TDW PIG-SIG V Operating And Maintenance Instructions Manual
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TDW PIG-SIG V Operating And Maintenance Instructions Manual

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PIG-SIG
V
®
Scraper Passage Indicator
Operating and Maintenance Instructions
00-3795-0384
January 2018
|

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Summary of Contents for TDW PIG-SIG V

  • Page 1 PIG-SIG ® Scraper Passage Indicator Operating and Maintenance Instructions 00-3795-0384 January 2018...
  • Page 2 Phone (918) 447-5100 Fax (918) 446-6327 E-mail: contact@tdwilliamson.com Explore the TDW Web site at www.tdwilliamson.com. ™ Trademark of T.D. Williamson, Inc. in the United States and foreign countries. ® Registered trademark of T.D. Williamson, Inc. in the United States and foreign country.
  • Page 3 Document Version History The list below shows the complete revision history of this document Date Version 02/2013 Document Release 12/2014 E005298 Revision to Pg 62 Language 01/2018 © 2018 All rights reserved T.D. Williamson, Inc.

  • Page 4: Table Of Contents

    Table of Contents Section I: Safety 1.0 Safety ..............1 Section II: 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 IV: Pipeline Under Pressure 1.0 THREAD-O-RING™...
  • Page 5 This page intentionally left blank. © 2018 All rights reserved T.D. Williamson, Inc.

  • Page 6: Safety

    Section I – Safety 1.0 Safety 1.0 SAFETY Throughout this publication, “Dangers,” “Warnings” and “Cautions” (accompanied by the International ⚠) are used to alert the customer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! ⚠...
  • Page 7 Section I – Safety This page intentionally left blank.

  • Page 8: Purpose

    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 tripped, activating the signaling mechanism.
  • Page 9 Section II – Introduction 2.0 Continued The PIG-SIG V Plug Assembly can be installed on or removed from a pressure pipeline using a TDW T- 101 series Drilling Machine and accessories. In some cases, a T-101 XL drilling machine may be required.
  • Page 10 Section II – Introduction Table 1. PIG-SIG V Flag Indicator With Manual-Reset Flag Flag Indicator THREAD-O-RING Plug Assembly Assembly Cap Nipple Set Screws and PTFE Grease Silicon Grease Allen Wrench Lubricant (Anti-Seize) Lubricant...
  • Page 11 Section II – Introduction Table 2. PIG-SIG V Electrical Indicator With Auto Reset Electrical Indicator THREAD-O-RING Plug Assembly Assembly Cap Nipple Set Screws and Allen PTFE Grease Silicon Grease Wrench Lubricant (Anti-Seize) Lubricant...
  • Page 12 Section II – Introduction Table 3. PIG-SIG V Combination Electrical Auto Reset with Manual Reset Flag Indicator Electrical Indicator THREAD-O-RING Plug Assembly Assembly Cap Nipple Set Screws and Allen PTFE Grease Silicon Grease Wrench Lubricant (Anti-Seize) Lubricant...
  • Page 13 A number of extension 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 or T-101b (or XL versions) drilling machine.
  • Page 14 Section II – Introduction B. THREAD-O-RING-Nipple Material. (Refer to Table 4.) Table 4. THREAD-O-RING Material Specifications Size and 2 NPS XXS, ASTM A 333 Grade 6 seamless steel Grade pipe Tensile 35,000 psi SMYS – 60,000 psi SMYS Requirements 13 ft.-lb. min. Avg. 3 Specimens Impact 10 ft.-lb.
  • Page 15 Section II – Introduction C. Pressure-Temperature Ratings (for Design Factor F). (Refer to Table Table 5. Pressure-Temperature Ratings for PIG-SIG V THREAD-O- † RING Nipple* Piping Code B31.3 B31.4 B31.8 Temp Temp (° F) (° C) – F=.72 F=.72 F=.60 F=.50...
  • Page 16 Section II – Introduction D. Electrical Specifications and Ratings. (Refer to Figure 2.2.) Figure 2.2. Electrical Indicator Switch Specifications NOTE: When a flag indicator is used in combination with an electrical switch; the switch will open or close momentarily when the flag is reset. Electrical ratings (refer to Tables 6-8): 10 amps continuous carry.
  • Page 17 Section II – Introduction Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN50014 1997 and EN50018 1994. The switch meets the North American Hazardous Locations Designations: Class I, Groups B, C, and D; Class II, Groups E, F, and G. The switch complies with UL (File No.
  • Page 18 Section II – Introduction E. Reference Standards. (Refer to Table 9.) Non-Hazardous Locations Type 1 enclosures are intended for indoor use primarily to provide a degree of protection against contact with the enclosed equipment. Type 3 enclosures are intended for outdoor use primarily to provide a degree of protection against windblown dust, rain, sleet, and external ice formation.
  • Page 19 Section II – Introduction Type 9 enclosures are for use indoors in locations classified as Class II, Groups E, F, or G, as defined in the National Electrical Code. Group E – Atmospheres containing metal dust. • Group F – Atmospheres containing carbon back, coal dust, or coke •...

  • Page 20: Pipeline Not Under Pressure

    If additional reinforcement is required, THREAD-O-RING nipples can be provided for attachment to various types of integrally-reinforced connections. If the PIG-SIG V indicator is replacing a PIG-SIG IV assembly, remove all PIG-SIG IV components.

  • Page 21: Installation Overview And Preparation

    PREPARATION Overview and 1.1 Initial Test Preparation NOTE: The PIG-SIG V will be shipped partially assembled, as shown in Figure 3.1. Figure 3.1. Verify PIG-SIG V Operation A. Before installation, assemble the flag indicator assembly cap onto the plug assembly. Push the cap downward until fully seated.
  • Page 22 1.0 Continued 1.2 Preparation NOTE: Since the PIG-SIG V indicator operates using magnets, it is vitally important that the internal threads of the fitting be free from all chips left from the tap. A. Using a “bottle” brush, clean the internal wall and threads of the fitting thoroughly (Figure 3.2).
  • Page 23 Section III – Pipeline Not Under Pressure 1.0 Continued Figure 3.4. Tighten Plug Body C. Note that the top of the plug assembly extends 1.38 inches above the nipple when set. This is normal.

  • Page 24: Plug Installation: Flange- Or Valve-Mounted

    Valve-Mounted mechanism offered; flange mounting does not affect the interchangeability between a PIG-SIG V and a PIG-SIG IV, but should be verified on a case basis. Extensions are offered for both wetted parts and signaling units.
  • Page 25 Section III – Pipeline Not Under Pressure This page intentionally left blank.

  • Page 26: Section Iv: Pipeline Under Pressure

    If additional reinforcement is required, THREAD-O-RING nipples can be provided for attachment to various types of integrally-reinforced connections. If the PIG-SIG V indicator is replacing a PIG-SIG IV assembly, remove all PIG-SIG IV components.

  • Page 27: Thread- O-Ring Nipple Installation

    1.0 THREAD- 1.0 THREAD-O-RING NIPPLE INSTALLATION O-RING Nipple 1. 1 Tapping Requirements Installation The PIG-SIG V plug assembly can be damaged and may not operate ⚠ CAUTION properly if the THREAD-O-RING nipple is not installed correctly or if the opening in the pipe is too small.
  • Page 28 API 1104, API 1107, or ASME Section IX. Low hydrogen electrode AWS-E-XX18 is recommended for use with TDW fittings. The use of low hydrogen electrodes is specifically recommended by certain welding specialists when the nipple is to be welded to pipelines operating in a high moisture area and/or a temperature below 50-degrees Fahrenheit.
  • Page 29 Section IV – Pipeline Under Pressure 1.0 Continued Follow established welding standard when welding the nipple onto the ⚠ WARNING line. Improper welding can cause rupture of the pipeline during or after welding. D. For proper weld penetration, a root gap should be introduced between the weld-end of the nipple and the surface of the pipe.
  • Page 30 2-1/16 inches to permit passage of the TDW PIG-SIG V plug assembly. Flanged Valves: Utilizing a new gasket, install the valve on the flanged fitting; consider the orientation of the valve.
  • Page 31 Section IV – Pipeline Under Pressure 1.0 Continued C. Measure from the top of the valve to the top of the PIG-SIG V nipple (Figure 4.2). Label this Measurement “J” and retain for use when setting the PIG-SIG V plug.

  • Page 32: Indicator Installation

    2.1 Initial Test Installation NOTE: Installation of the plug is the same for all PIG-SIG V types. When installing an indicator assembly already installed in a line, begin with Section IV, paragraph 2.3. A. Before installation, assemble the flag indicator assembly cap onto the plug assembly.
  • Page 33 F. Inspect the PIG-SIG V Plug holder (no. 00-8138- 0000-00) for damage. Ensure that the retainer balls are firm and will not allow the PIG-SIG V to fall off the plug holder. G. Insert the plug holder into the end of the boring bar (Figure 4.6).
  • Page 34 Attach the PIG-SIG V to the plug holder (Figure 4.9). The retainer balls in the holder should snap into groove in the PIG-SIG V. Do not let the plug holder bottom out in the PIG-SIG V. When properly positioned, there will be end play between the plug holder and plug (Figure 4.10).
  • Page 35 Section IV – Pipeline Under Pressure 2.0 Continued J. Check the O-ring on the PIG-SIG V for any damage. Replace if necessary. A damaged O-ring can create a hazardous environment from leaking ⚠ CAUTION fluids and result in personal injury and/or property damage.
  • Page 36 Section IV – Pipeline Under Pressure 2.0 Continued 2.3 Calculating the Travel Distance Determine the distance the PIG-SIG V needs to travel to be completely set in the tapping fitting. With the boring bar fully retracted and the feed tube at the zero mark on the body tube (Figure 4.14), measure...
  • Page 37 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 is always equal to 1-7/8 inches. Figure 4.18. Apply Thread Figure 4.19.
  • Page 38 The sum of measurements “G”+”J”+”K” should be the body tube of the T- 101b reading when the PIG-SIG V is completely set. Measure from the bottom of the feed tube and mark this measurement on the body tube...
  • Page 39 2.0 Continued 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” Measurement “J” = 4-1/2”...
  • Page 40 Section IV – Pipeline Under Pressure 2.0 Continued 2.5 Aligning the Plug A. Install the bleeder valve (Figure 4.24) into the 3/8 x ¼-inch bushing on the base of the T-101 DM (Figure 4.25). Leave the bleeder valve in the open position.
  • Page 41 SIG V setting operation. G. Rotate the crank handle clockwise until the mark is reached on the body tube (Figure 4.29) and the PIG-SIG V is tight inside the fitting. To prevent damage to the O-ring and threads, do not over- tighten.
  • Page 42 Figure 4.29. Mark on Body Tube IMPORTANT If the TOTAL SET 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 including measurements, and reset.
  • Page 43 PIG-SIG V. Ensure the hex drive does not rotate, otherwise the PIG-SIG V will unthread from the fitting. D. Check the seal on the PIG-SIG V by opening the bleeder valve on the drilling machine for several minutes (Figure 4.32). Leave the bleeder valve...
  • Page 44 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 remove the PIG-SIG V. Inspect the PIG-SIG V and O-ring and then reinstall.
  • Page 45 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-RING fitting. The top of the PIG-SIG V assembly is designed to extend 1.38-inches above the THREAD-O-RING fitting (Figure 4.37).
  • Page 46 Section IV – Pipeline Under Pressure 2.0 Installation Figure 4.36. Unscrew the Drilling Figure 4.37. Installed Plug Machine. Figure 4.38. Threaded Valve- Figure 4.39. Valve-Mounted Mounted Assembly - Assembled. Assembly - Assembled. NOTE: Refer to Section V for Indicator Installation instructions.

  • Page 47: Plug Recovery

    Section IV – Pipeline Under Pressure 3.0 Plug 3.0 PLUG RECOVERY 3.1 Preparations Recovery A. Remove the three set screws (Figure 4.40) and remove the flag indicator from the plug by pulling straight up. Do not turn the cap during the removal process.
  • Page 48 Section IV – Pipeline Under Pressure 3.0 Continued 3.2 Checking Operation of Tapping Valve A. Ensure the valve will open and close properly. Operate and visually check that the valve completely opens and closes (Figure 4.42). Depending on type of valve: Ball Valves: ensure stops and indicators are correctly set, or Gate Valves: Count the number of turns required...
  • Page 49 PIG-SIG V. A. Measure from the bottom of the one-inch hex drive recess in the PIG-SIG V to the face of the valve (Figure 4.45). Record this as Measurement “N.”...
  • Page 50 Section IV – Pipeline Under Pressure 3.0 Continued NOTE: An optional spacer may be installed to provide clearance to reduce the risk of valve contact with the plug body (Figures 4.47 and 4.48). Figure 4.47. Optional Adapter Figure 4.48. Installed Plug 3.4 Installing the Drilling Machine A.
  • Page 51 Measurements “M” + “N” should be the body tube reading when the plug holder contacts the bottom of the recess in the PIG-SIG V. H. Measure from the bottom of the feed tube and mark this measurement (the sum of “M” and “N”) on the body tube (Figure 4.52).
  • Page 52 Section IV – Pipeline Under Pressure 3.0 Continued ✎ 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” = 10”...
  • Page 53 3.0 Continued B. Rotate the feed tube clockwise to extend the boring bar until the plug holder contacts bottom of the one-inch hex drive recess in the PIG-SIG V. The feed tube should be at the mark on the body tube.
  • Page 54 T-101 drilling machine. Do not use force when aligning the ⚠ CAUTION plug holder and PIG-SIG V. Damage may occur to the PIG-SIG V. B. Apply slight pressure to the feed tube while slowly rotating the hex drive (Figure 4.56) until the plug holder aligns with the plug.
  • Page 55 B. Attach the crank handle to the ¾-inch hex drive. ⚠ WARNING If the PIG-SIG V cannot be removed, do not force the drilling machine as damage may occur. Do not proceed; call your Service Center. The fitting may need to be abandoned.
  • Page 56 Section IV – Pipeline Under Pressure 3.0 Continued Figure 4.60. Crank Handle. Figure 4.61. Close Bleeder Valve F. Continue rotating the hex drive counterclockwise until the zero mark on the body tube is reached. G. Close the tapping valve (Figure 4.62). H.
  • Page 57 3.8 Recovering the PIG-SIG V A. Hold the body tube and rotate the feed tube clockwise (Figure 4.66). Extend the boring bar until the PIG-SIG V can be removed from the plug holder (Figure 4.67). B. Remove and clean the PIG-SIG V (Figure 4.68).

  • Page 58: Indicator Installation

    Section V – Indicator Installation 1.0 Indicator 1.0 INDICATOR INSTALLATION 1.1 Installing the Indicator Installation A. Locate the three set screws used in the flag indicator body (Figure 5.1). B. Apply a bead of silicone grease lubricant around the housing O-ring (Figure 5.2). Figure 5.1.Set Screws Figure 5.2.
  • Page 59 Section V – Indicator Installation 1.0 Continued E. Push the flag down until it locks in the horizontal position (Figure 5.5). The PIG-SIG V is ready for operation. Follow these instructions for installation of all indicator types (Figure 5.6 and 5.7).

  • Page 60: Section Vi: Optional Features

    Transparent Cover no. 04-3993-0000 The optional transparent cover provides protection for the PIG-SIG V in high-snow load and heavy dust environments as well as general 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.
  • Page 61 Section VI – Optional Features 1.0 Continued 1.3 Indicator Conversion Kit Indicator Conversion Kit no. 04-3968-0000 (combo) no. 04-3968-0001 (electrical) Conversion kits are available for converting the PIG- SIG V from flag-only operation to either electrical-only or flag/electrical combination. Flag 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.

  • Page 62: Section Vii: Maintenance

    Section VII – Maintenance 1.0 PREVENTATIVE MAINTENANCE Once properly set in the line, the PIG-SIG V indicator Preventative is relatively maintenance-free. Routine inspection of Maintenance existing PIG-SIG V Scraper Passage Indicators is important to continued proper operation. If your PIG-...
  • Page 63 Section VII – Maintenance 1.0 Continued 1.3 Indicator Shaft Seal Replacement 1.3.1 To remove the existing seal: A. Place the indicator upside down so that you can see the magnet located inside the cap. This is a strong magnet. To avoid personal injury, take care to keep ⚠...
  • Page 64 Section VII – Maintenance 1.0 Continued C. Place the assembly back onto the cap and align the holes in the new seal with the holes in the cap. D. Install the four screws evenly back in to the assembly. Before tightening the screws, ensure that the assembly is square to the cap (Figure 7.3).
  • Page 65 Section VII – Maintenance 1.0 Continued J. Insert the bolt into the magnet and place it onto the spring. Slightly compress the spring to allow the threads of the bolt to engage the push rod. Tighten the bolt with a hex wrench 5 ft.-lb. K.
  • Page 66 Section VII – Maintenance 1.0 Continued 1.5 Magnet Replacement The magnet in the cap assembly is coated to protect the magnet from moisture. If the coating becomes chipped or damaged, the magnet may swell or come apart. If the magnet is damaged, it can be replaced by unscrewing one hex screw, removing the old magnet and replacing it with a new magnet (Figures 7.8 and Figure 7.9).
  • Page 67 Section VII – Maintenance 1.0 Continued The PTFE nose of the rocker arm should be slightly touching the switch. If there is a gap between the nose of the rocker arm and the switch then loosen the two nuts on the bottom of the electrical switch and slide the unit until it just begins to touch the rocker arm.

  • Page 68: Troubleshooting

    This water can freeze and not allow the magnet to move. Remove indicator and check for moisture. Plug assembly Verify that it is indeed a TDW THREAD- won’t thread on O-RING. to the The hole in the pipe may be too small or THREAD-O- not centered.
  • Page 69 Section VII – Maintenance All Types Plug stopped Contaminated plug: install a new filter (Cont.) working pack version. correctly. Wax build up in plug: consult with factory on other plug option. Trigger is Verify proper THREAD-O-RING was damaged. used for corresponding wall thickness of pipe.
  • Page 70 Inspect any time plug is removed. Replace annually. Plug Backup Replace each time the plug is removed. Ring 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.
  • Page 71 Section VII – Maintenance This page intentionally left blank.

  • Page 72: Section Viii: Application Guide

    In the standard PIG-SIG V model, the magnet in the lower plug body (trigger) housing is exposed to pipeline fluids which can result in attraction of magnetic debris (hot tapping filings and corrosion scale or powders).
  • Page 73 Known heavy wax crude lines • Ammonia: no copper-based (brass) components • (standard stainless PIG-SIG V okay) Acids • Caustics • High-temperature: consider magnet, spring, and • PTFE (PIG-SIG V trigger housing), and O-ring limitation Low Temperature: Consider material and • possible O-ring limitation...
  • Page 74 If TDW accepts any claim made under this Warranty, TDW’s liability, if any, shall be limited to, at TDW’s sole option, repair or replacement of the failed part or product, or a refund of the purchase price, less an allowance for services rendered for the product prior to the Warranty claim.
  • Page 75 PIG-SIG V ® Scraper Passage Indicator Operating and Maintenance Instructions tdwilliamson.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...

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