laced by DEPs. DEP 31.38.60.10-Gen. December 1998 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.5 1.1SCOPE 5 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS5 1.3DEFINITIONS 6 1.4CROSS-REFERENCES7 1.5SUMMARY OF MAIN CHANGES SINCE THE LAST REVISION.7 2.GENERAL CONSIDERATIONS8 2.1JUSTIFICATION FO
20、R HOT-TAPPING.8 2.2RESPONSIBILITIES8 2.3DOCUMENTATION.9 3.RESTRICTIONS ON APPLICATIONSAND OPERATIONALCONDITIONS11 3.1MATERIALS 11 3.2PROCESS FLUIDS.11 3.3PROCESS CONDITIONS.12 3.4HOT-TAP LOCATION.15 4.DESIGN. 17 4.1BASE MATERIALS17 4.2DESIGN CALCULATIONS17 4.3TYPE OF HOT-TAP CONNECTION.18 4.4SPECIFI
21、CATION OF FITTINGS.18 4.5COUPON REINFORCEMENT18 5.JOB EXECUTION.19 6.WELDING AND INSPECTION20 7.SPECIAL APPLICATIONS21 7.1GENERAL 21 7.2PRESSURE VESSELS21 7.3TANKS. 21 7.4MISCELLANEOUS EQUIPMENT (VALVES, PUMPS, STRAINERS, MIXERS, TURBINE HOUSINGS).21 7.5FLARE LINES21 8.PRESSURE TESTING22 8.1GENERAL
22、22 8.2STRENGTH TEST PRESSURES.22 8.3TESTING MEDIA.23 9.PERFORATION AND COMPLETION.24 10.REFERENCES25 11.BIBLIOGRAPHY.27 APPENDICES APPENDIX 1HOT-TAP PROCEDURE CHECK LIST.30 APPENDIX 2WELDING TEMPERATURE OF PIPEWALL - INITIAL PIPE WALL TEMPERATURE OF 25 C40 APPENDIX 3WELDING TEMPERATURE OF PIPEWALL -
23、 INITIAL PIPE WALL TEMPERATURE OF 150 C41 APPENDIX 4FORMULAE FOR MAXIMUM PRESSURE CALCULATION BASED ON FRACTURE TOUGHNESS PROPERTIES (OFF-PLOT PIPELINES ONLY). 42 APPENDIX 5TYPICAL WEIGHTS AND DIMENSIONS OF HOT-TAPPING EQUIPMENT44 DEP 31.38.60.10-Gen. December 1998 Page 3 APPENDIX 6HOT-TAP SAFE TEST
24、 PRESSURE RATIO45 DEP 31.38.60.10-Gen. December 1998 Page 4 1.INTRODUCTION 1.1SCOPE This DEP specifies requirements and gives recommendations for the planning and execution of “hot-tap“ branch connections onto piping systems and pipelines containing hydrocarbons under operating conditions. It has be
25、en developed to reflect current understanding of the technology and to improve safe practices in the field. It is intended to cover hot-tapping on carbon, carbon-manganese and high-strength low-alloy steels (e.g. API 5L grades B to X70), though many aspects may be relevant for other applications. Ho
26、t- tapping on other materials requires special consideration. This DEP is a revision of the previous publication of the same number dated December 1991. This DEP is not intended to cover subsea hot-tapping but many aspects would still be relevant for such applications. Due to the distinction made in
27、 the relevant standards between on-plot piping and off-plot pipelines or flowlines, a similar distinction is sometimes made within this DEP, but this has been avoided wherever possible. Additionally, it is assumed that the piping/pipeline systems are designed and operated in accordance with ASME B31
28、.3, B31.4, B31.8, or a combination thereof. The use of alternative standards would not be expected to conflict with any of the principles adopted in this DEP or most of the specific requirements. However, see (1.2) below. It is assumed that all hot-tap branch connections will be welded. Note:Where i
29、n accordance with the requirements of this DEP, or for other reasons, welding is not permitted, consideration may be given to the use of a non-welded system. Such systems are becoming increasingly available but require special considerations, including long-term integrity aspects. This DEP mainly co
30、nsiders hot-tapping on pipes but it is possible to perform hot-taps on tanks and other equipment as outlined in (7). It should also be noted that hot-tapping often requires the approval of the relevant statutory authorities. This DEP is relevant to the hot-tapping aspects of “stoppling“ operations;
31、although the specific stoppling activities are excluded from the scope of this DEP, they should be subject to similar procedural detail as the hot-tapping activities described herein. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distri
32、bution of this document is confined to companies forming part of the Royal Dutch/Shell Group or managed by a Group Company, and to Contractors nominated by them (i.e. the distribution code is “C“, as defined in DEP 00.00.05.05-Gen.). This DEP is intended primarily for use in exploration/production f
33、acilities and oil refineries, but it may also be applied in chemical plants, gas plants and supply/marketing installations. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of
34、 the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessar
35、y in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this DEP as closely as possible. 1.3DEFINITIONS 1.3.1General definitions The Contractor is the party which carries out all or
36、part of the design, engineering, DEP 31.38.60.10-Gen. December 1998 Page 5 procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufacture
37、s or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent
38、 or consultant authorised to act for, and on behalf of, the Principal. The word shall indicates a requirement. The word should indicates a recommendation. 1.3.2Specific definitions and abbreviations Asset operatorThe individual within the Principals organisation who is responsible for the operation
39、of the pipeline, piping or equipment to be hot-tapped. Branch pipeThe pipe which is to be connected to the run-pipe by means of the hot-tap. CouponSection of pipe cut out during the hot-tap cutting operation. HAZHeat Affected Zone Hot-tappingA method of making connections to piping (or other equipme
40、nt) by attaching a fitting to the system, usually by welding, followed by cutting through the pipe wall at the point of attachment utilising an appropriate (“hot-tapping“) machine. This operation is generally carried out on a live (“hot“) system without decommissioning or interrupting flow. Lock-O-R
41、ing flangeFlange with internal segments which can be moved from the outside to lock into the circumferential recess of a Lock-O- Ring plug. Lock-O-Ring plugPlug which can be set into position inside a hot-tap connection flange in order to retain internal pressure. NPSNominal Pipe Size Off-plot Pipel
42、inePipeline designed in accordance with ASME B31.4 or B31.8 (see Note below). On-plot PipingPiping system designed in accordance with ASME B31.3 (see Note below). Note:Some parts of a pipeline system, although physically located “off-plot“, may be designed in accordance with ASME B31.3. For the purp
43、oses of this DEP, such piping shall be considered to be on-plot. Similarly, some refinery piping, although physically located “on-plot“, may be designed in accordance with ASME B31.4 or B31.8. For the purposes of this DEP, such piping shall be considered to be off-plot. Operating conditionsAll condi
44、tions of piping and equipment when containing hydrocarbons under a positive internal pressure. Run pipeThe pipe into which a hot-tap is to be made. StopplingA hot-tapping operation which includes the insertion and setting of a sealing plug in the pipe in order to stop flow and withstand a certain fl
45、uid pressure. DEP 31.38.60.10-Gen. December 1998 Page 6 WPSWelding procedure specification 1.4CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced in this DEP are listed in (9). 1.5SUMMARY OF MAIN
46、CHANGES SINCE THE LAST REVISION The most significant change is the transfer of the requirements for welding and inspection, previously covered in Section 6, to the new DEP 30.10.60.30-Gen. Associated figures have also been transferred. Other main technical (i.e. non-editorial) changes are:- 3.2contr
47、adictory statements clarified and “hydrogen” defined 3.4requirements regarding hot-tap locations consolidated 7.4simplifiedtoarecommendationnottocarryouthot-tapoperationson miscellaneous equipment. DEP 31.38.60.10-Gen. December 1998 Page 7 2.GENERAL CONSIDERATIONS 2.1JUSTIFICATION FOR HOT-TAPPING Ho
48、t-tapping is potentially hazardous and therefore should only be undertaken when shown to be technically feasible and to offer a clear advantage over alternatives. The advantage may be economic and, in some situations, the safety and environmental risks may be less than those associated with more con
49、ventional methods. A decision on whether hot-tapping is to be applied shall be based on careful considerations including at least the following aspects: -safety; -condition of the pipe/equipment under consideration; -configuration of the connection; -code/statutory requirements; -operating conditions; -technical capabilities of the drilling equipment under the operating conditions (pressure, temperature, nature of product); -related welding problems; -economic aspects; -environmental/pollutionaspects. If hot-tapping is to be applied under conditions approaching the technical or operational