KOC.sa.019 - Safety Procedure for Hot-tapping

KOC.SA.019 - Safety Procedure for Hot-tapping Page 1 of 7

SAFETY PROCEDURE FOR HOT-TAPPING Document Number: KOC.SA.019 Approver: (Technical) Approver: (Administrative) Scope: Issue Date: Revision / Review Date:

Manager (IS) Manager (HSE) All KOC Directorates 30/05/2010 20/06/2012

Author: Document Coordinator: Control Tier: Issuing Group Next Review Date:

TL I&C (N&W) TL Standards Tier 3 IS Group 19/06/2015

1.0

Purpose / Scope The purpose of this procedure is to ensure that all hot-tapping work and hottap tool maintenance are carried out in accordance with a safe and approved manner. This procedure outlines the process for hot-tapping operations on inservice equipment by the concerned KOC and Contractor's employees in compliance with relevant standards.

2.0

Definitions

2.1

Access Fittings The Access fitting is a standard specialized fitting made for internal corrosion monitoring that mounted/installed to the pipe by direct welding. The standard 2” high-pressure type access fitting provides internal access to the system under full operating conditions up to 6,000psig.

2.2

Cutter Cylindrical toothed part of hot-tapping machine for making a bore by trepanning.

2.3

Hot-Tapping Technique of creating an opening on the equipment which is in-service by cutting or drilling a portion of a piping/pipeline/equipment within an attached fitting using machine. Welding a fitting is not considered as a part of hottapping work in this document.

2.4

In-Service Equipment Equipment, which is in service or not in use but not mothballed as per KOC standard.

2.5

Service Valve The service valve is a full-bore valve used for holding the pressure during hottapping operation.

2.6

Hot-Tap Machine Maintenance: Maintenance shall be carried out as per clause 19.0 of KOC-MP-038 “KOC Recommended Practice for Hot-Tapping and Plugging.”

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REQUIREMENTS  KOC HSEMS Element HSE-02-3  KOC HSEMS Element HSE-03-1  KOC HSEMS Element HSE-03-3  KOC HSEMS Element HSE-05-3

4.0

Key Responsibilities:

4.1

Permit Applicant  An appropriate Work Permit shall be raised by the Permit Applicant for hot work within a RESTRICTED or HAZARDOUS AREA and shall be submitted for authorization to the respective Permit Issuer in whose area of control the work is to be carried out.  Shall be responsible to prepare and sign the Job Safety Analysis (JSA) for the scheduled work.  Shall be responsible to ensure that worksite crew is fully aware by of the Job Safety Analysis (JSA) recommendations’.  Shall be responsible to ensure that the hot-tapping equipment operator has full knowledge and experience to operate of the equipment.  Shall be responsible to ensure that the “SPECIFIC CONTINGENCY PLANS” required as per clause 5.2.1 had been is developed, reviewed and approved by all concerned Teams.

4.2

Permit Issuer  Shall be responsible to identify all hot-tapping hazards and highlight these in the Hot Work Permit along with the necessary safety precautions..  Reviewing the hazards potential, precautions to be taken, and personnel protection specified whilst such operations are being performed.  Ensuring that all safety precautions and conditions detailed in the Permit to Work are adhered to and that all safety procedures are fully implemented.  A proper gas test is carried out when hot tapping operations are taken in either confined place or in open area.  Reviewing the Job Safety Analysis (JSA) for the scheduled work.  Ensure that approved Work Method Statement (by controlling team of the project) is available.  Issuing of the work permit should be at working spot and only after ensuring that all of the above are fulfilled and adhered to.

4.3

Worksite Supervisor  Hot tapping being a specialized and on-line job, Worksite Supervisor should have relevant previous experience and ensure that personnel involved have the required skill for carrying out the hot tapping.  Ensure that hot tapping machine is installed in such a way that the operator is positioned in upwind direction.  Ensuring appropriate fire extinguishers, gas monitors for flammable gas, toxic gas and oxygen, first aid kits, and safety signs and notices (where applicable) are available at the work area.

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Two way radio communication shall be made available between Worksite Supervisor and a representative from Operations Team in control room. Ensure that the cutter is retrieved, the isolation valve is closed and hot work operation is stopped safely, if any hazardous or potentially hazardous situation is observed e.g. leak or any other operational requirements. Inform Fire team of the area before start of work.

4.4

The Worksite Crew  Undertaking all hot-tapping works in a safe and effective manner as detailed in the Hot Work Permit and approved Hot-tapping Work Method Statement.  Hot-tapping shall be carried-out either by the KOC approved Contractor or by the KOC specialized Maintenance crew who has full knowledge of hottapping equipment and its operation, as decided by KOC.  Fully aware of the hazards involved in the task and that they understand the conditions detailed in the Permit to Work.  Adhering to all applicable safety precautions prior to and throughout the duration of the work.

5.0

Procedure

5.1

General All operations involving hot-tapping must be undertaken in accordance with the approved Work Method Statement (approved by controlling team) and the requirements of the Permit to Work Procedure, specifically this means under the control of a Hot Work Permit and before such a permit is prepared a risk assessment of the task to be undertaken must be completed.

5.2

Hazards Some of the hazards associated with hot-tapping operation are:  Leak from hot-tapping machine or flanges due to sealing failure  Cutter is jammed and cannot be retrieved.  Isolation valve not closing or passing

5.3

Key Safety Measures

5.3.1 General Precautions  Chapter 5 of API RP 2201 "Hazard Evaluation and Risk Reduction for HotTapping on In Service Equipment" shall be followed.  All safety requirements shall be identified, documented and implemented in accordance with KOC HSEMS procedure "Welding and Cutting (KOC.SA.021) and full compliance of HSEMS Permit to Work procedure (KOC.SA.004) before starting the work.  Job Safety Analysis (JSA) shall be prepared for hot-tapping operations in accordance with the KOC HSEMS procedure "Job Safety Analysis" (KOC.SA.024).  An emergency plan to be developed and approved before the commencement of the work. Control Tier: 3

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Specific Contingency Plans shall be prepared and approved by KOC. The plan shall include the following points as minimum: - “Operational Emergency" (OE) and the restart conditions (i.e. once the OE is over and operations are restored to normalcy). - Contingency plans shall include approved plans and readiness for emergency shut-down of the facility, deployment of operators, fire & safety personnel and mechanical fitters to carry out spading for positive isolations. Ensuring that all precautions and conditions detailed on the Permit to Work and Job Safety Analysis (JSA) are observed throughout the duration of the task especially, cordoning-off work area. Maximum allowable operating pressure of hot-tapping section during hottapping on live line shall be evaluated. Ensure that no other activity shall be carried out, which could affect the safety or integrity of equipment / facility / workers. Ensure that pipeline thickness at the area of the hot-tapping is suitable for the job and will not collapse after welding due to corrosion or any other factors. In case hot-tapping is to be carried out at a high elevation, the scaffolding shall be provided as per the "KOC Recommended Practice for Scaffolding" (KOC-L-025) and KOC HSEMS document “Control and Use of Scaffolding” (SA. KOC. 002). In case hot-tapping to be carried out in underground access pit, KOC Procedure "Entry into Confined Spaces" (SA-KOC-007) shall be followed. The personnel should be equipped with retrieval system. Continuously check the work area after issue of the Permit to Work to ensure that conditions have not changed since time of issue. Ensure the gas test are carried out by calibrated and certified (with validity date) gas detector prior to commencement of the task and wherever required continuously, throughout the duration of the task. Prior to and throughout all hot-tapping operations, check the following conditions, which may be stipulated in the Hot Work Permit. - Restrictions on other operations in the work area. Ensuring that any area in which the fire detection / protection has been inhibited is not left unattended. Check that access passageways are clear and that all means of escape from the area are fully operational and communicated to Worksite Crew members. Check for proper safety signs and notices at site. Use of iron (ferrous metal) hammer shall be prohibited. Non sparking tools under adequate supervision may be allowed. Hot-tapping machine shall be independently supported and it shall be ensured that its weight is not transferred to the equipment/pipeline that is being tapped. Areas, events or conditions that hot-tapping operations shall not be permitted are indicated in Appendix 1, Appendix 2 and Appendix 3 of “KOC Recommended Practice for Hot-Tapping and Plugging" (KOC-MP038).

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Hot-tapping shall not be carried out during high windy, stormy, dusty and wet atmospheric conditions unless approved by KOC. Proper covered enclosure shall be erected around the working spot and approved by KOC. Care shall be taken to ensure there is no hydrocarbon spillage. Fluid shall be fully transferred out from hot-tapping machine in an environmental friendly manner. Hot-tapping Site shall be provided with warning barricade with a horizontal radius not less than fifteen (15) meters. The construction equipment and the mobile equipment shall be stationed upwind, far away but not within the fifteen (15) meters radius. The HSE requirements of the content of pipe shall be ensured as per relevant Material Safety Data sheet (MSDS). Ensure that the operating pressure and temperature of equipment or piping being hot-tapped should at no time exceed the rated pressure and temperature of the cutting machine. Make sure pressure is not in excess of hot-tapping machine rating. Care should be taken to ensure that neither pressure nor temperature will rise appreciably during the hot-tapping operation as a result of a surge of pressure or a temperature rise of the fluid contents of the equipment being tapped. In addition to the above, ensure that the guidelines mentioned in the following clause of KOC Standard KOC-MP-038 “Recommended Practice for “Hot-Tapping and Plugging” are complied: - Clause 6.0 “HEALTH, SAFETY AND ENVIRONMENT.” - Clause 8.1.1 “Risk Assessment for Hot-tapping.” - Clause 8.2 “Specific Written Plans, Safety Plans and Contingency Plans.” - Clause 10.3 “Pre-Execution Checks and KOC Role.” - Clause 12.2 “Flow I Velocity in Pipelines and Piping."

5.3.2 Hot-Tapping Machine & Access Valve Check the following conditions apply with regard to hot-tapping machine, & access valve:  Safety guard, safety and ergonomic aspects of hot-tapping machine, & service valve shall comply with "Safe Use of Machinery" (BS PD 5304). Safety hazard with threaded fittings shall be considered and persons shall not work in its possible trajectory (in anticipation of its failure).  The hot-tapping machine & access valve shall be checked for its rating to ensure it can perform the intended job.  In addition to the above, ensure that the guidelines mentioned in the following clause of KOC Standard KOC-MP-038 “Recommended Practice for “Hot-Tapping and Plugging” are complied:  Clause 16.2 “Checking the Hot-Tap Machine, Drill and Cutter.”  Clause 16.3 “Checking and Shop Testing of Hot-Tap Valve.” 5.3.3 Protective Clothing and Equipment.

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Ensure that personnel at the site where hot-tapping is taking place wear appropriate protective clothing, which must not be contaminated with oil or grease. This may include:  Cotton coverall along with suitable aprons, sleeves and leggings as required for the job.  The hot-tapping machine operator must also use other personal protective equipments (such as goggles, helmet, face shield, hand gloves etc.) as appropriate to the job.  The Worksite Crew must be familiar with precautionary measures associated with breathing apparatus and escape mask and shall be trained for wearing of breathing apparatus or escape mask.  As the Hot-tapping Machine is a rotating equipment, therefore wearing of loose clothes like “Ghuttra” shall not be allowed.  In addition to the above, ensure that the guidelines mentioned in KOC HSEMS procedure Protective Clothing and Equipment, Document Number: KOC.SA.010 are complied. 5.4

Documentations  Hot-tapping Work Method Statement shall be made available at Site for entire duration of the operation.  The Manufacturer's instructions shall also be followed for performing the hot-tapping operation.  Hot-tapping shall not be done until all the required checklists (As mentioned in Appendix ‘4’ of Doc No. KOC-MP-038 “KOC recommended practice for Hot-Tapping and Plugging” are completely filled and agreed by KOC concerned Teams.  Upon completing the hot-tapping, the hot-tapping machine shall not be removed until the required checklist is completely filled and agreed by KOC concerned Teams.

6.0

Key Documents/Tools/References The selection of material covered by this procedure shall comply with the most recent edition of the references listed below, except as otherwise specified.

6.1

Company Specifications  KOC-EG-C-M-13 Mechanical Check List for Hot-Tapping on Existing Pipelines / Piping.  KOC-L-006 KOC Standard for Fire and Gas Detection Equipment.  KOC-L-009 KOC Standard for Fire Protection and Safety Equipment.  KOC-L-010 KOC, Part 1: Standard for Personal Protective Equipment (Ear, Eyes, Hand and Head Protection).  KOC-L-025 KOC Recommended Practice for Scaffolding.  (KOC-MP-038) KOC Recommended Practice for Hot-Tapping and Plugging.  KOC.GE.006 Management of Change Procedure.  KOC.HE.003 Gas Testing and Gas Test Standards.  KOC.SA.002 Control and Use of Scaffolding.  KOC.SA.004 Permit to Work Procedure.

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KOC.SA.010 Protective Clothing and Equipment. KOC.SA.018 Risk Assessment. Procedure and Guidelines KOC.SA.021Welding and Cutting Procedure KOC.SA.024 Job Safety Analysis. KOC.SA.007 Entry into Confined Spaces Procedure.

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International Standards API RP2201 - Safe Hot-Tapping Practice in the Petroleum and Petrochemical Industries.

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ABBREVIATIONS      

8.0

KOC – Kuwait Oil Company HSE – Health, Safety & Environment HSEMS – HSE Management System JSA – Job Safety Analysis P&ID – Piping & Instrumentation Diagram MSDS – Material Safety Data Sheet

HSE RECORDS (RETENTION PERIOD)   

Applicable Work Permits (Refer to Permit to Work Procedure, KOC.SA.004 for complete details) Pertinent JSA records (Refer to Job Safety Analysis procedure, KOC.SA.024 for complete details) Relevant transmittals/correspondences (5 years)

Review/Revision Log Review/Revision Date May 30, 2010

June 20, 2012

Document approver Manager (IS)

Document author TL I&C (N&W)

Manager (IS)

TL I&C (N&W)

Revision Details Final approved by HSEMS Implementation Committee and issued. Clause-1, added “in-service Equipment”. Clause 2, Definition of hot-tapping clarified, new definition for in-service Equipment added and clauses 2.4 & 2.5 deleted. Clauses 4 and 5 revised for clarity and avoiding duplications. Clause 6–specification numberings clarified for accuracy.

Control Tier: 3

Revision Date: 20-06-2012 Uncontrolled Copy if Printed