Danfoss JIP Hot Operating guide
Operating Guide
JIP Hot Tapping Machine Toolbox
JIP Hot Tapping Machine
DN 20-100
© Danfoss | 2022.03
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Operating Guide JIP Hot Tapping Machine Toolbox
1. Content
1. Content 2
2. Safety Instructions 3
2.1 General Safety Requirements 3
2.2 Safety Requirements at the Workside 4
2.3 Special Risks 5
2.4 The Signicance of Symbols used Safety 5
3. Description Danfoss Hot Tapping Machine Toolbox 6
3.1 Area of Use 6
3.2 Specications of the Danfoss Drilling Device 6
3.3 Danfoss JIP Hot Tap Valves with Hot Tapping Machine Toolbox 8
4. Operational Instructions 9
4.1 Branch Preparations before the Hot Tapping 9
4.1.1 Removing the Insulation 9
4.1.2 Adjusting the Hot Tap Valve 9
4.1.3 Welding of the Hot Tap Valve to the Main Line 9
4.1.4 Testing the Valve 10
4.2 Assembly of the Drilling Device 11
4.2.1 Assembly of the shaft for hole saws >32 mm 11
4.2.2 Assembly of the shaft for hole saws < 32 mm 12
4.2.3 Assembly of the Danfoss JIP Adapter Socket 12
4.2.4 Assembly of the Device to the Hot Tapping Valve 13
4.2.5 Installing the Feed Unit 13
4.2.6 Installing the Driving Unit 14
4.3 The Hot Tapping Process 15
4.3.1 Pressure Test 15
4.3.2 Starting the Driling Process 16
4.3.3 Adjusting the Feed 17
4.3.4 Releasing the Feed Unit 18
4.3.5 Closing the Valve and Releasing the Pressure 18
4.3.6 Disassembling the Machine 19
4.4 Creating the New Branch 19
4.5 Maintanance Plan and Spare Part List 20
4.6 Using the Chain Block 23
Page
Attachments:
A1 Safety Instructions in Regards to the Electrical Driving Unit 24
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Operating Guide JIP Hot Tapping Machine Toolbox
2. Safety Instructions
The user is well adviced to follow the safety instructions given in this manual. No warranty is
given for incorrect usage of the equipment or applications outside the scope of the Danfoss user
manuals!
If any questions occur or if you are unsure about certain aspects regarding the Danfoss hot
tapping machine toolbox, please don't hesitate to contact local Danfoss for support. It is
recommended to limit the pressure in the system to 12 bar during the operation.
2.1. General Safety Requirements
In the following chapters, the general and specic saftey instructions for the Danfoss hot tapping machine toolbox
are given and explained. The user is well adviced to read, understand and follow these instructions carefully.
Only qualied and trained person is allowed to execute hot tapping works with the Danfoss hot tapping tool.
Among the operators, there should be a control system to ensure that the skills and knowledge of the right
operation procedures are known and respected by all the working person taking part in hot tapping works. This
user manual has to be always available during the drilling works.
It is not allowed to use the device outside the application area described in this user manual without the
permission of hot tapping toolbox device manufacturer Danfoss.
Be aware that additional requirements can be given at the specific worksite.
For a safe usage of the equipment is essential to take the following general points into account:
• Never use the machine without being aware of the hazards. Take all the aspects from this user
manual and additional requirments into account.
• The staff must have the adequate skills and training in all the necessary phases of
the hot tapping work as well as in handling the equipment in question.
• Make sure that you always have a copy of this user manual with you which is available during the
hot tapping process. The Instruction may be downloaded from the manufacturer's
web-site (http://www.danfoss.com).
• The application area for this device is limited to water-based liquid uids of uid group 2
according to PED 2014/68/EU. The system parameters shall never exceed 200 °C and/or 40 bar of
pressure. See chapter 3 regarding the max. temperature and pressure this device can be used.
It is recommended to reduce the pressure in the system to 12 bar during the operation.
• Make sure that the chosen adapter including sealings is suitable for the system pressure, uid type
and temperature.
• Always make sure that the equipment is not damaged before starting the hot tapping process.
Only equipment in excellent condition shall be used.
• Only use original Danfoss spare parts for your own safety.
• Wear ear protection and a helmet.
• Wear suitable work clothes. Do not wear loose clothing or jewellery as they can be caught in moving
parts. For the protection from hot uid, wear heat resistant clothes, gloves and safety glasses.
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Operating Guide JIP Hot Tapping Machine Toolbox
• Any technical change at the hot tapping machine is not allowed.
• Read and follow the instruction manual for using the chain block.
• Take the general accident prevention regulations into account.
• Take the instructions for motor driven machines into account. Consider the hazards from
electric current and rotating parts (attachment A1). The electric drive shall never get wet.
2.2. Safety Requirements at the Worksite
The following aspects have to always be checked at the workside before using the Danfoss drilling device.
For drillings in district heating pipelines in Germany, the AGFW directive 432 has to be considered.
• Always make sure that it is possible to close the chosen Hot Tap valve. If the shutting
mechanism cannot be closed, the only way to remove the drilling device is to empty the main line.
• Double check the size of the used hole saw and pilot drill. Check that the valve closes after the
machine is assembled.
• Familiarize yourself with the Danfoss data sheet for the chosen valve type
• Make sure that the technical parameters (pressure, temperature, uid) in the system are not
exceeding the allowed values given in this user manual for the specic application
• Check that the device is assembled correctly as shown in this user manual
• Always make a pressure test to discover possible leakages at the shut-off valve and/or the drilling
device
• Make sure that all the rotating parts move freely
• Inspect the device according to the inspection plan given in this user manual
• Unauthorized persons should not be present at the worksite during hot tapping
• Check the location of the closest network shut-off valve at the worksite
• Make sure you know all emergency contacts. This concerns the contact persons on the site, the contact
to
the device manufacturer TONISCO System Oy (http://www.tonisco.com) and the local emergency
services
• Do the visual check of the worksite and take all the necessary measurements. Clean the work
environment from all unnecessary objects. Consider the space needed for shaft removal after drilling
• Make sure that all the necessary tools and equipment is available while drilling (e.g. chain block at high
pressures)
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Operating Guide JIP Hot Tapping Machine Toolbox
2.3. Special Risks
Release of Hot Water or Steam
Hot water or steam may escape the system due to mishandling. Make sure to wear prescribed safety
equipment when working with hot tapping machine.
When releasing the pressure from the drilling device, make sure to keep a sufcient distance between you
and the release hose. Always wear heat resistant safety gloves when removing the drilling machine from the
valve.
Hazards from Rotating Parts
Note that the drill shaft and drive components rotate during drilling. Be aware of the changes in the torque at
the shaft due to the varying cutting forces.Take a xed stand and turn the feed slowly.
If the hole saw gets stuck during the drilling, reduce the feeding speed or turn the wheel slightly backwards
until the hole saw can be rotated again.
Hazards Caused by the Pressure in the Pipeline
Most of the time, there is pressure present in the pipeline that is being drilled. It is recommended to reduce
the pressure in the system to 12 bar during the operation.
If the pressure in the mainline is > 12 bar it is highly recommended to use the chain block for a safe release
of the drilling shaft. This part is not included in the toolbox but can be purchased from Danfoss as an
accessory.
Requirements for the Operator
The hot tapping device may only be operated by persons who are trained, instructed and authorized to use it.
Operator must know the operating instructions and act accordingly.
2.4. The Signicance of the Symbols used Safety
WARNING: Warns of possible serious injury or death
if instructions are not monitored
CAUTION: Displays possible personal injury or damage,
if the instructions are not monitored.
NOTICE: Provides useful information
Italics: Provides important information, which must be observed
so that the device will not be damaged
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Operating Guide JIP Hot Tapping Machine Toolbox
3. Description Danfoss Hot Tapping Machine Toolbox
3.1 Area of Use
The Danfoss hot tapping device is intended to
accomplish new pipeline branches under pressure
in water-based heating and cooling systems at
branch dimensions DN15 - DN100.
The Danfoss drilling device body is designed for
maximum pressure of 40 bar and can be used as
described in the table on the right for the class
PN40.
However, for a pressure >12 bar additional
safety requirements have to be considered when
releasing the shaft or adjusting the feed.
3.2 Danfoss Hot Tapping Toolbox specifications
Device body contains the EPDM sealings. For max. temperatures follow the P-T diagram in chapter 3.
In Danfoss toolbox, an electric drive unit is included. This user manual focuses on the electric drive unit Metabo
BE1100 with following technical specications:
Metabo BE 1100Name of Drilling Device:
42CrMo4Body Material:
1200.0000Product Number:
Bxx xx= Id. for Month, YearMarking:
1Category acc. PED 97/23/EG:
DN 15 to DN 100Branch Dimension:
Water Based Heating and Cooling SystemsArea of Use:
liquidAgregate State of the Fluid:
40 bar Max. Working Pressure:
12 barRecommended max. Pressure
60 barTest Pressure:
160 °CMax. Working Temperature:
0 °CMin Working Temperature:
EPDMSealings:
hardened steel Ø20 mmDrill Shaft:
5,4 kgWeight Without Drive:
50 mmFeed Distance Feed Wheel:
150 mmMaximum Feed Distance:
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Operating Guide JIP Hot Tapping Machine Toolbox
Gear Fastening Screw
Drive Unit (Drilling Machine +
Reduction Gearbox):
Rotates the drilling shaft.
Feed Extension Socket
Chain Block*
Recommended for
high pressures >12
bar for a safe relase of
the drilling shaft after
the drilling.
Drilling Shaft:
Transfers the torque from
the driving unit to the pilot
drill and hole saw.
The length can be adjusted
by shaft extensions.
Feed
Locking Screw:
Feed Unit:
Consists of adjusting socket and the
actual feed socket, which together
are used to adjust the starting
position for the drilling and while
machining create the movement
towards the main pipe.
Chuck:
A connection piece between
the rotating shaft and the
hole saw and pilot drill.
Hole Saw:
Creates the actual hole in the
pipeline
Pilot Drill:
Cuts rst and creates a center hole
for the hole saw. Allows the uid in
the mainline to enter the valve, the
device body and the adapters to cool
the hole saw. The wire inside catches
the coupon cut by the hole saw.
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Device Body:
A part containing
the sealings and
bearings.Contains
locking grooves to
adjust the starting
position of the
drilling
Control Cock:
Necessarry for
the pressure test
and the release of
pressure after the
drilling.
Magnet:
Can be used in ferromagnetic
pipe materials to catch most of
the drilling waste.
Pressure Gauge:
or carrying out
the pressure test.
Can be used as a
pressure monitoring
during the drilling
process
*Chain block on special request
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Operating Guide JIP Hot Tapping Machine Toolbox
3.3 Danfoss JIP Hot Tap Valves for Hot tapping
The drilling device should be used to drill Danfoss JIP Hot Tap Ball Valves in a range from DN15 to DN100 and in
water-based heating and cooling systems. A connection between the machine body and the valve is realized by
threaded adapter pieces. Some adapter pieces are used for more than one nominal size by using adapter reduction
socket.
All adapters are designed to be used only for Danfoss JIP Hot Tap Valves. Keep in mind to control the allowed
pressure and temperature acc. chapter 3.1 and following Danfoss JIP Hot tap ball valves data sheet.
JIP Adapter <= DN50
JIP Adapter Socket
Standard valve versions
DN mm 15/20 25 32 40 50 65 80 100
PN 40 25
Hole saw diameter mm Ø15 Ø24 Ø24 Ø40 Ø40 Ø48 Ø65 Ø79
Code No. 065N0050 065N0051 065N0052 065N0053 065N0054 065N0055 065N0056 065N0057
06 5N1021 -
Tool box Code No.
06 5N1003 06 5N1004
JIP Adapter >= DN65
06 5N1002
OEM valve versions
DN mm 20 25 40
PN 40
Hole saw diameter mm Ø19 Ø32
Code No. 065N0070 065N0071 065N0072
Tool box Code No. 06 5N1022 065N1023
Depending on the valve length the shaft has to be adjusted. The recommended way to nd the correct shaft
lengths is shown in the pictures below.
- At rst, push the shaft forward so that the pilot drill touches the pipe surface.
- Measure the lengths between the lower shoulder of the shaft and the upper device body.
- The measured distance should be between 100 - 170 mm
- Adjust the length of the shaft if necessary as shown in chapter 4.2.1 and 4.2.2
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