NAVAL Hot Tapping Tool User Guide

KHLER
Valves - Representations and Sale

Industriestr, 77 b D - 51399 Burscheid
Tel +49 2174 7848-0 - Fax: +49 2174 7848-25
email: info@kaehler-armaturen.de
The NAVAL hot tapping system

enables connecting to an existing
pressurized pipeline
KHLER GmbH Armaturen
D-51399 Burscheid
NAVAL - Hot tapping tool
KHLER

Industriestr. 77 b D - 51399 Burscheid
Tel +49 2174 7848-0 - Fax: +49 2174 7848-25
Drilling procedure
Remove the main pipe insulation

Weld the ball valve onto the main line pipe
Mount the hot tapping tool on the valve
Carry out the drilling
Close the ball valve
Remove the Hot tapping tool
Connect the new supply line
Advantages of the NAVAL Hot tapping tool

All valves are full bore (only DN 150 + 200 red.)
Connecting new consumers to fully pressurized pipelines
No emptying of the net needed saves time and energy
No supply interruption of other costumers
Possible use of the valve for shut-off purposes
(also available with hand lever and long stem)
Hot tapping is easy and safe
New! With open/close-end stops
KHLER

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The Hot tapping tool is type tested since March 1999 under
Bauteil-Kenn-Nr. AR.303-14 of the TV Hamburg, Germany.
The field of application is restricted to
Temperature up to 200C and Pressure of 25 bar.
It is only applicable to NAVAL-Ball valves, which are fully-welded steel ball valves.
DN 20 125 full bore + DN 150 red. bore with adapter thread
DN 150
full bore + DN 200 red. bore with adapter flange
Safety labelings and recommendations:

AGFW set of rules worksheet FW 432:
"Operational minimum requirements for pipe branching in district heating by
means of Hot tapping procedure"
Suitable protective gloves, glasses and clothing are to be used in order to avoid
injuries. Ensure that the device is in a safe condition. Faulty parts
have to be replaced!
KHLER

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Stem cap size (hexagon)

DN 20 - 25
> SW 22
DN 32 - 40
> SW 27
DN 50 - 65
> SW 32
DN
80
> SW 36
DN 100 - 150
> SW 41
Features of the ball valve with adapter thread :
Full bore up to DN 125 (DN 150 red.)

Actuation by hexagon socket
Steel cap weldable with stem housing
End stops 90 (no 360 rotation)
Clear visibility of the ball-position
*) DN 150 with
internal thread
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The weldend opposite of the threaded weldend has to be machined before welding. The
profile has to match the main pipe it will be welded on.
Attention! The ball valve has to be open during welding!

Modification of the threaded welding end is not allowed before the hot tapping is
finished!
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Welding of the ball valve

The hot tapping valve can be welded onto the main pipe in a radial angle of
0-360 degrees.
The angle to the pipe centre line must be exactly 90 degrees. The hot tapping
Must not be carried out on the weld seam.
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The welding onto the mainpipe has to fulfill the applicable strength requirements.
If required, the connection can be strengthened with a connection ring.
Welding material must not reach the inner of the valve to prevent the hole saw
from getting stuck.
The tightness of the welded seam can be tested by mounting the hot tapping tool
on the valve and applying pressure through the flush valve.
Attention:
After welding the ball valve you have to test its functioning by
opening and closing the valve!
KHLER

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Standard circular hole saws are used with diameters between 24 - 146 mm
(18 mm HSS-Drill DIN1897 = DN 20).
Structure of the Hot tapping tool with threaded adapter
The total space requirement for hot tapping is a result of the valve length (L) + 800
(DN20=850) mm (tool plus stem upstroke).
KHLER

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Structure of the Hot tapping tool with flanged adapter

DN 150 with full bore
DN 200 with red. bore
L = 1441 mm
L = 1399 mm
Valve shown before procedure!
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BEFORE BORING
Assembly of the Hot tapping tool
Choose the DN-specific adapter and hole saw.
Screw the adapter on the tool. Please ensure that the
O-ring is undamaged.
Fix the hole saw on the thread of the drill-arbor (DN
25) or the arbor-combination (DN 32 to DN 200) and
fasten the arbor on the tool stem with a hexagon
screw.
Insert the 6,5 mm center drill into the arbor, so that the protrusion
(measure B) is 20 mm. Thew protrusion must not exceed 20 mm.
Screw out Part 1 (see tool drawing) to the marking in the thread.
Do not screw any further! The thread has a tolerance of only 10 mm.
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Adjusting the hot tapping tool

Attention: Ensure that the Adapter O-ring is not damaged. Richly apply grease to the Adapter & O-Ring
and thread & weldingends of the ball valve.
Screw the adapter with the help of the hook key on the thread of the completely opened ball valve until the
adapter O-ring closes tightly against valve weldend.
A rather high torque will be needed to overcome the resistance of the O-ring.
After that
Test the tighness of the valve/pipeline welding seam and the mounted hot tapping equipment by
applying pressure through the flush valve.
Release the snapping-unit by pulling it backwards and draw back the stem to its outmost position.
Move the stem into right position:
Separate 1-level stem

Standard stem, level 1
Separate 1-level stem
= DN 20
= DN 25
= DN 40
= DN 65
= DN 150FB
DN 32
DN 50
DN 150RB
DN 200RB
Slowly lower the stem towards the main pipe by rotating the feeding-unit (Part 1) clockwise until the
center drill meets the main pipe. After this, rotate one round backwards.
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Adjusting and handling of the drilling machine

Adjustment DN 25 (24 ) DN 200 (146 ):
1.
2.
3.
Drilling direction on right-drilling

Switch to drilling (not hammer!)
Center-drilling: 2. gear and level F = 460 R/min
Adjust the drilling machine with angle-gear on the stem

Open the flush valve and ensure that the hose end is located far away enough, so that the hot
flushing water with drillingsplinters will not cause any danger!
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Value-Table
Valve DN
Stem level
Saw
Gear
Speed level
20
18
20
B1
25
24
20
32
30
20
C1
40
38
20
B1
50
48
20
65
64
20
80
76
20
100
95
20
125/150
121
20
150/200
146
20
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Procedure
Turn on the drilling machine and drill the center hole by slowly and evenly rotating Part 1 (feeding
unit) clockwise. After protruding the main pipe, water will start running through the flush valve.
Now close the flush valve and turn off the drilling machine!
Adjust the drilling machine according to the DN-specific values given in the value table (drillingspeed will be reduced)
Open the flushing valve again to remove metal splinters created during the drilling!
Now turn on the drilling machine and proceed with the main drilling by slowly and evenly rotating
Part 1.
Attention!
The main line has to be at least one dimension bigger than the dimension of the hot
tapping valve.
When drilling valves DN20-40 into a mainpipe that is only one dimension bigger, the hot
tapping procedure has to be interrupted immediately after penetrating the main pipe wall.
The centerdrill protrusion over the hole saw must not exceed 20 mm(see table)!
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After drilling
Close the flush valve after sawing out the slice of the pipe!
Lift off the drilling machine and gear. Open the snapping unit by pulling and draw back
the drilling stem.
Close the hot tapping valve and open the flush valve to release pressure from the tool.
Remove the hot tapping tool and take off the metal piece from the center drill.
KHLER

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Hot tapping valve with weldend / flange

DN 150 with full bore
L = 921 mm
DN 200 with red. bore
L = 879 mm
Valve shown after procedure!
KHLER

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Material information and recommendations:

HSS-Drill 18
Hole saw 24
Hole saw 30
Hole saw 38
Hole saw 48
Hole saw 64
Hole saw 76
Hole saw 95
Hole saw 121
Hole saw 146
NAVAL 400071
Lenox 30015-15L,
Lenox 30019-19L,
Lenox 30024-24L,
Lenox 30030-30L,
Lenox 30040-40L,
Lenox 30048-48L,
Lenox 30060-60L,
Lenox 30076-76L,
Center drill with claw 6,5

(DN 25/24 - DN 200/146)
DIN 1897
Sandvik 3830-24-VIP
Sandvik 3830-30-VIP
Sandvik 3830-38-VIP
Sandvik 3830-48-VIP
Sandvik 3830-64-VIP
Sandvik 3830-76-VIP
Sandvik 3830-95-VIP
Sandvik 3820-121-VIP
Sandvik 3830-146-VIP
DIN 338/V
KHLER

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Summary:
Mount the DN-Adapter on the hot tapping valve (threaded except for DN150FB and DN 200RB).
Mount the hot tapping tool including correct hole saw and center drill on the adapter.
Choose the right stem level (DN 20 and DN150FB/DN200RB = only one level) according to the value table.
Adjust the drilling machine according to the instructions. Readjust after centerdrilling!
Manually lower the tool stem by rotating the Part 1 clockwise during drilling.
Open flush valve during drilling.
End the drilling by pulling back the tool stem.
Close flushing valve!
Close hot tapping valve an open flushing valve again.
Remove the tool from ball valve! DN 150FB and DN 200RB = cut off the mounting flange
KHLER

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Instruction for welding the

stemcap
To avoid stem leakage, it is
recommended to close the stem cap by
welding before isolating the pipe (EN
488).
Weldingprogress:
1. Remove cap seal
2. Clean the welding area
3. Close cap tightly and then open it
slightly.
4. Weld the cap with electric arc or
MIG- welding. NOT GAS WELDING!

NAVAL Hot Tapping Tool User Guide

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KHLER

Valves - Representations and Sale

The NAVAL hot tapping system