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HOT TAPPING AND PLUGGING IN

PETROLEUM INDUSTRIES
Make your connection without interruptions, the safest way!!!

5th – 7th February 2020


Kuala Lumpur, Malaysia

Major Benefits of Attending


By end of this course, delegates will be able to:
OUTLINE the economic and environmental benefits of plant and pipelines hot tapping and plugging
ENHANCE experience for proper selection of hot tapping and plugging tools for specific
applications
ACT properly during hazardous situations
DESCRIBE the procedure of hot tapping and plugging
PROVIDE better specification for the new and replacement of old elements of oil and gas piping
system
IMPROVE operational integrity and performance of hot tapping and plugging equipment
MINIMIZE hot tapping and plugging failures as a result of enhanced and additional abilities
REFLECT positively on organization reputation and standing in the industry
APPLY the safety precautions in conducting the hot tapping and plugging processing
APPLY HSE (Health, Safety & Environment) instructions when conducting plant and pipelines hot
tapping and plugging operations, resulting in better safety record keeping

With emphasis to operate the production plants to maximize the production, hot-tapping has become one of
the most popular method over other traditional branch-making methods.

Our instructor focuses on the practical aspects of the topic in hand, not on secondary subjects.

Why you Should Attend? Who Should Attend?


With emphasis to operate the production plants to This course has been specifically designed for:
maximize the production, hot-tapping has become 3 Plant Operation and Maintenance Engineers
one of the most popular method over other traditional 3 Pipeline Installations and Maintenance Engineers
branch-making methods. This interactive, application-
3 Technicians involved in Plant and Pipelines
driven Hot Tapping and Plugging in Petroleum Industries
Construction, Operation, Maintenance and
training course will highlight the added value that
Inspection
Hot Tapping and Plugging practices advised by API
Standards can offer to support engineers and technicians 3 Plant and Pipeline Welding Technicians and
working in pipelines installation and maintenance. It Engineers
will show how to safely use the equipment and apply 3 Health, Safety & Environment (HSE) Engineers and
the modern techniques in successful hot tapping and Professionals
plugging a pipe line.

Organized by:

For more details, contact hello@fdb.sg


Workshop Overview
Hot tapping, or pressure tapping, is the method of making a connection to existing piping or pressure vessels
without the interruption or emptying of that section of pipe or vessel. With this, a pipe or tank can continue
to be in operation whilst maintenance or modifications are being done. This course will give you an overall
information on a safe and successful hot tapping and plugging.

This interactive, application-driven Hot Tapping and Plugging in Petroleum Industries training course will
highlight the added value that Hot Tapping and Plugging practices advised by API Standards can offer to
support engineers and technicians working in pipelines installation and maintenance. It will show how to
safely use the equipment and apply the modern techniques in successful hot tapping and plugging a pipe
line.

This Hot Tapping and Plugging in Petroleum Industries training course will emphasize the application of
related recommended API practices for pipelines hot tapping and plugging, focus on proper equipment
selection, retrieval and interpretation of data from equipment manuals, preparatory actions prior to process
execution, and safely carry out the hot tapping and plugging process.

Training Methodology
This course will utilise a variety of proven adult learning techniques to ensure maximum understanding,
comprehension and retention of the information presented. The daily seminar sections will be highly
interactive and participative. It also involves detailed accompanying the presentation of videos showing
the equipment, the safety precautions, and the whole procedure of pipelines’ hot tapping and plugging.
Delegates are strongly encouraged to bring and analyse data from their own work domain; this adds greater
relevancy to the content.

PRE COURSE REQUIREMENTS


It is recommended for the participants to have a prior review of:
• API RP 2201: Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries
• API RP 2009: Safe Welding, Cutting, and Hot Work Practices in the Petroleum and Petrochemical Industries
• API RP 1107: Pipeline Maintenance Welding Practices
• API RP 77: Risk-based Approach for Managing Hydrocarbon Vapor Exposure during Tank Gauging, Sampling,
and Maintenance of Onshore Production Facilities
• API SPEC. 190H: Open-hole Isolation Equipment

Outline

Day 1
SESSION 2: PIPELINES HOT TAPPING AND PLUGGING
The Concept of Hot Tapping and Plugging
Hot Tapping and Plugging Applications
SESSION 1: OIL AND GAS PIPELINES
• Branch Connection Attachment
The Overview
• Monitor Installation
• Oil & Gas Processing Facilities
• Redirect Flow
• Oil & Gas Pipelines
• Defects Removal
• Applicable Standards & Recommended Practices
• Line Stopping
Layout of Oil & Gas Processing Facilities
Factors Affecting the Hot Tapping and Plugging
Layout of Oil & Gas Pipelines
Processes
• Components
• Pipe Sizes
• Relevant Functions
• Distance of Flanges
Glossary of Terms Used in Pipelines Hot Tapping and
• Distance to Welded Joints
Plugging Operations
• Distance to Valves
Plant Construction – Basic Details
Hot Tapping Orientation
Pipelines Construction – Basic Details
• Standard Orientation
Hot Tapping and plugging Standards
• Non-Standard Orientation
• API and ASME Related Standards
Topic Evaluation and Discussion
• International Standards
Individual / Group Exercise
Discussion
Outline

Day 2 DAY 3

SESSION 3: HOT TAPPING AND PLUGGING EQUIPMENT SESSION 5: HOT TAPPING AND PLUGGING HAZARDS AND
Types RISK REDUCTION
• Hand Driven In-service Hot Tapping Emergency Action Plan
• Hydraulic Hot Tapping Features and Relevant Hazards
• Electric Various Hazards
• Pneumatic • Physical
Hot Tapping – Cutter Selections • Thermal
Equipment Design Features and Construction • Chronic
Examples of Hot Tapping Equipment • Toxic
• Description • Combustible
• Specifications Hazards Risk Reduction
• Features and Fitting Applications of the Tapping Case Studies
Machines • Hot Tapping Economy
• The Sandwich Valves • Hot Tapping Hazards
Branch Connection Fitting • Hot Tapping Tool Stuck in Position – A Common
Thread O-Ring Flanged Fitting Occurrence
Spherical Three-Way Tee Individual / Group Exercise
Composite Warp
The Plugging Machine SESSION 6: QUESTION & ANSWERS
The Lock-up Ring Flanges & Plugs Free Session: Question & Answers Session
Wedge-lock Pipe Plug Course Wash-up and Review
Equipment Test Training Evaluation & Course Review
Freeze Plugging
Individual / Group Exercise CLOSE OUT

SESSION 4: HOT TAPPING AND PLUGGING PROCEDURE


Cases where Hot Tapping is Prohibited
Selection of Hot Tapping Location
Design Considerations
Preparatory Work for Hot Tapping
Technicians’ Qualifications and Skills
Hot Tapping of Line Pipes
Hot Tapping Basic Requirements and Operations
Welding Preparation, Procedure and Inspection
Hot Tapping Machine Installation
Hot Tapping Operations and Work Completion
Hot Tapping Check Lists
Line Stops
• Types
• Layout
• Operation
• Completion Ring
Topic Evaluation and Discussion
Individual / Group Exercise
program schedule
08:30 Registration
09:00 Morning Session Begins
10:40 - 11:00 Refreshments & Networking Break
12:45 Luncheon
14:00 Afternoon Session begins
15:30 - 15:50 Refreshments & Networking Break
17:00 Course Ends
Workshop facilitator

D. GOPALKRISHNA MURTI P.Eng


Equipment Reliability – Pipeline & Pressure Vessels Expert
Senior Consultant, Mechanical Engineering
Independent Consultant
Affiliated to the Augustus Group
Canada

PROFESSIONAL QUALIFICATION
• Professional Engineer, The Association of Professional Engineers and
Geoscientists of Alberta, Canada
• Fellow & Chartered Engineer, The Institution of Engineers, India
MEMBERSHIP/ AWARD/ CERTIFICATIONS
• American Society of Mechanical Engineers (ASME)
• The American Petroleum Institute (API)
• Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)
• Occupational Safety and Health Administration (OSHA)
• Many other recognitions for contribution to piping design codes and standards

KEY EXPERTISE
• Equipment Reliability • Flare and Vent Dispersion
• Storage Tanks • Radiation Calculation
• Pressure Vessels • Pump Piping Vibration
• Columns and Towers • Hydrocarbon Processing
• Boilers • Refinery
• Heat Exchangers • Plant Integrity
• Oil – Gas - Water Separation • Heavy and Light Oil Treating
• Piping Systems • Disposal Water
• Plant and Machinery • Desalination
• Plant Management • Codes and Standards
• Furnaces • Grass-root Plants
• Process Safety • Steam generation and Injection
• Piping Stress Analysis • Plant Relief System
• Pipeline • Field Troubleshooting
• Materials Selection

RELATED ONSITE TRAINING


• Design, Operation & Maintenance of Cross-country Pipelines
- A 4-day course for a batch of 18-20 young engineers at Kuwait Oil Company
• Design, Operation and Maintenance of Pressure Relief Systems
- For Qatar General Petroleum Corporation’s working engineers
• Design of ASME-B31.1/B31.3/B31.4/B31.8 Piping Systems
- A 5-day course at Qatar General Petroleum Corporation Training Centre, Doha, Qatar, designed for the
junior and senior engineering staff
• Basic Process Design and Plant Relief System at Kuwait Oil Company Training Centre
- A five-day course designed for the junior and mid-level engineers

HIGHLIGHTS
• Successfully implemented and maintained the fixed equipment reliability program for pressure vessels,
columns and towers, storage tanks, furnaces, boilers and heat exchangers, and piping systems in
accordance with company policies and guidelines and OSHA 1910.119 regulations
• Integrity study of old non-metallic tanks and piping and conducting the remaining life assessment studies
using integrity management tools for a refinery
• Prepared a Quantitative Risk Analysis (QRA) report for Alkylation Unit of a refinery and offered expert
comments and clear implementable recommendations out of this report
• Safety review of a new onshore LNG import and regasification terminal with a capacity of 1,500 mmscfd
of gas, with four full-containment 180,000 cubic meters LNG storage tanks. Advised on plant reliability
issues with respect low-temperature plant and equipment right at design stages
• Wrote the statutory requirements for storage of Bulk petroleum products for a Middle-Eastern oil-rich
country
• Started a new Mechanical Reliability and Material Support Team for 600,000 BPD West Kuwait oil production
facilities. Solved many recurring plant problems by providing permanent solutions. Carried out failure
analysis for plant and equipment and material selection for capacity expansion projects
• Conducted QRA Study of Underground Sour Oil & Gas Pipelines (containing 40,000ppm of H2S)
Workshop facilitator

• Design operations-and-maintenance-friendly pressure vessels


• Project aimed at recovery of 25,000 to 30,000 BPD of oil involving well-head facilities, steam generation,
oil-gas-water separation, flare-system and water treatment plant
• Designed 110 gpm water treatment plant and 15 GPM portable water plant
• Handled material selection for all static equipment (vessels, tanks, flare systems, Nitrogen Generation
System etc.) and pipelines for this front-end-engineering project worth US$ 300 million project
• Gas recycling projects in Bahrain involving high pressure gas injection facilities, gas lift facilities
• Undertook extensive studies to debottle-neck six tank batteries, solved numerous problems and improved
oil/gas recovery. Eliminated problems of excessive gas injection from wash tanks, manifold oil transfer
pumps, upgraded relief system. Involved in installation of 4 x 66 mmscfd gas dehydration units
• Detailed engineering of rotating equipment for various projects undertaken by the company in the areas
of oil and gas producing facilities, refineries, petrochemicals, and fertilizers projects. Also, worked as
Inspection Engineer and responsible for fabricated equipment
• Assisted Ammonia plant operators across USA to bring their facilities in line with CGA 2.1 2014 Storage and
Handling of Anhydrous Ammonia
• Based on his initiative, revised and added more than 30 ASME, API, ASTM, BSIA Codes and Standards
• Has full knowledge of various design codes such as ASME, API, ASTM, NACE, TEMA, AWWA, AWS, EJMA,
GPSA, HI, MSS, ISO
• Full knowledge of API 5L, 620, 650, 660, 571, 573, 579, 580, 581, 689, and 770
• Perform formal and informal audits of the fixed equipment reliability program to ensure compliance to all
applicable ASME, OSHA, API and other relevant standards
• Worked together with ASME B31.1, B31.3, B31.4 and B31.8 sub-committees to unify the Longitudinal Weld
Joint Efficiency Factor for various piping/pipeline material
• Experience working with major Oil & Gas Producers and major Engineering companies in North America,
Middle East and India
• Moderator of a WEB-based Technical Group of 1,200 engineers dedicated to safety and reliability in the
hydrocarbon processing industry

PUBLICATIONS
• Hydrocarbon Processing on Integrity and Reliability Management
• Design Operations and Maintenance Friendly Pressure Vessels – Part 1 & 2
• Consider the Precautions while Designing Solid or Cladded Stainless Equipment
• API-RP-550 – Manual on Installation of Refinery Instruments and Control System
• Design Operations and Maintenance Friendly Skid-Mounted Equipment
• Petroleum Pricing in India
• How to make ISO Pump-Sets Work in Plants Built in ASME Norms
• Overcome Technical Difficulties in Filed Pumps ordered to API 610/ISO 13709
• Supports Ease Stress on Fiberglass Piping
• Capital Costs Quickly Calculated
• Ball Valves to API Spec 6D
• A Brief History of Changes in API Standard 610 for Centrifugal Pumps – Part 1 & 2
• Improved Disposal Water Treatment in Bahrain’s Oil Fields
• Codes and Standards: Explore Alternative Engineering Options for Code Requirements
• Codes and Standards: How Much Fireproofing Do We Need?
• Renovate Produced-Water-Treating Facilities to Handle Increased Water-Cuts

D. GOPALKRISHNA MURTI, P.Eng, also known as Gopal, is an independent consultant currently based
in Canada with almost 50 years of vast experience in equipment integrity and reliability engineering
for storage tanks, pressure vessels, columns and towers, furnaces, boilers and heat exchangers,
and piping systems. He is involved in major designing and project engineering, resolving complex
design and code incompatibility issues, field troubleshooting, plant safety, integrity and reliability
management and more. He is an acknowledged Professional Engineer certified by The Association
of Professional Engineers and Geoscientists of Alberta, Canada, and a Fellow & Chartered Engineer
certified by The Institution of Engineers, India.

Gopal has huge experiences in assisting clients by analysing the plant and equipment design,
equipment failures, safety and reliability issues, operating and maintenance procedures, verify
operators’ compliance with the latest technical and regulatory standards, suggesting additional
measures needed to ensure compliance with the latest Code updates and operation-worthiness
issues. The industries covered are upstream oil and gas, LNG, downstream refineries, petro-chemical
and fertilizer industries, power generation facilities and cross-country pipelines.
Workshop facilitator

His personal experience is divided between major oil companies and the major engineering companies.
This blend of experience allows him to look into the facility reliability and safety issues from both sides
of the table that is as the Owner of the facilities as well as the Designer of the facilities.

Gopal is a regular column writer for the “Maintenance and Reliability” section of the Hydrocarbon
Processing magazine published from Houston and also a regular contributor to Chemical Engineering,
Pump Engineer, Oil & Gas Journal and the Society of Petroleum Engineers, USA. He also moderated
a group of 1200+ ace engineers. Gopal has more than 25 additions, revisions and initiation of new
standards to various international codes and standards.

Partial List Of Clients

3 Shell
3 Saudi Aramco
3 Bahrain Petroleum
3 BP
3 Emirates National Oil Company (ENOC)
3 Exxon Mobil
3 Kuwait Oil Company
3 Qatar Petroleum
3 Petrochemical Corporations of Singapore
3 Arab Gas
3 Brunei Shell Petroleum
3 Technip
3 Suncor Energy
3 Numaligarh Refinery Ltd
3 Bunge Loders Croklaan Oils
3 Aditya Birla Management Corporation
3 Husk Energy
3 Jacobs
3 NRG Tech Global Company
3 PanCanadian
3 Ranhill Power O&M
3 TeamQual Spec
3 TIU-Ops
3 TransAlta
3 White Energy Ethanol Plant Hereford
3 Worley Parsons

Testimonials

“The course was practical, relevant and Gopal included many cases and vast experiences”

“Very helpful to teach how to interpret ASME B31.3 Code and a good engineering practise.”

“It was a successful utilization of KOC subject matter expert in delivering this advanced training.”

“He is very experienced and has a lot to share”


R egistration Contact Willy Kwan (SGA 01003)
Direct Line: (65) 6825 9555
General Line: (65) 6825 9579

Form
General Fax: (65) 6316 8356
Email: willy.k@fdb.sg

HOT TAPPING AND PLUGGING IN PETROLEUM INDUSTRIES


5th – 7th February 2020 Hotel Accommodation
Accommodation is not included in
Registration Fees the training fee. To make a reservation
Early Bird Standard Fee for accommodation at the training
(Register and payment (Register after 05/01/2020) venue at our corporate rate, please
before 05/01/2020) contact the respective hotel.
1 delegate SGD 3,095 SGD 3,395 Kuala Lumpur, Malaysia

2 or more delegate SGD 3,195


Fee inclusive of course documentation, luncheons, refreshments and 15% services charge.
The above amount payable is net withholding taxes or any other taxes, if any, will be borne
by the customer.
Register at least 2 weeks before the training date to allow time for preparation of adequate
take-away and course provisions.

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Cancellations/Substitutions
Accounts Payable Name: _________________________________________________ If you are unable to attend, a substitute delegate is always welcome
at no additional charge. All bookings carry a 50% liability immediately
after a fully completed registration form has been received by the
FDB. Please note that a written notice of the cancellation must be
*Authorisation received via mail or fax 3 weeks prior to the event date in order to
obtain the balance of the event fee as a credit to be applied against
another FDB course. All fees are inclusive of a 15% service charge,
Signatory must be authorised to sign on behalf of contracting organisation. which is completely non-refundable and non-creditable. Cancellation
of any event with less than 3 weeks notice prior to the event date
carry a 100% liability; however the delegate will still be entitled to a
Name: ______________________________________________________________________ complete set of course documentation. If payment is not received by
the mutually agreed payment date, 10% penalty will be charged to
the bill. FDB will not be able to mitigate its losses for less than 50%
Position: ____________________________________________________________________ of the contract value in case of dispute with the client or cancellation
of this contract by any one party. In the event that FDB cancel the
event, FDB reserves the right to transfer this booking to another
event or to provide a credit of an equivalent amount to another event
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INDEMNITY: Should for any reason outside the control of FDB, the
venue or speakers change, or the event be cancelled due to an act
*This registration form is invalid without signature & company stamp of terrorism, extreme weather conditions or industrial action, FDB
shall endeavor to reschedule but the client hereby indemnifies and
*Mandatory field holds FDB harmless from and against any and all costs, damages
and expenses, including attorney fees, which are incurred by the
client.