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Petersen PeteStop 129 Series Instruction Manual

Inflatable line stop, pipe plugging system
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TM
PeteStop
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: sales@petersenproducts.com
®
Petersen
Warnings, Warranty, Terms and Conditions refer to http://www.petersenproducts.com.

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  • Page 1 PeteStop 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: sales@petersenproducts.com ® Petersen Warnings, Warranty, Terms and Conditions refer to http://www.petersenproducts.com.

  • Page 2: Table Of Contents

    Plug Deflation for Inflated Plugs ..........................40 10.1 Air or Gas................................... 40 10.2 Water ..................................42 10.3 Water with Air / Gas Pressurization ........................... 43 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 2 of 57 ® Petersen Products Co. All rights reserved.
  • Page 3 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) ..............57 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 3 of 57 ® Petersen Products Co. All rights reserved.

  • Page 4: Important Safety Instructions

    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.

  • Page 5: Piping Review And Assessment For Ils Selection

    1.3.6 Use two calibrated pressure gauges that agree for monitoring the inflation pressure. 1.3.7 Call Petersen with any questions or suggestions relating to the use of any Petersen product. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 5 of 57 ®...

  • Page 6: Application Engineering - Operator Fill Out This Section

    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.

  • Page 7: Pre-Work Inspection

    2.1 Verify the Yellow Warning Tag attached is the correct plug and to the project data list in 1.4.2 Front of Tag Back of yellow tag 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 7 of 57 ® Petersen Products Co. All rights reserved.
  • Page 8 (aka Line Stop Housing) 6. Flange Gaskets 12. Extra rubber bands for bundling 13. Spare Parts Kit (varies on ram size) 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 8 of 57 ® Petersen Products Co. All rights reserved.
  • Page 9 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 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 9 of 57 ® Petersen Products Co. All rights reserved.

  • Page 10: Gather The Necessary Equipment And Tools

    9. O-Ring Lubricant 5. Small Allen Wrench* 10. Optional Laser (or other acceptable measuring device) *Size will depend on kit 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 10 of 57 ® Petersen Products Co. All rights reserved.

  • Page 11: Line Stop Tool List

    3.1 Overview 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.

  • Page 12: Torque Figures

    421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 12 of 57 ® Petersen Products Co. All rights reserved.

  • Page 13: Reference

    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.

  • Page 14: Bundling The Pipe Plug

    Max 5% of rated pressure when not supported in a pipe. 5.1.2 Roll each end inward. Continue folding inward. 5.1.3 Maintain even folds on each end. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 14 of 57 ® Petersen Products Co. All rights reserved.
  • Page 15 Tuck in the bottom and top corners to reduce the 5.1.6 length of the bundle. Verify the bundled diameter will fit in the required hot tap hole. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 15 of 57 ® Petersen Products Co. All rights reserved.
  • Page 16 _______________________________________________________________________________________________ Only use enough rubber bands so that the bundle is 5.1.7 smaller than hot tap hole. 5.1.8 Bundling completed. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 16 of 57 ® Petersen Products Co. All rights reserved.

  • Page 17: Setup And Tapping The Pipe

    Caution shall be taken when launch equipment is not in standard configuration, Call engineering about nonstandard configurations and their customization 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 17 of 57 ® Petersen Products Co. All rights reserved.
  • Page 18 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 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 18 of 57 ® Petersen Products Co. All rights reserved.

  • Page 19: Installing The Ram

    Align the setscrew 7.1.3 pockets on the ram adapter with the plug directional arrows machined into the outer flange. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 19 of 57 ® Petersen Products Co. All rights reserved.
  • Page 20 Refer to the Table under Section 3.0 Torque Figures. Apply O-ring 7.1.5 grease to the connections. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 20 of 57 ® Petersen Products Co. All rights reserved.
  • Page 21 7.1.7 NOTE: ACME thread inflation rams are available options. Screw Size Torque 30 lbf * in Contact Petersen 1/4“ 76 lbf * in engineering for 3/8” 276 lbf * in details. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 21 of 57 ®...
  • Page 22 7.1.8 the plug with the plug orientation line on the setscrew. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 22 of 57 ® Petersen Products Co. All rights reserved.
  • Page 23 (before the coupling, if added). The distance is NOTE: Write the measurement on the Measurement Card. Keep measurement units consistent. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 23 of 57 ® Petersen Products Co. All rights reserved.
  • Page 24 7.1.11 through the packing seal. Avoid damage and scoring/marking/ rough handling of the inflation ram sections. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 24 of 57 ® Petersen Products Co. All rights reserved.
  • Page 25 7.1.12 the inflation ram. Insert plug into the launch cylinder. If required, install 7.1.13 the retraction post base. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 25 of 57 ® Petersen Products Co. All rights reserved.
  • Page 26 7.1.14 The retraction post aides the removal of the plug, after work is completed. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 26 of 57 ® Petersen Products Co. All rights reserved.
  • Page 27 7.1.16 Use a star pattern for balanced torque. Refer to Table under Section 3.0 Torque Figures. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 27 of 57 ® Petersen Products Co. All rights reserved.
  • Page 28 Use the D5 length 7.1.20 to measure from the first ram section. Mark on the inflation ram the exact measurement needed. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 28 of 57 ® Petersen Products Co. All rights reserved.
  • Page 29 Inflation Valve and the Pressure Monitor Port with mark on the Inflation Ram for a better visual of proper plug alignment. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 29 of 57 ® Petersen Products Co. All rights reserved.
  • Page 30 Bolts tapping valve flange. Use a star pattern 7.1.24 for balanced torque. Refer to Table under Section 3.0 Torque Figures. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 30 of 57 ® Petersen Products Co. All rights reserved.

  • Page 31: Plug Insertion

    NOTE: This measurement is easier to do as pictured, before lifting the launch cylinder up on the tapping valve. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 31 of 57 ® Petersen Products Co. All rights reserved.
  • Page 32 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. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 32 of 57 ® Petersen Products Co. All rights reserved.
  • Page 33 Verify while lowering the plug that the orientation mark on the ram stays in line with the pipeline. 8.1.5 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 33 of 57 ® Petersen Products Co. All rights reserved.
  • Page 34 Lower the ram until the stop collar on the inflation 8.1.6 ram is touching the retraction post base or packing seal. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 34 of 57 ® Petersen Products Co. All rights reserved.
  • Page 35 _______________________________________________________________________________________________ Anchor the plug in place with the ratchet puller or 8.1.7 strong back (refer to 8.1.7.1). 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 35 of 57 ® Petersen Products Co. All rights reserved.
  • Page 36 B - Thread the rods into the anchor lugs with a nut and washer on each rod. Then continue to Step 8.1.8 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 36 of 57 ® Petersen Products Co. All rights reserved.
  • Page 37 _______________________________________________________________________________________________ Connect inflation accessories.Refer to 2.1.2 8.1.8 Refer to the Inflation Manuals on the website. http://www.petersenproducts.com 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 37 of 57 ® Petersen Products Co. All rights reserved.

  • Page 38: Inflation Of The Plug

    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. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 38 of 57 ® Petersen Products Co. All rights reserved.

  • Page 39: If Pipeline Is Greater Than 12" Piping

    For more in-depth information on Water Inflation and Air Inflation, refer to the respective manual on our website under Product Selection/Instructions tab http://www.petersenproducts.com 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 39 of 57 ® Petersen Products Co. All rights reserved.

  • Page 40: Plug Deflation For Inflated Plugs

    10.1.1 Open the valve on the pressure monitor assembly. Disconnect the 10.1.2 air source. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 40 of 57 ® Petersen Products Co. All rights reserved.
  • Page 41 _______________________________________________________________________________________________ Use the vacuum generator to deflate the larger plugs. 10.1.3 Not needed for gas in most cases. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 41 of 57 ® Petersen Products Co. All rights reserved.

  • Page 42: Water

    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 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 42 of 57 ® Petersen Products Co. All rights reserved.

  • Page 43: Water With Air / Gas Pressurization

    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.

  • Page 44: Plug Removal

    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. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 44 of 57 ® Petersen Products Co. All rights reserved.
  • Page 45 Remove the inflation ram one section at a time. Move the pull block down to the next ram section each time. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 45 of 57 ® Petersen Products Co. All rights reserved.
  • Page 46 11.1.8 in the launch cylinder. Once the plug is fully 11.1.9 retracted, close the tapping valve. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 46 of 57 ® Petersen Products Co. All rights reserved.
  • Page 47 Disassemble the assembly in the reverse order it was assembled. 11.1.11 Report or document any damage or deformation to equipment or inflatables, Email sales: sales@petersenproducts.com 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 47 of 57 ® Petersen Products Co. All rights reserved.

  • Page 48: Maintenance And Care

    Large plugs maybe leak tested in smaller pipes 12.1.1.1 Cuts Punctures 12.1.1.2 and Abrasions 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 48 of 57 ® Petersen Products Co. All rights reserved.
  • Page 49 _______________________________________________________________________________________________ Bulges and 12.1.1.3 Cracks Loose or damaged fitting 12.1.1.4 Components and leaks 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 49 of 57 ® Petersen Products Co. All rights reserved.
  • Page 50 Verify that the plug is empty of water and dry prior to storage in a dry location. 12.1.5 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 50 of 57 ® Petersen Products Co. All rights reserved.
  • Page 51 12.1.6 Yellow Warning Tag with the plug. NOTE Return to Petersen Products to Refurbish and for Recertification. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 51 of 57 ® Petersen Products Co. All rights reserved.

  • Page 52: Troubleshooting

    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. 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 52 of 57 ® Petersen Products Co. All rights reserved.
  • Page 53 Replace with rated valve Not rated for application Contact PPC Time between installation Loose flange connection Re-Torque, refer to 7.1.2 Handling 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 53 of 57 ® Petersen Products Co. All rights reserved.
  • Page 54 Piping geometry or service inside pipping Folds creases of inflatable Flow Stop Issue Application issue Contact PPC DBB Issue Application issue Contact PPC 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 54 of 57 ® Petersen Products Co. All rights reserved.
  • Page 55 Contact owner of service valve Service valve leaking/ Depressurization of inflatable malfunctioning equipment Contact owner of vent valve or Vent valve malfunction 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 55 of 57 ® Petersen Products Co. All rights reserved.

  • Page 56: Acronyms/Definitions

    Positive seal Enhanced seal to back pressure Feet in ideal conditions, minimal leak Gallons per minute past expected HDPE Polyethylene Petersen Product Company Inner diameter pounds per square inch Inflatable Line Stop Request for quote in (“) inch Tapping Valve...

  • Page 57: Measurement Card (Https://Ilsconfigurator.petersenproducts.com/Home/129)

    All dimensions are assumed field measured with a tape measure (or laser) and an accuracy of +/- 1/32” up to 12 ft. and over 12 ft. +/- 1/16” 421 Wheeler Ave Fredonia, WI 53201 Phone: +1-262-692-3100/ 800-926-1926 Page 57 of 57 ® Petersen Products Co. All rights reserved.

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