Usa industries Gripsafe st User manual

www.USAIndustries.com

(713) 941-3797 • (800) 456-8721

315 State Street • S. Houston, TX 77587

Manufactured Exclusively by USA Industries, an ISO

9001:2015 Certified Company

For patent and trademark information, go to

https//www.USAIndustries.com/gripsafe-patents-trademarks/

INSTALLATION MANUAL

Small Double Block & Bleed (DBB) Plug

¾” – 4”*

*For 4” Schedules 120, 160 and XXH only. Additional 4” Schedules Require the GripSafe ST Large DBB Plug

Page 1 of 16

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FRM-22.1-Rev.H-SMDBB

Table of Contents

1. Introduction .......................................................................................................................... 1

2. Safety .................................................................................................................................. 2

3. Parts .................................................................................................................................... 3

4. Specifications ...................................................................................................................... 6

5. Preparing the GripSafe ST DBB Plug for Installation .......................................................... 8

6. Installing the GripSafe ST DBB Plug ................................................................................... 9

7. Positioning for Between the Seal Hydrotesting ................................................................. 12

8. GripSafe ST DBB Plug Removal ....................................................................................... 14

9. Installing and Using Safety Gag ........................................................................................ 15

1. Introduction

Thank you for choosing GripSafe ST pipe plugging technology. This manual covers the proper

use of this technology to ensure safe operating conditions. All necessary sockets and

wrenches to install this equipment are available for rental/purchase from USA Industries, LLC.

See Section 4 Table 2 for sockets.

The information in this manual is intended for the use of a GripSafe ST IIB plug in metallic

piping. If the intended use of this plug is for any piping other than metallic piping please contact

USA Industries Customer Service Department for technical support.

Do not use GripSafe ST equipment before fully reading and comprehending and

comprehending this manual

Failure to follow this manual in full may result in injury to personnel and

damage to equipment.

Page 2 of 16

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FRM-22.1-Rev.H-SMDBB

2. Safety

Failure to follow proper safety requirements may result in the GripSafe® Plug failing, which could lead to

personnel injury, material loss, and damage to equipment.

Wear proper PPE when performing any task with the GripSafe® Plug as defined by site safety rules. Always

follow site procedure for safely lifting 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; e.g. weldolet,

tee, etc.

Use care in the handling of the Wedge Studs. Never beat, hammer, or pry on the Wedge Studs. Never

remove the nut located on the Wedge Studs.

Pressure testing can be an extremely hazardous operation and safety precautions should be strictly adhered

to. Never stand or pass in front of any test plug while installed or while testing is in progress.

Do not make any 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

only, never apply pressure on the non-rated side of the plug.

Backpressure rating on the plug is in reference to the plugs ultimate holding capacity. Never exceed the

pressure capacity of the weakest component in a pressurized system. It is imperative that a system’s

components be studied prior to beginning a pressure test to confirm the maximum test pressure a system

can be subjected to in accordance with all applicable industry and site-specific standards.

It is recommended that water be used as the test medium. Venting all gases from the vessel being

pressurized is necessary before pressurizing the system.

In the event pneumatic testing is required, all attempts to limit potential damage to any personnel or

equipment must be made. USA Industries 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.

The Double Block and Bleed GripSafe Plug is designed to hold pressure originating from the vessel side and

Between the Seal area only.

Careful observation is needed at the location of the pipe where the Wedge Grippers make contact while

performing a hydrotest. If any deformation or swelling of the pipe is observed, stop immediately and slowly

release the pressure from the system. Contact USA Industries for further assistance.

At any time during hydrotesting, if a popping or clicking sound is heard, stop immediately and slowly release

the pressure from the system. Popping or clicking sounds during hydrotesting could be a sign of the Wedge

Gripper slipping, cracking, or plug components failing. Remove the plug from the pipe or fitting and inspect

for damage. Contact USA Industries for further assistance.

Ensure plug is clean of debris, fouling, and contaminants before each use. Each Wedge Grippers should

freely slide up and down in its slots with a full range of motion without any resistance. With impeded

movement due to debris, dirt, contaminants, or other fouling will cause the plug to not grip on the pipe’s inner

diameter, which can cause it to eject under pressure, leading to personnel injury or death, material loss, and

damage to equipment.

For any questions or concerns, contact USA Industries for technical assistance.

Page 3 of 16

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FRM-22.1-Rev.H-SMDBB

3. Parts

Figure 1: GripSafe ST Double Block and Bleed ¾”-2” (DBB) Diagram

Page 4 of 16

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FRM-22.1-Rev.H-SMDBB

Figure 2: GripSafe ST Double Block and Bleed 2-1/2”- 4” (DBB) Diagram

Page 5 of 16

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FRM-22.1-Rev.H-SMDBB

Table 1: GripSafe® Bill Of Materials

Nominal

Pipe Size

(in)

Schedule

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

(21)

(22)

(23)

(24)

(25)

(26)

Shaft

Thrust

Washer

Swivel

Pipe

Union

Fitting

Street

Elbow

Fitting

DBB

Pressure

Fill Sleeve

Compression

Tube

DBB

Spring

Plate

Spring

Plate

Alignment

Screw

Retraction

Spring

Wedge

Cone

Wedge

Cone

Alignment

Screw

Mid Ring

Bottom

Compression

Plate

Seal

Wedge

Gripper

Retaining

Dowel Pin

Wedge

Gripper

Wedge

Gripper

Spring

Wedge

Gripper

Stem Dowel

DBB Shaft

Internal

Plumbing

DBB Shaft

O-Ring

Compression

Hex Nut

Vent

Port

Sealing

Compression

Ring

O-Ring

Compression

Threaded

Insert

Compressi

on Ring O-

Ring

Spring

Plate and

Wedge

Cone

Alignment

Key

3/4

40,STD,40S

1

0

1

2

5

1

2

1

0

80,XS,80S

1

0

1

2

5

1

2

1

0

1

10

1

0

1

2

6

1

2

1

0

40,STD,40S

1

0

1

2

5

1

2

1

0

80,XS,80S

1

0

1

2

5

1

2

1

0

160

1

0

1

2

5

1

2

1

0

1-1/4

10

1

2

7

1

2

1

0

40,STD,40S

1

2

6

1

2

1

0

80,XS,80S

1

2

5

1

2

1

0

160

1

0

1

2

6

1

2

1

0

XX

1

0

1

2

6

1

2

1

0

1-1/2

10

1

2

7

1

2

1

0

40,STD,40S

1

2

6

1

2

1

0

80,XS,80S

1

2

5

1

2

1

0

160

1

2

6

1

2

1

0

XX

1

0

1

2

6

1

2

1

0

2

10

1

2

7

1

2

1

0

40,STD,40S

1

2

6

1

2

1

0

80,XS,80S

1

2

6

1

2

1

0

160

1

2

7

1

2

1

0

XX

1

2

5

1

2

1

0

2-1/2

10

1

2

7

1

4

1

2

40,STD,40S

1

2

6

1

4

1

2

80,XS,80S

1

2

6

1

4

1

2

160

1

2

7

1

2

1

0

XX

1

2

7

1

2

1

0

3

10

1

2

8

1

4

1

2

40,STD,40S

1

2

7

1

4

1

2

80,XS,80S

1

2

7

1

4

1

2

160

1

2

7

1

4

1

2

XX

1

2

7

1

4

1

2

3-1/2

10

1

2

8

1

4

1

2

40,STD,40S

1

2

7

1

4

1

2

80,XS,80S

1

2

7

1

4

1

2

XX

1

2

6

1

4

1

2

4

10

1

2

8

1

4

1

2

40,STD,40S

1

2

7

1

4

1

2

80,XS,80S

1

2

7

1

4

1

2

120

1

2

7

1

4

1

2

160

1

2

7

1

4

1

2

XX

1

2

7

1

4

1

2

Page 6 of 16

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FRM-22.1-Rev.H-SMDBB

4. Specifications

Figure 3: GripSafe ST Double Block and Bleed Diagram (DBB) Dimensions

Page 7 of 16

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FRM-22.1-Rev.H-SMDBB

Table 2: GripSafe ST DBB Plug Specifications

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)

Compression

Hex Nut Size

(in)

Backup Wrench

Size

(in)

Fill Port

Thread

Back Pressure

Vent Thread

Back

Pressure

Rating

(PSI)

Between the

Seal Test

Pressure (PSI)

SEL

Seal End

Length

Norm

Max.

3/4

40,STD,40S

GSST-D-S-0075-040

0.79

0.80 - 0.87

0.035

1.9

19.00

2.9

4.5

1/2

1/4 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

2.92

80,XS,80S

GSST-D-S-0075-080

0.71

0.72 - 0.79

0.035

1.9

19.00

2.2

3.5

1/2

1/4 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

2.92

1

10

GSST-D-S-0100-010

1.04

1.06 - 1.16

0.055

2.2

18.63

6.3

9.7

9/16

1/4 Open End

1/4 FNPSM

1/16 MNPT

10000

2500

3.17

40,STD,40S

GSST-D-S-0100-040

0.99

1.02 - 1.11

0.055

2.2

18.63

5.6

8.7

9/16

1/4 Open End

1/4 FNPSM

1/16 MNPT

10000

2500

3.17

80,XS,80S

GSST-D-S-0100-080

0.90

0.92 - 1.02

0.055

2.1

18.63

4.5

6.9

9/16

1/4 Open End

1/4 FNPSM

1/16 MNPT

10000

2500

3.17

160

GSST-D-S-0100-160

0.78

0.79 - 0.85

0.035

1.9

19.00

2.8

4.4

1/2

1/4 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

2.92

1 1/4

10

GSST-D-S-0125-010

1.38

1.39 - 1.54

0.068

3.9

19.00

15

23

3/4

3/8 Open End

1/4 FNPSM

1/8 MNPT

10000

2500

3.59

40,STD,40S

GSST-D-S-0125-040

1.31

1.33 - 1.48

0.068

3.8

19.00

13

20

3/4

3/8 Open End

1/4 FNPSM

1/8 MNPT

10000

2500

3.59

80,XS,80S

GSST-D-S-0125-080

1.21

1.23 - 1.38

0.065

3.6

19.00

11

17

3/4

3/8 Open End

1/4 FNPSM

1/8 MNPT

10000

2500

3.59

160

GSST-D-S-0125-160

1.11

1.12 - 1.22

0.055

2.3

18.63

7.2

11

9/16

1/4 Open End

1/4 FNPSM

1/16 MNPT

10000

2500

3.17

XX

GSST-D-S-0125-XX

0.86

0.87 - 0.94

0.045

1.9

19.00

3.5

5.5

1/2

1/4 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

2.92

1 1/2

10

GSST-D-S-0150-010

1.60

1.64 - 1.80

0.085

5.2

20.00

24

37

15/16

7/16 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

4.31

40,STD,40S

GSST-D-S-0150-040

1.53

1.56 - 1.73

0.085

5.0

20.00

21

33

15/16

7/16 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

4.31

80,XS,80S

GSST-D-S-0150-080

1.42

1.45 - 1.62

0.085

4.8

20.00

18

28

15/16

7/16 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

4.31

160

GSST-D-S-0150-160

1.27

1.30 - 1.44

0.068

3.7

19.00

12

19

3/4

3/8 Open End

1/4 FNPSM

1/8 MNPT

10000

2500

3.59

XX

GSST-D-S-0150-XX

1.05

1.08 - 1.16

0.055

2.2

18.63

6.3

9.8

9/16

1/4 Open End

1/4 FNPSM

1/16 MNPT

10000

2500

3.17

2

10

GSST-D-S-0200-010

2.03

2.05 - 2.28

0.130

6.8

20.75

47

75

1-1/8

9/16 Open End

1/4 FNPSM

3/8 MNPT

10000

2500

4.50

40,STD,40S

GSST-D-S-0200-040

1.94

1.97 - 2.19

0.130

6.6

20.75

42

65

1-1/8

9/16 Open End

1/4 FNPSM

3/8 MNPT

10000

2500

4.50

80,XS,80S

GSST-D-S-0200-080

1.81

1.84 - 2.06

0.130

6.2

20.75

36

55

1-1/8

9/16 Open End

1/4 FNPSM

3/8 MNPT

10000

2500

4.50

160

GSST-D-S-0200-160

1.60

1.64 - 1.80

0.085

5.2

20.00

24

37

15/16

7/16 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

4.31

XX

GSST-D-S-0200-XX

1.42

1.45 - 1.62

0.085

4.8

20.00

18

28

15/16

7/16 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

4.31

2 1/2

10

GSST-D-S-0250-010

2.51

2.57 - 2.77

0.125

10.6

21.38

85

135

1-5/16

9/16 Open End

1/4 FNPSM

3/8 MNPT

8000

2500

6.09

40,STD,40S

GSST-D-S-0250-040

2.34

2.38 - 2.61

0.125

9.9

21.38

75

115

1-5/16

9/16 Open End

1/4 FNPSM

3/8 MNPT

8000

2500

6.09

80,XS,80S

GSST-D-S-0250-080

2.20

2.24 - 2.46

0.125

9.4

21.38

65

100

1-5/16

9/16 Open End

1/4 FNPSM

3/8 MNPT

8000

2500

6.09

160

GSST-D-S-0250-160

2.00

2.06 - 2.25

0.125

6.8

20.75

46

70

1-1/8

9/16 Open End

1/4 FNPSM

3/8 MNPT

10000

2500

4.50

XX

GSST-D-S-0250-XX

1.69

1.74 - 1.89

0.085

5.4

20.00

27

42

15/16

7/16 Open End

1/4 FNPSM

1/4 MNPT

10000

2500

4.31

3

10

GSST-D-S-0300-010

3.07

3.10 - 3.44

0.193

15.1

22.13

150

230

1-1/2

3/4 Box End

1/4 FNPSM

3/8 MNPT

8000

2500

6.56

40,STD,40S

GSST-D-S-0300-040

2.88

2.92 - 3.25

0.193

14.1

22.13

130

200

1-1/2

3/4 Box End

1/4 FNPSM

3/8 MNPT

8000

2500

6.56

80,XS,80S

GSST-D-S-0300-080

2.71

2.75 - 3.09

0.190

13.2

22.13

110

175

1-1/2

3/4 Box End

1/4 FNPSM

3/8 MNPT

8000

2500

6.56

160

GSST-D-S-0300-160

2.50

2.56 - 2.76

0.125

10.5

21.38

85

130

1-5/16

9/16 Open End

1/4 FNPSM

3/8 MNPT

8000

2500

6.09

XX

GSST-D-S-0300-XX

2.18

2.24 - 2.42

0.125

9.3

21.38

55

85

1-1/8

9/16 Open End

1/4 FNPSM

3/8 MNPT

8000

2500

6.09

3 1/2

10

GSST-D-S-0350-010

3.56

3.61 - 3.96

0.204

20.4

22.75

225

350

1-11/16

7/8 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.22

40,STD,40S

GSST-D-S-0350-040

3.34

3.39 - 3.75

0.204

19.0

22.75

195

305

1-11/16

7/8 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.22

80,XS,80S

GSST-D-S-0350-080

3.16

3.21 - 3.56

0.208

17.7

22.75

175

270

1-11/16

7/8 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.22

XX

GSST-D-S-0350-0XX

2.60

2.66 - 2.86

0.125

10.9

21.38

95

145

1-5/16

9/16 Open End

1/4 FNPSM

3/8 MNPT

8000

2500

6.09

4

10

GSST-D-S-0400-010

4.04

4.10 - 4.51

0.220

27.9

23.25

325

505

1-7/8

15/16 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.97

40,STD,40S

GSST-D-S-0400-040

3.81

3.87 - 4.28

0.220

25.9

23.25

285

445

1-7/8

15/16 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.97

80,XS,80S

GSST-D-S-0400-080

3.61

3.67 - 4.08

0.220

24.2

23.25

255

395

1-7/8

15/16 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.97

120

GSST-D-S-0400-120

3.42

3.52 - 3.83

0.205

19.5

22.75

205

320

1-11/16

7/8 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.22

160

GSST-D-S-0400-160

3.23

3.33 - 3.64

0.205

18.3

22.75

185

285

1-11/16

7/8 Box End

1/4 FNPSM

1/2 MNPT

6000

2500

7.22

XX

GSST-D-S-0400-XX

2.96

2.99 - 3.34

0.193

14.4

22.13

135

215

1-1/2

3/4 Box End

1/4 FNPSM

3/8 MNPT

8000

2500

6.56

Page 8 of 16

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FRM-22.1-Rev.H-SMDBB

5. Preparing the GripSafe ST DBB Plug for Installation

5.1 The GripSafe ST DBB plug should be in the Retracted position (Not Ready to Install) from

the factory, see Figure 4.

5.2 Tighten the Compression Hex Nut(21) so that the DBB Spring Plate(3) is flush the

Wedge Cone(10), see Figure 5.

• Do not over tighten or torque the Compression Hex Nut(21) to the point that the

Seals(14) start to swell or extrude over the OD of the plug.

• In the Compressed state, shown in Figure 5, the GripSafe Plug will immediately

grip on the pipe upon insertion.

Figure 4: Not Ready to Install State (Retracted)

Figure 5: Ready to Install State (Compressed)

CHECK: Ensure plug is clean of debris, fouling, and contaminants before each use.

Each Wedge Gripper(16) should slide freely up and down in its slot with a full range of

motion and without resistance. Wedge Gripper(16) with impeded movement due to

debris, dirt, contaminants or other fouling will cause the plug to not grip on the pipe’s

inner diameter, which can cause the plug to eject under pressure, leading to personnel

injury or death, material loss, and damage to equipment.

Page 9 of 16

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FRM-22.1-Rev.H-SMDBB

6. Installing the GripSafe ST DBB Plug

6.1 Inserting the GripSafe ST DBB plug into the pipe.

• See Table 2 for clearance requirements and ensure the pipe ID falls within the

Internal Diameter Range.

6.2 Slowly push the plug into the pipe.

6.3 A slight rocking motion will assist installation.

• Once the Wedge Grippers(16) contact the inner diameter of the pipe, it will

automatically grip and removal of the plug at this point is not possible, see Section

8 for plug removal if necessary.

6.4 For pipe installation, push the GripSafe ST DBB plug further into the pipe to the desired

depth. The top of the DBB Spring Plate’s(7) slotted section must not be protruding past

the face of the pipe it is installed in. See Figure 6 for properly installed plug and Figure 7

for improperly installed plug. The top of the DBB Spring Plate’s(3) slotted section can be

inserted further into the pipe if necessary. For a welding neck installation, see Section 7.

CAUTION: Ensure pipe I.D. is clean. Debris, pipe scaling, and rust layer must be

removed to the deepest point the plug will be installed into. If the pipe is lined or has

irremovable product, STOP and contact USA Industries for support before proceeding.

Failure to do so may impede the wedge’s ability to grip and cause the plug to eject under

pressure. Be sure to wear proper PPE and follow all site guidelines.

Figure 7: GripSafe ST DBB incorrect Insertion Depth in a Sectioned Pipe

Figure 6: GripSafe ST DBB Minimum Insertion Depth in a Sectioned Pipe

USA Industries GripSafe ST User manual

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