DGS-PU-015_Rev-1

PIPING TIE - INS

Sep-2018

2 Sh t
P= (i.e. Method 1 equation F=E=T=1)
D
Where:
Sh = Maximum allowable hoop stress, in N/mm2, calculated from the relevant
toughness formula in Appendix 14.
D = Outside diameter of run-pipe, in mm.
t = Nominal thickness, in mm.
P = Maximum allowable operating pressure during welding, in N/mm2.
8.3.3.4 Velocity of Process Fluid
Minimum Velocity
Welding on a line under no-flow conditions (i.e. 0 m/s) or intermittent-flow conditions,
i.e. a flare line, shall not be attempted unless it has been confirmed that no explosive
or flammable mixture will occur during the welding operation. In this respect, it shall
be confirmed that no ingress of oxygen in the line is possible.
In cases where this requirement cannot be met, purging shall be used. A minimum
purge velocity of 0.4 m/s should be maintained.
Maximum Velocity
High liquid flow will usually cause rapid cooling of the weld area during the hot-tap
welding. Under these circumstances the minimum interpass temperatures may not
be attainable, resulting in undesired material properties. A suggested maximum
velocity for liquid flow during welding is 1.75 m/s. If the actual velocity is greater than
this figure, it is recommended to carry out heat loss tests at the actual hot-tap
location. In the event of rapid cooling (i.e. where the cooling rate is such that the
minimum specified interpass temperature is not achieved), special interpass heating
techniques may be needed or the welding procedure amended.
There is no restriction on maximum velocity for gas lines, subject to the attainment of
acceptable interpass temperatures.
8.3.4 Hot-Tap Location
Hot-taps shall not be executed upstream of rotating equipment unless strainers,
capable of removing machining swarf, are fitted.
The chosen location on the run-pipe should be checked and verified as suitable for
the hot-tap connection, taking into account the following factors, as a minimum:
 Layout of branch to be tied-in
 Diameter and ovality

Printed 02-Oct-18 Page 25 of 65

A0-IG-W-SP-001 (Rev.0) Specification for Welding,
Inspection & Testing of Hot Tap Connections

E = Quality Factor = 1 for seamless pipe, 0.85 for SAW

D = Outside Diameter of pipe, inch
t = Measured thickness of pipe, inch
c = Empirical correction factor for safety of operation = 3/32 inch (2.4 mm)
Y = Coefficient for effective stressed diameter = 0.4
 If the minimum flow velocity of 0.4 m/s could not be maintained, then it shall be
ensured that there is no oxygen ingress in to the system to be hot tapped and
there is no potential explosive environment inside the carrier pipe to be hot tapped.
Maintaining some minimum flow with inert gas purging is ideal.
a. For run pipe with thickness less than 6.4 mm, some minimum level of flow
during welding is required to minimize the potential of undesirable conditions
such as overheating liquids and burn through caused by elevated metal
temperatures. Moreover, fluid thermal expansion in closed systems are less
likely when flow is maintained,
b. For metal thickness between 1/4 in. (6.4 mm) and 1/2 in.(12.7 mm), minimize
the flow rate to reduce the risk of cracking and keep the risk of burn through
low,
c. For metal thickness greater than 1/2 in. (12.7 mm), the effect of flow rate is
negligible.
 Welding operations shall never be carried out on equipment which contains the
following:
a. Any mixture of gases or vapors within their flammable range or which may
become flammable as a result of the heat input during welding operation as
part of the hot tapping process.
b. Any substance which may undergo any reaction or decomposition leading to a
dangerous increase in pressure or explosion or attack of the metal.
c. Oxygen-enriched atmospheres in the presence of hydrocarbons or other
combustible materials, which may be, present either in the atmosphere or
deposited on the interior surface of the equipment or carrier pipe to be hot
tapped.
d. Compressed air in the presence of hydrocarbons or other combustible materials
that may be present either in the air or deposited on the interior surface of the
equipment.
e. Welding on process equipment in service shall not be allowed in circumstances
where the materials of construction are such that post-weld heat treatment is
necessary
f. Welding operations are also prohibited if the wall thickness of the process
equipment, piping system, vessel or tank is actually less than 5 mm.
g. Welding should not be carried out on clad or lined pipe or equipment.
h. Welding and hot tapping are prohibited on pipes and equipment that contain
the following hazardous media or conditions. Hazardous substances in small
quantities also prohibits hot tapping unless positive evidence has been obtained
that welding / hot tapping can be applied safely.

Issue Date: July-2019 Page 13 of 38

Copyright © 2019 Abu Dhabi Company for Offshore Petroleum Operations Ltd– ADNOC Offshore. All rights reserved
 Rev

DGS 1300 100 0

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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
PIPING TIE-INS

300 0.75

200 0.85

120 0.91

Less than 120 1.00

Method 2 - Charpy Toughness

For Off-Plot pipelines, an alternative maximum pressure shall also be calculated to

prevent failure by crack propagation. The relevant formulae are dependent on the
fluid within the pipeline and also whether or not the line is buried (see Appendix 14).
For all cases the pressure is given by:
P = 2 Sh t (i.e. Method 1 equation F=E=T=1)
D
Where :

Sh = Maximum allowable hoop stress, in N/mm2, calculated from the relevant

toughness formula in Appendix 14.

D = Outside diameter of run-pipe, in mm.

t = Nominal thickness, in mm.

P = Maximum allowable operating pressure during welding, in N/mm2.

8.3.3.4 Velocity of Process Fluid

Minimum Velocity :

Suggested minimum velocities :

• Liquid : 0.5 m/sec.

• Gas : 1.5 m/sec.

Welding on a line under no-flow conditions (i.e. 0 m/s) or intermittent-flow conditions,

i.e. a flare line, shall not be attempted unless it has been confirmed that no explosive
or flammable mixture will occur during the welding operation. In this respect, it shall
be confirmed that no ingress of oxygen in the line is possible.

In cases where this requirement cannot be met, purging shall be used. A minimum
purge velocity of 0.4 m/s should be maintained.

Maximum Velocity :

High liquid flow will usually cause rapid cooling of the weld area during the hot-tap
welding. Under these circumstances the minimum interpass temperatures may not
be attainable, resulting in undesired material properties. A suggested maximum
velocity for liquid flow during welding is 1.75 m/s. If the actual velocity is greater than
this figure, it is recommended to carry out heat loss tests at the actual hot-tap
______________________________________________________________________________________________________D
GS-1300-100/FH
 Rev

DGS 1300 100 0

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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
PIPING TIE-INS

location. In the event of rapid cooling (i.e. where the cooling rate is such that the
minimum specified interpass temperature is not achieved), special interpass heating
techniques may be needed or the welding procedure amended.

There is no restriction on maximum velocity for gas lines, subject to the attainment of
acceptable interpass temperatures.
8.3.4 Hot-Tap Location

Hot-taps shall not be executed upstream of rotating equipment unless strainers,

capable of removing machining swarf, are fitted.

The chosen location on the run-pipe should be checked and verified as suitable for
the hot-tap connection, taking into account the following factors, as a minimum:
• Layout of branch to be tied-in
• Diameter and ovality
• Pipe wall thickness
• Internal and/or external corrosion
• Defects in the pipe wall (e.g. laminations)
• Soundness of adjacent welds
• Internal deposits

(See section 8.6.3 for assessment methods).

8.3.5 Line Size

Heat loss tests should be performed for large lines due to the excessive heat loss at
the weld area during the hot-tap welding operation.
8.4 DESIGN
8.4.1 Base Materials

Base materials of the run-pipe and the branch connection shall be compatible in
terms of weldability. Materials having the same P number, as defined in ASME IX,
may be used as the basis of compatibility. However, where grades with special
numbers (SP-1 etc.) are to be used, a materials/welding specialist should review the
proposed materials.
8.4.2 Design Calculations

Branch connections shall be designed in accordance with the appropriate design

code, i.e.

1. On-Plot Piping: ANSI/ASME B31.1 Power Piping

ANSI/ASME B31.3 Process Piping

2. Off-Plot Pipeline: ANSI/ASME B31.4 (oil lines), or

ANSI/ASME B31.8 (gas lines)

______________________________________________________________________________________________________D
GS-1300-100/FH