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C.S.T.29 (PTY) LTD. WE CAN WORK UNDER PRESSURE. Corporate Information: Name of business: C.S.T 29 PTY Limited Business registration number: 2004/006596/07 VAT number: 4 310214780 Contact information: Head Office Physical Address: 2 Huggett Str Kempton Park 1619

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slide1
C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

          • Corporate Information:
  • Name of business: C.S.T 29 PTY Limited
  • Business registration number: 2004/006596/07
  • VAT number: 4310214780
  • Contact information:
  • Head Office
  • Physical Address: 2 Huggett Str
  • Kempton Park
  • 1619
  • Gauteng
  • South Africa
  • Tel: + 27 11 394 0212
  • Fax: + 27 11 394 0214
  • E-mail: [email protected]
  • Workshop
  • Physical Address: 17 Carolous Str
  • Trichardt
  • 2300
  • Secunda
  • South Africa
  • Tel: +27 17 638 1769
  • Fax: +27 17 638 0948
slide2
C.S.T.29 (PTY) LTD
  • Company Overview
  • Over the past 25 years C.S.T.29, together with our partner company, Power Technology Services in the U.K., have developed Hot Tapping and Line Stopping equipment of all sizes and pressures, with consideration to all products and temperatures, to suit our client requirements.
  • C.S.T.29 service Offerings:
  • Design
  • Fabrication
  • On-site welding
  • Pressure testing
  • Hot Tapping
  • Valve Management
  • Line stopping
  • Cold Cutting
  • Flange Facing
  • Our procedures and our C.S.T. in-house expertise and equipment enables:
  • The replacement, abandonment, additions and modifications of pipe work from 1/2“ up to 60” diameter without the need for shutdowns or interruptions to consumers or critical services.
  • Combined with the technical back up of recognised local Design and Draughting Consultants, C.S.T.29 has become the African market leader in this highly specialised service field.
  • Our equipment is available for sale and a maintenance service is also available.
slide3
C.S.T.29 (PTY) LTD
  • Quick Facts In a South African context:
  • We, as C.S.T.29:
  • Are members of SAPGA and is registered as a Gas Installer
  • Comply to the South African PER and SANS 347
  • Have appointed IRCA and work according to an ISO 9001: 2008 Quality System, introduced within C.S.T. 29 (Nov.2010), and we aim to get an IRCA 3 Diamond rating in 2011.
  • Work according to the OHSact No.85 of 1993 and according to the OHS Construction Regulations (Aiming towards full OHSAS 18001 and 18002 compliance)
  • Obtained a GREEN rating from Sasol Shared services on Safety and Quality.
slide4
C.S.T.29 (PTY) LTD
  • Quick Facts In a South African context (Continued):
  • Our experience within C.S.T.29:
  • 71 years fabrication experience.
  • 43 years combined in-house experience in Hot tapping & Line stopping.
  • 15 years cross-country Petrochemical and Gas pipeline construction and maintenance experience.
  • 9 years Valve management experience on water boards.
  • 9 years Cold cutting experience.
  • Are the local agents for EH Wachs Industrial & Utility products.
  • Manufacture all our Hot Tap & line stop fitting locally at our workshop in Trichardt (Mpumalanga)
slide5
C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

HOT TAPPING:

What does the Procedure say?

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C.S.T.29 (PTY) LTD
  • International Definition:
  • Hot Tapping:
  • “Hot Tapping is the precise process of drilling a hole in an on-stream operational piping system without spilling its contents or interrupting its flow.”
  • or in practical terms
  • “Hot Tapping is a means by which access is made to the inside of an operational pipeline, using either a drill or a circular cutter.”
  • Hot Tap Applications include:
  • Attachment of a branch connection to the line,
  • Installation of an internal probe or monitor,
  • To stop or redirect flow in a line for maintenance or repair purposes.
  • Implies positioning a branch fitting on an operating pressurised line, flowing or stagnant. Followed by cutting a hole in the header through the branch to allow connection to the flowing media. Normally implies using a welded fitting,
  • Can also be applied as a repair method to remove defects, i.e. dents.
slide7
C.S.T.29 (PTY) LTD

Extract from SASOL SGR-MOR-000011

Factors, which govern standard, hot tapping

a) Size on size hot taps is not permitted. The size of the hot tap branch shall be limited to a maximum of two pipe sizes smaller than the header size.

b) Hot tapping nearer than 460 mm to flange or threaded connection or approximately 70 mm to a weld seam should be avoided.

c) Hot taps shall not be made on circumferential or longitudinal welds.

d) A hot tap shall not be made on the radius of any fitting.

e) Tie-ins with a bore of more than one-half the header shall require the use of a split tee (full encirclement fitting). Those on one half the headers bore or smaller shall be an integrally reinforced branch fitting, e.g. a weldolet or saddle type sweepolet whenever reinforcing is required.

f) Some of the older hot tap equipment only allows hot tapping to be performed in the vertical up and down position. Enough free space with no obstruction above the pipe to be tapped shall be provided in these cases. Modern hot tapping machines do not have this restriction.

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Hot tap Configuration

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C.S.T.29 (PTY) LTD

Non Standard Taps

Off-Set Tap

Angle Tap

Inverted Tap

Bend Tap

Blind Tap

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C.S.T.29 (PTY) LTD

Hot Tap Orientation

Standard vertical tap - no unusual problems

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C.S.T.29 (PTY) LTD

Hot Tap Orientation

Angled vertical tap - no problems for

angles less than 45 degrees

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C.S.T.29 (PTY) LTD

Hot Tap Orientation

As the angle of tap rotates around there becomes more chance of the swarf from the tap coming back towards the valve and the tapping machine adapter resulting in problems closing the valve and with

drawing the cutter fully.

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C.S.T.29 (PTY) LTD

Hot Tap Orientation

As the angle of tap rotates around there becomes more chance of the swarf from the tap coming back towards the valve and the tapping machine adapter resulting in problems closing the valve and with

drawing the cutter fully.

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C.S.T.29 (PTY) LTD

Hot Tap Orientation

The measuring rod will tend to fall out. It is also considerably harder to install the drilling machine into position.

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C.S.T.29 (PTY) LTD

Clearance for Hot Tap

Longitudinal weld access

restricted by adjacent pipes

Longitudinal weld location at an alternative position in order to improve weld access

slide17
C.S.T.29 (PTY) LTD

Hot Tap Fittings

Hot Tap fittings are either bolted or welded to the header pipe line. A

tapping/drilling machine is attached to the valve, which is attached to the hot tap fitting. A cutter, attached to the tapping machine is inserted into the hot tap fitting through the valve and the tap is made. In the case of a permanent valve, a branch connection

can be made, allowing flow through the outlet.

Rules of Thumb:

For reduced-branch taps, weldneck flanges on a weld-o-let can be used, but the size of the branch must not exceed 50% of the header diameter, to ensure remaining strength is not compromised.

Where the branch will exceed 50% of the header diameter, Hot Tap fittings are full-branch or reduced-branch split tees, designed for use with Tapping Machines.

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Fabrication

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C.S.T.29 (PTY) LTD

Fit up of split tee for AIA inspection before welding

Spit tee being machined to clients specification

12” #600 Line Stop valve being pressure tested.

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C.S.T.29 (PTY) LTD

HOT TAP - CLASS 150

Fabrication & Test Plan

Compliance to ISO 9001: 2008

slide22
C.S.T.29 (PTY) LTD

CST29 Drilling Machine

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Hot Tap Fittings

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C.S.T.29 (PTY) LTD

Hot Tap Fittings:

Are equipped with ANSI Class 150, 300, 600, 900 or 1500 (SI PN 20, 50, 100, 150 or 250) weld neck RF or RTJ flanges.

The reduced-branch split tee fittings can also be furnished with “Completion-plug” flanges for use as bypass fittings.

Full-branch fittings are available in 2" - 60"(63mm-1,500 mm).

Reduced-branch fittings are available in any size or pressure configuration to meet customer needs.

Plugging (Stopple) Fittings allow a means of isolating the flow in a

piping system for repair, maintenance or pipe relocation activities,

by incorporating a completion plug inside the flange on the branch.

The only real difference between a hot tap and line stop split tee fitting is mostly the use of a “completion plug” flange in the neck of the line stop fitting.

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

On Site Welding

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C.S.T.29 (PTY) LTD
  • In-Service Welding for Hot Taps:
  • Welding onto an in-service piping system requires specially qualified welding procedures and trained personnel.
  • The main concerns for in-service welding are:
  • Burn through
  • Hydrogen Cracking of Fillet Welds
  • Chemical Reactions from Heat
  • With modern day low hydrogen welding techniques and properly qualified
  • procedures and welders, the above are not normally a concern, within tested limits.
  • In practice pipe wall thickness' down to 4mm (0.156") have been successfully welded in-service, with the appropriate procedures, and in special circumferences 3mm (0.125”). However, the normally accepted practical minimum is 4.8 mm (0.188”).
  • On pipelines the weld procedure and welding qualification includes the
  • provision for qualification and testing with highest expected rate of heat
  • loss, or restraint levels, and maximum carbon equivalent of the materials to
  • be welding.
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C.S.T.29 (PTY) LTD

In-Service Welding for Hot Taps (Continued):

Pipeline fittings are also normally also required to meet the CSA Z245.11 Steel fittings & CSA Z245.12 Steel flanges codes, where applicable. These specifications imply that all welds must be to ASME IX and subject 100% radiography to, ASME acceptance criteria.

On pressure piping systems (i.e. ASME B31.3 & ASME B31.1) there is no code, or regulatory requirement to consider any in-service welding consideration. It was highly recommended that ASME IX welding qualifications be supplemented by API recommended Practice 1107 for maintenance, however, API 1107 was due to be replaced by Appendix B in API 1104.

API 570 :

Requires that all repairs and alterations to the piping system must be done by an

organisation acceptable to the jurisdiction and must be authorized by the

inspector prior to its commencement.

All repairs and welding shall be done in accordance to the principles of ASME B31.3, or the code to which the piping system was built.

Any welding on piping components must be done in accordance with API Recommended Practice 2201, Procedures for Welding or Hot Tapping on Equipment ContainingFlammable or combustible liquids.

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C.S.T.29 (PTY) LTD
  • In-Service Welding for Hot Taps (Continued):
  • API 2201 specifically indicates that ASME IX does not cover in-service welding conditions and that API 1107 should be used to qualify both welding procedures and welders on pipe containing flammable or combustible liquids.
  • In addition, API 570 requires that the inspector shall use, as a minimum the "Suggested Hot Tap Checklist" contained in API 2201 for hot tapping performed on piping components.
  • API 2201 requires:
  • In advance of "hot tap" work the following should be prepared:
  • A detailed in-service welding procedure.
  • A hot-tap procedure.
  • A connection design.
  • Health, safety, fire protection, and other appropriate instructions.
  • *Always verify the header pipe wall thickness prior to in-service welding.
slide29
C.S.T.29 (PTY) LTD

Welding Sequence of Split Tee Fitting (Split Sleeves):

Sequence of welding is important. Weld the longitudinal-type seams of full-encirclement fittings first. If factors permit, weld both longitudinal-seams simultaneously. Should factors prohibit this, alternate side-to-side to avoid excessive distortion.

Do not weld both circumferential-type seams simultaneously. This may introduce excessive stresses into the fitting and piping system.

Longitudinal- seams should never be welded to the header/carrier pipe.

Where a full penetration longitudinal weld is desired, the use of a Backing Strip is strongly recommended, which should be specified when doing the design.

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Pressure Testing

slide31
C.S.T.29 (PTY) LTD
  • Pressure Testing of a Hot Tap Fitting or Split tee:
  • Prior to tapping the fitting should be pressure or leak tested. The pressure, or leak test, will subject the header pipe wall to an external pressure.
  • The intention of the appropriate design code requirement may be for the hot tapping/line stop fittings to be internally pressure tested .
  • Exceeding the piping system internal pressure may cause damage to the header pipe, making it difficult or impossible to complete the hot tapping and/or line stop operation, thereby compromising the integrity of the piping system .
  • The allowed safe external test pressure depends on :
  • The header (carrier) pipe diameter to thickness ratio,
  • Grade of material,
  • Roundness of the pipe
  • Local wall thickness loss
  • Corrosion
  • Mechanical damage, should also be a consideration.
  • *ASME VIII external pressures design principles can be applied, but there is a need to consider local deformation as well, which may result in causing a dent on the header pipe at the fitting branch opening location, during the pressure test.
slide33
C.S.T.29 (PTY) LTD

C.S.T. 29 (PTY) LTD

ALL C.S.T. HOT TAPPING

IS DONE AGAINST A QUALITY CONTROL PLAN

slide34
C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Hot Tap Animation

slide46
C.S.T.29 (PTY) LTD

Coupon retained

by ‘U’ Wire

slide55
C.S.T.29 (PTY) LTD

Coupon retained

by ‘U’ Wire

slide56
C.S.T.29 (PTY) LTD

Coupon and cutter

are withdrawn

slide60
Vent off

Product

C.S.T.29 (PTY) LTD

slide61
C.S.T.29 (PTY) LTD

Product

cleared

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Valve Management

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C.S.T.29 (PTY) LTD

Valve Management

  • Our aim is to save our clients, time and money by collecting critical data on all their Main Isolation, Cross Connection and critical valves across their distribution system. When the problematic valves have been identified we implement our fully automated Valve Exercising procedure on these valves to recover their performance. During the Valve Condition Analysis we also implement a basic exercising procedure. Periodically implementing a basic exercising procedure is critical as part of a successful valve maintenance program.
  • During our Valve Conditioning Analysis we collect comprehensive data on all the valves providing information such as:
  • What type of valve it is?
  • Whether the valve is operable?
  • Can it be repaired or should it be replaced?
  • What is the amount of torque required to operate it?
  • What is the position of the valve?
  • Whether the valve is left or right hand turn?
  • The amount of turns to open it?
  • Its exact GPS location?
  • C.S.T. offers an extensive valve refurbishment service.
  • Without the need for shutdowns and/or interruption to service.
  • This service includes the Valve Condition Analysis, Valve Performance Recovery and the External Valve Refurbishment.
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C.S.T.29 (PTY) LTD

PTFE Injection. Valve Stem Packing seal

  • The PTFE compound injection is relatively unknown in South-Africa but has been successfully implemented worldwide for many years. The valve stem packing injection procedure consists of injections of a PTFE compound at the gland area and external stem. If the main bonnet is leaking C.S.T will inject the bonnet area at the same time.
  • Any additional information regarding the procedure including the method statement and risk assessment is available on request.
  • These procedures will increase the longevity and operability of the valve. C.S.T.29 aims to provide full Valve Reconditioning without the need for shutdowns, down time or interruption to services.
slide66
C.S.T.29 (PTY) LTD

Valve chamber filled with water from leaking valve

C.S.T29 begins Valve leak sealing

Valve leak fixed and chamber dry!

Cost Effective

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Definition Of A Line Stop

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C.S.T.29 (PTY) LTD

Line Stop Definition:

Line stopping or line plugging is a means of isolating a piping system to provide a shut off where none exists. This process serves as a control, or temporary valve on a pipeline, that can be removed after alterations or valve replacements have been made on the isolated pipe section.

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C.S.T.29 (PTY) LTD

Typical size on size line stop fitting with completion plug

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Line Stop Animation

slide85
C.S.T.29 (PTY) LTD

Mid section can now be cut

out by means of cold cutting and modified/repaired

slide86
C.S.T.29 (PTY) LTD

Split frame cuts and bevels the line.

Line ready for welding.

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Cold Cutting

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C.S.T.29 (PTY) LTD

Cold Cutting

  • Split Frame
  • A full line of models cover 0,5 – 48 inch in pipe diameter
  • Cuts and bevels
  • Cuts any exotic metals including cement lined pipes
  • Split frame spits to fit over inline pipe and is also capable of
  • performing socket weld removal and chip less wheel cutting
  • Trav L Cutter
  • Cuts, bevels and for making Victaulic groves from 6 –
  • 72 inch pipe diameter.
  • Cuts any exotic metals including cement lined pipes
  • Ideal for field pipeline and buried pipeline maintenance.
  • Guillotine Saw
  • Cuts from 2 - 36 inch in diameter size
  • For the removal of redundant lines.
  • Demolition work
  • Cuts any exotic metals
  • Off shore platform leg cutting applications
  • Buried line maintenance
slide89
C.S.T.29 (PTY) LTD
  • Split frame was used to cut the gas line (split frame uses cold cutting technology -
  • Safety
  • No spark
  • No flame
  • No air born contamination
  • No chance of Explosion
  • Cost productive
  • No Hot Work Permit
slide90
C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Examples of Cold Cutting On Site

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C.S.T.29 (PTY) LTD

Two Trav-l’s cutting a 36” Water line

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C.S.T.29 (PTY) LTD

After modification/repair, the

mid section is connected to

the plugging housing

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C.S.T.29 (PTY) LTD

Mid section can now be

re-pressurized through the

vents and the plugging housing

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C.S.T.29 (PTY) LTD

Mid section can now be

re-pressurized through the

vents and the plugging housing

slide95
FLOW

C.S.T.29 (PTY) LTD

Upstream head is

removed first

slide96
FLOW

C.S.T.29 (PTY) LTD

Followed by Downstream

plugging head

slide97
FLOW

C.S.T.29 (PTY) LTD

Bypass can now be

de-commissioned

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C.S.T.29 (PTY) LTD

Completion plug is lowered through valve into throat of flange

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C.S.T.29 (PTY) LTD

Drive Segment is advanced to secure plug in position of flange

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C.S.T.29 (PTY) LTD

‘O’ Ring provides pressure seal

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C.S.T.29 (PTY) LTD

All fittings blanked off -

Job Complete

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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Flange Facing

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C.S.T.29 (PTY) LTD
  • Flange Facing
  • Its designed to quickly and easily machine full faced and raised face flanges from 4” (101 .6 mm) to 24”
  • (609.6mm) O.D. in any operating position. Utilizing a self centeringl.D. mounted mandrel and automatic squaring fixture, precise flange alignment is assured. Just tighten the mandrel “expansion nut” - No other adjustments or measurements are needed.
  • Advantage
  • Faces flanges from 4" (101.6mm) ID to 24“
  • (609.6mm) OD
  • Record grove, RMS 500, 250, 125 and 63
  • finishes
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C.S.T.29 (PTY) LTD

WE CAN WORK UNDER PRESSURE

Steve Green

Director

Thank You For Your Time

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