operation instruction jip hot tap equipment - danfoss...

1VI.KD.E1.02 © Danfoss 04/2014DEN-SMT/SI

JIP Hot Tap Equipment

Description

The equipment makes it possible to connect new branches to the net while in operation within the dimensions from DN 20 up to DN 100.This hot tap equipment should only be used in district heating systems. If another application is requested, please contact the producer.

Preparations

Notice: Generally good visibility and secured position is required on the place to drill and tap. To avoid injuries please make use of protective gloves, protective spectacles and protective clothing.

* Before every drilling the main tool has to be inspected. Please make sure that the drill/ hole-saw is in such a condition that the process can be carried through; otherwise the drill/hole saw has to be sharpened or renewed.

* Defective sealing and gaskets are to be renewed.

* All Screws, which hold the centre drill and the hole saw, have to be tightened very hard before every tapping process.

Important message

Please observe the German directive FW 432 from October 1998 (former: AGFW-directive 4.2.8 from June 1995). This directive contains: “Betriebliche Mindestanforderungen an die Erstellung eines Rohr-abzweiges an in Betrieb befindlichen Fernwärme-leitungen” (min. working instructions when connection branches to district heating pipes in operation according to the hot tap method).

Operation instruction

2 VI.KD.E1.02 © Danfoss 04/2014 DEN-SMT/SI

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Design

1. 065N8006 - Drill Ø15 2. 065N7997 - Hole saw Ø19 3. 065N8008 - Hole saw Ø24 4. 065N7998 - Hole saw Ø32 5. 065N8010 - Hole saw Ø40 6. 20100098 - Center drill inst.

20100100 - Hot tapping inst. 20100101 - Table of contents 7. 065N8013 - Hole saw ø40 8. 065N8089 - Hole saw ø32 9. 065N8012 - Hole saw ø2410. 065N8086 - Hole saw ø19 11. 065N8099 - Allen key set 12. 065N8101 - Service set 13. 065N8080 - Adapter ø26,9 14. 065N8087 - Adap. ø33,7-ø42,4 15. 065N8005 - Adap. ø48,3-ø60,3 16. 065N8084 - Adap. ø26,9-ø33,7 17. 065N8151 - Adap. ø48,3-ø60,3 18. 065N8103 - Feed tool 19. 065N8016 - Center drill 1/4"20. 065N8241 - Allen key 10 mm21. 065N8247 - Allen key 7 mm22. 80100022 - Allen key 5 mm23. 065N8248 - Allen key 4 mm24. 065N7996 - Screw coupling25. 065N8109 - Handle for feed tool26. 065N8090 - Schrewdriver27. 065N8130 - Hot tapping tool28. 80100100 - Handle

Design

1. 065N8102 - Reduction wrench 1:7 2. 065N8109 - Handle for feed

tool 3. 065N8130 - Hot tapping tool 4. 065N8112 - Service set 5. 065N8091 - Adapter ø76,1 6. 065N8094 - Adapter ø88,9 7. 065N8095 - Adapter ø114,3 8. 065N7995 - Stem for drilling

machine 9. 065N7996 - Screw coupling10. 065N8242 - Allen key 14 mm 11. 065N8103 - Feed tool 12. 065N8172 - Hole saw ø48 comp. 13. 065N8192 - Hole saw ø65 comp. 14. 065N8193 - Hole saw ø79 comp. 15. 20100099 - Center drill inst.

20100100 - Hot tapping inst. 20100102 - Table of contents

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Operation instruction JIP Hot Tap Equipment


Removing the insulation

Note:Remove the insulation and clean the surface of the main pipe carefully.

Adjust the hot tap valve

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DNConical

lock screwValve

OperationValve

Code No.

20 Allen Key 5 Flat screw driver 065N0106

25 Allen Key 7 Allen Key 10 065N0111







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Note:Before adjusting the hot tap valve remove the conical lock screw ① from hot tap valve, operate the valve and set it back to fully open position ③ using correct tools.



Adjust the hot tap valvecontinuous

Welding of the hot tap valve

Note:It is important that the valve is handled in a way to prevent grind particles or other foreign particles to get into the valve. The hot tap valve MUST be in completely open position.

Adjust the weld end of the hot tap valve by means of a grinding machine to the rounding of the main pipe.

Note:The hot tap valve can be welded on to the pipe in whatever direction you wish, but with an angle of 90° on center line of the main pipe. During welding the hot tap valve MUST be in completely open position.

The valve has to be welded on by electric arc welding. Since you are going to drill through the valve, it is very important to make sure that no welding material enters the valve.

90°



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Tools mountingJip Hot tap Drill / Hole saw Hole Ø Adapter

20 Drill Ø 15 mm Ø 26,9

25Hole saw Ø 24 mm Ø 33,7 - Ø 42,4

32

40 Hole saw Ø 40 mm Ø 48,3 - Ø 60,3

Jip Hot tap Drill / Hole saw Hole Ø Adapter

50 Hole saw Ø 40 mm Ø 48,3 - Ø 60,3

65 Hole saw Ø 48 mm Ø 76,1

80 Hole saw Ø 65 mm Ø 88,9

100 Hole saw Ø 79 mm Ø 114,3

Note:Respective adapter and drill/hole-saw should be selected according to the valve size.

Mounting

Note:Adapter is mounted using special handle following by hole-saw and hot-tapping tool as shown on the drawing above.



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Installing feeding tool

Note:To achieve a central pressure on the drill equipment, it is recommended to use the enclosed feeding tool.



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Reduction wrench

Note:For hot tap valves larger than DN 50 a reduction wrench is to be used. This is also reccomended for the smaller valves.

Mounting

Note:Always operate with low speed and without applying high pressure on the drilling spindle.

Recommended maximum speeds of the drilling are shown in the table on the right.

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Hot-tap valve size

Maximum drilling speed

(rev/min)

Using reduction wranch

20

400 rev/min

Recommended

25

32

40250 rev/min

50

65 200 rev/min

Obligatory80 150 rev/min

100 120 rev/min



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Installing Water hose

Note:The outlet hose is to be connected firmly with the coupling of the flush valve. The free end of the hose has to be placed far away from the place of drilling and it has to be fastened to avoid uncontrolled leak of hot water.



The drilling process

Note:Before starting the process of drilling by means of the hole-saw, it is to be checked that the center drill of the hole-saw does not prevent the ball from closing. The drill equipment is pulled back to stop-face and then the ball is closed carefully. If the center drill is projected too far into the passage of the valve, then the tool has to be dismounted and the center drill has to be re-adjusted.

90°

Note:When started - point of no returnDon’t pull back again, you can damage the barb, and loose the cut out discLook out for reflex pulling back when the center drill is through the main pipe wallApply moderate pressure on the feed toolsmaller drilling and sawing chipsless risk of loosing the discIf hole saw gets stuck do not pull back, reverse the drilling machineAdapt flushing ball valve to the situationAvoid immerging the hole saw too deeply into the water flow in the main pipe.When drilling large DN under high pressureLook out for forces on the drilling shaft, pushing drilling machine, feed tool and gear against yourself.

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Before and during drilling the packing box nut on the main tool is to be tightened manually to achieve optimal tightness, but at the same time the drill equipment must be smooth-running.

At the process of drilling it is important that a necessary differential pressure is achieved through optimal opening of the flush valve, at that moment, when the circular blank has been cut out. The pressure is necessary to keep the cut away circular blank up in the hole-saw. Therefore do not enter the drill equipment further into the main pipe than necessary.

The drilling processcontinuous

Note:

When the drill/hole-saw is through the wall of the main pipe then pull the drill/hole-saw carefully all the way back to the stop-face.

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32mm



90°

Note:

Turn the ball of the hot tap valve 90° to closed position by using a screwdriver/ Allen key. Make sure that water does not run from the hose. Since the ball in the hot tap valve has no automatic stop, you may have to adjust the position of the ball until it is in correctly closed position.

Remove the cut out piece

Remove the cut out piece

Note:

Now the hot tap tool is to be dismounted in opposite order and the cut out piece should be removed.

Note:

Afterwards the valve can be opened and the conical screw mounted and tightened. To get a fully welded pipe system you must place a weld round the conical screw.

The drilling processcontinuous


12 VI.KD.E1.02 Produced by Danfoss A/S © 04/2014

The functioning of thelock-screw

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To illustrate the correct function of the conical lock-screw description is divided two scenarios (a and b). Both scenarios are based on external demands to design and to the valves being installed in underground district heating systems.The design of the valve optimized for pre-insulated systems and insulation can be done without unnecessary adaption and the requirements in EN 488 regarding fully welded district heating systems are fulfilled.

Welding the conical lock-screw:

a) After welding in the valve, but before extending the pipe systemIf the valve should function as an end valve for a longer period - before the pipeline is extended - an end plate is welded on the free end of the valve. In this case the conical lock-screw is sealed with a suitable sealing material (Teflon band) according to correct guidelines for good workmanship and hereafter fastened with a common Allen key.

b) After extending the pipe system, but before insulating and covering the diggingWhen the work extending the pipe system has been finished and the valve is opened, the conical lock-screw is dismounted, so that the valve can be turned into open position. Hereafter the conical lock-screw is mounted again and fastened. Finally a welding seam is placed around the conical lock-screw.

Attention - alternative 1!

It is important to pay attention to the fact that the simple O-ring situated at the stem of the valve is not securing tightness on a longer view. The final and absolute tightness is reached by placing the final welding seam around the lock-screw. Hereby you fulfill the requirements to a fully welded system.

Attention - alternative 2!

If you, for some reason, do not want to fulfill the requirements for a fully welded system, you can omit the welding seam. In this case the conical lock-screw is sealed with a suitable sealing material (f.e. Teflon band) according to correct guidelines for good workmanship and hereafter fastened with a common Allen key. Danfoss A/S consider this solution acceptable and the risk for untightens is minimal. Danfoss A/S does however not grant any guarantee for tightness.

Insulation

When installation had been finalized insulation should be established.


operation instruction jip hot tap equipment - danfoss...

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