KOPPL PIPELINE SERVICES

MODEL 250 HOT TAPPING MACHINE

Operator’s Instruction Manual

 Koppl Model 250 Hot Tapping Machine

General Specifications

Hot Tapping Range: 6” through 30”

Pressure / Temperature Rating: 1480 psig @ 100° F. or 700 psig @ 500° F.

Boring bar Travel: 48”, 60”, and 72”

Feed Rate: 5 turns per inch

Power Systems: Dual Hydraulic Motors or Dual Electric Motors

Weight: 1050 lbs (bare machine)

 Operating Instructions for Model 250 Hot Tap Machine

1.0 Introduction

The purpose of this manual is to provide operating instructions for the Model 250 hot tap
machine. Read and understand this manual in its entirety before attempting to operate the hot tap
machine.

2.0 Model 250 Assembly Instructions

Caution: The following instructions are to acquaint the new Model 250 user with how the
machine is assembled. Do not attempt to energize or use the Model 250 until this manual is read
and understood in its entirety.
2.1 Position the Model 250 tapping machine horizontally in a clean area and check
that the boring is fully retracted.
2.2 Select the proper tapping adapter corresponding to the valve class and size.
Carefully check the condition of the mating flanges, and clean as necessary.
Position the adapter carefully, install the gasket provided, then bolt the adapter
to the mating flange on the front of the tapping machine. Ensure fasteners are
evenly tightened in a star pattern sequence.
2.3 Place the crank handle on the feed screw at the end of the machine. Extend the
boring bar six inches past the end of the adapter by turning the crank handle
counterclockwise.
2.4 Install the cutter driver on the end of the boring bar using high-collar lock washers.
2.5 Mount the cutter to the cutter driver using high-collar lock washers. Ensure
fasteners are evenly tightened in a star pattern sequence. Verify cutter is sharp
and free of damage.
2.6 Install pilot drill using shoulder screw and lock nut. Verify the drill is
sharp and catch wires toggle freely. Ensure drill extension and catch wire
location are appropriate for the main size and wall thickness and the
selected cutter.
2.7 Turn the crank handle clockwise until the boring bar is in its fully retracted
position.
3.0 Operator Safety Instructions

3.1 Read and understand this manual in its entirety before attempting to operate or
service the Model 250.

3.2 Inspect the equipment. Never assume that someone else has left the machine
ready to use.

3.2.1 Check moving parts for free operation and absence of obstruction.
3.2.2 Verify that the cutter, driver, and pilot drill are tight.
 3.2.3 Verify that the valve adapter gasket is in place and that the adapter is
bolted securely to the head of the machine.

3.3 Know what you are hot tapping. Know what material is contained in the pipe
or vessel, along with its temperature and pressure. Hot or dangerous materials
require special handling. Ask for a Safety Specialist and a Hot Tap Specialist
assistance if you have any reason to feel a tap is out of the ordinary or that the
pressurized product is hazardous.

3.4 Avoid dangerous operating environments

3.4.1 Never operate this machine without adequate lighting. You must be
able to see well to operate this machine safely.
3.4.2 Never operate this machine from an unstable or over-extended
position.

3.5 Disconnect power supply before mounting, removing, or making any

adjustments to this machine.

3.6 Wear safe apparel. This machine rotates with incredible power. You cannot
resist or overpower its rotation. No loose clothing or jewelry shall be worn that
could be caught or entangled in moving parts.

3.7 Use safety equipment. PPE shall include at a minimum use of safety shoes and
glasses. Additional PPE shall be in accordance with local requirements and in
consideration of system product and site conditions.
3.8 Stay alert. Do not operate this machine if ill or if drowsy from fatigue or
medication. Maintain bystanders at a safe distance and minimize nearby
distractions while operating this machine.
3.9 Protect hydraulic lines. Keep hydraulic lines clear of sharp edges, foot and
vehicle traffic, and excessive heat or stress.

3.10 Avoid accidental starts. Never transport the machine while connected to an
energized power supply. Ensure that the control valve and power supply are off
prior to making or breaking hydraulic hose connections.

3.11 Stay within specifications. Never exceed the Model 250 specifications printed
herein.

4.0 Hot Tapping Instructions

4.1 Review machine assembly. Verify the following:

4.1.1 The tapping adapter is securely fastened

4.1.2 The cutter driver is securely fastened

 4.1.3 The cutter is sharp and securely fastened

4.1.4 The pilot drill sharp and secured

4.1.5 The pilot drill is appropriately positioned with its catch wires toggling
freely

4.1.6 Seals and gaskets are appropriate for the service and in good condition

4.1.7 The boring is bar lightly lubricated and free of dirt

4.1.8 The feed screw turns easily and smoothly

4.1.9 The boring bar retracted fully providing clearance for the valve gate/ball
to be closed

4.1.10 The bleeder valve is securely installed

4.2 Review the jobsite

4.2.1 Ensure there is a safe and secure place for you to stand while attaching
and operating the machine
4.2.2 Identify where would you move quickly in the event of an emergency

4.2.3 Ensure plant/building safety and operations personnel are aware of the hot
tap operation planned

4.2.4 Verify with on-site representative that system contents and conditions are
as expected

4.3 Review the hot tap connection

4.3.1 Verify that the weld appears to be sound and free of porosity

4.3.2 Verify fitting-valve joint is properly made up

4.3.3 Verify that the valve opens and closes completely

4.3.4 Verify valve fasteners / packing nut(s) are tight

4.4 Completing the hot tap

4.4.1 Determine the number of turns (at 5 turns per inch) required to
complete the tap based on the distance from the tapping adapter flange
to the tip of the pilot bit and to the cutter teeth, the distance from the
surface of the pipe through the tapping valve, and the expected travel
through the cut based on the cutter and main size and the pipe wall
thickness.
4.4.2 Note the number turns required for the cutter to reach the centerline of
the pipe and for the pilot to reach the opposite side of the pipe.

Warning: These limits must not be exceeded when performing a typical

single-cut hot tap.

4.4.3 Attach the fully retracted Model 250 machine to the tapping valve using
appropriate fasteners and gaskets.

4.4.4 Crack open the bleeder valve on the machine.

4.4.5 Cycle the tapping valve to verify clearance between pilot and
valve gate / ball.

4.4.6 Open the tapping valve.

4.4.7 Pressure test the entire assembly and check the fitting, valve, and machine
for leaks.

Warning: Test pressures significantly higher than the present operating pressure of
the pipe or vessel being hot tapped may damage that pipe or vessel.

4.4.8 Attach the crank handle to the end of the feed screw. Rotate the handle
counterclockwise to advance the boring bar forward until the pilot drill
touches the pipe, then back off the pipe 1 turn. Verify the number of
turns is consistent with determination from step 4.4.1 above.

4.4.9 Supply power to the tapping machine.

4.4.10 Position control lever to start the tapping machine.

4.4.11 Carefully advance the pilot bit, noting the number of turns expected to
pass through the pipe wall thickness.

4.4.12 Stop feeding at the first sign of pilot break through (anticipate visual,
audible, and tactile indications of system fluid entering the tapping
adapter and/or venting at the bleeder valve). Back off 1 turn and stop
the tapping machine.

4.4.13 When system fluid is emitted, shut the bleeder valve.

4.4.14 Start the tapping machine and finish drilling the pilot hole.

4.4.15 Note the number of turns required for the cutter teeth to reach the pipe.
Verify the number of turns is consistent with determination from Step
4.4.1 above.

Caution: Never start or stop the tapping machine with the pilot drill or cutter
teeth in contact with the pipe. Always back off 1 turn prior to starting or
stopping the machine to avoid cutter and pilot damage.
4.4.16 With the machine running, carefully advance the cutter into the pipe
keeping in mind the total number of turns expected to complete the tap
determined in Step 4.1.1 above. Do not exceed the number of turns
required for the cutter to reach the centerline of pipe, or for the pilot drill
to reach the other side of the pipe determined in Step 4.1.2 above if
performing a single-cut hot tap.
4.4.17 When audible and tactile indications suggest that the cut is complete, and
the total number of turns advanced is at or near the number expected,
stop the machine and carefully advance the cutter several turns to verify
that the cut is complete.
4.4.18 Retract the cutter completely until it stops. Verify the number of turns is
consistent with the total turns advanced to ensure the cutter has not hung
up outside of the tapping adapter.
4.4.19 Secure flow of hydraulic fluid to the machine.
4.4.20 Shut the isolation valve.

4.4.28 Depressurize and drain the tapping machine through the bleeder valve.

Caution: Without exceptional procedures, hot taps will always release some of
the system fluid when the machine is removed. Be prepared and aware of
surrounding personnel and equipment and potential hazards from discharged or
spilled system fluid.

Note: Gate valves will, on occasion, leak after a hot tap due to pipe shavings
becoming caught in the seat of the valve. Be prepared for some pressure release.
Cycling the valve gate with the bleeder valve partially open (if safe to do so) will
usually clear the shavings.

4.4.29 Remove the Model 250 from the isolation valve.

4.4.30 Wipe the outboard area of the valve bore free of any accumulated pipe
shavings.

4.4.31 Wipe down the machine, removing pipe shavings and system fluid.

4.4.32 Inspect the machine, cutter, and pilot, note any wear, damage, or
loosening of fasteners that require repair, replacement, or servicing
prior to next use.