MAINLINE Kleiss MCS120-24 Guía del usuario
Kleiss MCS120-24 System Manual
Flow Stopping System / 2” - 4” up to 120 psiFlow Stopping System / 2” - 4” up to 120 psi
1
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
Kleiss MCS120-24 System OverviewKleiss MCS120-24 System Overview
The Kleiss inatable stopping systems meet the needs of the North
American Natural Gas LDCs by providing a ow control system that is
easy to use and eective at stopping o ow in various pipe materials
and a wide range of pipe diameters.
The Kleiss MCS120-24 System consists of four major components:
1) tting to access the pipe, 2) tapping / completion tool, 3) inatable stopper, and 4) stopping tool.
The Kleiss MCS120-24 System (all tools) has a maximum operating pressure of 120 psi. The inatable stoppers have a
design safety factor of 3. The balance of the tools have a design safety factor of 2.
The Kleiss MCS120-24 System is designed to handle ow control on pipe sizes 2” to 4” on steel pipes.
(Kleiss & Co., who developed the system, has reviewed and approved this manual.)
Table of Contents:
1.0 General Safety Information: .................................................. 2
2.0 System Specications: ........................................................... 2
3.0 Typical Site Set Up and Sequence: ........................................ 4
4.0 Equipment: ............................................................................. 9
5.0 Preparatory Steps: ................................................................ 15
6.0 Tapping Operation: .............................................................. 15
7.0 Stopping Operation: ............................................................. 22
8.0 Retrieving MDS Stopper: .................................................... 29
9.0 Plugging Operation: ............................................................. 32
10.0 General Maintenance: ........................................................ 35
APPENDIX A: Stopper Testing and Verication....................... 36
APPENDIX B: Tower Positioning and Distances ..................... 38
APPENDIX C: Manual Updates ................................................ 42
2
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
1.0 General Safety Information:
NOTE: Before using the Kleiss MCS120-24 System make certain you read the instruction manual completely and are
comfortable and familiar with the operation of the tools. If you have any questions, concerns or feel there is conicting
information, please contact Mainline Control Systems (MCS) before proceeding at 844-FLO-STOP.
NOTE: The purpose of the Kleiss MCS120-24 System is to tap and stop ow in natural gas lines sizes 2” through 4”
operating at a maximum of 120 psi. Review and follow your company safety procedures for operations involving tapping
and stopping live natural gas lines.
2.0 System Specifications:
2.1 General2.1 General
A) Pipe diameter between 2” and 4”
B) Pipe material = steel
C) Maximum operating pressure of 120 psi
NOTE: Tools are designed and built with a safety factor to allow +10% (+12 psi) for operation on 120 psi MAOP
systems or in abnormal operating conditions.
D) Tool to tting connection of 2-1/2” BSP threads
2.2 Tapping Tool and Completion Tool Kit Specications2.2 Tapping Tool and Completion Tool Kit Specications
A) Maximum operating pressure of 120 psi (see NOTE in 2.1C)
B) Cutter available
a) 1.93” (49 mm) steel [Part# 13200130]
C) 1/4” (6.3 mm) pilot drill used for all materials [Part #14300060]
D) Air motor & compressor requirements
a) Connection to the air motor ~ 1/2” NPT
b) 90 psi measured at the inlet of the air motor during operation
c) Refer to manufacturer air motor specications guide
E) Oiler / separator required to be used to extend the life of the air motor
a) Use standard pneumatic oil in tool
F) Weights
a) Tapping tool with cutter ~ 21 lbs.
b) Completion tool without completion plug attached ~ 6 lbs.
c) Air motor ~ 11 lbs.
d) Shipping weight in case ~ 53 lbs.
G) Dimensions
a) Tapping tool height with cutter ~ 29”
b) Completion tool height ~ 14”
c) Storage case ~ 38” length x 18” width x 6” height
3
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
2.3 Stopping Tool Kit Specications2.3 Stopping Tool Kit Specications
A) Maximum operating pressure of 120 psi (see NOTE in 2.1C)
B) Weights
a) Stopping tool ~ 29 lbs.
b) Ball valve ~ 8 lbs.
c) Shipping weight in case ~ 59 lbs.
C) Dimensions
a) Stopping tool height with stopper rod completely extended ~ 4’ 8”
b) Stopping tool height with stopper set ~ 3 feet
c) Storage case ~ 38” length x 18” width x 6” height
D) By-pass / vent port
a) 3/4” tap size in tool
b) 1” camlock male coupling
2.4 MDS Inatable Stopper Specications2.4 MDS Inatable Stopper Specications
A) Sizes
a) 2” Pipe ID [Part #23100375]
b) 2.5” Pipe ID [Part #23100376]
c) 3” Pipe ID [Part #23100380]
d) 4” Pipe ID [Part #23100385]
B) Ination pressure of 175 psi or 2x system pressure if unable to achieve 175 psi by compressor or nitrogen
C) Design burst pressure of 525 psi
D) Operating temperature range of 5° F (- 15° C) to 140° F (60° C)
E) Maximum temperature range of 158° F (70° C) for up to 30 minutes
2.5 Vent Stack Specications2.5 Vent Stack Specications
A) Height assembled ~ 112”
B) 1” camlock male coupling
C) Air hose to venturi connection
D) Hose (standard) of 10 m, 1” camlock connection F x F
E) Ground rod included
F) Weight (less hose) ~ 27 lbs.
G) Air supply and ow capacity rates =
Air Supply Flow Capacity
Working Pressure
(PSI)
Air Consumption
(ft3/min)
Blow Out Volume
(ft3/hr)
80 13 24300
120 13 21200
4
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
2.6 Hand Pump (Pressure and Vacuum Pump)2.6 Hand Pump (Pressure and Vacuum Pump)
A) 1 positive pressure connection
B) 1 negative pressure (vacuum) connection
C) 10 foot air hose with quick disconnects included
D) Weight ~ 12 lbs.
2.7 Maximum Flow Rates2.7 Maximum Flow Rates
A) Maximum design ow rate = 10 ft/sec (3.048 m/sec)
B) For reducing speed, use by-pass / vent port
NOTE: The system is designed to be used in controlled stop o applications, and is not intended to be used to
stop ows in severely ruptured pipes. Flow should be reduced before attempting stop o.
3.0 Typical Site Set Up and Sequence:
It is important to understand the MCS stopping tools and their operation completely. It is also important to understand the
complete job and sequence of steps to perform a safe stop. Safety of the operators on the job site is the most important
factor so pre-plan the whole job including the stopping and retrieval sequences.
The following examples are typical installations. Example I (yellow background) illustrates stoppers positioned towards
each other. Example II (blue background) illustrates stoppers positioned away from the work area. Both congurations
work equally well. For additional set up illustrations, see Appendix B or contact your distributor / MCS representative.
Remember to consider the ancillary steps like purging / venting the area to be worked on and back pressuring stoppers for
removal. The features of the MCS120-24 oer options to make these processes ecient.
5
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
Example I – Stopping Sequence: Stoppers Positioned Towards Each Other (Most Flexible)Example I – Stopping Sequence: Stoppers Positioned Towards Each Other (Most Flexible)
STOPPING TOWER DISTANCES
Nominal Pipe Size A
(minimum)B L1* = Steel Welding L2 = PE, CI, and Mechanical
2” 32” 16” 20” -
3” 38” 19” 20” -
4” 46” 23” 24” -
A = minimum distance between towers
B = stopper length
L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks
reaching the inatable stopper
1) If a by-pass in the work area is being used (through our MCS tool or another), initiate the by-pass ow rst.
2) Always insert rst inatable stopper WITH the ow of gas.
3) Always inate the stopper as quickly as practical.
4) Suggested stopper setting sequence is tower #1, #2, #3, #4. Set all 4 stoppers.
5) First inated stopper is now in a no ow condition. Reset stopper for best possible seal (deate, reposition stopper
rod, inate).
6) Always allow stoppers to settle for 10 minutes prior to beginning pipeline work. This allows the stopper to
acclimate to internal pipe conditions. Verify system pressures, ination pressures, and any bleed-by before starting
pipeline work. Adjust as necessary.
7) Use the by-pass / vent port on tower #2 or #3 to purge the work area. Utilize the MCS vent stack to assist in
evacuating the work area. This connection can also be used to inject nitrogen into the work zone.
8) Keep by-pass / vent ports on towers #2 and #3 open to atmosphere during work to keep gas away from the work
area. Follow company procedures for venting and purging gas.
9) This set up can easily be used on both single feed and dual feed systems.
6
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
Example I – Stopper Retraction Sequence: Stoppers Positioned Towards Each OtherExample I – Stopper Retraction Sequence: Stoppers Positioned Towards Each Other
NOTE: Always equalize pressure on both sides of the stopper before deation or removal.
1) Deate stoppers #2 and #3.
2) Use by-pass / vent ports on tower #1 and #2 to equalize pressures on stoppers #1 and #4. Equalize slowly.
3) Use by-pass / vent port on tower #3 to purge air from the repaired area.
4) Use system pressure gauge on tower #1, #2, #3, or #4 to determine if stoppers are equalized.
5) When pressure is equalized, deate stoppers #1 and #4. Retract all stoppers.
6) Remove tools and install completion plugs.
7
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
Example II – Stopping Sequence: Stoppers Positioned Away From Work AreaExample II – Stopping Sequence: Stoppers Positioned Away From Work Area
STOPPING TOWER DISTANCES
Nominal Pipe Size A
(minimum)B L1 = Steel Welding L2 = PE, CI, and Mechanical
2” 16” 16” 20” -
3” 19” 19” 20” -
4” 23” 23” 24” -
A = minimum distance between towers
B = stopper length
L1* = distance from stopper/tower to work area - use standard industry & company practices to minimize heat transfer & sparks
reaching the inatable stopper
1) If a by-pass in the work area is being used (through our MCS tool or another), initiate the by-pass ow rst.
2) Always insert rst inatable stopper WITH the ow of gas.
3) Always inate the stopper as quickly as practical.
4) Suggested stopper setting sequence is tower #3, #4, #2, #1. Set all 4 stoppers.
5) First inated stopper is now in a no ow condition. Reset stopper for best possible seal
(deate, reposition stopper rod, inate).
6) Always allow stoppers to settle for 10 minutes prior to beginning pipeline work. This allows the stopper to
acclimate to internal pipe conditions. Verify system pressures, ination pressures, and any bleed-by before
starting pipeline work. Adjust as necessary.
7) Use the by-pass / vent port on tower #2 or #3 to purge the work area. Utilize the MCS vent stack to assist in
evacuating the work area. These connections can also be used to inject nitrogen into the work zone.
8) Keep all by-pass / vent ports on towers open to atmosphere during work to keep gas away from the work area.
Follow company procedures for venting and purging gas.
8
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
Example II – Stopper Retraction Sequence: Stoppers Positioned Away From Work AreaExample II – Stopper Retraction Sequence: Stoppers Positioned Away From Work Area
NOTE: Always equalize pressure on both sides of the stopper before deation or removal.
1) Deate stopper #2.
2) Back pressure stopper #4 through the system pressure ports in towers #3 and #4.
3) Deate stopper #4.
4) Equalize pressure on stoppers #1 and #3 through the by-pass / vent port between towers #3 and #4.
5) Use the by-pass / vent port in tower #1 or #2 to purge air from repaired area.
6) Use system pressure gauge on tower #1 or #2 to determine stoppers are equalized.
7) Deate and remove stoppers.
8) Remove tools and install completion plugs.
NOTE: For additional set up illustrations, see Appendix B.
9
Kleiss MCS120-24 System Manual v.1.1 March 2021 |
www.MainlineControlSystems.com
4.0 Equipment:
Tapping Case [Part # MCSTK120-0204-001]:Tapping Case [Part # MCSTK120-0204-001]:
12
34
5
6
78910
12
13 14
11
PART # DESCRIPTION
1) 11000070 Ratchet (1/2” square)
2) 11000120 Ratchet (20 mm square)
3) 13200130 Steel and Cast Iron Cutter
(1004HM 49 mm)
4) 13200130 Cutter Grease (250 ml)
5) 14700015 Air Motor (small 20 mm square)
6) 10310905 Drilling Rod (650 mm
25 mm x 20 mm square)
7) 10311057 Drilling Dome
8) 14300060 Pilot Drill
(6.3 mm with retainer spring)
PART # DESCRIPTION
9) 99512506 Hexagonal Key (4 mm)
10) 11005310 Hook Assembly Wrench (58-62)
11) 10310817 Plugging Spindle
12) 10310950 Plugging Dome
13) 10310780 Adapter (3/4” WW x 3/8” )
14) 10310800 Tapping Device / Hot Tap Tool
(LB-493HD)
Case
Foam Interior
Tabla de contenidos
