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MAINLINE Kleiss MCS60-38 Manual

Flow stopping system / 3” - 8” up to 60 psi
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Kleiss MCS60-38 System Manual
Flow Stopping System / 3" - 8" up to 60 psi
Flow Stopping System / 3" - 8" up to 60 psi

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Summary of Contents for MAINLINE Kleiss MCS60-38

  • Page 1 Kleiss MCS60-38 System Manual Flow Stopping System / 3” - 8” up to 60 psi Flow Stopping System / 3” - 8” up to 60 psi...

  • Page 2: Table Of Contents

    3. The balance of the tools have a design safety factor of 2.5. The Kleiss MCS60-38 System is designed to handle flow control on pipe sizes 3” to 8” on all pipe material – cast iron, polyethylene, steel and PVC pipes.

  • Page 3: General Safety Information

    Mainline Control Systems (MCS) before proceeding at 844-FLO-STOP. NOTE: The purpose of the Kleiss MCS60-38 System is to tap and stop flow in natural gas lines sizes 3” through 8” 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • 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 MCS60-38 offer options to make these processes efficient. Kleiss MCS60-38 System Manual v.15 May 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 MCS60-38 System Manual v.15 May 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 MCS60-38 System Manual v.15 May 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 MCS60-38 System Manual v.15 May 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 10: Equipment

    PE and PVC Cutter 9) 13100080 (1003 56.5 mm x 3/8") 19) 11005310 Hook Assembly Wrench (58-62) 10) 10800248 Air Motor (small 20 mm square) 99518863 Case (Peli 1700) 99310015 Foam Interior Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 11 Air Motor Drilling Rod Bayonet Lock Ratchet Feed Tube Tapping Device / Hot Tap Tool Drilling Dome Bleed Valve Drilling Dome Plugging Spindle Cutters Drilling Dome Pilot Drill Bleed Valve Completion Plug Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 12 Silicone Grease Aerosol stamped “S”) 99500003 Case (Explorer) Ring Adapter for PE Fittings 99500019 Foam Interior 10311031 / (2-1/2” x 2-1/2” x 1-1/4” / 10310955 stamped “P”) 9) 10311031 3” Ring Adapter Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 13 By-Pass / Vent Port Safety Bumper Stopping Tower Gear Box Gear Box Lock Assembly Gear Box Cranking Handle Full Port Ball Valve Chute Fitting Ring Adapters “P” “S” “3 in” MDS Stopper Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 14 Fitting / Completion Plug / Completion Cap: PART # DESCRIPTION 90401010 to Polyethylene Fitting 90401040 (size specific) Stainless Steel 90004001 to Saddle Fitting 90004028 (size specific) Steel Fitting 3) 11009050 (3” – 8”) Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 15 9) BPT-1 By-Pass Tee Assembly 10) AHA-1 Air Hose Adapter MDS Stopper Test Adapter 11) 12100731 (MCS60-38) Air Motor Oiler / Water 12) 49101380 Separator Unit (Complete) ACCESSORY COMBINATIONS: Side 1 Side 2 Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 16 14300060 14300060 Chute 99518681 (#1) 99518681 (#1) 23100353 23100354 MDS Stopper (2.75” - 3.54” / (3.54” - 4.72” / (Pipe ID Range) 70 mm - 90 mm) 90 mm - 120 mm) Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 17: 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 18 Then attach cutter adapter to cutter. Figure A: Steel and cast iron cutter [13200140] and pilot drill [14300060]. Figure B: PE and PVC cutter [13100080] and pilot drill [14300060]. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 19 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 20 Do this by either rotating the feed tube until it locks in place or pulling up on drilling rod. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 21 (cut) & 70-75 RPM’s free speed (non-cut). Make certain the oiler / separator is in place. NOTE: If issues with air motor occur, tapping can be completed by hand using the ratchet. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 22 (Be aware of the fact that the pressure inside the pipeline may automatically move the rod upwards. Avoid being above the rod with your hands or face.) WARNING: Always control the drilling rod. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 23 To remove the majority of the steel may take multiple insertions. Clean and store tapping tool in its case.  Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 24: 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 25  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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 26 NOTE: For 8” only, make certain the stopper tip is  rotated so the rounded curve of the stopper tip will slide along angled part of chute when deployed. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 27 “click” is heard after insertion.) Using the same Kleiss silicone spray you used  on the stopper, lightly spray the open end of the chute. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 28 Tighten the brass collar by means of the hooked  wrench and make sure the MDS Stopper stays in the right position. When doing this, make certain the valve doesn’t inadvertently turn. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 29 Using the crank handle, lower the gear box down until appropriate height indicator on rod is visible on top of the gear box. (This lowers the chute into the pipeline.) Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 30 Try NOT to rotate the stopper rod when inserting. Stop pushing the stopper rod downwards when the depth indicator mark is at the brass locking component. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 31 Inflate stopper as rapidly as possible to ensure the best seal on pipeline wall. NOTE: If 120 psi is not obtainable, then inflate to a minimum of 2 times system pressure to achieve stop off. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 32 / vent port 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 33: Retrieving Mds Stopper

    Pressure inside the pipeline will assist with the evacuation. Connect the hand pump to the stopper inflation  connection and pull a vacuum on the stopper to make it as compact as possible. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 34 If you are still having trouble with the stopper, try pulling another vacuum. Once the stopper is all the way retracted in the  tower, lock the stopper rod by operating the orange handle. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 35 Unlock 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. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 36 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 37: Plugging Operation

    You will hear a positive click. Fully retract the plug into the dome.  Install the dome onto the ball valve and tighten the  dome by hand. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 38  Place the ratchet handle on top of the plug spindle.  Push the plugging spindle fully downwards. Screw the plug into the fitting with the ratchet  until bottomed-out and tight. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 39 After the plug seal has been verified, pull the  plug spindle fully upwards (out of the completion plug). Remove the dome from the valve.  Remove the valve from the ring adapter.  Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 40 Screw the completion cap onto the fitting.  Disassemble the completion tool.  Clean and store the completion tool and valve in  their respective cases. Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 41: 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 42: 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 43 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 44: Appendix B: Tower Positioning And Distances

    A = minimum distance between towers | B = stopper length | L1 = minimum distance from stopper/tower to work area 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 MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 45 A = minimum distance between towers | B = stopper length | L1 = minimum distance from stopper/tower to work area L2 = distance from stopper/tower to work area ( measurement is a guide only, follow manufacturer’s fitting recommendations) Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 46 A = minimum distance between towers | B = stopper length | L1 = minimum distance from stopper/tower to work area L2 = distance from stopper/tower to work area ( measurement is a guide only, follow manufacturer’s fitting recommendations) Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 47 A = minimum distance between towers | B = stopper length | L1 = minimum distance from stopper/tower to work area L2 = distance from stopper/tower to work area ( measurement is a guide only, follow manufacturer’s fitting recommendations) Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

  • Page 48: Appendix C: Manual Updates

    2) Edited cast iron pipe sizing/equipment table (section 4.0) from nominal pipe size to OD range 3) Tapping operation a) Added step to rotate drilling rod clockwise to assist in retracting cutter 4) Stopper tower operation a) Added new step of greasing stopper rod Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 49 844-FLO-STOP www.MainlineControlSystems.com (V15 May 2020) Kleiss MCS60-38 System Manual v.15 May 2020 www.MainlineControlSystems.com...

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