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Kleiss MCS120-24 System Manual

Flow Stopping System / 2” - 4” up to 120 psi

Summary of Contents for Kleiss MCS120-24

Page 1: ...Kleiss MCS120 24 System Manual Flow Stopping System 2 4 up to 120 psi Flow Stopping System 2 4 up to 120 psi...

Page 2: ...24 System all tools has a maximum operating pressure of 120 psi The inflatable stoppers have a design safety factor of 3 The balance of the tools have a design safety factor of 2 The Kleiss MCS120 24...

Page 3: ...re 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 fitting connection of 2 1 2 BSP threads 2 2 Tapping To...

Page 4: ...Stopper Specifications 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 Inflation pressure of 175 psi or 2x system pressure if unabl...

Page 5: ...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 operato...

Page 6: ...s inflate the stopper as quickly as practical 4 Suggested stopper setting sequence is tower 1 2 3 4 Set all 4 stoppers 5 First inflated stopper is now in a no flow condition Reset stopper for best pos...

Page 7: ...e on both sides of the stopper before deflation or removal 1 Deflate 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...

Page 8: ...ITH the flow of gas 3 Always inflate the stopper as quickly as practical 4 Suggested stopper setting sequence is tower 3 4 2 1 Set all 4 stoppers 5 First inflated stopper is now in a no flow condition...

Page 9: ...ion or removal 1 Deflate stopper 2 2 Back pressure stopper 4 through the system pressure ports in towers 3 and 4 3 Deflate stopper 4 4 Equalize pressure on stoppers 1 and 3 through the by pass vent po...

Page 10: ...130 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 14300...

Page 11: ...ompletion Tool Components Tapping Tool and Completion Tool Components Plugging Dome Air Motor Feed Tube Drilling Dome Cutter Pilot Drill Drilling Rod Bayonet Lock Plugging Spindle Plugging Dome Bleed...

Page 12: ...Rod Complete 2 94200010 Silicone Grease Aerosol 3 12100390 Pipeline Pressure Gauge 0 to 160 psi 4 12100360 Inflation Pressure Gauge 15 to 210 psi 5 10311030 Ring Adapter for Steel 2 1 2 x 2 1 2 x 1 3...

Page 13: ...MainlineControlSystems com Stopping Tool Components Stopping Tool Components Internal Stopper Inflation Pressure Gauge System Pipeline Pressure Gauge Stopping Tower MDS Stopper Chute By Pass Vent Port...

Page 14: ...DS Stoppers MDS Stoppers PART DESCRIPTION 1 23100375 MDS Stopper Size 2 2 23100380 MDS Stopper Size 3 3 23100385 MDS Stopper Size 4 Fitting Completion Plug Completion Cap Fitting Completion Plug Compl...

Page 15: ...1 Vent Stack with Hose 3 10310860 Magnetic Head Attaches to Tapping Tool 4 13200098 Coupon Remover 3 8 Connection 5 12100740 Safety Fitting Silver 6 BPGT 1 By Pass Gauge Tree 7 BPC 1 By Pass Cap 8 BPV...

Page 16: ...material per company standards and specifications Before welding steel fitting on main remove the completion cap and plug from fitting When welding if there is concerns about warping the fitting inst...

Page 17: ...e threads are clean and the device operates freely Visually inspect the drilling dome and verify o rings are in place Attach the drilling dome to the hot tapping device Tighten the connection by means...

Page 18: ...ts Grease rod with silicone grease for a smooth installation Then install the drilling rod through the hot tapping device and dome Install the cutter onto the drilling rod and tighten the cutter Retra...

Page 19: ...t lock on tapping device Carefully lower drilling rod until pilot drill touches the surface of the pipeline to be tapped When doing this make sure the bayonet lock is in a free position and does not l...

Page 20: ...ce NOTE If issues with air motor occur tapping can be completed by hand using the ratchet Use the air motor to turn the drilling rod clockwise While the drilling rod is rotating clockwise slowly hand...

Page 21: ...d with black handle Put ratchet on top of drilling rod and hold it Unlock the bayonet lock then loosen the black handle in a controlled way so you prevent the rod from coming up with excessive force I...

Page 22: ...rench to remove tapping device from drilling dome Remove cutter and pilot drill from drilling rod The cutter should contain the drilling coupon Use the necessary tools Coupon Remover to remove the cou...

Page 23: ...should be in good visual condition The condition of the gasket can be verified when conducting the vacuum test on the stopper prior to inserting the stopper into the gas system NOTE Extra stopper rod...

Page 24: ...ion and seal Connect hand pump to the stopper inflation connection on the top end of the stopper rod This is the offset connection With the valve open pull a vacuum to 15 on the stopper to make it as...

Page 25: ...od or a MDS Stopper Test Adapter 12100731 After the stopper stabilizes wait a minimum of 10 minutes to make certain the same pressure is maintained within the MDS Stopper NOTE Do not inflate the stopp...

Page 26: ...ms com Lightly spray the chute Loosen black locking handle on stopping dome to slide dome down to cover the chute Push brass cap to the bottom of the rod Insert stopper rod with stopper attached into...

Page 27: ...the hooked wrench and make sure the MDS Stopper stays in the right position When doing this make certain the valve doesn t inadvertently turn Close the valve of the by pass vent port Open the ball val...

Page 28: ...ing Push all the way down Lock the stopper rod with black knob Recommended If needed or applicable attach By Pass Gauge Tree BPGT 1 to by pass vent port NOTE Additional options are available in the 4...

Page 29: ...pipe itself then inflate to a minimum of 2 times system pressure to achieve stop off Install safety fitting on inflation pressure port Allow the stopper to stabilize inside the pipeline for at least 1...

Page 30: ...ne in a variety of ways Refer to examples in Section 3 0 of this manual and your gas company procedures ALWAYS EQUALIZE PRESSURE Once pressure is equalized open the inflation valve of the MDS Stopper...

Page 31: ...chute up out of the pipeline Tighten black locking handle Close the ball valve Open the by pass vent valve in order to evacuate the stopping tool Loosen the brass collar between the stopping tool and...

Page 32: ...om the stopping tool Unscrew brass cap and pull stopper rod out of tower Clean and store MDS Stopper in transportation case Do not leave it on the ground Inspect the stopper for damages Clean the stop...

Page 33: ...letion plug onto the plug spindle The connection is good when the detent balls of the plug spindle grip the completion plug You will hear a positive click Fully retract the plug into the dome Install...

Page 34: ...the plugging spindle fully downwards Screw the plug into the fitting with the ratchet until bottomed out and tight Test to make sure there is a seal by opening the bleed valve on the dome and relievin...

Page 35: ...adapter Remove the ring adapter from the fitting by means of the hooked wrench Prior to placing the completion cap inspect the completion plug again for any leakage Screw the completion cap onto the...

Page 36: ...cutter and pilot bits Grease the tapping device if needed 10310800 Inspect gauges for any damage and ensure they are reading zero and function properly Inspect stopper rod for bends and or damage Clea...

Page 37: ...ly inspect the stopper for weak spots and integrity Discard stopper if weak spots are found Continue with inspection if everything looks OK OK Examples Coating is coming off but individual threads are...

Page 38: ...he condition of the stopper is still uncertain or additional stopper testing is desired insert the stopper into a piece of pipe within the stopper s pipe ID range Make certain the test set up is in a...

Page 39: ...One Side of Work Area Illustration of One Side of Work Area 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...

Page 40: ...tration of One Side of Work Area Illustration of One Side of 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...

Page 41: ...tion of One Side of Work Area Illustration of One Side of Work Area STOPPING TOWER DISTANCES Nominal Pipe Size A minimum B L1 Steel Welding L2 PE CI and Mechanical 2 16 16 20 3 16 19 20 4 16 23 24 A m...

Page 42: ...ation of One Side of Work Area Illustration of One Side of 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...

Page 43: ...42 Kleiss MCS120 24 System Manual v 1 1 March 2021 www MainlineControlSystems com 844 FLO STOP www MainlineControlSystems com...

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