KOROSI SPECINDO

Corrosion Monitoring Equipment, Chemical Injection, Sampling

Engineering Doc. No.:
System and DBB Valve
KS-MNL-ENG-01-01-Rev 3

INSTALLATION, OPERATION & MAINTENANCE

INSTRUCTIONS
HOT TAP TOOL

Rev Date Prepared Checked Approved Description

0 Jun/19, 2007 Eko S Hary P GM Issued for approval
1 August 14/, 2015 Surya K. J LB/SK/JW GM Issued for approval
2 March 25/, 2016 Surya K. J LB/SK/JW GM Issued for approval
3 Jan 23, 2017 S. Kusman Bambang TS Issued for use
IOM Hot Tap Tool KOROSI SPECINDO

Table of Contents
SECTION I .................................................................................................................................. 2
DESCRIPTION............................................................................................................................ 2
1. Introduction .......................................................................................................................... 2
2. Specification ......................................................................................................................... 3
3. Equipment ............................................................................................................................. 3
4. Safety .................................................................................................................................... 3
4.1. Bleeder valve connection .................................................................................................. 3
4.2. Warnings and cautions ...................................................................................................... 4
5. TKS - T - HT Hot Tap Machine and Equipment Nomenclature .......................................... 4
5.1. Hot Tap Machine .............................................................................................................. 4
5.2. Adapter .............................................................................................................................. 5
5.3. Drill bit .............................................................................................................................. 5
6. General Consideration: ......................................................................................................... 5
6.1. Feed (Manual) ................................................................................................................... 6
SECTION II ................................................................................................................................. 7
TAPPING OPERATION ............................................................................................................. 7
1. General Information ............................................................................................................. 7
2. Preparation for Tapping Using Drill Bit ............................................................................... 7
3. Select Equipment .................................................................................................................. 7
3.1 Install Valve Adapter ........................................................................................................ 8
3.2 Insert drill bit and retainer spring...................................................................................... 8
3.3 Install bleeder valve .......................................................................................................... 9
3.4 Tests for pressure tightness ............................................................................................... 9
3.5 Rotate feed tube counterclockwise ................................................................................... 9
4. Tapping Process .................................................................................................................. 10
4.1 Install Hot Tap Machine to Service Valve ...................................................................... 10
4.2 Rotate feed tube clockwise ............................................................................................. 10
4.3 Mark on the body tube .................................................................................................... 11
4.4 Attach ratchet handle ...................................................................................................... 11
4.5 Complete tap ................................................................................................................... 12
4.6 Retract drill bit ................................................................................................................ 12
4.7 Recovery sequence.......................................................................................................... 12
SECTION III.............................................................................................................................. 13
MAINTENANCE ...................................................................................................................... 13
1. General Maintenance .......................................................................................................... 13
2. Hot Tap Machine Disassembly........................................................................................... 13
3. Hot Tap Machine Assembly ............................................................................................... 16

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IOM Hot Tap Tool KOROSI SPECINDO

SECTION I
DESCRIPTION

1. Introduction

This manual is designed to provide the operated with factory recommended operation and
maintenance instructions for safe and effective use of the TKS - T - HT Hot Tap Machine.
Learn the capabilities of the equipment. The equipment is designed with adequate safety factors;
however, do not exceed factory recommended specifications under any circumstance.
Practice all safety precautions and procedures insure operator safety and satisfactory result. Read
the entire manual before operating the TKS - T - HT Hot Tap Machine. Use a test setup on a short
length of pipe before going into the field for actual operations.
Follow the manual for all operation and maintenance procedures. Should any special questions arise
concerning the hot tap machine or its use, contact KOROSI SPECINDO.

The TKS - T - HT Hot Tap Machine is shown in Figure 1

WARNING:
Do not attempt a drilling operation which would
depart from the procedures described in this
manual. Attempting such a departure could
present a hazardous situation resulting in
personal injury and/or property damage. Do not
alter this machine or any of its component parts.
Use only KOROSI SPECINDO adapters,
accessories and replacement parts manufactured
or recommended by KOROSI SPECINDO. Any
alteration of this machine, or us of adapters,
accessories or parts not manufactured or
recommended by KOROSI SPECINDO could
cause the machine to mal-function, resulting in
damage to a machine and/or personal injury.

Fig. 1. TKS - T - HT Hot Tap Machine

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IOM Hot Tap Tool KOROSI SPECINDO

2. Specification
The specifications of the drilling machine are shown in Table 1.

SPECIFICATIONS:
Table 1. MODEL TKS - T - HT HOT TAP MACHINE

Maximum operating pressure and temperature ................................... 1440 PSI @ 1000F

.............................................................................................................
700 psi @ 5000F
Drill bit size ...........................................................................................
19 mm, 34.5 mm
Maximum boring bar travel................................................................... 18 inches
Machine weight .................................................................................... 32 lbs
Rate of travel ........................................................................................ Manual feed: 1/8” per
Resolution of feed tube
Operation.............................................................................................. Basic machine is manually
operated
Minimum clearance ............................................................................. 1.5 meters

3. Equipment
Table 2 provides a list of equipment used in performing various options with the TKS - T - HT Hot
Tap Machine along with references to pages in this manual.

Table 2
TKS6000 T-HT HOT TAP EQUIPMENT LIST

NOMENCLATURE DESCRIPTION & FUNCTION SIZES AVAILABLE

1. TKS - T - HT Hot Manual or power driven
Tap Machine machine which taps into pipe.

2. Service Valve Extension that attaches hot Threaded: 1”, 1¼”, 1½”,
tap machine threads end to 2”, 3”
service valve and houses drills Flanged: 2”, 3”, 4”, 150 lb,
300 lb, 600 lb

3. Drill Bit Drill bit function to make hole 19 mm (1” system) and
in pipe. 34.5 mm (2” system)

4. Safety

Learn location and function of all safety features built into the Model TKS - T - HT Hot Tap
Machine and related equipment.
Protective clothing is recommended whenever working around machinery. Suggestions are: hard hat,
gauntlet gloves, safety goggles, safety shoes, garments to cover exposed areas of skin, and
breathing apparatus when toxic atmosphere exists.

4.1. Bleeder valve connection

The bleeder valve connection is located on the hot tap machine near bottom of body tube. See
Figure 2. The bleeder valve serves to purge air from fitting and serves to bleed off pressure after
drilling is completed, the drill retracted and the tapping valve is closed.

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Fig. 2. Bleeder Valve Connection

4.2. Warnings and cautions

The purpose of WARNINGS and CAUTIONS in this manual is to call the operator's attention to
possible danger of injury to personnel and/or property damage to equipment and deserve careful
attention and understanding.

5. TKS - T - HT Hot Tap Machine and Equipment Nomenclature

5.1. Hot Tap Machine

1. Ratchet wrench & Handle

2. Feed Tube

3. T-Bar

4. Body Tube

5. Bleeder Valve

6. Boring Bar
7. Drill Bit

Fig. 3. Part of Hot tap

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IOM Hot Tap Tool KOROSI SPECINDO

5.2. Adapter

Fig. 4. Adapter

5.3. Drill bit

Fig. 5. Drill bit

6. General Consideration:
To get a better understanding of how the drilling hot tap machine, the operator should remove hot
tap machine from its case and try each of the following.

A. Hold hex drive with ratchet handle and rotate feed tube clockwise by hand. Notice that boring
bar extends, but does not rotate. See Figure 6.

Fig. 6. Turn Feed Tube

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IOM Hot Tap Tool KOROSI SPECINDO

B. Hold feed tube and rotate hex drive clockwise with ratchet handle. Notice that the boring bar
rotates, but does not extend or retract. See Figure 7.

Fig. 7. Turn Ratchet Handle

C. Hold hex drive and rotate feed tube counterclockwise. The boring bar retracts, but does not rotate.
D. With ratchet handle, rotate hex drive clockwise. Note that boring bar and feed tube rotate and
boring bar extends.
E. With ratchet handle, rotate hex drive counterclockwise. Note that boring bar rotates and retracts.

6.1. Feed (Manual)

The TKS - T - HT HOT TAP MACHINE is a manual feed machine. Clockwise rotation of the feed tube
extends the boring bar and counterclockwise rotation retracts the boring bar. With the socket head
set screw tightened, turning the hex drive clockwise both turns and extends the boring bar. One
revolution of the hex drive will extend the boring bar 1/8”.

CAUTION: When tapping, be sure you do not OVERFEED. 0ver feeding, and
underfeeding also, will damage the hollow drill, blind drill or hole saw.

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IOM Hot Tap Tool KOROSI SPECINDO

SECTION II
TAPPING OPERATION
1. General Information
It is strongly recommended that the operator become familiar with all TKS - T - HT Hot Tap
Machine operation procedures. Practice operating the machine to get "the feel" of the controls
before doing an actual tapping job in the field. A test setup should be made on a short -length of
pipe to practice the tapping procedure.

2. Preparation for Tapping Using Drill Bit

The use of drill bit is recommended only for size-on-size taps. If used on other than size-on-size, a
flat plate cutting condition will be encountered as pipe diameter and wall thickness increase, making
completion of the tap and retention of coupon difficult. Therefore, a drill is recommended for other
than size-on-size.

3. Select Equipment
A. Select proper service valve, attach to access fitting (figure 8, and open to full open position).
The service valve must allow the hollow drill to pass through the bore unobstructed without
damage to the drill bit or service valve. The bore should be unobstructed by seat ring lugs, etc.
The bore of the service valve must be round and the minimum inside diameter must correspond
to thru bore minimum inside diameter.

Fig. 8. Service Valve

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IOM Hot Tap Tool KOROSI SPECINDO

B. Select proper drill bit, and hot tap adapter.

3.1 Install Valve Adapter

CAUTION: Use only KOROSI SPECINDO hot tap adapters to assure correct alignment of
equipment. Misalignment can result in equipment damage.

Use Teflon tape sealant or sealing compound on threads of hot tap adapter to assure a tight seal.
Thread adapter to hot tap. See Figure 9.

Fig. 9. Attach Adapter Hammer Nut to Hot Tap

3.2 Insert drill bit and retainer spring

While holding body tube, rotate feed tube clockwise to extend boring bar until retainer spring can be
removed.
Insert drill bit into boring bar and attach retainer Spring/See Figure 10.

Retainer Spring

Fig. 10. Insert Drill bit in Hot Tap

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3.3 Install bleeder valve

Install bleeder valve and nipple.

Fig.11. Bleed Valve

3.4 Tests for pressure tightness

Test setup for pressure tightness by pressuring through bleeder valve on hot tap machine.

3.5 Rotate feed tube counterclockwise

Hold body tube of drilling machine and rotate feed tube counterclockwise until feed tube is at zero
mark on body tube. See Figure 12. Drill is completely retracted.

0
1
2

Fig. 12. Zero Indicated on Body tube

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IOM Hot Tap Tool KOROSI SPECINDO

4. Tapping Process

4.1 Install Hot Tap Machine to Service Valve

CAUTION: When using flanged adapter, make sure

bore of tapping valve and bore of fitting
are in alignment. Using Brass Hammer
tighten hammer nut to service valve

Fig. 13. Install Hot Tap Machine

Pour cutting oil into Access Fitting to approximate depth of 1 inch. Attach machine to service valve.
Operate service valve to make sure it opens and closes without interference from tip of pilot drill. Be
sure valve is in full open position before continuing to next step.

4.2 Rotate feed tube clockwise

By rotating feed tube clockwise, extend drill until it contacts pipe (See Figure 14). The feed tube
should be at the first mark on body tube (lower in distance).

Fig.14. Rotate Feed Tube

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4.3 Mark on the body tube

Before continue tapping ensure get pipe thickness. Marking on body tube dimension of pipe
thickness. This is to avoid drill bit through the other side of pipe during tapping.

Fig. 15. Mark for pipe thickness

4.4 Attach ratchet handle

Attach ratchet handle to 3/4" hex drive. See Figure 16. While a ratchet handle is furnished, best
results will be obtained if handle is rotated 360° while cutting. Turn clockwise only. The rate of
advance for the drill is determined by the advance of the feed tube. Do not over feed to prevent
damage to the hollow drill. Eight revolutions of the feed tube will lower the hollow drill one inch.

Fig. 16. Attach and turn Ratchet

Pressure gauge will going up if drill bit penetrate pipe wall. Continue tapping until feed tube easy to
turn.

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4.5 Complete tap

When mark (total travel distance) is reached on body tube, tap should be complete. At this point, the
feed tube should turn with little effort. The "feel" and rate of feed confirm the tap to be complete.

4.6 Retract drill bit

By rotating feed tube counterclockwise, retract drill bit until feed tube is at the zero mark on body tube
or until it comes to firm stop.

4.7 Recovery sequence

Close service valve.

Bleed off pressure trapped in valve adapter by opening bleeder valve on drilling machine, Stand clear
of bleeder valve.
Remove machine from tapping valve.

CAUTION: High temperature tap — after each high temperature tap above 350° F, or taps in
corrosive fluids, replacement of packing is recommended. (For procedure to replace packing, see
Section III.) Equipment damage might otherwise result.

A. Result with Drill bit

Fig. 17. Result of tapping with drill bit

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IOM Hot Tap Tool KOROSI SPECINDO

SECTION III
MAINTENANCE
1. General Maintenance
The TKS - T - HT Hot Tap Machine has been designed for rugged service and requires a minimum
amount of maintenance. A reasonable amount of care will keep the machine in top operating condition
for a long period of time. Following are recommendations for proper care and handling.

A. The exposed end of the boring bar should be protected when machine is not in use.
B. Use an open end or adjustable type flat wrench on the two flat surfaces provided when attaching
the machine to a service valve or adapter hammer nut.
C. After each use, clean dirt and foreign material from exterior of machine.
D. Care should be taken not to damage hex drive at top of machine.
E. Lubricate ratchet handle regularly with oil.
F. After each tap, inspect drill for any damage.
G. Disassemble and lubricate each part every six (6) months or Twenty (20) taps, whichever comes
first, following the procedures.
H. High temperature tap-after each high temperature tap above 350° F, or taps in corrosive fluids,
replacement of packing is recommended. Procedures for packing replacement follow.
I. The drill bit is part to be protected from corrosion by an oil coating. These parts should be
inspected regularly and recoated with oil before storing.

2. Hot Tap Machine Disassembly

A. Hold body tube and rotate feed tube clockwise until boring bar is fully extended from body tube.
The feed tube should be at the 18" mark on the body tube. See Figure 18.

Fig. 18. Extend Boring Bar

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B. Using packing wrench provided, remove retainer nut next to bearing at top of machine by turning
counterclockwise. See Figures 19 and 20.

Fig. 19. Loosen Retainer Nut

Fig. 20. Remove Retainer Nut

C. Remove snap ring and three piece thrust bearing at top of machine. Sea figure 21 and 22

Fig. 21. Remove Snap Ring

Fig. 22. Remove three Piece Thrust Bearing

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IOM Hot Tap Tool KOROSI SPECINDO

E. Using packing wrench provided, remove packing retainer nut from body tube by turning
clockwise threads are left handed. Remove packing. See Figures 23.

Fig. 23. Remove Packing Retainer Nut

F. Remove boring bar through bottom of machine. See figure 24

Fig. 24 Remove Boring Bar

G. Hold body tube and rotate feed tube counterclockwise until threads are disengaged. With draw
body tube from feed tube. See Figure 25.

Fig. 25. Withdraw Body Tube from Feed Tube

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IOM Hot Tap Tool KOROSI SPECINDO

3. Hot Tap Machine Assembly

Assembly procedures are basically the reverse of steps C through F, Hot Tap Machine Disassembly.
However, the following additional information is provided and refers to various steps in the
disassembly procedures.
1. Grease all parts prior to assembly.
2. Replace packing (step E & F). Replace packing with high temperature packing. Enough sections
should be used to make a stack 1" high. The grooves should be greased and inserted one section
at a time with the lip toward the bottom. See Figure 27.

Fig. 26. Grease Packing

3. Packing retainer nut (step C & D). Inspect packing retainer nut. A nylon insert on the side serves
as a lock washer. Inspect this insert for condition.

4. Packing retainer nut (step C & D). Remember that the packing retainer nut has left handed
threads. Turn counterclockwise to install. Tighten firmly, making sure that boring bar will rotate
without excessive torque.

5. Install thrust bearing (step D). When replacing three pieces thrust bearing at top of machine,
grease each bearing individually. Inspect snap ring. See Figure 28.

Fig. 27. Grease Bearing and Install

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IOM Hot Tap Tool KOROSI SPECINDO

PRODUCT WARRANTY

1. Products manufactured by Korosi Specindo are warranted free from defects in material and
workmanship for a period of one (1) year from date of shipment from factory. The warranty on
components not manufactured by KOROSI SPECINDO shall not exceed the warranty of the
component manufacturer.
2. If defect under this Warranty appears, Korosi Specindo, at its option, will repair or replace the
defective part or product, or refund the purchase price, less an allowance for services rendered
by product prior to claim, and in no event will KOROSI SPECINDO be responsible for
consequential or incidental damages.
3. Claims for breach of warranty must be made in writing immediately upon discovery and sent by
registered mail to KOROSI SPECINDO, Jl. Pangeran Jayakarta No.76 JAKARTA, INDONESIA
10730. Defective products or parts must be held for inspection by KOROSI SPECINDO or, at
KOROSI SPECINDO option, returned to KOROSI SPECINDO F.O.B., its factory.
4. This Warranty shall not apply to any product or component which has been repaired or altered
by anyone other than KOROSI SPECINDO, or has become defective due to misuse, negligence
or casualty, or has been operated or maintained contrary to KOROSI SPECINDO printed
instructions.
5. Remedies available to an owner for breach of this Warranty are expressly limited to an action to
recover for the value of repairs or replacements due hereunder and KOROSI SPECINDO liability
for incidental or consequential damages are hereby expressly excluded to the full extent
permitted by applicable law.
6. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANT-ABILITY AND FITNESS FOR
USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON KOROSI SPECINDO PART,
AND KOROSI SPECINDO NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON
TO ASSUME FOR IT. ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF
PRODUCT.

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 No. DoC : KRT-03-01

7
5 16
17
22 8 14
2 18
12 19
20

1 3 10 11 21
13 15
4 6 9

KOROSI SPECINDO
JAKARTA - INDONESIA

HOT TAP ASSY

18"