MAINLINE Kleiss MCS60-38, Manual

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: ...to 8 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...

Page 3: ...TE Tools are designed and built with a safety factor to allow 10 6 psi for operation on 60 psi MAOP systems or in abnormal operating conditions D Tool to fitting connection of 2 1 2 BSP threads 2 2 Ta...

Page 4: ...4 70 mm 90 mm Pipe ID Part 23100353 b 3 54 4 72 90 mm 120 mm Pipe ID Part 23100354 c 4 72 6 29 120 mm 160 mm Pipe ID Part 23100355 d 6 29 8 46 160 mm 215 mm Pipe ID Part 23100356 B Inflation pressure...

Page 5: ...important to understand the MCS stopping tools and their operation completely It is also important to understand the complete job and sequence of steps to perform a safe stop Safety of the operators o...

Page 6: ...flow of gas 3 Always inflate the stopper as quickly as practical 4 Suggested stopper setting sequence is tower 1 2 3 4 Set all 4 stoppers 5 First inflated stopper is now in a no flow condition Reset...

Page 7: ...on both sides of the stopper before deflation or removal 1 Deflate stoppers 2 and 3 2 Use by pass vent ports on tower 1 and 2 to equalize pressures on stoppers 1 and 4 Equalize slowly 3 Use by pass ve...

Page 8: ...nflatable stopper WITH the flow of gas 3 Always inflate the stopper as quickly as practical 4 Suggested stopper setting sequence is tower 3 4 2 1 Set all 4 stoppers 5 First inflated stopper is now in...

Page 9: ...n or removal 1 Deflate stopper 2 2 Back pressure stopper 4 through the system pressure ports in towers 3 and 4 3 Deflate stopper 4 4 Equalize pressure on stoppers 1 and 3 through the by pass vent port...

Page 10: ...6 10310816 Drilling Dome 2 1 2 7 10310800 Tapping Device Hot Tap Tool LB 493HD 8 11000120 Ratchet 20 mm square 9 13100080 PE and PVC Cutter 1003 56 5 mm x 3 8 10 10800248 Air Motor small 20 mm square...

Page 11: ...ng Tool and Completion Tool Components Tapping Tool and Completion Tool Components Feed Tube Air Motor Drilling Dome Cutters Pilot Drill Drilling Rod Bayonet Lock Plugging Spindle Drilling Dome Bleed...

Page 12: ...Gasket Set MCS60 38 7 10311030 Ring Adapter for Steel and Stainless Steel Saddle Fittings 2 1 2 x 2 1 2 x 1 3 4 stamped S 8 10311031 10310955 Ring Adapter for PE Fittings 2 1 2 x 2 1 2 x 1 1 4 stampe...

Page 13: ...s Stopping Tool Components Internal Stopper Inflation Pressure Gauge System Pipeline Pressure Gauge Safety Fitting Stopping Tower Gear Box Assembly MDS Stopper Chute By Pass Vent Port Gear Box Lock Ge...

Page 14: ...er Size 3 54 4 72 90 mm 120 mm 3 23100355 MDS Stopper Size 4 72 6 29 120 mm 160 mm 4 23100356 MDS Stopper Size 6 29 8 46 160 mm 215 mm Fitting Completion Plug Completion Cap Fitting Completion Plug Co...

Page 15: ...Vent Stack with Hose 3 10800854 Magnetic Spindle with Handle 4 13200098 Coupon Remover 3 8 Connection 5 12100740 Safety Fitting Silver 6 BPGT 1 By Pass Gauge Tree 7 BPC 1 By Pass Cap 8 BPVA 1 By Pass...

Page 16: ...14300060 14300060 14300060 Chute 99518681 1 99518681 1 99518682 2 99518682 2 MDS Stopper Pipe ID Range 23100353 2 75 3 54 70 mm 90 mm 23100354 3 54 4 72 90 mm 120 mm 23100355 4 72 6 29 120 mm 160 mm 2...

Page 17: ...re you have the appropriate tips adapters on your electrofusion processor that will fit the 4 0 mm pins When installing PE fittings as part of the electrofusion process make certain to allow the fitti...

Page 18: ...reely Visually inspect the drilling dome and verify o rings are in place Attach the drilling dome to the hot tapping device Tighten the connection by means of the hooked wrench Attach pilot drill to c...

Page 19: ...or PVC skip this step Grease rod with silicone grease for a smooth installation Then install the drilling rod through the hot tapping device and dome Install the cutter onto the drilling rod and tigh...

Page 20: ...ward position Hold the drilling rod firmly so it doesn t drop pull out the bayonet lock on tapping device Carefully lower drilling rod until pilot drill touches the surface of the pipeline to be tappe...

Page 21: ...reads are exposed This ensures the pilot drill is not on the pipe and is in the proper position to start drilling Place air motor on drilling rod square Operator should ensure the air compressor is wo...

Page 22: ...the pipe wall and secondly when the cutter is completely through To retract cutter and coupon continue spinning the drilling rod clockwise while rotating the feed tube counterclockwise until you have...

Page 23: ...ch 11005310 to remove tapping device from drilling dome Use cutter wrench 10310835 to remove cutter from drilling rod The cutter should contain the drilling coupon Use the necessary tools Coupon Remov...

Page 24: ...condition of the gasket can be verified when conducting the vacuum test on the stopper prior to inserting the stopper into the gas system NOTE Extra stopper rod gaskets should always be available Nev...

Page 25: ...n and seal Connect hand pump to the stopper inflation connection on the top end of the stopper rod This is the offset connection With the valve open pull a vacuum to 15 on the stopper to make it as co...

Page 26: ...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 Using rod Using MDS Stoppe...

Page 27: ...lect the proper chute from the sizing table in Section 4 0 NOTE Locate the cute identification number stamped 1 or 2 on the bottom of the chute Connect the chute into the bottom of the stopping tower...

Page 28: ...opping tower onto the ball valve and turn the tower clockwise until some resistance is experienced Position the stopping tower so stopper will be inserted into the correct position Reference arrow on...

Page 29: ...ication on the rods of the tower These indications identify the position of the chute inside the pipeline based on the size of the pipe NOTE The left rod shows indications for cast iron polyethylene a...

Page 30: ...ine and you can commence inserting the stopper into the pipeline Attach safety bumper Unlock the stopper rod by operating the orange handle Push the stopper rod downwards You may have to use a little...

Page 31: ...section Prior to stopper inflation verify system pipeline pressure is displaying on proper gauge The MDS Stopper inflation pressure gauge will be indicating a negative pressure system pipeline pressur...

Page 32: ...the pipeline for at least 10 minutes Evacuate or purge pipeline work area Use the by pass vent port on tower and vent stack if desired Do this in accordance with your gas company procedures by pass v...

Page 33: ...MDS Stopper and in front of the MDS Stopper This can be done in a variety of ways Refer to examples in Section 3 0 of this manual and your gas company procedures ALWAYS EQUALIZE PRESSURE Once pressur...

Page 34: ...he rod Pull the rod up until you catch If the rod will only raise 6 12 you may be caught on the crimp of the stopper Still applying upward pressure turn the rod side to side to walk the stopper past t...

Page 35: ...tion moving the chute out of the pipeline NOTE Keep control of the handle Lock the gear assembly Close the ball valve Open the by pass vent valve in order to evacuate the stopping tool Unlock the bras...

Page 36: ...west position to expose the chute Disconnect the MDS Stopper from the stopping tool Push stopper rod to lowest position to expose the stopper connection Clean and store MDS Stopper in transportation c...

Page 37: ...lling dome together Verify bottom o ring is in place o ring Connect the completion plug onto the plug spindle The connection is good when the detent balls of the plug spindle grip the completion plug...

Page 38: ...ing spindle is at the top of the dome Keep control of the spindle Verify drilling dome bleed valve is closed Open the ball valve Place the ratchet handle on top of the plug spindle Push the plugging s...

Page 39: ...st to make sure there is a seal by opening the bleed valve on the dome and relieving the pressure in the dome After the plug seal has been verified pull the plug spindle fully upwards out of the compl...

Page 40: ...ing adapter from the fitting by means of the hooked wrench Prior to placing the completion cap inspect the completion plug again for any leakage Screw the completion cap onto the fitting Disassemble t...

Page 41: ...t drill Grease the tapping device if needed 10310800 Inspect gauges for any damage and ensure they are reading zero and function properly Inspect stopper rod for bends and or damage Check to make sure...

Page 42: ...inspect the stopper for weak spots and integrity Discard stopper if weak spots are found Continue with inspection if everything looks OK OK Examples Coating is coming off but individual threads are n...

Page 43: ...the condition of the stopper is still uncertain or additional stopper testing is desired insert the stopper into a piece of pipe within the stopper s pipe ID range Make certain the test set up is in...

Page 44: ...Illustration of One Side of Work Area STOPPING TOWER DISTANCES Nominal Pipe Size A minimum B L1 Steel Welding L2 PE CI and Mechanical 3 40 20 18 9 4 44 22 24 12 6 52 26 30 18 8 72 36 36 24 A minimum d...

Page 45: ...ork Area Illustration of One Side of Work Area STOPPING TOWER DISTANCES Nominal Pipe Size A minimum B L1 Steel Welding L2 PE CI and Mechanical 3 20 20 18 9 4 22 22 24 12 6 26 26 30 18 8 36 36 36 24 A...

Page 46: ...Area Illustration of One Side of Work Area STOPPING TOWER DISTANCES Nominal Pipe Size A minimum B L1 Steel Welding L2 PE CI and Mechanical 3 24 20 18 9 4 24 22 24 12 6 24 26 30 18 8 24 36 36 24 A min...

Page 47: ...k Area Illustration of One Side of Work Area STOPPING TOWER DISTANCES Nominal Pipe Size A minimum B L1 Steel Welding L2 PE CI and Mechanical 3 20 20 18 9 4 22 22 24 12 6 26 26 30 18 8 36 36 36 24 A mi...

Page 48: ...d steel welding distance L1 in table in Section 3 0 and Appendix B 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 rot...

Page 49: ...48 Kleiss MCS60 38 System Manual v 15 May 2020 www MainlineControlSystems com 844 FLO STOP www MainlineControlSystems com V15 May 2020...