SurTap™ System Operation with VersaTap™ Fittings Manual Instruction... · The SurTap™ tapping...

GF Piping Systems

SurTap™ System Operation with VersaTap™ Fittings Manual

GEORG FISCHER CENTRAL PLASTICS of 18 GF PIPING SYSTEMS

Thank you for selecting Georg Fischer Central Plastics’ products. GFCP strives to deliver the best technology and materials combined with rugged, durable construction to provide a productive and reliable connection for your polyethylene system.

To ensure this product lives up to all expectations, it is important to receive proper training from an authorized instructor and to read and comply with this instruction manual before attempting to use the SurTap™ system.

This manual is intended to provide a general introduction to the tools and steps required for proper use of the SurTap™ system with VersaTap™ fittings. GFCP assumes no liability in connection with the data contained herein, nor assumes liability for the operation, safety, or use of third party tools and equipment in conjunction with this system. All data is accepted at the user’s risk.

GFCP strongly recommends that VersaTap™ electrofusion fittings be installed only by persons that have received training from an authorized instructor, that have a strong working knowledge of polyethylene and heat fusion, and that have demonstrated their understanding of these requirements by making electrofusion joints that have been qualified by destructive testing. Persons responsible for the joining of polyethylene pipe for regulated gas applications must qualify according to the requirements of Title 49 Code of Federal Regulations, Part 192.285. Other regulations may also apply depending on the application, local codes, and/or jurisdictional oversight of state and local regulating agencies.

All rights reserved, in particular the rights of duplication and distribution as well as translation.

Duplication and reproduction in any form (print, photocopy, microfilm or electronic) requires the

written permission of Georg Fischer Central Plastics, LLC.


Table of Contents Safety Notes and Warning Symbols ...................................................................................................... 4

General Information ................................................................................................................................. 5

Kit Contents ............................................................................................................................................... 6

SurTap™ Operating Instructions ........................................................................................................... 7

Completion Plug Installation ................................................................................................................. 13

Coupon Removal from Low Torque Cutter ........................................................................................ 15

Care and Maintenance .......................................................................................................................... 17

Optional Accessories ............................................................................................................................. 18


Safety Notes and Warning Symbols

Safety notes are included in this manual where appropriate however, this manual does not purport to address all of the safety concerns associated with its use. It is the responsibility of the user of this manual to establish appropriate safety and health practices and to determine the applicability of regulatory limitations prior to use.

Symbols are used throughout this manual to indicate the potential for danger, injury, and/or material damage, and to alert the user of important information related to the fusion process. Symbols indicate that particular attention should be given and that an action is necessary.

Symbol Meaning

Attention! – Important Information! Possible danger, damage, or risk of injury.

Best Practice – This symbol is used to indicate an instruction that is considered to be a “best practice”. This practice is highly recommended and potentially vital to success.

Prohibited! – This symbol is used to indicate a practice, material, tool, or action that is specifically prohibited in conjunction with instructions in this manual.

Electrofusion fittings and equipment are not to be considered as “explosion proof”. Caution should be exercised when working with generators and other electrical power

sources. Tapping tools have sharp edges. Use with care to avoid injury. Tools should be in good working order and inspected before use for wear and/or damage.

Damaged or worn tools should not be used until repaired or replaced.

These instructions pertain solely to the operation of the SurTap™ Hot-tapping Tool Kit. These instructions must be followed carefully. Observe all safety precautions prescribed by your company, the pipeline owner, and those prescribed by equipment manufacturers whose equipment may be used in conjunction with the SurTap™ and VersaTap system.

Specific procedure and rules apply to each step of the installation and use process, including: (1) the installation of the VersaTap™ fittings; (2) the hot-tapping process; (3) the use of other manufacturer’s tools or equipment in conjunction with the SurTap™ equipment; (4) the plugging operation; and (5) re-accessing an existing VersaTap™ fitting when necessary. These safety procedures include, but are not limited to: (a) traffic management; (b) jobsite and ditch safety; (c) pressure test procedures; (d) gas venting procedures; (e) static discharge mitigation procedures; (f) wearing the appropriate PPE; etc.

Failure to observe these procedures may cause personal injury and/or property damage. Each Operator must be properly trained in the use of this equipment prior to conducting and performing the following steps in a live natural gas application.


General Information

The SurTap™ and VersaTap™ system provides an access/entry point to live pipelines for the purpose of camera or other equipment insertion into the pipeline.

The SurTap™ tapping system is a kit that consists of a hot tapping tool, knife valve, completion plug installation tool, and related tools.

The SurTap™ tapping system is designed to be used with the VersaTap™ access fitting that is electrofused the pipeline. The VersaTap™ fitting includes a threaded completion cap, and an internal threaded completion plug.

Adapters can be added to the VersaTap fitting threads to allow connection to tools to enable insertion into pressurized pipes of cameras, inflatable bladders, tracer devices, or other equipment small enough to pass through the 1.8 inch tap bore diameter.

The SurTap™ system can be fitted with valves and gauges to allow pressure testing and monitoring to be completed through the tool while connected to the VersaTap™ fitting.


Kit Contents

360063170 FSEQ, KIT, HOT TAP,SURTAP™,VERSATAP™,,,,,GFCP,COMPLETE IN

CARRYING CASE,,, Item Part # Item Description Qty

1 360062587 SURTAP,HOT TAP ASSEMBLY, GFCP VERSATAP 1

2 360062593 SURTAP,HOT TAP,CUTTER,1.75 DIA 2

3 360064877 O-RING, SQUARE PROFILE, BUNA-N 70 DUROMETER, # 334 3

4 360062606 SUR TAP,HOT TAP,INTEGRATED KNIFE VALVE 1

5 360062612 SURTAP,HOT TAP,WRENCH, COMB. SPANNER -OPEN END 1

6 360063167 SURTAP,HOT TAP, COUPON REMOVAL TOOL, 1

7 360063168 SURTAP,HOT TAP,COMPLETION PLUG,INSTALLATION TOOL 1

8 360063169 CASE, CARRYING, ON WHEELS, WITH FOAM 1 Not Shown


SurTap™ Operating Instructions

The following instructions are for the use of the SurTap™ system and assume that the proper procedures have been used while installing the VersaTap™ electrofusion fitting and that the fitting has cooled to the minimum rough handling stage as defined by Georg Fischer Central Plastics electrofusion installation procedure.

1. Remove the cap from the VersaTap™ fitting by rotating counterclockwise.

2. Remove the completion plug by rotating counterclockwise using the completion plug tool in the kit. The completion plug can be locked onto drive by turning the Locking Knob clockwise until tight.


3. Install the Valve and Fitting Adapter* by turning clockwise onto the fitting threads. Seat firmly to seal the connection.

Tip: The VersaTap fitting threads are plastic and susceptible to damage from misalignment. Make certain the adapter is properly started onto the plastic fitting threads when threading together. The adapter should turn freely without much resistance; if not, remove the adapter fully, and check the threads on the VersaTap™ for damage. If no damage has occurred, begin the procedure again.

*Shown with optional mini valve and pressure gage.

If pressure testing through the Fitting Adapter and Integrated Valve (using the optional mini valve and pressure gage) close the Integrated valve lever, connect a pressure hose to the quick connect fitting on the relief valve, and pressurize the fitting and valve assembly. Close mini relief valve and remove pressure hose. Test joint as required. Once the pressure test is completed, open mini valve lever to release pressure, or slowly open the integrated valve as shown below.


4. Before installing SurTap device onto the valve, make sure that the low torque cutter is installed properly. Loosen the collet nut and push the arbor tube assembly down to give sufficient access to the quick change device. Depress the chrome ring on the quick change device to retract drive pins and carefully screw on the low torque cutter clockwise all the way to the base of the threads. Next, release the chrome ring and rotate the low torque cutter counterclockwise (loosen) until the pins snap into the cutter. It isn’t necessary for the cutter to be installed tight on the threads since it will be driven by the pins on the quick change device.

5. Once the low torque cutter is

installed, the cutter drive and arbor tube should be fully retracted by depressing the brake lever, and pulling the arbor shaft in the direction shown. Turn the Cutter Drive counterclockwise lightly with the supplied wrench until a slight resistance against the stop is felt.

Do not force beyond the point that resistance is felt.


6. Once the arbor tube is fully retracted, the

SurTap™ device can be installed on the OPEN valve. Insure that the rectangular rubber gasket on the mating face of the integrated valve is in place.

7. Tighten the Quick Release Nut with the supplied wrench to seat the gasket on the SurTap™ tool against the valve.

8. Once the tool is installed and tightened,

verify that the valve is in the open position. Verify that the collet nut is loose; then push the arbor tube down until it comes to a hard stop as the cutter contacts the pipe in preparation for hot tapping.


9. Tighten the collet nut with supplied wrench and using a marker put a reference line around the arbor tube to serve as a position indicator to verify that the arbor tube does not move or slip during tapping. Monitor the mark, if it moves, stop and tighten the nut more.

10. Place the wrench on the arbor tube hex and turn clockwise. There will be resistance until the cutter breaks through the inside of the pipe; continue until a positive stop is felt, but do not force further. The tool is designed with enough travel to accommodate 2” IPS thru 12” IPS DR11 wall thicknesses yet not touch the bottom side of a 2” IPS pipe.

11. Verify that the mark on the arbor tube has not moved from its initial position. If it has moved then the tapping step should be repeated to ensure that the cutter has completely penetrated through the pipe. If it has not moved, then retract the cutter by rotating cutter drive counter clockwise until it reaches the positive stop.


12. Once the tapping step is completed the arbor tube must be retracted in order to close the valve. Standing to the side of the tool, loosen the collet nut, and with a hand gripped around the arbor shaft, depress the brake lever with the other hand and allow the arbor shaft to slowly extend fully in a controlled manner. Allowing the shaft to extend quickly and slam against the top may damage the tool.

For safety purposes when hot tapping under pressure, never position yourself over the top of the tool.

13. Close valve, depress Pressure Relief Valve to exhaust gas pressure the carefully remove SurTap™ Tool by using the supplied wrench to loosen the spanner nut. Make sure that the integrated valve and fitting adapter do not loosen from the VersaTap™ fitting threads during this action. A small amount of pressure will be released when the seal breaks between the valve and the tool. The hot tap operation is completed and the VersaTap fitting and valve are now ready to accept the 3rd party insertion application device.


Completion Plug Installation 1. Place completion plug on the square drive of the plug installation tool

and push up into the cap. Rotate locking knob clockwise to secure completion plug to drive. Ensure gasket is in place before mounting tool on the valve. Tighten onto valve using spanner wrench.

2. Open valve and push the tee handle down until the plug reaches the fitting. While applying downward pressure, rotate tee handle counterclockwise until the completion plug starting thread snaps into place. Continue to apply downward pressure and begin turning the handle clockwise to screw the plug into the VersaTap™ fitting threads. Continue to tighten until substantial resistance is felt indicating that the plug threads have reached the bottom and seated the plug.


3. Loosen Locking Knob and pull Tee Handle up and close the valve. Depress Pressure Relief Valve to verify gas shut off.

4. Remove Completion Plug Installation Tool with supplied wrench. Check for leaks around the completion plug using soap or optional pressure gage. If plug leakage is found, use the completion plug installation tool to adjust plug tightness. If no leaks are present, remove valve and fitting adapter from VersaTap™ fitting with the supplied spanner wrench.

5. Re-install plastic cap hand tight. Check for leaks as necessary.


Coupon Removal from Low Torque Cutter

1. Use reverse of cutter installation procedure to remove low torque cutter from SurTap Tool. Push Arbor tube down to give sufficient access to low torque cutter. Depress chrome ring to pull drive pins from cutter and rotate cutter counterclockwise to remove from arbor tube threads.

2. Once the cutter is removed, push T-

handle into hex-shaped coupon removal tool using one hand to hold in place. Screw cutter onto T-handle shaft enough to hold it.


3. Allow hex body to extend over the cutter while turning slightly until the unit pins engage the cutter.

4. While holding the Hex Body with the cutter pointing upwards, turn the T-handle until coupon comes out of the end of the cutter. Inspect cutter closely for damage or excessive wear. Replace if necessary.


Care and Maintenance Proper care and maintenance will extend the life and use of the tool.

Lubrication points:

Arbor Shaft

Threaded Shaft on Cutter Drive

Cutter Drive

Completion Plug Installation Tool

Georg Fischer Central Plastics 39605 Independence, Shawnee, OK 74804 • Tel. (405) 273-6302 / (800) 654-3872,Fax (800) 733-5993 e-mail: [email protected] • www.gfcp.com

GEORG FISCHER PIPING SYSTEMS

Part Number 10014100 REVISION 05/2018

Optional Accessories These accessories have 2” NPT connections that can be assembled to aftermarket valves.

Jameson Launch Tube Adapter:

Part number: 360064094 SURTAP, HOT TAP, LAUNCH TUBE SET, FOR JAMESON SYSTEM, GFCP TOOLS

The technical data are not binding. They neither constitute expressly warranted characteristics nor guaranteed properties nor a guaranteed durability. They are subject to modification. Our General Terms of Sale apply.

Item Part # Item Description Qty

1 360062600 Quick Change Adapter 2" NPT 1

2 360062601 VersaTap™Fitting Adapter 2" NPT 1

3 TDW Knife Valve

4 360064877Square Profile Oring #334 “not shown”

1

Item Part # Item Description Qty

1 360062603 Launch Tube 1

2 360062602 Flanged Adapter Head 1

3 360062589 Quick Change Nut 1

SurTap™ System Operation with VersaTap™ Fittings Manual Instruction... · The SurTap™ tapping...

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