Vetter 9987076900 Operational manual

Art. no. 9987076900 | © Vetter GmbH I 07/19 I Subject to modications and errors.
Industrial Pneumatics.
Translation of the original
operating manual
VETTER 1bar cone pipe stopper
Keep in a safe place for future use

Vetter 1bar cone pipe stopper
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Contents
1. Introduction ......................................................3
2. Safety ............................................................4
2.1 Symbols in this manual .....................................4
2.2 Personal protective equipment..............................5
2.3 Intended use ...............................................6
2.4 Personnel requirements.....................................7
2.5 General information ........................................7
2.6 Residual risk ................................................7
3. Operating the cone pipe stopper ................................11
3.1 Preparing to insert the cone pipe stopper .................11
3.2 Inserting the cone pipe stopper into a pipe ................ 13
3.3 Shoring ..................................................14
3.4 Shutting o the pipeline ..................................14
3.5 Draining the pipeline .....................................15
3.6 Water and compressed air check .......................... 15
4. Care, maintenance intervals and storage......................... 16
4.1 Care ......................................................16
4.2 Maintenance intervals .................................... 17
4.3 Storage................................................... 18
5. Technical data:..................................................19
6. List of materials and compatibilities .............................19
6.1 Material list ...............................................19
6.2 Temperature resistance ...................................19
6.3 Compatibilities list ........................................19

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1. Introduction
In order to operate the cone pipe stopper safely and without
malfunctions, it is essential to be familiar with and to follow this
operating manual and the safety information contained therein.
In addition, the applicable occupational health and safety regula-
tions and accident prevention regulations must be complied with,
together with the generally recognised rules of technology.
This operating manual is a component of the product and must
be retained throughout the product’s service life. If the product
is transferred or sold to another party, the user manual must also
be transferred to the subsequent user. Knowledge of and compli-
ance with the user manual is a prerequisite for using cone pipe
stoppers.
You can nd the latest version of this operating manual on our
website, “www.vetter.de” under “Support”.

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2. Safety
2.1 Symbols in this manual
Read the operating manual!
The following symbols are used in the text to indicate safety information
and warnings:
DANGER!
This combination of symbol and signal word indicates an imminently
dangerous situation that will result in death or serious injury unless
avoided.
WARNING!
This combination of symbol and signal word indicates a potentially
dangerous situation that could result in death or serious injury unless
avoided.
CAUTION!
This combination of symbol and signal word indicates a potentially
dangerous situation that could result in minor or light injury unless
avoided.
NOTE!
This combination of symbol and signal word indicates a potentially
dangerous situation that could result in property damage unless
avoided.
This symbol highlights useful tips and recommendations, as
well as information on ecient and trouble-free operation.

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2.2 Personal protective equipment
Safety gloves
Safety gloves protect the wearer’s hands against friction, abrasion,
puncture wounds or deeper injuries.
Safety shoes
Safety shoes protect the wearer’s feet against crushing, falling
objects and slipping on slippery surfaces.
Face, head and ear protection
Face protection protects the wearer’s eyes and face against ames,
sparks or embers, as well as hot particles and waste gases. Head
protection protects the wearer’s head against falling objects, sus-
pended loads and impact with stationary objects. Ear protection
protects the wearer against hearing damage caused by noise.
Protective clothing
Protective clothing is close-tting work clothing with a low tear
strength, with tight-tting sleeves and with no protruding parts.

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2.3 Intended use
Cone pipe stoppers may only be lled with compressed air, and only
using original lling devices. Filling using lling devices procured from
third parties shall be considered contrary to the intended use.
Cone pipe stoppers are used exclusively to shut o pipes that are intend-
ed for that purpose, to test for leaks in pipelines, and to create a bypass.
The intended use also includes the following:
9Observing all the information in this user manual
9Compliance with the maintenance and care intervals specied in the
section “Care, maintenance intervals and storage”
Any use other than that described here shall be considered contrary
to the intended use. Usage of the cone pipe stoppers contrary to the
intended use includes the following:
9Improper operation, handling or maintenance of the cone pipe
stoppers
9Operating the cone pipe stoppers with faulty safety equipment or
improperly attached or non-functioning lling devices
9Failure to observe the information in the user manual regarding stor-
age, operation and maintenance of the cone pipe stoppers
9Inadequate monitoring of accessory parts that are subject to wear
9Improperly performed maintenance work
9Filling the cone pipe stopper system with ammable, hazardous or
aggressive gases and uids
9Operation outside the permissible temperature range or in a tropical
environment
9Operating the system in a potentially explosive atmosphere
9Operating the system in a corrosive or contaminated environment
9Operating the system in the vicinity of strong magnetic elds
9Use by private users or users without technical instruction and training
The entire cone pipe stopper may only be used in a temperature range
from -20°C cold-resistant to +55°C heat-resistant.

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2.4 Personnel requirements
This section describes the qualications required for persons performing
the various tasks:
An instructed person is a person who has veriably been instructed
by the owner about the tasks to which said person has been entrusted,
and who has been informed of the possible dangers associated with
improper behaviour. This instruction was provided by a person trained
and qualied in the relevant discipline.
An expert is a person who, thanks to his or her technical training and
experience, possesses sucient knowledge in the eld of pipe shut-o
devices and is familiar with the applicable national occupational health
and safety regulations, accident prevention regulations and generally
recognised rules of technology (e.g. trade association rules, DIN and
EN standards, technical rules of other EU member states or other states
which are party to the Agreement on the European Economic Area) to
the extent that he or she is able to assess the condition and reliability of
pipe shut-o devices. (Source: BGI 802)
2.5 General information
Compliance with all the applicable occupational health and safety rules,
accident prevention regulations (e.g. safety rules of the civil engineering
trade associations) and the generally recognised rules of technology is
assumed.
2.6 Residual risk
Even when all the safety regulations are complied with, residual risks
remain when operating the cone pipe stopper, as described below.
Asthe owner/operator, make sure that all persons who work on and with
the inatable pipe stopper system are aware of the residual risks. Follow
the instructions that prevent residual risks from causing accidents or
damage.
During operation of the cone pipe stopper, there are various residual
risks and potential hazards that every operator should be aware of:
During operation of the inatable pipe stopper system, risks to
the operator may occur or the pipe stopper system and other
material assets may become damaged in the following cases:
- Operation and handling of the cone pipe stopper by personnel who
are not trained and experienced
- Use contrary to the intended use
- Improper maintenance
No modications or conversions to pipe stoppers, lling devices and
lling hoses are permitted. The cone pipe stopper may only be operated
with genuine Vetter lling devices and lling hoses. If third-party parts
are used, safety may be impaired.

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During a water pressure check, the pipeline to be checked must not be
directly connected to a pressurised line (e.g. hydrant).
Before and after each use, check that the cone pipe stopper and acces-
sories are in perfect working order. During the visual inspection, look out
for the following possible damage:
9Separation
9Cuts
9Punctures
9Eects of heat/acid
9The nipples and couplings must be clean, undamaged and fully
functioning.
Outside pipelines, 1bar cone pipe stoppers may only be lled to a max-
imum of 0.2bar for the visual inspection.
All the control devices are tted with a safety relief valve corresponding
to the maximum permissible operating pressure for the pipe stopper or
test pipe stopper. If the maximum operating pressure of 1bar is exceed-
ed, the safety relief valve vents. The tolerance for opening and closing
the safety relief valves must not exceed ± 10%. The set pressure must
not be altered.
If the lead seal on the valve bonnet has been removed, safe functioning
is no longer guaranteed and the safety relief valve must be replaced. The
permissible inlet pressure to the control devices (labelled on the inlet
coupling) must not be exceeded.
Ejection of the cone pipe stopper
DANGER!
Risk of death due to ejection of cone pipe stopper!
A cone pipe stopper that is ejected from the pipe can cause life-threat-
ening injuries.
– Keep away from the vicinity of the pipe’s opening.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.

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Flooding of the working area
DANGER!
Risk of death due to remaining in the working area in the
event of ooding!
A leak in the cone pipe stopper when there is water trapped in the
pipe can result in death by drowning due to ooding of the pipe.
– After lling and shoring the cone pipe stopper, do not remain in the
danger zone.
– Make sure that there are no persons present in the shaft or pipe
during the lling, testing and draining procedures.
– Before removing the shoring, check that the pipe is depressurised
and completely drained.
Release of gases from shut-o lines
DANGER!
Risk of death due to escaping gases from shut-o lines!
Escaping gases from shut-o lines can lead to life-threatening poison-
ing or asphyxiation.
– Before working in the working area, take precautionary measures
against the release of gases.
Waste gases and lack of oxygen in the pipe
DANGER!
Risk of death due to waste gases and lack of oxygen in the
pipe!
Waste gases and a lack of oxygen can lead to life-threatening poison-
ing or asphyxiation.
– Check the oxygen concentration before and during work in the pipe.
– Wear safety gloves, safety shoes, face, head and ear protection, pro-
tective clothing and respiratory protection.

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Bursting of the cone pipe stopper
WARNING!
Health risk due to bursting of the cone pipe stopper!
The cone pipe stopper may burst while in use. Bursting of the cone
pipe stopper may result in loss of hearing and pressure trauma.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.
– Carry out maintenance and an inspection after any damage to the
cone pipe stopper.
– Immediately put a defective cone pipe stopper out of operation.
– Before inserting the cone pipe stopper, clean the pipe and remove
any sharp and rough materials.
Gases and dusts
WARNING!
Risk of poisoning from gases and dusts!
Inhaling toxic gases and dusts can result in severe or fatal damage to
health.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.
– Make sure that the opening of the pipe is unobstructed.
– Ensure sucient air circulation.
Viruses and bacteria
WARNING!
Risk of infection from viruses and bacteria!
Inhalation of or contact with viruses and bacteria can result in severe
or fatal damage to health.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.
– Maintain and clean the cone pipe stopper at regular intervals.