Summary of Contents for MAINLINE Kleiss MCS120-24
- Page 1 Kleiss MCS120-24 System Manual Flow Stopping System / 2” - 4” up to 120 psi Flow Stopping System / 2” - 4” up to 120 psi...
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Page 2: Table Of Contents
1) fitting to access the pipe, 2) tapping / completion tool, 3) inflatable stopper, and 4) stopping tool. The Kleiss MCS120-24 System (all tools) has a maximum operating pressure of 120 psi. The inflatable stoppers have a design safety factor of 3. The balance of the tools have a design safety factor of 2. -
Page 3: General Safety Information
Mainline Control Systems (MCS) before proceeding at 844-FLO-STOP. NOTE: The purpose of the Kleiss MCS120-24 System is to tap and stop flow in natural gas lines sizes 2” through 4” operating at a maximum of 120 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 MCS120-24 System Manual v.1.1 March 2021 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 MCS120-24 offer options to make these processes efficient. Kleiss MCS120-24 System Manual v.1.1 March 2021 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 MCS120-24 System Manual v.1.1 March 2021 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 MCS120-24 System Manual v.1.1 March 2021 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 MCS120-24 System Manual v.1.1 March 2021 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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 10: Equipment
Tapping Device / Hot Tap Tool 14) 10310800 Drilling Rod (650 mm (LB-493HD) 6) 10310905 25 mm x 20 mm square) Case 7) 10311057 Drilling Dome Foam Interior Pilot Drill 8) 14300060 (6.3 mm with retainer spring) Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... - Page 11 Ratchet Bayonet Lock Feed Tube Tapping Device / Hot Tap Tool Drilling Dome Bleed Valve Drilling Dome Plugging Ratchet Plugging Spindle Cutter Pilot Drill Plugging Dome Bleed Valve Plugging Dome Completion Plug Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 12 Full Bore Ball Valve (2-1/2”) 4) 12100360 (-15 to 210 psi) Flow Stop Tool 10) 12100200 Ring Adapter for Steel (Tower and Dome) 5) 10311030 (2-1/2” x 2-1/2” x 1-3/4”) Case Foam Interior Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 13 Stopping Tool Components: System / Pipeline Pressure Gauge Internal / Stopper Inflation Pressure Gauge Stopper Rod Stopping Tower By-Pass / Vent Port Chute MDS Stopper Full Port Ball Valve Fitting Ring Adapters Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 14 MDS Stopper Size 4” Fitting / Completion Plug / Completion Cap: Fitting / Completion Plug / Completion Cap: PART # DESCRIPTION 1) 99518590 2” Steel Fitting 2) 99518580 3” – 4” Steel Fitting Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 15 9) BPT-1 By-Pass Tee Assembly 10) AHA-1 Air Hose Adapter 11) 12100221 MDS Stopper Test Adapter Air Motor Oiler / Water 12) 49101380 Separator Unit (Complete) ACCESSORY COMBINATIONS: Side 1 Side 2 Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 16: Preparatory Steps
Install the ball valve onto the adapter ring of the fitting and tighten the valve by hand to compress the o-ring. Operate the valve to ensure smooth operation. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... - Page 17 Tighten the connection by means of the hooked wrench. Attach pilot drill to cutter adapter. Secure pilot drill with allen wrench. Then attach cutter adapter to cutter. Steel cutter [13200130] and pilot drill [14300060] Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 18 Retract the drilling rod and cutter completely into the drilling dome. No part of the cutter should be visible. When retracted into the drilling dome, the cutter should be in the position as shown in the picture. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 19 Locate the maximum drilling depth by measuring 1-7/8” down from the bottom of the feed tube. Place a mark on the brass tapping tube. (In picture, 1-7/8” 3/4” tape was used.) Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 20 NOTE: You will feel less resistance twice - once in the beginning when the pilot drill has perforated the pipe wall and secondly when the cutter is completely through. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 21 Avoid being above the rod with your hands or face.) WARNING: Always control the drilling rod. Close the ball valve. Release pressure from the dome by opening bleed valve. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 22 Clean and store tapping tool in its case. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 23: 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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... - Page 24 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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 25 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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 26 Push brass cap to the bottom of the rod. Insert stopper rod with stopper attached into the top of the stopping tower. Tighten brass cap. Verify ball valve is closed. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 27 Lock the tower at this position using black locking handle. (The chute is now in the correct position inside the pipeline and you can commence inserting the stopper into the pipeline.) Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 28 Prior to stopper inflation, verify system / pipeline pressure is displaying on proper gauge. system / pipeline pressure The MDS Stopper inflation pressure gauge will be indicating a negative pressure. internal / inflation pressure Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 29 (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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 30: Retrieving Mds Stopper
Unlock the stopper rod using black knob. Pull the stopper rod completely upwards. You may need to use some force to do this. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... - Page 31 Loosen the brass collar between the stopping tool and the ball valve by means of the hooked wrench. When doing this, make certain the valve doesn’t inadvertently turn. Remove the stopping tool from the ball valve. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 32 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 case. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 33: Plugging Operation
Install the dome onto the ball valve and tighten the dome by hand. Make certain the plugging spindle is at the top of the dome. Keep control of the spindle. Verify drilling dome bleed valve is closed. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... - Page 34 After the plug seal has been verified, pull the plugging spindle fully upwards (out of the completion plug). Remove the dome from the valve. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 35 Screw the completion cap onto the fitting. Disassemble the completion tool. Clean and store the completion tool and valve in their respective cases. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 36: 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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... -
Page 37: 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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... - Page 38 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 MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 39: 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 NOTE: Always inflate stopper #2 first, if possible. Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com... - Page 40 A = minimum distance between towers B = stopper length L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks reaching the inflatable stopper Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 41 A = minimum distance between towers B = stopper length L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks reaching the inflatable stopper Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
- Page 42 A = minimum distance between towers B = stopper length L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks reaching the inflatable stopper Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...
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Page 43: Appendix C: Manual Updates
844-FLO-STOP www.MainlineControlSystems.com Kleiss MCS120-24 System Manual v.1.1 March 2021 www.MainlineControlSystems.com...