MAINLINE Kleiss MCS7-2PVC User guide

Kleiss MCS7-2PVC System Manual
Flow Stopping System / 2” up to 7.5 psiFlow Stopping System / 2” up to 7.5 psi

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Kleiss MCS7-2PVC System OverviewKleiss MCS7-2PVC 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 MCS7-2PVC 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 MCS7-2PVC System (all tools) has a maximum operating pressure of 7.5 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 MCS7-2PVC System is designed to handle ow control on pipe sizes up to 2” on PVC pipe. See Section 4.0 to
identify and install the correct components before operating the equipment.
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: ........................................ 3
4.0 Equipment: ............................................................................. 8
5.0 Preparatory Steps: ................................................................ 12
6.0 Tapping Operation: .............................................................. 12
7.0 Stopping Operation: ............................................................. 18
8.0 Retrieving MDS Stopper: .................................................... 25
9.0 Plugging Operation: ............................................................. 28
10.0 General Maintenance: ........................................................ 32
APPENDIX A: Stopper Testing and Verication....................... 33
APPENDIX B: Tower Positioning and Distances ..................... 35

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1.0 General Safety Information:
NOTE: Before using the Kleiss MCS7-2PVC 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 MCS7-2PVC System is to tap and stop ow in 2” natural gas lines operating at a
maximum of 7.5 psi. Review and follow your company safety procedures for operations involving tapping and stopping
live natural gas lines.
NOTE: When operating the Kleiss MCS7-2PVC System on non-metallic lines, 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 = 2” (2.375” OD)
B) Pipe material = PVC
C) Maximum operating pressure = 7.5 psi
2.2 Kit Specications2.2 Kit Specications
A) Storage case
a) Shipping weight = 65 lbs.
b) Dimensions = 57” length x 17” width x 7” height
B) Tapping tool
a) 1.161” PVC cutter [Part #13100030]
b) 0.25” PVC pilot drill [Part #15001055]
c) Tapping tool weight with cutter = 8 lbs.
d) Tapping tool height with cutter = 18”
C) Completion tool
a) Completion tool weight without completion plug attached = 5 lbs.
b) Completion tool height = 12”
D) Stopping tool
a) Stopping tool weight = 8 lbs.
b) Slide gate valve weight = 7 lbs.
c) Stopping tool height with gauge rod completely extended = 3 feet, 7 inches
d) Stopping tool height with stopper set = 2 feet, 7 inches
e) By-pass / vent port

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2.3 MDS Inatable Stopper Specications2.3 MDS Inatable Stopper Specications
A) MDS Stopper size = 1.96” – 2.16” (50 mm – 55 mm) [Part #23000096]
B) Ination pressure = 2x system pressure and/or 22 psi maximum
NOTE: If the condition of the interior of the pipe being stopped is unknown, it is a recommended practice to
inate the stopper to the maximum ination pressure to obtain the best stop o possible.
C) Design burst pressure = 170 psi
D) Operating temperature range = 5° F (- 15° C) to 140° F (60° C)
E) Maximum temperature range = 158° F (70° C) for up to 30 minutes
2.4 Hand Pump (Pressure and Vacuum Pump)2.4 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 = 65 ft/sec (19.8 m/sec)
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 (green 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 MCS7-2PVC 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” 22” ” ” 11” *
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
2” 22” ” ” 11” *
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 and Stopping Case [Part # MCS007-2PVC-001]:Tapping and Stopping Case [Part # MCS007-2PVC-001]:
PART # DESCRIPTION
1) & 2) 99540001 Slide Gate Valve (2-1/2”)
3) & 4) 99505007 Chute # 0
5) 14700015 Grease
6) & 7) 99400955 Stopper Pressure Gauge
(-15 to 45 psi)
8) & 9) 12000460 Tower Compact P4
10) & 11) 99400956 Line Pressure Gauge
(0 to 15 psi)
12) & 13) 99518939 Chute Adapter
14) 99540020 Plugging Spindle
15) & 16) 23000096 MDS Stopper 1.96” – 2.16”
(50 mm – 55 mm)
17) 99540010 Drilling Dome (2-1/2”)
18) 12400245
Control Gauge Pipeline
Pressure Between Tools
(9 psi)
19) 10500050 Drilling Tool P900
PART # DESCRIPTION
20) 13100030 1.16” Cutter
21) 99540021 Set Seals (For Plugging Spindle)
22) 99540022 Set Seals (For Connector
Gauge Rod / Stopper)
23) 99540011 Set Seals (For Drilling Dome)
24) 99518943 Set Seals (For Chute Adapter)
25) 99512503 Hex Wrench 2 mm
26) 15001050 Pilot Drill
27) 10200205 Drilling Rod
28) 10310847 Plugging Spindle Wrench
29) 10200190 Wring Rod
30) 11000175 Wrench 22
31) 11000175 Wrench 22
32) 11000180 Wrench 24
33) 11000180 Wrench 24
12000880 Case + Foam Interior

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Tapping Tool and Completion Tool Components:Tapping Tool and Completion Tool Components:
Feed Tube
Cutter
Drilling Rod
Tapping
Device Lock
Plugging Spindle
Completion Plug
Tapping Device
Drilling Dome
Bleed Valve
Drilling
Dome
Drilling Dome
Pilot Drill

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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 Assembly
By-Pass /
Vent Port
Chute Lock
Slide Gate
Valve
Chute Adapter
Gauge Rod
Chute

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Fitting / Completion Plug / Completion Cap:Fitting / Completion Plug / Completion Cap:
PART # DESCRIPTION
1) 96008230 PVC Fitting (2”)
Accessories:Accessories:
PART # DESCRIPTION
1) 22500011 Hand Pump with Hose

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5.0 Preparatory Steps:
Make certain proper MDS Stopper is available.
Make certain proper tting is available.
Attach PVC tting per company standards and specications.
 For PVC applications, if pipe is brittle, an additional repair clamp may be necessary for support. Install the
repair clamp next to the tting in the area where the stopper will be inated.
Pressure test attached tting per company standards and specications.
6.0 Tapping Operation:
With tting and repair clamp (if necessary)
installed, attach the slide gate valve to the tting.
Operate the valve to ensure smooth operation.
Take the hot tapping device out of the case and
inspect the device for dirt and debris. Make sure
the threads are clean, the o-ring is in place, and the
device operates freely.
Visually inspect the drilling dome and verify the
o-ring is in place.

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Attach the drilling dome to the hot tapping device.
Attach the pilot drill to the drilling rod using an
allen wrench.
Grease the 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.

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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.)
Lock the drilling rod by operating the orange
tapping device lock.
With slide gate valve open (pulled out), install the
complete tapping tool onto the valve.
When doing this, make certain the valve doesn’t
inadvertently turn.
Position feed tube so it is ush with the bottom
thread.
Verify drilling dome bleed valve is closed.

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Unlock the drilling rod by operating the orange
tapping device lock. Lower the drilling rod until
the pilot drill touches the surface of the pipeline to
be tapped.
After the pilot drill is in contact with the pipeline,
lock the drilling rod by operating the orange
tapping device lock.
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 the drilling rod handle through the top of the
drilling rod.
Use the handle to turn the drilling rod clockwise
(down) to cut the pipe.

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The tapping procedure is nished when the
drilling rod can rotate without any resistance.
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.
WARNING: Always control the drilling rod.
Unlock the drilling rod by operating the orange
tapping device lock. Then pull the drilling rod
completely upwards above the slide gate valve.
(If assistance to get the cutter out is needed, turn
the drilling rod clockwise.)
(NEVER turn the drilling rod counterclockwise.
This can damage the cutter.)
(Be aware of the fact that the pressure inside
the pipeline may automatically move the rod
upwards. Avoid being above the rod with your
hands or face.)
WARNING: Always control the drilling rod.
Close the slide gate valve.
Release pressure from the dome by opening bleed
valve.

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Remove the complete tapping tool from the slide
gate valve.
When doing this, make certain the valve doesn’t
inadvertently turn.
Disassemble the tapping tool.
NOTE: When taking apart the tapping tool, the
cutter should contain the drilling coupon. Use the
necessary tools to remove the coupon from the
cutter.
Clean and store tapping tool in its case.

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7.0 Stopping Operation:
Install the appropriate gauges on the appropriate
couplings at the top of the gauge rod.
Gold: The gold connection gauge will indicate the
pressure inside the pipeline in front of the MDS
Stopper.
Silver: The silver connection gauge indicates the
ination pressure of the inatable stopper.
system / pipeline pressure
internal / ination pressure
Verify that the coupling on the bottom of the
gauge rod contains a seal. The seal should be in
good condition.
NOTE: Extra gauge rod seals should always be
available.
Never use the stopping tool if the seal is not inside
the coupling.
Visually inspect that the stopper is in good
condition without weak spots or concern for
integrity.
(If the condition of the stopper is uncertain, refer
to Appendix A for additional stopper testing and
verication.)
Pre-bend the hose of the MDS Stopper as this will
facilitate the positioning of the stopper into the
pipeline through the chute.
NEVER pre-bend the MDS Stopper on the
frame!!! This can damage the frame and it will not
help as the internal frame is rigid.

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Attach the MDS Stopper to the gauge rod.
Tighten the connections by means of a pair of
wrenches. Always use two wrenches to ensure
tight connection and seal.
Connect hand pump to the stopper ination
connection on the top end of the gauge rod.
(This is the silver connection.)
With the valve open, pull a vacuum to -15 psi on
the stopper to make it as compact as possible.
Close the valve after evacuation.