TDW PIG-SIG V Operating And Maintenance Instructions Manual Download Page 4

Page: 4 / 75

Section

: Safety

1.0 Safety ................................................................ 1

Section

: Introduction

1.0 Purpose ............................................................. 3

2.0 Description ........................................................ 3

Section

III

: Pipeline Not Under Pressure

1.0 Installation Overview and Preparation ............ 16

2.0 Plug Installation: Flange- or Valve-Mounted .. 19

Section

: Pipeline Under Pressure

1.0 THREAD-O-RING™ Nipple Installation .......... 22

2.0 Indicator Installation ........................................ 27

3.0 Plug Recovery ................................................. 42

Section

: Indicator Installation

1.0 Indicator Installation ....................................... 53

Section

: Optional Features

1.0 Optional Features ........................................... 55

Section

VII

: Maintenance

1.0 Preventative Maintenance .............................. 57

2.0 Troubleshooting .............................................. 63

Section

VIII

: Application Guide

1.0 Recommended Applications ........................... 67

Table of Contents

Summary of Contents for PIG-SIG V

Page 1: ...00 3795 0384 January 2018 Operating and Maintenance Instructions PIG SIG V Scraper Passage Indicator...

Page 2: ...er in which this equipment is used and the training and competence of the operators Should any difficulty arise at any time in the use of this equipment please contact T D Williamson immediately Failu...

Page 3: ...hts reserved T D Williamson Inc The list below shows the complete revision history of this document Date Version 02 2013 Document Release 12 2014 E005298 Document Version History 01 2018 Revision to P...

Page 4: ...tion Flange or Valve Mounted 19 Section IV Pipeline Under Pressure 1 0 THREAD O RING Nipple Installation 22 2 0 Indicator Installation 27 3 0 Plug Recovery 42 Section V Indicator Installation 1 0 Indi...

Page 6: ...r product or property damage 1 1 General Ensure the safety features and operating procedures of the drilling machine are understood Do not attempt to make a tap or set a PIG SIG V plug assembly withou...

Page 7: ...2 Section I Safety This page intentionally left blank...

Page 8: ...a pipeline to detect the passage of a pig or sphere The PIG SIG V indicator has a trigger that extends into the pipeline through a welded fitting that has been tapped When a pig passes the trigger is...

Page 9: ...ng All PIG SIG V units are omni dimensional Flag indicator with manual reset flag see Table 1 Electrical indicator with auto reset see Table 2 Combination electrical auto reset with manual reset flag...

Page 10: ...troduction Table 1 PIG SIG V Flag Indicator With Manual Reset Flag Flag Indicator Assembly Cap Plug Assembly THREAD O RING Nipple Set Screws and Allen Wrench PTFE Grease Lubricant Anti Seize Silicon G...

Page 11: ...duction Table 2 PIG SIG V Electrical Indicator With Auto Reset Electrical Indicator Assembly Cap Plug Assembly THREAD O RING Nipple Set Screws and Allen Wrench PTFE Grease Lubricant Anti Seize Silicon...

Page 12: ...PIG SIG V Combination Electrical Auto Reset with Manual Reset Flag Indicator Electrical Indicator Assembly Cap Plug Assembly THREAD O RING Nipple Set Screws and Allen Wrench PTFE Grease Lubricant Ant...

Page 13: ...ension lengths up to 10 feet are available to elevate the indicator The PIG SIG V indicator can be installed on a line under pressure without taking the line out of service using the TDW T 101 T 101a...

Page 14: ...less steel pipe Tensile Requirements 35 000 psi SMYS 60 000 psi SMYS Impact Requirements 13 ft lb min Avg 3 Specimens 10 ft lb min One Specimen Only Impact Temperature 50 F Chemical Requirements Compo...

Page 15: ...250 29 to 121 3743 3743 3120 2600 2080 300 149 3620 3017 2514 2011 350 177 3493 2911 2425 1940 400 204 3369 2808 2340 1872 450 232 3072 3246 2246 1872 1497 500 260 2985 Pressures are in pounds per sq...

Page 16: ...h enclosure is sealed for protection against corrosion water dust and oil as defined in NEMA 1 3 4 4X 6 7 9 13 and IP67 as defined in IEC 529 The switch enclosure meets the European Hazardous Location...

Page 17: ...mperature range is 40 F 40 C to 185 F 85 C The switch housing is epoxy coated aluminum and zinc with fluorosilicone seals IEC Standards Ex dIICT6 IP67 Table 6 AC Volts Pilot Duty 600 VAC 720 VA Amps a...

Page 18: ...ide a degree of protection against corrosion windblown dust and rain splashing water and hose directed water Type 6 enclosures are intended for indoor and outdoor use primarily to provide a degree of...

Page 19: ...ectrical Code Group E Atmospheres containing metal dust Group F Atmospheres containing carbon back coal dust or coke dust Group G Atmospheres containing flour starch or grain dust Table 9 Conforming I...

Page 20: ...ce a nipple has been welded to the pipe it is recommended that a drilling machine be used to cut the opening in the pipe wall so that the nipple will act as a guide and ensure proper alignment The ope...

Page 21: ...he cap downward until fully seated B Install the three set screws and tighten to 1 5 ft lb C Set the flag and operate the trigger a couple of times to ensure the unit functions correctly Figure 3 1 D...

Page 22: ...dy into the fitting and start threads Be careful not to cross thread B Use a one inch hex wrench or the PIG SIG V plug holder and crescent wrench to tighten Figure 3 4 The plug will become more diffic...

Page 23: ...18 Section III Pipeline Not Under Pressure 1 0 Continued C Note that the top of the plug assembly extends 1 38 inches above the nipple when set This is normal Figure 3 4 Tighten Plug Body...

Page 24: ...ions are not interchangeable due to specific sizing for location Before installing the TDW THREAD O RING flange the sealing faces of both flanges and gasket should be inspected for signs of damage or...

Page 25: ...20 Section III Pipeline Not Under Pressure This page intentionally left blank...

Page 26: ...nipple has been welded to the pipe it is recommended that a drilling machine be used to cut the opening in the pipe wall so that the nipple will act as a guide and ensure proper alignment The opening...

Page 27: ...inch drill B The nipple must be welded so that it is on the top centerline of the pipe and perpendicular to it CAUTION The PIG SIG V plug assembly can be damaged and may not operate properly if the T...

Page 28: ...ure atmosphere NOTE Weld procedures and welders should be qualified to current API 1104 API 1107 or ASME Section IX Low hydrogen electrode AWS E XX18 is recommended for use with TDW fittings The use o...

Page 29: ...and pipe wall thickness should be 4 1 4 to 4 1 2 inches If that combination would exceed 4 1 2 inches grind some off the weld end of the nipple to obtain a shorter nipple or decrease the amount of th...

Page 30: ...For All Valves After the valve has been installed check the nipple for swaging distortion caused by possible over tightening of the valve This can be done using a THREAD O RING gauging tool if availa...

Page 31: ...surement J D Prepare the T 101b drilling machine with a 1 7 16 inch drill Install and tap through the pipe following instructions in the drilling machine manual E Close the tapping valve bleed the pre...

Page 32: ...to ensure the unit functions correctly Figure 4 3 Figure 4 3 Verify PIG SIG V Operation D After the test remove the set screws and pull the cap off the plug assembly NOTE Installation of the plug is t...

Page 33: ...bly Figure 4 5 E Ensure that the drilling machine is set up with the drilling machine adapter for PIG SIG V installation no 00 0706 0016 00 F Inspect the PIG SIG V Plug holder no 00 8138 0000 00 for d...

Page 34: ...ioned there will be end play between the plug holder and plug Figure 4 10 Figure 4 9 Attach PIG SIG to Plug Holder Figure 4 10 PIG SIG on Plug CAUTION Clean the threads of the THREAD O RING nipple bef...

Page 35: ...the threaded adapter Figure 4 13 M Using a marker pen place a mark on the body tube at the base of the feed tube N Slowly rotate the feed tube counterclockwise Figure 4 14 until the feed tube is at ze...

Page 36: ...istance was measured and recorded before the tap was made B Threaded Valves With the PIG SIG fully retracted measure from the bottom of the feed tube to the mark made on the body tube Figure 4 16 Flan...

Page 37: ...pply the wrench to the drilling machine D Threaded Valves Measure from the face of the valve to the mark made on the adapter Figure 4 20 Record this as Measurement G E Measurement K for the PIG SIG V...

Page 38: ...of the feed tube and mark this measurement on the body tube Figure 4 23 See EXAMPLE on following page NOTE An optional spacer may be installed to provide clearance to reduce the risk of valve contact...

Page 39: ...inued Figure 4 23 Measurements G J and K EXAMPLE Setting a two inch PIG SIG V using a threaded adapter and assuming Measurement G to be 2 5 8 inch The Measurement J is 4 1 2 inch Measurement G 2 5 8 M...

Page 40: ...onal injury may result from blowing material Consider the dangers of product when purging from the drilling machine adapter B Open the tapping valve slightly to purge air through the bleeder valve on...

Page 41: ...Figure 4 27 T 101b Both of these methods lock the feed tube and boring bar together permitting extension and rotation of the boring bar at the same time F Attach the crank handle to the inch hex driv...

Page 42: ...T distance cannot be attained the PIG SIG V may not be completely set DO NOT REMOVE VALVE Check all measurements If the plug needs to be removed follow the removal instructions check all work includin...

Page 43: ...te the feed tube counterclockwise approximately 24 turns retracting the plug holder two inches above the PIG SIG V Ensure the hex drive does not rotate otherwise the PIG SIG V will unthread from the f...

Page 44: ...leeder Valve NOTE Should leakage occur it indicates the following possibilities PIG SIG V is not completely set O ring on the PIG SIG V is damaged To correct the leak close the bleeder valve and remov...

Page 45: ...licable secure the drilling machine to lifting equipment D Unscrew the drilling machine from the tapping valve Figure 4 36 E Remove the tapping valve F Install the PIG SIG V indicator on the THREAD O...

Page 46: ...nstallation Figure 4 36 Unscrew the Drilling Machine Figure 4 37 Installed Plug Figure 4 38 Threaded Valve Mounted Assembly Assembled Figure 4 39 Valve Mounted Assembly Assembled NOTE Refer to Section...

Page 47: ...the external threads Figure 4 41 Figure 4 40 Remove Set Screws Figure 4 41 Apply Thread Paste D Select the appropriate tapping valve whether flanged or threaded and install the tapping valve onto the...

Page 48: ...ount the number of turns required to open and close the valve completely Record the number of turns on the Measurement Card and measure the length of the stem above the operating handle in the open Fi...

Page 49: ...to the face of the valve Figure 4 45 Record this as Measurement N B Close the tapping valve Figure 4 46 Figure 4 45 Measurement N Figure 4 46 Close Tapping Valve C Measurement M is the distance from...

Page 50: ...to the adapter only Figure 4 50 Do not apply the wrench to the drilling machine D Threaded Valves Measure from the face of the valve to the mark made on the adapter Figure 4 51 Record this as Measurem...

Page 51: ...ad Paste Figure 4 50 Tighten Drilling Machine Figure 4 51 Measurement M G Add Measurements M N The sum of Measurements M N should be the body tube reading when the plug holder contacts the bottom of t...

Page 52: ...ure 4 54 Installed Bleeder Valve EXAMPLE Removing a two inch PIG SIG V using a threaded adapter and assuming Measurement M to be 3 inches and Measurement N is 10 inches Measurement M 3 Measurement N 1...

Page 53: ...IG SIG V The feed tube should be at the mark on the body tube C If the feed tube is approximately one inch above the mark on the body tube Figure 4 55 the plug holder did not align with the hex drive...

Page 54: ...ely Extend the plug holder by rotating the feed tube clockwise until the stop is reached D The feed tube should be at the mark on the body tube Figure 4 57 Figure 4 56 Crank Handle Figure 4 57 Mark on...

Page 55: ...Slowly rotate the crank handle counterclockwise until the pressure starts to flow past the PIG SIG V Figure 4 60 D Purge air through the bleeder valve E After air is completely purged close the bleed...

Page 56: ...ure 4 62 H Open the bleeder valve and bleed off the trapped pressure from the drilling machine Figure 4 63 I Remove the bleeder valve from the 3 8 x inch bushing Figure 4 64 J If applicable secure the...

Page 57: ...ure 4 67 B Remove and clean the PIG SIG V Figure 4 68 C Remove the O ring Figure 4 69 D Replace the O ring E If required prepare the machine for re installation of the PIG SIG V Figure 4 66 Rotate Fee...

Page 58: ...til it is fully seated The indicator cap will completely cover the external threads on the nipple Check set screw holes to see set screw groove Turn the indicator to desired flag orientation Figure 5...

Page 59: ...lectrical Only Indicator Figure 5 7 Flag Electrical Combination Indicator 1 2 Extension Installation If the indicator is installed on a 1 to 10 foot extension it is installed exactly the same as the i...

Page 60: ...al protection for the PIG SIG V unit The transparent cover is placed over the PIG SIG V unit and secured by inserting the provided pin through both holes on the bottom of the cover 1 2 Spacer An optio...

Page 61: ...ag to Electrical Conversion to electrical only indicator will allow for a signal to be sent through the SCADA system electronically without the use of a visual flag indicator Flag to Combination Conve...

Page 62: ...1 1 Flag Operation Ensure the flag is properly positioned When looking at the TDW flag the flag should be in the horizontal position Figure 7 1 This is the proper position before pig passage Once the...

Page 63: ...flag in the upward position or remove the stainless steel cover to access the mounting hardware F Remove the four screws that are located around the shaft G Remove the assembly off the cap and remove...

Page 64: ...d Install one snap ring on one side of the short rod F Install the latch Slide the large pin through the back of the latch Figure 7 4 with one snap ring affixed to one end Figure 7 5 Figure 7 4 Instal...

Page 65: ...t and the seal Ensure the seal did not tear 1 4 Filter Pack In the event that the filter pack or magnet needs replacement a new magnet assembly holder with filter pack can be purchased A filter pack m...

Page 66: ...lacing it with a new magnet Figures 7 8 and Figure 7 9 Figure 7 8 Magnet Disassembled Figure 7 9 Magnet Assembled 1 6 Proper Electrical Switch Adjustment The gap between the electrical switch and the...

Page 67: ...e unit until it just begins to touch the rocker arm Once set re tighten the two nuts and re install the unit Figure 7 10 Note that the distance can only be adjusted while the unit is installed on a pl...

Page 68: ...upper portion of the plug This water can freeze and not allow the magnet to move Remove indicator and check for moisture Plug assembly won t thread on to the THREAD O RING Nipple Verify that it is ind...

Page 69: ...ing in damage Electrical or Combo Electrical switch is not sending electrical signal Proper switch adjustment refer to electrical switch instruction in the manual and ensure the switch is adjusted pro...

Page 70: ...Backup Ring Replace each time the plug is removed NOTE These time frames are suggestions from TDW Times may vary depending on the pipeline product and the environment that the unit is exposed to Elect...

Page 71: ...66 Section VII Maintenance This page intentionally left blank...

Page 72: ...tiveness of the magnet Liquid or relatively high pressure gas combined with turbulence due to high flow rate can kick up heavy amounts of magnetic particulates Heavy wax pushed into the PIG SIG V trig...

Page 73: ...ater sea water Highly corroded pipes where iron shaving fillings debris is known to be present low viscosity Refined products with corrosion or other ferrous debris 1 2 Applications Requiring Special...

Page 74: ...or inspection by TDW or at TDW s option returned to TDW s factory Customer shall prepay shipping charges and shall pay all duties and taxes as applicable for products or parts returned to TDW for warr...

Page 75: ...com TDW Pub No 00 3795 0384 ECN E008294 Copyright 2018 All rights reserved T D Williamson Inc Printed in the U S A Revised January 2018 Operating and Maintenance Instructions PIG SIG V Scraper Passag...

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