MAINLINE Kleiss MCS120-24 User guide

Kleiss MCS120-24 System Manual
Flow Stopping System / 2” - 4” up to 120 psiFlow Stopping System / 2” - 4” up to 120 psi

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Kleiss MCS120-24 System OverviewKleiss MCS120-24 System Overview
The Kleiss inatable stopping systems meet the needs of the North
American Natural Gas LDCs by providing a ow control system that is
easy to use and eective at stopping o ow in various pipe materials
and a wide range of pipe diameters.
The Kleiss MCS120-24 System consists of four major components:
1) tting to access the pipe, 2) tapping / completion tool, 3) inatable stopper, and 4) stopping tool.
The Kleiss MCS120-24 System (all tools) has a maximum operating pressure of 120 psi. The inatable stoppers have a
design safety factor of 3. The balance of the tools have a design safety factor of 2.
The Kleiss MCS120-24 System is designed to handle ow control on pipe sizes 2” to 4” on steel pipes.
(Kleiss & Co., who developed the system, has reviewed and approved this manual.)
Table of Contents:
1.0 General Safety Information: .................................................. 2
2.0 System Specications: ........................................................... 2
3.0 Typical Site Set Up and Sequence: ........................................ 4
4.0 Equipment: ............................................................................. 9
5.0 Preparatory Steps: ................................................................ 15
6.0 Tapping Operation: .............................................................. 15
7.0 Stopping Operation: ............................................................. 22
8.0 Retrieving MDS Stopper: .................................................... 29
9.0 Plugging Operation: ............................................................. 32
10.0 General Maintenance: ........................................................ 35
APPENDIX A: Stopper Testing and Verication....................... 36
APPENDIX B: Tower Positioning and Distances ..................... 38
APPENDIX C: Manual Updates ................................................ 42

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1.0 General Safety Information:
NOTE: Before using the Kleiss MCS120-24 System make certain you read the instruction manual completely and are
comfortable and familiar with the operation of the tools. If you have any questions, concerns or feel there is conicting
information, please contact Mainline Control Systems (MCS) before proceeding at 844-FLO-STOP.
NOTE: The purpose of the Kleiss MCS120-24 System is to tap and stop ow in natural gas lines sizes 2” through 4”
operating at a maximum of 120 psi. Review and follow your company safety procedures for operations involving tapping
and stopping live natural gas lines.
2.0 System Specifications:
2.1 General2.1 General
A) Pipe diameter between 2” and 4”
B) Pipe material = steel
C) Maximum operating pressure of 120 psi
NOTE: Tools are designed and built with a safety factor to allow +10% (+12 psi) for operation on 120 psi MAOP
systems or in abnormal operating conditions.
D) Tool to tting connection of 2-1/2” BSP threads
2.2 Tapping Tool and Completion Tool Kit Specications2.2 Tapping Tool and Completion Tool Kit Specications
A) Maximum operating pressure of 120 psi (see NOTE in 2.1C)
B) Cutter available
a) 1.93” (49 mm) steel [Part# 13200130]
C) 1/4” (6.3 mm) pilot drill used for all materials [Part #14300060]
D) Air motor & compressor requirements
a) Connection to the air motor ~ 1/2” NPT
b) 90 psi measured at the inlet of the air motor during operation
c) Refer to manufacturer air motor specications guide
E) Oiler / separator required to be used to extend the life of the air motor
a) Use standard pneumatic oil in tool
F) Weights
a) Tapping tool with cutter ~ 21 lbs.
b) Completion tool without completion plug attached ~ 6 lbs.
c) Air motor ~ 11 lbs.
d) Shipping weight in case ~ 53 lbs.
G) Dimensions
a) Tapping tool height with cutter ~ 29”
b) Completion tool height ~ 14”
c) Storage case ~ 38” length x 18” width x 6” height

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2.3 Stopping Tool Kit Specications2.3 Stopping Tool Kit Specications
A) Maximum operating pressure of 120 psi (see NOTE in 2.1C)
B) Weights
a) Stopping tool ~ 29 lbs.
b) Ball valve ~ 8 lbs.
c) Shipping weight in case ~ 59 lbs.
C) Dimensions
a) Stopping tool height with stopper rod completely extended ~ 4’ 8”
b) Stopping tool height with stopper set ~ 3 feet
c) Storage case ~ 38” length x 18” width x 6” height
D) By-pass / vent port
a) 3/4” tap size in tool
b) 1” camlock male coupling
2.4 MDS Inatable Stopper Specications2.4 MDS Inatable Stopper Specications
A) Sizes
a) 2” Pipe ID [Part #23100375]
b) 2.5” Pipe ID [Part #23100376]
c) 3” Pipe ID [Part #23100380]
d) 4” Pipe ID [Part #23100385]
B) Ination pressure of 175 psi or 2x system pressure if unable to achieve 175 psi by compressor or nitrogen
C) Design burst pressure of 525 psi
D) Operating temperature range of 5° F (- 15° C) to 140° F (60° C)
E) Maximum temperature range of 158° F (70° C) for up to 30 minutes
2.5 Vent Stack Specications2.5 Vent Stack Specications
A) Height assembled ~ 112”
B) 1” camlock male coupling
C) Air hose to venturi connection
D) Hose (standard) of 10 m, 1” camlock connection F x F
E) Ground rod included
F) Weight (less hose) ~ 27 lbs.
G) Air supply and ow capacity rates =
Air Supply Flow Capacity
Working Pressure
(PSI)
Air Consumption
(ft3/min)
Blow Out Volume
(ft3/hr)
80 13 24300
120 13 21200

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2.6 Hand Pump (Pressure and Vacuum Pump)2.6 Hand Pump (Pressure and Vacuum Pump)
A) 1 positive pressure connection
B) 1 negative pressure (vacuum) connection
C) 10 foot air hose with quick disconnects included
D) Weight ~ 12 lbs.
2.7 Maximum Flow Rates2.7 Maximum Flow Rates
A) Maximum design ow rate = 10 ft/sec (3.048 m/sec)
B) For reducing speed, use by-pass / vent port
NOTE: The system is designed to be used in controlled stop o applications, and is not intended to be used to
stop ows in severely ruptured pipes. Flow should be reduced before attempting stop o.
3.0 Typical Site Set Up and Sequence:
It is 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 on the job site is the most important
factor so pre-plan the whole job including the stopping and retrieval sequences.
The following examples are typical installations. Example I (yellow background) illustrates stoppers positioned towards
each other. Example II (blue background) illustrates stoppers positioned away from the work area. Both congurations
work equally well. For additional set up illustrations, see Appendix B or contact your distributor / MCS representative.
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 MCS120-24 oer options to make these processes ecient.

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Example I – Stopping Sequence: Stoppers Positioned Towards Each Other (Most Flexible)Example I – Stopping Sequence: Stoppers Positioned Towards Each Other (Most Flexible)
STOPPING TOWER DISTANCES
Nominal Pipe Size A
(minimum)B L1* = Steel Welding L2 = PE, CI, and Mechanical
2” 32” 16” 20” -
3” 38” 19” 20” -
4” 46” 23” 24” -
A = minimum distance between towers
B = stopper length
L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks
reaching the inatable stopper
1) If a by-pass in the work area is being used (through our MCS tool or another), initiate the by-pass ow rst.
2) Always insert rst inatable stopper WITH the ow of gas.
3) Always inate the stopper as quickly as practical.
4) Suggested stopper setting sequence is tower #1, #2, #3, #4. Set all 4 stoppers.
5) First inated stopper is now in a no ow condition. Reset stopper for best possible seal (deate, reposition stopper
rod, inate).
6) Always allow stoppers to settle for 10 minutes prior to beginning pipeline work. This allows the stopper to
acclimate to internal pipe conditions. Verify system pressures, ination pressures, and any bleed-by before starting
pipeline work. Adjust as necessary.
7) Use the by-pass / vent port on tower #2 or #3 to purge the work area. Utilize the MCS vent stack to assist in
evacuating the work area. This connection can also be used to inject nitrogen into the work zone.
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.

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Example I – Stopper Retraction Sequence: Stoppers Positioned Towards Each OtherExample I – Stopper Retraction Sequence: Stoppers Positioned Towards Each Other
NOTE: Always equalize pressure on both sides of the stopper before deation or removal.
1) Deate 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 / vent port on tower #3 to purge air from the repaired area.
4) Use system pressure gauge on tower #1, #2, #3, or #4 to determine if stoppers are equalized.
5) When pressure is equalized, deate stoppers #1 and #4. Retract all stoppers.
6) Remove tools and install completion plugs.

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Example II – Stopping Sequence: Stoppers Positioned Away From Work AreaExample II – Stopping Sequence: Stoppers Positioned Away From Work Area
STOPPING TOWER DISTANCES
Nominal Pipe Size A
(minimum)B L1 = Steel Welding L2 = PE, CI, and Mechanical
2” 16” 16” 20” -
3” 19” 19” 20” -
4” 23” 23” 24” -
A = minimum distance between towers
B = stopper length
L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks
reaching the inatable stopper
1) If a by-pass in the work area is being used (through our MCS tool or another), initiate the by-pass ow rst.
2) Always insert rst inatable stopper WITH the ow of gas.
3) Always inate the stopper as quickly as practical.
4) Suggested stopper setting sequence is tower #3, #4, #2, #1. Set all 4 stoppers.
5) First inated stopper is now in a no ow condition. Reset stopper for best possible seal
(deate, reposition stopper rod, inate).
6) Always allow stoppers to settle for 10 minutes prior to beginning pipeline work. This allows the stopper to
acclimate to internal pipe conditions. Verify system pressures, ination pressures, and any bleed-by before
starting pipeline work. Adjust as necessary.
7) Use the by-pass / vent port on tower #2 or #3 to purge the work area. Utilize the MCS vent stack to assist in
evacuating the work area. 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.

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Example II – Stopper Retraction Sequence: Stoppers Positioned Away From Work AreaExample II – Stopper Retraction Sequence: Stoppers Positioned Away From Work Area
NOTE: Always equalize pressure on both sides of the stopper before deation or removal.
1) Deate stopper #2.
2) Back pressure stopper #4 through the system pressure ports in towers #3 and #4.
3) Deate stopper #4.
4) Equalize pressure on stoppers #1 and #3 through the by-pass / vent port between towers #3 and #4.
5) Use the by-pass / vent port in tower #1 or #2 to purge air from repaired area.
6) Use system pressure gauge on tower #1 or #2 to determine stoppers are equalized.
7) Deate and remove stoppers.
8) Remove tools and install completion plugs.
NOTE: For additional set up illustrations, see Appendix B.

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4.0 Equipment:
Tapping Case [Part # MCSTK120-0204-001]:Tapping Case [Part # MCSTK120-0204-001]:
12
34
5
6
78910
12
13 14
11
PART # DESCRIPTION
1) 11000070 Ratchet (1/2” square)
2) 11000120 Ratchet (20 mm square)
3) 13200130 Steel and Cast Iron Cutter
(1004HM 49 mm)
4) 13200130 Cutter Grease (250 ml)
5) 14700015 Air Motor (small 20 mm square)
6) 10310905 Drilling Rod (650 mm
25 mm x 20 mm square)
7) 10311057 Drilling Dome
8) 14300060 Pilot Drill
(6.3 mm with retainer spring)
PART # DESCRIPTION
9) 99512506 Hexagonal Key (4 mm)
10) 11005310 Hook Assembly Wrench (58-62)
11) 10310817 Plugging Spindle
12) 10310950 Plugging Dome
13) 10310780 Adapter (3/4” WW x 3/8” )
14) 10310800 Tapping Device / Hot Tap Tool
(LB-493HD)
Case
Foam Interior

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Tapping Tool and Completion Tool Components:Tapping Tool and Completion Tool Components:
Plugging Dome
Air Motor
Feed Tube
Drilling
Dome
Cutter
Pilot Drill
Drilling Rod
Bayonet
Lock
Plugging Spindle
Plugging Dome
Bleed Valve
Completion Plug
Ratchet
Tapping Device / Hot Tap Tool
Drilling Dome
Bleed Valve
Plugging Ratchet

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Stopping Case [Part # MCS120-0204-001]:Stopping Case [Part # MCS120-0204-001]:
1
2 3 45
6
8
910
7
PART # DESCRIPTION
1) 12100300 Stopper Rod Complete
2) 94200010 Silicone Grease Aerosol
3) 12100390 Pipeline Pressure Gauge
(0 to 160 psi)
4) 12100360 Ination Pressure Gauge
(-15 to 210 psi)
5) 10311030 Ring Adapter for Steel
(2-1/2” x 2-1/2” x 1-3/4”)
PART # DESCRIPTION
6) 11000210 Wrench (27 mm)
7) 11000210 Wrench (27 mm)
8) 12100255 Hook Assembly Wrench
(95-100 mm)
9) 12100120 Full Bore Ball Valve (2-1/2”)
10) 12100200 Flow Stop Tool
(Tower and Dome)
Case
Foam Interior

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Stopping Tool Components:Stopping Tool Components:
Internal / Stopper Ination
Pressure Gauge
System / Pipeline Pressure Gauge
Stopping
Tower
MDS Stopper
Chute
By-Pass / Vent Port
Full Port Ball Valve
Fitting Ring Adapters
Stopper Rod

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MDS Stoppers:MDS Stoppers:
PART # DESCRIPTION
1) 23100375 MDS Stopper Size 2”
2) 23100380 MDS Stopper Size 3”
3) 23100385 MDS Stopper Size 4”
Fitting / Completion Plug / Completion Cap:Fitting / Completion Plug / Completion Cap:
PART # DESCRIPTION
1) 99518590 2” Steel Fitting
2) 99518580 3” – 4” Steel Fitting

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Accessories:Accessories:
1
2
3
4
5
6
7
8
9
10
11
Side 1
12
Side 2
PART # DESCRIPTION
1) 22500011 Hand Pump with Hose
2) 59003176 1” Vent Stack with Hose
3) 10310860 Magnetic Head - Attaches to
Tapping Tool
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 Vent Adapter
9) BPT-1 By-Pass Tee Assembly
10) AHA-1 Air Hose Adapter
11) 12100221 MDS Stopper Test Adapter
12) 49101380 Air Motor Oiler / Water
Separator Unit (Complete)
ACCESSORY COMBINATIONS:
96
5
8

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Sizing Table [Equipment Part #’s]:Sizing Table [Equipment Part #’s]:
STEEL PIPE
Nominal Pipe Size 2” 3” 4”
Fitting 99518590 99518580 99518580
Pilot Drill 14300060 14300060 14300060
MDS Stopper
(Pipe ID Range)
23100375
(2”)
23100380
(3”)
23100385
(4”)
5.0 Preparatory Steps:
Select proper MDS Stopper from the sizing table in Section 4.0.
Select proper tting from the sizing table in Section 4.0.
Attach selected tting, based on pipe material, per company standards and specications.
 Before welding steel tting on main, remove the completion cap and plug from tting.
 When welding, if there is concerns about warping the tting, install test cap assembly on tting with valve
open to vent heat.
Pressure test attached tting per company standards and specications.
6.0 Tapping Operation:
Mount the ring adapter onto the tting and tighten
the ring by means of the hooked wrench. Tighten
completely.
Position the valve so that when the valve is open
the handle is up.
Install the ball valve onto the adapter ring of the
tting and tighten the valve by hand to compress
the o-ring.
Operate the valve to ensure smooth operation.

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Take the hot tapping device out of the case and
inspect the device for dirt and debris. Make sure
the threads are clean and the device operates
freely.
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 cutter adapter. Secure pilot
drill with allen wrench. Then attach cutter adapter
to cutter.
Steel cutter [13200130] and pilot drill [14300060]
A:

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If cutting through steel or cast iron, grease the
cutter and pilot drill with the cutting grease for
better drilling results.
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 tighten
the cutter.
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.

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Install the complete tapping tool onto the ball
valve and tighten the tool.
When doing this, make certain the valve doesn’t
inadvertently turn.
Position feed tube so it is ush with the bottom
thread.
Make sure the ball valve is open. (The ball valve
is open if the handle is in an upward position.)
Hold the drilling rod rmly 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 tapped.
When doing this, make sure the bayonet lock is in
a free position and does not lock into the drilling
rod.
After the pilot drill is in contact with the pipeline,
lock the feed tube to the drilling rod at the closest
hole on the drilling rod using the bayonet lock. Do
this by either rotating the feed tube until it locks in
place or pulling up on drilling rod.
Locate the maximum drilling depth by measuring
1-7/8” down from the bottom of the feed tube.
Place a mark on the brass tapping tube. (In picture,
3/4” tape was used.) 1-7/8”

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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.)
Place air motor on drilling rod square.
Operator should ensure the air compressor is
working properly at 90 psi measured at the inlet of
the air motor.
Refer to manufacturer air motor specications
guide.
Make certain the oiler / separator is in place.
NOTE: If issues with air motor occur, tapping can
be completed by hand using the ratchet.
Use the air motor to turn the drilling rod
clockwise.
While the drilling rod is rotating clockwise slowly
hand feed the cutter downward by turning the feed
tube handles clockwise to cut the pipe.
(Do not feed the cutter too quickly and cause a
bind and potential cutter breakage. Especially on
steel and cast iron.)
The tapping procedure is nished when the
drilling rod can rotate without any resistance or
the maximum drilling depth mark is reached.
NOTE: You will feel less resistance twice - once
in the beginning when the pilot drill has perforated
the pipe wall and secondly when the cutter is
completely through.