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TDW POLYSTOPP Operation And Maintenance Instruction

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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.
1

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  • Page 1 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.
  • Page 2 TDW France-22-E-03-09...
  • Page 3 Should any difficulty arise at any time in the use of this equipment, please contact TDW immediately. T.D. Williamson (France) S.A.S. 11, rue de l’Atome – Z.I.

  • Page 4: Table Of Contents

    Preparations Tapping the Line Section IV: Plugging the Line Introduction Plugging the Main Line  Section V: Setting the Completion Plug with the POLYSTOPP Completion Machine Preparing the completion machine Installing the plug Removal of the valve Section VI: Maintenance Introduction ...

  • Page 5: Section I: Introduction

    System is designed for use on 315 and 355 mm • plug the main line, keeping the line in polyethylene pipe. service. The system is designed for use with TDW • to complete the job by setting a Electrofusion Saddle Fittings. The fittings completion plug, enabling removal of permit access to a line to plug it while line work all tapping/plugging equipment.

  • Page 6: Scope Of Applications

    A • To set a completion plug in the TDW departure from prescribed polyethylene electrofusion saddle fitting. procedures could present a hazardous situation causing A complete job will consist of the following...

  • Page 7: System Components

    315- and 355 mm lines. This A. The tapping machine used with this system plugging machine consist of a control bar, is the TDW T-203 tapping machine for both housing, a jacking mechanism for lowering 315 and 355 mm pipe.
  • Page 8 Figure 6. completion plug must be inserted into the  neck of the fitting using the POLYSTOPP completion machine. The completion plug is lowered through the valve and threaded into position in the neck of the fitting. An O-ring provides a seal.

  • Page 9: Safety

    SHORTSTOPP II System. B. Ground the equipment as follows: 1. Before making the tap, attach the TDW provided ground strap assembly from ground to the valve-support. Figure 9 : Plugging Fitting 2. When using the plugging machine for plugging or completion plug setting, 3.3 Related Publications...

  • Page 10: Introduction

    1.0 Introduction  The POLYSTOPP 10" Valve is a full-opening temporary valve used with TDW drilling or tapping machines and SHORTSTOPP ® II plugging equipment. It is recoverable after the tap is complete and a completion plug is set in ®...

  • Page 11: Operating Instructions

    TDW France-22-E-03-09 2.0 Operating instructions 2.1 Installation  The POLYSTOPP 10" Valve (valve design will be changed after September 2019) can be installed on a ® ® TDW POLYSTOPP PE or SHORTSTOPP fitting 315 and 355 mm. Put the support plate on the lower face of the valve with specific nuts Put the centering device onto the plug of the fitting.
  • Page 12 Fig 10. Internal bypass on POLYSTOPP® 10" valve (valve design will be changed after September 2019) C. When opening the internal bypass, do not force the bypass valve. The internal by-pass valve must remain open so that pressure is equalized on both sides of the valve disc before opening the valve.

  • Page 13: Introduction

    TDW France-22-E-03-09 Section III: Tapping 315 and 355 mm Lines w/the T-203 Tapping Machine D. After the scope of the work has been defined, 1.0 Introduction the equipment must be selected, assembled, When tapping a 315 or 355 line, the T-203 and inspected to ensure proper working order.
  • Page 14 TDW France-22-E-03-09 washer on each bolt. Tighten bolts wrench- tight. Figure 15. Install bolt and Nut H. Retract cutter fully into housing. Zero will show in one of the four tapping machine sight windows. The boring bar may require turning slightly to align zero.
  • Page 15 TDW France-22-E-03-09 Figure 17. Measurements A. Take and record measurement A. This is the distance from the face of the tapping machine adapter flange to the tip of the pilot drill. See Figures 17 and 18. Figure 19. Take and record Measurement B Figure 18.
  • Page 16 TDW France-22-E-03-09 E. The sum of distance C and the lower-in distance (B+A) is the total boring bar travel required to complete the tap. This number will be visible in the travel indication port when the tap is completed. F. If a completion plug is to be set after the...
  • Page 17 TDW France-22-E-03-09 B. After test is completed, leave tapping valve and bleeder valve open. 3.7 Selecting Power Unit A. If using air motor drive: 1. Prepare air motor. Minimum air supply must be 105 cfm (2,9736 cubic meter per minute) at 90 psi (6 bar).

  • Page 18: Tapping The Line

    TDW France-22-E-03-09 4.0 Tapping the Line 4.1 Making the Tap Turn feed screw adjusting counterclockwise to relieve spring tension. See Figure 25. Figure 26. Open Air Control Valve Note: RPM can be checked easily by observing the numbers as they come around in the travel indication port.
  • Page 19 H. If needed, chips can be removed from the line by using the POLYSTOPP cleaning 4.2 Remove Tapping Machine machine. A. Remove bleeder valve Figure 27. Remove Chips & coupon CAUTION: Cutter teeth are very sharp.

  • Page 20: Section Iv: Plugging The Line

    TDW France-22-E-03-09 Section IV: Plugging the Line 1.0 Introduction This section provides procedures for temporarily plugging 315-355 mm line while work is being performed. The line may be kept in service during plugging operations by plugging it at two locations to isolate the line section in between and running a bypass around the isolated area.
  • Page 21 TDW France-22-E-03-09 Figure 29. Plugging Head Halves C. Insert the upper plugging head half, then reposition the control bar handles to the folded position and insert the lower half onto the control bar, as shown in Figure 30. Figure 30. Install Plugging Head and Secure D.
  • Page 22 TDW France-22-E-03-09 WARNING: Do not use a sealing element that is cut or is not pliable. A damaged sealing element can result in excessive gas leaks during plugging operations. Figure 32. Lubricate Sealing Element Figure 33. Attach Sealing Elements F. Attach a 315-355 mm sealing element.
  • Page 23 Fully retract the plugging head into the plugging head housing. This can be done with the jacking mechanism. Tighten the bar lock clamp to keep the control bar in the retracted position. The plugging head is now ready for use.  2.2 Install the 8” x 10” spool adapter onto the POLYSTOPP 10" Valve Figure 37.
  • Page 24 TDW France-22-E-03-09 2.3 Install the Plugging Machine A. After the plugging head has been installed, mount the plugging machine on the spool adapter. Make sure the larger outlet on the plugging head housing points toward the area to be isolated, as shown in Figure 38.
  • Page 25 TDW France-22-E-03-09 Figure 40. Typical Bypass Layout 2.4 Plugging the Main Line In a double position operation, the downstream plugging head must be set first. In a 2-way feed line where flow is in both directions, the plugging machine farthest from a regulating station is considered the downstream plugging head.
  • Page 26 TDW France-22-E-03-09 Figure 41. Lower Plugging Head...
  • Page 27 TDW France-22-E-03-09 WARNING: Do not stand over the control bar while lowering or raising control bar with the jack. 2.6 Setting the Plugging Head A. If this is a double position job, set the down- stream plugging head first. Twist the top control bar handle clockwise to disengage the locking pin.
  • Page 28 TDW France-22-E-03-09 Figure 44. Set Control Bar Latch D. Tighten the control bar clamp (Figure 45). The plugging head is now in a secure position. Remove the control bar handles. Figure 45 Tighten Control Bar Clamp If this is a double-position job, set the upstream plugging head. Repeat steps A through D.
  • Page 29 Figure 46. Keep Handle above 90 Degrees I. Remove the control bar handles. J. Close the POLYSTOPP® 10" Valve. K. Open the bleeder valve to bleed off trapped pressure. After pressure bleeds off, remove the bleeder valve. WARNING: Vent pressure bleed valve away from work area and personnel. Stand clear of vent when bleeder valve is opened.

  • Page 30: Section V: Setting The Completion Plug With The Polystopp

    This machine is fitted with a pressure compensating cylinder, which balances out the thrust exerted on the control bar. Fig. 47 NOTE : This machine can only be used to fit threaded plugs of POLYSTOPP® Fittings! Put the completion machine onto the flat adaptor. Screw the plug holder onto the plug.

  • Page 31: Installing The Plug

    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. Screw the completion machine onto the adapter by hand until it reaches the stop.

  • Page 32: Removal Of The Valve

    TDW France-22-E-03-09 Unlock the control bar with the knurled nut. Fig. 52 (valve design will be changed after September 2019 – Wheel of completion will be updated) Lower the control bar until it touches the upper saddle. Screw the plug down with the hand wheel to the stop. Be certain to continue through slight resistance from the O-ring seal.
  • Page 33 TDW France-22-E-03-09 Design of POLYSTOPP® 10’’ valve that will become available after September 2019.  Fig. 53 - POLYSTOPP 10" Valve  Fig. 54 - Removal of POLYSTOPP 10" Valve, reinforcement collar and valve support Remove the plug holder. Fig. 55 - Removal of Plug Holder...

  • Page 34: Section Vi: Maintenance

    TDW France-22-E-03-09 Section VI: Maintenance 1.0 Introduction Only routine maintenance is required to maintain TDW equipment in good working order. Cleaning and lubricating equipment after each job before returning to storage is most important. For additional maintenance information, consult the following publications: T-203 Tapping Machine: TDW Pub.
  • Page 35 TDW France-22-E-03-09 C. Remove the pivot ball retainer snap ring and F. Remove the ball pivot mechanism from the nut and clear any debris. Follow the housing (Figure 58). procedure in steps D through K. D. Remove the retainer ring from the top of the housing (Figure 56).
  • Page 36 TDW France-22-E-03-09 Figure 62. Inspect Actuators for Wear F. Reinstall the jack or control bar lock unit on the ball pivot of the plugging housing. 2.4 Adjusting Jack System Drag A. The jack system drag needs to be checked prior to each job with the plugging head, without the sealing element, attached.

  • Page 37: Polystopp

    TDW France-22-E-03-09   3.0 POLYSTOPP Completion 4.0 SHORTCUTT Valve Machine ® SHORTCUTT Valve relatively maintenance-free. Any component can be 3.1 Disassembly Procedures replaced easily. A parts list and assembly diagram On a clean workbench with easy access, the are shown below.
  • Page 38 TDW France-22-E-03-09 Table 1 Thrust Collar/Bearing Qty. Description Part Number Thrust Bearing 00-7447-002 Thrust Washer 0-6813-0001 Thrust Washer 00-6813-0002 Replacement Bearing 00-1014- 0007-01 re-places Bearing 00-1014-0007 and Thrust Washer 00-1407-0001. The 00-1014-0007 thrust bearing used prior to January 1994 has been...
  • Page 39 TDW France-22-E-03-09 Appendix I: Parts Lists Parts List No. 1 POLYSTOPP System for PE Pipes Big Sizes 315-355 mm Description Part Number T-203 Drilling Machine 12303981 08.3501081.0000.00 SHORTSTOPP Plugging Machine 8 x 12 75.0537.0100.0400.10 POLYSTOPP Completion Machine POLYSTOPP 10" Valve...
  • Page 40 TDW France-22-E-03-09 Figure 64. T-203 Tapping Machine (Parts List 1)
  • Page 41 TDW France-22-E-03-09 Parts List 2 T-203 Tapping Machine Item Description Part Number Air Drive Tapping Machine 05-2173-0000 Body Tube 05-0261-0001 Gear Case 05-0222-0002 Seal Gland 05-0261-0003 Boring Bar 05-0353-0004 Drive Tube 06-0261-0005 Worm Gear 00-1663-0001 Feed Screw 05-0261-0007 Feed Ball Race...
  • Page 42 TDW France-22-E-03-09 Parts List 3 T-203 Tapping Machine (Continued) Item Description Part Number Air Drive Pipe Bushing (not shown) 00-0644-0002 Anchor Shackle with Round Pin 00-1666-0001 Seal 00-0114-0038 Square Key 00-0642-0007 O-ring 00-0118-0002 Square Key 00-0640-0004 Square Key 00-0639-0014 Shoulder Screw...
  • Page 43 TDW France-22-E-03-09 Figure 65. SHORTSTOPP II Dual Control Bar Assembly...
  • Page 44 TDW France-22-E-03-09 Parts List No. 3 (Figure 65) SHORTSTOPP II Dual Control Bar Assembly Item Description Dual Control Bar Assembly Shaft, Inner Control Bushing, Bronze Bearing O-Ring O-Ring Shaft, Outer Control Marker, Control Bar Connector, Lower Handle Connector, Upper Handle...
  • Page 45 TDW France-22-E-03-09 Figure 66. SHORTSTOPPII Jack Assembly...
  • Page 46 TDW France-22-E-03-09 Parts List No. 4 (Figure 66) SHORTSTOPP II Jack Assembly Item Description Jack Assembly Housing, Jack Control Spring, Belleville Actuator, Lower Control Release, Lower Actuator Pin, Sel-Lok Spring, Compression Actuator, Upper Control Cap, Jack Housing Capscrew, Skt Hd...
  • Page 47 TDW France-22-E-03-09 PARTS LIST No. 5 COMPLETION MACHINE ASSEMBLY No. 75.0537.0100.0400.10 ITEM QTY. DESCRIPTION PART No. Machine body 07-0703-0001-0000-00 Compensating cylinder 07-0703-0002-0000-01 Control bar 07-0703-0003-0000-01 Piston 07-0703-0004-0000-00 Cover for compensating cylinder 07-0703-0005-0000-00 Lock nut for control bar 07-0703-0006-0000-00 Plugging tool adapter...
  • 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 POLYSTOPP Big Sizes 315-355 PE 100 Description Part Number Description Part number Installation Plugging POLYSTOPP® Valve 10’’ Plugging machine assembly 75.1046.0100.0300.01 Std plugging head assembly 8”x12” Valve/pipe support 315 - 355 75.1539.0100.0250.20 08.3331.0000.0000.00 Flat Adapter PM / valves ➔ Reinforcement tool for PE fittings 75.1539.0206.0250.10...
  • Page 52 11, Rue de l’Atome – ZI - BP 50081 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 ©...

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