Universal Tapping Saddle for Ductile Iron Pipe,PVC pipe,Steel Pipe etc

The universal tapping saddle also called wide range tapping saddle, is suitable for a wide range of pipes, include ductile iron pipe ,steel pipe,GRP pipe,AC pipe etc, it is used to split water from mains to sub-pipes and can be adapted to different pipe outside diameters by adjusting the length of the stainless steel bands used to wrap the pipe, thus reducing stock.

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Specification

Universal DCI saddle with Stainless Steel strap ,flange outlet –PN10/PN16

Saddle standard:comply with EN545

Flange standard:EN1092-2,ANSI B16.47/ANSI B16.5,AS4087

Coating standard:EN30677

Test standard: EN12266-1

Working pressure and Temperature

Size DN50 to 2000

Temperature from -10℃ to 120℃ for EPDM gasket

Temperature from -10℃ to 82℃ for NBR gasket

Connection for PVC , HDPE,DI,Steel,GRP etc pipe which pipe OD is in our saddle range

Suitable for portable water ,neutral liquids and sewage

WRAS,ACS,DVGW,NSF approved

Material and Drawing Catalogue Installation Instruction

Product Video

Play Video about saddle clamp

How Universal Tapping Saddle Work?

1, align the centre of the ductile iron head with the rubber ring in place with the centre of the hole to be drilled

2, attach the stainless steel band to the pipe and pass it through the bolt hole in the ductile iron head

3, tighten the bolts, in the process of tightening, the stainless steel band holds the pipe, by tightening the bolt, the steel band clamps the pipe, the ductile iron head and the pipe squeeze the rubber ring, so that it deforms to form a seal.

4, use the drill to drill holes in the top of the pipe through the inner diameter of the flange

5, install the valves, fittings and other components, which are connected to the flange of the universal tapping saddle by their own flanges.

Saddle Tap for PVC Pipe

Using a saddle tap for PVC (Polyvinyl Chloride) pipes involves specific considerations to ensure a secure and leak-free connection. Here’s a detailed guide on the requirements, components, and installation process for a saddle tap on a PVC pipe:

Special Requirements for Saddle Tap on PVC Pipe

Material Compatibility:
- Ensure the saddle tap is made of materials compatible with PVC to prevent chemical reactions and ensure a good seal. Common materials include PVC, stainless steel, or other non-corrosive metals.
Gasket:
- Use a high-quality gasket compatible with PVC to create a watertight seal between the saddle and the pipe. EPDM or Nitrile rubber gaskets are commonly used for this purpose.
Design:
- The saddle should be designed specifically for PVC pipes, considering the flexibility and potential for thermal expansion of PVC.
Clamping Mechanism:
- A robust clamping mechanism is essential to secure the saddle to the PVC pipe. This typically includes stainless steel bolts, clamps, or straps.
Pipe Thickness:
- Ensure the saddle tap is suitable for the thickness of the PVC pipe being tapped. The saddle should be able to accommodate the pipe wall thickness without causing damage.

Installation Process for Saddle Tap on PVC Pipe

Preparation:
- Clean the surface of the PVC pipe where the saddle will be installed. Remove any dirt, debris, or contaminants to ensure a good seal.
Positioning the Saddle Tap:
- Place the saddle tap on the PVC pipe at the desired location for the branch connection. Align it carefully to ensure proper positioning.
Sealing:
- Ensure the gasket is correctly positioned between the saddle and the PVC pipe. This gasket is crucial for creating a watertight seal.
Securing the Saddle Tap:
- Tighten the clamps or bolts on the saddle tap to secure it firmly onto the PVC pipe. Ensure even tightening to prevent leaks and avoid over-tightening, which could crack the PVC pipe.
Tapping the Pipe:
- Using an appropriate tapping tool, drill or cut a hole into the PVC pipe through the saddle’s outlet. The tapping tool should be suitable for PVC to avoid cracking or damaging the pipe.
- The size of the hole should match the outlet size of the saddle tap to ensure proper flow and connection.
Connecting the Branch Line:
- Attach the branch line to the outlet of the saddle tap. Ensure all connections are secure and leak-proof.
- PVC cement or appropriate fittings may be used to secure the branch line connection.
Testing:
- Test the connection by pressurizing the system and checking for leaks around the saddle tap and the new branch connection.
- Tighten any bolts or clamps if necessary to stop any leaks.

Advantages of Using Saddle Taps on PVC Pipes

Minimal Disruption: Allows for the addition of new connections without significant disruption to the existing pipeline.
Cost-Effective: Generally more affordable and quicker to install compared to other methods of creating branch connections.
Ease of Installation: Requires fewer tools and less technical expertise compared to other fittings.
Versatility: Suitable for various applications, including water supply systems, irrigation systems, and industrial applications.

Key Considerations

Avoid Excessive Force: PVC pipes can be brittle, especially in cold temperatures. Avoid over-tightening bolts or clamps to prevent cracking.
Thermal Expansion: Consider the effects of thermal expansion and contraction on PVC pipes, especially in environments with significant temperature fluctuations.
Regular Inspection: Periodically inspect the saddle tap and branch connection for signs of wear, damage, or leaks, and perform maintenance as needed.

By adhering to these special requirements and following the proper installation process, a secure and reliable branch connection can be made to a PVC pipe using a saddle tap.

Saddle Tap for Steel Pipe

Since steel pipes are metal pipes with higher hardness, tapping saddles made of relatively narrow metal materials are usually selected when selecting tapping saddles. This design can provide greater strength and stability and ensure the reliability of connections in high-pressure environments.

Installation Steps and Precautions
Cleaning the Pipe Surface:

Ensure that the steel pipe surface is clean and free of rust and debris to ensure good sealing of the tapping saddle.
Positioning and Fixing the Tapping Saddle:

Place the tapping saddle in the desired opening position and make sure it is properly aligned.
Secure the tapping saddle to the steel pipe with high-strength bolts or U-bolts. Due to the high hardness of the steel pipe, the proper tools and torque should be used when securing the tapping saddle to ensure that the pipe is not damaged.
Installing the Sealing Gasket:

Place a high-quality sealing gasket (usually made of EPDM rubber) between the tapping saddle and the steel pipe to ensure the sealing performance of the connection.
Drilling:

Use a dedicated drilling tool to drill through the tapping saddle on the steel pipe. This tool should be suitable for steel to ensure the drilling process is smooth and the hole is clean.
When drilling, be careful not to create burrs or damage the pipe.
Connecting the Branch Pipe:

Connect the branch pipe to the outlet of the tapping saddle and ensure that all connections are secure and leak-free.
If necessary, welding or other high-strength connection methods can be used to enhance the connection stability.
Testing and Inspection:

After installation is complete, perform a system pressure test and check for leaks at the tapping saddle and branch pipe connections.
If any leaks are found, tighten the bolts or replace the sealing gasket immediately.
Maintenance and Care
Regular Inspection:

Regularly inspect the tapping saddle and branch pipe connections to ensure there is no corrosion, loosening, or leaks.
Enhanced inspection frequency is recommended, especially when used in harsh environments.
Corrosion Prevention:

If the steel pipe and tapping saddle are in a corrosive environment, it is recommended to use corrosion-resistant coatings or materials to extend the service life of the equipment.
Fastener Maintenance:

Regularly inspect and tighten the bolts to ensure the connections are secure.
By following these steps and precautions, you can ensure the safety and reliability of using tapping saddles for branch connections on steel pipes. This method is not only suitable for water systems but also widely used in gas pipelines and various industrial piping systems.

Tapping Saddle for HDPE Pipe

Due to the soft and easily deformable nature of HDPE (high-density polyethylene) pipes and their tendency to deform during thermal expansion and contraction, special attention should be paid to the following points when selecting tapping saddles:

Choosing the Right Tapping Saddle
Material Compatibility:

Ensure that the tapping saddle material is compatible with the HDPE pipe. Tapping saddles made of ductile iron , polyethylene materials are usually chosen to avoid issues caused by material incompatibility.
Large Support Surface:

Select tapping saddles with large support surfaces (as below photo, we need to design the tapping saddle for HDPE pipe much longer than the one for steel, ductile iron etc metal pipe) to distribute the pressure, prevent excessive local stress on the HDPE pipe, and reduce the risk of deformation.
Flexible Design:

Choose tapping saddles with designs that allow for thermal expansion and contraction to adapt to the thermal expansion and contraction characteristics of HDPE pipes and ensure long-term reliability.
High-Quality Sealing Gasket:

Select high-quality sealing gaskets (such as EPDM rubber gaskets) to maintain good sealing during thermal expansion and contraction to prevent leaks.
Installation Steps and Precautions
Surface Cleaning:

Thoroughly clean the HDPE pipe surface to ensure there are no debris or contaminants that could affect the installation and sealing of the tapping saddle.
Proper Positioning and Fixation:

Place the tapping saddle accurately at the desired opening position and ensure it is tightly fitted to the HDPE pipe.
Secure the tapping saddle to the pipe using the appropriate tools and torque to avoid excessive force that could deform the pipe.
Installing the Sealing Gasket:

Place the appropriate sealing gasket between the tapping saddle and the HDPE pipe to ensure there are no gaps after installation and maintain the seal.
Drilling:

Use dedicated drilling tools to drill through the HDPE pipe under the installed tapping saddle.
Ensure that the drilling tool is suitable for HDPE material to avoid damaging the pipe during drilling.
Connecting the Branch Pipe:

Connect the branch pipe to the outlet of the tapping saddle using appropriate fittings and sealing materials to ensure there are no leaks at the connection.
Welding or other reliable connection methods can be used to enhance the connection strength.
Testing and Adjusting:

After installation, perform a system pressure test to check for leaks at all connections.
If leaks or other issues are found, adjust or replace the relevant parts immediately.
Maintenance and Care
Regular Inspection:

Regularly inspect the tapping saddle and branch pipe connections, especially after experiencing temperature changes, to ensure there are no deformations, loosening, or leaks.
Increase inspection frequency when using in extreme temperature conditions.
Consideration for Thermal Expansion and Contraction:

Provide sufficient space and flexibility to accommodate thermal expansion and contraction of HDPE pipes to avoid pipe damage due to environmental temperature changes.
Fastener Maintenance:

Regularly inspect and properly secure bolts and clamps to ensure the connection is secure and sealed.
By following these guidelines, you can ensure the safety and reliability of using tapping saddles for branch connections on HDPE pipes. This method is not only suitable for water systems but also widely used in other pipeline systems that require flexibility and durability.

Tapping Saddle for Ductile Iron Pipe

Due to the high strength characteristics and the fact that ductile iron pipe is typically used for mid-to-low pressure systems, tapping saddles are typically made of ductile iron or steel when used on ductile iron pipe. This is done because ductile iron or steel tapping saddles are able to provide the high strength and durability that is required to handle the environment and pressure requirements of ductile iron pipe.

Choosing the Right Tapping Saddle
Material Selection:

Select a tapping saddle made of ductile iron or steel, as these materials are able to provide the necessary strength to withstand the pressures inside the pipe and ensure long-term reliability.
Design and Specifications:

Ensure the design and specifications of the tapping saddle are suitable for the diameter and wall thickness of the ductile iron pipe, providing a secure installation and connection.
Sealing Performance:

Select a tapping saddle with a high-quality sealing gasket, such as an EPDM or Nitrile rubber gasket, to ensure the connection remains sealed and does not leak under mid-to-low pressure conditions.
Corrosion Protection:

Since ductile iron pipe may be exposed to corrosive environments, the tapping saddle should have good corrosion resistance. Galvanized steel or coated steel tapping saddles are a good choice.
Installation Steps and Precautions
Surface Cleaning:

Clean the surface of the ductile iron pipe to ensure there is no rust, dirt, or other contaminants that could prevent the sealing gasket from making good contact with the pipe surface.
Proper Positioning and Fixation:

Place the tapping saddle accurately at the desired location for the tap and ensure it fits snugly against the pipe.
Secure the tapping saddle to the pipe using high-strength bolts or U-bolts. Due to the high strength of ductile iron pipe, the proper tools and torque should be used when securing the tapping saddle to the pipe.
Installing the Sealing Gasket:

Place a high-quality sealing gasket between the tapping saddle and the ductile iron pipe to ensure there are no gaps after installation and to prevent leaks.
Drilling:

Use a dedicated drilling tool to drill through the ductile iron pipe under the installed tapping saddle.
Ensure that the drilling tool is suitable for ductile iron material to avoid damaging the pipe during drilling.
Connecting the Branch Pipe:

After installation, perform a system pressure test to check for leaks at all connections.
If any issues are found, adjust or replace the relevant components immediately.
Maintenance and Care
Regular Inspection:

Regularly inspect the tapping saddle and branch pipe connections to ensure there are no loosening, corrosion, or leaks, especially after exposure to harsh conditions.
Increase inspection frequency when using in extreme temperature conditions.
Fastener Maintenance:

Regularly inspect and properly secure bolts and clamps to ensure the connection is secure and sealed.
Corrosion Protection:

If the ductile iron pipe and tapping saddle are exposed to a corrosive environment, appropriate corrosion protection should be applied, such as coating with a corrosion-resistant coating or using corrosion-resistant materials.
By following these guidelines, you can ensure the safety and reliability of using tapping saddles for branch connections on ductile iron pipe. This method is not only suitable for mid-to-low pressure water systems but also widely used in other industrial piping systems.