Tapping saddle
Tapping saddle is a specialized pipe fitting used to create a branch connection from an existing pipeline without the need for cutting or welding. It allows for a new connection while the main pipeline remains in operation
The wide rang tapping saddle is able to suit different outside diameter of the main pipe by adjusting the length of steel band, so it can be used for the tapping saddle for the PVC pipe, ductile iron pipe, HDPE pipe, steel pipe and so on. The requirement is that the outside diameter of the pipe should be in our designed range . Also, we can change the length of the steel band according to the requirement of the customers, so it can be used for the pipe that the customers specify.
Tapping saddle with thread outlet
Tapping saddle with thread outlet
Feature
Wide range type
Saddle standard:comply with EN545
Coating standard:EN30677
Test standard: EN12266-1
Working pressure and Temperature
size DN50 to DN400 ,working pressure 20bar ,test pressure 30bar
Temperature from -10℃ to 120℃ for EPDM gasket
Temperature from -10℃ to 82℃ for NBR gasket
Suitable for potable water ,neutral liquids and sewage
WRAS,ACS,DVGW,NSF approved
Drawing
tapping saddle single band head drawing
tapping saddle double bands head drawing,For bigger outlet size which is bigger than 2″ and bigger pipe size which bigger than DN300,We suggest use double bands instead one band
tapping saddle stainless steel band drawing,For ductile iron, steel ,GRP etc rigid pipe，Width 40mm stainless steel band is ok, but for plastic pipe ,it is better use wider Stainless steel band,60mm width stainless steel band is suggested
Material
| No. | Parts Name | Material |
|---|---|---|
| 1 | Body | Ductile iron |
| 2 | Bands | Stainless Steel |
| 3 | Protect Cover | Rubber |
| 4 | Gasket | EPDM |
Ductile iron head dimension(unit mm)
| Head DN | Srewed outlet | Band No. | A | B |
|---|---|---|---|---|
| 50-200 | 3/4" | 1 | 150 | 70 |
| 50-200 | 1" | 1 | 150 | 70 |
| 50-200 | 1 1/4" | 1 | 150 | 70 |
| 50-200 | 1 1/2" | 1 | 150 | 70 |
| 100-300 | 1" | 1 | 195 | 92 |
| 100-300 | 1 1/4" | 1 | 195 | 92 |
| 100-300 | 1 1/2" | 1 | 195 | 92 |
| 100-300 | 2" | 1 | 195 | 92 |
| 150-400 | 2" | 2 | 216 | 157 |
| 150-400 | 1 1/2" | 2 | 216 | 157 |
| 150-400 | 3" | 2 | 216 | 157 |
Stainless steel bands dimension(unit mm)
| size | Bands Thickness | Bolts length f | Bolts thread length |
|---|---|---|---|
| 54-64 | 1.5 | M12*120 | 100 |
| 60-77 | 1.5 | M12*120 | 100 |
| 77-95 | 1.5 | M12*120 | 100 |
| 98-119 | 1.5 | M12*120 | 100 |
| 102-122 | 1.5 | M12*120 | 100 |
| 120-150 | 1.5 | M12*150 | 130 |
| 125-135 | 1.5 | M12*120 | 100 |
| 139-160 | 1.5 | M12*120 | 100 |
| 150-180 | 1.5 | M12*150 | 130 |
| 151-171 | 1.5 | M12*120 | 100 |
| 160-185 | 1.5 | M12*120 | 100 |
| 170-195 | 1.5 | M12*120 | 100 |
| 173-198 | 1.5 | M12*120 | 100 |
| 195-220 | 1.5 | M12*120 | 100 |
| 200-230 | 1.5 | M12*150 | 130 |
| 223-248 | 1.5 | M12*120 | 100 |
| 230-250 | 1.5 | M12*120 | 100 |
| 250-280 | 1.5 | M12*150 | 130 |
| 285-315 | 1.5 | M12*150 | 130 |
| 315-340 | 1.5 | M12*120 | 100 |
| 320-345 | 1.5 | M12*120 | 100 |
| 330-355 | 1.5 | M12*120 | 100 |
| 355-380 | 1.5 | M12*120 | 100 |
| 385-400 | 1.5 | M12*120 | 100 |
| 400-425 | 1.5 | M12*120 | 100 |
| 410-435 | 1.5 | M12*120 | 100 |
Other range is also available upon request
Please note dimension may vary at our discretion
Video for tapping saddle
Pressure test for tapping saddle
How to assemble tapping saddle
Tapping saddle installation
Installing a tapping saddle involves several steps to ensure a secure and leak-free connection. Here’s a step-by-step guide:
Prepare the Equipment:
- Tapping saddle kit (including gasket and bolts)
- Drill or tapping machine
- Wrenches and other hand tools
- Safety gear (gloves, goggles)
Shut Off the Pipeline (if necessary):
- For some installations, the main pipeline may need to be shut off, but many tapping saddles allow for installation without interrupting the flow.
Clean the Pipe Surface:
- Clean the area where the saddle will be installed. Remove any dirt, debris, or corrosion to ensure a good seal.
Position the Saddle:
- Place the tapping saddle on the main pipeline, aligning it properly with the desired branch location.
- Ensure the gasket is properly seated between the saddle and the pipe.
Secure the Saddle:
- Tighten the bolts on the tapping saddle evenly. It’s important to follow the manufacturer’s torque specifications to avoid over-tightening or under-tightening.
Drill the Hole:
- Use a drilling or tapping machine to cut a hole through the pipe wall via the saddle’s outlet. Many tapping saddles come with a built-in valve, allowing for a controlled and contained drilling process.
- If using a hot tapping machine, follow the specific instructions for that device.
Complete the Tap:
- Once the hole is drilled, remove any drilling equipment, ensuring no debris falls into the pipe.
Connect the Branch Pipe:
- Attach the branch pipe to the outlet of the tapping saddle. Secure it according to the manufacturer’s instructions, typically involving tightening additional bolts or clamps.
Test the Connection:
- Slowly restore the flow in the main pipeline (if it was shut off) and check for leaks around the tapping saddle.
- If leaks are detected, tighten the bolts as needed or recheck the gasket positioning.
Secure and Finish:
- Ensure all connections are tight and the branch pipe is securely attached.
- Verify that the tapping saddle and the new branch connection are functioning properly.
By following these steps, you can install a tapping saddle safely and effectively, ensuring a secure and efficient branch connection to the main pipeline.
What is the difference between Tapping Sleeve and Tapping Saddle?
The main differences between a tapping saddle and a tapping sleeve lie in their design, application, and installation processes:
Tapping Saddle
Design:
- A tapping saddle, also known as a saddle clamp, typically consists of a single piece that wraps around the pipe and has an outlet where the branch connection is made.
- It usually includes a rubber gasket to ensure a secure and leak-proof seal between the saddle and the pipe.
Application:
- Tapping saddles are commonly used for making smaller diameter branch connections from larger main pipelines.
- They are often used in situations where quick installation and lower cost are priorities.
Installation:
- The tapping saddle is clamped onto the pipe using bolts that tighten the saddle around the pipe.
- It requires a hole to be drilled or tapped into the main pipe to allow fluid to flow into the branch connection.
Tapping Sleeve
Design:
- A tapping sleeve is a larger, two-piece assembly that completely encircles the main pipe and provides a more robust and secure connection.
- It often includes a larger sealing gasket and can accommodate larger branch connections compared to a tapping saddle.
Application:
- Tapping sleeves are typically used for making larger diameter branch connections or when working with higher pressure systems.
- They are chosen for applications where a more durable and secure connection is necessary.
Installation:
- The tapping sleeve is bolted around the main pipe, providing a stronger and more secure attachment.
- Similar to tapping saddles, a hole is drilled or tapped into the main pipe, but the installation process is generally more complex and may require more tools and time.
Summary
- Tapping Saddle: Smaller connections, quicker and simpler installation, lower cost, used for lower pressure systems.
- Tapping Sleeve: Larger connections, more secure and durable, used for higher pressure systems, more complex and time-consuming installation.
Tapping Saddle
Tapping Sleeve
What is Saddle Tap?
Saddle tapping is a method used to create a branch connection from an existing main pipeline without cutting and removing a section of the pipe. This process involves using a saddle tap (or saddle clamp) to make a new connection point.
Dry tap VS Wet tap
Dry Tap
Definition: A dry tap refers to a process of making a branch connection to a pipeline or main without the presence of liquid in the pipe. Essentially, the main pipeline is empty or dry during the tapping procedure.
Process:
- Isolation: The section of the pipeline where the tap will be performed is isolated, typically by closing valves upstream and downstream.
- Draining: The isolated section is drained to ensure it is completely dry.
- Installation of Tapping Equipment: The tapping saddle or sleeve is installed on the dry section of the pipe.
- Tapping: A hole is drilled or cut into the pipe. Since there is no liquid, the tapping can be done without concerns about leaks or spills.
- Connection: The branch line is connected to the tapping point.
- Reactivation: The pipeline is reactivated by opening the isolation valves, allowing fluid to flow through the main and the new branch.
Advantages:
- No risk of liquid leakage during the tapping process.
- Safer for maintenance personnel since there is no exposure to pressurized liquid.
- Simpler cleanup and preparation process.
Wet Tap
Definition: A wet tap, also known as a live tap or hot tap, is the process of making a branch connection to a pipeline while it is still under pressure and filled with liquid. The main pipeline remains operational during the tapping procedure.
Process:
- Installation of Tapping Equipment: A specialized tapping sleeve or saddle is installed on the pressurized pipe. This equipment includes a valve that can be closed after the tap is completed.
- Sealing: The tapping equipment is sealed to prevent leaks.
- Tapping: A hole is drilled or cut into the pipe through the valve. The valve remains closed during the drilling process to prevent leaks.
- Valve Operation: Once the hole is made, the valve is closed to isolate the tapping point from the main pipeline.
- Connection: The branch line is connected to the tapping point.
- Reactivation: The valve is opened to allow fluid to flow from the main pipeline into the new branch line.
Advantages:
- No need to shut down the main pipeline, maintaining continuous service.
- Ideal for critical pipelines where shutdown is not feasible or is costly.
- Minimizes downtime and operational disruptions.
Differences
Pipeline Status:
- Dry Tap: The pipeline is drained and isolated; no liquid is present.
- Wet Tap: The pipeline remains pressurized and full of liquid; no isolation or draining required.
Operational Impact:
- Dry Tap: Requires pipeline shutdown and draining, causing service interruption.
- Wet Tap: Allows continuous operation without service interruption.
Safety and Risk:
- Dry Tap: Safer in terms of handling as there is no liquid under pressure, reducing risk of spills.
- Wet Tap: Requires more specialized equipment and safety measures to handle pressurized liquid, increasing complexity and potential risk.
Equipment and Process Complexity:
- Dry Tap: Simpler equipment and procedure since the pipe is dry.
- Wet Tap: Requires specialized tapping sleeves or saddles with valves to manage the pressurized liquid.
Summary
- Dry Tap: Suitable for situations where the pipeline can be safely shut down and drained. Simpler and safer but requires service interruption.
- Wet Tap: Ideal for situations where continuous operation is critical. More complex and requires specialized equipment and safety measures to handle pressurized liquid.
Tapping Saddle and Valve
A tapping saddle and valve combination is commonly used to create a branch connection from an existing pipeline while allowing for control over the flow of fluid through the new branch. Here’s an overview of the components, their purpose, and the installation process:
Components
Tapping Saddle:
- Body: Encircles the main pipeline and provides a secure connection point for the branch.
- Gasket: Ensures a leak-proof seal between the saddle and the pipeline.
- Clamps/Bolts: Secure the saddle to the main pipeline.
- Outlet: Provides the connection point for the valve and subsequent branch piping.
Valve:
- Type: Common types include gate valves, ball valves, or corporation stop valves.
- Function: Controls the flow of fluid from the main pipeline to the branch. It can be opened or closed to start or stop the flow.
- Connection: Attaches to the outlet of the tapping saddle.
Purpose
- Branch Connection: The combination allows for a new branch connection without shutting down the main pipeline.
- Flow Control: The valve provides the ability to control the flow of fluid into the new branch, allowing for maintenance or adjustments without affecting the main pipeline.
- Leak Prevention: The gasket and secure clamping mechanisms ensure a leak-proof connection.
Installation Process
Preparation:
- Clean the section of the main pipeline where the tapping saddle will be installed to ensure it is free of debris and contaminants.
Positioning the Tapping Saddle:
- Place the tapping saddle around the main pipeline at the desired location for the branch connection.
- Ensure the gasket is correctly positioned to create a watertight seal.
Securing the Tapping Saddle:
- Tighten the bolts or clamps to secure the saddle to the pipeline. Ensure even tightening to maintain a good seal without damaging the pipe.
Valve Installation:
- Attach the valve to the outlet of the tapping saddle. The type of connection (e.g., threaded, flanged) will depend on the specific valve and saddle design.
- Ensure the valve is securely attached and properly aligned.
Tapping the Pipeline:
- Using the appropriate tapping tool, drill or cut a hole into the main pipeline through the outlet of the tapping saddle. The tapping tool will typically pass through the valve to create the opening.
- This step should be done carefully to avoid damaging the pipe or creating an uneven hole.
Sealing and Testing:
- Once the hole is created, close the valve to prevent fluid from escaping.
- Test the connection by slowly opening the valve and checking for leaks around the tapping saddle and valve assembly. Tighten any bolts or clamps if necessary to stop leaks.
Connecting the Branch Line:
- Attach the branch line to the valve. Ensure the connection is secure and leak-proof.
- Open the valve to allow fluid to flow into the new branch line as needed.
Key Considerations
- Pressure Rating: Ensure the tapping saddle and valve are rated for the operating pressure of the main pipeline.
- Pipe Material Compatibility: The materials of the tapping saddle and valve should be compatible with the pipeline material (e.g., HDPE, PVC, steel).
- Thermal Expansion: For HDPE or other flexible pipes, consider the effects of thermal expansion and ensure the tapping saddle can accommodate these changes.
- Regular Maintenance: Periodically inspect the tapping saddle and valve assembly for signs of wear, corrosion, or leaks, and perform maintenance as required.
By following these steps and considerations, a secure and reliable branch connection with flow control can be established using a tapping saddle and valve.
