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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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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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April 2016
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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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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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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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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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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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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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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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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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2.4 Process to Review Whether Hot Tapping is Appropriate
Gambar
3
Procces
review
whether
hot
tapping
is
Appropriate
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2.5 Decision Process for Authorizing Hot Tapping Tap
Gambar 4 Decision Process for authorizing Hot Tapping Tap.
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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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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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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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c. Gambar ( As Built Drawing) KonstuksiHot Tap.
d.
Dan lain – lain.
9.
Berita acara serah terima pekerjaan.
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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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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)
MAIN PROCEDURE - PIPE To WELDOLETCODE AND SPECIFICATION : API 1104 (2007 Edition)
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
MAIN PROCEDURE - PIPE To WELDOLETCODE AND SPECIFICATION : API 1104 (2007 Edition)
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 : -
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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 : -
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Laporan Tugas Kelompok
STUDI KASUS HOT TAPPING PADA PIPA GAS BUMI
Kelompok C
April 2016
18
LAMPIRAN 3 Form pelaksanaan Hot Tapp API
RP 2201
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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
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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?
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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.
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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
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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.
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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
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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