MUELLER CO. Shur Stop 68 PE Operating Instructions Manual

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opERAtinG inStRUctionS MAnUAL

MUELLER

GAS

Shur Stop Unit 68 PE Line Stopping System

6" – 8"

TABLE OF CONTENTS PAGE

General Information 2

Equipment, Parts and Dimensions 3-5

Operating Instructions 6-12

Troubleshooting and Storage 13

Notes 14-15

SDR 11 - 11.5 - 13.5

WARNING:

1. Read and follow instructions carefully. Proper training and periodic review regarding the use of this equipment is essential to prevent possible serious injury and/or property damage. The instructions contained

herein were developed for using this equipment on ttings of Mueller

manufacturer only, and may not be applicable for any other use.

2. Do not exceed the pressure ratings of any components or equipment. Exceeding the rated pressure may result in serious injury and/or property damage.

3. Safety goggles and other appropriate protective gear should be used. Failure to do so could result in serious injury.

4. Pressure test, check for and repair leaks in all ttings and components

each time one is installed or any joint or connection is broken. Failure

to nd and repair a leak from any source in the ttings, by-pass lines

or equipment could result in an explosion and subsequent serious injury and/or property damage.

5. MUELLER® Drilling Machines and Equipment have been carefully designed and engineered to work together as a unit. The use of equipment manufactured by someone other than Mueller Co. may cause excessive wear or a malfunction of the MUELLER machines.

Reliable Connections

Customer Service Center

Decatur, Illinois

800.798.3131

www.muellergas.com

moreinfo@muellercompany.com

All warranties, expressed or implied, for Mueller Drilling Machines are

rendered null and void if the machines are used with shell cutters or

equipment manufactured by someone other than Mueller Co.

Overview

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

General Information and Equipment

The Shur Stop PE stopping system allows NO BLO stopping operations on 6" and 8" (SDR 11 - 11.5 - 13.5) polyethylene pipes operated up to a maximum operating pressure of 125 psig (Actual MAOP will be dependent on the operating pressure of the PE pipe).

This manual describes all operations including drilling, stopping and completion plug insertion.

Basic Equipment Required

1. Electrofusion Fitting

2. Centering Clamp

3. Slide Gate Valve

4. Stopping Machine

5. Cleaning / Inspection Machine

6. Combination Drilling / Completion

Machine

Stopping Bar

Stopping Machine

Slide Gate Valve

Electrofusion Fitting

eQUiPMeNT

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Equipment, Parts and Dimensions

1. Electrofusion Fitting

Each tting is composed of:

• Electrofusion housing with metal

bushing.

• Completion Plug with two O-rings.

• Completion Cap with one O-ring.

NOTE: These ttings are compatible with any universal processor available on the market equipped with a barcode pen / scanner.

Ø1

Electrical Parameters

• Input voltage 220 V (180 – 240 V)

• Frequency of power supply current

50 Hz

• Output voltage 8 V – 48 V

• Power 3.5 KW

Electrofusion Fitting

DIMENSIONS – Inches (mm)

PE PIPE Ø Ø1 A B WT – lbs (kg) Turns*

6" 10.24 (260) 7.64 (194) 5.90 (150) 4.33 (110) 57.3 (26) 8" 13.00 (330) 9.76 (248) 7.59 (193) 5.62 (143) 100.0 (45)

5 ± 1/4

41/4 ± 1/4

eleCtrofusion fitting

Hex-Head Screw

Completion

*Number of revolutions to install completion plug

Flange

O-ring

Plug

O-rings

Metal

Bushing

2. Centering Clamp for Electrofusion Fittings

The Centering Clamp is used to properly align the Electrofusion Fittings to the pipe during the fusion process. It is designed to evenly distribute the clamping force applied by the operator.

DIMENSIONS – Inches (mm)

L W H WT – lbs (Kg)

16.57 (421) 1.97 (50) 36.49 (927) 35.27 (16)

Centering Clamp

Swivel Holder

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Equipment, Parts and Dimensions

3. Slide Gate Valve

The Slide Gate Valve consists of a sliding gate housed between two

at bodies; pressure is held rmly

by two O-rings, one above and one

underneath. The valve is tted with

an internal pressure equalizer which allows easy opening when pressure varies between the upper and lower parts of the valve. To open and close the valve, turn the operating square approximately a quarter turn.

CAUTION: Never leave the

valve with the gate in the closed position when not in use. In the event that the gate is stuck, loosen the screws holding the two valve bodies, bring the gate to the open position and retighten the screws.

slide gate ValVe

Lower Valve Body

Lower Flange

Equalization Valve

Upper Flange

Gate

Upper Valve Body

Operating Square

DIMENSIONS – Inches (mm)

PE PIPE L W H PASSAGE ØA WT – lbs (Kg)

6" – 8" 21.25 (540) 16.41 (417) 6.73 (171) 7.67 (195) 77.1 (35)

4. Stopping Machine

The Stopping Machine is composed

of:

• A stopping machine with bypass

valve, bleed valve and available gas source (equalizer);

• An expanding stopper consisting of

Short Handle

two anges.

On the upper part of the stopping bar there is an operating square that when turned (clockwise) the two

anges compress resulting in the

expansion of the sealing ring. The result is full contact between the

sealing ring and the inner wall of the pipe, ensuring complete gas control. The affect is 100% stop off.

Stopper

DIMENSIONS – Inches (mm)

PE PIPE L W H WT – lbs (Kg)

6" 20.86 (530) 15.74 (400) 31.86 (812) 77.1 (35) 8" 22.91 (582) 16.25 (413) 41.92 (1065) 88.1 (40)

Long Handle

Sealing Ring

stopping maChine

Operating Square

Safety

Ring

Bleed Valve

Ball Valve

for By-pass

Front Flange

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Equipment, Parts and Dimensions

5. Cleaning / Inspection Machine

This device is used to allow cleaning of the pipe in which the stopper will be working. It also allows inspection

of the ttings internal threads

and cleaning if necessary before installing completion plug.

DIMENSIONS – Inches (mm)

L W H WT – lbs (Kg)

12.51 (318) 12.44 (316) 31.85 (809) 11.4 (5.2)

Cleaning / inspeCtion maChine

Viewer (inside)

Bleed Valve

Brush

Rod

6. Drilling / Completion Machine

The Drilling Machine allows tapping operations through Shur-Stop 6" and

8" PE ttings. Specially designed

cutters recover virtually all shavings and are equipped with pilot bit for coupon retention.

DIMENSIONS – Inches (mm)

L ØW H WT – lbs (Kg)

12.44 (316) 12.44 (316) 66.53 (1690) 143.3 (65)

PE PIPE HOLE Ø

6" 4.88 (124) 8" 6.88 (175)

SCOPE OF MACHINE

MACHINE M.O.P (psi) AMBIENT TEMP. (°F) PIPE MATERIAL

Standard 125 -4/+122 Polyethylene

drilling maChine

Hydraulic Motor

Motor Support

Guiding

Columns

Hydraulic

Distributor

Drilling Bell

Shell

Cutter

Pilot Bit

ØW

MUELLER

MACHiNe Use

ASSEMBLY AND USE

1. Position the electrofusion tting

on the pipe. Remove the completion plug O-rings and thread completion plug into tting (A.).

Internal Plug

Electrofusion Fitting

2. Position the Centering Clamp over

the tting with the lower plate open

(B.) centering the pin on the central hole of the completion plug (B1.) and close the lower plate (B2.).

Positioner

Lower

Plate

Shur StopTM Unit 68 PE Line Stopping System

Operating Instructions

D1.

B2.

3. Align the pipe holder to the axis of the pipe (C.).

5. Perform the electrofusion referring to the technical data shown on page 3 and fitting barcode.

6. Allow sufficient time for cooling.

7. Turn the screw of the centering

clamp counter-clockwise (e.).

B1.

Central

Hole

Pipe Holder

4. At this point rotate the screw of the centering clamp until the pipe holder is in contact with the pipe (D. & D1).

CAUTION: The best compression is the one where it is impossible to insert a sheet of paper between the fitting and the pipe.

Screw

8. Turn the lower plate and remove the centering clamp (F. & F1.).

9. Unscrew the completion plug, thoroughly clean the seat and insert the sealing O-ring lubricating it with PURITY-FG Spray or equivalent.

10. Install the appropriate vent / purge fittings as required by company practice (G. & G1).

11. Allow sufficient time for cooling.

12. Prepare the slide gate valve with

the lower ring of suitable diameter and attach to the electrofusion fitting (H.).

6 7

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Operating Instructions

Preparation of Drilling Machine

1. Remove the machine body from

the metal box.

2. Attach the pilot bit to the shell cutter arbor (A. & A1.).

Pilot Bit

F1.

G1.

Vent Fitting

PE Pipe 6"– 8"

20"

A1.

3. Attach shell cutter to arbor (B.).

4. Retract boring bar until shell cutter

is fully inside machine housing.

Shell

Cutter

Slide Gate Valve

Eyebolt

Adjustment Flange

Combined Wrench

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Operating Instructions

5. Lift and position the drilling machine onto the slide gate valve in the open position. Tighten the bolts in a criss-cross pattern.

Then turn the feed tube clockwise to lower the shell cutter until the pilot bit comes in contact with the pipe (C.).

Motor Support

Guiding Columns

Collar

Graduated Scale

Bushing with

Control Dowel

Anti-Slide

10. Turn the hydraulic distributor lever clockwise (G.).

Lever

turned 90°

clockwise:

shaft turns

clockwise

11. Turn the feed screw clockwise to begin drilling.

12. When the shell cutter makes

contact with the pipe, turn off hydraulic operator and stop drilling.

13. Loosen the knob on the graduated scale.

14. Turn the graduated scale 90° clockwise.

15. Then turn the knob on the

graduated scale until it is tight (H.)

16. Loosen the collar using the knob.

CAUTION: After each opening

and closing of the valve, remove the operating wrench to prevent accidental movement.

6. Turn the feed tube a quarter

turn counter-clockwise to avoid jamming when drilling begins.

7. Position the motor support, onto the boring bar operting square. Ensure guide coulumns are lined up with housings (D.).

NOTE: There is an opening at the very top of the shaft. This is to allow the insertion of a pin, which ensures that the motor support bushing does not slide out (e.).

8. Connect the hoses coming from the hydraulic control unit to the quick couplings of the hydraulic operator ensuring the lever is in the neutral position (F.).

9. Start the hydraulic control unit.

Lever in Neutral Position: Shaft Stopped

Hose Coming from Hydraulic Control Unit

Graduated Scale

Knob

Collar

Hydraulic

Operator

Hose Coming

from Hydraulic

Control Unit

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Operating Instructions

17. Move the collar down to bring the lower part (indicated by the tip of the arrow) in correspondence to the line below the diameter of the pipe on which the operation is being carried out (i.).

Collar

18. Loosen the knob on the graduated scale, turn the graduated scale 90° counter-clockwise and then tighten the knob (J.).

Graduated Scale

Knob

19. Turn on hydraulic power and begin drilling until the pipe coupon detaches. The location of the collar indicates the farthest travel the machine can be operated safely without drilling too far.

20. Return the hydraulic operator lever to the neutral position (K.)

Lever in

Nuetral

21. Turn off the hydraulic power and

the hydraulic control unit.

22. Turn the feed screw counterclockwise until the shell cutter is

inside of the drilling bell.

23. Close the slide gate valve.

24. Attach relief piping (L.).

Bleed Valve

Flexible Pipe

25. Purge the residual pressure above the closed gate a suitable distance from possible sources of ignition.

26. Remove hoses from the

hydraulic control unit and operator.

27. Remove the drilling machine.

28. Carry out the cleaning operation

using the cleaning inspection machine equiped with nylon wire brush (M.).

Cleaning /

Inspection

Machine

with

Viewer

29. Proceed with stopping operation.

30. Check the operation of the

expanding stopper. If the sealing ring does not expand evenly on the entire perimeter, it is necessary to lubricate the walls surrounding the ring with PURITY-FG Spray or equivalent (walls are compressed by two steel langes). Expand and retract the sealing ring a few times until the expansion is uniform. In the event that the stopper is not used for a long time, it is recommended to completely disassemble the stopper, replace the sealing ring and lubricate thoroughly. After reassembling the stopper, wipe the outer side of the ring that comes into contact with the inner side of the pipe.

31. Clean and lubricate the stopper bar and the sealing disk to provide smooth operation and to allow centering of the stopper during the expansion phase.

32. Position the stopping machine (N.) on the slide gate valve.

NOTE: There are 2 handles on the stopping machine. The longer one should always be on the upstream side.

Long Handle

Short Handle

Brush

MUELLER



Shur StopTM Unit 68 PE Line Stopping System

Operating Instructions

33. Perform the same operations on

the second tting and install the by-

pass between the two machines.

Equalize the pressure (O.) of the rst slide gate valve. For this operation rotate the knob that controls equalizing valve counter-clockwise until it stops.

Counter Clockwise

Equalization Valve

34. Open the slide gate valve.

35. Open the machine by-pass.

36. Open the machine by-pass

located on the second stopping machine.

37. Purge the air in the by-pass through the drain valve located on the downstream stopping machine.

38. Open the second slide gate valve without acting on the internal pressure equalizer, as pressure is already equal above and below the gate.

39. Ensure the proper operation of the by-pass and check for leaks.

40. Leaving the safety ring loose, lower the stopper and position the long handle between the pins on

the saftey ring. If this is difcult,

repeat previous step. If necessary, add stopping bar weights to top of stopping machine in order to assist lower stopper into pipe. Take care to ensure the plug is at a 90° position with respect to the pipe axis. Once the hole has been passed, place the plug in the downstream direction.

Long Handle

Short

Handle

No. 1

CAUTION: The plug should

never be inserted and expanded on the upstream side.

41. Turn the ratchet handle clockwise and gradually expand the

sealing ring of the stopper. During this operation slide the rod from top to bottom and vice versa to properly position the stopper in the pipe (P.).

42. Expand the sealing ring to obtain a positive shut-off. DO NOT overtighten.

CAUTION: The torque applied to the ratchet spanner should not

exceed 48 ft-lb for the 6ʺ plug.

The torque applied to the ratchet spanner should not exceed 52 ft-lb

for the 8ʺ plug.

43. If leakage occurs between the stopper bar and the sealing disk gradually tighten the Allen screws.

44. Repeat the same operations on the second stopper machine.

45. Purge remaining gas through No. 1 and No. 2 (Q.).

46. Tighten the safety ring.

No. 2

10 11

MUELLER

47. Make the repairs.

48. Before decompressing the

the sealing ring, it is necessary to equalize the pressure upstream and downstream of the same stopper.

When only gas comes out of the

vent No. 2, close the respective gate valve letting the gas equalize pressure. It is now possible to test the new connections (r.).

49. Decompress the sealing ring of the stopper by operating counter- clockwise on the ratchet handle until a hard stop and retract the stopper inside the stopping machine.

50. Repeat the same operations on the second stopping machine (s.).

51. Close the related slide gate valves (T.).

52. Bleed the gas contained in the by-pass at a suitable distance from possible sources of ignition (U.)

53. Remove the by-pass and the

stopping machines (v.).

Shur StopTM Unit 68 PE Line Stopping System

Operating Instructions

Vent Open for Purging

Hose

No. 2

No. 1



Vent Closed

No. 1

Vents Closed



No. 2

Bleed Valve

No. 2

No. 1

No. 2

No. 1

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Operating Instructions

Preparation of Drilling Machine

To Insert Completion Plug

1. Attach completion plug holder

support to the drilling machine shaft (A. & A1.).

Plug holder

support

Allen Key to

Tighten Allen

Screws

A1.

Allen Screws

2. For the 6ʺ, screw the inserting

tool onto the completion plug by alighing two of the four holes. Tighten the locking screws but do not tighten completely, leaving some minimal play between the two parts (B.).

Allen Key with Round End for Tightening M8 Set Screws

Inserting Tool

Internal Plug

Allen Key for tightening Allen Screws

Plug Holder Flange

4. Attach the inserting tool and plug onto the plug holder support and tighten the spring detents (D.).

Screwdriver

to tighten the

M12 Spring

Detents

Spring

Detents

5. Lubricate the O-ring of the internal plug with PURITY-FG Spray or equivalent and retract the plug into the machine adapter.

Internal Plug

Closing Flange

6. Assemble the completion machine

on the slide gate valve, open the equalization valve and then open the slide gate valve.

7. Turn the feed screw clockwise and move the completion plug

towards the tting.

8. Install the ratchet handle (e.).

3/4ʺ Ratchet

Spanner

9. Fully tighten the completion plug, taking care to SIMULTANEOUSLY turn both the ratchet and the lead screw clockwise.

10. Bleed any residual pressure off using the bleed valve (see point 28 on page 9) and check the completion plug for leaks.

11. Remove the ratchet and turn the feed screw of the machine counter- clockwise until the shaft is released from the plug holder support.

12. Remove the completion machine, the slide gate valve and the plug holder support (F.).

13. Install the completion cap (G.).

3. For 8ʺ, place the plug holder ange on the completion plug and

attach it with the provided screws (C.).

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Troubleshooting / Storage

TrOUBLesHOOTiNG

proBlem Cause solution

Drilling time too long Worn cutter Replace the cutter.

Gas leakage between the

drilling shaft and the screw Worn O-rings Replace the O-rings.

Inadequate sealing of the stopper No lubrication performed on the With PURITY-FG Spray or equivalent,

oblique walls of the sealing ring lubricate the angled walls of the sealing ring expanding and retracting it completely.

No lubrication performed on the Lubricate the sealing disk with sealing disk of the plug bell PURITY-FG Spray or equivalent.

Presence of residue on the bottom Clean again using the of the pipe inspection / cleaning machine.

Inadequate sealing of the Insufcient tightening of the screws sealing disk of the ange that compress the Tighten the screws slightly.

sealing disk

Inadequate sealing of the valve Equalization valve not closed Close the equalization valve.

Residue on the sealing O-ring Before the next use, replace the O-rings.

sTOrAGe

In case of long periods of inactivity, the equipment must be stored taking suitable precautions for the place it is stored in and the duration of the

storage:

• Store the equipment in a closed

place.

• Protect the equipment for humidity

and extreme changes in the temperature.

• Prevent corrosive substance

coming into contact with the equipment.

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Notes

MUELLER

Shur StopTM Unit 68 PE Line Stopping System

Notes

Gas (North America)

1.800.798.3131

Reliable Connections

The trademarks, logos and service marks displayed in this document herein are the property of Mueller Co., LLC, its afliates or other third parties.

Products marked with a section symbol ( § ) are subject to patents or patent applications. For details, visit www.mwppat.com. These products are intended for use in potable water applications. Please contact your Mueller Sales or Customer Service Representative concerning any other application(s).

www.muellergas.com moreinfo@muellercompany.com

Form 13932 – 11/18

MUELLER CO. Shur Stop 68 PE Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual