Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Summary of Contents for Petersen 128 Series
- Page 1 128 Series Line Stop Plug Instruction Manual 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: sales@petersenproducts.com...
-
Page 2: Table Of Contents
128 Series Line Stop Plug WARNING Read and understand before using Petersen Line Stop Plugs! Failure to comply may result in property damage, serious injury or death! These instructions must be available to all users. Train all personnel for proper use. -
Page 3: Important Safety Instructions
Use two accurately calibrated pressure gauges that agree to monitor the inflation pressure. Verify that the pipeline flow is stopped. Contact the project engineer or Petersen if needed. Safety is the highest priority. Petersen Products 128 Series Important Safety Instructions 1... -
Page 4: Pre-Installation Inspection
Petersen recommends inspecting the line stop plugs after every use. Covers can be damaged when inserting into a hot tap. Often line stop plugs can be refurbished and recertified by Petersen Products to like-new condition or set interval to match quality standards. - Page 5 If using a Retraction System, verify that all Retraction System components are complete. 10. Ram Removal Plate 13. Ram Section, 36 inches 11. Ram Section, 24 inches 14. Pull Block Assembly 12. Ram Coupling 15. Pulley Assembly Petersen Products 128 Series Pre-installation Inspection 3...
-
Page 6: Assembly Overview
Assembly Overview Pressure Monitor Hose Inflation Hose Launch Cylinder Tapping Valve Inflation Ram Pulley Directional Shoe Line Stop Plug Rachet Puller Rotating Elbow Packing Seal Petersen Products 128 Series Assembly Overview 4... -
Page 7: Hot Tap Insertion Tool Checklist
Overview The Petersen Hot Tap Insertion System can be used on almost any size pipeline or system. Use the tool list as a guideline. Each job may require tools above and beyond what is listed. -
Page 8: Calculating The Head Pressure
Once the drill is used the valve will be pressurized. Fix all leaks before using the drill. Open the Tapping Valve completely. Use the Hot Tapper Drill Adapter to the Tapping Valve. See the Hot Tap Drill manufacturer for detailed operation and maintenance information. Petersen Products 128 Series Calculating the Head Pressure 6... -
Page 9: Attaching The Rotating Elbow Assembly
The Rotating Elbow Assembly is available with Thread and Set Screw type connections for the Inflation Ram Adapter. Inspect the O-Rings for any possible physical damage. Petersen recommends ordering multiple O-Rings. Use the Allen Wrench to loosen the Set Screws on the Cone. - Page 10 Slide the Cone over the Line Stop Plug. Use the Allen Wrench to tighten the Set Screws. Remove and store the tag in a safe space. Screw Size Torque 30 in·lb 1/4″ 76 in·lb 3/8″ 276 in·lb Set Screw Rotating Elbow Cone Line Stop Plug Petersen Products 128 Series Attaching the Rotating Elbow Assembly 8...
-
Page 11: Assembling The Launch Cylinder
Bolt each Launch Cylinder section together. Use a star pattern for balanced torque. Complete the pattern three times 30%, 70%, 100% to the torqueing sequence. See Torque Figures on page 5. Gasket Launch Cylinder Launch Cylinder Valve Valve Bolt Petersen Products 128 Series Assembling the Launch Cylinder 9... -
Page 12: Measuring The Assembly
Add M2 to the radius M3 to determine M4. Note: M3 is the distance from the OD of the pipe to the centerline. Find M3 by dividing the OD by 2. Note: M2+M3=M4 Tapping Valve Measure M2 Measure M3 Pipe Petersen Products 128 Series Measuring the Assembly 10... - Page 13 Combine the length of the Launch Cylinders, the width of the Packing Seal, and the thickness of the Ram Removal Plate (if the Retraction System is used) to determine M6. Measure M6 Launch Cylinder Ram Removal Plate (optional) Packing Seal Measure M6 Measure M6 Petersen Products 128 Series Measuring the Assembly 11...
-
Page 14: Attaching The Main Stop Collar
Torque 1” & 1-1/2” 1/4” 3/16” 14 ft·lb 1-7/8” 5/16″ 1/4” 27 ft·lb 2-1/2” 3/8” 5/16” 47 ft·lb Measure M8 Inflation Ram Section Main Stop Collar Socket Head Cap Screw Petersen Products 128 Series Attaching the Main Stop Collar 12... -
Page 15: Assembling The Insertion System
If height clearance is sufficent, fully assemble the Inflation Ram. Attach the Packing Seal and Ram Assembly End to the Inflation Ram. Note: Apply O-Ring lubricant to the Packing Seal if needed. Ram End Assembly Packing Seal Main Stop Collar Petersen Products 128 Series Assembling the Insertion System 13... - Page 16 Note: M3 is the distance from the OD of the pipe to the centerline. Find M3 by dividing the OD by 2. Screw Size Torque 30 in·lb 1/4″ 76 in·lb 3/8″ 276 in·lb Main Stop Collar Measure M3 – M1 M3 – M1 Set Screw Gasket Centering Anchor Petersen Products 128 Series Assembling the Insertion System 14...
-
Page 17: Attaching The Insertion System
See image on Page 16 if needed. If using the Retraction System, attach the Ram Removal Plate to the Packing Seal. Hand-tighten the bolt to secure the Ram Removal Plate to the Packing Seal. Petersen Products 128 Series Attaching the Insertion System 15... - Page 18 Launch Cylinder. Use a hoist to lift the Launch Cylinder assembly on the flange of the Tapping Valve. Install a gasket in between the Tapping Valve and the Launch Cylinder. Petersen Products 128 Series Attaching the Insertion System 16...
- Page 19 Attach the ratchet puller. Loop the the chain over the Inflation Ram. Connect each end to the Eyebolts. Insert the Gauge on the quick connect port on the Packing Seal to monitor the head pressure. Inflation Ram Gauge Rachet Puller Quick Eyebolt Connect Port Petersen Products 128 Series Attaching the Insertion System 17...
-
Page 20: Inserting The Plug
If the Inflation Ram is already fully assembled lower the untill the Main Stop Collar reaches the Packing Seal. Use O-Ring lubricant if needed. Skip to Step 5. Note: Maintain correct plug orientation during insertion. Main Stop Collar Rachet Puller Packing Seal Petersen Products 128 Series Inserting the Plug 18... - Page 21 Mark on the Inflation Ram to confirm correct orientation. Lower the inflation Ram until the Main Stop Collar reaches the Packing Seal. Use O-Ring lubricant if needed. Anchor the plug in place with the Rachet Puller. Petersen Products 128 Series Inserting the Plug 19...
-
Page 22: Air Inflation Kit
Air Inflation Kit If using water inflation skip to the water inflation section, Page 22. Pressure Gauge Low Presure Alarm Inflation Hose Pressure Monitor Hose Pressure Monitor Inflation Controler Relief Valve Valve Assembly Petersen Products 128 Series Air Inflation Kit 20... -
Page 23: Assembling The Air Inflation Kit
Close the valve on the Inflation Controller before connecting air supply. Connect the Inflation Source Air line to the Inflation Controller. Inflation Ram Pressure Inflation Hose Monitor Hose Pressure Monitor Valve Relief Valve Low Pressure Alarm Gauge Inflation Controller Gauge Petersen Products 128 Series Assembling the Air Inflation Kit 21... - Page 24 If using a Low Pressure Alarm, set the alarm according to alarm set procedure. NOTE Petersen recommends to use two calibrated gauges to verify the Plug Inflation Pressure. Gauge Low Pressure Alarm Gauge NOTE Trip hazard. Keep the hoses coiled when not in use to prevent equipment damage.
-
Page 25: Deflating Air From The Line Stop Plugs
The 1.5” Port Pump is rated for 100 gpm max flow and 100 psi max air source. Water Pump Outlet Pump Air Source Air Source Plug Inflation with Air Water Pump Inlet Pump Bypass Flow Totalizer Petersen Products 128 Series Deflating Air from the Line Stop Plugs 23... -
Page 26: Operating The Water Flow Totalizer
Attach the Water Hose and Pressure Monitor Hose to the Inflation Ram Pulley Assembly. Inflation Ram Water Hose Pressure Monitor Hose Attach the other end of the Pressure Monitor Hose to the Low Pressure Alarm. Attach Pressure Monitor Valve Assembly to the Low Pressure Alarm. Petersen Products 128 Series Water Inflation Controller 24... - Page 27 Attach the Water Hose to the Water Pressure Monitor Assembly and to the Water Inflation Controller outlet. Attach the water supply line to the Water Source Connection of the Water Inflation Controller. Connect the air source line to the Pump Air Source Connection of the Water Inflation Controller. Petersen Products 128 Series Water Inflation Controller 25...
-
Page 28: Inflating The Line Stop Plug With Water
High pressure plugs can be topped off with air or nitrogen after they are filled with water. Turn on the Low Pressure Alarm. If the pressure drops below the alarm setpoint then the alarm will sound. Petersen Products 128 Series Water Inflation Controller 26... -
Page 29: Deflating Water From The Line Stop Plugs
Verify that the Water Pump Outlet hose drains into a tank or area that can collect the water pumped out of the line stop plug. Zero the batch counter to track the output. Petersen Products 128 Series Water Inflation Controller 27... - Page 30 Maximum vertical lift from the pipe invert is 18 ft. The Pump will only lift 18 ft on the inlet side. Pipeline pressure can assist with water deflation. If needed, Petersen can make line stop plugs that displace water with air for lifts over 18 ft.
-
Page 31: Removing The Line Stop Plug
After one section of the Inflation Ram is retracted, attach a Stop Collar at the lower Ram section to prevent the Ram from falling back down into the pipe. Remove the Inflation Ram one section at a time. Move the Pull Block down each time. Petersen Products 128 Series Removing the Line Stop Plug 29... - Page 32 Tapping Valve NOTE Use a Catch Pan or Drain Hoses when opening the Valves on the Launch Cylinders. Open the bottom Valve on the Launch Cylinder to release the pressure. Valve Petersen Products 128 Series Removing the Line Stop Plug 30...
-
Page 33: Cleaning And Storing
Verify that the line stop plug is empty of water and dry prior to storage in a dry location. Keep the instructions with the line stop plug. Do not use the product if there is significant wear or damage or return to Petersen for repair and recertification. Call Petersen with any questions. We’re here to help.