1. tugas kelompok hot tap kel c wi 30

8/17/2019 1. Tugas Kelompok Hot Tap Kel C WI 30

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TUGAS KELOMPOK

STUDI KASUS

HOT TAPPING PADA PIPA GAS BUMI

PT. GASINDO ENERGI

Disusun Untuk Memenuhi Salah SatuPersyaratan Penilaian Kursus Profesi

Welding

Inspector

Disusun oleh :

Kelompok C

Dwi Mulyono WI‐30‐008 Abdullah M WI‐30‐001

M Fais H WI‐30‐033 Edi Kurniawan WI‐30‐009

M Muhcson WI‐30‐018 Eko Susanto WI‐30‐010

Kun M Wafda WI‐30‐015 M Marten WI‐30‐016

Raditya H WI‐30‐021 Hari Purwanto WI‐30‐032

Kelber P WI‐30‐022

WELDING INSPECTOR CPURSE ANGKATAN XXX

RESEARCH CENTER FOR MATERIAL SCIENCE

UNIVERSITAS INDONESIA

MARET 2016


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Laporan Tugas Kelompok

STUDI KASUS HOT TAPPING PADA PIPA GAS BUMI

Kelompok C

April 2016

1

Daftar Isi Hal.

1. Umum

1.1

NamaProyek 1

1.2

Lokasi 1

1.3

Lingkup Kerja 1

1.4

Data / Spesifikasi Teknis 1

1.5

Standart dan Code yang di gunakan 1

2. Job Analysis

2.1

Hot Tapping Activity Flow 2

2.2

Tinjauan Keekonomian 3

2.3

Teknik Operasi 8

2.4

Process to Review Whether Hot Tapping is Appropriate 10

2.5 Decision Process for Authorizing Hot Tapping Tap 11

2.6 Organisasi Proyek 12

2.7

Daftar Personil, Kompetensi dan Kualifikasi 12

3. PERSIAPAN

3.1

Rencana Tertulis 12

3.2 Kondisi Khusus (Apabila Ada) 13

3.3

Spesifikasi Mesin Hot Tap, Mesin Las, Retrivier Kit dan

Kelengkapannya. 13

4. PELAKSANAAN HOT TAPPING 14

5. PENYELESAIAN PEKERJAAN 14

LAMPIRAN

1. Organisasi Proyek

2. WPS & PQR

3. Form pelaksanaan Hot Tapp API RP 2201


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Kelompok C

April 2016

2

1. UMUM

1.1

Nama Proyek

ProyekHot TappingPipa Gas Ф20’’ Milik PT. Gasindo Energi.

1.2

Lokasi

Lokasipekerjaaninidilaksanakan di area PT. GasindoEnergi (Pipeline to PLTG).

1.3

Lingkup Kerja

Melakukan pemasangan 1 unit Hot Tapping pada pipapenyalur gas milik PT.

Gasindo Energi berdasa rkan standard dan code.

1.4 Data /Spesifikasi Teknis

Tabel 1 Spesifikasi pipa

No Diskripsi Fluida Long(km) Material WT(Inch) P (PSIG) Flow(MCFD)Year

Built

Year

Commisioning

1 Pipeline Gas 60 API 5LX 52 0,472 500 45 2011 4

Tabel 2 Spesifikasi Hot Tapping

No Diskripsi Jumlah Diameter

(inch) Jenis Fungsi

1 Hot Tapping 1 2 Flush Disc Coupon Corrosion

Monitoring

1.5 Standart dan Code yang di gunakan

1.

SNI 13‐4129‐1996/Rev.2002 “Prosedur Pengelasan atau Hot Tapping Pada

Peralatan yang Berisi Fluida Mudah Terbakar”.

2.

API Recommended Practice 2201 “Safe Hot Tapping Practices in the

Petroleum and Petrochemical Industries”.

3.

API

Recommended

Practice

1104

“Welding

of

Pipeline

and

Related

Facilities”.

4.

API Recommended Practice 107 “Pipeline Maintenance Welding Practices”.


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STUDI

KASUS

HOT

TAPPING

PADA

PIPA

GAS

BUMI

Kelompok C

April 2016

3

2. JOB ANALYSIS

2.1 Hot Tapping Activity Flow

Gambar 1 Typical Hot Tap Activity Flow

Job analisis Pekerjaan Hot Tapping telah di buat berdasarkan flow chart diatas

dengan keterangan sebagai berikut:

1.

Job analisis Hot Tapping telah sesuai

2.

Evaluasi kondisi kerja

3.

Implementasi prosedur safety

4.

Pelaksanaan pekerjaan

5. Pekerjaan.


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Kelompok C

April 2016

4

2.2 Tinjauan Keekonomian

Kelebihan metode Hot Tapping dibandingkan dengan metode Shut ‐down.

1.

Sistem operasional tetap berjalan, tidak terjadi penghentian.

2.

Tidak ada gas yang dibuang ke atmosfir (zero gas

lost ).

3.

Tidak ada pemotongan, penyetelan dan pengelasan pada ruas pipa

4.

Menghemat biaya (gas/production/opportunity loss, waste time, labour

cost ).

5. Meningkatkan keselamatan pekerjaan.

6.

Meminimalisir kewajiban perusahaan untuk memberitahukan kepada

pelanggan mengenai penghentian pasokan gas.

Langkah asesmen keokonomian:

1.

Tentukan kondisi fisik pipa eksisting.

2.

Hitung biaya metode shut ‐down.

3.

Hitung biaya motode hot tapping.

4. Evaluasi penghematan gas, apabila menggunakan metodehot tapping.

5.

Bandingkan kedua metode tersebut dan tetapkan piilihan.

Langkah Menentukan

Kondisi

Fisik

Pipa

Eksisting

1.

Data teknis atau spesifikasi dan umur pipa.

2. Riwayat operasi dan pemeliharaan.

3.

Pengukuran tebal sisa dinding pipa di titik hot tapping (up‐date 28 hari).

4.

Prakiraan cuaca, arah dan kecepatan angin padahari “H”.

5.

Kondisi geografis dan lingkungan sekitar.

Langkah II Perhitungan Biaya Metode Shut‐Down.

1.

Rumus volume Gas Lost .

Vg (Mcf) = .. .,

(1)

dimana:

Vg = Volume gas lost (Mcf).


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Kelompok C

April 2016

5

D = Diameter pipa (inches)

P = Tekanan pipa rata – rata (psig).

L = Panjang ruang pipa yang diblokir (feet)

2.

Rumus volume Purge Gas (Nitrogen).

Vpgas (Mcf) = . . , (2)

diketahui:

L = 60000 m = 196850,39 feet

OD = 12,75 in. @ Wall Thickness = 11,80 in

ID = 500 psig

Berdasarkan Persamaan 1 dan 2 didapatkan:

Volume gas lost, Vg = 5102 Mcf

Volume purge gas, Vpgas = 330 Mcf

diketahui:

Hargajual gas = US.$ 51.020 = Rp. 561.220.000 (a)

Harga purge gas (Nitrogen) = US.$ 3.628 = Rp. 39.930.000 (b)

Opportunity loss penjualan gas danlistrk :

Asumsi waktu pengerjaan metode shut down = 3 hari

Oppurtunity lost penjualan gas selama 3 hari:

45 Mcf . 3 hari . US.$ 10 = US.$ 1350 = Rp. 14.850.000 (c)

Opportunity lost produksi/penjualan listrik pihak PLTG, selama 3 hari:

50000 kW . 3 hari . US.$ 0,07 = US.$ 10500 = Rp. 115.500.000 (d)

Perkiraan biaya metode Shut Down

Tabel 3 Perkiraan biaya metode Shut ‐Down

No Uraian Harga

1 Gas lost (blow ‐down) Rp. 561.220.000

2 Purge gas (Nitrogen) Rp. 39.930.000

3 Opportunity lost penjualan gas Rp. 14.850.000


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Kelompok C

April 2016

6

4 Opportunity lost produksi/penjuaanlistrik PLTG Rp. 115.500.000

5 Sewaalat (Mesin Las & Tools) Rp. 20.000.000

6 Material (A/F Weldolet, Electrode, NDT) Rp. 15.000.000

7 Upah/Jasa (Welder, Asst, Pipe Fitter, TukangPipa) Rp. 20.000.000

8 BiayaOperasional (Mob/demob,HSE, Konsumsi) Rp. 30.000.000

Jumlah Rp. 816.500.000

Langkah III Perhitungan biaya Hot Tapping

Tabel 4 Perkiraan biaya metode Hot Tapping

No Uraian Harga

1 Sewa alat (Hot Tap,

Mesinlas, Retriever Kit, Tools) Rp. 60.000.000

2 Material (A/F Weldolet, Electrode, NDT) Rp. 15.000.000

3 Upah/jasa (Welder, Asst, Pipe Fitter, TukangPipa) Rp. 20.000.000

4 Biayao perasional (Mob/demob, HSE, Konsumsi) Rp. 20.000.000

Jumlah Rp. 115.000.000

Langkah IV Evaluasi penghematan gas metode Hot Tapping

Tidak ada gas lost , Vg = 5102 Mcf

Tidakmembutuhkan purge gas, Vpgas = 330 Mcf (kecualipasca NDT A/F

Weldodetdiabaikan)

diketahui:

Harga jual gas = US.$ 10 per‐Mcf.

Harga gas purging (Nitrogen) = US.$ 11 per‐Mcf.

Kurs Valas USD 1 = Rp. 11.000,‐

Peng hematan gas:

Tidak ada gas lost US.$ 51.020 = Rp. 561.220.000.

Tanpa Purge gas (Nitrogen) US.$ 3.630 = Rp. 39.930.000.


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Kelompok C

April 2016

7

Langkah V Perbandingan biaya metode Hot Tap vs Shut ‐Down

Tabel 5 Perbandingan biaya metode Hot Tap vs Shut Down (000)

No Uraian Hot ‐Tap Shut ‐Down

1 Gas lost

(blow

‐down) ‐ 561.220

2 Purge gas (Nitrogen) ‐ 39.930

3 Opportunity lost penjualan gas ‐ 14.850

4 Opportunity lost produksi/penjuaanlistrik PLTG ‐ 115.500

5 Sewaalat (Mesin Las & Tools) 15.000 20.000

6 Material (A/F Weldolet, Electrode, NDT) 60.000 15.000

7 Upah/Jasa (Welder, Asst, Pipe Fitter, TukangPipa) 20.000 20.000

8 BiayaOperasional (Mob/demob,HSE, Konsumsi) 20.000 30.000

Jumlah 115.000 816.500

Kesimpulan:

Secara keseluruhan biaya metode Hot Tapping jauh lebih rendah dibandingkan

dengan metode Shut ‐Down, yaitu dengan selisih sebesarRp. 701.500.000, Hal

ini dikarenakan pada metode Hot Tap tidak ada:

1. Gas lost

2. Purge gas

3. Oppurtunity lost penjualan gas

4. Oppurtunity lost produksi/penjualan listrik pihak PLTG

Maka, ditetapkan pilihan menggunakan metode Hot Tapping.


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Kelompok C

April 2016

8

2.3 Teknik Operasi

Tekanan operasi terhadap ketebalan aktual

P =

. (3)

dimana:

D = Nominal outside diameter of pipe, in (mm)

E = Longitudinal joint factor

F = Design factor obtained

P = Design pressure (psig)

S = Specified minimum yield strength (kPa) MPa

T = Temperature derating

t = nominal wall thickness, in (mm)

Diketahui:

Outside pipe diameter, OD = 12,75”

Actual wall thickness,tact = 0,472”

Spesifikasi pipa API 5L X52, SYMS, S = 52.000 psi

Tekanan, P = 500 psi

Design factor, F = 0,60

Longitudinal Joint factor E = 0,8

Temperature Derating Factor, T = 0,9 (Temperatur normal 400’F)

Sehingga diperoleh ketebalan minimum tmin

tmin = .,

..,.,., = 0,14”

kesimpulan : tact 0,472” >tmin 0,14” (ketebalan dinding pipa memenuhi syarat)

Tekanan operasi terhadap ketebalan kritis Hot Tapping

Ketebalan kritis Hot Tapping, yaitu tebal sisa dinding pipa untuk menahan

tekanan internal ketika mengalami terdampak panas pengelasan (HAZ ).

Ketebalan Kritis = Tebal aktual – tebal daerah HAZ


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STUDI

KASUS

HOT

TAPPING

PADA

PIPA

GAS

BUMI

Kelompok C

April 2016

9

Berdasarkan hasil uji laboratorium, tebal daerah terdampak panas (HAZ ),

berkisar 2, atau 0,0787 in. Ketabalan sisa (kritis) akibat HAZ yang dibolehkan

maksimal 60% dari ketebalan actual, sehingga:

Asumsi tact –

tHAZ

= 0,472”

–

0,0787”

= 0,3933”

Ketebalan kritis, tcr 60% dari tact = 60%.0,472” = 0,2832”

Jadi ketebalan kritis, tcr = 0,2832”.

Maka, tekanan operasi maksimum yang diperbolehkan ketika pengelasanHot

Tapping, dengn tcr = 0,2832” adalah:

Pmax = ..,.,.,.,

, = 998 psig

Kesimpulan ketika Hot Tapping, pada tekanan operasi= 500 psig relatip aman,

karena Pops =

500

psig

lebih

rendah

dari

padaPmax

= 998

psig.

Gambar 2 Denah situasi dan Hot Tapping point .


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STUDI

KASUS

HOT

TAPPING

PADA

PIPA

GAS

BUMI

Kelompok C

April 2016

10

2.4 Process to Review Whether Hot Tapping is Appropriate

Gambar

3

Procces

review

whether

hot

tapping

is

Appropriate


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STUDI

KASUS

HOT

TAPPING

PADA

PIPA

GAS

BUMI

Kelompok C

April 2016

11

2.5 Decision Process for Authorizing Hot Tapping Tap

Gambar 4 Decision Process for authorizing Hot Tapping Tap.


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Kelompok C

April 2016

12

2.6 Organisasi Proyek

Organisasiproyekterlampir.

2.7

Daftar Personil,

Kompetensi

dan

Kualifikasi

Daftar personil, kompetensi dan kualifikasi terlampir.

3. PERSIAPAN

3.1 Rencana Tertulis

1.

Desain koneksi, Titik Hot Tap dan ketebalan pipa.

2.

Prosedur Hot Tapping.

3.

Prosedur pengelasan.

4.

Safety , Health & Environment (SHE).

5. Prosedur dan instruksi, termasuk persyaratan perusahaan dan pemakai.

6.

Kompetensi dan kualifikasi personil.

3.2 Kondisi Khusus (Apabila Ada)

3.3

Spesifikasi Mesin Hot Tap, Mesin Las, Retrivier Kit dan Kelengkapannya.

Persyaratan mesin hot tap sebeum memulai pekerjaan:

1.

Mesinhot tap, pisaubor (cutter ) harus diinspeksi dengan seksama untuk

menjamin kehandalannya dan dapat tetap terpasang pada peralatan jika

terjadi masalah mekanis atau kebocoran pada katup hot tap.

2.

Mempunyai batas operasional (rating) tekanan dan temperature maksimum

tertentu yang tidak boleh dilampaui.

3.

Mesin hot tap dinyatakan sesuai, jika tekanan dan temperature fluida di

dalam saluran pipa atau bejana berada dalam batas operasional (rating)

mesin tersebut.

4.

Material dan seals mesin hot tap harus compatible dengan fluida di dalam

saluran pipa atau bejana yang akan di hot tap.

5.

Material pisau bor/cutter harus tajam, berkualitas tinggi, agar penetrasi

pengeborannya efektif.


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STUDI

KASUS

HOT

TAPPING

PADA

PIPA

GAS

BUMI

Kelompok C

April 2016

13

6. Dapat menahan dan mengangkat hasil potongan (coupon).

7.

Dalam kondisi darurat (jika mesin hot tap tidak dapat dilepaskan), untuk

sementara mesin hot tap harus dapat bertahan di tempatnya.

8.

Diameter maksimum

lubang

hot

tap

pada umumnya

berkisar

50

‐70%

terhadap diameter pipa yang akan di hot tap.

Komponen mesin hot tap

Gambar 5 Komponen mesin hot tap.


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Kelompok C

April 2016

14

4. PELAKSANAAN HOT TAPPING

1.

Pernyataan Kehadiran Personil yang Bertanggungjawab Selama Proses Hot

Tapping Berlangsung.

2.

Area Koneksi Telah Diidentifikasidan Ditandai.

3.

Perhitungan Ketebalan Pipa Memenuhi Persyaratan.

4.

Contingency Plan Termasuk Emergency Action Plan.

5. PengecekanTerhadap Adanya Uap Mudah Terbakar, Oksigen dan Kontaminan

Udara Berbahaya.

6.

Melaksanakan Asesmen Potential Safety & Health Hazard .

7.

Personnel Protective Equipment (PPE) , Termasuk Pakain Tahan Api.

8.

Dokumen / Surat Ijin Telah Tersedia dan Disetujui:

a.

SPK pelaksanaan Hot Tapping.

b. Surat Ijin Kerja Panas (Hot Permit ).

c.

WPS & PQR. (Terlampir)

9.

Tim Pemadam Kebakaran dan Perlengkapannya Siap di Lokasi Hot Tapping.

5.

PENYELESAIAN PEKERJAAN

Penyelesaian Hot Tapping dilaksanakan sesuai prosedur sebagai berikut:

1.

Proses hot tap dilaksanakan secara no‐stop, sampai selesai dan katup

ditutup.

2.

Penyelesaian penetrasi pemboran, diindikasi dengan berkurangnya daya

tahan engkol tangan atau peningkatan putaran (rpm) prime mover .

3.

Proses penarikan batang bor dan penutupan katup sesuai dengan buku

panduan mesin Hot Tap.

4.

Dilarang mengambil coupon yang jatuh.

5.

Cairan dan uap yang terperangkap di dalam mesin Hot Tap

harus dikeluarkan.

6.

Personil pemadam kebakaran, menunggu selama 30 menit.

7.

Pengecekan terakhir, kemungkinan masih ada kebocoran.

8.

Laporan akhir pelaksanaan Hot Tap meliput:

a.

SNI 13‐4129‐1996/Rev.‐2002 : “DaftarHot Tap yang disarankan”.

b.

API RP 2201 Appendix A, B, C, dan D.


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Kelompok C

April 2016

15

c. Gambar ( As Built Drawing) KonstuksiHot Tap.

d.

Dan lain – lain.

9.

Berita acara serah terima pekerjaan.


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Kelompok C

April 2016

16

LAMPIRAN 1. Organisasi Proyek


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Project Manager PT. Gasindo Energi

STRUKTUR ORGANISASI PROYEK

HOT TAPPING PADA PIPA GAS BUMI PT. GASINDO ENERGI

HSE Officer Document &Report Admin

Project ControlFinance &

Administration

Project

Admin

Welding Hot Tap

TeamInspection Team NDT Team


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Kelompok C

April 2016

17

LAMPIRAN 2.

WPS

&

PQR


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DATA

By

: WPS/KLPC/WI-XXX-2016/001 Date

: PQR/KLPC/WI-XXX-2016/001

Type

MAIN PIPE : WELDOLET :

Material : API 5LX .52 Material : Weldolet WPHY.52

SMYS (psi) : 60.000 psi SMYS (psi) : 60.000 psi

Wall Thickness (mm) : 0.472 in Wall Thickness (mm) : 0.472 in

Outside Diameter (Inch) : 12.75 in Outside Diameter (Inch) : 2 in

JOINT DESIGN : RUNS : (3 - 5 passes)

RANGE OF QUALIFIED

Base Metal : Yield strength > 42000 psi - < 65000 psi

Out Side Diameter (pipe) : > 4.50 - 12.75 in

Wall Thickness : ≤ 0.5 in

FILLER METALS

AWS Specification : AWS A5.5

AWS Classification : E 7018 for All

Low Hidrogen

Size Electrode : 2.5 mm for Root

3 mm for Other

Group No : 3

Electrode Flux (Class) : F2

Trade Name : ESABManufacture : ESAB PT. Karya Yasantara Sakti

Travel Speed

Class Dia. Type Amp.

(mm) (mm) Polar. Range

ROOT SMAW E - 7018 2.5 mm DCRP 60 - 110 20 - 23 71-80

FILLER SMAW E - 7018 3.0 mm DCRP 60 - 110 23 - 28 85-105

CAPPING SMAW E - 7018 3.0 mm DCRP 60 - 110 22 - 26 100-200

WELDING PROCEDURE SPECIFICATION (WPS)

MAIN PROCEDURE - PIPE To WELDOLETCODE AND SPECIFICATION : API 1104 (2007 Edition)

Company Name : PT. KELOMPOK C : GROUP C

WPS No : MARCH, 29 2016

Supporting PQR No

Welding Process : SMAW : MANUAL

1040-1790

Filler Metal Current

Volt Range

890-1350

1400-2850

Electrode Size and Number Of Beads

Heat Input (J/ mm)(mm/minutes)

Pass or

Weld Layer

(s)

Process


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Joint Design : Single V groove

Position : 5G (Fixed)

Derection Of Welding : Down Hill

No. Of Welder : 1 (one)

Stringer or Weave Bead : String for Root

Weaving for Another Pass

Cleaning : Grinding and Brushing

Type of Alligment Device : External Clamp Or Tack Welding

Type Removal of Clamp : N/A

Heat Treatment : N/A

Time Between Pass : max. 4 Minutes

Stress Relief : N/A

Shielding Gas and Flow Rate : N/A

Shielding Flux : N/A

Non Destructive Testing : Destructive Testing :

1. Visual Test : 100% 1. Tensile Test

2. Dye Penetrant Test : 100% 2. Nick Break Test

Prepared By Reviewed and Approved By Autorizhed By,

( Kelompok C ) ( Rep. Kelompok C ) ( Rep. RCMS UI )

TECHNIQUE

Requirement for PQR

CODE AND SPECIFICATION : API 1104 (2007 Edition)

MAIN PROCEDURE - PIPE To WELDOLET

WELDING PROCEDURE SPECIFICATION (WPS)


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DATA

By

: WPS/KLPC/WI-XXX-2016/001 Date

: PQR/KLPC/WI-XXX-2016/001

Type

MAIN PIPE : WELDOLET :

Material : API 5LX .52 Material : Weldolet WPHY.52

SMYS (psi) : 60.000 psi SMYS (psi) : 60.000 psi

Wall Thickness (mm) : 0.472 in Wall Thickness (mm) : 0.472 in

Outside Diameter (Inch) : 12.75 in Outside Diameter (Inc : 2 in

JOINT DESIGN : RUNS : 4 passes

AWS Specification : AWS A5.5

AWS Classification : E 7018 for All

Size Electrode : 2.5 mm for Root

: 3 mm for Other

Group No : 3

Trade Name : ESAB

Position Heat Treatment

Position of Groove : 5G (Fixed) Preheat : N/A

Welding Direction : Down Hill PWHT : N/A

Joint Design : Single V groove

No. Of Welder : 1 (one)

Stringer or Weave Bead : String for Root, weaving for filler and capping

No of Bead : 4

Cleaning : Grinding and BrushingType of Alligment Device : Tack Welding

Type Removal of Clamp : N/A

Time the Between Pass : 4 minutes

Method or Back Gauging : N/A

TECHNIQUE

Supporting PQR No

Welding Process : SMAW : MANUAL

FILLER METALS

PROCEDURE QUALIFICATION RECORD (PQR)


Company Name : PT. KELOMPOK C : GROUP C

WPS No : MARCH, 29 2016


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Tensile Test

Specimen Width Thickness Area Max. Load YS TS Fracture

No (mm) (mm) (mm2) (Kgf) Kgf/mm

2Kgf/mm

2 Location

T1 25.4 12 207.77 7500 30.01 39.35 Base Metal

T2 25.4 12 207.77 7475 30.92 40.21 Base Metal

Bend Test

Specimen

No.

FB-1

FB-2

RB-1

RB-2

Nick Break Test

Mechanical Test Conduct by : RCMS-UI Laboratory Test No : DT/RCMS/001

Dye Penetrant Test Conduct by : RCMS UI Report No : PT/RCMS/001

Welder Name : Jono

Date

Prepared By Reviewed and Approved By Autorizhed By,

( Dwi Mulyono ) ( Rep. Group C ) ( Rep. RCMS UI )

Face Bend

Root Bend

8025

1043,478

3.8

Remark

8725

E 7018/ 3mm

7521

20.4

79

1196,203

25

21.9

No Discontinuity

No Discontinuity

No Discontinuity

No Discontinuity

85

23.5

11590

22.9

90

Type Of Bend Test

Welding Parameters

4Pass No

3.7Time Between Pass, minutes

1416,667

1 2

E 7018/ 2.5 mm

PROCEDURE QUALIFICATION RECORD (PQR)

3

Duration Time per Layer, minutes

Accepted

E 7018/ 3mm E 7018/ 3mm

1450,000

3.7


Result

Type & Size Electrode, mm

Ampere, A

Volt, V

Travel Speed, mm/minutes

Heat Input, J/mm

Accepted

3.5

: MARCH, 23rd 2015

Sepecimen No. Result

NB-1 No Discontinuity

NB-2 No Discontinuity


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KUALIFIKASI JURU LAS

Nomor : W-001

Tanggal kualifikasi : 27 Januari 2005

Nama : KosimTempat dan tgl. lahir : Jakarta, 12 Desember 1975

Alamat : Pasuruan - Jatim

Perusahaan : PT XYZ

Nomor WPS : W PS - 101

Nomor PQR : PQR - 101

Standar : API Standard 1104, 20th ed. 2005

Data kualifi kasi

Jenis kualifikasi : Single qualification

Proses las : SMAW

Sifat listrik : DCEP

Posisi : Fixed, horizontal

Arah pengelasan : Naik

Spesifikasi material : API 5L X42

Diameter : 6.625 in.

Tebal : 0.280 in.

Desain sambungan : Single V groove

Back Weld / Backing strip : Tidak ada

Bahan pengisi : E – 7018 G

Gas pelindung : Tidak ada

Flux pelindung : Tidak ada

Jenis pemeriksaan / pengujian

Visual : Ya – dengan hasil baik

Radiography : Ya – dengan hasil baik

Tensile : Ya – 2 bh dengan hasil baik

Nick-break : Ya – 2 bh dengan hasil baik

Root bend : -

Face bend : Ya – 2 bh dengan hasil baik

Side bend : -

Lain2 : -


26/36

KUALIFIKASI JURU LAS

Nomor : W-002

Tanggal kualifikasi : 27 Januari 2005

Nama : Agus BTempat dan tgl. lahir : Jakarta, 09 Februari 1971

Alamat : Klaten - Jateng

Perusahaan : PT XYZ

Nomor WPS : W PS - 102

Nomor PQR : PQR - 102

Standar : API Standard 1104, 20th ed. 2005

Data kualifi kasi

Jenis kualifikasi : Single qualification

Proses las : GMAW

Sifat listrik : DCEP

Posisi : Fixed, horizontal

Arah pengelasan : Turun

Spesifikasi material : API 5L X52

Diameter : 12.750 in.

Tebal : 0.500 in.

Desain sambungan : Single V groove

Back Weld / Backing strip : Tidak ada

Bahan pengisi : ER70S-6

Gas pelindung : Argon 50% & CO2 50%

Flux pelindung : Tidak ada

Jenis pemeriksaan / pengujian

Visual : Ya – dengan hasil baik

Radiography : Ya – dengan hasil baik

Tensile : -

Nick-break : -

Root bend : -

Face bend : -

Side bend : -

Lain2 : -


27/36


28/36


29/36



Kelompok C

April 2016

18

LAMPIRAN 3 Form pelaksanaan Hot Tapp API

RP 2201


30/36

PPENDIXA EXAMPLE HOTT P CHECKLISTS

This checklist is

an

example

of

a type

of

aid some facilities use as a reminder to accomplish the steps involved in hot tap oper

ations

in

an orderly manner. Particular circumstances

of

obs

may

dictate additional preparatory steps. A checklist like this may

be

retained as a record of he job.

Location __________________________________________________

__

Dare

________________________________________________

_

Job __________________________________________

__

r e p ~ e d b y ______________________________________________

_

Table 1 Before Starting the Hot

Tap

Initials

Checked

Each of the following

considerations

should

e satisfied

BEFORE ST RTING THE

HOTT P

Date Time by

I Review/follow hot tap machine manufacturer s operating instructions.

2 Have the contents

of

he line or vessel to

be

hot tapped or welded been assessed, and

MSDSs

reviewed

for

health hazards,

to

assure procedure

is

appropriate?

3

Is the material in the line or vessel stable under heated conditions?

4

Has the connection been designed per Section 6 requirements?

Do the flanges, bolts,

gaskets,

pipe, and valve to be

installed meet the

code for

the

line or vessel to be

hot

tapped?

6 Has

the

welding procedure specification been developed as covered in this s t a n d ~ d

7

Have approved work permits e.g., Hot Work, Hot

Tap,

Entry) been obtained?

8

Review manufacturer s instructions to ensure that the hot tapping machine has suitable pressure, temperature

ratings, and adequate cutter travel for this job.

9

Has the valve been pressure tested and the cover fitted to assure that it will work and fit properly?

10

Has

the exact

location ofthe

hot

tap been

identified

and

marked on the

line or equipment?

Is the area to be hot tapped located on a line in which flow has been established or below the liquid level

of

he

tank or vessel?

12

Has the area to be welded been inspected

for

thickness and freedom from existing welds, laminations, hydro-

gen attack, or other metallurgical imperfections?

13

Are tests

and

inspections current?

14 f

laminations or defects have been found, has a thorough engineering evaluation been made

by

a qualified per-

son to determine if and how to proceed with the work?

15

Has the metallurgy of he line or vessel been established, and is it compatible with the connecting fitting?

16 Can

the

welding and tapping area support

the

weight of

he hot

tapping

machine,

and is there adequate hoisting

and support for

the hot

tapping

machine

and subsequent piping?

17 IfPWHT of he welded area is required, was

an

appropriate review conducted in accordance with 6.6.

18

Is there sufficient external clearance to install the hot tapping machine and extract the cutter through the valve?

19

Is there sufficient internal clearance to retract the cutter and coupon through the valve?

20 Is

the hot

tap fitting of he

proper length

to

accommodate operation of the hot tapping machine?

21

Have

oxygen, combustible gas, and atmosphere contamination tests been conducted in the hot tap area?

22

Has

a dedicated fire watch person been assigned

and

appropriate training and fire fighting equipment provided?

23 Has the Fire

Watch

person been provided with a list ofduties as outlined in Table 2?

24

Are

all personnel in

the

area equipped

with

appropriate personal protective equipment?

24

Is

there adequate storage area

and

room for operational needs and emergency access or egress?

25 Has a procedure been prepared

and

in place

to

isolate the work area in the event of a failure

and

material release?

26

Are personnel trained to implement the contingency procedure?

27

Have

the requirements been defined

for

weld inspection

and for

pressure testing,

and is

all of he testing equip-

menton hand

and in

good working condition?

19


31/36

20

API

RECOMMENDED PRACTICE 2201

Table 2 Example of Fire Watch Duties

Initials

Checked

FIRE

WATCH DUTIES

INCLUDE

Date Time by

1 Being able

to

communicate effectively with personnel in area

2

Watching

for fires in all exposed areas

3

Knowing how to use the assigned

fire

suppression equipment

4 Knowing how

to activate

the facility fire

alarm

Trying to extinguish a

fire

only when obviously within the capacity o he equipment

available

(extinguisher or

hose)

6

Activating the fire alarm when available equipment is not sufficient

to

suppress

minor

fire .

7

Maintaining a watch for at least

1

/2

hour after completion

o

welding, hot tap or other hot

work

until the area

has

been inspected

and found

to

be free

ofleaks

and

ignition sources fires, hot spots or smoldering materials)

.. .

Note: FacJhties may choose to reqmre subsequent follow-up observations to check for leaks .

Table 3 Before Welding

Initials

Checked

Each

of the following considerations should e satisfied

BEFORE WELDING

Date

Time by

1

Are the welders qualified

for

the approved welding procedure (specification)

to

be used?

2 Is a preheat

o

he weld area required?

3

Is the fitting properly positioned to prevent misalignment o he hot tapping machine?

4 Have the pressure and temperature o he contained materials been reduced as much as the process operation

will allow?

Have the

flow

, pressure,

and

level considerations o 6.3, 6.9 and 9.1 been considered?

Table

4 Before

Cutting

Initials

Checked

Each

of the following considerations should be satisfied

BEFORE CUTTING

Date Time

by

1

Has the weld been inspected and tested?

2 Has the hot tap fitting been pressure tested?

3

Have the hot tap

valve,

packing, gasket, and bolts been checked

for

leakage?

4

Have the packing or seals on the hot tapping machine been checked?

Has the bleed offvalve been checked to assure it will hold, is operable, and is not obstructed?

6

Are all bolts on the pilot and cutter bit tight? (e.g., torqued to specification)

7 Is the coupon catcher

on

the pilot bit?

8 Is the valve centered on the flange?

9

Has cutting depth been calculated to avoid cutting the opposite

side

o he pipe?

10

Has the boring bar been run through the valve to assure free passage?

Have

the hot tapping machine and valve been purged, if r

ec

ommended?

Table 5 Before Removing the Hot Tapping Machine

Initials

Each of the

following

considerations should

e

satisfied Checked

II

EFORE

REMOVING

THE HOT TAP

MACHINE

Date Time by

1

Have the manufacturer s instructions been

followed to

be sure that the boring bar is fully retracted before clos-

ing

the hot tap valve?

2

as the hot tap valve been closed?

3 Has

the bleeder valve been opened?

4 Has all ofthe pressure been bled from the hot tapping machine before removing the bolts from the flange?

Have provisions been

made to

contain or control any liquid or gas in the hot tapping machine?


32/36

SAFE HOT TAPPING PRACTICES N THE PETROLEUM PETROCHEMICAL INDUSTRIES

21

Table

6 After

Removing the Hot Tapping Machine

Date

Checked

FTER

REMOVING THE HOT T PPING M CHINE

Time Initials by

The hot tap machine should be cleaned, removing the hydrocarbons/chemicals from the line or equipment.

2

All rags, absorbent pads, and other cleaning materials must be disposed

o

properly

3

When the work is completed a follow-up job site visit may be done

by

operations and craft personnel to see

that:

3a

The work is complete,

3b) No safety hazards have been introduced during the work activity.

Note: All o the

checklists included

in

these tables

are

provided

only as

examples.

They

are not intended for adoption without

review and customizing for individual circumstances.

The

titles and responsibilities used

in

these checklists

are

representative

o

practice used

by

some facilities

in the

petroleum and petrochemical

industry.

Facilities choosing to adopt a similar list should

base

it

on their

own

organization structure, titles, assigned responsibilities, and specific hot

tap

and work permitting procedures.


33/36

APPENDIX

B EXAMPLE

HOT TAPPING REQUEST FORMS

EXAMPLE

OF

HOT TAP REQUEST FOR EQUIPMENT IN SERVICE Page 1

of

2)

Note: Before initiating this request, refer

to

Facility HOTTAP PROCEDURES for

more

information. A separate request is required for each

individual hot tap.

To

Dm

e

(Operations Manager

of

equipment involved)

The following hot tap or hot work is proposed for your approval on piping, vessels, tanks, etc., in service in your area, or in an

area affecting your operations:

UnrtorAiea __

Location

Project Description - - - - - - - -

- - - - - - - - - - - -

- - - - - - - - - - - - - -- - - - - - - - -

Alternate Solution or Remarks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Management

of

Change Review Completed by: Date _

From

In i t ia tor - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Department _

Approved by Operations Manager

Involved- - - - - - - - - - - - - - - - -

Date _

Return this form with both sides filled out to the Initiator who will obtain approvals as follows:

Pressure Equipment Supervisor - - - -

- - - -- - - -

- - - - - -- - -

Date _

Health and Safety Representative Date _

The Initiator handling this work will use this j01m

to

secure Fire and Safety Penn

ts

( Hot Work ).

In

all cases, the operating

department involved is responsible to positively identify the exact location o he hot tap or associated welding work

Return this completed form to the inspector or person providing oversight for pressure equipment in the area where work is to

be

performed.

Note: The titles and responsibilities

used

in this checklist are representative

of

practice used by some facilities in the petroleum and petrochemi-

cal industry

Facilities

cho

osing to adopt a similar list should base

it

on their

own

organization structure, titles, assigned responsibilities

and

spe-

cific

hot tap

and

work pennitting procedures.

23


34/36

24

API

RECOMMENDED PRACTICE 2201

EXAMPLE

OF

HOT

TAP REQUEST

FOR

EQUIPMENT IN SERVICE Page 2 of

2

TO

BE

FILLED

OUT BY

INITIATOR

TYPE

OF

PROPOSED INSTALLATION

HEADER

OR

VESSEL INFORMATION

LINE SIZE in.) METALLURGY

OPERATING PRESSURE PSIG TEMPERATURE F

PROCESS DESCRIPTION _

BRANCH CONNECTION INFORMATION

LINE SIZE

in.) .

FLANGE RATING SI

GASKET MATERIAL METALLURGY

INITIATOR DATE____

A

location sketch of the proposed hot tap is recommended. The hot tap location must have scaffolding where required for

access), insulation must be removed and the equipment must be marked for the exact hot tap location prior to notifying Pressure

Equipment Inspection.

TO

BE

FILLED OUT BY

THE AREA

INSPECTOR AND PRESSURE

EQUIPMENT

ENGINEER

WALL THICKNESSAT HOT TAP LOCATION in.) DETERMINED BY:

DATE:

WELD DETAIL NUMBER:

l

PROCEDURE X-RAY

2 PROCEDURE _____ X-RAY

3

PROCEDURE X-RAY

INSPECTOR:

-

TESTS REQUIRED:

A) NOZZLE PSIG MEDIUM

B) REINFORCING

PAD

PSIG

MEDIUM

C) BLOCK VALVE: HYDROSTATIC SEAT EACH SIDE

AT

_ PSIG

AREA INSPECTOR

DATE

PRESSURE EQUIPMENT ENGINEER

DATE

_

TO BE FILLED

OUT BY

THE M AINTENANCE

DEPARTMENT

HOT TAP MACHINE:

MAKE _ MACHINE RATING PSIG

AT

_

F

MODEL _ _ _ PRESSURE TESTED

AT

PSIG

SERIAL O.

__________________

_ B

Y

DATE

MAINTENANCE DEPARTMENT REPRESENTATIVE_____________________

DATE

Note: The titles and responsibilities used in this form are representativeofpractice by some facilities in the petroleum and petrochemical indus

try Facilities choosi

ng

to adopt a similar form should base it

on

their own organization structure, titles, ass igned responsibilities and specific hot

tap

and

work permitting procedures.


35/36

APPENDIX

C EXAMPLE

OF WELDERS INSTRUCTIONS PRIOR TO HOT TAPPING

WELDING SAFETY TASK REVIEW WSTR)-PREPARATION FOR HOT TAPPING

Review the Hot

Tap

plan and verifY that

all workers

understand their duties.

All members o

he crew are

to

be present for the Weld-

ing Safety Task Review (WSTR) including pipe

foreman,

welding

foreman,

pipe welder, pipefitter, and helper.)

Discuss proper clearance for hot tap machine

Discuss hot tap request fonn infonnation and requirements (thickness

o

pipe to be welded, temperature

o

pipe to be welded, pres-

sure

in line and product in line to be

welded).

Discuss proper welding procedure with welder or welders that are going

to

be involved with welding process (location o machine

plus setting o amperage on machine).

VerifY

that the right location or area was ultrasonic tested for thickness and marked for weld attachment o hot tap fitting .

Discuss how to clean area to

be

welded, prior

to

welding.

Discuss required

tools

to be

used

for cleaning pipe, grinding tacks, grinding stringer. (If power tools are not recommended, what

alter-

native

tools

must

be

used

.)

Discuss gap needed

for

root pass between stub and existing header.

Discuss need

to

electrically bond (ground) ground cable

to

hot tap fitting

Discuss

amount o

penetration needed on stringer bead. Avoid excess amount

o

weld penetration which could interfere with drilling

of hot tap; don t back weld fittings.)

Discuss requirement

to

clean out Hot tap stub

and

remove all debris at completion o weld.

Note:

WELDING SUPERVISOR MUST BE PRESENT FROM WSTR MEETING THROUGH WELDING OF STRINGER BEAD.

The above is a generic example

of

nstructions

used

with welders preparing

or

a hot tap

t

is not intended or adoption without review

and

con-

forming to specific acility needs. Facilities choosing to adopt a similar list should base it

on

their own organizat ion structure titles assign ed

responsibilities

and

specific

hot

tap

and

work permittin g procedures.

25


36/36

APPENDIX D EXAMPLE IN SERVICE HOT TAP EMERGENCY ACTION PLAN

A Hot Tap Emergency Plan does not replace the facility's established emergency action plan, but rather is a supplement for

this special type ofwork. The plan addresses what specific problems could arise and what to do if hings go wrong during a Hot

Tap (Some examples include: leaks; losing the hot tap coupon; hot tap machine becoming stuck and unable to be withdrawn;

cutting through the opposite side

of

a pipe; or, significant loss

of

containment

of

process materials.)

1

This plan has been communicated to all parties involved:

( ) Operations ( ) Craft persons ( ) Firewatch

2 Firewatch has been familiarized with equipment on site:

) Firewatch Equipment:

)Contractor

Equipment )Facility Equipment

)EmergencyPP

3 Emergency Action Plan:

A.

Emergency Equipment Description, including personal protective equipment for emergency response (such as

SCBA, specific gloves, bunker gear, chemical suit, etc.):

B. Exact Location

C. Process Material: MSDS Hazard Ratings

Temperature:

Fi re__ Reactivity

Pressure: Health Other

D. Attach field sketch of isolation points to be used in the event of an emergency situation. (Isolation points must

be tagged.) _

E. List action steps to

be

taken in the event

of

an emergency. (provide reference sketch when appropriate and

SpecifyPPE)

F f storage tank, note isolation valves to be chained and locked on sketch:

Is liquid level3 ft above weld location? )Yes )No

4. Facility representative coordinating emergency action plan response:

Nan1e

of

Facility Representative: Phone

Alternate Facility Representative: Phone

1. tugas kelompok hot tap kel c wi 30

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