February 11
th
, 2019
3
OPERATING PROCEDURE
Initial Set Up
1. Clean all components of the System-One prior to use paying particular attention to any “O”
rings, grooves and matching surfaces. Any dirt in these areas should be wiped off.
2. Clean the area of the pipe where the saddle will be positioned, removing all corrosion and
scale so that the saddle rubber will seal properly.
3. Also clean the area around the pipe where the chains will contact it to remove heavy scale.
This will ensure the chains will seat correctly and not loosen when any scale under them is
crushed.
4. Failure to carry out 2 and 3 may allow the saddle to move and gas to escape.
5. Select the correct size of saddle to match the pipe size and place it on the pipe
(Photo 1).
When working on steel pipe an appropriate sized PLCS adhesive silicone gasket must first be attached to the
underside/rubber side of the saddle. To attach silicone gasket first clean and dry the saddle rubber, peel off the
protective paper backing, stick the silicone gasket to the underside of the saddle and press firmly.
(Photo 1) (Photo 2)
6. Install the valve on top of the saddle and secure it to the pipe using the chains.
7. Push the chain bolts through the holes in the pivot pins, add the washers and screw the
nuts on one thread only by hand.
8. Install the other ends of the chains in the chain pull up hooks making sure that two pins from
each chain are installed in the two slots.
9. Close the valve gate at this stage to stiffen the whole valve and prevent it flexing.
10. Tighten the chains equally and alternately using the valve wrench. Do not completely
tighten one chain before tightening the other. Always use the short ALH wrench (part # 46-
A0012). DO NOT overtighten or use a longer wrench as this may put too much tension on
the chains and could damage the valve
.
11. Tap the chains lightly with a hammer to ensure that all links lie flat against the pipe.
12. Re-tighten the chains making sure you use the chain steady wrench around the closest link
to the eyebolt, to prevent the chain twisting. Do not over-tighten
(Photo 2)
.
(Note - Check the condition of the chains frequently and lubricate with a light oil to prevent
rusting. Occasionally clean with a wire brush.)
13. Operate the valve gate with the valve wrench and check it opens and closes fully and easily.
If the gate does not operate easily you may have over-tightened the chains causing the
valve to flex.
IMPORTANT – NEVER stand on the valve to use as a step when climbing out of the
excavation. You may damage the valve or cause it to slip around the pipe.
