Danfoss JIP Operating guide

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

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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