Petersen Pipe Plugs

Petersen® Warnings, Warranty, Terms and Conditions refer to http://www.petersenproducts.com.

PeteStopTM Inflatable Line Stop, Pipe Plugging System

129 Series

Instruction Manual

Petersen Pipe Plugs

www.PetersenProducts.com 421 Wheeler Avenue, PO Box 340, Fredonia, Wisconsin 53201-0340, USA

Phone: (262) 692-3100 or 1-800-926-1926 Fax: (262) 692-2418 or 1-800-669-1434

Email: [email protected]

http://www.petersenproducts.com/

_______________________________________________________________________________________________

421 Wheeler Ave Fredonia, WI 53201

Phone: +1-262-692-3100/ 800-926-1926

Petersen® Products Co. All rights reserved.

Page 2 of 57

Table of Contents

1.0 Important Safety Instructions ...................................................................................................................................... 4

1.1 Safety is Everyone’s Responsibility ............................................................................................................................... 4

1.2 Personal Safety ............................................................................................................................................................. 4

1.3 Piping Review and Assessment for ILS Selection ........................................................................................................ 5

1.4 Application Engineering – Operator Fill out this Section ........................................................................................... 6

2.0 Pre-Work Inspection .................................................................................................................................................... 7

2.1 Verify the Yellow Warning Tag attached is the correct plug and to the project in 1.4.2 Data List ................................ 7

2.2 Gather the necessary equipment and tools. ................................................................................................................ 10

3.0 Line Stop Tool List .................................................................................................................................................... 11

3.1 Overview ...................................................................................................................................................................... 11

3.2 Tool List ....................................................................................................................................................................... 11

3.3 Flanged Launch housing ............................................................................................................................................. 11

3.4 Torque Figures ............................................................................................................................................................ 12

4.0 Reference .................................................................................................................................................................. 13

4.1 Inflatable Plug Launched and Plug in Launch housing ............................................................................................... 13

5.0 Bundling the Pipe Plug .............................................................................................................................................. 14

5.1 Bundle the Plug before inserting into Launch Housing ............................................................................................... 14

6.0 Setup and Tapping the Pipe...................................................................................................................................... 17

6.1 Setup ........................................................................................................................................................................... 17

7.0 Installing the Ram ..................................................................................................................................................... 19

7.1 Ram Installation ........................................................................................................................................................... 19

8.0 Plug Insertion ............................................................................................................................................................ 32

8.1 Inserting the plug ......................................................................................................................................................... 32

9.0 Inflation of the Plug ................................................................................................................................................... 38

9.1 Determine if inflation by Water, Air, Nitrogen, Grout or other medium ........................................................................ 38

9.2 If the pipeline is more than half-full of liquid: ............................................................................................................... 38

9.3 If the pipeline is less than half-full of liquid: ................................................................................................................. 38

9.4 If pipeline is greater than 12” piping: ........................................................................................................................... 39

10.0 Plug Deflation for Inflated Plugs ................................................................................................................................ 40

10.1 Air or Gas................................................................................................................................................................... 40

10.2 Water ......................................................................................................................................................................... 42

10.3 Water with Air / Gas Pressurization ........................................................................................................................... 43

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11.0 Plug Removal ............................................................................................................................................................ 44

11.1 Removal of the plug ................................................................................................................................................... 44

12.0 Maintenance and Care .............................................................................................................................................. 48

12.1 Maintenance and care ............................................................................................................................................... 48

13.0 Troubleshooting ........................................................................................................................................................ 52

13.1 When inserting a plug into a vertical pipeline: ........................................................................................................... 52

13.2 For proper deployment: ............................................................................................................................................. 52

13.3 Pro Tips: .................................................................................................................................................................... 52

13.4 Safety Tips: ................................................................................................................................................................ 52

14.0 Acronyms/Definitions ................................................................................................................................................ 56

15.0 Revisions ................................................................................................................................................................... 56

16.0 History ....................................................................................................................................................................... 56

Measurement Card (https://ilsconfigurator.petersenproducts.com/Home/129) .................................................................... 57

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Page 4 of 57

1.0 Important Safety Instructions

WARNING Pressure forces are involved in many Inflatable Line Stop situations that may cause injury or even death. Focus and care is required to ensure the safe use of any Inflatable Line Stop, as pressure forces increase as pressure and pipe diameter increase.

1.1.1 All pipe plugs shall be restrained adequately in accordance with design of the PeteStop™ Inflatable Line Stop system.

1.1.2 Debris or protrusions into the pipeline may damage a seal or reduce the pressure rating.

1.1.3 Do not exceed the pressures on the plug label.

1.1.4 Petersen Products recommends inflatable devices shall not be used as the primary isolation or protection point for personnel downstream.

1.1.5 Due to project variability, these general instructions must be adapted by a competent professional for each specific project. Instructions and training must be provided to all PeteStopTM Inflatable Line Stop users and workers on the job.

CAUTION Keep all personnel out of the Danger Zone, e.g.

1.2.1 PPC recommends adequate Personal Protective Equipment (PPE) to be used per operator policy and procedure.

1.2.2 PPC recommends the operator determine if the area is considered a Confined Space and to refer to Occupational Safety and Health Administration (OSHA) (29CFR 1910.146), Safe Confined Space Entry. Follow all federal, local and site specific codes, standards and regulations.

1.1 Safety is Everyone’s Responsibility

1.2 Personal Safety

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CAUTION Polyethylene (HDPE) or new pipelines with remains of grease or agents directly decrease the efficiency and holding strength of the PeteStopTM Inflatable Line Stop.

1.3.1 Thoroughly inspect the PeteStopTM Inflatable Line Stop, before each use. Refer to Section 12.0.

1.3.2 PPC recommends to never inflate an inflatable plug, outside of a pipe, above 5% of rated inflated pressure.

1.3.3 Verify airline connections and hoses are not damaged or leaking.

1.3.4 Use two calibrated pressure gauges for measuring the pipeline operating pressure.

1.3.5 Prepare to equalize pressure on both sides of plug before installation and removal.

1.3.6 Use two calibrated pressure gauges for monitoring the inflation pressure.

1.3.7 Call Petersen with any questions or suggestions relating to the use of any Petersen product.

1.3 Piping Review and Assessment for ILS Selection

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Phone: +1-262-692-3100/ 800-926-1926


Page 6 of 57

SAFETY Ensure that all project information and data is accurate. If assumptions are made, please specify and whenever there is doubt contact Petersen Products engineering for application and product technical assistance. Understand your completeness of application data is paramount to project safety.

1.4.1 Overview

It is important to understand what your requirements are and how to deploy the ILS safely. There are many configurations to choose from based on your application. The piping configuration should also be reviewed to ensure pressure or flow differentials are not created or have means to mitigate (e.g. leak downstream of isolation point).

1.4.2 Data List

Pipe Size / Wall Thickness / Material / Internal Coating

Design Pressure / Temperature / Flow Rate

Operating Pressure / Temperature / Flow Rate

Product / Service/ Medium

Plug Inflation Medium

Piping Design Code

Duration of Line Stop

Purpose of Line Stop

ISO or Piping Drawing Provided

Obstructions at Isolation Location

Fitting Type / Requirements / Orientation/ Piggable

Flange Type / Rating

Fitting Location (Above / Below Ground)

Service Valve Bore

Service Fitting Bore

Expected Inflation Source

Expected Hot Tap Hole Size

1.4 Application Engineering – Operator Fill out this Section

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2.0 Pre-Work Inspection

SAFETY Survey the work area for unsafe conditions. Verify all people working with the plug have read and understand the IMPORTANT SAFETY INSTRUCTIONS listed at the beginning of this work instruction.

2.1 Verify the Yellow Warning Tag attached is the correct plug and to the project in 1.4.2 Data List

Back of yellow tag

Front of Tag

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Page 8 of 57

2.1.1 Compare the Order Conformation to the Packing List.

1. Line Stop Plug 7. Packaging Seal

2. Centering Anchor 8. Eyebolts

3. Inflation Ram Connector 9. Flange Bolts

4. Inflation Ram Sections 10. Stop Collars

5. Launch housing 11. Inflation Ram Pulley Assembly (aka Line Stop Housing)

6. Flange Gaskets 12. Extra rubber bands for bundling

13. Spare Parts Kit (varies on ram size)

13

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Page 9 of 57

2.1.2 Additional Accessories, depending on application

1. Retraction Assembly

2. Strong back

3. Coupon Support

4. Ram Adapter Assembly

5. Bundling Sleeve – used when rubber bands cannot be used

6. Inflation Accessories Kit (pictured is a nitrogen kit) – each kit is adjusted to inflation

6

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Page 10 of 57

2.2.1 Refer to the Hot Tap Insertion Tool Checklist.

1. Ratchet Puller 6. Tape Measure

2. Socket* 7. Wrench*

3. Torque Wrench* 8. Marker

4. Allen Wrench* 9. O-Ring Lubricant

5. Small Allen Wrench* 10. Optional Laser (or other acceptable measuring device)

*Size will depend on kit

2.2 Gather the necessary equipment and tools.

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Page 11 of 57

3.0 Line Stop Tool List

3.1.1 The Petersen Hot Tap Insertion System may be used on most any size pipeline or system and therefore may require a variety of tools to match. This list is intended to assist in determining which tools to prepare for a job but is not a replacement for the judgement of an experienced contractor. Different jobs may require specific tools above and beyond what is listed.

3.2.1 Ratchet Chain Puller For inserting and securing plug and for retraction with retraction kit.

3.2.2 Marker or Paint Stick For marking on steel, fabric, or painted surfaces.

3.2.3 Tape Measure or Laser To set insertion depth on Inflation Ram or Bundling Sleeve strap lengths.

3.2.4 O-Ring Lubricant Inflation Ram and Packing Seal O-Rings.

3.2.5 Allen Wrench 1/8" Set screws for 1 inch and 1-7/8-inch diameter Inflation Ram.

3.2.6 Allen Wrench 3/32" Set Screws for 1-1/2-inch Inflation Ram.

3.2.7 Allen Wrench 3/16" Set screws for 2-1/2-inch Inflation Ram, 1-inch stop collar, and centering guides.

3.2.8 Allen Wrench 1/4" Stop Collar for 1-7/8-inch diameter Inflation Ram.

3.2.9 Allen Wrench 5/16" Stop Collar for 2-1/2-inch Inflation Ram.

3.2.10 Pipe Wrench Attaching NPT Launch housing and Packing Seal.

3.2.11 Pipe Thread Sealant Attaching NPT Launch housing and Packing Seal.

3.2.12 Lubricant Attaching Hardware to flanges

3.3.1 Torque Wrench and Socket Match the values listed in the table below for the Launch housing.

3.3.2 Wrench For reaction force against Torque Wrench (match socket size).

Torque Figures

Class 150 Flanges Class 300 Flanges

Size Bolt Wrench Torque Bolt Wrench Torque

3 5/8" 15/16" 110 lbf * ft

4 5/8" 15/16" 110 lbf * ft

5 3/4" 1-1/8" 195 lbf * ft

6 3/4" 1-1/8" 195 lbf * ft 3/4" 1-1/8" 195 lbf * ft

8 3/4" 1-1/8" 195 lbf * ft 7/8" 1-5/16" 310 lbf * ft

10 7/8" 1-5/16" 310 lbf * ft 1" 1-1/2" 465 lbf * ft

12 7/8" 1-5/16" 310 lbf * ft 1-1/8" 1-11/16" 685 lbf * ft

14 1" 1-1/2" 465 lbf * ft. 1-1/8" 1-11/16" 685 lbf * ft

16 1" 1-1/2" 465 lbf * ft 1-1/4" 1-7/8" 960 lbf * ft

18 1-1/8" 1-11/16" 605 lbf * ft

20 1-1/8" 1-11/16" 605 lbf * ft

24 1-1/4" 1-7/8" 960 lbf * ft

30 1-1/4" 1-7/8" 960 lbf * ft

Per ASTM torque standard: Torque = Force * Length

3.1 Overview

3.2 Tool List

3.3 Flanged Launch housing

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Page 12 of 57

NOTE: Sequence the torque in a star pattern. Complete the pattern three times 30%, 70%, 100% to the sequence.

3.4.1 Torque Patterns

WARNING

Immediately before every use re-torque the attachment of the inflation ram to the plug. On this bolted joint, torque it to 3.4.1. It is essential to wait 15 minutes between each torque sequence to allow the bolts to stretch and settle with the fabric before applying next torque application.

3.4 Torque Figures

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Page 13 of 57

4.0 Reference

https://ilsconfigurator.petersenproducts.com/Home/129 PeteStopTM ILS system Configurator

Last page of this manual is a Measurement Card, use this as a guide (keep the measurement units consistent)

The D1-D6 measurements on the Measurement Card correlate with the measurements from the PeteStop™ ILS Configurator measurements on the Petersen website.

All dimensions are assumed field measured with a tape measure an accuracy of +/- 1/32” up to 12 ft. and over 12 ft. +/- 1/16”.

Do not use the product if there is significant wear or damage. Return to Petersen for evaluation.

PPC has all the equipment required for inflation, deflation, and pressure monitoring of all plugging systems.

Contact PPC with any questions or suggestions relating to the use of any Petersen product.

4.1 Inflatable Plug Launched and Plug in Launch housing

PeteStop™ Inflatable Line Stop Configurator

https://ilsconfigurator.petersenproducts.com/Home/129

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Phone: +1-262-692-3100/ 800-926-1926


Page 14 of 57

5.0 Bundling the Pipe Plug

5.1.1

Inflate and stretch out the plug. Max 5% of rated pressure when not supported in a pipe.

5.1.2 Roll each end inward.

5.1.3 Continue folding inward. Maintain even folds on each end.

5.1 Bundle the Plug before inserting into Launch Housing

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Page 15 of 57

5.1.4 Fold until the end discs touch to the inside.

5.1.5 Fold the cylinder to create a round bundle. Verify that the sealing rings are inside.

5.1.6

Add rubber bands. Tuck in the bottom and top corners to reduce the length of the bundle. Verify the bundled diameter will fit in the required hot tap hole.

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Page 16 of 57

5.1.7 Only use enough rubber bands so that the bundle is smaller than hot tap hole.

5.1.8 Bundling completed.

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Page 17 of 57

6.0 Setup and Tapping the Pipe

6.1.1

Install line stop fitting (aka sleeve or saddle) and tapping valve (aka service valve) on pipe, according to the manufacturer’s instructions. Use a fitting as required for each application taking into account jurisdictional service requirements.

NOTE: 129 series standard configuration is typically launched with line stop fitting perpendicular to the line.

Caution shall be taken when launch equipment is not in standard configuration,

Call engineering about nonstandard configurations and their customization

6.1 Setup

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Page 18 of 57

NOTE Record the measurements in the Measurement Card (see last page). Keep measurement units consistent.

This is a critical measurement and good practice is to measure from pipe to flange on both sides to make sure that the fitting and flange are square. The demo item is idealized and field scenarios may dictate multiple measurements are required. D1 may be an average of these measurements.

6.1.2

Measure the distance from the pipe ID to the top of the valve flange gasket. (Includes pipe wall thickness). This is D1. NOTE: Required to calculate D4.

NOTE: Write the measurement on the Measurement Card. Keep measurement units consistent.

6.1.3 Once the measurement is taken, commence Hot Tapping operation according to job specific requirements.

For more in-depth information on Hot Tapping, refer to the respective manual on our website under Product Selection/Instructions tab

http://www.petersenproducts.com


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Phone: +1-262-692-3100/ 800-926-1926


Page 19 of 57

7.0 Installing the Ram

NOTE If a ram adapter assembly is not needed, see Step 7.1.6.

7.1.1

If needed, clean the inflation port, flange gasket, and ram adapter assy.

Bolt Size Torque

1/2″ 80 lbf * ft.

5/8″ 159 lbf * ft.

3/4′′ 254 lbf * ft.

7/8″ 400 lbf * ft.

7.1.2 Inspect the torque on the flange nuts.

7.1.3

Place the ram adapter assembly end on the inflation port flange. Align the setscrew pockets on the ram adapter with the plug directional arrows machined into the outer flange.

7.1 Ram Installation

Flange Bolt

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Page 20 of 57

7.1.4

Tighten the ram adapter nuts to secure the ram adapter. Use a star pattern to apply balanced torque. Refer to the Table under Section 3.0 Torque Figures.

7.1.5 Apply O-ring grease to the connections.

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Page 21 of 57

7.1.6 Install one section of the inflation ram to the plug.

7.1.7

Align the plug orientation line with a setscrew. This will later align the plug inflation direction with the pipe direction. NOTE: ACME thread inflation rams are available options. Contact Petersen engineering for details.

Screw Size Torque

#10 30 lbf * in

1/4“ 76 lbf * in

3/8” 276 lbf * in

Install here

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Page 22 of 57

7.1.7.1

Setscrew rams have female ends and require a ram coupling with male ends to connect. Threaded rams have male and female ends and do not require couplings.

CAUTION DO NOT mark the orientation line on the Launch housing. Plugs may shift in the launch housing before deploying. Marking the ram will assure the plug orientation alignment with the pipe.

7.1.8

Use a marker to mark the inflation ram on the opposite end of the plug with the plug orientation line on the setscrew.

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Page 23 of 57

7.1.9

Measure The distance from underneath the flange where it meets the fabric, to far end of the FIRST Inflation Ram section (Ignore the coupling). The distance is D2. NOTE: Required to calculate D5.

NOTE: Write the measurement on the Measurement Card. Keep measurement units consistent.

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Page 24 of 57

7.1.10

Slide the center anchor over the inflation ram section. Secure the center anchor with a setscrew or stop collar, depending on the kit. The center anchor should be flush with the bottom of the plug flange.

7.1.11

Apply O-ring grease to this full length of the inflation ram. The entire length of the ram is a sealing surface through the packing seal. Avoid damage and scoring/marking/ rough handling of the inflation ram sections.

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Page 25 of 57

7.1.12

Slide the flange gasket and packing seal on the inflation ram. Insert plug into the launch housing.

7.1.13 If required, install the retraction post base.

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Page 26 of 57

7.1.14

Add a temporary stop collar on the ram to hold the packing seal in place. The retraction post aides the removal of the plug, after work is completed.

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Page 27 of 57

7.1.15

Insert the eyebolts. Position the eye bolts in line, not parallel. Verify that the eye bolts do not interfere with the valve on the packing seal.

7.1.16

Lightly lubricate the bolt and nut threads. Tighten the bolts to secure the packing seal to the launch housing flange. Use a star pattern for balanced torque. Refer to Table under Section 3.0 Torque Figures.

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Page 28 of 57

7.1.17

Measure the distance from the base of the launch housing to the top of the packing seal. (Or retraction post base, if used).

This is D3. NOTE: Required to calculate D4.

7.1.18

Set Stop Collar D4= Pipe ID to top of packing flange to top of stop collar to plug fabric (bottom of plug flange. NOTE: To set stop collar distance, for plug insertion.

D1 + D3 = D4

Single Ram Dimension

7.1.19

NOTE: Stop collar position, when installing the additional ram sections.

For Multiple Ram Sections

D4 – D2 = D5

Measure from the base of

the launch housing.

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Page 29 of 57

7.1.20

Install the remaining ram sections. Also, apply O-ring grease to these sections. Use the D5 length to measure from the first ram section. Mark on the inflation ram the exact measurement needed.

7.1.21

Attach the stop collar to the inflation ram at mark.

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Page 30 of 57

7.1.22

Mark the Set Screw on the last Inflation Ram section with an orientation line. Verify that the mark aligns with the mark on the first Inflation Ram section. Attach the Inflation Ram Pulley Assembly to the end of the Inflation Ram. Torque all setscrews. If possible, align the Inflation Valve and the Pressure Monitor Port with mark on the Inflation Ram for a better visual of proper plug alignment.

NOTE High forces may require a strongback to secure the plunge flange.

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Page 31 of 57

7.1.23

If possible, align the Inflation Valve and the Pressure Monitor Port with mark on the inflation ram for a better visual of proper plug alignment. Verify that the gasket is between launch housing and tapping valve, then bolt the launch housing to the tapping valve.

7.1.24

Bolt the launch housing to the tapping valve flange. Use a star pattern for balanced torque. Refer to Table under Section 3.0 Torque Figures.

Bolts

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Page 32 of 57

8.0 Plug Insertion

8.1.1

Measure the height from the top of the packing seal to the bottom of the pulley assembly. This is D6. NOTE 1: The Dimension is required to verify that the plug is fully retracted, when removing the deflated plug. NOTE 2: This measurement is easier to do as pictured, before lifting the launch housing up on the tapping valve.

8.1 Inserting the plug

Measure from the top of the packing flange

to the bottom of the pulley assy.

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Page 33 of 57

8.1.2 Engage the ratchet puller to the lower the plug into the pipeline.

CAUTION Keep all essential and non-essential personnel out of the line of fire as the inflation ram may rise until the centering guide contacts the packing seal.

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Page 34 of 57

8.1.3 Fully open the tapping valve.

8.1.4

Use a gauge selection range to calibrate and to check the pipeline pressure. Fix any possible leaks. Verify that the pipeline operating pressure is less than half the plug rated inflation pressure. Remove the temporary stop collar.

CAUTION Keep all personnel out of the line of fire as the Inflation Ram may fall with the stop collar removed. It is recommended to secure the inflation ram during this operation.

8.1.5

Verify while lowering the plug that the orientation mark on the ram stays in line with the pipeline.

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Page 35 of 57

8.1.6

Lower the ram until the stop collar on the inflation ram is touching the retraction post base or packing flange.

8.1.7

Anchor the plug in place with the ratchet puller or strong back (refer to 8.1.7.1).

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Page 36 of 57

8.1.7.1

If Required, anchor the inflation ram with a strongback. A - Attach the anchor lugs. B - Thread the rods into the anchor lugs with a nut and washer on each rod. Then continue to Step 8.1.8

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Page 37 of 57

8.1.8

Connect inflation accessories. Refer to 2.1.. Refer to the Inflation Manuals on the website. http://www.petersenproducts.com


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Page 38 of 57

9.0 Inflation of the Plug

For more in-depth information on Water Inflation and Air Inflation, refer to the respective manual on our website under Product Selection/Instructions tab


CAUTION Do Not inflate more than 20% over the pipeline pressure until the Inflation Ram is anchored into the correct position. The maximum rated pressure assumes the plug is fully inserted into a proper sized pipe.

CAUTION Filling with Water or Other liquid is often advisable with larger in diameter and higher-pressure plugs for safety.

9.1.1 Determine application of the plug, driven by client specification

9.1.2 What pressure is required to fill the plug and what source will this come from

9.1.3 Will water, or other fluid be used to fill the plug, and approved by client

9.1.4 If the plug were to burst, can the fluid come in contact with pipeline service?

9.1.5 HP plugs are, by standard, water filled and pressurized with air or nitrogen.

9.1.6 Medium determined by size of inflatable, pressure, temperature, service.

9.2.1 The plug can be inflated directly with water.

9.3.1 The plug must first be inflated with air to take shape.

9.3.2 Inflate to the lesser of 5 psi or 10% above the pipeline pressure.

9.3.3 High pressure plugs can be pressurized with air or nitrogen after they are filled with water

CAUTION For maximum safety, remove as much air as possible, by venting through the Inflation Ram.

9.1 Determine if inflation by Water, Air, Nitrogen, Grout or other medium

9.2 If the pipeline is more than half-full of liquid:

9.3 If the pipeline is less than half-full of liquid:


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Page 39 of 57

9.4.1 Recommend using water if condition allows.

9.4.2 Inflate with air to the lesser of 5 psi or 10% above pipeline pressure.

9.4.3 Inflate the plug with water. When the pressure in the plug climbs close to the maximum rated pressure or the flow rate drops too far release air pressure from inside the plug. Stop the pump and then close the Water Inflation Valve.

9.4.4 Open the valve at the Pressure Monitor Assembly to release any air.

9.4.5 Close the Pressure Monitor and continue inflating with water.

9.4.6 Once the Pressure Monitor Valve is releasing water, then all the air is out.

9.4.7 To monitor the inflation pressure with a water hose that is filled with water:

CAUTION Do Not exceed the maximum rated pressure.

NOTE: Add 0.433psi to the gauge readings for every foot that the gauge is above the invert of the pipe. If the gauge is below the invert of the pipe, remove 0.433psi from the gauge reading for every foot below the invert of the pipe.

For more in-depth information on Water Inflation and Air Inflation, refer to the respective manual on our website under Product Selection/Instructions tab


9.4 If pipeline is greater than 12” piping:


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Page 40 of 57

10.0 Plug Deflation for Inflated Plugs

For more in-depth information on Water Inflation/Deflation and Air Inflation/Deflation, refer to the respective manual on our website under Product Selection/Instructions tab


10.1.1

Equalize the pressure on both sides of the plug. Open the valve on the pressure monitor assembly.

10.1.2 Disconnect the air source.

10.1 Air or Gas


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Page 41 of 57

10.1.3

Use the vacuum generator to deflate the larger plugs. Not needed for gas in most cases.

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Page 42 of 57

CAUTION Never exceed the pressure rating of the plug when displacing water. Stop adding air when water no longer discharges from pump outlet. Continue deflating until all air is out of plug.

10.2.1 Close the valve on the plug water inflation hose.

10.2.2

Switch the water hoses to the other connection ports. The hose that was connected on the water source connection is now connected to the water pump outlet. The hose that was connected to the water pump outlet is now connected to the water source connection.

10.2.3 Verify that the water pump outlet hose drains into a tank or area that can collect the water pumped out of the plug.

10.2.4 Open the valves on the water inflation hose and begin deflating the plug.

10.2.5 Continue pumping until water completely stops.

10.2.6 Reverse pump utilization on water inflation

10.2 Water

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10.3.1 Disconnect the air source.

10.3.2 Equalize the head pressure on both sides of the plug.

10.3.3 Open the valve on the pressure monitor assembly.

10.3.4 Close the valve on the plug water inflation hose.

10.3.5

Switch the water hoses to the other connection ports. The hose that was connected on the water source connection is now connected to the water pump outlet. The hose that was connected to the water pump outlet is now connected to the water source connection.

10.3.6 Verify that the water pump outlet hose drains into a tank or area that can collect the water pumped out of the plug.

10.3.7 Open the valves on the water inflation hose and begin deflating the plug.

10.3.8 Continue pumping until water completely stops.

10.3.9 Reverse pump utilization on water inflation

NOTE Maximum vertical lift from the pipe invert is 18 ft. The pump will only lift 18 ft. Pipeline pressure can assist with water deflation. If needed, Petersen can make plugs that displace water with air for lifts over 18 ft.

NOTE As the water is displaced with air, the plug may float if submerged and the pump will evacuate the water and air. Remove the plug only after it is deflated completely.

10.3 Water with Air / Gas Pressurization

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11.0 Plug Removal

11.1.1

Open valve on inflation ram pulley assembly to allow air to vent when removing the plug from the pipe.

11.1.2 Remove the ratchet puller

11.1.3 Remove the strongback, if using a strongback.

11.1.4 If using a retraction system, attach the retract system components to the retraction post base.

NOTE The Retraction Post is rated for maximum 5 feet of Ram in a vertical position.

11.1.5 Replace inflation ram pulley assembly with a pull block to give more lift.

11.1 Removal of the plug

Valve

Ratchet Puller

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11.1.6

Attach the ratchet puller to the pull block and over the retraction post pulley.

11.1.7

Use the stop collar to hold the ram from falling back into the launch housing. Remove the inflation ram one section at a time. Move the pull block down to the next ram section each time.

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Page 46 of 57

11.1.8

Repeat until the plug is fully in the launch housing.

11.1.9

Once the plug is fully retracted, close the tapping valve.

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Page 47 of 57

11.1.10 Drain the launch housing.

11.1.11

Disassemble the assembly in the reverse order it was assembled.

Report or document any damage or deformation to equipment or inflatables, Email sales: [email protected]

mailto:[email protected]

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Phone: +1-262-692-3100/ 800-926-1926


Page 48 of 57

12.0 Maintenance and Care

12.1 Maintenance and care

12.1.1 Before and every use carefully inspect for abrasions, tears, movement of clamps, air leaks or any other signs of deterioration or defect. Large plugs maybe leak tested in smaller pipes

12.1.1.1 Cuts

12.1.1.2 Punctures and Abrasions

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Page 49 of 57

12.1.1.3 Bulges and Cracks

12.1.1.4

Loose or damaged fitting

Components and leaks

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Page 50 of 57

12.1.2

Clean with mild soap and water, disinfect if necessary*. Never clean with solvents or petroleum products!

*Contact PPC about questions or concerns about disinfectant and cleaner use.

12.1.3 The plug may be inflated for cleaning and inspection.

12.1.3.1

Do not exceed 5% of the plugs rated pressure when outside of a pipe. Contact PPC engineering for more information.

12.1.4

Do not allow the plug to remain in sunlight (UV) for long periods to prevent damage.

12.1.5

Verify that the plug is empty of water and dry prior to storage in a dry location.

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Page 51 of 57

12.1.6

Keep the instructions and the yellow Warning Tag with the plug.

NOTE Return to Petersen Products to Refurbish and for Recertification.

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Phone: +1-262-692-3100/ 800-926-1926


Page 52 of 57

13.0 Troubleshooting

13.1.1 The plug may sag down into an empty pipe or float up in a full pipe causing a poor seal.

13.2.1 Push the plug into the pipeline so that approximately half the plug is in the pipeline.

13.2.2 Inflate plug to approximately 5% above pipeline pressure.

13.2.3 As the plug starts to inflate, the inflation pressure should pull the plug into the pipeline as the plug expands.

13.2.4 Use the Ratchet Puller to push the plug until the stop collar stops the Inflation Ram at the insertion distance.

13.2.5 If the plug does not completely seal, repeat the process several times.

13.3.1 Rubber bands may slide or snap off. This is normal and the rubber bands do not affect the operation of the plug.

13.3.2 Rubber bands are standard. If stringent foreign material exclusion (FME) procedures are in place, the rubber bands may be replaced with insertion sleeves.

13.3.3 The deflated length of the plug is always longer than the pipe ID dimension. In most cases, there is some force required to press the plug into the pipe to the correct set-dimensions noted by the inflation ram stop collar.

13.3.4 The location of the stop collar is of critical importance. The top of the plug must seat at the pipe ID.

13.3.5 Caution shall be used when deflating the plug. Watch for water/air locks if excessive force is required to lift the plug.

13.3.6 Fluids may become trapped between plys and cause the plug to require more force to lift out of service.

13.3.7 Always check plug for damage after use and clean prior to storage/recertification.

13.3.8 The plug will provide a “workable” seal. The exact site conditions vary and pipe wasting, pipe tolerances, scaling, solids, etc. may be present in the line. Always consider mitigation techniques for a small amount of leak by such as using double block and bleed. When the highest quality seal is required sealing rings and other methods may be required to minimize leak by the plug.

13.3.9 Plugs work great in less than 0.5ft/s flow.

13.3.10 Plugs work best with friction in the pipeline, solids, metal shavings, imperfections in pipe, out of roundness, scaling, are typically not a problem.

13.3.11 The ratchet puller should be left engaged when the plug is in operation.

13.4.1 Always check alignment between fittings and launch equipment and use.

13.4.2 Always follow safe rigging practices.

13.4.3 Always follow site-specific safety requirements.

13.4.4 Always wear appropriate PPE.

13.4.5 Adhere to all local jurisdictional requirements.

13.1 When inserting a plug into a vertical pipeline:

13.2 For proper deployment:

13.3 Pro Tips:

13.4 Safety Tips:

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Page 53 of 57

PROBLEM POSSIBLE CAUSES ACTION

Received visibly damaged inflatable

Shipping Inspect per PPC guidance Contact PPC

Threaded or flanged connection issue

Shipping Contact PPC

Lift point issue Lift device location Obstruction of lift device Lift point rating

Seek Rigging Competency Contact PPC

Equipment stack up too long for work area

Cylinder spool length Cylinder ram length Bundled length of inflation

Request multi-piece assembly Request bundled length reduction Contact PPC

Inflatable not going into bore (valve, nozzle, hot tapped)

Anchor size issues

Diameter of bundled inflatable or anchor larger than the valve or hot tapped diameter

Contact PPC

Pressure test issues with equipment

Gasket bolted connections not adequately aligned or torqued Threaded connections not adequately engaged

Inspect bolted connections Inspect threaded connections Contact PPC

Equipment packing seal leaking

Scoring on inflation ram Packing fell out/missing Debris on Inflation Ram/packing Packing used too many times

Check ram for obvious scoring or damage. Repair or replace ram section. Replace missing or damaged packing Wipe clean and re-lubricate Replace packing and re-lubricate

Equipment vent valve issue

Debris in the valve seat Bolted or threaded connection issue Not rated for application

Flush out valve Inspect Replace with rated valve Contact PPC

Loose flange connection Time between installation Handling

Re-Torque, refer to 7.1.2

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Page 54 of 57


Inflatable not inflating or Inflatable not holding pressure

Inflation medium supply issue Loose Ram connections Inflatable integrity lost

Inspect all fittings and connections for leaks

Inspect for missing O-rings and tighten any loose connections

Inspect for damage or excessive wear and tear

Contact PPC

Plug not going to set position

Dimensional error Debris in the pipeline or hot tap Flow in pipeline greater Hot tapped diameter too big or too small

Double check using ref. Using manual or procedure Discuss with pipping owner Discuss with pipping owner for root causes and PPC Discuss with Contractor. Always specify proposed hot tap hole to PPC in the RFQ Contact PPC

Plug tears off ram

Damage from hot tapped edge High Flow Application Pressure not equalized

Contact PPC IMMEDIATELY

Sealing strips rip off

Damage from hot tapped edge High Flow Pipping inside surface condition

Contact PPC Plug sometimes may be used without rings or refurbished

Not a workable seal

Application requirements or project specifications Pipping inside condition – build up, debris, troughing Piping geometry or service inside pipping Folds creases of inflatable

Contact PPC IMMEDIATELY

Flow Stop Issue Application issue Contact PPC

DBB Issue Application issue Contact PPC

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Page 55 of 57


Not able to equalize pressure

Open ended pipe downstream of inflatables No equalization point upstream or downstream of inflatable Non looped system

Contact PPC

Retraction issue - (Inflatable depressurization), binding, Valve issue

Fluid in plug Fluid trapped between plies Inflation ram bent Water lock.

Remove as fluid as possible prior to lifting Verify other causes are not at work and use more force Evaluate safe ways to remove by force Bleed-off launch tube

Depressurization of inflatable equipment

Service valve leaking/ malfunctioning Vent valve malfunction

Contact owner of service valve Contact owner of vent valve or PPC

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Phone: +1-262-692-3100/ 800-926-1926


Page 56 of 57

14.0 Acronyms/Definitions Acronym Definition

% Percent/percentage

100%/perfect seal No leak past seal multi-plug, special circumstance such as DBB/ redundant plug situations

Aka Also known as

DBB Double block and bleed

ft. Feet

gpm Gallons per minute

HDPE Polyethylene

ID Inner diameter

ILS Inflatable Line Stop

in (“) inch

IOM Instruction Operation Manual

Launch housing aka Line Stop Cylinder

Lbf * ft. Foot pound

Lbf * in. Inch pound

Acronym Definition

LD Lost Distance

Line Stop Fitting aka Sleeve or Saddle

max Maximum

MD Measured Distance

OD Outer Diameter

Positive seal Enhanced seal to back pressure in ideal conditions, minimal leak past expected

PPC Petersen Product Company

psi pounds per square inch

RFQ Request for quote

Tapping Valve aka Service Valve

TTD Total Travel Distance

UV Ultraviolet

Workable seal Any seal Safely managed by contractor

x Times

15.0 Revisions

Date Revision Process Revised by Name/ Title Edited by Name/ Title Approved by Name/ Title

10/27/2021 A IOM K. Kissinger/ Engineer C. Knop / Technical Writer T. Muldoon/ President

11/15/2021 B IOM P. Lundman/Owner C. Knop / Technical Writer T. Muldoon/ President

16.0 History Date Revision History

10/27/2021 A New Release

11/15/2021 B Update Measurement card and their definitions

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Page 57 of 57

Measurement Card (https://ilsconfigurator.petersenproducts.com/Home/129)

Measurement (maintain

units)

D1 The distance from the pipe ID to the top of the valve flange gasket. (Includes pipe wall thickness)

Required to calculate D4.

D2 The distance from underneath the flange where it meets the fabric, to far end of the FIRST Inflation Ram section (Ignore the coupling).


D3 The distance from the base of the Launch housing. \to the top of the packing seal. (Or retraction post base, if used).


D4 Set Stop Collar

D4= Pipe ID to Top of Packing flange. Top of Stop Collar to Plug Fabric (Bottom of Plug Flange.

D1 + D3 = D4 (Single Ram Dimension)

(To Set Stop collar distance, for plug insertion)

D5 For Multiple Ram Sections

D4 – D2 = D5 (Stop collar position, when installing the additional Ram sections)

D6 The height from the top of the packing flange to the bottom of the pulley assembly. The dimension is required to verify that the plug is

fully retracted, when removing the deflated plug.

All dimensions are assumed field measured with a tape measure

(or laser) and an accuracy of +/- 1/4” up to 12 ft. and over 12 ft.

+/- 1/2”

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Petersen Pipe Plugs