Related Manuals for MAINLINE Kleiss MCS60-1016
Summary of Contents for MAINLINE Kleiss MCS60-1016
- Page 1 Kleiss MCS60-1016 System Manual Flow Stopping System / 10” - 16” (18” PE) up to 60 psi Flow Stopping System / 10” - 16” (18” PE) up to 60 psi...
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Page 2: Table Of Contents
3. The balance of the tools have a design safety factor of 2.5. The Kleiss MCS60-1016 System is designed to handle flow control on pipe sizes 10” to 16” (18” PE) on all pipe material – cast iron, polyethylene, steel and PVC pipes. To accommodate the various pipe materials and sizes the tapping tool and stopping tool are outfitted with the appropriate fitting, cutter, chute, and stopper. -
Page 3: General Safety Information
Mainline Control Systems (MCS) before proceeding at 844-FLO-STOP. NOTE: The purpose of the Kleiss MCS60-1016 System is to tap and stop flow in natural gas lines sizes 10” through 16” (18” PE) operating at a maximum of 60 psi. Review and follow your company safety procedures for operations involving tapping and stopping live natural gas lines. - Page 4 E) Ground rod included F) Weight (less hose) = 27 lbs. G) Air supply and flow capacity rates = Air Supply Flow Capacity Working Pressure Air Consumption Blow Out Volume (PSI) /min) /hr) 24300 21200 Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 5: Typical Site Set Up And Sequence
Remember to consider the ancillary steps like purging / venting the area to be worked on and back pressuring stoppers for removal. The features of the MCS60-1016 offer options to make these processes efficient. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 6 8) Keep by-pass / vent ports on towers #2 and #3 open to atmosphere during work to keep gas away from the work area. Follow company procedures for venting and purging gas. 9) This set up can easily be used on both single feed and dual feed systems. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 7 4) Use system pressure gauge on tower #1, #2, #3, or #4 to determine if stoppers are equalized. 5) When pressure is equalized, deflate stoppers #1 and #4. Retract all stoppers. 6) Remove tools and install completion plugs. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 8 These connections can also be used to inject nitrogen into the work zone. 8) Keep all by-pass / vent ports on towers open to atmosphere during work to keep gas away from the work area. Follow company procedures for venting and purging gas. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 9 6) Use system pressure gauge on tower #1 or #2 to determine stoppers are equalized. 7) Deflate and remove stoppers. 8) Remove tools and install completion plugs. NOTE: For additional set up illustrations, see Appendix B. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 10: Equipment
Plugging (2” male connection) 10) 13200727 PE and PVC Pilot Drill 21) 99513365 Feeding Rod with Bridge 11) 11000120 Ratchet (square, 20 mm) 99500003 Case (Explorer) 99300250 Wooden Interior 99300251 Foam Interior Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 11 Bayonet Lock Feed Tube Tapping Device / Hot Tap Tool Dome Adapter Ring Blow Down Valve Plug Spindle Cutters Handle Pilot Drill Plug Spindle Assembly Drilling Dome Completion Plug Adapter Completion Plug Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 12 Valve Wrench (square, 19 mm) 16) 99401705 Pressure Equalizing Hose 17) 10200190 Jacking Handle 18) 12100740 Safety Fitting (silver) 19) 99000705 Safety Fitting (gold / claw) 20) 99000740 Air Motor Adapter (claw) 12242100 Case with Interior Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 13 System / Pipeline Pressure Gauge Internal / Stopper Inflation Pressure Gauge Safety Fitting Jack Assist Stopper Rod Gear Box Air Ratchet Gear Box Assembly Stopping Tower By-Pass / Vent Port Slide Gate Valve Chute MDS Stopper Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 14 Fitting / Completion Plug / Blind Flange / Stud Bolts: PART # DESCRIPTION 90403010 to Polyethylene Fitting 90403050 (size specific) Stainless Steel 90502160 to Saddle Fitting 90502220 (size specific) Steel Fitting 3) 12100051 (10” – 16”) Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 15 Steel and Cast Iron Pilot Drill 16) 13200726 (1/2”) Steel and Concrete Pilot Drill 17) 14300053 (requires adapter 10310785) 18) 10310785 Pilot Drill Adapter (3/4” to M12) ACCESSORY COMBINATIONS: Side 1 Side 2 Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 16 (9.84” - 12.40” / (12.40” - 15.74” / (12.40” - 15.74” / (Pipe ID Range) 225 mm - 275 mm) 250 mm - 315 mm) 315 mm - 400 mm) 315 mm - 400 mm) Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 17: Preparatory Steps
Use valve wrench to check if slide gate valve opens and closes. Take the tapping device out of the case and inspect the device visually for irregularities. Make sure the threads are clean and the device operates freely. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 18 Thread the tapping device on to the dome adapter ring by means of the hook assembly wrench. Install the drilling rod through the middle of the tapping device and drilling dome. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 19 Retract the cutter completely into the drilling dome. No part of the cutter should be visible. When retracting into the drilling dome, the cutter should be in the position as shown in the picture. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 20 Attach complete tapping tool, with gasket in place, to top of slide gate valve using nuts and washers. Check gasket. Position feed tube so it is flush with the bottom thread. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 21 Do Locked this by either rotating the feed tube until it locks in place or pulling up on drilling rod. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 22 NOTE: If issues with air motor occur, tapping can be completed by hand using the ratchet. Attach feeding rod with bridge to bridge stands. Lower feeding rod with bridge down to air motor. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 23 3 threads exposed. (NEVER turn the drilling rod counterclockwise. This can damage the cutter.) Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 24 Close slide gate valve. Disconnect valve equalization hose at the lower connection. This releases the pressure above the slide gate valve. Release pressure from the dome by opening blow down valve. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 25 Disconnect equalization hose to blow down tapping dome before removal. Clean and store tapping tool in its case. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 26: Stopping Operation
NEVER pre-bend the MDS Stopper on the frame!!! This can damage the frame and it will not help as the internal frame is rigid. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 27 Verify negative pressure is maintained for 5 minutes to ensure seal and integrity of MDS Stopper and complete stopper rod. This is what a well evacuated MDS Stopper looks like! Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 28 Spray the front of the stopper around the nose. Do NOT spray the body of the stopper. NOTE: If excess spray gets on the body of the stopper, clean off stopper with wet rag using only water. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 29 With some force, pull black cap off from tower until stopper rod is completely exposed. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 30 Using the gear box air ratchet, drive the threaded rods down through the gear box. This allows the chute attachment component to be visible at bottom of flow stopping tower. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 31 Using the gear box air ratchet, drive the threaded rods up through the gear box to completely retract the chute into the tower. Grease stopper rod with Kleiss silicone grease. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 32 Use leak soap if necessary. Correct any blow-by or leaks before continuing stopping operation. Make sure equalization hose is connected to the slide gate valve to equalize pressure above and below the slide gate valve. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 33 3 threads are showing above the gear box. This positions the chute into the main. Unlock the stopper rod by loosening the black thumb screws. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 34 Lock the stopper rod by tightening the black thumb screws. Recommended: If needed or applicable, attach By- Pass Gauge Tree [BPGT-1] to by-pass / vent port. NOTE: Additional options are available in the 4.0 Accessories section. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 35 (Do this in accordance with your gas company procedures.) Verify inflation pressure and system pressure remains stable. You may now start your work on the pipeline. NOTE: Continue to monitor gauges on stopping towers. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 36: Retrieving Mds Stopper
Pressure inside the pipeline will assist with the evacuation. Connect the hand pump to the hand pump adapter and pull a vacuum on the stopper to make it as compact as possible. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 37 Pull the stopper rod completely upwards. You may need to use some force to do this. Hint: If you feel some resistance, use the jack assist until the pressure has lessened, then continue to pull up by hand. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 38 Lock the stopper rod by tightening the black thumb screws. Using the gear box air ratchet, drive the threaded rods up through the gear box to completely retract the chute into the tower. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 39 Open the by-pass / vent port in order to evacuate the stopping tool. Disconnect flow stopping tool from the slide gate valve. Remove by-pass / vent port. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 40 Slide the jack assist to the highest most position on the stopper rod. Disconnect the MDS Stopper from the stopping tool. (Push stopper rod to lowest position to expose the stopper connection.) Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 41 Do not leave it on the ground. Inspect the stopper for damages. Clean the stopper with a cloth. Place a protection cap over the thread. Remove gauges. Clean and store stopping tool in its cases. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 42: Plugging Operation
Pull plug up in to drilling dome. With gasket in place, attach drilling dome using nuts and washers. Check gasket. Attach handle. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 43 Marks For threaded plug: Push down plug spindle assembly through valve and onto fitting. Turn clockwise to thread plug onto fitting. Continue until it bottoms out. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 44 After the plug seal has been verified, unbolt the drilling dome and remove the dome up and over the completion tool. Unbolt the slide gate valve and remove the valve up and over the completion tool. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 45 Attach the blind flange, with gasket in place, to fitting using stud bolts. Check gasket. Disassemble the plugging tool. Clean and store the completion tool and valve in their respective cases. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 46: General Maintenance
(well-maintained equipment extends the life) NOTE: MCS recommends that the complete set of tools be inspected, serviced, and tested by an authorized MCS service center on a two year rotation or sooner. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... -
Page 47: Appendix A: Stopper Testing And Verification
Discard stopper if weak spots are found. Continue with inspection if everything looks OK. Bad Examples: Discard stoppers shown below since individual threads are exposed, starting to fray, and loose from coating. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 48 After the stopper stabilizes, wait a minimum of 10 minutes to make certain the same pressure is maintained within the MDS Stopper. NOTE: Do not inflate the stopper outside of a pipe as it can damage the stopper. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 49: Appendix B: Tower Positioning And Distances
L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks reaching the inflatable stopper L2** = distance from stopper/tower to work area - measurement is a guide only, follow manufacturer’s fitting recommendations NOTE: Always inflate stopper #2 first, if possible. Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 50 L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks reaching the inflatable stopper L2** = distance from stopper/tower to work area - measurement is a guide only, follow manufacturer’s fitting recommendations Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 51 L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks reaching the inflatable stopper L2** = distance from stopper/tower to work area - measurement is a guide only, follow manufacturer’s fitting recommendations Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
- Page 52 L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks reaching the inflatable stopper L2** = distance from stopper/tower to work area - measurement is a guide only, follow manufacturer’s fitting recommendations Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...
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Page 53: Appendix C: Manual Updates
Added steps for connection and disconnection of equalization hose on slide gate valve 7) Stopping tower operation a) Added new step of greasing stopper rod b) Added steps for connection and disconnection of equalization hose on slide gate valve 8) Added air motor guidelines Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com... - Page 54 844-FLO-STOP www.MainlineControlSystems.com Kleiss MCS60-1016 System Manual v.15 June 2020 www.MainlineControlSystems.com...