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

Page 10 of 16

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FRM-22.1-Rev.H-SMDBB

6.5 Use a crow’s foot attached to a torque wrench to torque the Compression Hex Nut(21)

while holding the Backup Hex or flats on the Shaft(1) stationary with a wrench until the

Minimum Compression Torque (Table 2) is reached.

6.6 Verify integrity of the Seals(14)

6.7 Use proper fittings to install a manual hydrotest pump to the Swivel Pipe Union Fitting(3).

• Pressurize to 500 psig or 75% of target pressure for 10 minutes to ensure both Seals(14)

are seated. Then proceed to desired pressure. Observance of pressure drop may not be

an indication of leakage. USA Industries Seals(14) will creep under pressure until they are

fully seated. This creep will increase the pressure test volume. Depending on the test

volume size, this may be by such a trivial amount it will not be seen on a gauge. For

relatively small test volumes a noticeable gradual loss in pressure may be observed during

this creep phase. Seating the Seals(14) is obtained by reapplying pressure until the

pressure becomes stable. This seal creep may also be observed when the system is

subjected to the full pressure. Resolution to the creep is the same at high pressure and

while verifying integrity.

6.8 The GripSafe ST DBB plug is now safely installed to accept rated hydrotest and backpressure

pressures.

TEMPERATURE NOTE: If welding is to occur on the pipe while the plug is installed,

the Seal(9) should be installed a minimum of 6” from the center of an active weld to

prevent it from degrading or ultimately failing due to melting. For post weld heat treats,

bake-outs, etc., the Seal(14) should be at least 12” from the nearest edge of the

heating element, and the temperature at the depth the plug is installed at should not

exceed 220° F. If a high temperature bake out is being performed (400° F or higher)

increase the installation depth as much as possible. It is recommended to always

monitor the pressure behind the plug (ORB) and/or between the seals (DBB) and stop

work immediately if any pressure drop is detected. In addition, the pipe’s external

surface temperature should always be monitored corresponding to the plug’s seal

location to ensure damage to the seal does not occur.

CAUTION: Using an impact wrench is not recommended as it can damage both the

Spring Plate Alignment Screw(8) and Wedge Cone Alignment Screw(11) for sizes

¾” – 2” or Spring Plate and Wedge Cone Alignment Key(26) for sizes 2-1/2” and

above.

CAUTION: Failure to use a backup wrench to keep the shaft stationary will place

excessive stress on the Wedge Cone Alignment Screw(11) for sizes ¾” – 2”, or

Spring Plate and Wedge Cone Alignment Key(26) for sizes 2-1/2” and above, which

could cause failure, resulting in a stuck plug and/or cause it to eject under pressure.

Page 11 of 16

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FRM-22.1-Rev.H-SMDBB

• It may be desirable to attach a gauge and vent hose assembly, backpressure monitoring

tee, to the backpressure Vent Port(22) to bleed off any backpressure. The hose should be

long enough to redirect any vapor coming out of the vessel to a safe location away from

workers that may be in the area. A valve may also be attached to this port to allow safe

backpressure removal during plug removal, Section 8. If using a backpressure monitoring

tee it may be useful to have a pressure gauge on the bull side of the tee while connecting

the run side to the backpressure Vent Port(22) and a ball valve. Further advantages can

be made by attaching a hose to the ball valve on the monitoring tee and running the hose

to vent to a safe location away from workers that may be in the area.

CAUTION: Fast flowing gases or liquids through hosing can cause hose whip. Take

caution to avoid this, failure to do so may result in injury to personnel or damage to

equipment.

CAUTION: Do not stand directly in front of the GripSafe ST Double Block and Bleed at

any time. Installed plugs should always be treated in this manner irrespective if the plug

has backpressure on it or not.

CAUTION: If backpressure develops, constant observation of pressure observed

through the use of an attached gauge and physical observation of pipe integrity is

necessary to ensure safety to personnel and equipment. Any bulging, enlargement or

tapering of the pipe is an indication of over pressuring. The Backpressure Rating listed

in Table 2 is for the pressure holding capability of the GripSafe ST Double Block and

Bleed and could be well beyond the system design limitations in which it is being used

to test.

Page 12 of 16

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FRM-22.1-Rev.H-SMDBB

7. Positioning for Between the Seal Hydrotesting

7.1 If using the plug to hydrostatically test a weld, ensure proper Depth of Insertion by using

the following method:

1. Measure the Weld Zone Depth, distance from the pipe or fitting end to the

center of weld area to be tested.

2. Measure the Mid Ring’s(12) center distance, distance from the top of the

Compression Hex Nut(21) to the center distance of the Mid Ring(12). Note:

When measuring the center distance of the Mid Ring(12), make sure that the

plug is in the Compressed state as shown in Figure 5.

3. Subtract the Weld Zone Depth from the Mid Ring’s(12) center distance.

4. Insert the plug while measuring from the pipe or fitting end to the top of the

Compression Hex Nut(21) and stop inserting when the reading on the

measuring tape matches the difference found in step 3 of this subsection.

Example:

Mid Ring’s(12) Center Distance = 17.25”

Weld Zone Depth = 2.53”

Mid Ring’s(12) Center Distance – Weld Zone Depth = 17.25” – 2.53” =

14.72”

Figure 8: Insertion Depth for Testing Weld

Page 13 of 16

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FRM-22.1-Rev.H-SMDBB

5. From the calculation, and as shown in Figure 8, the plug should be inserted into the

fitting until the distance from the top of the Compression Hex Nut(21) to the end of

the fitting is 14.72”.

Figure 9: Permissible Insertion Depth with Backpressure Rating

Figure 10: Impermissible Insertion Depth with No Backpressure Rating

CAUTION: Gripping failure may occur if the Gripping Wedges are not fully inserted into

the pipe or fitting. If any of the Wedge Gripper’s(16) surface is visible beyond the end

of the pipe or fitting end, represented in Figure 10, the GripSafe plug may not hold any

backpressure. Advancement of the plug into the vessel being tested is necessary so

none of the Wedge Gripper’s(16) surface is visible beyond the end of the pipe or fitting

end shown in Figure 9. Care should be taken to not cover the weld area with the

Seal(14) as it could render a false outcome of a hydrotest.

Page 14 of 16

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FRM-22.1-Rev.H-SMDBB

8. Removal of GripSafe ST DBB Plug

8.1 Depressurize system through hydrotest pump’s bleed off valve.

8.2 Remove hydrotest equipment from the Swivel Pipe Union Fitting(3).

8.3 Ensure there is no backpressure on the GripSafe ST DBB plug.

8.4 Loosen the Compression Hex Nut(21).

• Once the seal has broken free from the pipe’s inner diameter water may flow out

from the pipe, be prepared to capture this if desired. Continue loosening the

Compression Hex Nut(21) until the Wedge Grippers(16) are fully relaxed.

8.5 Remove the GripSafe ST DBB plug from the pipe.

• Clean and store for later use or return to USA Industries.

• Wedge Grippers(16) texture may become plugged with pipe scale and rust

through several uses of the plug. Inspection of this surface after each use is

necessary to keep the gripping strength at peak performance. To clean, simply use

mild dishwashing soap and a stiff stainless steel bristled brush such as a welding

brush. If plugging is persistent, use of a household rust remover along with a stiff

stainless steel bristled brush should be sufficient. Rinse plug clean of any residual

chemicals with tap water and dry thoroughly.

• Inspect Wedge Grippers’(16) freedom of motion. Each Wedge Gripper(16)

should slide freely up and down in its slot with a full range of motion and without

resistance.

• Store out of direct sunlight in an area not exposed to above 150° F, UV light and

excessive heat will cause Seal(14) degradation over time.

NOTE: Use caution to ensure the Swivel Pipe Union Fitting(3) does not become

unthreaded or loosened during removal of the hydrotesting equipment when testing is

complete. Failure to do so may cause leaks when the plug is used again. Use

appropriately fixed size wrenches, not adjustable wrenches.

CAUTION: SLOWLY open Vent Port(22) to relieve any back pressure. Care must be

taken when opening valves or loosening fittings if any inadvertent backpressure was

introduced to the vessel. Failure to do so may result in hazardous pressure flow and/or

fittings becoming violently hazardous projectiles that may cause injury to personnel and

damage to equipment. If utilizing a backpressure monitoring tee, fast flowing gases or

liquids through hosing can cause hose whip. Take caution to avoid this, failure to do so

may result in injury to personnel and damage to equipment.

NOTE: Do not remove the Compression Nut(21) from the Shaft(1). If this happens,

immediately reinstall the component.

Page 15 of 16

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FRM-22.1-Rev.H-SMDBB

9. Installing and Using Safety Gag

9.1 Slide the loosely assembled Safety Gag over the pipe before inserting the plug.

9.2 Follow the plug installation instructions in Sections 5-7 to install the GripSafe ST DBB

before continuing to step 8.4.

9.3 Place the pear-shaped link over the Back Pressure Vent Port(22).

9.4 Push the clamp further down the pipe to remove all slack in the chain. Ensure that the

chain is not snagged, twisted, or knotted, and is tight from the gag bolt to the pear-shaped

link.

9.5 Starting with the two bolts nearest the pipe, snug all of the bolts on the clamp. For the two

bolts nearest the pipe, turn an additional 1/3-1/2 turn.

• When properly installed, the Safety Gag should be firmly clamped and not be able

to rotate, slide, or tilt in any fashion when pushed or pulled.

• See Figure 9 for an example of a properly installed Safety Gag.

9.6 Reverse steps 9.1-9.5 to uninstall.

Figure 10: Properly Installed Safety Gag on Pipe

NOTE: Safety Gags are not required but are recommended to provide a layer of

protection in the unlikely event of plug discharge.

Page 16 of 16

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FRM-22.1-Rev.H-SMDBB

GripSafe® ST is a registered trademark of USA Industries.

USA Industries GripSafe ST User manual

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