Petersen PeteStop 129 Series User manual

Petersen®Warnings, Warranty, Terms and Conditions refer to http://www.petersenproducts.com.
PeteStopTM Inflatable Line Stop, Pipe Plugging System
129 Series
Instruction Manual
Petersen Pipe Plugs
www.PetersenProducts.com
421 Wheeler Avenue, PO Box 340, Fredonia, Wisconsin 53201-0340, USA
Phone: [phone] or 1-800-926-1926
Fax: [phone] or 1-800-669-1434
Email: [e-mail]

_______________________________________________________________________________________________
421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
Page 2 of 57
Table of Contents
1.0 Important Safety Instructions ......................................................................................................................................4
1.1 Safety is Everyone’s Responsibility...............................................................................................................................4
1.2 Personal Safety .............................................................................................................................................................4
1.3 Piping Review and Assessment for ILS Selection ........................................................................................................5
1.4 Application Engineering –Operator Fill out this Section...........................................................................................6
2.0 Pre-Work Inspection....................................................................................................................................................7
2.1 Verify the Yellow Warning Tag attached is the correct plug and to the project data list in 1.4.2 ..................................7
2.2 Gather the necessary equipment and tools.................................................................................................................10
3.0 Line Stop Tool List ....................................................................................................................................................11
3.1 Overview......................................................................................................................................................................11
3.2 Tool List.......................................................................................................................................................................11
3.3 Flanged Launch Cylinder.............................................................................................................................................11
3.4 Torque Figures ............................................................................................................................................................12
4.0 Reference..................................................................................................................................................................13
4.1 Inflatable Plug Launched and Plug in Launch Cylinder...............................................................................................13
5.0 Bundling the Pipe Plug..............................................................................................................................................14
5.1 Bundle the Plug before inserting into launch cylinder .................................................................................................14
6.0 Setup and Tapping the Pipe......................................................................................................................................17
6.1 Setup ...........................................................................................................................................................................17
7.0 Installing the Ram .....................................................................................................................................................19
7.1 Ram Installation...........................................................................................................................................................19
8.0 Plug Insertion ............................................................................................................................................................31
8.1 Inserting the plug.........................................................................................................................................................31
9.0 Inflation of the Plug ...................................................................................................................................................38
9.1 Determine if inflation by Water, Air, Nitrogen, Grout or other medium........................................................................38
9.2 If the pipeline is more than half-full of liquid:...............................................................................................................38
9.3 If the pipeline is less than half-full of liquid:.................................................................................................................38
9.4 If pipeline is greater than 12” piping: ...........................................................................................................................39
10.0 Plug Deflation for Inflated Plugs................................................................................................................................40
10.1 Air or Gas...................................................................................................................................................................40
10.2 Water.........................................................................................................................................................................42
10.3 Water with Air / Gas Pressurization...........................................................................................................................43

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11.0 Plug Removal............................................................................................................................................................44
11.1 Removal of the plug...................................................................................................................................................44
12.0 Maintenance and Care..............................................................................................................................................48
12.1 Maintenance and care...............................................................................................................................................48
13.0 Troubleshooting ........................................................................................................................................................52
13.1 When inserting a plug into a vertical pipeline:...........................................................................................................52
13.2 For proper deployment:.............................................................................................................................................52
13.3 Pro Tips: ....................................................................................................................................................................52
13.4 Safety Tips:................................................................................................................................................................52
14.0 Acronyms/Definitions ................................................................................................................................................56
15.0 Revisions...................................................................................................................................................................56
16.0 History.......................................................................................................................................................................56
Measurement Card (https://ilsconfigurator.petersenproducts.com/Home/129)....................................................................57

_______________________________________________________________________________________________
421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
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1.0Important Safety Instructions
WARNING
Pressure forces are involved in many Inflatable Line Stop situations that may cause injury
or even death.
Focus and care is required to ensure the safe use of any Inflatable Line Stop, as pressure
forces increase as pressure and pipe diameter increase.
1.1.1
All pipe plugs shall be restrained adequately in accordance with design of the PeteStopTM
Inflatable Line Stop system.
1.1.2
Debris or protrusions into the pipeline may damage a seal or reduce the pressure rating.
1.1.3
Do not exceed the pressures on the plug label.
1.1.4
Petersen Products recommends inflatable devices shall not be used as the primary isolation or
protection point for personnel downstream.
1.1.5
Due to project variability, these general instructions must be adapted by a competent professional
for each specific project. Instructions and training must be provided to all PeteStopTM Inflatable Line
Stop users and workers on the job.
CAUTION
Keep all personnel out of the Danger Zone, e.g.
1.2.1
PPC recommends adequate Personal Protective Equipment (PPE) to be used per operator policy
and procedure.
1.2.2
PPC recommends the operator determine if the area is considered a Confined Space and to refer
to Occupational Safety and Health Administration (OSHA) (29CFR 1910.146), Safe Confined
Space Entry. Follow all federal, local and site specific codes, standards and regulations.
1.1 Safety is Everyone’s Responsibility
1.2 Personal Safety

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421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
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CAUTION
Polyethylene (HDPE) or new pipelines with remains of grease or agents directly decrease
the efficiency and holding strength of the PeteStopTM Inflatable Line Stop.
1.3.1
Thoroughly inspect the PeteStopTM Inflatable Line Stop, before each use. Refer to Section 12.0.
1.3.2
PPC recommends to never inflate an inflatable plug, outside of a pipe, above 5% of rated inflated
pressure.
1.3.3
Verify airline connections and hoses are not damaged or leaking.
1.3.4
Use two calibrated pressure gauges that agree for measuring the pipeline operating pressure.
1.3.5
Prepare to equalize pressure on both sides of plug before installation and removal.
1.3.6
Use two calibrated pressure gauges that agree for monitoring the inflation pressure.
1.3.7
Call Petersen with any questions or suggestions relating to the use of any Petersen product.
1.3 Piping Review and Assessment for ILS Selection

_______________________________________________________________________________________________
421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
Page 6 of 57
SAFETY
Ensure that all project information and data is accurate. If assumptions
are made, please specify and whenever there is doubt contact Petersen
Products engineering for application and product technical assistance.
Understand your completeness of application data is paramount to
project safety.
1.4.1 Overview
It is important to understand what your requirements are and how to deploy the ILS safely. There are many
configurations to choose from based on your application. The piping configuration should also be reviewed to ensure
pressure or flow differentials are not created or have means to mitigate (e.g. leak downstream of isolation point).
1.4.2 Data List
Pipe Size / Wall Thickness /
Material / Internal Coating
Design Pressure / Temperature
/ Flow Rate
Operating Pressure /
Temperature / Flow Rate
Product / Service/ Medium
Plug Inflation Medium
Piping Design Code
Duration of Line Stop
Purpose of Line Stop
ISO or Piping Drawing Provided
Obstructions at Isolation
Location
Fitting Type / Requirements /
Orientation/ Piggable
Flange Type / Rating
Fitting Location (Above / Below
Ground)
Service Valve Bore
Service Fitting Bore
Expected Inflation Source
Expected Hot Tap Hole Size
1.4 Application Engineering –Operator Fill out this Section

_______________________________________________________________________________________________
421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
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2.0Pre-Work Inspection
SAFETY
Survey the work area for unsafe conditions.
Verify all people working with the plug have read and understand the IMPORTANT
SAFETY INSTRUCTIONS listed at the beginning of this work instruction.
2.1 Verify the Yellow Warning Tag attached is the correct plug and to the project data list in 1.4.2
Back of yellow tag
Front of Tag

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421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
Page 8 of 57
2.1.1
Compare the order conformation to the packing list
1. Line Stop Plug 7. Packaging Seal
2. Centering Anchor 8. Eyebolts
3. Inflation Ram Connector 9. Flange Bolts
4. Inflation Ram Sections 10. Stop Collars
5. Launch Cylinder 11. Inflation Ram Pulley Assembly
(aka Line Stop Housing)
6. Flange Gaskets 12. Extra rubber bands for bundling
13. Spare Parts Kit (varies on ram size)
13

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421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
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2.1.2
Additional Accessories Depending on Application
1. Retraction Assembly
2. Strong back
3. Coupon Support
4. Ram Adapter Assembly
5. Bundling Sleeve –used when rubber bands cannot be used
6. Inflation Accessories Kit (pictured is a nitrogen kit) –each kit is adjusted to inflation
6

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421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
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2.2.1
Refer to the Hot Tap Insertion Tool Checklist.
1. Ratchet Puller 6. Tape Measure
2. Socket* 7. Wrench*
3. Torque Wrench* 8. Marker
4. Allen Wrench* 9. O-Ring Lubricant
5. Small Allen Wrench* 10. Optional Laser (or other acceptable measuring device)
*Size will depend on kit
2.2 Gather the necessary equipment and tools.

_______________________________________________________________________________________________
421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
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3.0Line Stop Tool List
3.1.1
The Petersen Hot Tap Insertion System may be used on most any size pipeline or system and
therefore may require a variety of tools to match. This list is intended to assist in determining which
tools to prepare for a job but is not a replacement for the judgement of an experienced contractor.
Different jobs may require specific tools above and beyond what is listed.
3.2.1
Ratchet Chain Puller
For inserting and securing plug and for retraction with retraction
kit.
3.2.2
Marker or Paint Stick
For marking on steel, fabric, or painted surfaces.
3.2.3
Tape Measure or Laser
To set insertion depth on Inflation Ram or Bundling Sleeve strap
lengths.
3.2.4
O-Ring Lubricant
Inflation Ram and Packing Seal O-Rings.
3.2.5
Allen Wrench 1/8"
Set screws for 1 inch and 1-7/8-inch diameter Inflation Ram.
3.2.6
Allen Wrench 3/32"
Set Screws for 1-1/2-inch Inflation Ram.
3.2.7
Allen Wrench 3/16"
Set screws for 2-1/2-inch Inflation Ram, 1-inch stop collar, and
centering guides.
3.2.8
Allen Wrench 1/4"
Stop Collar for 1-7/8-inch diameter Inflation Ram.
3.2.9
Allen Wrench 5/16"
Stop Collar for 2-1/2-inch Inflation Ram.
3.2.10
Pipe Wrench
Attaching NPT Launch Cylinder and Packing Seal.
3.2.11
Pipe Thread Sealant
Attaching NPT Launch Cylinder and Packing Seal.
3.2.12
Lubricant
Attaching Hardware to flanges
3.3.1
Torque Wrench and Socket
Match the values listed in the table below for the launch cylinder.
3.3.2
Wrench
For reaction force against Torque Wrench (match socket size).
Torque Figures
Class 150 Flanges
Class 300 Flanges
Size
Bolt
Wrench
Torque
Bolt
Wrench
Torque
3
5/8"
15/16"
110 lbf * ft
4
5/8"
15/16"
110 lbf * ft
5
3/4"
1-1/8"
195 lbf * ft
6
3/4"
1-1/8"
195 lbf * ft
3/4"
1-1/8"
195 lbf * ft
8
3/4"
1-1/8"
195 lbf * ft
7/8"
1-5/16"
310 lbf * ft
10
7/8"
1-5/16"
310 lbf * ft
1"
1-1/2"
465 lbf * ft
12
7/8"
1-5/16"
310 lbf * ft
1-1/8"
1-11/16"
685 lbf * ft
14
1"
1-1/2"
465 lbf * ft.
1-1/8"
1-11/16"
685 lbf * ft
16
1"
1-1/2"
465 lbf * ft
1-1/4"
1-7/8"
960 lbf * ft
18
1-1/8"
1-11/16"
605 lbf * ft
20
1-1/8"
1-11/16"
605 lbf * ft
24
1-1/4"
1-7/8"
960 lbf * ft
30
1-1/4"
1-7/8"
960 lbf * ft
Per ASTM torque standard: Torque = Force * Length
3.1 Overview
3.2 Tool List
3.3 Flanged Launch Cylinder

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Note: Sequence the torque in a star pattern. Complete the pattern three times 30%, 70%, 100% to the sequence.
3.4.1
Torque Patterns
WARNING
Immediately before every use re-toruqe the attachment of the inflation ram to
the plug. On this bolted joint, torque it to 3.4.1. It is essential to wait 15 minutes
between each torque sequence to allow the bolts to stretch and settle with the
fabric before applying next torque application.
3.4 Torque Figures

_______________________________________________________________________________________________
421 Wheeler Ave Fredonia, WI 53201
Phone: [phone]
Petersen®Products Co. All rights reserved.
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4.0Reference
https://ilsconfigurator.petersenproducts.com/Home/129 PeteStopTM ILS system Configurator
Last page of this manual is a Measurement Card, use this as a guide (keep the measurement units consistent)
Measure Distance (D1)
Distance from face of the valve flange to the top of the pipe
Lost Distance (D3)
Distance from base of the launch cylinder, without gasket, to the top of the packing seal or
retraction post base, if used
D5 measurement
If the formula results in negative number, no additional ram section required. If formula results in
positive number, additional ram section required to accommodate for additional required length.
Set stop collar at calculated location. If negative number, measure from end of ram towards
launch cylinder for stop collar placement. If positive, place stop collar on additional ram section
away from launch cylinder.
All dimensions are assumed field measured with a tape measure an accuracy of +/- 1/32”up to 12 ft. and over 12 ft. +/- 1/16”.
Do not use the product if there is significant wear or damage. Return to Petersen for evaluation.
PPC has all the equipment required for inflation, deflation, and pressure monitoring of all plugging systems.
Contact PPC with any questions or suggestions relating to the use of any Petersen product.
4.1 Inflatable Plug Launched and Plug in Launch Cylinder

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421 Wheeler Ave Fredonia, WI 53201
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5.0Bundling the Pipe Plug
5.1.1
Inflate and stretch out the plug.
Max 5% of rated pressure when not supported in a
pipe.
5.1.2
Roll each end inward.
5.1.3
Continue folding inward.
Maintain even folds on each end.
5.1 Bundle the Plug before inserting into launch cylinder

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5.1.4
Fold until the end discs touch to the inside.
5.1.5
Fold the cylinder to create a round bundle.
Verify that the sealing rings are inside.
5.1.6
Add rubber bands.
Tuck in the bottom and top corners to reduce the
length of the bundle.
Verify the bundled diameter will fit in the required hot
tap hole.

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5.1.7
Only use enough rubber bands so that the bundle is
smaller than hot tap hole.
5.1.8
Bundling completed.

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6.0Setup and Tapping the Pipe
6.1.1
Install line stop fitting
(aka sleeve or saddle)
and tapping valve (aka
service valve) on pipe,
according to the
manufacturer’s
instructions.
Use a fitting as
required for each
application taking into
account jurisdictional
service requirements.
NOTE: 129 series standard configuration is typically launched with line stop fitting perpendicular to
the line.
Caution shall be taken when launch equipment is not in standard configuration,
Call engineering about nonstandard configurations and their customization
6.1 Setup

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421 Wheeler Ave Fredonia, WI 53201
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NOTE
Record the measurements in the Measurement Card (see last page). Keep
measurement units consistent.
This is a critical measurement and good practice is to measure from pipe to flange on both sides to make sure that the
fitting and flange are square.
The demo item is idealized and field scenarios may dictate multiple measurements are required. D1 may be an average
of these measurements.
6.1.2
Measure the distance
through the open
tapping valve from
the top of the uncut
pipe to the top of the
flange gasket.
Add to the
measurement the
thickness of the pipe.
The sum is D1 (MD).
NOTE: This may be
measured inside or
outside the valve.
NOTE: Write the measurement on the Measurement Card. Keep measurement units consistent.
6.1.3
Once the measurement is taken, commence Hot Tapping operation according to job specific
requirements.
For more in-depth information on Hot Tapping, refer to the respective manual on our
website under Product Selection/Instructions tab
http://www.petersenproducts.com

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Phone: [phone]
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7.0Installing the Ram
NOTE
If a ram adapter assembly is not needed, see Step 7.1.6.
7.1.1
If needed, clean
the inflation port,
flange gasket, and
ram adapter assy.
Bolt Size
Torque
1/2″
80 lbf * ft.
5/8″
159 lbf * ft.
3/4′′
254 lbf * ft.
7/8″
400 lbf * ft.
7.1.2
Inspect the torque
on the flange nuts.
7.1.3
Place the ram
adapter assembly
end on the inflation
port flange.
Align the setscrew
pockets on the
ram adapter with
the plug directional
arrows machined
into the outer
flange.
7.1 Ram Installation
Flange Bolt