NAVAL Hot Tapping Tool User Guide

NAVAL - Hot tapping tool

Valves - Representations and SaleIndustriestr, 77 b – D - 51399 BurscheidKÄHLERTel +49 2174 7848-0 - Fax: +49 2174 7848-25email: [email protected]

The NAVAL hot tapping system

enables connecting to an existing pressurized pipeline

KÄHLER GmbH Armaturen D-51399 Burscheid


Valves - Representations and SaleIndustriestr. 77 b – D - 51399 BurscheidKÄHLERTel +49 2174 7848-0 - Fax: +49 2174 7848-25email: [email protected]

Advantages of the NAVAL Hot tapping toolAll valves are full bore (only DN 150 + 200 red.)Connecting new consumers to fully pressurized pipelinesNo emptying of the net needed – saves time and energyNo supply interruption of other costumersPossible use of the valve for shut-off purposes(also available with hand lever and long stem) Hot tapping is easy and safe

New! With open/close-end stops

Drilling procedure

• Remove the main pipe insulation• Weld the ball valve onto the main line pipe• Mount the hot tapping tool on the valve• Carry out the drilling• Close the ball valve• Remove the Hot tapping tool• Connect the new supply line

Safety labelings and recommendations:AGFW set of rules worksheet FW 432: "Operational minimum requirements for pipe branching in district heating bymeans of Hot tapping procedure" “Suitable protective gloves, glasses and clothing are to be used in order to avoid injuries. Ensure that the device is in a safe condition. Faulty partshave to be replaced!



The Hot tapping tool is type tested since March 1999 underBauteil-Kenn-Nr. AR.303-14 of the TÜV Hamburg, Germany.

The field of application is restricted toTemperature up to 200°C and Pressure of 25 bar.

It is only applicable to NAVAL-Ball valves, which are fully-welded steel ball valves.DN 20 – 125 full bore + DN 150 red. bore with adapter threadDN 150 full bore + DN 200 red. bore with adapter flange



Stem cap size (hexagon) DN 20 - 25 > SW 22DN 32 - 40 > SW 27DN 50 - 65 > SW 32DN 80 > SW 36DN 100 - 150 > SW 41

*) DN 150 withinternal thread

Features of the ball valve with adapter thread :• Full bore up to DN 125 (DN 150 red.) • Actuation by hexagon socket• Steel cap weldable with stem housing• End stops 90° (no 360º rotation) • Clear visibility of the ball-position



The weldend opposite of the threaded weldend has to be machined before welding. Theprofile has to match the main pipe it will be welded on.

Attention! The ball valve has to be open during welding! Modification of the threaded welding end is not allowed before the hot tapping isfinished!



Welding of the ball valveThe hot tapping valve can be welded onto the main pipe in a radial angle of 0-360 degrees.

The angle to the pipe centre line must be exactly 90 degrees. The hot tapping Must not be carried out on the weld seam.



The welding onto the mainpipe has to fulfill the applicable strength requirements.If required, the connection can be strengthened with a connection ring.

Welding material must not reach the inner of the valve to prevent the hole sawfrom getting stuck.

The tightness of the welded seam can be tested by mounting the hot tapping toolon the valve and applying pressure through the flush valve.

Attention:After welding the ball valve you have to test its functioning by opening and closing the valve!



Standard circular hole saws are used with diameters between 24 - 146 mm(18 mm HSS-Drill DIN1897 = DN 20). Structure of the Hot tapping tool with threaded adapter

The total space requirement for hot tapping is a result of the valve length (L) + 800 (DN20=850) mm (tool plus stem upstroke).



Structure of the Hot tapping tool with flanged adapterDN 150 with full bore L = 1441 mm DN 200 with red. bore L = 1399 mm

Valve shown before procedure!

Assembly of the Hot tapping tool

Choose the DN-specific adapter and hole saw.

Screw the adapter on the tool. Please ensure that theO-ring is undamaged.

Fix the hole saw on the thread of the drill-arbor (DN 25) or the arbor-combination (DN 32 to DN 200) and fasten the arbor on the tool stem with a hexagonscrew.



BEFORE BORING

Insert the 6,5 mm center drill into the arbor, so that the protrusion (measure B) is 20 mm. Thew protrusion must not exceed 20 mm.

Screw out Part 1 (see tool drawing) to the marking in the thread.

Do not screw any further! The thread has a tolerance of only 10 mm.



Adjusting the hot tapping tool

Attention: Ensure that the Adapter O-ring is not damaged. Richly apply grease to the Adapter & O-Ring and thread & weldingends of the ball valve.

Screw the adapter with the help of the hook key on the thread of the completely opened ball valve until the adapter O-ring closes tightly against valve weldend.A rather high torque will be needed to overcome the resistance of the O-ring.

After that

• Test the tighness of the valve/pipeline welding seam and the mounted hot tapping equipment byapplying pressure through the flush valve.

• Release the snapping-unit by pulling it backwards and draw back the stem to its outmost position.

• Move the stem into right position: Separate 1-level stem = DN 20Standard stem, level 1 = DN 25 - DN 32Standard stem, level 2 = DN 40 - DN 50Standard stem, level 3 = DN 65 - DN 150RB

Separate 1-level stem = DN 150FB - DN 200RB

• Slowly lower the stem towards the main pipe by rotating the feeding-unit (Part 1) clockwise until thecenter drill meets the main pipe. After this, rotate one round backwards.


Valves - Representations and SaleIndustriestr. 77 b – D - 51399 Burscheid

Open the flush valve and ensure that the hose end is located far away enough, so that the hot flushing water with drillingsplinters will not cause any danger!

KÄHLERTel +49 2174 7848-0 - Fax: +49 2174 7848-25email: [email protected]

Adjust the drilling machine with angle-gear on the stem

Adjusting and handling of the drilling machine

Adjustment DN 25 (24 ∅ ) – DN 200 (146 ∅ ):

1. Drilling direction on right-drilling2. Switch to „drilling“ (not hammer!)3. Center-drilling: 2. gear and level F = 460 R/min



D22024125C122030132B122038240E12048250C12064365B12076380A120953100A1201213125/150A1201461150/200

B122018 120

Speed levelGearBSaw ∅Valve DN

Value-Table

Stem level

Attention! The main line has to be at least one dimension bigger than the dimension of the hot tapping valve.When drilling valves DN20-40 into a mainpipe that is only one dimension bigger, the hot tapping procedure has to be interrupted immediately after penetrating the main pipe wall.

The centerdrill protrusion over the hole saw must not exceed 20 mm(see table)!


Procedure

Turn on the drilling machine and drill the center hole by slowly and evenly rotating Part 1 (feedingunit) clockwise. After protruding the main pipe, water will start running through the flush valve.Now close the flush valve and turn off the drilling machine!Adjust the drilling machine according to the DN-specific values given in the value table (drilling-speed will be reduced)Open the flushing valve again to remove metal splinters created during the drilling!Now turn on the drilling machine and proceed with the main drilling by slowly and evenly rotatingPart 1.



After drilling

Close the flush valve after sawing out the slice of the pipe!Lift off the drilling machine and gear. Open the snapping unit by pulling and draw backthe drilling stem.

Close the hot tapping valve and open the flush valve to release pressure from the tool.

Remove the hot tapping tool and take off the metal piece from the center drill.



Hot tapping valve with weldend / flangeDN 150 with full bore L = 921 mmDN 200 with red. bore L = 879 mm

Valve shown after procedure!



Material information and recommendations:HSS-Drill Ø 18 NAVAL 400071 DIN 1897Hole saw Ø 24 Lenox 30015-15L, Sandvik 3830-24-VIPHole saw Ø 30 Lenox 30019-19L, Sandvik 3830-30-VIPHole saw Ø 38 Lenox 30024-24L, Sandvik 3830-38-VIPHole saw Ø 48 Lenox 30030-30L, Sandvik 3830-48-VIPHole saw Ø 64 Lenox 30040-40L, Sandvik 3830-64-VIPHole saw Ø 76 Lenox 30048-48L, Sandvik 3830-76-VIPHole saw Ø 95 Lenox 30060-60L, Sandvik 3830-95-VIPHole saw Ø 121 Lenox 30076-76L, Sandvik 3820-121-VIPHole saw Ø 146 Sandvik 3830-146-VIP

Center drill with claw Ø 6,5 DIN 338/V(DN 25/Ø24 - DN 200/Ø146)



Summary:

• Mount the DN-Adapter on the hot tapping valve (threaded except for DN150FB and DN 200RB).

• Mount the hot tapping tool including correct hole saw and center drill on the adapter.

• Choose the right stem level (DN 20 and DN150FB/DN200RB = only one level) according to the value table.

• Adjust the drilling machine according to the instructions. Readjust after centerdrilling!

• Manually lower the tool stem by rotating the Part 1 clockwise during drilling.

• Open flush valve during drilling.

• End the drilling by pulling back the tool stem.

• Close flushing valve!

• Close hot tapping valve an open flushing valve again.

• Remove the tool from ball valve! DN 150FB and DN 200RB = cut off the mounting flange



Instruction for welding the stemcap

To avoid stem leakage, it is recommended to close the stem cap by welding before isolating the pipe (EN 488).

Weldingprogress:

1. Remove cap seal2. Clean the welding area3. Close cap tightly and then open it

slightly.4. Weld the cap with electric arc orMIG- welding. NOT GAS WELDING!

Documents

NAVAL Hot Tapping Tool User Guide