USA Industries GripSafe User manual

®
INDUSTRIES, INC.
INDUSTRIES, INC.
Since 1982
INSTALLATION MANUAL
GripSafe Patents:
US: 9,927,058, 9,810,364 | CA: 3,004,787 | European Registration: 00624264-0001
Other US and Foreign Patents Pending
Large Double Block and Bleed (DBB) Plug
www.USAIndustries.com [phone] • [phone]
315 State Street • S. Houston, TX 77587

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
Contents
1. Introduction 2
2. Safety 3
3. Parts 4
4. Specications 7
5. Preparing the GripSafe DBB Plug for Installation 10
6. Installing the GripSafe DBB Plug 11
7. Positioning for Between the Seal Hydro Testing 15
8. GripSafe DBB Plug Removal 17
9. GripSafe Liing Device 19
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 to personnel and 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 Section 8, Table 3 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 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
2. Safety
⚠ Failure to follow proper safety requirements may result in the GripSafe plug failing, which could lead to personnel
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.
⚠ Use care in the handling of the Wedge Studs. Never beat, hammer, or pry on the Wedge Studs, and never remove
the nut located on the Wedge Studs.
⚠ 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 performing 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 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Since 1982
Piping Isolation & Testing Products • Tube Plugs • Orifice Plates • Heat Exchanger Tooling • Custom Machining • Rental Services
302 State Street, South Houston, TX 77587
[phone] • [phone]
[e-mail] • www.USAIndustries.com
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
3. Parts (is manual references the part numbers identied below throughout the document)
Figure 1: GripSafe DBB Diagram
Page 4of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Since 1982
Piping Isolation & Testing Products • Tube Plugs • Orifice Plates • Heat Exchanger Tooling • Custom Machining • Rental Services
302 State Street, South Houston, TX 77587
[phone] • [phone]
[e-mail] • www.USAIndustries.com
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
Table 1: GripSafe Bill of Materials
Page 5of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Since 1982
Piping Isolation & Testing Products • Tube Plugs • Orifice Plates • Heat Exchanger Tooling • Custom Machining • Rental Services
302 State Street, South Houston, TX 77587
[phone] • [phone]
[e-mail] • www.USAIndustries.com
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
Table 1: GripSafe Bill of Materials Continued
Page 6of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Since 1982
Piping Isolation & Testing Products • Tube Plugs • Orifice Plates • Heat Exchanger Tooling • Custom Machining • Rental Services
302 State Street, South Houston, TX 77587
[phone] • [phone]
[e-mail] • www.USAIndustries.com
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
4. Specications
Figure 2: GripSafe DBB Dimensions Diagram
Page 7of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
Table 2: GripSafe DBB Specications
Page 8of 24
Norm Max.
10,10S GS-D-S-0600-010 5.98 6.044 - 6.422 0.375 32 11.25 85 130 1-1/16" 1/4" FNPT 1/4" MNPT 3300 2500
40,STD,40S GS-D-S-0600-040 5.69 5.752 - 6.129 0.375 31 11.25 75 110 1-1/16" 1/4" FNPT 1/4" MNPT 3600 2500
80,XS,80S GS-D-S-0600-080 5.39 5.448 - 5.823 0.375 28 11.25 60 95 1-1/16" 1/4" FNPT 1/4" MNPT 4000 2500
120 GS-D-S-0600-120 5.13 5.188 - 5.562 0.375 26 11.25 55 80 1-1/16" 1/4" FNPT 1/4" MNPT 3900 2500
160 GS-D-S-0600-160 4.81 4.874 - 5.246 0.375 24 11.25 50 75 3/4" 1/4" FNPT 1/4" MNPT 3850 2500
XX GS-D-S-0600-XX 4.52 4.584 - 4.955 0.375 22 11.25 50 75 3/4" 1/4" FNPT 1/4" MNPT 3700 2500
10,10S GS-D-S-0800-010 7.95 8.016 - 8.404 0.375 58 13.22 190 270 1-1/4" 1/4" FNPT 1/2" MNPT 3200 2500
20 GS-D-S-0800-020 7.75 7.812 - 8.199 0.375 58 13.22 175 265 1-1/4" 1/4" FNPT 1/2" MNPT 3350 2500
30 GS-D-S-0800-030 7.70 7.758 - 8.145 0.375 56 13.22 170 260 1-1/4" 1/4" FNPT 1/2" MNPT 3400 2500
40,STD,40S GS-D-S-0800-040 7.61 7.668 - 8.054 0.375 54 13.22 165 250 1-1/4" 1/4" FNPT 1/2" MNPT 3475 2500
60 GS-D-S-0800-060 7.44 7.500 - 7.885 0.375 52 13.22 155 235 1-1/4" 1/4" FNPT 1/2" MNPT 3625 2500
80,XS,80S GS-D-S-0800-080 7.25 7.312 - 7.696 0.375 50 13.22 140 215 1-1/4" 1/4" FNPT 1/2" MNPT 3800 2500
100 GS-D-S-0800-100 7.06 7.124 - 7.507 0.375 45 13.22 105 160 1-1/4" 1/4" FNPT 1/2" MNPT 3725 2500
120 GS-D-S-0800-120 6.81 6.874 - 7.256 0.375 43 13.22 100 155 1-1/4" 1/4" FNPT 1/2" MNPT 3725 2500
140 GS-D-S-0800-140 6.63 6.688 - 7.069 0.375 42 13.22 95 150 1-1/16" 1/4" FNPT 1/4" MNPT 3925 2500
160 GS-D-S-0800-160 6.44 6.500 - 6.880 0.375 40 13.22 95 145 1-1/16" 1/4" FNPT 1/4" MNPT 3825 2500
XX GS-D-S-0800-XX 6.50 6.562 - 6.943 0.375 40 13.22 95 145 1-1/16" 1/4" FNPT 1/4" MNPT 3750 2500
10,10S GS-D-S-1000-010 10.05 10.107 - 10.505 0.375 88 13.20 235 270 1-1/4" 1/4" FNPT 3/4" MNPT 2725 2500
20 GS-D-S-1000-020 9.88 9.937 - 10.335 0.375 88 13.20 235 270 1-1/4" 1/4" FNPT 3/4" MNPT 2800 2500
30 GS-D-S-1000-030 9.76 9.823 - 10.220 0.375 86 13.20 225 270 1-1/4" 1/4" FNPT 3/4" MNPT 2875 2500
40,4STD,40s GS-D-S-1000-040 9.65 9.707 - 10.103 0.375 86 13.20 215 270 1-1/4" 1/4" FNPT 3/4" MNPT 2950 2500
60,XS,80S GS-D-S-1000-XS 9.38 9.437 - 9.832 0.375 78 13.20 195 270 1-1/4" 1/4" FNPT 3/4" MNPT 3100 2500
80 GS-D-S-1000-080 9.19 9.249 - 9.643 0.375 76 13.20 140 215 1-1/4" 1/4" FNPT 3/4" MNPT 3225 2500
100 GS-D-S-1000-100 8.94 8.999 - 9.392 0.375 76 13.20 135 210 1-1/4" 1/4" FNPT 3/4" MNPT 3400 2500
120 GS-D-S-1000-120 8.69 8.749 - 9.141 0.375 74 13.20 135 205 1-1/4" 1/4" FNPT 1/2" MNPT 3425 2500
140,XX GS-D-S-1000-140 8.38 8.437 - 8.827 0.375 72 13.20 130 195 1-1/4" 1/4" FNPT 1/2" MNPT 3475 2500
160 GS-D-S-1000-160 8.13 8.187 - 8.576 0.375 70 13.20 125 190 1-1/4" 1/4" FNPT 1/2" MNPT 3475 2500
10,10S GS-D-S-1200-010 12.02 12.077 - 12.485 0.375 116 13.20 200 270 1-1/4" 1/4" FNPT 3/4" MNPT 2300 2500
20 GS-D-S-1200-020 11.88 11.937 - 12.345 0.375 118 13.20 200 270 1-1/4" 1/4" FNPT 3/4" MNPT 2375 2500
30 GS-D-S-1200-030 11.72 11.777 - 12.184 0.375 118 13.20 200 270 1-1/4" 1/4" FNPT 3/4" MNPT 2425 2500
STD,40S GS-D-S-1200-STD 11.63 11.687 - 12.093 0.375 122 13.20 200 270 1-1/4" 1/4" FNPT 3/4" MNPT 2475 2500
40 GS-D-S-1200-040 11.56 11.625 - 12.031 0.375 122 13.20 200 270 1-1/4" 1/4" FNPT 3/4" MNPT 2500 2500
XS,80S GS-D-S-1200-XS 11.38 11.437 - 11.842 0.375 124 13.20 200 270 1-1/4" 1/4" FNPT 3/4" MNPT 2575 2500
60 GS-D-S-1200-060 11.25 11.313 - 11.717 0.375 128 13.20 175 270 1-1/4" 1/4" FNPT 3/4" MNPT 2725 2500
80 GS-D-S-1200-080 11.00 11.061 - 11.464 0.375 128 13.20 175 265 1-1/4" 1/4" FNPT 3/4" MNPT 2850 2500
100 GS-D-S-1200-100 10.69 10.749 - 11.151 0.375 132 13.20 170 255 1-1/4" 1/4" FNPT 3/4" MNPT 2900 2500
120,XX GS-D-S-1200-120 10.38 10.437 - 10.837 0.375 132 13.20 160 250 1-1/4" 1/4" FNPT 3/4" MNPT 2950 2500
140 GS-D-S-1200-140 10.13 10.187 - 10.586 0.375 134 13.20 160 240 1-1/4" 1/4" FNPT 3/4" MNPT 2950 2500
160 GS-D-S-1200-160 9.75 9.813 - 10.210 0.375 134 13.20 150 230 1-1/4" 1/4" FNPT 3/4" MNPT 3025 2500
10S GS-D-S-1400-010S 13.25 13.311 - 13.725 0.375 155 15.12 270 413 1-5/8" 1/4" FNPT 1" MNPT 1925 2500
10 GS-D-S-1400-010 13.13 13.187 - 13.601 0.375 152 15.12 265 405 1-5/8" 1/4" FNPT 1" MNPT 1950 2500
20 GS-D-S-1400-040 13.00 13.063 - 13.476 0.375 152 15.12 250 380 1-5/8" 1/4" FNPT 1" MNPT 1975 2500
30,STD,40S GS-D-S-1400-STD 12.88 12.937 - 13.333 0.375 147 15.12 235 360 1-5/8" 1/4" FNPT 1" MNPT 2025 2500
40 GS-D-S-1400-040 12.75 12.811 - 13.223 0.375 147 15.12 220 335 1-5/8" 1/4" FNPT 1" MNPT 2050 2500
XS,80S GS-D-S-1400-XS 12.63 12.687 - 13.098 0.375 144 15.12 205 315 1-5/8" 1/4" FNPT 1" MNPT 2100 2500
60 GS-D-S-1400-060 12.44 12.499 - 12.909 0.375 144 15.12 210 325 1-5/8" 1/4" FNPT 1" MNPT 2425 2500
80 GS-D-S-1400-080 12.13 12.187 - 12.596 0.375 140 15.12 205 315 1-5/8" 1/4" FNPT 1" MNPT 2550 2500
100 GS-D-S-1400-100 11.75 11.811 - 12.218 0.375 140 15.12 200 305 1-5/8" 1/4" FNPT 1" MNPT 2725 2500
120 GS-D-S-1400-120 11.44 11.499 - 11.904 0.375 140 15.12 195 295 1-5/8" 1/4" FNPT 1" MNPT 2750 2500
140 GS-D-S-1400-140 11.13 11.187 - 11.591 0.375 135 15.12 185 285 1-5/8" 1/4" FNPT 1" MNPT 2800 2500
160 GS-D-S-1400-160 10.81 10.875 - 11.277 0.375 135 15.12 180 275 1-5/8" 1/4" FNPT 1" MNPT 2825 2500
Back
Pressure
Rating
(PSI)
Between the
Seal Test
Pressure
(PSI)
12
6
8
10
Tool Length
(in)
Fill & Vent
Port Thread
Back
Pressure Vent
Thread
14
Tool
Diameter
(in)
Torque Range
(ft-lbs)
Compression Hex
Nut
Socket Size
(in)
Nominal
Pipe Size
(in)
Schedule Part Number
Rec.
ID Range*
(in)
Approx.
Tool Weight
(lbs)
Nominal Pipe
ID Clearance
(in)

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
Table 2: GripSafe DBB Specications Continued
Page 9of 24
Norm Max.
10S GS-D-S-1600-010S 15.25 15.311 - 15.735 0.375 212 15.12 265 420 1-5/8" 1/4" FNPT 1" MNPT 1950 2500
10 GS-D-S-1600-010 15.13 15.187 - 15.611 0.375 210 15.12 255 395 1-5/8" 1/4" FNPT 1" MNPT 1975 2500
20 GS-D-S-1600-020 15.00 15.063 - 15.486 0.375 206 15.12 245 370 1-5/8" 1/4" FNPT 1" MNPT 2000 2500
30,STD,40S GS-D-S-1600-STD 14.88 14.937 - 15.360 0.375 199 15.12 230 350 1-5/8" 1/4" FNPT 1" MNPT 2025 2500
40,XS,80S GS-D-S-1600-XS 14.63 14.687 - 15.108 0.375 192 15.12 200 305 1-5/8" 1/4" FNPT 1" MNPT 2100 2500
60 GS-D-S-1600-060 14.31 14.375 - 14.795 0.375 192 15.12 205 315 1-5/8" 1/4" FNPT 1" MNPT 2200 2500
80 GS-D-S-1600-080 14.00 14.063 - 14.481 0.375 188 15.12 200 305 1-5/8" 1/4" FNPT 1" MNPT 2300 2500
100 GS-D-S-1600-100 13.56 13.625 - 14.041 0.375 188 15.12 195 295 1-5/8" 1/4" FNPT 1" MNPT 2350 2500
120 GS-D-S-1600-120 13.19 13.249 - 13.663 0.375 182 15.12 185 285 1-5/8" 1/4" FNPT 1" MNPT 2400 2500
140 GS-D-S-1600-140 12.75 12.811 - 13.223 0.375 182 15.12 180 275 1-5/8" 1/4" FNPT 1" MNPT 2500 2500
160 GS-D-S-1600-160 12.44 12.499 - 12.909 0.375 178 15.12 175 270 1-5/8" 1/4" FNPT 1" MNPT 2525 2500
10S GS-D-S-1800-010S 17.25 17.311 - 17.745 0.375 270 15.12 395 605 1-5/8" 1/4" FNPT 1" MNPT 1725 2500
10 GS-D-S-1800-010 17.13 17.187 - 17.621 0.375 265 15.12 380 580 1-5/8" 1/4" FNPT 1" MNPT 1750 2500
20 GS-D-S-1800-020 17.00 17.063 - 17.496 0.375 260 15.12 365 555 1-5/8" 1/4" FNPT 1" MNPT 1775 2500
STD,40S GS-D-S-1800-STD 16.88 16.937 - 17.370 0.375 254 15.12 345 530 1-5/8" 1/4" FNPT 1" MNPT 1800 2500
30 GS-D-S-1800-030 16.75 16.811 - 17.243 0.375 250 15.12 330 505 1-5/8" 1/4" FNPT 1" MNPT 1825 2500
XS,80S GS-D-S-1800-XS 16.63 16.687 - 17.118 0.375 247 15.12 315 480 1-5/8" 1/4" FNPT 1" MNPT 1850 2500
40 GS-D-S-1800-040 16.50 16.563 - 16.994 0.375 245 15.12 295 450 1-5/8" 1/4" FNPT 1" MNPT 1975 2500
60 GS-D-S-1800-060 16.25 16.311 - 16.740 0.375 240 15.12 290 440 1-5/8" 1/4" FNPT 1" MNPT 2025 2500
80 GS-D-S-1800-080 15.75 15.811 - 16.238 0.375 235 15.12 280 425 1-5/8" 1/4" FNPT 1" MNPT 2100 2500
100 GS-D-S-1800-100 15.31 15.375 - 15.800 0.375 230 15.12 270 415 1-5/8" 1/4" FNPT 1" MNPT 2175 2500
120 GS-D-S-1800-120 15.08 15.137 - 15.561 0.375 225 15.12 265 405 1-5/8" 1/4" FNPT 1" MNPT 2175 2500
140 GS-D-S-1800-140 14.50 14.563 - 14.984 0.375 224 15.12 255 390 1-5/8" 1/4" FNPT 1" MNPT 2275 2500
160 GS-D-S-1800-160 14.06 14.125 - 14.543 0.375 219 15.12 245 375 1-5/8" 1/4" FNPT 1" MNPT 2350 2500
10S GS-D-S-2000-010S 19.19 19.249 - 19.693 0.375 330 15.32 325 510 1-5/8" 1/4" FNPT 1-1/2" MNPT 1550 2500
10 GS-D-S-2000-010 19.13 19.187 - 19.631 0.375 324 15.32 320 495 1-5/8" 1/4" FNPT 1-1/2" MNPT 1550 2500
20,STD,40S GS-D-S-2000-STD 18.88 18.937 - 19.380 0.375 317 15.32 295 450 1-5/8" 1/4" FNPT 1-1/2" MNPT 1600 2500
30,XS,80S GS-D-S-2000-XS 18.63 18.687 - 19.128 0.375 308 15.32 270 410 1-5/8" 1/4" FNPT 1-1/2" MNPT 1650 2500
40 GS-D-S-2000-040 18.44 18.499 - 18.939 0.375 298 15.32 250 380 1-5/8" 1/4" FNPT 1-1/2" MNPT 1850 2500
60 GS-D-S-2000-060 18.00 18.063 - 18.501 0.375 292 15.32 240 370 1-5/8" 1/4" FNPT 1-1/2" MNPT 1875 2500
80 GS-D-S-2000-080 17.56 17.625 - 18.061 0.375 285 15.32 235 360 1-5/8" 1/4" FNPT 1-1/2" MNPT 1925 2500
100 GS-D-S-2000-100 17.06 17.125 - 17.558 0.375 278 15.32 230 350 1-5/8" 1/4" FNPT 1-1/2" MNPT 2000 2500
120 GS-D-S-2000-120 16.63 16.687 - 17.118 0.375 281 15.32 220 340 1-5/8" 1/4" FNPT 1-1/2" MNPT 2050 2500
140 GS-D-S-2000-140 16.12 16.183 - 16.612 0.375 270 15.32 215 330 1-5/8" 1/4" FNPT 1-1/2" MNPT 2075 2500
160 GS-D-S-2000-160 15.69 15.751 - 16.178 0.375 259 15.32 210 320 1-5/8" 1/4" FNPT 1-1/2" MNPT 2125 2500
10,10S GS-D-S-2400-010 23.13 23.187 - 23.651 0.375 431 15.32 395 600 1-5/8" 1/4" FNPT 1-1/2" MNPT 1300 2500
20,STD,40S GS-D-S-2400-STD 22.88 22.937 - 23.400 0.375 422 15.32 360 555 1-5/8" 1/4" FNPT 1-1/2" MNPT 1325 2500
XS,80S GS-D-S-2400-XS 22.63 22.687 - 23.148 0.375 414 15.32 330 505 1-5/8" 1/4" FNPT 1-1/2" MNPT 1350 2500
30 GS-D-S-2400-030 22.50 22.563 - 23.024 0.375 409 15.32 320 490 1-5/8" 1/4" FNPT 1-1/2" MNPT 1550 2500
40 GS-D-S-2400-040 22.25 22.311 - 22.770 0.375 400 15.32 315 485 1-5/8" 1/4" FNPT 1-1/2" MNPT 1575 2500
60 GS-D-S-2400-060 21.69 21.749 - 22.206 0.375 382 15.32 310 470 1-5/8" 1/4" FNPT 1-1/2" MNPT 1625 2500
80 GS-D-S-2400-080 21.19 21.249 - 21.703 0.375 388 15.32 300 460 1-5/8" 1/4" FNPT 1-1/2" MNPT 1650 2500
100 GS-D-S-2400-100 20.56 20.625 - 21.076 0.375 374 15.32 290 445 1-5/8" 1/4" FNPT 1-1/2" MNPT 1700 2500
120 GS-D-S-2400-120 20.00 20.063 - 20.511 0.375 372 15.32 285 435 1-5/8" 1/4" FNPT 1-1/2" MNPT 1725 2500
140 GS-D-S-2400-140 19.50 19.563 - 20.009 0.375 366 15.32 275 420 1-5/8" 1/4" FNPT 1-1/2" MNPT 1750 2500
160 GS-D-S-2400-160 18.94 18.999 - 19.442 0.375 360 15.32 265 410 1-5/8" 1/4" FNPT 1-1/2" MNPT 1825 2500
10,10S GS-D-S-3000-010 29.00 29.063 - 29.556 0.375 679 15.32 275 420 1-5/8" 1/4" FNPT 1-1/2" MNPT 900 2500
STD,40S GS-D-S-3000-STD 28.88 28.937 - 29.430 0.375 673 15.32 260 400 1-5/8" 1/4" FNPT 1-1/2" MNPT 900 2500
XS,80S GS-D-S-3000-XS 28.63 28.687 - 29.178 0.375 661 15.32 240 370 1-5/8" 1/4" FNPT 1-1/2" MNPT 900 2500
30 GS-D-S-3000-030 28.38 28.437 - 28.927 0.375 650 15.32 205 315 1-5/8" 1/4" FNPT 1-1/2" MNPT 900 2500
10 GS-D-S-3600-010 35.00 35.063 - 35.586 0.375 989 15.32 295 455 1-5/8" 1/4" FNPT 1-1/2" MNPT 625 2500
STD,40S GS-D-S-3600-STD 34.88 34.937 - 35.460 0.375 982 15.32 285 435 1-5/8" 1/4" FNPT 1-1/2" MNPT 625 2500
XS,80S GS-D-S-3600-XS 34.63 34.687 - 35.208 0.375 968 15.32 260 395 1-5/8" 1/4" FNPT 1-1/2" MNPT 625 2500
30 GS-D-S-3600-030 34.38 34.437 - 34.957 0.375 954 15.32 250 385 1-5/8" 1/4" FNPT 1-1/2" MNPT 625 2500
30
36
Part Number
Rec.
ID Range*
(in)
Approx.
Tool Weight
(lbs)
24
18
20
Nominal Pipe
ID Clearance
(in)
Back
Pressure
Vent Thread
Back
Pressure
Rating
(PSI)
Between the
Seal Test
Pressure
(PSI)
Tool Length
(in)
16
Nominal
Pipe Size
(in)
Schedule Fill & Vent
Port Thread
Tool
Diameter
(in)
Torque Range
(ft-lbs)
Compression Hex
Nut
Socket Size
(in)

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
5. Preparing the GripSafe DBB Plug for Installation
5.1 e GripSafe DBB should be in the “Ready to Install” position from the factory.
Figure 3: GripSafe Plug and Pipe Concentricity
Page 10 of 24
If the pipe ID is within 0.200” of the max
ID Range, a 1/8” concentricity alignment
between the plug OD and the pipe ID must
be maintained to obtain the max pressure
rating.
Figure 4:
“Not Ready to Install” State (Retracted)
Figure 5:
“Ready to Install” State (Energized)

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
• Ensure the Compression Hex Nuts⑱are tightened to the point where the Spring Plate
Hub⑳is in the energized state, ush to the Retainer Plate⑰.
• Do not over tighten or torque nuts to the point that the Seal⑩ starts to swell or extrude over
the OD of the plug.
• In the “Ready to Install” state (see Figure 5), the GripSafe plug will immediately grip on
the pipe upon insertion.
CAUTION: Make sure plug is clean of debris and contaminants. Each Wedge Gripper⑤should slide
freely up and down in its slot with a full range of motion and no resistance. Wedge Grippers⑤with
impeded movement due to debris, dirt or contaminants will cause the plug to not grip on the pipe’s
ID which can cause it to eject under pressure, potentially leading to injury or death, material loss,
and/or damage to equipment.
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.
6.1 Insert the GripSafe DBB plug evenly into the pipe.
• See Table 2 for Operational ID Range and clearance requirements.
• For using GripSafe Liing Device, see Section 8.
• When the Gripping Wedges come into contact with
the pipe I.D., evenly push the GripSafe
DBB plug further into the pipe.
• A slight rocking motion will assist in
insertion.
• Once the Gripping Wedges have begun
entering the pipe, each will be in
independent contact with the pipe I.D.
Retraction or removal of the plug at this
juncture is not possible unless the Compression
Nuts⑱are loosened. See Section 7 for
plug removal.
• Insert plug until the top of the Spring Plate
Hub⑳is at least ush with the end of the pipe (see Figure 6).
Figure 6: GripSafe DBB Minimum
Insertion Depth in a Sectioned Pipe
Page 11 of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
• If insertion into the pipe proves problematic in the “Ready to Install” state (see Figure 5), it may
be advantageous to insert the plug in the “Not Ready to Install” state (see Figure 4). To do so,
loosen all Compression Hex Nuts⑱to the top of their respective All-read Shas⑪. Care
should be taken to not completely remove the Compression Hex Nuts⑱from the assembly. In
this orientation, the Gripping Wedges will be fully retracted and the plug can be inserted freely
into the pipe.
Caution: In this orientation, it is important to note the plug will not be immediately gripping the pipe
upon insertion. Only aer tightening the Compression Hex Nuts⑱while the plug is in the pipe, to
advance the bottom of the Spring Plate Hub⑳to contact the top of the Retainer Plate⑰will the
plug be securely gripping the pipe. Continue installation with Step 6.2.
TEMPERATURE NOTE:
If welding is to occur while the plug is inside the pipe we recommend that the top of the Spring Plate
Hub⑳be at minimum of 12” into the pipe beyond the location welding is to occur. USA Industries’
Urethane Seals (Tri-Ply™)⑩can withstand 180° continuous and 225° Fahrenheit for short durations.
If high-temperature seals are needed, contact USA Industries for alternative sealing solutions.
Monitoring of pipe temperature at the seal location is recommended to prevent seal failure.
6.2 Evenly tighten the Compression Nuts.
• Using a star pattern (see Figure 7), turn each Compression Hex Nut⑱a maximum of 3 full
revolutions before moving to the next nut. Repeat until 50% target torque is achieved on all nuts,
and then increase to 100% target installation torque and continue torqueing in a star pattern.
Aer completing the star pattern at 100% of the target torque, use a circular pattern to conrm
all nuts are torqued correctly.
• Minimal torque will be required for the rst several passes, but torque will increase notably aer
the Seals⑩begin to compress against the pipe ID.
NOTE: To help center the plug in the pipe it may be desirable to tighten the two bottom-most
Compression Hex Nuts⑱to expand the Seals⑩under them, thereby liing the plug up to center.
A short push of the plug will reset the Wedge Grippers⑤to accommodate the new centered position
respective to the rest of the plug body. Normal installation should commence once the plug is centered.
is may be desirable in the event the plug is noticeably not in the center of the pipe and test pressures
are not achieved while the plug is at Maximum Compression Torque or the plug is not within the 1/8”
concentricity limit if the pipe ID is within 0.200” of maximum range.
Page 12 of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
6.3 Verify integrity of the Seals⑩.
• If the plug is being used for pressure testing, use proper ttings to install a hydro test
pump to the Backpressure Vent Port⑲; otherwise, install a cap to seal o the system or a
backpressure monitoring tee.
• Increase pressure to 25% of target pressure or 150 psig, whichever is less. Observance of a
pressure drop may not be an indication of leakage. e Seals⑩will creep under pressure
until they are fully seated. is 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 Seals⑩is obtained by reapplying pressure until the pressure
becomes stable. is 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.
CAUTION: If the plug is being used for pressure testing, careful observation is needed on the Wedge
Gripper Nuts③travel. On Figure 8, pressure can be added to the system since the Wedge Gripper
Nuts③are still far from the Spring Plate Halo⑮. On Figure 9 however, no additional pressure can
be added to the system since the Wedge Gripper Nuts③have reached their maximum travel.
CAUTION: Careful observation is needed at the location of the pipe where the Wedge Grippers make
contact while performing a hydro test. 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.
Page 13 of 24
Figure 8: Wedge Grippers Safe to Travel Figure 9: Wedge Grippers Maximum
Travel Reached

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
CAUTION: If at any time during hydro testing a popping or clicking sound is heard, STOP
IMMEDIATELY and slowly release the pressure from the system. Popping or clicking sounds during
hydro testing could 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
for further assistance.
• It may be desirable to attach a gauge and vent hose assembly, or a backpressure monitoring
tee, to the Backpressure Vent Port⑲to bleed o any backpressure. e hose should
be long enough to redirect vapor coming out of the vessel to a safe location away from
personnel that may be in the area. A valve may also be attached to this port to allow safe
backpressure removal before plug extraction (see Section 7). If using a backpressure
monitoring tee, it may be useful to have a pressure gauge on the branch side of the tee
while connecting the run side to the Backpressure Vent Port⑲and 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 owing gases or liquids through hosing can cause hose whip. Take caution to avoid
this, failure to do so may result in injury and/or equipment damage.
CAUTION: Do not stand directly in front of the GripSafe DBB plug 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. e
Backpressure Rating listed in Table 1 is for the pressure holding capability of the GripSafe Outboard
Wedge Double Block and Bleed and could be well beyond the system design limitations in which it
is being used to test.
Page 14 of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
7. Positioning for Between the Seal Hydro Testing
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 tting end to the center of weld
area to be tested.
2. Obtain the Plug Insertion Depth from Table 3 in respect to the Weld Neck Flange being
tested.
3. Subtract the Plug Insertion Depth from the Weld Zone Depth.
4. If the dierence is a negative number, insert the plug while measuring from the pipe or
tting end to the top of the Spring Plate Hub/Halo ⑮/⑳ and stop inserting when the
reading on the measuring tape matches the dierence found in Step 3.
Example: Testing a weld on a 14” Class 150 Weld Neck Flange.
• Weld Zone Depth: 5.00”
• 12” Class 150 Plug Insertion Depth obtained from Table 3: 6.14”
• Weld Zone Depth – Plug Insertion Depth = 5.00 – 6.14 = -1.14
From the calculation, the top face of the Spring Plate Hub/Halo⑮/⑳ should be
1.14” out past the end of the weld neck ange (see Figure 8).
5. If the dierence is a positive number, measure from the pipe or tting end into the pipe
or tting by the dierence found in Step 3 and make a mark on the ID of the pipe or
tting. Insert the plug until the top of the Spring Plate Hub/Halo⑮/⑳ is aligned to this
mark.
Example: Testing a weld on a 14” Class 600 Weld Neck Flange.
• Weld Zone Depth: 8.38”
• 12” Class 600 Plug Insertion Depth obtained from Table 3: 6.63”
• Weld Zone Depth – Plug Insertion Depth = 8.38 – 6.63 = 1.75”
From the calculation, the top face of the Spring Plate Hub/Halo⑮/⑳ should be
1.75” into the weld neck ange’s end (see Figure 9).
Page 15 of 24
Table 3: GripSafe ORB DBB Depth Insertion

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
Page 16 of 24
CAUTION: Gripping failure may occur if the Gripping Wedges are not fully inserted into the pipe or
tting. If any of the Wedge Gripper’s⑤surface is visible beyond the end of the pipe or tting end,
represented in Figure 11, the GripSafe plug may not hold any back pressure. Advancement of the plug
into the vessel being tested is necessary so none of the Wedge Gripper’s⑤surface is visible beyond
the end of the pipe or tting end shown in Figure 10. Care should be taken to not cover the weld area
with the Seal⑩ as it could render a false outcome of a hydro test. e plug may be out of center with the
pipe. To help center the plug in the pipe it may be desired to tighten the two bottom most Compression
Hex Nuts⑱to expand the Seal⑩under them, thereby liing the plug up to center. A short push of the
plug will reset the Wedge Grippers⑤to accommodate the new centered position respective to the rest of
the plug body.
Normal installation should commence once plug is centered. is may be desirable in the event the plug is
noticeably not in the center of the pipe and test pressures are not achieved while the plug is at Maximum
Compression Torque or the plug is not within the 1/8” concentricity limit if the pipe ID is within 0.200”
of max range.
Figure 10: Permissible Insertion Depth
with Back Pressure Rating
Figure 11: Impermissible Insertion Depth
with No Back Pressure Rating

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
8. GripSafe DBB Plug Removal
8.1 Depressurize the system through the hydro test pump and drain all water from the
Test Vent Port and Test Fill Port.
8.2 Remove hydro test equipment and or gauges from the Test Ports①.
NOTE: Use caution to ensure the Test Ports①do not become unthreaded or loosened within the
plug during removal of the hydro testing equipment when testing is complete. Failure to do so may
cause internal leaks when the plug is used again. Use appropriately sized wrenches.
8.3 Ensure there is no back pressure on the GripSafe DBB plug.
CAUTION: SLOWLY open Vent Port⑲to relieve any back pressure. Care must be taken when opening
valves or loosening ttings if any inadvertent backpressure was introduced to the vessel. Failure to do
so may result in hazardous pressure ow and/or ttings becoming violently hazardous projectiles that
may damage personnel and/or equipment. If utilizing a backpressure monitoring tee, fast owing
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 equipment.
8.4 Loosen the Compression Hex Nuts⑱in an even star pattern as to not place the whole
load on one bolt.
• If a Compression Hex Nut⑱runs free during loosening, run the nut back to ush with the top of
the Spring Plate. e Seal⑩act as a spring containing a large amount of force, too great for one
All readed Sha⑪to handle.
• Once the seal has broken free from the pipe ID, continue loosening the Compression Hex Nuts⑱
until it is even with the top of the All readed Sha⑪.
NOTE: Do not remove the Compression Hex Nut⑱from the All readed Sha⑪. If this happens,
immediately reinstall the components.
CAUTION: Ensure that all Compression Hex Nuts⑱maintain a load on them during the entire
loosening process. Having all Compression Hex Nuts⑱loose but one, means that a large load is le on
one All readed Sha⑪and the risk of breakage is probable. Once the seals have relaxed enough to
break the seal from the pipe ID the plug is now in a much more relaxed state and Compression Hex
Nuts⑱can be loosened in full.
8.5 Remove the GripSafe DBB plug from the pipe.
• Clean and store for later use or return to USA Industries, Inc.
• Store out of direct sunlight in an area not exposed to above 150⁰F UV. Excessive heat will cause
seal degradation over time.
Page 17 of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Si nce 1982
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
• Wedge Gripper⑤texture may become packed with pipe scale and rust aer several uses of
the plug. Inspection of this surface aer use is necessary to keep the gripping strength of the
Gripping Wedges at peak performance. To clean, simply use a mild dishwashing soap and a
sti stainless steel bristled brush such as a welding brush. If plugging is persistent, use of a
household rust remover along with a sti stainless steel bristled brush should be sucient.
Rinse plug clean of residual chemicals with tap water and dry thoroughly.
Page 18 of 24

INDUSTRIES, INC.
INDUSTRIES, INC.
Since 1982
Piping Isolation & Testing Products • Tube Plugs • Orifice Plates • Heat Exchanger Tooling • Custom Machining • Rental Services
302 State Street, South Houston, TX 77587
[phone] • [phone]
[e-mail] • www.USAIndustries.com
GripSafe Patents:
US – 9,927,058, 9,810,364 | CA – 3,004,787 | European Registration – 00626264-0001
Other US and Foreign Patents Pending
www.USAIndustries.com | [phone]
©2019, USA Industries, Inc.
FRM-23.1 Rev.B
9. GripSafe Liing Device
Page 19 of 24
Figure 12: GripSafe Liing Device Diagram