Instruction Manual PE-25/32/37 Tapping Machines & POLYTAPP Valves
Nov 2016, Revision 2 Document Number 3000111 2 M.T. Deason Company, Inc. PO Box 101807 Birmingham, AL 35210 Phone: 205 956 2266 Fax: 205 956 1911 www.mtdeason.com Page 1 of 17
INTRODUCTION TO TAPPING MACHINE & POLYTAPP VALVE These instructions are designed to provide the operator with factory recommended procedures for safe and effective use of MTD Tapping Machines. This equipment is designed to tap through the MTD POLYTAPP Valve System. Under no circumstances should you exceed factory recommended specifications. Utilize all safety precautions and procedures to ensure operator safety. MTD recommends that the operator has read and is completely familiar with this entire manual before operating any Tapping Machine. MTD recommends that the operator be trained in accordance with this instruction manual and perform test taps under pressure prior to field operations. Prior to use please contact M. T. Deason Company with any questions or concerns. POLYTAPP VALVE TAPPING MACHINE Page 2 of 17
CAUTION: Do not proceed with any tapping operation which will depart from the procedures described in this instruction manual. Any such departure could result in personal injury or property damage. Any alteration to any tapping machine nullifies and cancels all warranties. Contact MTD for replacement parts or maintenance. Any alteration any MTD Tapping Machine, adapter or accessory may result in personal injury or equipment malfunction. MTD Tapping Machines are designed to make hot taps on polyethylene pipe as part of the MTD POLYTAPP system. Any universal processor equipped with 4.7mm fusion terminals may be utilized for fusing components of the MTD POLYTAPP System. All Tapping Machines are equipped with fast feed for advancement of body tube and slow feed for cutting. Tapping Machine Specifications PE 25 PE 32 PE 37 Part Number TRI1080 TRI1082 TRI1082 37 Max Operating Pressure 250psi 250psi 250psi Max Operating 115 F 115 F 115 F Temperature Tap Sizes * 2, 4 2, 4, 6 2, 4, 6, 8 Main Sizes 2 and above 2 and above 2 and above Feed Rates Fast (Feed Tube) Slow (Boring Bar) 1.00 per 360 Turn 0.04 per 360 Turn 1.00 per 360 Turn 0.04 per 360 Turn Maximum Travel 25 32 37 Machine Weight 38lbs 43lbs 48lbs Length (Extended) 63 79 86 * Tap sizes listed are for taps made through POLYTAPP valves. 1.00 per 360 Turn 0.04 per 360 Turn Page 3 of 17
SAFETY Operator must be familiar with location and function of all safety features included with tapping machine and related equipment. WARNINGS and CAUTIONS The purpose of WARNINGS and CAUTIONS in these instructions is to call attention to possible danger of injury to personnel or property damage to equipment and warrants complete attention and understanding. WARNING CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and damage to equipment. Indicates a potentially hazardous situation which, if not avoided, may result in personal injury and damage to equipment. It may also be used to alert against unsafe practices. PROTECTIVE CLOTHING Protective clothing is recommended whenever working with machinery. MTD encourages utilization of hard hats, gloves, safety goggles, steel toed boots, garments to cover exposed areas of skin, and breathing apparatus if toxic atmosphere exists. PROPER GROUNDING Polyethylene pipe can hold an electrostatic charge that may be hazardous to personnel and equipment. Utilize your company s procedures regarding grounding technique and system to eliminate this hazard. Many natural gas companies proceed to wrap the outside diameter of the pipe a wet cloth prior to installing the saddle, valve and tapping machine. Grounding rods for this type application are also utilized throughout the natural gas industry. POLYETHYLENE PIPE SUPPORTS Pipe may require support during tapping. In the event that support is required, utilize wood, sand bags, or pipe stands to support pipe. Page 4 of 17
TAPPING MACHINE & COMPONENTS 1 Tap Depth Indicator (Graduated in inches) Ratchet Handle 2 Feed tube Feed Tube Travel Stop 3 Body Tube (graduated in inches) Pilot Retention Clip 4 Boring Bar Spanner Wrench Page 5 of 17
POLYTAPP Adapter Wrench POLYTAPP Accessory Kit Includes: POLYTAPP Tapping Adapter POLYTAPP Cutter & Pilot POLYTAPP Test Cap Optional Equipment Air Motor Torque-Reduction Gearbox POLYTAPP Clamp Page 6 of 17
PIPE & SADDLE PREPARATION & FUSION 1 Clean Pipe with wet cloth to remove excess dirt and contaminates. 2 Place MTD TRI FUSION branch saddle on cleaned area of pipe and mark for scraping. 3 Remove saddle and mark entire fusion Zone. 4 Peel marked area with rotary peeler to remove oxidation, contaminates. CAUTION: improper scraping on pipe will result in fusion failure 5 After scraping, utilize alcohol wipes or alcohol, and a clean, lint free cloth to clean scraped area of pipe. 6 Clean saddle fusion mat with alcohol wipes or alcohol, and a clean, lint free cloth. CAUTION: Do Not Use Less than 96% Isopropyl Alcohol. Make sure alcohol is dry prior to beginning fusion. Page 7 of 17
7 Remove saddle fitting from bag and attach to main by utilizing plastic undercarriage, nylon straps, or clamping device. 8 Tighten fitting until it does not move when released. Rotate fitting on main until outlet is level. 9 Once outlet is level, tighten fitting to final tension for fusion. It is imperative for a tight fit between saddle fitting and main. Tighten installation hardware until saddle fitting comes into tight contact with main, yielding no movement or gap between fitting and pipe. Assure proper tightness has been achieved by grasping the outlet of the saddle fitting and attempting to rotate it on the main with reasonable force. If fitting yields no movement, it is ready for fusion. 10 Re check outlet with level before fusion. NOTE: Pipe Ovality may create a gap between fusion mat and pipe. If this occurs, remove saddle from main and re round pipe prior to fusion. WARNING: TIGHTEN SADDLE FITTING WITH HAND TOOLS ONLY. USE OF PNEUMATIC OR AIR TOOLS IS STRICTLY PROHIBITED! OVERTIGHTENING CAN CAUSE FAILURE OF CLAMPING COMPONENTS! 11 Attach processor leads to fitting (4.7 mm pins). 12 Fuse saddle fitting to main following company procedures. Ensure that total cooling time for this fitting has completely elapsed before proceeding. Page 8 of 17
FITTING PREPARATION & FUSION OF POLYTAPP VALVE 1 Peel entire outlet of saddle fitting with pipe & outlet peeler. 2 Wipe outlet of saddle fitting and inside of POLYTAPP Valve coupler with alcohol wipes or alcohol, and a clean, lint free cloth. *Instructions are provided with each POLYTAPP Valve. 3 Secure valve to branch saddle for fusion utilizing an MTD POLYTAPP Clamp. 4 Attach processor leads to fitting (4.7 mm pins) and fuse POLYTAPP Valve to saddle following company procedures. 5 Ensure that cooling time printed on fitting label has elapsed before removing POLYTAPP clamp. NOTE: This is not Total Cooling Time which must be fully observed before proceeding. Page 9 of 17
6 Open valve and test fusion joints utilizing POLYTAPP test cap with gauge per company procedure required pressure and time. Page 10 of 17
TAPPING MACHINE OPERATIONS To better understand how the tapping machine operates, the operator should remove the tapping machine from its case and prepare the machine for the hot tap: 1 Retract feed tube to 0 by rotating it counter clockwise while restraining the body tube from turning. 2 Retract tap depth indicator (boring bar) to 0 inches by utilizing the ratchet handle to rotate it counter clockwise while restraining both the body and feed tubes from turning. The serrated groove at the lower end of the tap depth indicator is 0 inches. The tap depth indicator is graduated in ¼ intervals. NOTE: Body tube travel distances are predetermined ranges of travel which will place the point of the pilot at the surface of the pipe. These measurements are presented by a ½ range in order to account for thread makeup. This helps ensure that the cutter components have passed completely through the body of the valve, and are ready to begin tapping the pipe wall. In this example (4 Hot Tap on 6 SDR 11 Pipe) the body tube travel distance must be set between 16 and 16½. In this example, it is set at 16¼ which places the 4 pilot tip in contact with the surface of 6 pipe. Page 11 of 17
3 Thread tapping adapter onto end of tapping machine and tighten with provided spanner wrench. 4 Advance feed tube to 6, providing room to attach pilot to boring bar. Attach pilot and cutter by sliding pilot into boring bar, and tapping pilot retention clip through hole in boring bar. After attaching pilot and cutter, retract feed tube back to 0. TIP: Wrap a strip of tape around the retainer clip to prevent loss of cutter if pin breaks. 5 Insert pilot and cutter into outlet of POLYTAPP valve and attach tapping adapter to threaded portion of valve by turning entire tapping machine assembly. Ensure that the tapping adapter does not loosen at the joint indicated above. After adapter has been tightened to valve, re tighten tapping machine to adapter with spanner wrench. Before proceeding, double check tap depth indicator remains at 0 6 Ensure that valve is in open position before continuing. 7 Advance feed tube until pilot touches pipe. Ensure cutter has passed through valve by checking distance against travel chart (Pg. 16) Page 12 of 17
9 Lock feed tube to body tube by tightening travel stop as shown to restrict movement of feed tube during tap. 10 Make note of required tap depth for the pipe SDR and size being tapped. It may be helpful to place a strip of tape on the required depth mark for reference. 11 Advance tap depth indicator (boring bar) to appropriate depth by attaching ratchet handle, and rotating in a clockwise motion 12 Once tap depth has been reached, remove travel stop and rotate feed tube clockwise ¼ turn to ½ turn to check that cutter has passed through pipe wall. If no resistance is met, pipe has been successfully tapped. If resistance is encountered, replace travel stop and advance tap depth indicator ¼ to finish tapping pipe wall. Hot Tap is Complete. Page 13 of 17
11 Retract tap depth indicator back to 0 by flipping ratchet direction switch on ratchet handle and rotating in a counter clockwise motion. 12 Ensure travel stop has been removed from tapping machine. 13 Retract feed tube back to 0 by rotating in a counter clockwise motion. 14 Close valve following rotation direction labeled on top of valve operator. 15 Pull up on ring to open bleeder valve. Ensure that pressure gauge reads 0 before removing adapter from valve. WARNING: VENT PRESSURE AWAY FROM EQUIPMENT AND PERSONNEL. STAND CLEAR OF VENT WHEN PRESSURE IS BEING RELEASED. Page 14 of 17
16 Loosen tapping adapter from valve. 17 Remove tapping machine, cutter, pilot, and adapter from valve. 18 Remove cutter from tapping machine, and remove set screw from side of cutter. 19 Tap blunt end of pilot against a block of wood to dislodge coupon from cutter. 20 Remove pilot from cutter. 21 Shavings will be retained inside cutter behind coupon. At this point, with valve in off position, remove threads from outlet of valve with polyethylene pipe cutter. After threads are removed follow manufacturer s instructions for butt fusion or electrofusion to valve outlet. After testing for leaks turn valve to the open position. Hot tap is now complete, placing new lateral line in service. Page 15 of 17
Tap Size (Tap Main) Travel Dimensions Body Tube Measurement Tap Depth Indicator Measurement 2 2 SDR 9 2 2 SDR 11 2 2 SDR 13.5 PE 25 19.50 to 20.00 PE 32/37 14.75 to 15.25 1.75 1.50 1.50 2 3 SDR 9 1.75 2 3 SDR 11 PE 25 19.75 to 20.25 PE 32/37 14.75 to 15.25 1.50 2 3 SDR 13.5 1.50 2 4 SDR 9 1.75 2 4 SDR 11 PE 25 19.25 to 19.75 PE 32/37 14.75 to 15.25 1.50 2 4 SDR 13.5 1.50 2 6 SDR 9 2.00 2 6 SDR 11 PE 25 19.25 to 19.75 PE 32/37 14.75 to 15.25 1.75 2 6 SDR 13.5 1.75 2 8 SDR 9 2.00 2 8 SDR 11 PE 25 19.75 to 20.25 PE 32/37 14.75 to 15.25 2.00 2 8 SDR 13.5 1.75 4 4 SDR 9 2.50 4 4 SDR 11 PE 25 20.25 to 20.75 PE 32/37 15.75 to 16.25 2.50 4 4 SDR 13.5 2.25 4 6 SDR 9 2.50 4 6 SDR 11 PE 25 20.75 to 21.25 PE 32/37 16.00 to 16.50 2.00 4 6 SDR 13.5 2.00 Page 16 of 17
4 8 SDR 9 2.50 4 8 SDR 11 PE 25 20.75 to 21.25 PE 32/37 16.50 to 17.00 2.25 4 8 SDR 13.5 2.00 4 12 SDR 9 2.75 4 12 SDR 11 PE 25 20.75 to 21.25 PE 32/37 16.25 to 16.75 2.50 4 12 SDR 13.5 2.25 6 6 SDR 9 3.50 6 6 SDR 11 PE 32/37 20.75 to 21.25 3.00 6 6 SDR 13.5 2.75 6 8 SDR 9 3.00 6 8 SDR 11 PE 32/37 22.00 to 22.50 2.75 6 8 SDR 13.5 2.50 6 10 SDR 9 3.00 6 10 SDR 11 PE 32/37 21.25 to 21.75 2.75 6 10 SDR 13.5 2.50 6 12 SDR 9 3.00 6 12 SDR 11 PE 32/37 21.00 to 21.50 2.75 6 12 SDR 13.5 2.50 8 8 SDR 9 4.00 8 8 SDR 11 PE 32/37 28.50 to 29.00 3.75 8 8 SDR 13.5 3.50 8 12 SDR 9 3.75 8 12 SDR 11 PE 32/37 28.25 to 28.75 3.50 8 12 SDR 13.5 3.00 Page 17 of 17