MUELLER CO. Shur Stop 68 PE Instruction Manual

Customer Service Center
Decatur, Illinois
800.798.3131
www.muellergas.com
[e-mail]
All warranties, expressed or implied, for Mueller Drilling Machines are
rendered null and void if the machines are used with shell cutters or
equipment manufactured by someone other than Mueller Co.
WARNING:
1. Read and follow instructions carefully. Proper training and periodic
review regarding the use of this equipment is essential to prevent possible
serious injury and/or property damage. The instructions contained
herein were developed for using this equipment on ttings of Mueller
manufacturer only, and may not be applicable for any other use.
2. Do not exceed the pressure ratings of any components or equipment.
Exceeding the rated pressure may result in serious injury and/or property
damage.
3. Safety goggles and other appropriate protective gear should be used.
Failure to do so could result in serious injury.
4. Pressure test, check for and repair leaks in all ttings and components
each time one is installed or any joint or connection is broken. Failure
to nd and repair a leak from any source in the ttings, by-pass lines
or equipment could result in an explosion and subsequent serious injury
and/or property damage.
5. MUELLER®Drilling Machines and Equipment have been carefully
designed and engineered to work together as a unit. The use of equipment
manufactured by someone other than Mueller Co. may cause excessive
wear or a malfunction of the MUELLER machines.
!
Reliable Connections
TM
Shur StopTM
Unit 68 PE
Line Stopping
System
6" – 8"
SDR 11 - 11.5 - 13.5
MUELLER®
GAS
opERAtinG inStRUctionS MAnUAL
TABLE OF CONTENTS PAGE
General Information 2
Equipment, Parts and Dimensions 3-5
Operating Instructions 6-12
Troubleshooting and Storage 13
Notes 14-15

MUELLER® Shur StopTM Unit 68 PE Line Stopping System
General Information and Equipment
2
The Shur Stop PE stopping system
allows NO BLO stopping operations
on 6" and 8" (SDR 11 - 11.5 - 13.5)
polyethylene pipes operated up
to a maximum operating pressure of
125 psig (Actual MAOP will be
dependent on the operating pressure
of the PE pipe).
This manual describes all operations
including drilling, stopping and
completion plug insertion.
Basic Equipment Required
1. Electrofusion Fitting
2. Centering Clamp
3. Slide Gate Valve
4. Stopping Machine
5. Cleaning / Inspection Machine
6. Combination Drilling / Completion
Machine
Slide Gate Valve
Stopping Machine
Stopping Bar
Electrofusion Fitting
Overview
5
6
3
1
4
2

2. Centering Clamp for
Electrofusion Fittings
The Centering Clamp is used to
properly align the Electrofusion
Fittings to the pipe during the
fusion process. It is designed to
evenly distribute the clamping
force applied by the operator.
MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Equipment, Parts and Dimensions
3
Swivel
Holder
H
LW
Centering Clamp
DIMENSIONS – Inches (mm)
LW H WT – lbs (Kg)
16.57 (421) 1.97 (50) 36.49 (927) 35.27 (16)
DIMENSIONS – Inches (mm)
PE PIPE ØØ1 A BWT – lbs (kg) Turns*
6" 10.24 (260) 7.64 (194) 5.90 (150) 4.33 (110) 57.3 (26) 5 ± 1/4
8" 13.00 (330) 9.76 (248) 7.59 (193) 5.62 (143) 100.0 (45) 41/4± 1/4
1. Electrofusion Fitting
Each tting is composed of:
• Electrofusion housing with metal
bushing.
• Completion Plug with two O-rings.
• Completion Cap with one O-ring.
NOTE: These ttings are
compatible with any universal
processor available on the market
equipped with a barcode pen /
scanner.
Electrical Parameters
• Input voltage 220 V (180 – 240 V)
• Frequency of power supply current
50 Hz
• Output voltage 8 V – 48 V
• Power 3.5 KW
eQUiPMeNT
O-rings
O-ring
Completion
Plug
Flange
Metal
Bushing
eleCtrofusion fitting
A
B
Ø1
Ø
Hex-Head Screw
Electrofusion Fitting
*Number of revolutions to install
completion plug

H
W
A
L
MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Equipment, Parts and Dimensions
45
4. Stopping Machine
The Stopping Machine is composed
of:
• A stopping machine with bypass
valve, bleed valve and available gas
source (equalizer);
• An expanding stopper consisting of
two anges.
On the upper part of the stopping
bar there is an operating square that
when turned (clockwise) the two
anges compress resulting in the
expansion of the sealing ring.
The result is full contact between the
sealing ring and the inner wall of the
pipe, ensuring complete gas control.
The affect is 100% stop off.
3. Slide Gate Valve
The Slide Gate Valve consists of a
sliding gate housed between two
at bodies; pressure is held rmly
by two O-rings, one above and one
underneath. The valve is tted with
an internal pressure equalizer which
allows easy opening when pressure
varies between the upper and lower
parts of the valve. To open and close
the valve, turn the operating square
approximately a quarter turn.
CAUTION: Never leave the
valve with the gate in the closed
position when not in use. In
the event that the gate is stuck,
loosen the screws holding the two
valve bodies, bring the gate to the
open position and retighten the
screws.
DIMENSIONS – Inches (mm)
PE PIPE L W H PASSAGE ØA WT – lbs (Kg)
6" – 8" 21.25 (540) 16.41 (417) 6.73 (171) 7.67 (195) 77.1 (35)
slide gate ValVe
stopping maChine
!
L
W
H
Long Handle
Bleed
Valve
Ball Valve
for By-pass
Stopper
Safety
Ring
Sealing Ring
Front Flange
DIMENSIONS – Inches (mm)
PE PIPE L W H WT – lbs (Kg)
6" 20.86 (530) 15.74 (400) 31.86 (812) 77.1 (35)
8" 22.91 (582) 16.25 (413) 41.92 (1065) 88.1 (40)
Upper Valve Body
Equalization Valve
Upper Flange
Gate
Lower Flange
Lower Valve Body
Operating Square
Operating Square
Short Handle

MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Equipment, Parts and Dimensions
5
6. Drilling / Completion Machine
The Drilling Machine allows tapping
operations through Shur-Stop 6" and
8" PE ttings. Specially designed
cutters recover virtually all shavings
and are equipped with pilot bit for
coupon retention.
5. Cleaning / Inspection Machine
This device is used to allow cleaning
of the pipe in which the stopper will
be working. It also allows inspection
of the ttings internal threads
and cleaning if necessary before
installing completion plug.
Cleaning / inspeCtion maChine
H
LW
Bleed
Valve
Brush
Rod
Viewer (inside)
drilling maChine
PE PIPE HOLE Ø
6" 4.88 (124)
8" 6.88 (175)
DIMENSIONS – Inches (mm)
L ØW H WT – lbs (Kg)
12.44 (316) 12.44 (316) 66.53 (1690) 143.3 (65)
SCOPE OF MACHINE
MACHINE M.O.P (psi) AMBIENT TEMP. (°F) PIPE MATERIAL
Standard 125 -4/+122 Polyethylene
DIMENSIONS – Inches (mm)
LW H WT – lbs (Kg)
12.51 (318) 12.44 (316) 31.85 (809) 11.4 (5.2)
Hydraulic Motor Hydraulic
Distributor
Motor Support
Guiding
Columns
Drilling Bell
H
L
ØW
Pilot Bit
Shell
Cutter

ASSEMBLY AND USE
1. Position the electrofusion tting
on the pipe. Remove the completion
plug O-rings and thread completion
plug into tting (A.).
2. Position the Centering Clamp over
the tting with the lower plate open
(B.) centering the pin on the central
hole of the completion plug (B1.) and
close the lower plate (B2.).
MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Operating Instructions
6 7
3. Align the pipe holder to the axis of
the pipe (C.).
4. At this point rotate the screw of the
centering clamp until the pipe holder
is in contact with the pipe (D. & D1).
CAUTION: The best
compression is the one where it
is impossible to insert a sheet of
paper between the fitting and the
pipe.
5. Perform the electrofusion
referring to the technical data
shown on page 3 and fitting
barcode.
6. Allow sufficient time for cooling.
7. Turn the screw of the centering
clamp counter-clockwise (e.).
8. Turn the lower plate and remove
the centering clamp (F. & F1.).
9. Unscrew the completion plug,
thoroughly clean the seat and insert
the sealing O-ring lubricating it with
PURITY-FG Spray or equivalent.
10. Install the appropriate
vent / purge fittings as required by
company practice (G. & G1).
11. Allow sufficient time for cooling.
12. Prepare the slide gate valve with
the lower ring of suitable diameter
and attach to the electrofusion fitting
(H.).
MACHiNe Use
B2.
D1.
e.
A.
Electrofusion
Fitting
Internal Plug
B1.
Pin Central
Hole
B.
Positioner Lower
Plate
C.
Pipe Holder
D.
Screw
!

Preparation of Drilling Machine
1. Remove the machine body from
the metal box.
2. Attach the pilot bit to the shell
cutter arbor (A. & A1.).
3. Attach shell cutter to arbor (B.).
4. Retract boring bar until shell cutter
is fully inside machine housing.
G1.
MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Operating Instructions
7
F.
F1.
G.
PE Pipe 6"– 8"
20"
Vent Fitting
H.
Combined Wrench
A.
Pilot Bit
A1.
B.
Shell
Cutter
Adjustment Flange
Eyebolt
Slide
Gate
Valve

8. Connect the hoses coming from
the hydraulic control unit to the quick
couplings of the hydraulic operator
ensuring the lever is in the neutral
position (F.).
9. Start the hydraulic control unit.
MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Operating Instructions
8
10. Turn the hydraulic distributor
lever clockwise (G.).
11. Turn the feed screw clockwise
to begin drilling.
12. When the shell cutter makes
contact with the pipe, turn off
hydraulic operator and stop drilling.
13. Loosen the knob on the
graduated scale.
14. Turn the graduated scale 90°
clockwise.
15. Then turn the knob on the
graduated scale until it is tight (H.)
16. Loosen the collar using the knob.
5. Lift and position the drilling
machine onto the slide gate valve in
the open position. Tighten the bolts
in a criss-cross pattern.
Then turn the feed tube clockwise
to lower the shell cutter until the pilot
bit comes in contact with the pipe
(C.).
CAUTION: After each opening
and closing of the valve, remove
the operating wrench to prevent
accidental movement.
6. Turn the feed tube a quarter
turn counter-clockwise to avoid
jamming when drilling begins.
7. Position the motor support, onto
the boring bar operting square.
Ensure guide coulumns are lined up
with housings (D.).
NOTE: There is an opening at the
very top of the shaft. This is to
allow the insertion of a pin, which
ensures that the motor support
bushing does not slide out (e.).
D.
F.
Hydraulic
Operator
Lever in Neutral Position:
Shaft Stopped
G.
Lever
turned 90°
clockwise:
shaft turns
clockwise
!
C.
Hose Coming
from Hydraulic
Control Unit
H.
Collar
Graduated
Scale
Knob
Hose Coming
from Hydraulic
Control Unit
e.
Anti-Slide
Pin
Graduated
Scale
Collar
Motor
Support
Bushing with
Control Dowel
Guiding
Columns

MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Operating Instructions
9
17. Move the collar down to bring
the lower part (indicated by the tip
of the arrow) in correspondence to
the line below the diameter of the
pipe on which the operation is being
carried out (i.).
18. Loosen the knob on the
graduated scale, turn the graduated
scale 90° counter-clockwise and
then tighten the knob (J.).
19. Turn on hydraulic power and
begin drilling until the pipe coupon
detaches. The location of the collar
indicates the farthest travel the
machine can be operated safely
without drilling too far.
20. Return the hydraulic operator
lever to the neutral position (K.)
21. Turn off the hydraulic power and
the hydraulic control unit.
22. Turn the feed screw counter-
clockwise until the shell cutter is
inside of the drilling bell.
23. Close the slide gate valve.
24. Attach relief piping (L.).
25. Purge the residual pressure
above the closed gate a suitable
distance from possible sources of
ignition.
26. Remove hoses from the
hydraulic control unit and operator.
27. Remove the drilling machine.
28. Carry out the cleaning operation
using the cleaning inspection
machine equiped with nylon wire
brush (M.).
i.
Collar
K.
Lever in
Nuetral
L.
Flexible Pipe
M.
29. Proceed with stopping operation.
30. Check the operation of the
expanding stopper. If the sealing
ring does not expand evenly on
the entire perimeter, it is necessary
to lubricate the walls surrounding
the ring with PURITY-FG Spray or
equivalent (walls are compressed
by two steel langes). Expand and
retract the sealing ring a few times
until the expansion is uniform. In the
event that the stopper is not used
for a long time, it is recommended to
completely disassemble the stopper,
replace the sealing ring and lubricate
thoroughly. After reassembling the
stopper, wipe the outer side of the
ring that comes into contact with the
inner side of the pipe.
31. Clean and lubricate the stopper
bar and the sealing disk to provide
smooth operation and to allow
centering of the stopper during the
expansion phase.
32. Position the stopping machine
(N.) on the slide gate valve.
NOTE: There are 2 handles on
the stopping machine. The longer
one should always be on the
upstream side.
J.
Graduated
Scale
N.
Long Handle Short Handle
Cleaning /
Inspection
Machine
with
Viewer
Brush
Bleed Valve
Knob

MUELLER® Shur StopTM Unit 68 PE Line Stopping System
Operating Instructions
10 11
33. Perform the same operations on
the second tting and install the by-
pass between the two machines.
Equalize the pressure (O.) of the rst
slide gate valve. For this operation
rotate the knob that controls
equalizing valve counter-clockwise
until it stops.
34. Open the slide gate valve.
35. Open the machine by-pass.
36. Open the machine by-pass
located on the second stopping
machine.
37. Purge the air in the by-pass
through the drain valve located on
the downstream stopping machine.
38. Open the second slide gate
valve without acting on the internal
pressure equalizer, as pressure is
already equal above and below the
gate.
39. Ensure the proper operation of
the by-pass and check for leaks.
Q.
No. 1
No. 2
O.

Pin
Equalization Valve
Counter
Clockwise
CAUTION: The plug should
never be inserted and expanded
on the upstream side.
41. Turn the ratchet handle
clockwise and gradually expand the
sealing ring of the stopper. During
this operation slide the rod from top
to bottom and vice versa to properly
position the stopper in the pipe (P.).
42. Expand the sealing ring to obtain
a positive shut-off. DO NOT over-
tighten.
CAUTION: The torque applied
to the ratchet spanner should not
exceed 48 ft-lb for the 6ʺ plug.
The torque applied to the ratchet
spanner should not exceed 52 ft-lb
for the 8ʺ plug.
43. If leakage occurs between the
stopper bar and the sealing disk
gradually tighten the Allen screws.
44. Repeat the same operations on
the second stopper machine.
45. Purge remaining gas through
No. 1 and No. 2 (Q.).
46. Tighten the safety ring.
40. Leaving the safety ring loose,
lower the stopper and position the
long handle between the pins on
the saftey ring. If this is difcult,
repeat previous step. If necessary,
add stopping bar weights to top of
stopping machine in order to assist
lower stopper into pipe. Take care to
ensure the plug is at a 90° position
with respect to the pipe axis. Once
the hole has been passed, place the
plug in the downstream direction.
P.
Long Handle Short
Handle
!
!