USA Industries GRIPSAFE Series User manual

Patents & Trademarks
- US PATENTS: 9,927,058 | 9,810,364 | D894,349 | 10,746,339
- CANADIAN PATENT: 3,004,787
- CANADIAN INDUSTRIAL DESIGN: CA 186293
- EUROPEAN PATENT: 3,377,797 B1
- EUROPEAN PATENT [Germany]: 602016051864.3
- EUROPEAN UNION DESIGN REGISTRATION: 00628264-001
- INTERNATIONAL TRADEMARK REGISTRATION: 1550298
- Other US and Foreign Patents Pending
®
INSTALLATION MANUAL
www.USAIndustries.com
[phone] • [phone]
315 State Street • S. Houston, TX 77587
Small Double Block and Bleed (DBB) Plug
Manufactured Exclusively by USA Industries, Inc.
an ISO 9001:2015 Certifi ed Company

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
Contents
1. Introduction 2
2. Safety 3
3. Parts 4
4. Specications 6
5. Preparing the GripSafe DBB Plug for Installation 8
6. Installing the GripSafe DBB Plug 9
7. Positioning for Between the Seal Hydro Testing 12
8. Instructions for Cooling Flow Between the Seals 13
9. GripSafe DBB Plug Removal 14
1. Introduction
USA Industries, Inc. thanks you for choosing GripSafe pipe plugging technology. is manual covers the
proper use of this technology to ensure safe operating conditions.
WA R NI NG :
Do not use GripSafe equipment before fully reading and comprehending this manual. Failure to follow
this manual in full may result in injury and/or damage to equipment.
All necessary sockets, wrenches and liing device to install this equipment are available for rental or purchase
from USA Industries, Inc. See Section 4, Table 2 for sockets and check valves and Table 4 for liing device.
e information in this manual is for the use of a GripSafe plug in metallic piping. If the intended use of
this plug is for any piping other than metallic piping, please contact USA Industries, Inc.’s Customer Service
Department for technical support.
Page 2of 16

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
2. Safety
Failure to follow proper safety requirements may result in the GripSafe plug failing, which could lead to injury,
material loss, and/or damage to equipment.
Wear proper Personal Protective Equipment (PPE) when performing any task with the GripSafe plug as dened by
site safety rules. Always follow site procedure for safely liing and operating equipment.
Never install the GripSafe plug in a position where the Gripping Wedge would be located over weld droop or ridge.
Never install the Seals or Gripping Wedge over a section of pipe that is missing its interior wall; i.e. weldolet, tee,
etc.
Pressure testing can be a hazardous operation and safety precautions are important. Never stand or pass in front
of a test plug during installation, testing, and removal.
Do not make adjustments to the plug, safety equipment, or vessel while the plug is under pressure.
Do not exceed rated pressure stamped on the plug. Plugs are rated for holding pressure in one direction; never
apply pressure on the non-rated side of the plug.
Backpressure rating on the references the plugs ultimate holding capacity. Never exceed the pressure capacity of
the weakest component in a pressurized system. Study your system’s components prior to beginning a pressure
test to ascertain and conrm that the maximum test pressure of your system is subjected to is in accordance with
all applicable industry and site-specic standards.
We recommend using Water as the test medium. Before pressurizing the system, vent all gases from the vessel.
If pneumatic testing, all attempts to limit potential damage to personnel or equipment is critical. USA Industries,
Inc. recommends Nitrogen as the medium for pneumatic testing as it does not support combustion. Follow
provisions outlined in ASME PCC-2 Repair of Pressure Equipment and Piping when testing pneumatically.
Carefully observe the location of the pipe where the Wedge Grippers make contact when performing a hydro test.
If you observe any deformation or swelling of the pipe, stop immediately and slowly release the pressure from the
system. Contact USA Industries, Inc. for further assistance.
If you hear a popping or clicking sound at any time during a hydro test, STOP IMMEDIATELY and slowly release
the pressure from the system. Popping or clicking sounds during hydro testing may be a sign of the Wedge Gripper
slipping, cracking, or one of the plug components failing. Remove the plug from the pipe or tting and inspect for
damage. Contact USA Industries, Inc. for further assistance.
Make sure the plug is clean of debris and contaminants. Each Wedge Gripper should freely slide up and down in
its slot with a full range-of-motion, and incur no resistance. If you experience impeded movement due to debris,
dirt or contaminants, the plug may not grip the pipe’s ID securely, which can cause plug ejection under pressure,
potentially leading to injury, death, material loss, and/or damage.
For any questions or concerns, contact USA Industries, Inc. for technical assistance.
Page 3of 16

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
3. Parts (is manual references the part numbers identied below throughout the document)
Figure 1: GripSafe Mid-Grip DBB Diagram
Figure 2: With Optional Valve and Port for Cooling (Upon Request)
Page 4of 16

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
Table 1: GripSafe Bill of Materials
Page 5of 16

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
4. Specications
Figure 2: GripSafe DBB Dimensions Diagram
Page 6of 16

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
Table 2: GripSafe DBB Specications
Page 7of 16
Nominal
Pipe Size
(in)
Schedule Part Number
Tool
Diameter
(in)
Rec.
ID Range
(in)
Nominal
Pipe ID
Clearance
(in)
Approx.
Tool
Weight
(lbs)
Tool
Length
(in)
Torque Range
(ft-lbs)
Comp.
Hex Nut
Socket
Size
(in)
Backup
Wrench Size
(in)
Fill Port
Thread
Back
Pressure
Vent
Thread
Back
Pressure
Rating
(PSI)
Between
the
Seal Test
Pressure
(PSI)
Norm Max.
3/4
40,STD,40S GS-D-S-0075-040 0.79 0.81 - 0.91 0.035 2.5 25.38 3.0 5.0 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
80,XS,80S GS-D-S-0075-080 0.71 0.73 - 0.80 0.035 2.4 25.38 2.0 3.5 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
1
10 GS-D-S-0100-010 0.99 1.01 - 1.15 0.103 2.8 25.38 5.5 8.5 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 2825 2500
40,STD,40S GS-D-S-0100-040 0.99 1.02 - 1.15 0.055 2.7 25.38 5.5 8.5 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
80,XS,80S GS-D-S-0100-080 0.90 0.93 - 1.04 0.055 2.6 25.38 1.5 7.0 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
160 GS-D-S-0100-160 0.78 0.80 - 0.90 0.035 2.5 25.38 3.0 5.0 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
1-1/4
10 GS-D-S-0125-010 1.31 1.35 - 1.49 0.130 6.0 2 7.7 5 10 20 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 2350 2500
40,STD,40S GS-D-S-0125-040 1.31 1.35 - 1.49 0.068 6.0 27.75 10 20 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
80,XS,80S GS-D-S-0125-080 1.21 1.25 - 1.37 0.065 5.7 27.75 10 20 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
160 GS-D-S-0125-160 1.11 1.14 - 1.26 0.055 3.0 25.38 7. 0 11.0 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
XXH GS-D-S-0125-XXH 0.85 0.87 - 0.98 0.045 2.5 25.38 4.0 6.0 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
1-1/2
10 GS-D-S-0150-010 1.53 1.58 - 1.73 0.157 6.7 27.75 20 30 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 2125 2500
40,STD,40S GS-D-S-0150-040 1.53 1.58 - 1.73 0.085 6.7 27.75 20 30 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
80,XS,80S GS-D-S-0150-080 1.42 1.47 - 1.62 0.085 6.3 27.75 20 30 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
160 GS-D-S-0150-160 1.27 1.31 - 1.45 0.068 5.9 27.75 10 20 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
XXH GS-D-S-0150-XXH 1.05 1.08 - 1.20 0.055 2.8 25.38 6.0 10.0 9/16 1/4 Open End 1/4” FNPSM 1/16 MNPT 10000 2500
2
10 GS-D-S-0200-010 1.94 2.00 - 2.25 0.220 8.2 27.75 30 50 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 1825 2500
40,STD,40S GS-D-S-0200-040 1.94 2.00 - 2.25 0.130 8.2 27.75 30 50 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
80,XS,80S GS-D-S-0200-080 1.81 1.87 - 1.99 0.130 7.7 27.75 30 50 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
160 GS-D-S-0200-160 1.60 1.65 - 1.81 0.085 6.9 2 7.75 25 35 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
XXH GS-D-S-0200-XXH 1.42 1.47 - 1.62 0.088 6.3 27.75 15 25 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 10000 2500
2-1/2
10 GS-D-S-0250-010 2.34 2.40 - 2.64 0.291 22.8 32.25 60 100 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 1975 2500
40,STD,40S GS-D-S-0250-040 2.34 2.40 - 2.64 0.125 22.8 32.25 60 100 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 8000 2500
80,XS,80S GS-D-S-0250-080 2.20 2.26 - 2.41 0.125 21.8 32.25 60 100 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 8000 2500
160 GS-D-S-0250-160 2.00 2.06 - 2.21 0.125 20.8 32.25 55 85 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 8000 2500
XXH GS-D-S-0250-XXH 1.69 1.74 - 1.89 0.085 7. 2 27.75 25 40 15/16 7/16 Open End 1/4” FNPSM 1/4 MNPT 8000 2500
3
10 GS-D-S-0300-010 2.88 2.97 - 3.16 0.385 27. 8 32.25 150 200 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 1725 2500
40,STD,40S GS-D-S-0300-040 2.88 2.97 - 3.16 0.193 27.8 32.25 150 200 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 8000 2500
80,XS,80S GS-D-S-0300-080 2.71 2.80 - 3.01 0.19 0 26.4 32.25 125 175 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 8000 2500
160 GS-D-S-0300-160 2.50 2.56 - 2.74 0.125 25.0 32.25 80 140 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 8000 2500
XXH GS-D-S-0300-XXH 2.18 2.24 - 2.39 0.125 21.8 32.25 60 100 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 8000 2500
3-1/2
10 GS-D-S-0350-010 3.34 3.44 - 3.67 0.416 32.5 32.25 200 325 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 1575 2500
40,STD,40S GS-D-S-0350-040 3.34 3.44 - 3.67 0.204 32.5 32.25 200 325 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500
80,XS,80S GS-D-S-0350-080 3.16 3.26 - 3.45 0.208 31.0 32.25 180 290 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500
XXH GS-D-S-0350-XXH 2.60 2.66 - 2.84 0.125 25.8 32.25 115 165 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500
4
10 GS-D-S-0400-010 3.81 3.92 - 4.21 0.454 37.9 32.25 220 340 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 1500 2500
40,STD,40S GS-D-S-0400-040 3.81 3.92 - 4.21 0.220 37.9 32.25 200 300 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500
80,XS,80S GS-D-S-0400-080 3.61 3.72 - 3.93 0.220 35.3 32.25 155 245 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500
120 GS-D-S-0400-120 3.42 3.52 - 3.72 0.205 32.7 32.25 250 350 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500
160 GS-D-S-0400-160 3.23 3.33 - 3.53 0.205 32.7 32.25 200 325 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500
XXH GS-D-S-0400-XXH 2.95 3.01 - 3.20 0.205 30.5 32.25 175 275 1-7/8 1 Box End 1/4” FNPSM 3/8 FNPT 6000 2500

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
5. Preparing the GripSafe DBB Plug for Installation
5.1 e GripSafe DBB plug should be in the relaxed position from the factory. ere are
two methods of insertion of the plug.
Method 1: Auto-Locking, the preferred method, allows the Wedges⑪to immediately conform
and engage to the pipe ID ensuring the plug is immediately incapable of being pushed out of the
pipe in the event of accidental discharge of pressure, i.e. when the Wedges⑪are fully inserted
into the pipe.
Method 2: Free Insertion is used when the plug is met with an obstruction in the pipe that is not
allowing free entry of the plug into the pipe, i.e. weld droop or other pipe interior discontinuity.
5.2 Method 1: Auto-Locking for immediate gripping upon insertion
• Expand the Wedge Grippers⑪to the end of the Wedge Cone⑫by advancing the Compression
Hex Nut㉑(see Figure 3). At this point, the Wedge Grippers⑪expanded outside diameter will
be larger than the ID of the pipe.
• e plug is ready to be installed, continue to Section 6.
Figure 3: Immediate Gripping Upon Insertion
Page 8of 16

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
5.3 Method 2: Free Insertion for free entry into the pipe or tting
• Ensure the plug is in the relaxed position (see Figure 4).
• e Compression Hex Nut㉑should be nger tight.
• e Wedge Grippers⑪should be fully retracted under the bodyline of the plug’s OD and should
t inside the pipe (see Figure 4).
• e plug is ready to be installed, continue to Section 6.
6. Installing the GripSafe DBB Plug
CAUTION: Ensure pipe I.D. is clean, and loose debris is removed to the deepest point the plug will be
installed into. If the pipe is lined or has an irremovable product, and contact USA Industries, Inc.
for support before proceeding. Failure to do so may impede the wedges ability to grip and cause the
plug to eject under pressure. Be sure to wear proper PPE and follow all site guidelines.
Figure 4: No Immediate Gripping Upon Insertion
Page 9of 16

www.USAIndustries.com | [phone]
©2021, USA Industries, Inc.
FRM-22.1 Rev.G
For most current patent and trademark identifi cations, go to:
https://www.USAIndustries.com/piping-isolation-products/Gripsafe-Patents-Trademarks/
TEMPERATURE NOTE:
If welding is to occur while the plug is inside the pipe then the Sealing Compression Ring⑥must
be at least 12 inches into the pipe beyond the location welding is to occur. USA Industries Urethane
Seals (Tri-Ply™) can withstand 225° Fahrenheit for short durations. If high temperature seals are needed
contact USA Industries for alternative sealing solutions.
6.1 Method 1: Auto-Locking (see Step 5.2) – immediate gripping upon insertion
installation
• See Table 2 for clearance requirements, and to ensure the pipe ID falls within the Internal
Diameter Range.
• Slowly push the plug into the pipe, the Compression Spring⑯shown in Figure 3 will
compress into the Spring Cup⑨and allow the Wedge Grippers⑪to retract forward,
decreasing its expanded outside diameter until they match the ID of the pipe.
• Once the Wedge Grippers⑪contact the ID of the pipe, they will automatically grip; removal
of the plug at this point is not possible. See Section 8 for plug removal if necessary.
• A slight rocking motion may assist installation.
• Ensure that the Test Port is oriented to the top of the GripSafe DBB when installing.
• Insert plug to the desired depth. e Sealing Compression Ring⑥must be inserted ush
with the pipe, or tting face at a minimum.
• If insertion into the pipe proves problematic in this orientation use Method 2.
• Continue to Step 6.3.
6.2 Method 2 (see Step 5.3) – Free entry into a pipe or tting installation
CAUTION: In this orientation, it is important to note that the plug will not immediately grip the pipe
upon insertion. Only aer tightening the Compression Hex Nut⑬to advance the Wedge Grippers⑪
will the plug engage the pipe ID and be able to withstand backpressure.
• See Table 1 for clearance requirements, and to ensure the pipe ID falls within the Internal
Diameter Range.
• Insert plug to the desired depth. e Sealing Compression Ring⑥must be inserted ush with
the pipe or tting face at a minimum.
• Continue to Step 6.3.
6.3 Tighten the Compression Hex Nut㉑
• Use a crow’s foot attached to a torque wrench to turn the Compression Hex Nut㉑while holding
the backup hex or wrench ats on the S h a  ①, stationary with a mechanic’s end wrench.
• Continue tightening until the Minimum Compression Torque (see Table 2) is met.
Page 10 of 16