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MAINLINE Kleiss MCS60-2 System Manual

Flow stopping system/2” up to 60 psi
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Kleiss MCS60-2 System Manual
Flow Stopping System / 2" up to 60 psi
Flow Stopping System / 2" up to 60 psi

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Summary of Contents for MAINLINE Kleiss MCS60-2

  • Page 1 Kleiss MCS60-2 System Manual Flow Stopping System / 2” up to 60 psi Flow Stopping System / 2” up to 60 psi...
  • Page 2 3. The balance of the tools have a design safety factor of 2.5. The Kleiss MCS60-2 System is designed to handle flow control on pipe sizes up to 2” on PVC and steel pipe. See Section 4.0 to identify and install the correct components before operating the equipment.
  • Page 3 Mainline Control Systems (MCS) before proceeding at 844-FLO-STOP. NOTE: The purpose of the Kleiss MCS60-2 System is to tap and stop flow in 2” natural gas lines 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 5 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 MCS60-2 offer options to make these processes efficient. Kleiss MCS60-2 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 MCS60-2 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 MCS60-2 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 MCS60-2 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 10 16) 10310225 Spare O-Ring Set Drilling Rod 8) 10500082 (430 mm / 19.90”) 17) 10310600 Hot Tapping Tool (LB493-C) Pilot Drill Case + Foam Interior 9) 14300060 (6.3 mm with retainer spring) Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 11 Tapping Tool and Completion Tool Components: Drilling Rod Air Motor Tapping Device Lock Tapping Device Feed Tube Ratchet Drilling Dome Drilling Dome Bleed Valve Cutters Plugging Spindle Pilot Drill Drilling Dome Completion Plug Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 12 Line Pressure Gauge 12) 12100023 (0 to 60 psi) 6) 12100740 Safety Fitting (silver) Inflation Pressure Gauge 7) 97200010 Silicone Grease Aerosol 13) 12100022 (-15 to 140 psi) Case + Foam Interior Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 13 System / Pipeline Pressure Gauge Internal / Stopper Inflation Pressure Gauge Safety Fitting Stopper Rod Stopping Tower By-Pass / Vent Port Locking Pin Chute Assembly Chute Ball Valve MDS Stopper Chute Adapter Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 14 MDS Stopper Size 2” Fitting / Completion Plug / Completion Cap: Fitting / Completion Plug / Completion Cap: PART # DESCRIPTION 1) 90004200 2” PVC Fitting (2.375” OD) 2) 11009039 2” Steel Weld Fitting Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 15 8) BPT-1 By-Pass Tee Assembly 9) AHA-1 Air Hose Adapter 10) 12100221 MDS Stopper Test Adapter Air Motor Oiler / Water 11) 49101380 Separator Unit (Complete) ACCESSORY COMBINATIONS: Side 1 Side 2 Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 16 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 17 Steel cutter [13200120] and pilot drill [15001055]. For best results and life of the pilot drill, designate one pilot drill to be used specifically for PVC and one specifically for steel applications. Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 18 Position feed tube so it is flush with the bottom  thread. Make sure the ball valve is open. (The ball valve  is open if the handle is in an upward position.) Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 19 1-1/4” Rotate the feed tube counterclockwise until 3  additional threads are exposed. (This ensures the pilot drill is not on the pipe and is in the proper position to start drilling.) Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 20 3 threads exposed. (NEVER turn the drilling rod counterclockwise. This can damage the cutter.) Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 21  The cutter should contain the drilling coupon. Use the necessary tools [Coupon Remover - 13200098] to remove the coupon from the cutter. Clean and store tapping tool in its case.  Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 22 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 23  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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 24 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. Lightly spray the chute.  Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 25 Tighten brass cap.  Grease stopper rod.  Verify ball valve is closed.  Install the flow stopping tower onto the ball valve  and turn the tower clockwise until some resistance is experienced. Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 26 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 27 Lock the tower at this position using locking pin.  (The chute is now in the correct position inside the pipeline and you can commence inserting the stopper into the pipeline.) Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 28 Lock the stopper rod with black knob.  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 MCS60-2 System Manual v.15 May 2020 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 30 Connect the hand pump to the stopper inflation  connection and pull a vacuum on the stopper to make it as compact as possible. Unlock the stopper rod using black knob.  Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 31 Pull the stopper rod completely upwards. You may  need to use some force to do this. Unlock locking pin.  Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 32 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 33 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 34  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. Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 35 Screw the plug into the fitting with the ratchet  until bottomed-out and tight. Test to make sure there is a seal by opening the  bleed valve on the dome and relieving the pressure in the dome. Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 36 (out of the completion plug). Remove the dome from the valve.  Remove the valve from the ring adapter.  Remove the ring adapter from the fitting by means  of the hooked wrench. Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 37 Screw the completion cap onto the fitting.  Disassemble the completion tool.  Clean and store the completion tool and valve in  their respective cases. Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 38 (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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 39 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 40 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 41 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 42 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 43 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 44 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 MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 45 4) Tapping operation a) Added step to rotate drilling rod clockwise to assist in retracting cutter 5) Stopper tower operation a) Added new step of greasing stopper rod 6) Added air motor guidelines Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...
  • Page 46 844-FLO-STOP www.MainlineControlSystems.com (V15 May 2020) Kleiss MCS60-2 System Manual v.15 May 2020 www.MainlineControlSystems.com...