MAINLINE Kleiss MCS60-38 User manual

Kleiss MCS60-38 System Manual
Flow Stopping System / 3” - 8” up to 60 psiFlow Stopping System / 3” - 8” up to 60 psi

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Kleiss MCS60-38 System OverviewKleiss MCS60-38 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 MCS60-38 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 MCS60-38 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 MCS60-38 System is designed to handle ow control on pipe sizes 3” 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 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: ............................................................. 23
8.0 Retrieving MDS Stopper: .................................................... 32
9.0 Plugging Operation: ............................................................. 36
10.0 General Maintenance: ........................................................ 40
APPENDIX A: Stopper Testing and Verication....................... 41
APPENDIX B: Tower Positioning and Distances ..................... 43
APPENDIX C: Manual Updates ................................................ 47

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1.0 General Safety Information:
NOTE: Before using the Kleiss MCS60-38 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 MCS60-38 System is to tap and stop ow in natural gas lines sizes 3” through 8”
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 MCS60-38 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 3” and 8”
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 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 60 psi (see NOTE in 2.1C)
B) Cutters available
a) 2.2” (56.5 mm) cast iron and steel [Part #13200140]
b) 2.2” (56.5 mm) polyethylene and PVC [Part #1310080]
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 ~ 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 35 RPM’s load speed (cut) & 70-75 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 ~ 23 lbs.
b) Completion tool without completion plug attached ~ 13 lbs.
c) Air motor ~ 11 lbs.
d) Shipping weight in case ~ 65 lbs.
G) Dimensions
a) Tapping tool height with cutter ~ 29”
b) Completion tool height ~ 17”
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 60 psi (see NOTE in 2.1C)
B) Weights
a) Stopping tool ~ 46 lbs.
b) Ball valve ~ 8 lbs.
c) Shipping weight in case ~ 94 lbs.
C) Dimensions
a) Stopping tool height with stopper rod completely extended ~ 7 feet
b) Stopping tool height with stopper set ~ 4 feet
c) Storage case ~ 56” length x 16” width x 12” 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) 2.75” – 3.54” (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) 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 (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 MCS60-38 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
3” 40” 20” 18” 9” *
4” 44” 22” 24” 12” *
6” 52” 26” 30” 18” *
8” 72” 36” 36” 24” *
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 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
3” 20” 20” 18” 9” *
4” 22” 22” 24” 12” *
6” 26” 26” 30” 18” *
8” 36” 36” 36” 24” *
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 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 # MCSTK060-0308-001]:Tapping Case [Part # MCSTK060-0308-001]:
1
13
2345 6789
12
14 15 16 17 18
19
1110
PART # DESCRIPTION
1) 10310835 Cutter Wrench (56.5 mm)
2) 90090035 Test Cap Assembly 2-1/2"
3) 14700015 Cutter Grease (250 ml)
4) 13200140 Steel and Cast Iron Cutter
(1004HM 56.5 mm x 3/8")
5) 94200020 Silicone Grease Canister
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)
PART # DESCRIPTION
11) 10310905 Drilling Rod (650 mm
25 mm x 20 mm square)
12) 99512506 Hexagonal Key (4 mm)
13) 10800846 Plug Spindle (20 mm square)
14) 10310830 Spare Seal Set
15) 14300060 Pilot Drill
(6.3 mm with retainer spring)
16) 14300060 Pilot Drill
(6.3 mm with retainer spring)
17) 10310780 Adapter (3/4" WW x 3/8" )
18) 10310780 Adapter (3/4" WW x 3/8" )
19) 11005310 Hook Assembly Wrench (58-62)
99518863 Case (Peli 1700)
99310015 Foam Interior

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Tapping 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 Valve
Completion Plug
Ratchet
Tapping Device / Hot Tap Tool
Drilling Dome
Bleed Valve

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Stopping Case [Part # MCS060-0308-001]:Stopping Case [Part # MCS060-0308-001]:
12
5
78 10 11
12 13 14 15 16
4
6
3
9
PART # DESCRIPTION
1) 12100025 Flow Stopping Tower
MCS60-38
2) 12100741 Safety Bumper
3) 12100120 Full Bore Ball Valve (2-1/2")
4) 99518682 Chute # 2
5) 99518681 Chute # 1
6) 12100750 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” /
stamped “P”)
9) 10311031 3” Ring Adapter
PART # DESCRIPTION
10) 12100022 Ination Pressure Gauge
(-15 to 120 psi)
11) 12100023 Pipeline Pressure Gauge
(0 to 60 psi)
12) 11000190 Wrench (32 mm)
13) 11000190 Wrench (32 mm)
14) 12100255 Hook Assembly Wrench
(95-100 mm)
15) 12100740 Safety Fitting (silver)
16) 94200010 Silicone Grease Aerosol
99500003 Case (Explorer)
99500019 Foam Interior

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Stopping Tool Components:Stopping Tool Components:
Internal / Stopper Ination Pressure Gauge
System / Pipeline Pressure Gauge
Safety Fitting
Stopping
Tower
Gear Box
Assembly
MDS Stopper
Chute
By-Pass / Vent Port
Gear Box Lock
Gear Box Cranking Handle
Full Port Ball Valve
Fitting Ring Adapters
Stopper Rod
“P” “S”
Safety Bumper
“3 in”

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MDS Stoppers:MDS Stoppers:
PART # DESCRIPTION
1) 23100353 MDS Stopper Size 2.75” – 3.54” (70 mm – 90 mm)
2) 23100354 MDS Stopper 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 / Completion Cap:
1
2
3PART # DESCRIPTION
1) 90401010 to
90401040
Polyethylene Fitting
(size specic)
2) 90004001 to
90004028
Stainless Steel
Saddle Fitting
(size specic)
3) 11009050 Steel Fitting
(3” – 8”)

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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) 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 Vent Adapter
9) BPT-1 By-Pass Tee Assembly
10) AHA-1 Air Hose Adapter
11) 12100731 MDS Stopper Test Adapter
(MCS60-38)
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]:
POLYETHYLENE PIPE
Nominal Pipe Size 3” 4” 6” 8”
Fitting 90401010 90401020 90401030 90401040
Ring Adapter 10311031 /
10310955 (“P”)
10311031 /
10310955 (“P”)
10311031 /
10310955 (“P”)
10311031 /
10310955 (“P”)
Cutter 13100080 13100080 13100080 13100080
Pilot Drill 14300060 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)
23100356
(6.29” - 8.46” /
160 mm - 215 mm)
CAST IRON PIPE
Pipe OD Range 3.46”-4.33” 4.49”-5.27” 6.61”-7.48” 8.85”-9.68”
Fitting 900004001 900004003 90004008 90004013
Ring Adapter 10311030 (“S”) 10311030 (“S”) 10311030 (“S”) 10311030 (“S”)
Cutter 13200140 13200140 13200140 13200140
Pilot Drill 14300060 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)
23100356
(6.29” - 8.46” /
160 mm - 215 mm)
STEEL PIPE
Nominal Pipe Size 3” 4” 5” 6” 8”
Fitting 11009050 11009050 11009050 11009050 11009050
Ring Adapter 10311031 (“3 in”) 10311030 (“S”) 10311030 (“S”) 10311030 (“S”) 10311030 (“S”)
Cutter 13200140 13200140 13200140 13200140 13200140
Pilot Drill 14300060 14300060 14300060 14300060 14300060
Chute 99518681 (#1) 99518681 (#1) 99518682 (#2) 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)
23100355
(4.72” - 6.29” /
120 mm - 160 mm)
23100356
(6.29” - 8.46” /
160 mm - 215 mm)
PVC PIPE
Nominal Pipe Size 3” 4”
Fitting
(Pipe OD Range)
90004027
(3.5”)
90004028
(4.5”)
Ring Adapter 10311031 (“3 in”) 10311031 /
10310955 (“P”)
Cutter 13100080 13100080
Pilot Drill 14300060 14300060
Chute 99518681 (#1) 99518681 (#1)
MDS Stopper
(Pipe ID Range)
23100353
(2.75” - 3.54” /
70 mm - 90 mm)
23100354
(3.54” - 4.72” /
90 mm - 120 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 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.
 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:
Mount the appropriate ring adapter onto the tting
and tighten the ring by means of the hooked
wrench. Tighten completely.
For appropriate ring adapter, reference tables on
page 15.
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.
Figure A:
Steel and cast iron cutter [13200140] and pilot
drill [14300060].
Figure B:
PE and PVC cutter [13100080] and pilot drill
[14300060].
A: B:

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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.
If cutting through PE 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 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.