How to Weld a Sensor Port?

What type of product is conveyed through the pipe?

Is the area where the welding is to take place classified as hazardous?

I have seen three scenarios:

If in non-hazardous area and no concern for metal shavings in product line, drill a hole just a hair smaller than the socket then bevel the hole outward (tapper) towards the top with a grinder, finally weld the socket in place.

If the area is hazardous, pay to have the socket "hot tapped" in line. You can Google "Hot Tap" for additional information.

If there are concerns about metal fragments being introduced into the product line during cutting/grinding, remove the section of pipe, install the socket, clean debris from the pipe section and re-install pipe section.

If the pipeline is a water main, the acceptable method pursuant to AWWA Standard is to "Wet Tap" the main (main must be under pressure) to insure that the metal shavings are effectively flushed out during the drilling process. Most sensors made for water main service usually feature threads and come with a specialized manufacturer's insertion tool which allows the sensor to be installed when the main is under pressure. This process assures that there is minimal contamination of the potable water inside the main. Be sure to heavily chlorinate (by total immersion or swabbing) the sensor port prior to insertion!

The easiest way to do this is not to weld at all (unless you just enjoy welding). I attach 1/2" pipes to 6" water mains all the time (sometimes hundreds a week). Use either a hole saw (hard) or a plasma cutter (easy) to cut your hole. Then buy a pipe saddle fitting with the size outlet you require. Done in 30 seconds.

Those saddles may be acceptable for aboveground sprinkler headers, branch lines, and other in-building water service lines, but they are not acceptable for buried water main duty and process lines in water treatment plants, nor are they AWWA approved for water main service of any type or configuration.

Hundreds a week? If you work a 40 hour week that is 2400 minutes - if you did 200 per week that would be 1 every 12 minutes?

Busy fellow!

I have 25 employees.

This PDF gives fairly detailed instructions for the installation of a Threadolet to accommodate a flow sensor in a large pipe. You may find it helpful.

http://www.veris-inc.com/literature/io_150.pdf

In refineries we called these socolet.

Ron

Thanks for all the input. By the way, when do we normally use sweepolet?

Yip