GF GFCP HVTT Repair Fitting and Peeling Kit Owner's manual

Brand: GF

Model: GFCP HVTT Repair Fitting and Peeling Kit

Type: Owner's manual

GF Piping Systems

Georg Fischer Central Plastics

39605 Independence, Shawnee, OK 74804

• Tel. (405) 273-6302 / (800) 654-3872

www.gfcp.com

GEORG FISCHER PIPING SYSTEMS

Product Part Number 360065314

Manual Part Number 360093783 REV C

OPERATION MANUAL

HVTT Repair Fitting

and Peeling Tool Kit

Page 2 of 17 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.

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.

This manual is intended to provide a general introduction to the tools and steps

required for proper use of the product. 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 its products and 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 fusion 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.

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

written permission of Georg Fischer Central Plastics, LLC.

Page 3 of 17 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.

Table of Contents

Safety Notes and Warning Symbols...................................................................................................... 4

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

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

Operating Instructions ............................................................................................................................. 7

Preparing the Fittings for Electrofusion ............................................................................................... 11

Preparation for Electrofusion ................................................................................................................ 13

Care and Maintenance .......................................................................................................................... 16

Replacement Items ................................................................................................................................ 17

Page 4 of 17 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.

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 fusion equipment are not to be considered as “explosion proof”.

Caution should be exercised when working with generators and other electrical power

sources.

Tools may 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.

Repair operations on live pressurized systems can result in escaping gas and/or static

discharge. Follow all federal, state, local, and company guidance for grounding, static

mitigation, and personal protective equipment when working in this environment.

These instructions pertain solely to the operation of the subject product. 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 subject product(s).

Failure to observe these procedures may cause personal injury and/or property damage.

Each Operator must be properly trained in the use of this product or equipment prior to

conducting and performing the following steps in a live natural gas application.

Page 5 of 17 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.

General Information

This product is for the repair of leaking HVTT caps

. It can be used in cases

where the cap is damaged and cannot be tightened, or when replacement

with an OEM cap is not possible. This cap repair system contains a tool

specifically designed to remove the threads by peeling the tower of the

HVTT to accept the Electrofusion Repair Fitting. Inspect all threads and

ensure that the peeling tool can be attached. If the peeling tool cannot be

attached, the repair system should not be used. The fitting is designed in a

way that the gas in a pressurized system can be safely vented away from

the electrofusion zone of the fitting.

This product is not intended for and may not be suitable for use with other

similar fittings produced by other manufacturers.

HVTT refers to polyethylene high volume tapping tees historically produced under the tradename of UPONOR and

used for gas distribution service.

Page 6 of 17 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.

Kit Contents

360065314 – HVTT Repair Fitting and Peeling Kit

Part#

Description

QTY

360065300

Peeling Tool

360092853

Repair Fitting

360002966

Test Cap

360003020

4.7 x 4.0 Pin Adapter Set

360093548

Multi-Purpose Wrench

Page 7 of 17 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.

Operating Instructions

It is very important that all oils, glue, dirt, and sand be removed before and after removal of the cap.

Clean Body with Water then Alcohol

After cleaning remove cap

If coupon in the punch has dropped, and there is a large volume

of gas escaping from the punch, the hole must be sealed before

proceeding. The use of a rubber gasketed #12 Sheet Metal

Roofing Screw installed with a magnetic nut driver has been

found to work well.

Page 8 of 17 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.

Using the supplied wrench, turn the punch counter clockwise to

expose 4 threads to allow mounting of the peeling tool. This will

expose some threads on the punch for the peeling tool

mounting. DANGER!!! DO NOT REMOVE THE PUNCH!

Verify both the punch and HVTT tower are clean and free

of heavy rust and oil. Clean with wire brush and alcohol if

necessary.

4 threads should be exposed

Page 9 of 17 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.

Install the Peeling Tool by turning the knob, indicated by the

arrow, clockwise down onto the punch. It will bottom out on the

top of the tee.

Pay attention that the punch does not screw down during this

operation. If needed, the provided wrench can be used to hold

the punch in place during installation.

Once Peeling Tool is installed begin rotating the handles clockwise as

shown. While applying and even amount of pressure downwards on the

handles. As the tool progresses remove the plastic strings every couple

of turns. Continue until tool reaches the bottom stop and becomes

noticeably more difficult to turn.

Page 10 of 17 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.

After the tool reaches the bottom of its travel, remove the plastic strings.

Return the tool to the top by turning the handles counter clockwise. Do

not spin the handles, this could cause the tool to come off prematurely

or jam tool at the top requiring additional tools to un-jam for next use.

Pay Attention that the punch remains stationary and does not

turn out of the fitting during this operation. The supplied wrench

can be used to hold the punch stationary if needed.

Remove Peeling Tool by turning knob counterclockwise as shown

Pay Attention that the punch remains stationary and does not

turn out of the fitting during this operation. The supplied wrench

can be used to hold the punch stationary if needed.

Page 11 of 17 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.

Preparing the Fittings for Electrofusion

Remove fitting from bag

Remove Cap

Remove Completion Plug by turning counter clockwise with supplied tool

Page 12 of 17 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.

Clean fusion areas of the fittings with 90% or

greater Isopropyl Alcohol or Acetone

After the alcohol has evaporated, assemble

fitting by pushing down in the direction shown

until it contacts the top of the punch. Once the

fitting reaches the punch start rotating the fitting

clockwise until it threads onto the punch and

stops. Typically this will be the number of

threads that were showing on the steel punch.

Page 13 of 17 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.

Preparation for Electrofusion

Ensure there is no gas pressure build-up in the fusion zone of the fitting during the fusion or cooling

process. Methods for accomplishing this include using squeeze-off tools, or venting. Included in the kit is

a HVTT Test Cap which can be used as a vent cap during the Electro Fusion Process to remove gas from

the fusion area via a connected hose.

Follow your company safety procedure when working in a gaseous environment.

Insert Pin Adapters into fitting

Page 14 of 17 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.

Attach fusion leads to fitting. The HVTT Repair

Fitting is a barcode entry fitting so there is no

particular cable connection configuration

required.

Fuse fitting using normal procedures and allow

fusion to cool completely before installing

completion plug and cap.

Page 15 of 17 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.

Re-install Completion Plug clockwise, first by

hand being careful not to cross thread. Finish

installing with special supplied wrench until plug

is just below flush.

Do not overtighten completion plug.

Overtightening will make it difficult to install the

cap in the next step.

Re-install Cap clockwise being careful not to

cross thread, screw down hand tight. Check for

leaks to complete the repair.

Page 16 of 17 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.

Care and Maintenance

Care should be taken to guarantee the performance of the peeling tool. The cutting inserts in this tool are

made of carbide which is a very hard material and will provide an excellent service life. Care must be

taken to protect them from impacts that will fracture the cutting edge.

Inspect all of the tools supplied in the kit at each use for damage, dirt, debris, or foreign substances.

Ensure that all moving parts turn freely. Clean before and after each use. The supplied protective cap

must be used when tool is not in service.

If the carbide inserts are damaged, they will not cut as designed. If they are chipped, it is possible to

rotate the insert to use an undamaged surface by loosening the screw. If broken or worn beyond useable

condition, replacement inserts are available.

Loosen screw rotate cutter to unused position and

retighten.

Page 17 of 17 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.

Replacement Items

Part#

Description

360040079

Cutting Insert

360040971

Insert Screw

360092853

HVTT Repair Fitting

360003020

4.7 x 4.0 Pin Adapter Set

360093548

Multi-Purpose Wrench

GF GFCP HVTT Repair Fitting and Peeling Kit Owner's manual

GF GFCP HVTT Repair Fitting and Peeling Kit Owner's manual

GF GFCP HVTT Repair Fitting and Peeling Kit Owner's manual

Related papers

Other documents