COURSE OVERVIEW:

In the modern industrial landscape, the ability to perform maintenance and modifications on live pipelines is essential to avoid costly production shutdowns. This course provides a comprehensive technical guide to Hot Tapping and Plugging (HT&P) operations, allowing for new connections or section isolations while the system remains under pressure. Participants will learn the intricate mechanics of the specialised machinery used to cut into live lines and the safety protocols required to manage the inherent risks of working on energized systems.

The procedure for hot tapping involves a precise sequence of events, starting with the installation of a reinforced fitting and a permanent valve. This training focuses on the metallurgical considerations of "in-service" welding, where the flowing product acts as a heat sink, increasing the risk of hydrogen cracking. The scope includes the selection of cutters and pilot drills, the calculation of tapping speeds, and the management of the "coupon" to ensure it is successfully retrieved after the cut is completed.

Plugging operations, often used in conjunction with hot tapping, provide a temporary seal to allow for the repair or replacement of pipeline segments. This course covers the various types of plugging heads, including pivot and folding designs, and the bypass arrangements necessary to maintain flow downstream. Coverage includes the critical steps of equalisation and isolation verification. By the end of this course, attendants will understand the rigorous planning and execution standards needed to perform HT&P operations safely and efficiently.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Define the fundamental concepts and benefits of hot tapping and plugging.

2.  Identify the components of a hot tapping machine and their functions.

3.  Calculate the appropriate cutting speeds and feeds for various pipe materials.

4.  Apply API 2201 standards for safe hot tapping practices in the petroleum industry.

5.  Evaluate the weldability of live pipelines through ultrasonic thickness measurement.

6.  Select the correct tapping fittings: Welded tees, split tees, and mechanical saddles.

7.  Execute the sequence for a successful coupon recovery during the tapping process.

8.  Describe the operation of plugging machines and the deployment of isolation heads.

9.  Design a bypass system to maintain service during a pipeline section isolation.

10.  Manage the risks of thermal expansion and pressure fluctuations during the operation.

11.  Troubleshoot common equipment issues such as jammed cutters or seal leaks.

12.  Conduct a comprehensive pre-job safety meeting and risk assessment for HT&P.

13.  Perform post-operation inspections and the final removal of temporary equipment.

TARGET AUDIENCE:

Maintenance Engineers, Pipeline Technicians, Safety Officers, and Field Supervisors are responsible for the execution and oversight of in-service pipeline modifications.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.