TDW POLYSTOPP Operation And Maintenance Instruction Download Page 1

Page: 1 / 52

TDW France-22-E-03-09

POLYSTOPP



for PE PIPE

Big sizes 315 - 355 mm

Operation and Maintenance Instructions*

*The present transitional version of the manual should be updated, upon the

launching of the new design valves.

Summary of Contents for POLYSTOPP

Page 1: ...ance 22 E 03 09 1 POLYSTOPP for PE PIPE Bigsizes315 355mm Operation and Maintenance Instructions The present transitional version of the manual should be updated upon the launching of the new design v...

Page 2: ...TDW France 22 E 03 09 2...

Page 3: ...with work on pipe containing liquids or gases under pressure The purchaser of this equipment is responsible for the manner in which this equipment is used and the training and competence of the operat...

Page 4: ...355 mm Lines with the T 203 Tapping Machine 1 0 Introduction 13 2 0 General Information 13 3 0 Preparations 13 4 0 Tapping the Line 18 Section IV Plugging the Line 1 0 Introduction 20 2 0 Plugging the...

Page 5: ...ludes equipment for tapping into the line plugging the main and installing a completion plug in the fitting in order to remove the tapping valve Some components of the 315 355 mm system are shown in F...

Page 6: ...ent or use of parts not manufactured or recommended by TDW could cause the machine to malfunction causing damage to the equipment and or injury to personnel Before taking this equipment to the field f...

Page 7: ...d 355 mm taps See figure 2 Figure 2 T 203 Tapping Machine C The SHORTSTOPP II 8x12 Folding Head Plugging Machine is used with this system to plug 315 and 355 mm lines This plugging machine consist of...

Page 8: ...B Tapping and plug setting machine adapters are used to connect various equipment components to the POLYSTOPP 10 valve They are flanged on the lower end to match the valve and threaded on the upper en...

Page 9: ...cates a potentially hazardous situation which if not avoided may result in minor to moderate injury and damage to equipment It may also be used to alert against unsafe practices 4 3 Proper Grounding P...

Page 10: ...illing or tapping machines and SHORTSTOPP II plugging equipment It is recoverable after the tap is complete and a completion plug is set in the TDW SHORTSTOPP or POLYSTOPP fitting 1 1 Site Preparation...

Page 11: ...specific nuts C Put the centering device onto the plug of the fitting D Put the Plug centering device onto the fitting E Put the reinforcement tool around the outlet of the fitting F Install the valv...

Page 12: ...d can damage the valve possibly resulting in personal injury Do not use any tool other than the handle provided to operate the valve B The POLYSTOPP 10 Valve must not be opened against differential pr...

Page 13: ...two connections for blow down of the isolated section and equalization of pressure D After the scope of the work has been defined the equipment must be selected assembled and inspected to ensure prop...

Page 14: ...boring bar Install and tighten nut to secure cutter assembly as shown in Figure 15 Figure 15 Install bolt and Nut H Retract cutter fully into housing Zero will show in one of the four tapping machine...

Page 15: ...is the distance from the top face of the tapping valve including gasket to the top of the pipe to be tapped See Figures 17 and 19 Figure 19 Take and record Measurement B C Add Measurement A to Measure...

Page 16: ...o be set after the tapping operation take and record measurement H for later use See Figures 17 and 21 This is the distance from the valve face including gasket to the bottom of the grove in the neck...

Page 17: ...e to the carrier pipe making it difficult or impossible to complete the tapping and or line plugging operation B After test is completed leave tapping valve and bleeder valve open 3 7 Selecting Power...

Page 18: ...rving the numbers as they come around in the travel indication port Count for 15 seconds and multiply by four to determine rpm CAUTION Speeds higher than 37 rpm may cause damage and premature wear to...

Page 19: ...Machine A Remove bleeder valve Figure 27 Remove Chips coupon CAUTION Cutter teeth are very sharp Wear gloves and handle cutter with extreme care when removing chips B After tapping has been completed...

Page 20: ...t holes All internal threads should be inspected for wear and a light coating of lubricating oil applied to reduce friction If using a plugging machine with a jack check the drag on the jacking mechan...

Page 21: ...the control bar as shown in Figure 30 Figure 30 Install Plugging Head and Secure D Secure with button head screw and the brass washer at the bottom of the bar as shown in Figure 31 Figure 31 Secure Pl...

Page 22: ...operations Figure 32 Lubricate Sealing Element Figure 33 Attach Sealing Elements F Attach a 315 355 mm sealing element G Tighten cap screws on each half evenly and firmly as shown in Figure 34 Torque...

Page 23: ...Open Plugging Head F Lubricate the sealing elements around the edges with grease Figure 36 Figure 36 Lubricate Sealing Elements H Fold and lock the plugging head in the closed position and remove the...

Page 24: ...re 38 Tighten nuts evenly Figure 38 Install Plugging Machine valve design will be changed after September 2019 B Install a ground strap from ground to the valve support C Install the bleeder valve and...

Page 25: ...nough to purge air from both adapter housings and the bypass hose through the downstream bleeder valve WARNING Vent pressure bleed valve away from work area and personnel Stand clear of vent when blee...

Page 26: ...TDW France 22 E 03 09 Figure 41 Lower Plugging Head...

Page 27: ...as it opens Note Handles may rotate several degrees beyond 180 degrees before locking in the open position Figure 42 Open Plugging Head B When the handles lock in the open position turn the plugging...

Page 28: ...in the isolated section is zero psi or zero bar and handles are properly positioned G Snug up the control bar latches if necessary after purging H Remove the handles from the plugging machine control...

Page 29: ...e seal is broken This could cause injury H Retract the plugging head machine fully using the jack Do not lower the jack handle more than 90 degrees to the control bar as shown in Figure 46 When fully...

Page 30: ...trol bar Fig 47 NOTE This machine can only be used to fit threaded plugs of POLYSTOPP Fittings A Put the completion machine onto the flat adaptor B Screw the plug holder onto the plug C Attach the plu...

Page 31: ...ut THE COMPLETION MACHINE IS NOW READY FOR USE 2 0 Installing the plug 2 1 Install the completion machine adapter onto the POLYSTOPP 10 Valve 2 2 Install the completion machine A Screw the completion...

Page 32: ...0 mark and the threaded knurled nut on the compensation cylinder G Release the control bar from the plug by pulling and turning the shaft with the hand wheel turn in a counter clockwise direction H Re...

Page 33: ...that will become available after September 2019 Fig 53 POLYSTOPP 10 Valve Fig 54 Removal of POLYSTOPP 10 Valve reinforcement collar and valve support B Remove the plug holder Fig 55 Removal of Plug H...

Page 34: ...rol bar by using a crocus cloth or a lapping compound B Keep the control bar coated with a light machine oil when not in use However it must be wiped clean before using or the jack may not function pr...

Page 35: ...Figure 58 Figure 58 Remove Ball Pivot Mechanism G Clean and remove any debris and replace O Rings in the throat of the housing and the internal channel of the pivot ball Lubricate both with silicone g...

Page 36: ...lugging head without the sealing element attached Continual adjustments may be required in the field as components wear or break B Additional drag can be created by advancing the drag adjust set screw...

Page 37: ...tenance reassemble in the following order A The control bar Insert the bar into the compensating cylinder B When the completion machine has been completely disassembled replace all the following O rin...

Page 38: ...ary to discard the old softer thrust washer and use the new harder thrust washer to ensure the softer one does not become a bearing race C Inspect all O rings and replace if cut cracked flattened or h...

Page 39: ...rts List No 1 POLYSTOPP System for PE Pipes Big Sizes 315 355 mm Description Part Number T 203 Drilling Machine 12303981 SHORTSTOPP Plugging Machine 8 x 12 08 3501081 0000 00 POLYSTOPP Completion Mach...

Page 40: ...TDW France 22 E 03 09 Figure 64 T 203 Tapping Machine Parts List 1...

Page 41: ...pring 00 0136 0170 14 Worm 05 0261 0014 15 Flywheel 05 0222 0015 16 Worm Bearing Retainer 05 0261 0016 17 Taper Lock Bushing 00 1641 0003 18 Flywheel Cover 05 0972 0018 19 Lower in Crank not shown 00...

Page 42: ...48 ESNA Nut 00 0003 0005 49 Spring Washer 00 5753 0001 50 Bleeder Valve not shown 00 0774 0001 51 Nipple not shown 00 0220 0001 52 Square Key 00 0640 0002 53 Bolt 00 0203 1000 10 54 Boring Bar Protec...

Page 43: ...TDW France 22 E 03 09 Figure 65 SHORTSTOPP II Dual Control Bar Assembly...

Page 44: ...er Control 2 1 Bushing Bronze 2 1 Bearing 2 2 O Ring 3 1 O Ring 4 1 Shaft Outer Control 5 1 Marker Control Bar 9 2 Key 10 1 Connector Lower Handle 11 1 Connector Upper Handle 14 1 Spring 15 1 Pin Hand...

Page 45: ...TDW France 22 E 03 09 Figure 66 SHORTSTOPP II Jack Assembly...

Page 46: ...tor 5 2 Pin Sel Lok 6 1 Spring Compression 7 1 Actuator Upper Control 8 1 Cap Jack Housing 9 3 Capscrew Skt Hd 10 1 Clamp Control Bar 11 2 Screw Shldr 12 1 Handle Adjustable 13 1 Screw Half Dog Set 14...

Page 47: ...adapter 07 0703 0007 0000 01 8 1 Polyurethane ring 07 0703 0008 0000 00 9 1 Compression stop 07 0703 0009 0000 00 10 1 Parallel key 5 X 5 X 20 00 5147 0505 0200 00 11 1 O ring 3 16 in nom OD 4 625 in...

Page 48: ...TDW France 22 E 03 09 Fig 67...

Page 49: ...TDW France 22 E 03 09 Parts List No 7 POLYSTOPP Valve 10 See Figure 68 TO BE ADDED UPON NEW DESIGN VALVE LAUNCHING...

Page 50: ...TDW France 22 E 03 09 TO BE ADDED UPON NEW DESIGN VALVE LAUNCHING Fig 68...

Page 51: ...55 SRD 17 08 3331 1504 0000 00 Sealing Element 150 Psi MWP 8 x12 315 SDR 11 08 2332 0010 0001 00 Sealing Element 150 Psi MWP 8 x12 315 SDR 17 08 2332 0012 0006 00 Sealing Element 150 Psi MWP 8 x12 355...

Page 52: ...081 67802 Bischheim Cedex Phone 33 0 3 88 19 72 38 Fax 33 0 3 88 19 72 19 E mail tdw commercial tdwilliamson com Visit TDW s website at www tdwilliamson com TDWFrance Pub 22 E 03 09 MAY 2019 Copyright...

Search results

Summary of Contents for POLYSTOPP

Reviews:

Related manuals for POLYSTOPP

Brands by name

Popular brands

TDW POLYSTOPP, Operation And Maintenance Instruction

Search results

Summary of Contents for POLYSTOPP

Reviews:

Related manuals for POLYSTOPP

Brands by name

Popular brands