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Petersen 128 Series, Instruction Manual, Page: 23 / 33

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Petersen Products 128 Series  

Assembling the Air Inflation Kit 

21

 

Assembling the Air Inflation Kit 

Pressure Monitor Side 

 

Connect the Pressure Monitor Hose and Inflation Hose to the Inflation Ram Assembly. 

 

Attach one or two Gauges to the Pressure Monitoring Valve Assembly. 

 

Connect the Low Pressure Alarm to the Pressure Monitor Hose.  

 

Connect the Pressure Monitoring Valve Assembly to the Low Pressure Alarm. 

 

Inflation Side 

 

Connect one Gauge to the Inflation Controller.  

 

Connect the Relief Valve to the Inflation Controller. 

 

Connect the Inflation Hose to the Inflation Controller. 

 

CAUTION

 

Close the valve on the Inflation Controller before connecting air supply. 

 

Connect the Inflation Source Air line to the Inflation Controller. 

 

 

 

Pressure 

Monitor Hose 

Inflation Hose 

Inflation Ram 

Pressure 

Monitor Valve 

Gauge 

Gauge 

Low Pressure Alarm 

Inflation Controller 

Relief Valve 

Summary of Contents for 128 Series

Page 1: ...p Plug Instruction Manual www PetersenProducts com 421 Wheeler Avenue PO Box 340 Fredonia Wisconsin 53201 0340 USA Phone 262 692 3100 or 1 800 926 1926 Fax 262 692 2418 or 1 800 669 1434 Email sales p...

Page 2: ...nch Cylinder 5 Torque Figures 5 Calculating the Head Pressure 6 Tapping the Pipe 6 Attaching the Rotating Elbow Assembly 7 Assembling the Launch Cylinder 9 Measuring the Assembly 10 Attaching the Main...

Page 3: ...ted by an engineerfor each specific project Instructions and training must be provided to all plug users and workers on thejob Personnel Safety CAUTION Keep all personnel away from the plug end area W...

Page 4: ...acking Seal 8 Inflation Ram Coupling 3 Centering Anchor 9 Inflation Ram Pulley Assembly 4 Eyebolts 10 Stop Collars 5 Inflation Ram Sections 11 Flange Gaskets 6 Flange Bolts 12 Line Stop Plug NOTE Pete...

Page 5: ...t Puller 5 Tape Measure 2 Socket 6 Wrench 3 Torque Wrench 7 Marker 4 Allen Wrench 8 O Ring Lubricant If using a Retraction System verify that all Retraction System components are complete 10 Ram Remov...

Page 6: ...cts 128 Series Assembly Overview 4 Assembly Overview Launch Cylinder Tapping Valve Inflation Hose Pressure Monitor Hose Rachet Puller Packing Seal Rotating Elbow Line Stop Plug Directional Shoe Inflat...

Page 7: ...r 2 1 2 inch Inflation Ram 1 inch stop collar centering guides Allen Wrench 1 4 Stop Collar for 1 7 8 inch diameter Inflation Ram Allen Wrench 5 16 Stop Collar for 2 1 2 inch Inflation Ram Pipe Wrench...

Page 8: ...lug are the same for liquid water or air 68 9 kPa 10 psi of water 98 9 kPa 10 psi air Pressures from gasses e g air nitrogen are compressible and more dangerous than water Gas will expand to its origi...

Page 9: ...ng Elbow Assembly The Rotating Elbow Assembly is available with Thread and Set Screw type connections for the Inflation Ram Adapter Inspect the O Rings for any possible physical damage Petersen recomm...

Page 10: ...the Line Stop Plug The bend of the Rotating Elbow should follow the natural curve of the Line Stop Plug Note The plug will tend to follow the large diameter wheel on the Directional Shoe when enterin...

Page 11: ...ented at the bottom for draining process fluid when the job is complete Close each Valve Insert the Gasket between the Flanges on each Launch Cylinder Bolt each Launch Cylinder section together Use a...

Page 12: ...pivot when positioned at a 90 angle M1 Measure the distance from the top flange of the Tapping Valve to the top of the OD of the pipe Determine the radius of the pipe Add M2 to the radius M3 to deter...

Page 13: ...ion Ram section Fit the sections together if needed M5 Combine the length of the Launch Cylinders the width of the Packing Seal and the thickness of the Ram Removal Plate if the Retraction System is u...

Page 14: ...length the assembly M4 M6 M1 1 8 inches 1 gasket M7 Subtract the length of the assembly from the Ram length M5 M7 M8 Attatch the Main Stop Collar at M8 Tighten the Socket Head Cap Screws to secure th...

Page 15: ...g lubricant to the O Rings on the Inflation Ram Couplings Connect each ram section together Tighten the Set Screws to secure each Ram section in place See figure below for torque Screw Size Torque 10...

Page 16: ...lar approximately 6 below the Ram End Assembly but above the Packing Seal Note Apply O Ring lubricant to the Packing Seal if needed 4 Slide a Gasket and the Centering Anchor on the Ram below the Packi...

Page 17: ...Elbow and Plug The Orientation Line should align with the curvature of the Plug and direction of insertion Use the mark as a guide when lowering the Plug into the Pipe Note Use the Orientation Line an...

Page 18: ...t extend past the end of the Launch Cylinder Attach a Stop Collar to the Inflation Ram flush with the top of the Packing Seal to secure the Line Stop Plug in position If installing vertically connect...

Page 19: ...the bolts to secure the Assembly in place Use a star pattern for balanced torque Complete the pattern three times 30 70 100 to the torquing sequence See Torque Figures on page 5 Attach the ratchet pu...

Page 20: ...ssembly to lower the Inflation Ram and Plug into the pipe Loosen the Stop Collar that is against the Packing Seal to allow the Line Stop Plug to lower down into the pipe NOTE The Insertion System can...

Page 21: ...bly Install the remaining ram section with the stop collar Tighten the Set Screws to secure the Ram sections together 4 4Loosen the Set Screws and remove the Initial Stop Collar Slowly lower the Plug...

Page 22: ...lation Kit 20 Air Inflation Kit If using water inflation skip to the water inflation section Page 22 Pressure Gauge Low Presure Alarm Inflation Hose Pressure Monitor Hose Pressure Monitor Valve Assemb...

Page 23: ...Connect the Pressure Monitoring Valve Assembly to the Low Pressure Alarm Inflation Side Connect one Gauge to the Inflation Controller Connect the Relief Valve to the Inflation Controller Connect the...

Page 24: ...oiled when not in use to prevent equipment damage CAUTION Do not over inflate Maintain the pressure at 2X the pipeline pressure but less than maximum rated plug pressure Adjust the Regulator on the In...

Page 25: ...plug Disconnect the air source and open the valve on the Pressure Monitor Assembly The Vacuum Generator may be used to deflate the larger plugs with air Water Inflation Controller Overview The 1 5 Po...

Page 26: ...e quantity of water display the Batch then press and hold the Display button To change units from gallons to liters hold the Calibrate button and press the Display button Assembling the Water Hoses an...

Page 27: ...and to the Water Inflation Controller outlet Attach the water supply line to the Water Source Connection of the Water Inflation Controller Connect the air source line to the Pump Air Source Connection...

Page 28: ...tor Assembly to release any air NOTE Do not allow the pressure to drop below 5 psi from 5 of the line pressure To monitor the inflation pressure with a water hose that is filled with water Add 0 433 p...

Page 29: ...connected on the Water Source Connection is now connected to the water pump outlet The hose that was connected to the water pump outlet is now connected to the Water Source Connection Verify that the...

Page 30: ...nly lift 18 ft on the inlet side Pipeline pressure can assist with water deflation If needed Petersen can make line stop plugs that displace water with air for lifts over 18 ft Never exceed the pressu...

Page 31: ...the Ram sections to the Ram Removal Plate Tighten the Set Screws to secure the Ram Sections in place Attach the Pully Assembly to the Ram Sections Tighten the Set Screws to secure the Pully Assembly...

Page 32: ...nt M6 from the stop collar to verify that the Inflation Ram is fully retracted See M6 on Page 11 Once the Line Stop Plug is fully retracted close the Tapping Valve NOTE Use a Catch Pan or Drain Hoses...

Page 33: ...llow the line stop plug to remain in sunlight for extended periods of time to prevent damage Verify that the line stop plug is empty of water and dry prior to storage in a dry location Keep the instru...

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