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ABU DHABI MARINE OPERATING COMPANY
SP-1005

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COPYRIGHT © ABU DHABI MARINE OPERATING COMPANY - ADMA-OPCO

All rights reserved. The information contained in this document is regarded as confidential. Recipient(s) other than ADMA-
OPCO's employees undertake both during the continuance of their services to ADMA-OPCO and after termination to maintain
in safe custody and not to use any such information for any purpose other than a purpose falling within the scope of the
Agreement or Contract under which this document was supplied. Recipient(s) further agree not to dispose of, make copies, in
whole or in part of such information or permit the use or access of the same by any Third Party unless the prior written
permission of ADMA-OPCO Manager Facilities Engineering is obtained.

D DESIGNATION SP-1005
O
C SPECIFICATION
U FOR
M TITLE WELDING, INSPECTION & TESTING
E OF
N HOT TAP CONNECTIONS
T

AUTHORITY NAME TITLE B.UNIT/DIV SIGNATURE DATE

TECHNICAL
M. H. Fahmy LWE Prod./ID
CUSTODIAN

STANDARDS M.Khalid Elshobary SSL Dev./FED

INTEGRITY
Mahdi Al-Marzooqi FITL Prod./ID
ASSURANCE

APPROVAL Christopher J. Houghton IM Prod./ID

ENDORSEMENT Abdul Aziz Al-kayoumi AGM(P-A) Production

CONTROL STAMP

The soft copy of this document

on ADMA-OPCO Web is
Controlled.
When printed, it is considered
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 TABLE OF CONTENTS

1. INTRODUCTION....................................................................................................................... 5
1.1 BACKGROUND ........................................................................................................... 5
1.2 SCOPE ........................................................................................................................... 5
1.3 COVERAGE ................................................................................................................. 5
1.4 EXCLUSIONS .............................................................................................................. 5
1.5 REFERENCED STANDARDS ................................................................................... 6
1.6 ABBREVIATIONS....................................................................................................... 6
1.7 DEFINITIONS.............................................................................................................. 6
1.8 USE OF LANGUAGE .................................................................................................. 7
1.9 LESSON LEARNT....................................................................................................... 7
2. QUALITY ASSURANCE .......................................................................................................... 8
2.1 QUALITY ASSURANCE SYSTEM........................................................................... 8
2.2 QUALITY PLAN.......................................................................................................... 9
3. GOVERNING CODES .............................................................................................................. 9

4. PERSONNEL AND RESPONSIBILITIES........................................................................... 10

5. MATERIALS OF CONSTRUCTION ................................................................................... 11

5.1 PIPE AND FITTINGS MATERIALS ...................................................................... 11
5.2 CARBON EQUIVALENT ......................................................................................... 11
5.3 SOUR SERVICE ........................................................................................................ 11
5.4 CONNECTING FITTINGS....................................................................................... 11
5.5 VALVES ...................................................................................................................... 11
6. PREPARATION OF MATERIALS & EQUIPMENT........................................................ 12
6.1 PRE-INSPECTION OF CARRIER PIPE................................................................ 12
6.2 LIMITING FACTORS .............................................................................................. 12
6.3 PREPARATION OF THE HOT TAP AREA PRIOR TO WELDING ................ 13
7. SUPERVISION AND SAFETY REQUIREMENTS ........................................................... 15
7.1 WELD SUPERVISION.............................................................................................. 15
7.2 HOT TAP OPERATION SAFETY REQUIREMENTS......................................... 15
8. WELDING CONTROL ........................................................................................................... 16
8.1 WELD PROCEDURE SPECIFICATION ............................................................... 16
8.2 WELDING PROCESS ............................................................................................... 16
8.3 RUN OF PIPE AND FITTING MATERIALS ........................................................ 16
8.4 DIAMETER GROUP & MATERIAL THICKNESS GROUP.............................. 17
8.5 PIPELINE OPERATING CONDITIONS ............................................................... 17
8.6 JOINT DESIGN.......................................................................................................... 17
8.7 ELECTRICAL CHARACTERISTICS .................................................................... 17
8.8 PREHEAT ................................................................................................................... 17
8.9 INTERPASS TEMPERATURE................................................................................ 18

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 8.10 FILLER METAL AND CONSUMABLES .............................................................. 18
8.11 BEAD TECHNIQUE.................................................................................................. 19
8.12 SPEED OF TRAVEL ................................................................................................. 19
8.13 WELDING EQUIPMENT......................................................................................... 19
8.14 CLEANING................................................................................................................. 19
8.15 ESSENTIAL VARIABLES........................................................................................ 19
8.16 WELD PROCEDURE QUALIFICATION.............................................................. 20
9. WELDING RUN SEQUENCE................................................................................................ 21
9.1 FULL ENCIRCLEMENT FITTINGS ..................................................................... 21
9.2 WELDOLET AND NOZZLE FITTINGS & REINFORCEMENT ...................... 22
10. INSPECTION OF HOT TAP WELDS.................................................................................. 22
10.1 VISUAL INSPECTION ............................................................................................. 22
10.2 HARDNESS EXAMINATION.................................................................................. 22
10.3 MAGNETIC PARTICLE EXAMINATION ........................................................... 22
10.4 ULTRASONIC EXAMINATION............................................................................. 23
10.5 NDT STANDARDS OF ACCEPTABILITY............................................................ 23
11. PRESSURE TESTING............................................................................................................. 23

FIG.1: HOT TAPPING ...................................................................................................................... 25

FIG.2: LONGITUDINAL WELD SEAMS (DIMENSIONS IN MILLIMETERS) .................. 26

FIG.3: ATTACHMENT OF RUN ON/RUN OFF PLATES OF BACKING BAR/STRIP ...... 27

FIG.4: YOKE-TYPE CLAMP .......................................................................................................... 28

FIG.5: WELDING SEQUENCE FOR CIRCUMFERENTIAL WELDS................................... 29

FIG.6: WELDING SEQUENCE FOR CIRCUMFERENTIAL WELDS................................... 30

FIG.7: WELDOLET FITTING WELD DETAILS........................................................................ 31

FIG.8: WELDING PROCEDURE QUALIFICATION TEST ASSEMBLY ............................. 32

FIG.9: WELDER QUALIFICATION TEST ASSEMBLY .......................................................... 33

FIG.10: LOCATION FOR HARDNESS IMPRESSIONS............................................................ 34

FIG.11: WELDING SEQUENCE OF WELDING NOZZLE AND REINFORCING PAD .... 35

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 APPENDIX-A: HOT TAPPING DESIGN CHECK LIST ........................................................... 36

APPENDIX – B: HOT TAPPING PERMIT CHECK LIST ........................................................ 41

APPENDIX – C: RECORD OF APPROVAL TESTS OF WELDING PROCEDURE ........... 44

APPENDIX - D: AUTHORITIES & RESPONSIBILITIES ........................................................ 45

APPENDIX-E: ABBREVIATIONS ................................................................................................. 46

APPENDIX-F: DEFINITIONS......................................................................................................... 47

APPENDIX-G: REFERENCED DOCUMENTS ........................................................................... 48

APPENDIX - I: AUTHORIZATION HISTORY OF SP-1005 ....................................................... 50

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 1. INTRODUCTION
1.1 Background
Revision (Rev.1) of SP-1005 Rev.0 was found necessary to incorporate and
highlight the main issues listed below:
a. Latest referenced Standards Engineering Documents & International Standards.
b. Experiences, lessons learnt and users feedback on SP-1005 since its issue for
implementation as Rev.0 on November 1987.
c. The latest ADMA-OPCO requirements regarding the key issues such as
QA/QC and document control requirements.
d. The latest update/changes in ADMA-OPCO organization, roles &
responsibilities of respective authorities.
Authorization history of this document is listed in Appendix - H of this
Specification.
1.2 Scope
This Specification specifies ADMA-OPCO minimum requirements for welding,
inspection and testing in preparation for hot tapping operations on Carbon steel
pipelines and process piping under pressure. Hot tapping operations shall comply
with API RP 2201, API STD 1104 and this Specification.
1.3 Coverage
This Specification covers hot tapping operations on pipe of minimum 6.3mm (¼")
residual thickness.
1.4 Exclusions
1.4.1 Pipe with residual wall thickness less than 6.3mm (¼") is excluded from this
Specification.
1.4.2 This Specification shall not apply to piping operating at temperatures below 50
deg F (10 deg C) since the high cooling rates would increase the cracking
propensity unless job specific procedures have been qualified by Contractor and
Approved by ADMA-OPCO.
N.B:
Spiral welded pipes shall not be hot tapped.

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 1.5 Referenced Standards
1.5.1 General
The latest edition (at the time of the contract award) of the Documents listed in
Appendix-G shall to the extent specified herein, represent part of this Specification.
The latest edition/revision of ADMA-OPCO Standards Engineering Documents
shall be utilized as indicated in the Status List SL-001.
ADMA-OPCO Standards Engineering Documents are developed, maintained &
controlled by the Standards Authority as stipulated in ADMA-OPCO PRO-00.
1.5.2 Equivalent Standards
Standard Documents equivalent to those referred to herein shall not be substituted
without written approval from ADMA-OPCO. Approval of equivalent Standard
Documents will not, in any way, remove responsibility from the Fabrication
Contractor / Manufacturer to meet the best practices and/or requirements of the
Standard Engineering Documents referred to herein, in the event of conflict.
Where differences and/or conflicting issues occur between the referenced
documents themselves or the requirements of this Specification, the requirements of
this Specification shall take precedence unless otherwise advised by ADMA-
OPCO. However major conflicts shall be reported in writing to ADMA-OPCO for
arbitration/resolution.
Where this Specification states no overriding requirements over the Standard
Engineering Documents requirements, the later shall apply in full.
The Contractor shall equip himself with copies of all the referenced Standard
Engineering Documents referred in Appendix-G of this Specification and shall
make them readily available to all ADMA-OPCO, or nominated representative,
personnel involved in the work.
1.6 Abbreviations
The abbreviations used in this Specification are listed in Appendix-E.
1.7 Definitions
The definitions used for the hot tapping Procedure are listed in Appendix-F.

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 1.8 Use of Language
Throughout this Specification, the words ‘will’, ‘may’, ‘should’ and ‘shall’, when used
in the context of actions by ADMA-OPCO or others, have specific meanings as
follows:
a. ‘Will’ is used normally in connection with an action by ADMA-OPCO and / or
nominated representative, rather than by a Contractor or Vendor.
b. ‘May’ is used where alternatives are equally acceptable.
c. ‘Should’ is used where provision is preferred.
d. ‘Shall / Must’ is used where a provision is mandatory / vital.
1.9 Lesson Learnt
Lessons learned related to the scope of this document shall be fed to ADMA-OPCO
Lessons Learnt System, as appropriate.

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 2. QUALITY ASSURANCE
2.1 Quality Assurance System
2.1.1 Services and activities associated with hot tapping shall only performed by
Contractors specifically approved by ADMA-OPCO.
2.1.2 Contractors shall operate Quality Management Systems (QMS) within their
organizations, which ensure that the requirements of this Specification document
are fully achieved.
2.1.3 The Contractor’s quality management system shall be based on the latest issue of
ISO 9001 Series and accredited by an international certifying agency.
The Contractor’s quality manual shall provide details for the preparation of a
quality plan, which shall include provisions for the QA/QC activities related to hot
tapping.
When an approved Contractor revises their Quality Management System that
affects the ADMA-OPCO approved Quality / Inspection & Test Plan, then the
revised Quality/Inspection & Test Plan shall be re-submitted for ADMA-OPCO
approval before commencement of any hot tapping activities.
2.1.4 The effectiveness of the Contractor's quality management system may be subject to
monitoring by ADMA-OPCO or its representative and may be audited following an
agreed period of notice.
2.1.5 The Contractor shall make regular QA audits on all their Sub-
Contractors/Suppliers. Details of these audits shall be made available to ADMA-
OPCO when requested.
2.1.6 The Contractors shall maintain sufficient Inspection and Quality Assurance staff,
independent of the service provider management, to ensure that the QMS is
correctly implemented and that all related documentation is available.
2.1.7 The use of Sub-Contractors for any activities associated with hot tapping shall
require specific Approval from ADMA-OPCO.

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 2.2 Quality Plan
2.2.1 Contracted activities associated with hot tapping shall be performed in accordance
with an Approved Quality Plan (QP).
2.2.2 The level of detail required in the Quality Plan shall be commensurate with the
scope of services to be provided under the Contract.
2.2.3 The quality of services activities are essential factors in hot tapping.
2.2.4 During hot tapping quality assurance/quality control issues are the responsibility of
the Contractor. Integrity Assurance Authority or TPA Representative shall be
consulted as appropriate.

3. GOVERNING CODES
Design, welding, inspection and testing of Hot Tap connections shall be in accordance with
API RP 2201, API STD1104 unless otherwise specified in this Specification.

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 4. PERSONNEL AND RESPONSIBILITIES
4.1 The authorities listed in Appendix-D are primarily responsible to the extent
specified herein for satisfying the requirements of this Specification.
4.2 It is the responsibility of the Job Officer assigned to arrange for approval of all the
necessary documents, and to obtain the resources from the concerned authorities to
ensure that work is carried out successfully and in the most effective and safe
manner meeting all technical and operational requirements.
4.3 The Contractor shall carry out a heat flow study and review of previous experience
of the welding to be carried out, taking into account the actual fluids, operating
conditions and local thicknesses involved, and ensure that the operation is safe to
carry out, in accordance with this Specification (including Appendices-A and A.1)
and API RP 2201. The Contractor shall submit this study report for approval by
ADMA-OPCO.
4.4 The qualification of personnel engaged in quality control aspects associated with
hot tap operations shall be in accordance with requirements of ADMA-OPCO SP-
1031.
4.5 Authorization for the hot tapping operation shall be obtained from the Engineering,
Integrity Assurance, Operating, and HSE Authorities.
4.6 The welding procedure shall be approved by Integrity Assurance Authority prior to
the commencement of work.

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 5. MATERIALS OF CONSTRUCTION
Material specifications and manufacturers test procedures relating to carrier pipe, hot tap
fittings and valves are described below.
5.1 Pipe and Fittings Materials
This Specification applies to welding steel Pipe and fittings materials which shall
conform to:
5.1.1 For Line pipe
API Spec. 5L or Applicable ASTM Standards & ADMA-OPCO SP-1000.
5.1.2 For Piping
Applicable ASTM Standards, ADMA-OPCO STD-108, ADMA-OPCO STD-126
ADMA-OPCO STD-127, ADMA-OPCO STD-128 & ADMA-OPCO SP-1000.
5.2 Carbon Equivalent
5.2.1 The carbon content of all weldable steel shall be restricted to a maximum of 0.25%
and the carbon equivalent value (CE) shall not exceed 0.42% when calculated
according to the following formula.

Mn Cr + Mo + V Ni + Cu
CE = C + + + %
6 5 15
5.2.2 Where the chemical composition or material Specification differs significantly from
that required, additional precautions will be necessary and Integrity Assurance
Authority shall be consulted for resolution.
5.3 Sour Service
Materials for hot tapping to be used for sour service lines and piping shall comply
with the requirements of ISO 15156 (NACE MR0175) & ADMA-OPCO SP-1000.
5.4 Connecting Fittings
Connecting fittings such as weldolets, split tees, saddles, nozzles etc shall be
designed to ASME B31.3 unless otherwise specified. The design shall include the
specifications of gaskets and bolts.
5.5 Valves
Full-bore gate or ball valves shall be specified to enable withdrawal of the pipe
coupon. Before hot tapping commences each valve shall be tested for full body
pressure rating and for tight shut off as called for in ADMA-OPCO Standard
STD-115 & STD-116.

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 6. PREPARATION OF MATERIALS & EQUIPMENT
6.1 Pre-Inspection of Carrier Pipe
Pre-Inspection of line pipe to determine location of Hot Tap shall be done as
follows under close supervision of Integrity Assurance Authority or TPA
Representative.
6.1.1 Paint, wrapping or insulation material shall be carefully removed from the pipe in
the proposed area of attachment for a length extending to 600mm (24") either side
of the proposed location of the fitting.
6.1.2 The section of pipe to which the fitting is to be welded shall be thoroughly cleaned
with a wire brush for a distance extending 150 mm (6") either side or the location
of the fitting. After cleaning, the pipe shall be visually examined for corrosion and
signs of mechanical damage.
6.1.3 The exposed pipe shall be checked with calipers to ensure that any ovality is within
the acceptable tolerances.
6.1.4 The position of the new branch connection shall be chosen to avoid crossing any
existing pipe longitudinal or circumferential welds.
6.1.5 For longitudinally welded line pipe the longitudinal fitting welds shall be displaced
from the pipe weld by a minimum of 15°.
6.1.6 Hot tapping, which would result in the fitting edge fillet weld being closer than
460cm (18") to a flange or threaded connection, or 75 mm (3") to a welded seam,
shall be avoided.
6.1.7 100% of a band 150mm (6") wide centered over the proposed attachment weld
locations shall be examined ultrasonically to ensure that all pipe wall thicknesses
are 6.3mm (0.25") minimum and free from laminations, inclusions and other
injurious defects. Twin crystal compression wave Probe 5 MHZ type shall be used
in accordance with ASME Section-V.
6.1.8 Operators/Inspectors qualification shall be as called in Section 10 of this
Specification.
6.2 Limiting Factors
The external environment for welding must be free of a source of ignition. No
welding should begin until a safe limit has been established. This must be checked
by measuring the atmosphere with an explosimeter (refer to hot work permit and
Appendix-A).

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 6.3 Preparation of the Hot Tap Area Prior to Welding
Only two types of hot tap fitting are permitted: full encirclement fittings and
Weldolets. Preparation of the hot tap area immediately prior to welding shall be
carried out under close supervision of ADMA-OPCO representative as described
below.
6.3.1 Full Encirclement Fittings
The following requirements apply to full encirclement fittings:-
a. The matched ends of the fitting shall be identified by a painted band. Ends
shall be identified further by a number stamped on upper and lower fitting
halves at the band ends. The bands must match for correct fitting alignment
when installed on the pipe. The fitting numbers must also correspond.
b. To control the quality, profile, strength and stress concentration of the fitting
edge to line pipe circumferential fillet welds, it is essential that the gap between
the fitting and the line pipe shall be as small as possible. In no cases shall the
maximum gap be larger than 3mm. To achieve that, corrective methods shall
be performed wherever necessary to achieve correct fit, as follows:-
b.1 Grind fitting as necessary to achieve a proper gap.
b.2 Grind the pipe seam weld projection but do not thin the pipe wall below
the minimum design wall thickness.
b.3 Ensure that the line pipe where the weld footprint will be, and the edge of
the fitting is ground to bright metal.
b.4 Use chain boomers or other mechanical means to assist in installation of
fitting. Refer to Fig.4 for details of a yoke-type clamp.
b.5 Ensure that the surfaces to be welded and the root crevice are free from
grease and paint.
c. The completed fitting circumferential weld preparation shall comply with
Fig.5.
NB
The fillet leg length is increased by the gap size in order to maintain the weld
strength; minimum throat thickness must exceed or match the minimum design
wall thickness.
d. The standard preparation for "Full encirclement Fitting" longitudinal welds is
shown in Fig.2. However, should it be found necessary to alter a weld
preparation profile, this should be done by oxy-acetylene flame cutting and
grinding to a smooth finish. The weld preparation shall be crack detected by
MPI. Grinding is to be adequate to remove all heat-affected material.
NB.
The longitudinal welding directly on to the line pipe shall not be permitted.

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 e. The root gap for the longitudinal weld preparation is not critical as the backing
strip prevents any fusion of fitting, to the pipeline. However, the work shall be
carried out within the tolerances detailed in fig. 2 in order to avoid excessive
deposition of weld metal.
f. Before finally clamping the tee, the backing strips shall be slid into the
machined recess at the root of the longitudinal seams. The backing strips shall
have a cross section of 25 mm x 3mm (1”x 1/8") and conform to BS EN 10025
type S275JR or equivalent. Temporary run-on/run-off plates shall be attached
to the backing strip as shown in Fig. 3.
NB
The run-on/off plates must not be attached to the line pipe, and if they are
attached to the fitting, the fitting must have appropriate pre-heat.
g. After clamping the tee, all remaining surface grease and paint in and around the
recess of the branch and the tee fitting weld preparation shall be removed in
preparation for welding the longitudinal seam.
6.3.2 Weldolet Fittings & Nozzles
The following requirements shall be applied to weldolet fittings and nozzles:-
a. Where pipe curvature requires grinding of the weldolet fitting or nozzle weld
preparation shall be carried out to ensure a proper fit.
b. A uniform gap of 1.6 mm to 3 mm (1/16" to 1/8") between fitting and pipe
surface shall be ensured. Wire spacers can be inserted into the gap before tack
welding fitting to pipe. Spacers must be removed after tacking and prior to
final welding.
NB
These shall be purpose designed self-reinforcing nozzles which compensate for
the branch hole after it is cut. Nozzles requiring reinforcing pads may only be
used at ADMA-OPCO discretion for liquid systems up to 600# rating and gas
or multiphase systems up to 300# rating.
6.3.3 Temporary Pipe Supports
Temporary pipe supports shall be installed during the hot tapping operation. These
supports shall accommodate the weight of the hot tap fitting and pipe cutting
equipment, support deadweight loading and restrain the pipework from movements
caused by dynamic loads.

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 7. SUPERVISION AND SAFETY REQUIREMENTS
7.1 Weld Supervision
All welding must be supervised by a suitably qualified and experienced welding
technician or welding engineer in the employ of the Contractor under surveillance
by Integrity Assurance Authority or TPA Representative (Welding Inspector) who
is fully aware of safety requirements which shall be observed throughout the hot
tapping operation.
7.2 Hot Tap Operation Safety Requirements
Upon completing and obtaining the hot tap authorization/Approval as described in
Section 4 and before proceeding with the hot tap operation the following conditions
shall also be satisfied:
7.2.1 A qualified ADMA-OPCO supervisor and specialized hot tap Contractor's
representative shall be present during the hot tap operation.
7.2.2 Suitable fire extinguishers and pressurized fire hoses shall have been provided and
a fire watch established.
7.2.3 All other required conditions for hot tapping as stipulated in the ADMA-OPCO
HSE Regulations have been taken into account.

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 8. WELDING CONTROL
8.1 Weld Procedure Specification
8.1.1 The procedure specification with all the required information (see 8.2 to 8.13
below) shall be submitted to ADMA-OPCO for review and approval using the form
in Appendix-C.
8.1.2 Four copies of the WPS are required for approval purposes by Integrity Assurance
Authority. All copies must be clear and legible especially with respect to
Contractor's and any third party inspection stamps and signatures. One approved
copy giving ADMA-OPCO's reference number will be returned to and shall be held
by the Contractor for reference by the "site" or "in-plant" Inspector:-
8.2 Welding Process
8.2.1 For fittings of 75 mm (3") NPS and above welds shall be made by one of the
following welding processes or by a combination of those processes:
a. Shielded Metal Arc welding (SMAW).
b. Gas Tungsten Arc welding (GTAW).
8.2.2 For small bore fittings below 75 mm (3") NPS Gas Tungsten Arc Welding process
shall be used.
8.3 Run of Pipe and Fitting Materials
All materials which are applicable to the procedure shall be identified. All carbon
steel materials shall be grouped as follows:
8.3.1 Specified minimum yield strength of 42,000 psi (290 MPa) and less.
8.3.2 Specified minimum yield strength of more than 42,000 psi (290 MPa) but less than
65,000 psi (448 MPa).
8.3.3 Specified minimum yield strength of 65,000 psi (448 MPa) or more.

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 8.4 Diameter Group & Material Thickness Group
All the ranges of diameters and material thicknesses over which the procedure is
applicable shall be identified as follows:
8.4.1 Diameter Groups
a. Under 75 mm (3") NPS:
b. 75 mm (3") NPS to 300 mm (12") NPS;
c. Over 300 mm (12") NPS
8.4.2 Thickness Groups
a. 6.3 mm (¼") to 12.7 mm (½") inclusive.
b. Over 12.7 mm (½") up to 19 mm (¾").
c. Over 19 mm (¾").
8.5 Pipeline Operating Conditions
Maximum, actual anticipated and minimum pipeline operating conditions of
pressure, flow, temperature and contents for which the procedure is applicable shall
be identified on the welding procedure specification (WPS).
8.6 Joint Design
Joint design/preparation shall be carried out per Fig. 2 & Fig. 7.
NB:
For fillet welds the minimum leg lengths and maximum convexity and/or concavity
must be specified.
8.7 Electrical Characteristics
Current polarity, voltage and amperage for each electrode size and type shall be
specified.
NB:
Maximum allowable welding currents for deposition onto the line pipe shall be 170
A for wall thicknesses 12.7mm (½") and greater, and 150 A for wall thicknesses
below 12.7 mm (½"). No welding shall be permitted on material where any part of
the line pipe is less than 6.3mm thick (¼").
8.8 Preheat
Subject to satisfactory mechanical and hardness tests during weld procedure
qualification, preheat of the pipe and fitting in the area of welding shall not be made
other than that required for the removal of surface moisture. Heat shall be applied
by an oxy-propane torch with a preheat diffuser head.

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 8.9 Interpass Temperature
Interpass temperature shall not exceed 250 °C (482°F). Touch pyrometers or
temperature-indicating crayons shall be used for monitoring purposes.
8.10 Filler Metal and Consumables
Filler metal and consumables shall be specified as follows:
8.10.1 Shielded Metal Arc Welding (SMAW)
a. Low Hydrogen electrodes to AWS A5.1 type EXX16 or EXX18 shall be used.
b. The manufacturers recommendations regarding storage and baking shall be
followed. Baking shall reduce the Hydrogen levels in electrodes to less than 5
mils H2 per 100 grams of deposited weld metal.
c. Electrodes can be oven stored, after baking in accordance with the
manufacturer's recommendations to achieve the above Hydrogen level, with
humidity controlled at 0.6% max. Heated quivers shall be used to maintain
these conditions during the welding operation.
d. Any electrodes left over at the end of each day shall be re-baked as above.
Electrodes shall be baked not more than three times and then discarded.
e. To minimize the possibility of burn through the electrode sizes of Table-8.10.1
shall be used:
TABLE-8.10.1

Fittings/Weld Details Electrode Size

3.25mm 4mm 5mm

(1/8”) (5/32”) (3/16”)

Encirclement fittings
Longitudinal seam - root pass *
Longitudinal seam - next two passes * *
Longitudinal seam - remainder of passes * *
Buttering passes *
Circumferential fillet weld - root & second pass *
Subsequent passes *
Weldolets & Nozzles
All passes *

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 8.10.2 Gas Tungsten Arc Welding (GTAW)
a. Filler metal 2.4mm (3/32") size to AWS A5.18 specification shall be used.
b. Tungsten electrodes of 2.4mm (3/32") size to AWS A5.12 specification shall
be used.
c. Shielding gas shall be Argon of 99.9% purity.
8.11 Bead Technique
Stringer bead technique shall be adopted.
8.12 Speed of Travel
Travel speed range in mm/min (inch/min) for each pass shall be stated.
8.13 Welding Equipment
a. Welding equipment shall generally comply with the requirements of BS 2633.
b. Gas Tungsten Arc Welding (GTAW) equipment shall use a high frequency
starting device. A "Gas Lens" shall also be used to improve gas shielding of the
weld pool.
8.14 Cleaning
Power tools or hand tools should be used for removing slag and/or weld spatter.
Electrical tools shall be of 110 Volts type.
8.15 Essential Variables
A welding procedure specification (WPS) shall be re-established and a new
welding procedure shall be re-qualified when any of the changes listed hereafter
(beyond or below the range established in the weld procedure) are made to the to
the welding procedure. Changes other than those given hereafter may be made in
the procedure without the necessity for re-qualification, provided that the welding
procedure specification is revised to show these changes.
8.15.1 Any change in pipe, or fitting materials groups.
8.15.2 Any change in the position of the pipe or attachment from the position used during
the procedure qualification.
8.15.3 Any change in material thickness
8.15.4 Any change in speed of travel

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 8.16 Weld Procedure Qualification
8.16.1 Full Encirclement Fittings
a. A test assembly for hot tap welding procedure qualification shall be prepared
by following all of the details of the procedure specification. The assembly for
procedure qualification is shown in Fig.8.
b. The cooling effects due to pipeline operating conditions during hot tapping and
welding, e.g. pressure, temperature, flow rate, fluid density, etc., shall be
reproduced in procedure qualification
c. These test considerations shall include circulation of fluid inside the test pipe,
using non-combustible materials of similar conductivity; the fluid circulation
shall be subject to Approval by Integrity Assurance Authority or TPA
Representative.
d. The welding procedure shall be qualified to API RP 1104 Appendix-B (In
service welding).
8.16.2 Weldolets & Nozzles
Qualification shall comply with the requirements of API Std 1104.
8.16.3 Additional Requirements
Butt and fillet welds including base metal and HAZ of the test pieces shall be
hardness tested by applying the Vickers method with 10 kg load. Indentations shall
be made along traverses, as shown in Fig.10. Hardness values anywhere in the weld
and heat affected zone shall not exceed 250 Hv10 for sour service. For non sour
service lines the hardness values shall not exceed 300 Hv10.
8.16.4 Welder Qualification
Welders shall be qualified to API RP 1104. The test assembly shall be that shown
in Fig. 8 or 9.

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 9. WELDING RUN SEQUENCE
9.1 Full Encirclement Fittings
9.1.1 Longitudinal Seams
a. Where the length of the fitting is 750mm (3D) or over, a minimum of two
welders shall work on each seam. The seams shall be welded simultaneously.
b. Welding shall commence in the centre of the fitting and progress to each end.
Starts shall be carefully ground and overlapped as illustrated in Fig. 6.
c. This method of welding shall continue until a cross sectional thickness of 10
mm-12 mm (0.4"-0.5") of weld metal has been deposited along the entire weld
length. The welding may then progress in the direction of preference to the
completion.
d. Carefully remove run-on/run-off plates by grinding through the protruding
backing strip. Check ground ends of longitudinal welds for soundness by MPI
before commencing circumferential welds.
9.1.2 Circumferential Welds
a. Two welders shall be employed to work on opposite sides of the pipe as shown
in Fig. 5e.
b. A buttering technique as detailed in Fig.5c shall be used to reinforce the pipe
wall. Additional reinforcement shall be applied over the buttering passes where
the gap between the fitting and pipe exceeds 1.6mm (1/16") as shown in Fig.
5d.
c. The first bead shall be deposited as close as possible to the fitting without
impinging on, or making any attachment to it. The required fillet leg length and
gap between the pipe and fitting shall determine the number of buttering runs
required. Starts and stops of each pass shall be staggered by not less than
25mm (1").
d. The first pass in the throat of a fillet weld (run 7 in Fig. 5F) shall not be
extended beyond one electrode run out before being reinforced by the
deposition of run 8.
e. The technique shall be used progressively around the joint until the throat of
the fillet weld is sealed.
f. It is important that after completion of the first fillet weld the fitting assembly
is allowed to cool to ambient temperature before welding commences for the
fillet weld at the opposite end of the tee.
g. Each fillet weld shall have a throat thickness slightly in excess of the pipe wall
thickness.

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 9.2 Weldolet and Nozzle Fittings & Reinforcement
9.2.1 Each fitting shall be tack welded to the carrier pipe using a full size weld pass. The
ends of the tack welds shall be taper dressed to permit full fusion with the root pass.
9.2.2 After completion of the root pass a buttering layer shall be applied to the pipe as
shown in Fig. 7.
9.2.3 A full penetration weld with moderate reinforcement is required. Refer to Fig. 7 for
weld details.
9.2.4 The weld shall be completed in one cycle.
9.2.5 Welding sequence for nozzle and reinforcing pad to the carrier pipe shall be carried
out as illustrated in fig. 11. (Note the requirement of Section 11.3).

10. INSPECTION OF HOT TAP WELDS

10.1 Visual Inspection
10.1.1 The weld shall he examined visually at the root pass stage to ensure that fusion has
occurred. Completed welds shall be visually examined to check freedom from
obvious defects and ensure that the toe of the welds blend uniformly with pipe
surfaces.
10.1.2 Light grinding of the final weld profile is permissible in order to provide a smooth
transition with the pipe surface, but grinding must not undercut the surface of the
pipe.
10.2 Hardness Examination
A Brinell Hardness of 237 maximum for sour service or 280 HB for non-sour
service shall be required for the fitting weld cap. The Telebrineller™ portable
hardness tester or equivalent approved by Integrity Assurance Authority or TPA
Representative shall be used for field tests.
NB:
Grinding of the cap pass shall be required for an accurate hardness reading. Welds
over 237 HB for sour service or 280 HB for non-sour service shall be quarantined
and shall be reported to Engineering Division.
10.3 Magnetic Particle Examination
All finished attachment welds shall be magnetic particle examined in accordance
with ASME Section V using magnetic flow methods. Particular attention shall be
paid to the toe areas of full encirclement fitting circumferential welds.

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 10.4 Ultrasonic Examination
10.4.1 Full ultrasonic testing shall be applied to the completed welds. Such testing shall
cover a band 50mm (2") wide centred on each attachment weld. The full length of
each weld shall be examined in accordance with ASME Section V.
10.4.2 Due to the location and configuration of these welds it is essential that skilled
operators and inspectors be selected to test and interpret results. A Phase I CSWIP-
UST-1-83 qualification is required.
10.5 NDT Standards of Acceptability
The requirements detailed in API recommended pipe line maintenance welding
practices API STD 1104 Appendix-B, shall be followed.

11. PRESSURE TESTING

11.1 The existing line must be checked for external pressure loading in accordance with
ASME Section VIII or BS 5500 unless otherwise advised by Engineering
Authority.
11.2 Prior to hot-tap cutting, the welded fitting shall normally be hydrotested using
treated water to ADMA-OPCO STD-102 or oil at a minimum of 1.25 x pipeline
internal design pressure unless otherwise recommended by the fitting manufacturer,
design code or Engineering Authority.
11.3 In case of reinforced nozzle the hydrotest shall be made prior to welding the
reinforcing pad to nozzle welds.
NB:
The reinforcing pad to line pipe fillet weld must be completed and subject to NDE
prior to pressure testing, so that the branch hole is adequately reinforced.
11.4 Leak testing for the tightness of reinforcing pads shall be made using air firstly at
5.5bar (80psig) and then at 0.34bar (5psig), and soapy water.
NB:
Personnel must be kept well clear during all phases of this test, behind barriers
which must resist penetration in case of bursting.
11.5 Hydrostatic test water shall be inhibited and controlled as stated in ADMA-OPCO
Standard STD-102.
11.6 On completion of the hydrotest all water shall be drained/removed and pipe walls
thoroughly dried.

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 11.7 Where it is considered impractical to remove residual hydrotest water, alternative
testing fluid shall be used and Engineering Division shall be consulted in this case.
11.8 For hot-tap connections made onto lines with an operating temperature above 90°C
(194°F), thermal relief facilities are required on the test equipment. Engineering
Division shall be consulted in this case.
11.9 Pressure testing operations shall he carried out fully in accordance with
ADMA-OPCO HSE-102 for HSE Regulations Manual.

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 FIG.1: HOT TAPPING

1. Fitting is welded to the line.

2. Permanent valve is installed on the fitting.
3. A tapping machine makes the tap into the line through the valve.
4. Valve is closed and tapping machine is removed.
5. Branch connection is added.
6. Valve is opened and the new connection is out into service

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 FIG.2: LONGITUDINAL WELD SEAMS (DIMENSIONS IN MILLIMETERS)

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 FIG.3: ATTACHMENT OF RUN ON/RUN OFF PLATES OF BACKING BAR/STRIP

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 FIG.4: YOKE-TYPE CLAMP

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 FIG.5: WELDING SEQUENCE FOR CIRCUMFERENTIAL WELDS

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 FIG.6: WELDING SEQUENCE FOR CIRCUMFERENTIAL WELDS

ELEVATION: SEAMS IN HORIZONTAL/VERTICAL POSITION

Welding sequence
-Welding to commence in the centre of tee
-Starts to be overlapped and ground;
-welding to continue in this manner until 10mm to 12mm in cross sectional thickness is deposited.

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 FIG.7: WELDOLET FITTING WELD DETAILS

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 FIG.8: WELDING PROCEDURE QUALIFICATION TEST ASSEMBLY

NB:
This (6G) Test position qualifies procedure for all positions. Test may be performed in other
positions which will qualify procedure for that position only.

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 FIG.9: WELDER QUALIFICATION TEST ASSEMBLY

NB:
This (6G) test position qualifies the welder for all positions. Tests may be performed in other
positions which will qualify the welder for that position only.

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 FIG.10: LOCATION FOR HARDNESS IMPRESSIONS

Reading should be spaced 1 mm below the surface

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 FIG.11: WELDING SEQUENCE OF WELDING NOZZLE AND REINFORCING PAD

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 APPENDIX-A: HOT TAPPING DESIGN CHECK LIST

Location/Line Number: Date:

Line Size/Schedule Thickness:
Hot Tap Size:
The following to be completed and Approved by Engineering & Integrity Assurance Authorities as
indicated below:
Action
Item Description Findings
by
1. Existing Pipeline
1.1 Has exact location of Hot Tap been identified and marked? EA
1.2 Is chosen position clear of other welds/attachments? IAA
1.3 Is there sufficient clearance to install, operate and remove Hot Tap
EA
equipment?
1.4 Have ovality checks been completed? IAA
1.5 Is pipe wall free from laminations/ Hydrogen Induced Cracking
IAA
(HIC)?
1.6 Original pipeline material specification EA
1.7 Original design minimum thickness EA
1.8 Measured minimum thickness? (See Appendix- A Note A.3) IAA
1.9 Pipeline class rating? (See Appendix -A Note A.2) EA
1.10 Measured pipe wall temperature? IAA
2. Pipeline Contents

2.1 Pipeline product description? OPA

2.2 Is product/line suitable for Hot-tap (See Appendix -A Note A.1) OPA/EA
2.3 Normal operating:
- Pressure. bar (psig) ……………………
OPA
- Temperature. °C (° F) ……………………
- Flow velocity. m/S (Ft/S ……………………
2.4 Safe Max. working pressure during hot work (See Appendix -A
EA
Notes A.2,A.3 & A.4)?
2.5 Are normal operating conditions within those acceptable for
EA/OPA
Hot Tap (See Appendix A-1 Notes A.2, A.3, A.4 &A. 6)?
If not, what means are proposed to change them and maintain their EA/OPA
acceptability during Hot Tap?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………

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 APPENDIX-A: HOT TAPPING DESIGN CHECK LIST (Cont’d.)

Action
Item Description Findings
by
3. Branch Connection

3.1 Type of branch fitting to be used EA

3.2 Are branch fittings and flanges adequate for both normal service
conditions and original pipeline design pressure. (See 2.4 & EA
Appendix-A. A.2, A.3 & A.4)?

3.3 Is fitting correct length to accommodate Hot Tap equipment? EA

3.4 Are backing strips required? IAA

4. Inspection & Testing

4.1 Method and extent of inspection required? IAA

4.2 Connection test pressure and method IAA

4.3 Has pipeline been checked safe for external pressure loading? EA

AUTHORITY NAME TITLE SIGNATURE DATE

Prepared By

Reviewed By

Integrity Assurance

Engineering

Site Managemnt

LEGENDS:
IAA = Integrity Assurance Authority
EA = Engineering Authority
OPA = Operating Authority
HSEA = HSE Authority

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 APPENDIX –A: HOT TAPPING DESIGN CHECK LIST (Cont’d)

Design Checklist Explanatory Notes

These notes shall be used as a guide to assist filling the Design checklist (Appendix A).
A.1 Hot Tapping shall not normally be carried out on lines containing:
A.1.1 Flammable mixtures of gases/vapours containing sufficient oxygen to sustain combustion.
A.1.2 Substances which may decompose or attack the pipe metal under the initiation of a welding
hot-spot.
A.1.3 Compressed air, oxygen or oxygen-rich mixtures.
A.1.4 Lines which have received or require PWHT by reason of code or process shall not be
considered for hot tapping.
NB.
Guidance shall be sought from Engineering Authority where the product may fall into any of
the above categories.
A.2 The pressure and temperature during welding and hot tapping is restricted to 3.44 bar
(50psig) and temperature to between 10°C and 120°C (50°F - 250°F). However, in no
circumstances should the service pressure and temperature exceed 75.84bar (1100psig) and
120°C (250°F) during hot work/coupon cutting operations.
A.3 The Safe Maximum Working Pressure during Hot Work is dependent upon wall thickness,
pipeline material and the design code of the pipeline. The wall thickness to be used shall
normally be the "Original Design Minimum Thickness" unless the "Measured Minimum
Thickness" is less in which case the latter shall be used. The chosen thickness will then be
reduced by 2.4 mm (3/32") to account for possible reduction in wall strength during
welding.

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 A.4 Unless otherwise advised by Technical Authority, the Safe Maximum Working Pressure (P)
in psig in line during hot tap operation shall be calculated using ANSI/ASME B31.3 design
formula as follows:-
A.4.1 When the thickness (t) is less than D/6

2.S .E.(t − c)
P=
( D − 2Y )

where
S = Basic Allowable Stress at metal temperature (Ksi)
E = Quality Factor = 1 for seamless pipeline
= 0.85 for ERW
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

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 APPENDIX A: HOT TAPPING DESIGN CHECK LIST (CONT’D.)
A.4.2 When the thickness (t) is equal to or greater than D/6
Special consideration shall be given for that case. Engineering Authority shall advice the
design parameters of the calculation when such case arises.
A.4.3 When materials specification of the run pipe is unknown
When such case arises and unless otherwise advised by Engineering Authority, the run pipe
materials specification can be assumed API Spec. 5L Grade A by default.
Accordingly the basic Allowable Stress (S) in the Design formula of 4.1 above, should be
substituted as S = 16Ksi.
A.5 Check the heat dissipation calculation shall be performed and the minimum flow velocity
specified..
A.6 During welding, product flow velocities shall be maintained in the range 0.4 - 1.22 m/s (1.3
- 4 ft/s) (liquid) or above 0.4 m/s (1.3 ft/s) gas. The welding or Hot Tap procedure will
normally recommend a specific flowrate to achieve required cooling rate during welding. If
not, then the minimum flow velocity should be used. Should such velocity be difficult to
achieve at the Calculated Maximum Allowable Working Pressure (MAWP), Engineering
Authority shall be consulted.
A.7 Hot Tapping on flare lines or other lines where flow is intermittent or slow shall only be
considered if flow can be maintained at a minimum 0.4 m/s (1.3 ft/s) under the action of an
inert purge.

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 APPENDIX – B: HOT TAPPING OPERATION CHECK LIST
The following items must be checked and approved by ADMA-OPCO representatives of Engineering,
Integrity Assurance, Operating and HSE Authorities as indicated below.
Location: Date : …………………………………………………
Hot Work Permit No.: Hot Work Permit Issued By : …………………………
Hot Tap Permit No.: Gas Test Made by : ……………………… …………..
Hot Tap Design Procedure Ref.: Modification Request No.: ………………
Items to be checked Findings Action
By
1. Documentation
1.1 Has welding Procedure Specification (WPS) been approved by IAA
Integrity Assurance Authority or TPA Representative?
1.2 Has Hot Tap Design Procedure been completed and approved by EA
Engineering Authority representative?
1.3 Has a procedure to isolate the work area in the event of a failure been HSEA/
prepared and are personnel trained to implement this procedure? OPA
2. Pipeline Before Welding
2.1 Does the location of Hot Tap exactly correspond with that given in EA/OP
Hot Tapping Procedure? A
2.2 Has the area to be welded been thoroughly cleaned and degreased? IAA
2.3 Measured wall thickness of Header …….. mm….. inch IAA
2.4 Is the Header free from defects in the weld area? IAA
2.5 Line being Hot Tapped - Fluid Handled ……………… )
- Pressure (q) ………… bar (PSI) ……………………… OPA
o o
- Temperature ………… C ( F) ………
2.6 Does fluid, temperature and pressure comply with that stated in
OPA
approved procedure?
2.7 Can pressure and flow rate stated in procedure be achieved and
OPA
controlled during welding?
2.8 Signature of person responsible for controlling process conditions
OPA
during welding?
2.9 Do all materials comply with approved procedures? IAA
2.10 Is the Welder qualified to the laid down procedure? IAA
2.11 Is there sufficient clearance to operate the Hot Tapping equipment? EA
2.12 Are the Hot Tapping equipment and pipeline adequately supported? EA/OP
A
2.13 Is the fitting in the correct length to accommodate the Hot Tapping
EA
machine?
2.14 How will communications be established between control room and
OPA
work site?

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 APPENDIX – B: HOT TAPPING OPERATION CHECK LIST (Cont’d.)
Items to be checked Findings Action By
3. After Completion of Welding
3.1 Does fabrication meet required acceptance Standard? IAA
3.2 Apply test pressure specified in procedure? EA/IAA
3.3 Witness test pressure? IAA
3.4 Has the valve been tested for leakage? EA/IAA
3.5 Has the bore of the valve been checked for cutter clearance? EA
3.6 Is the valve in position centred on the flange? EA
4. Hot Tapping Machine Prior to Fitting on Branch
4.1 Has the packing been checked ………… machine hydraulically
EA/IAA
tested?………
4.2 Pilot bit and cutter have been checked for loss of teeth on cutter and
EA
coupon catcher (ball, spring or wire clip) is on pilot insert bit?
4.3 All bolts on cutter and pilot are tight? EA
4.4 Cutter pin and set screws are in place to protect against loss of bit? EA
4.5 Pilot bit length is sufficient to catch coupon? EA)
4.6 Has the measurement diagram been completed and attached to check
EA
list?
4.7 Bleed off valve is tight and not plugged? EA
5. After Fitting Hot Tapping Machine on Branch
5.1 Assembly has been pressure tested at working pressure of ….. bar
EA/IAA
(PSIG) and is satisfactory?
5.2 Assembly is purged and checked to be oxygen free? HSEA
5.3 Machine has been test run and all actions checked? EA

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 APPENDIX – B: HOT TAPPING OPERATION CHECK LIST (Cont’d.)

Items to be checked Findings Action By

6. After Completion of Hot Tap
6.1 Wind machine fully up and check measurements before closing valve EA
6.2 Close valve slowly until it starts to seat, back off slightly and open
EA
bleeder valve to blow chips out of seats.
6.3 Open bleed and be sure valve is holding before removing machine. EA

AUTHORITY NAME TITLE SIGNATURE DATE

Prepared By

Reviewed By

Integrity Assurance

Engineering

Site Managemnt

GENERAL NOTE:
Above items are standard checks, personnel should be alert for any unusual conditions that may
arise during entire operation.
LEGENDS:
IAA = Integrity Assurance Authority
EA = Engineering Authority
OPA = Operating Authority
HSEA = HSE Authority

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 APPENDIX – C: RECORD OF APPROVAL TESTS OF WELDING PROCEDURE

Contractor’s Name Procedure details: Test record no.

Location of test: Procedure no. (and revision no.)

Code:
Welding process(es) Parent material(s)
Joint type Specification(s)
Welding position(s) Material group(s) (see table 1)
Test piece position Dimensions of test piece
Weld preparation (dimensioned sketch) Run sequence and completed weld dimensions
(sketch)

Method of preparation and cleaning Welding conditions

Welding consumables Run no.:

Filler material Size(s):

Make and type
Current:

Composition Voltage.:
Baking treatment Polarity.:
Travel speed – R.O.L.
Second side treatment Post-weld heat treatment
Specification
Method
Temperature Method Control Control
Preheat Soak temperature
Interpass
Soak Time

Safe maximum working pressure of run pipe:

Run pipe contents:
Product temperature, Min.: ………………. Max.:………………..:
Product flow velocity, Min.:……………….. Max::………………….

Originator : Date: Welders identity

Name: Mark
Extend of approval:
Range of materials
Range of thickness(es)
Range of diameters

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 APPENDIX - D: AUTHORITIES & RESPONSIBILITIES

The authorities listed below are primarily responsible to the extent specified herein for satisfying the
requirements of this Specification.

SITE
AL
DAS ASSET US ASSET ZK ASSET
HYLEH
AUTHORITY

OPERATING Das Process Towers & Pipelines Zakum Central SBE

Operations TL Operations TL Operations TL
Das Utilities TL Oil & Gas Towers & Pipelines
Operations TL Operations TL
Utilities Operations Oil & Gas Operations
TL TL
Utilities Operations
TL

Facilities Facilities Integrity Facilities Integrity Facilities

INTEGRITY Integrity TL TL TL Integrity
ASSURANCE
TL

ENGINEERING Disciplines Disciplines Disciplines Disciplines

Engineering Engineering Engineering Engineering
TL(FED) TL(FED) TL(FED) TL(FED)

Technical HSE Advisor (Das) HSE Advisor (US) HSE Advisor (ZK)
HSE Safety Eng.
(Diving /
Site HSE Section Fields Safety Fields Safety
Leader (Das) Engineer (US) Engineer (ZK) Marine)

Standards Standards Section Standards Section Standards

STANDARDS Section Section
AUTHORITY Leader Leader
Leader Leader

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 APPENDIX-E: ABBREVIATIONS

Abbreviation Description

ADMA-OPCO Abu Dhabi Marine Operating Company

API American Petroleum Institute

BSI British Standards Institute

HAZ Heat Affected Zone

HTO Hot Tap Operation

ISO International Organization for Standardization

MPI Magnetic Particle Inspection

QA Quality Assurance

QAS Quality Assurance System

QC Quality Control

QMS Quality Management System

SP Specification

TPA Third Party Agency

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 APPENDIX-F: DEFINITIONS
F.1 General Definitions

Term Definition

ADMA-OPCO The Abu Dhabi Marine Operating Company.

Contractor The Company contracted to undertake the works of a Project and is

accountable to ADMA-OPCO's nominated representative. It is also applicable
to the Company contracted to undertake the Third Party Inspection &
Verification Tasks (TPA) on behalf of ADMA-OPCO.

Quality Assurance All those planned and systematic actions (QA) necessary to ensure quality i.e.
to provide adequate confidence that a product or service will be fit for its
intended purpose.

Quality Management The structure organization, responsibilities, activities, resources and events
System that together provide organized procedures and methods of implementation to
ensure the capability of the organization to meet quality requirements.

Quality Manual A Document setting out the general quality policies, procedures and practices
of an organization.

Quality Plan A document prepared by the Contractor setting out the specific quality
practices, resources and activities relevant to a particular project.

F.2 General Definitions

Term Definition

Hot Tap Operation The method of attaching branch connections by welding onto pipelines under
pressure is known as hot tapping (fig 1). Connections can be made by this
method with minimum interference with the process operation, and without
de-pressurizing and purging pipelines and equipment.

Blow-Through Blow-through occurs when unmelted metal beneath the weld root no longer
has the strength to contain the internal pressure in the pipeline.

Buttering Run One or more layers of weld metal deposited on the run Pipe outer surface.
Buttering is used to reinforce the pipe wall, reduce the risk of underbead
cracking and minimize the depth of the heat-affected zone (HAZ).

Temper-Bead Temper-bead(s) are deposited on top of the last runs of weld metal that were
deposited directly on to the Pipe and fitting, at the pipe to fitting weld toe.
The function of tempering run(s) is to reduce the hardness of heat-affected
zone microstructures in the toe region.

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 APPENDIX-G: REFERENCED DOCUMENTS

Unless otherwise specified, the latest edition of the Standard Engineering Documents listed below
shall to the extent specified herein, represent part of this Standard.

Designation Title

ADMA-OPCO

HSE-102 HSE Safety Regulations Manual

SP-1031 Quality Control Personnel For Fabrication & Construction

STD-102 Corrosion Inhibition of Hydrostatic Test water and Stored Water

STD-115 Gate Valves

STD-108 Flanges

STD-116 Ball Valves

STD-126 Bolting For Pipping
STD-127 Gaskets
STD-128 Piping Fittings

SP-1000 Materials for Sour Services

American Petroleum Institute (API)

Spec. 5L Specification for Line Pipe

Std 1104 Standard Welding of Pipelines and Related Facilities

RP 2201 Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries

American Society of Mechanical Engineers (ASME)

B31.3 Process Piping

Section-V ASME Boiler and Pressure Vessel code –Section V For Nondestructive Examination

Section-VIII ASME Boiler and Pressure Vessel code –Section VIII For Rules for Construction of
Pressure Vessels

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 APPENDIX-G: REFERENCED DOCUMENTS (CONT’D.)

Designation Title
American Welding Society (AWS)

A5.1 Filler Metals for Gas Shielded Arc Welding Low Alloy steel

A5.12 Tungsten Arc Welding Electrodes

A5.18 Carbon Steel Filler Metals for Gas Shielded Arc Welding

British Standards Institute (BSI)

BS 5500 Specification for unfired Fusion Welded Pressure Vessels

BS 2633 Specification for Class I Arc Welding of Ferritic Steel Pipework for Carrying Fluids

BS EN 10025 Hot rolled products of structural steels

National Association of Corrosion Engineers (NACE)

Petroleum and natural gas industries Materials for use in H2S-containing

Environments in oil and gas production:
MR0175/ISO 15156 Part 1: General principles for selection of cracking-resistant materials
Part 2: Cracking-resistant carbon and low alloy steels, and the use of cast irons
Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys.

CSWIP

CSWIP A Guide to Certification Scheme for Weldment Inspection Personnel

International Organization for Standardization (ISO)

9001 Quality Management Systems - Requirements.

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 APPENDIX - H: AUTHORIZATION HISTORY OF SP-1005

Issue / BY Name TITLE DIV DATE

Rev. No.

ORIGINATOR M.H.FAHMY WE ED. 11-87

0 REVIEW M.K.ELSHOBARY SE ED. 11-87
APPROVAL A.E.RASHID HQA ED. 11-87
ENDORSEMENT Dr. R.J.EL ASSAR EM. ED. 11-87

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