MAINLINE Kleiss MCS60-1016 User guide

Kleiss MCS60-1016 System Manual
Flow Stopping System / 10” - 16” (18” PE) up to 60 psiFlow Stopping System / 10” - 16” (18” PE) up to 60 psi

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Kleiss MCS60-1016 System OverviewKleiss MCS60-1016 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 MCS60-1016 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 MCS60-1016 System (all tools) has a maximum operating pressure of 60 psi. The inatable stoppers have a
design safety factor of 3. The balance of the tools have a design safety factor of 2.5.
The Kleiss MCS60-1016 System is designed to handle ow control on pipe sizes 10” to 16” (18” PE) 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 outtted with the appropriate tting, cutter, chute, and stopper. See the Sizing Table in Section 4.0 to
identify and install the correct components before operating the equipment.
The basic operation of the equipment is the same for all pipe materials. When working on non-metallic pipe materials,
make sure the equipment is grounded per your company operating practices.
(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: ................................................................ 16
6.0 Tapping Operation: .............................................................. 16
7.0 Stopping Operation: ............................................................. 25
8.0 Retrieving MDS Stopper: .................................................... 35
9.0 Plugging Operation: ............................................................. 41
10.0 General Maintenance: ........................................................ 45
APPENDIX A: Stopper Testing and Verication....................... 46
APPENDIX B: Tower Positioning and Distances ..................... 48
APPENDIX C: Manual Updates ................................................ 52

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1.0 General Safety Information:
NOTE: Before using the Kleiss MCS60-1016 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 MCS60-1016 System is to tap and stop ow in natural gas lines sizes 10” through 16”
(18” PE) operating at a maximum of 60 psi. Review and follow your company safety procedures for operations involving
tapping and stopping live natural gas lines.
NOTE: When operating the Kleiss MCS60-1016 System on non-metallic pipe materials, please follow company
procedures for grounding equipment for discharge of any static electricity.
2.0 System Specifications:
2.1 General2.1 General
A) Pipe diameter between 10” and 16” plus up to 18” polyethylene
B) Pipe material of cast iron, polyethylene, steel or PVC
C) Maximum operating pressure of 60 psi
NOTE: 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 tting connection of 4” ANSI 150 ange
2.2 Tapping Tool and Completion Tool Kit Specications2.2 Tapping Tool and Completion Tool Kit Specications
A) Maximum operating pressure of 60 psi (see NOTE in 2.1C)
B) Cutters available
a) 3.8” (96.5 mm) cast iron and steel [Part #13200725]
b) 3.8” (96.5 mm) polyethylene and PVC [Part #13100100]
C) Pilot drills available
a) 0.5625” (14.3 mm) cast iron and steel [Part #14300054]
b) 0.433” (11.0 mm) polyethylene and PVC [Part #13200727]
D) Air motor & compressor requirements
a) Connection to the air motor ~ 3/4” NPT
b) 90 psi measured at the inlet of the air motor during operation
c) Air volume through the motor should operate the air motor at 20 RPM’s load speed (cut) & 40 RPM’s free
speed (non-cut)
d) 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, stabilizing bridge, and bridge stands = 67 lbs.
b) Completion tool without plug attached = 38 lbs.
c) Air motor = 31 lbs.
d) Shipping weight in case = 152 lbs.
G) Dimensions
a) Tapping tool height with cutter, stabilizing bridge, and bridge stands = 51”
b) Completion tool height = 37”
c) Storage case = 57” length x 17” width x 12” height

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2.3 Stopping Tool Kit Specications2.3 Stopping Tool Kit Specications
A) Maximum operating pressure of 60 psi (see NOTE in 2.1C)
B) Stopping Case Weights
a) Stopping tool = 116 lbs.
b) Stopping case shipping weight = 260 lbs.
C) Stopping Case Dimensions
a) Stopping tool height with stopper rod completely extended
and gear box cranked to highest position = 12’ 11”
b) Stopping tool height with stopper set = 10’ 7”
c) Storage case = 85-1/2” length x 19-1/2” width x 19-1/2” height
D) Stopping Accessories Case Weights
a) Slide gate valve = 34 lbs.
b) Stopping accessories case shipping weight = 88 lbs.
E) Stopping Accessories Case Dimensions
a) Slide gate valve height = 5” (9-1/2” with bolts)
b) Storage case = 30” length x 28” width x 10-1/2” height
F) By-pass / vent port
a) Full 4” ANSI 150 (3-3/4”) tap size
b) 4” ANSI 150 ange connection
2.4 MDS Inatable Stopper Specications2.4 MDS Inatable Stopper Specications
A) Sizes
a) 8.85” – 10.82” (225 mm – 275 mm) Pipe ID [Part #23101357]
b) 9.84” – 12.40” (250 mm – 315 mm) Pipe ID [Part #23101358]
c) 12.40” – 15.74” (315 mm – 400 mm) Pipe ID [Part #23101359]
B) Ination pressure of 120 psi or 2x system pressure if unable to achieve 120 psi by compressor or nitrogen
C) Design burst pressure of 350 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 = 22 ft/sec (6.7 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 MCS60-1016 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
10” 88” 44” 40” 30”
12” 106” 53” 40” 36”
14” 106” 53” 40” 42”
16” 114” 57” 40” 48”
18” 114” 57” N/A 54”
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
L2** = distance from stopper/tower to work area - measurement is a guide only, follow manufacturer’s tting recommendations
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
10” 44” 44” 40” 30”
12” 53” 53” 40” 36”
14” 53” 53” 40” 42”
16” 57” 57” 40” 48”
18” 57” 57” N/A 54”
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
L2** = distance from stopper/tower to work area - measurement is a guide only, follow manufacturer’s tting recommendations
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 # MCSTK060-1016-001]:Tapping Case [Part # MCSTK060-1016-001]:
1
2
345
7
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PART # DESCRIPTION
1) 10310916 Drilling Rod (865 mm 25 mm x
7/8", square, 20 mm)
2) 90004080 Bridge Stands (2 rods)
3) 10800250 Air Motor
(large type, square, 20 mm)
4) 10310800 Tapping Device / Hot Tap Tool
(LB-493HD)
5) 10310826 Drilling Dome
(2” female x 4” ange 150#)
6) 10310830 Spare Seal Set
7) 10310270 Hex Key (3 mm) [set of 2]
8) 14300054 Steel and Cast Iron Pilot Drill
(requires adapter)
9) 10310785 Pilot Drill Adapter (3/4” to M12)
10) 13200727 PE and PVC Pilot Drill
11) 11000120 Ratchet (square, 20 mm)
PART # DESCRIPTION
12) 13100100 PE and PVC Cutter
(1003 96.5 mm x 7/8")
13) 13200725 Steel and Cast Iron Cutter
(1004HM 96.5 mm x 7/8")
14) 10310925 Cutter Assembly Bolts [set of 4]
15) 14700014 Cutter Grease (500 ml)
16) 94200020 Silicone Grease Canister
17) 11005310 Hook Assembly Wrench (58-62)
18) 12242500 Dome Adapter Ring
(1-1/4” x 16 mm)
19) 10310828 Completion Tool Adapter
(1-1/4” male x 2” male)
20) 12242500 Service Rod Assembly for
Plugging (2” male connection)
21) 99513365 Feeding Rod with Bridge
99500003 Case (Explorer)
99300250 Wooden Interior
99300251 Foam Interior

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Tapping Tool and Completion Tool Components:Tapping Tool and Completion Tool Components:
Drilling Dome
Air Motor
Ratchet
Cutters
Feeding Rod with Bridge
Tapping Device / Hot Tap Tool
Plug Spindle
Assembly
Pilot Drill
Plug
Spindle
Handle
Drilling Rod
Dome Adapter Ring
Bridge Stands
Completion Plug
Feed Tube
Bayonet Lock
Blow Down Valve
Completion
Plug Adapter

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Stopping Case [Part # MCS060-1016-002]:Stopping Case [Part # MCS060-1016-002]:
2
46
1
35
PART # DESCRIPTION
1) 12241000 Flow Stopping Tower
MCS60-1016
2)
12100044
99519097
For By-Pass: 8 Stud
Bolts (5/8” x 4”), 16
Nuts, & 16 Washers
For Slide Gate Valve:
16 Nuts & 16 Washers
3) 12242220 Bolts for Stopper Rod
Removal [set of 2]
4) 12101040 Socket for Gear Box
Air Ratchet
5) AR-1 Gear Box Air Ratchet
6) By-Pass / Vent Port /
Test Fitting (4” ANSI)
12241500 Case with Interior
12 34
567 8
10
13 14 15 16 17
11
9
12
18 19
20
PART # DESCRIPTION
1) 12241300 Chute # 1
2) 12242000 Slide Gate Valve
3) 12241310 Chute # 2
4) 12241320 Chute # 3
5) 11000201 Wrench (41 mm) [set of 2]
6) 94200020 Silicone Grease
7) 99600450 Brush
8) 94200010 Silicone Grease Aerosol
9) 99510080 Gasket (4" ANSI) [set of 4]
10) 99519645 Gasket Set (MCS60-1016)
11) 12242210 Hand Pump Adapter
12) 99301338 Wrench for Stopper Rod Removal
13) 12100022 Ination Pressure Gauge
(-15 to 160 psi)
14) 12100023 Pipeline Pressure Gauge
(0 to 60 psi)
15) 59512950 Valve Wrench (square, 19 mm)
16) 99401705 Pressure Equalizing Hose
17) 10200190 Jacking Handle
18) 12100740 Safety Fitting (silver)
19) 99000705 Safety Fitting (gold / claw)
20) 99000740 Air Motor Adapter (claw)
12242100 Case with Interior

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Stopping Tool Components:Stopping Tool Components:
By-Pass / Vent Port
System / Pipeline Pressure Gauge
Stopping Tower
Safety Fitting
Chute
MDS Stopper
Slide Gate Valve
Gear Box Assembly
Internal / Stopper Ination Pressure Gauge
Stopper Rod
Jack Assist
Gear Box
Air Ratchet

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MDS Stoppers:MDS Stoppers:
PART # DESCRIPTION
1) 23101357 MDS Stopper size 8.85” – 10.82” (225 mm – 275 mm)
with Shock Absorber Hose
2) 23101358 MDS Stopper size 9.84” – 12.40” (250 mm – 315 mm)
with Shock Absorber Hose
3) 23101359 MDS Stopper size 12.40” – 15.74” (315 mm – 400 mm)
with Shock Absorber Hose
Fitting / Completion Plug / Blind Flange / Stud Bolts:Fitting / Completion Plug / Blind Flange / Stud Bolts:
1
2
3PART # DESCRIPTION
1) 90403010 to
90403050
Polyethylene Fitting
(size specic)
2) 90502160 to
90502220
Stainless Steel
Saddle Fitting
(size specic)
3) 12100051 Steel Fitting
(10” – 16”)

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Accessories:Accessories:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Side 1
15
Side 2
16
17
18
PART # DESCRIPTION
1) 22500011 Hand Pump with Hose
2) 59003176 1” Vent Stack with Hose
3) SVS-2-IND 2” Vent Stack with
Industrial Hose
4) 10800853 Magnetic Spindle
5) 13605135 Coupon Remover
(7/8” connection)
6) 12242210 Hand Pump Adapter
7) 99000705 Safety Fitting (gold / claw)
8) 12100740 Safety Fitting (silver)
9) BPGT-1 By-Pass Gauge Tree
10) BPC-1 By-Pass Cap
11) BPVA-1 By-Pass Vent Adapter
12) BPT-1 By-Pass Tee Assembly
13) AHA-1 Air Hose Adapter
14) 12242200 MDS Stopper Test Adapter
(MCS60-1016)
15) 49101380 Air Motor Oiler / Water
Separator Unit (complete)
16) 13200726 Steel and Cast Iron Pilot Drill
(1/2”)
17) 14300053 Steel and Concrete Pilot Drill
(requires adapter 10310785)
18) 10310785 Pilot Drill Adapter (3/4” to M12)
ACCESSORY COMBINATIONS:
12 9
8
11

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Sizing Table [Equipment Part #’s]:Sizing Table [Equipment Part #’s]:
POLYETHYLENE PIPE
Nominal Pipe Size 10” 12” 14” 16” 18”
Fitting 90403010 90403020 90403030 90403040 90403050
Cutter 13100100 13100100 13100100 13100100 13100100
Pilot Drill 13200727 13200727 13200727 13200727 13200727
Chute 12100450 (#1) 12100460 (#2) 12100460 (#2) 12100470 (#3) 12100470 (#3)
MDS Stopper
(Pipe ID Range)
23101357
(8.85” - 10.82” /
225 mm - 275 mm)
23101358
(9.84” - 12.40” /
250 mm - 315 mm)
23101358
(9.84” - 12.40” /
250 mm - 315 mm)
23101359
(12.40” - 15.74” /
315 mm - 400 mm)
23101359
(12.40” - 15.74” /
315 mm - 400 mm)
CAST IRON PIPE
Pipe OD Range 10.71” - 11.61” 12.99” - 13.98” 15.16” - 16.14” 16.54” - 17.32” 17.32” - 18.31”
Fitting 90502160 90502180 90502200 90502210 90502220
Cutter 13200725 13200725 13200725 13200725 13200725
Pilot Drill 14300054 14300054 14300054 14300054 14300054
Pilot Drill Adapter 10310785 10310785 10310785 10310785 10310785
Chute 12100450 (#1) 12100460 (#2) 12100470 (#3) 12100470 (#3) 12100470 (#3)
MDS Stopper
(Pipe ID Range)
23101357
(8.85” - 10.82” /
225 mm - 275 mm)
23101358
(9.84” - 12.40” /
250 mm - 315 mm)
23101359
(12.40” - 15.74” /
315 mm - 400 mm)
23101359
(12.40” - 15.74” /
315 mm - 400 mm)
23101359
(12.40” - 15.74” /
315 mm - 400 mm)
NOTE: Verify actual pipe OD and wall thickness to make certain tting and stopper dimensions will work.
STEEL PIPE
Nominal Pipe Size 10” 12” 14” 16”
Fitting 12100051 12100051 12100051 12100051
Cutter 13200725 13200725 13200725 13200725
Pilot Drill 14300054 14300054 14300054 14300054
Pilot Drill Adapter 10310785 10310785 10310785 10310785
Chute 12100450 (#1) 12100460 (#2) 12100470 (#3) 12100470 (#3)
MDS Stopper
(Pipe ID Range)
23101357
(8.85” - 10.82” /
225 mm - 275 mm)
23101358
(9.84” - 12.40” /
250 mm - 315 mm)
23101359
(12.40” - 15.74” /
315 mm - 400 mm)
23101359
(12.40” - 15.74” /
315 mm - 400 mm)

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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 blind ange, gasket, and plug from tting.
 Kleiss Gastool PE ttings use a 4.0 mm fusion pin. Ensure you have the appropriate tips/adapters on your
electrofusion processor that will t the 4.0 mm pins.
 When installing PE ttings, as part of the electrofusion process, make certain to allow the tting to completely
cool down for the entire “cooling time” before tapping the main.
Pressure test attached tting per company standards and specications.
6.0 Tapping Operation:
Attach slide gate valve, with gasket in place, to
tting outlet using nuts and washers.
Check gasket.
Attach pressure equalizing hose to slide gate
valve.
Use valve wrench to check if slide gate valve
opens and closes.
Take the tapping device out of the case and inspect
the device visually for irregularities. Make sure
the threads are clean and the device operates
freely.

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Begin to assemble the tapping tool by attaching
the dome adapter ring to the drilling dome.
Tighten the connection by means of the hook
assembly wrench.
Thread the tapping device on to the dome adapter
ring by means of the hook assembly wrench.
Install the drilling rod through the middle of the
tapping device and drilling dome.

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Attach pilot drill to drilling rod then attach proper
cutter by means of the cutter assembly bolts.
Figure A:
Steel and cast iron cutter [13200725] and pilot
drill [14300054] with adapter [10310785]. Thread
the pilot drill into the drilling rod.
Figure B:
PE cutter [13100100] and pilot drill [13200727].
Secure the pilot drill using the set screw on the
drilling rod.
A: B:
If cutting through steel or cast iron, grease the
cutter and pilot drill with the cutting grease for
better drilling results.
If cutting through PE or PVC, skip this step.
Retract the cutter completely into the drilling
dome. No part of the cutter should be visible.
When retracting into the drilling dome, the cutter
should be in the position as shown in the picture.

19
Kleiss MCS60-1016 System Manual v.15 June 2020 |
www.MainlineControlSystems.com
Attach complete tapping tool, with gasket in place,
to top of slide gate valve using nuts and washers.
Check gasket.
Position feed tube so it is ush with the bottom
thread.