OPPLE

PLUGGING

MACHINE

Jl. Baung No.3ALenteng Agung JagakarsaSouth Jakarta 12610 - INDONESIA

bsm@brilian-sm.com+62 21 7815850

www.brilian-sm.com

Dimensions and Data Sheet

Plugging Machine

Plugging Heads Sealing Elements

Size Weight Weight

Inches DN Lbs. Kg. Lbs. Kg.

4 100 7 3 1 0.5

6 150 25 11 2 0.9

8 200 50 23 2 0.9

10 250 90 41 4 2

12 300 150 68 5 2

14 350 185 84 7 3

16 400 260 118 9 4

18 450 455 206 12 5

20 500 525 238 19 9

22 550 670 304 24 11

24 600 870 395 37 17

26 650 1050 476 40 18

30 750 1610 730 64 29

36 900 3025 1372 77 35

Plugging Heads & Sealing Element

Description

Line stopping is a means of temporally inserting a plugging device to shut off the flow of anin-service piping system. Line stopping can be used to isolate sections of pipe for repair,maintenance, or reconfiguration such as adding valve. If used with a bypass, work can beperformed without service interruptions.

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Dimensions and Data Sheet

Approximate Dimensions for Determining Machine ClearancesSize A+ B+ C

Inches DN Inches Mm Inches mm Inches mm Inches mm

4 100 11 280 14 356 58 1473 72 1829

6 150 14 356 17 432 58 1473 75 1905

8 200 17 432 19 483 85 2159 104 2642

10 250 20 508 23 533 85 2159 108 2743

12 300 22 559 25 610 85 2159 110 2794

14 350 24 610 32 787 124 3150 156 3962

16 400 27 686 35 889 124 3150 159 4039

18 450 30 762 39 991 124 3150 163 4140

20 500 32 813 42 1041 124 3150 166 4216

22 550 35 889 46 1168 166 4216 212 5385

24 600 37 940 52 1321 166 4216 218 5537

26 650 40 1015 52 1321 166 4216 218 5537

30 750 45 1143 60 1524 166 4216 226 5740

36 900 52 1321 67 1803 166 4216 233 5918

L

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

PT. Brilian Sukses mandiri manufactures a complete High Pressure PipePlugging System for the temporary blockage of and pipe a valve is not ourstandards system is designed for 1000 psig differential across plugging head.

PT. Brilian Suskses Mandiri expert is the enhancement and refinementwith placed around Indonesia to cover all sizes of pipes.

We will be there on time and get the job done.

Line Stop ProcedureBRILIAN SUKSES MANDIRI

Plugging Without Shutdown

3. Line Plug 4. Recover Valves

2. Make Taps1. Weld Fittings

Line Stop ProcedureBRILIAN SUKSES MANDIRI

Line Stop Stopple Plug

Step 1

AFTER A HOT TAP MAKES IT’S LIVE HOLE IN THE PIPE. A LINESTOPPING MACHINE IS BOLTED TO THE TAPPING VALVE.

Step 2

THE TAPPING VALVE IS OPENED. PIPE CONTENTS ENTER THE LINESTOP MACHINE.

Step 3

THE LINE STOP MACHINE ACTUATOR INSERTS A HIGH - PRESSURESTEEL PLUGGING HEAD DOWN THROUGH THE OPEN VALVE ANDINTO THE PIPE THROUGH THE HOLE...

Step 4

...WHERE A ROLLER CONTACTS THE PIPE INNER WALL, AND THEPLUGGING HEAD WALKS AND PIVOTS INTO THE SEALING POSITION.

Step 5

THE PLUGGING HEAD’S FIBER - REINFORCED ELASTOMETRIC SEAL-ING ELEMENT IS NOW TEMPORARILY PLUGGING THE PIPE. DOWN-STREAM OF THE PLUG, THE PIPE CAN BE DEPRESSURIZED, DRAINEDAND MODIFIED OR REPAIRED.

ONCE WORK ONE THE PIPE IS COMPLETED. THE DOWNSTREAM ISREPRESSURIZED AND THE PLUGGING HEAD REMOVED.

BRILIAN SUKSES MANDIRI

Installing a Completion Plug

Line Stop Procedure

01.After a Line Stop job is done, a Completion Plug setting machine isattached to the tapping valve, and a Completion Plug is loweredthrough the valve into the throat of our special completion flange.

02.Next, high speed steel retainer segments are advanced from insidethe flange, into a deep groove in the steel Completion Plug.

03.With the plug’s massive O-Ring sealing the flange bore, the tappingvalve and machinery can be depressurized and removed.

1. Operating Considerations

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Line Stop Procedure

Tapping The LineA. Tap with the line flowing to disperse chips cut from the line. Follow instructions

provided in tapping machine manual.

B. Use only STOPPLE fittings for installation. SADWICH Valves are recommended to

assure proper alignment and sufficient bore clearance for STOPPLE cutters, STOP-

PLE plugging heads, and LOR Plugs.

C. Use TDW STOPPLE cutters and corresponding pilots with the tapping machine.

Standard cutters are not compatible with STOPPLE operations.

D. After mounting the SANDWICH Valve, open and close it to make sure the valve

functions properly. Consult SANDWICH Valve manual to ensure proper operation.

E. Provide connections on the pipeline :

1. For pressure relief and/or drain of the isolated section before making repairs.

2. For purging and equalizing pressure in the new section of line before retract-

ing the plugging heads.

F. Provide a pressure gauge for checking the pressure in the plugging head housing.

The gauge may be installed along with the bleeder valve by using a tee in the

bleeder valve connection.

G. Use a crane large enough for the weight of the machinery to be lifted.

WARNING:

All components of the plugging machine are extremely heavy. Make sure the crane

used has an adequate lifting capability to avoid possible injury to personnel or equip-

ment.

2. PREPARATIONS FOR USE

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Line Stop Procedure

2.1 Preparing the Plugging MachineA. Inspect the O-ring on top of the housing to make sure it is clean and undamaged.

Mount the STOPPLE cylinder on the plugging head housing with cylinder control

valve and housing equalization connection facing the same direction.

B. Place the STOPPLE cylinder and plugging head housing in a level (horizontal) posi-

tion with equalization connection facing up. Support the upper end of the cylinder

adequately. Block the housing flange to prevent rolling.

C. Connect hydraulic hoses from the power unit to the control valve.

D. Start the power unit. Conduct prestart checks, starting and operating procedures,

as contained in the appropriate operator’s manual.

E. Extend the control bar by moving the control valve handle to the down position.

Do not overextend the control bar. Stop extension when end of bar is flush with

plugging head housing or just enough to install the plugging head.

F. To install the plugging head to the control bar, support the plugging head level on

the same center as the control bar. Nosepiece of the plugging head must face the

same direction as the control valve and equalization connection.

G. Attach plugging head to control bar with the two special bolts and nuts provided.

2. PREPARATIONS FOR USE

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Line Stop Procedure

2.2 Preparing the Plugging HeadA. Extend plugging head to permit nose removal. Top of con-

trol bar head should remain inside of housing to help sup-

port plugging head weight.

B. Remove the nose bolts and nosepiece from the yoke.

C. Inspect plugging head components and perform necessary

maintenance as follows.

D. Install the sealing element.1. Position the sealing element on the yoke evenly. It should fit snugly over the

face of the yoke, and bolt holes should align. The element may hove some cur-vature to it and may not lay flat. This will cause some misalignment of holesuntil the cup is pressed flat by the nosepiece.

2. Position the nosepiece on the element. Start all bolts by hand, and threadeach down snugly again the nosepiece.

3. Refer to Table 4, “Torque Table” and find the recommended torque rangesfor the size of plugging head being used. Minimum torque must always be ap-plied. The need to apply additional torque depends on several varying factors,such as the condition of threads, compressibility of the sealing element andfriction on the bolt wearing surfaces.

4. Tighten the nose bolts gradually. Tighten one bolt until it is snug, then moveto a blot on the opposite side of the nosepiece to tightened. Keep movingback and forth across the face of the nosepiece, from one bolt to another un-til the element has expanded evenly and is tight.

5. Visually check around the face of the yoke making sure the sealing element isuniformly centered and no part of the sealing ring is visible. If the sealing ele-ment is not on correctly, disassemble the plugging head and start again.

6. Coat the sealing element lip thoroughly with heavy grease before using.7. Retract plugging head carefully making sure sealing element goes into hous-

ing uniformly without binding. Use screwdrivers to guide each side of thesealing element into the housing, to prevent the lip from pulling inside-out,while retracting plugging head.

2. PREPARATIONS FOR USE

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Line Stop Procedure

2.3 Install MachineA. Before listing machine, consider the total length and weight of the STOPPLE cylin-

der and housing and make sure weight handling equipment has the capacity to lift

it.

B. Center Machine on SANDWICH Valve and install with equalization connection fac-

ing the section to be isolated. The equalization connections on the machine and on

the pipe need to be in alignment with each other.

C. Install bleeder valve on STOPPLE plugging head housing. Make up piping connec-

tion for refilling and pressure equalization.

D. Picture below shows the arrangement of the equipment installed on a double

STOPPLE operation with a temporary bypass.

3. SETTING THE PLUGGING HEAD

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Line Stop Procedure

3.1 On-Stream ApplicationThe following precautions must be observed for an on-stream application:

A. Before lowering plugging head into line, temporary bypass must be open.

B. Lower and set downstream plugging head into line.

C. Lower and set upstream plugging head into line.

D. When job is complete, equalize pressure form upstream (high pressure) side.

E. Retract upstream plugging head first.

F. If using STOPPLE Plugging Machine, or Machines, without a bypass, flow in the

pipeline must be stopped prior to setting the plugging heads.

3.2 Setting the Plugging HeadA. Open internal bypass on SANDWICH Tapping Valve.

B. Purge air from STOPPLE plugging head housing through bleeder valve. Close

bleeder valve when purge complete.

WARNING:Vent pressure bleed valve away form work area and personnel. Stand clear ofvent when bleeder valve is opened. Otherwise, personal injury may result formblowing material.

C. Leave internal bypass on SANDWICH Valve open to equalize pressure on both side

of the disc.

D. Open SANDWICH Valve. When fully opened, close internal bypass.

E. Set downstream plugging machine first. Extend stopple plugging head into seal-

ing position slowly by moving control lever down. The sealing element has reached

full set position when the number on the control bar, as observed through the ob-

servation hole, corresponds with the predetermined travel distance.

3. SETTING THE PLUGGING HEAD

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Line Stop Procedure

3.2 Setting the Plugging HeadF. If control bar stalls before measured position is reached, raising and lowering the

control bar one or two inches may be necessary to reach full position.

G. When the plugging head is set, return the control valve lever to neutral position,

and hole to make sure it corresponds with the calculated distance required to set

the plugging head.

H. Tighten the cap screws on the bar-lock clamp using the hex wrench provided.

Torque the cap screws as follows :

6” to 12” size - 50 ft. lbs.14” to 34” size - 100 ft. lbs.36” to 48” size - 125 ft. lbs.

G. Set the upstream plugging machine by lowering plugging head into line.

H. After both plugging head are positioned in the line, recheck the number (calculated distance) in

the observation hole of each plugging machine. The exact number, or fraction thereof, must be

in the same position as originally viewed before the pressure in isolated section can be relieved.

If the number has moved UP in the observation hole, connect hydraulic hoses, loosen clamps,

and lower the plugging head until the measured distance is reached.

I. The section between the two machines is now isolated. Close the valves on the equalization

lines. Vent and drain the isolated section of pipe completely.

J. Verify the seal of the plugging head through a valve connection before starting the work on the

isolated section if there is any leakage, repeat the plugging head setting procedures and verify

the seal. If leakage continues, remove the STOPPLE Plugging Machine, install a new sealing ele-

ment, and reset the plugging head.

K. If the isolated section of the line is to be cut. However, if flame cutting is used, and when weld-

ing in the new section is planned, make sure the cut is no closer to the fitting than three pipe di-

ameters, and a minimum of 2 feet.

4. REMOVING THE PLUGGING HEAD

BRILIAN SUKSES MANDIRI

Stopple Plugging Machine

Line Stop Procedure

4.1 Equalizing PressureA. When equalizing pressure with the line shut down, always fill and equalize from

the side of the job with the highest static pressure. Retract the high-pressure side

plugging machine first.

B. For an on-stream operation, equalize from the upstream side and retract upstream

machine first.

CAUTION:Pressure must be equalized across the plugging head before the head can be withdrawn. Ifa line pressure differential exists, the plugging head will remain locked in the line. At-tempts to retract will result in damage to the machine. Equalize pressure before retract-ing, keep it equalized.

4.2 Retract Plugging HeadA. Connect hydraulic hoses.

B. Retract plugging head by moving control valve up slowly. Continue retracting until

zero appears in the observation hole.

C. Close SANDWICH Tapping Valve.

D. Close equalization valve.

E. Open bleeder valve and bleed all pressure from housing.

WARNING:Vent pressure bleed valve away from work area and personnel. Stand clear of vent when bleed-er valve is opened. Otherwise, personal injury may result from blowing material.

F. Remove plugging machine. Drain housing before removal.

G. Install LOR Plug.