Operation instruction
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).
DEN-SMT/SI |
VI.KD.E1.02 © Danfoss 04/2014 |
1 |
Operation instruction |
JIP Hot Tap Equipment |
|
|
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. |
|
|
|
|
|
|
7. |
20100101 - Table of contents |
|
|
|
|
|
|
065N8013 - Hole saw ø40 |
|
|
|
|
|
|
|
8. |
065N8089 - Hole saw ø32 |
|
|
|
|
|
|
9. |
065N8012 - Hole saw ø24 |
|
|
|
|
|
|
10. |
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 mm |
|
|
||||
21. |
065N8247 - Allen key 7 mm |
|
|
|
|
|
|
22. |
80100022 - Allen key 5 mm |
|
|
|
|
|
|
|
|
|
|
|
|
||
23. |
065N8248 - Allen key 4 mm |
|
|
|
22 |
|
|
24. |
065N7996 - Screw coupling |
|
|
|
|||
25. |
065N8109 - Handle for feed tool |
|
|
21 |
23 |
24 |
|
26. |
065N8090 - Schrewdriver |
|
|
||||
27. |
065N8130 - Hot tapping tool |
|
|
|
25 |
|
|
28. |
80100100 - Handle |
|
|
|
|
|
|
|
|
|
|
26 |
|
|
27 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
28 |
|
|
|
|
|
||||
Design |
|
|
|
|
|
|
|
1. |
065N8102 - Reduction |
|
|
|
|
|
|
2. |
wrench 1:7 |
|
|
|
|
|
|
065N8109 - Handle for feed |
|
|
|
|
|
||
3. |
tool |
|
|
|
|
|
|
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 |
|
|
|
|
|
|
9. |
machine |
|
|
|
|
||
065N7996 - Screw coupling |
|
|
|
|
|||
|
|
|
|
|
|||
10. |
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 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2 |
VI.KD.E1.02 |
© Danfoss 04/2014 |
|
|
|
|
DEN-SMT/SI |
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 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
DN |
Conical |
Valve |
Valve |
|
|
|
|
lock screw |
Operation |
Code No. |
|
|
||
|
|
|
|
||||
|
20 |
Allen Key 5 |
Flat screw driver |
065N0106 |
|
|
|
|
25 |
Allen Key 7 |
Allen Key 10 |
065N0111 |
|
|
|
|
32 |
Allen Key 7 |
Allen Key 10 |
065N0116 |
|
|
|
Note: |
40 |
Allen Key 7 |
Allen Key 10 |
065N0121 |
|
|
|
50 |
Allen Key 7 |
Allen Key 10 |
065N0126 |
||||
Before adjusting the hot tap valve |
|||||||
|
|
|
|
||||
remove the conical lock screw |
65 |
Allen Key 10 |
Allen Key 14 |
065N0131 |
|||
from hot tap valve, operate the |
80 |
Allen Key 10 |
Allen Key 14 |
065N0136 |
|||
valve and set it back to fully open |
100 |
Allen Key 10 |
Allen Key 14 |
065N0141 |
|||
position using correct tools. |
|
|
|
|
|
|
|
DEN-SMT/SI |
VI.KD.E1.02 © Danfoss 04/2014 |
|
|
3 |
Operation instruction |
JIP Hot Tap Equipment |
|
|
Adjust the hot tap valve continuous
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.
Welding of the hot tap valve
Note: |
90° |
|
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.
4 |
VI.KD.E1.02 © Danfoss 04/2014 |
DEN-SMT/SI