What is the Joint Tester?

Joint Tester is used for testing the joint point of the two pipe. Regular pipe test plugs are used as joint tester instead of JT but consumption water of that way is more than the JT applications. So the JT is preferred instead of regular pipe test plugs.

• Wheels (Allow transport / move the JT)
• Air Filling Point(Allow to inflated the JT)
• Pressure Gauge (Observe the test pressure inside the pipe)
• Air/Water Filling Point (Filling air or water as per test type. After filling, allow to observe test pressure outside of the pipe by connecting pressure gauge.)
• Inflatable Parts (Allow to seal the test area)
• Test Area (Covers joint length)

How to choose the correct Joint Tester?

• Measure the internal diameter of the pipe and select matched size/model of the JT.
• Measure the joint length and select the suitable JT length. JT Length (L) = Joint Length (l) + 300 mm
• Determine the test method. Is it air leak test or water leak test?
• Check the required test pressure as per project standard and select the suitable operation pressure (working pressure) in Plugco Catalog.

Using the Joint Tester (JT)

Application the Joint Tester (JT)

Step 1: Before using the jt

1.1. Read the Plugco Safety Manuel.

1.2. Wear the personal protective equipment such as shoes with steel nose, glass, glove…..

Follow safety rules of international and local authorities!

1.3. Inspect the JT and all accessories for surface tears, cuts or any other damage. Inspect the JT whether there are tears, cuts, cracks or another damage, or not by using soapy water. The leaks will cause the soap bubbles.

Warning! Never clean with solvents, hydrocarbons or other aggressive agents; the plug can be damaged or even destroyed.

Size of the pipe and JT should be matched

1.4 Choose the proper size of the plug. Be sure that the diameter of plug. Select a JT that is manufactured for the actual size, pressure, temperature, and chemical requirements suits for your pipeline size and application.

1.5. Thoroughly clean the pipeline, especially joint points before insertion of the JT. Remove all objects and sharp edges in the pipeline.

1.6. Check the length of air hose and water hoses. Make sure that they are not short and enough long to reach test location.

1.7. Be sure that length of JT is sufficient to perform the test. Joint lengths are variable as per joint length. JT Length(L)=Joint Length(l)+300 mm

1.8. Move the JT pipeline where you want to test. JT have the wheels that allow to make easy transportation through the pipeline. JT should be deflated during transportation.

1.9. Centralize the JT at the joint of two pipe with adjustment bolts.

1.10 Plug the air hose to the air jack. Make sure that there is no leakage and damage on the air jack and air hoses.

1.11. Before filling the air into JT, make sure that you are out of dangerous zone.

Warning! Never enter the Dangerous Zone while the JT under pressure.

Step 2: Operation of the JT

2.1 Fill the air into JT until 1 bar. Check pressure from the control device. If pressure not drop (there is no leakage), go on to increase the pressure until 2,5 Bar. During the filling air, follow the pressure gauge. Do not exceed the max. allowed inflation pressure which stated on JT, usually 2,5 Bar.

Use calibrated pressure gauge

2.2 Connect the pressure control set to hose and open the valve. The air or water will fill to test area.

2.3 Observe rise of pressure from the manometer. When the pressure is reached the 0,2 bar for air or 0,5 bar for water, close the filling valve, as per EN 1610.

2.4 Remove pressure control set and connect the pressure gauge to monitor the pressure during test period.

2.5. Wait the time which is stated at the EN 1610 (table-3) and then check the point for leakage. For example, 5 minutes for DN800 and 7minutes for DN1000.

2.6. After checking the joint of the pipeline, if there is no leakage and no pressure drop, move to the next joint point which will be checked.

Step 3: Storage

3.1 After finish the testing of all joint point, remove the JT from manhole.

3.2 Thoroughly clean the inflatable parts of JT with water or detergent and wait until dry.

3.3 Store the JT at room temperature in a dark store.

Please Consult to Plugco for questions.

Thank you for choosing us…

Bahcelievler Mah. Dumlupinar 5. Sok No: 2/2, Corum, Turkey

• 1. General Information about Pipe Plug
  • 1.1. What is the Pipe Plug?
  • 1.2. Safety Precautions Before Use
• 2. Selecting the Suitable Pipe Plugs
  • 2.1. Back Pressure – Back Pressure Chart
  • 2.2. Temperature Effect
  • 2.3. Diameter of Pipeline, Access Opening and Shape of Pipeline
  • 2.4. Chemical Resistance Table of Rubber Material of Pipe Plug
• 3. Reception of Pipe Plug (Removing Package- Inspection-Storage)
• 4. Application Procedure of the Pipe Plug
  • 4.1. Personel Protective Equipment
  • 4.2. Insertion of the Pipe Plug in a Pipe
  • 4.3. Dangerous Zone
  • 4.4. Connection of Accessories on the Pipe Plug
  • 4.5. Supporting the Pipe Plug
  • 4.6. Inflation of the Pipe Plug
• 5. Procedure of After Testingg
• 6. Storage
• 7. Warranty
• 8. Application Drawings of the Pipe Plug/Pipe Test Plug

1. General Information About Pipe Plugs

1.1 What is The Pipe Plug?

Pipe plugs are designed for temporary sealing of pipelines in sewerage, water line systems for maintenance or non-pressurized line testing as well as gas, oil and hydrocarbon pipelines.

Pipe plugs consist of two main products;

• Inflatable Pipe Plugs
• Inflatable Pipe Plugs with Bypass (Flow-through Pipe Plug)

They can be used for three cases:

I. Temporary sealing or stopping the flow: Pipe plugs can be used for temporary blocking the flow in a pipeline (Figure-1) or to prevent the entry of dirt and other contaminants during construction, maintenance or repair of the pipeline.

II. Testing: Leak/ tightness testing is performed by pipe plugs using water (Figure – 2 / 3) or air (Figure – 4).

III. Bypassing the Flow: The Pipe Test Plugs can be used for dewatering application (Figure – 5) as well as for the flow deviation in a pipeline (Figure – 6).

INFLATABLE PIPE PLUG – Model PP

The main purpose of the pipe plug is blocking the pipelines or channels to stop flow temporarily. They can be also used for leak testing and repairing or maintenance of water, oil pipelines with different materials such as steel, plastic, HDPE etc. (Figure 7)

Pipe plug includes an inflation port for inflating the pipe plug and holding hooks for carrying. PlugCo can design the pipe plug with holding hooks on both sides as per the client’s requirement.

FLOW-THROUGH PIPE PLUG

The Flow-through plug model is the same as the pipe plug model with the exception that it includes a bypass connection. The bypass connection allows water to fill inside the pipeline. It can also be used for bypassing the water flow and discharging it to another line and leak testing as well as de-watering or deviating the flow. (Figure 8)

1.2 Safety Precautions Before Use

Before operation of pipe plug, the PlugCo Safety and User Manual must be carefully read and understand. Important safety rules and guidelines are outlined in this handbook.

Operators of pipe plug should be trained and authorized persons!

2. Selecting the Suitable PlugCo Pipe Plug

2.1 Back Pressure – Back Pressure Chart

Calculate the Back Pressure that the pipe plug must withstand before choosing the plug.

Back Pressure: The pressure of the fluid in a pipeline acting on the pneumatic plug sealing in the pipe. If there is only static pressure, It can be the elevation difference between the upstream and downstream ends of the pipe line. In other terms, the height of the water column behind the pipe plug (Figure – 9 / 10). For example, ten (10) meters water column behind the plug means 1 Bar Back Pressure. The surface area and shape of the water column are not important. Only the height of water column needs to be considered.

The specified back pressure on the technical data sheet is only valid for dry concrete pipe applications. Thus, we can recommend the Smart Plug, a product in our range, for any application where back pressure needs to be calculated regardless of the material or condition of the pipeline.

How to calculate the back-pressure force on the pipe plug:

• Measure the inner diameter (D) of the pipeline to be sealed by the pipe plug
• Calculate the surface area of the pipeline cross section (A)
• Calculate the total force that pipe plug must withstand from following equation (F)

F = P * A * 10 (N) A = π * D² / 4 F = P * π * D² / 4 * 10 (N)
A – Surface Area (cm²)
P – Back Pressure (bar)
D – Inner diameter of pipeline (cm) F – Total Force (N)

Example: The inner diameter of pipe= 500 mm. Water behind the pipe plug: 5-meter

F = P * A * 10 (N) A = π * D² / 4
A = 3,14 * 252 / 4 = 490 cm² F = 0,5 * 490 = 245 kg = 245 * 10 = 2450 N

BACK PRESSURE CHART

THIS TABLE ONLY INCLUDES 1,0 1,5 BAR AND 2,5 BAR INFLATING (WORKING) PRESSURE.
CONSULT PLUGCO FOR OTHER WORKING PRESSURES. THIS IS ONLY APPLICABLE FOR DRY CONCRETE PIPES.

2.2 Temperature Effect

Determine the temperature that the plug will be exposed to.

The environmental temperature should not exceed 70 degree Celsius for SBR + NR mixed rubber and 60 degree Celsius for CR (Neoprene) Rubber. Heat can damage the pipe plug permanently.

The lowest temperature at which the pipe plugs maintain their sealing characteristic in the pipeline is -20 degree Celsius for both SBR + NR mixed and CR Rubber.

2.3 Diameter of Pipeline, Access Opening and Pipe Shape

Before operation, always measure the inner diameter of pipeline, in which the plug will be inserted, and make sure that pipe diameter is within the range specified on the plug (Figure – 11). The maximum and minimum allowable pipe diameter are marked on every inflatable pipe plug.

There are two situations that annoy the choice of plug.

1. Access opening: Underground and industrial piping does not always having equal-sized access point which is limiting the choice of the suitable pipe plug. (Figure-12) So be sure that the diameter of the access opening where the plug will be inserted .

D1: Deflated Diameter of Pipe Plug
D2: Diameter of Manhole
D1>D2

2. Pipe Shape: The pipe plugs can only be used for cylindrical pipes. Define the shape of the pipe where the plug will be used.

If case the access opening is limited and/or the shape is not cylindrical (Egg, square … etc), PlugCo advices to use the Conical Plug which is suitable for this kind of applications

2.4 Chemical Resistance Table for Rubber Material

Check the chemical resistance table for rubber material and consider it while selecting the pipe plug or consult the manufacturer.

Rubber types of Plugco pneumatic plugs with regard to their resistance to chemicals

If the media to be used is not in this table, please check the standard ISO/TR 7620, or consult the manufacturer about the usage of Plugco Inflatable pipe plug.

3. Reception of Pipe Plug

(Removing Package – Inspection-Storage)

• Removing the Package: Do not use the sharp items such as knife, screwdrivers and similar, for removing the packing, since they can damage the pipe plug.

Note: Only exceptionally the pipe plug may be under the vacuum during the transportation. Once received, immediately release the vacuum. Insert the air into the plug until it reaches the original cylindrical form.

• Inspection: Inspect the plug and related equipment (control device, air hose….) for damage before and after each use. (Figure -13)

Inflate the pipe plug up to 0.1 bar and check the connection points on the plug by using the soapy water or immerse the pipe plug fully in water. The leaks, if any, will cause the soap bubbles. Look very carefully for evidence if any part of the pipe plug has been damaged, weakened or missing.

Visually inspect the accessories (control device, air hose …).
And also, they can be inspected in the same way as pipe plug by using the soapy water.

WARNING!! Do not use the pipe plug if it has or shows any signs of wear or deterioration and contact PlugCo team.

– At first reception and before/after each use, clean the pipe plug with a solution of water and detergent (Figure – 14). After cleaning, flush the pipe plug with clean water and allow it to dry thoroughly before using.

– Storage: Cleaned plug can be stored suspended vertically or placed horizontally and in dry and dark space at temperature between 15 ® 25-degree Celcius.
It should be free from sharp edges and should not touch steel or concrete floor directly. Wood palets is suitable for plugs stand on

WARNING!! Do not clean the pipe plug with solvent or petroleum fluids which may damage the pipe plug!

Never use solvent, hydrocarbon and other aggressive substances for cleaning the PlugCo pipe plug. The use of such substances can damage or even destroy the pipe plug.

4. Application Procedure of Pipe Plug

4.1 Protective Equipment and Safety

◦ Use and wear related safety and protective equipment.

◦ Before entering the manhole or confined space, thoroughly check for hazardous gasses and proper oxygen levels. If necessary, ventilate the confined space. Strictly follow the confined space safety procedures.

4.2 Insertion of pipe plug in a pipe

• Before inserting the pipe plugs properly clean the interior of pipeline:

Clean the pipe from any debris or foreign substances (Figure – 15) which may reduce the back pressure holding capability before the pipe plug is installed. Foreign substances may include grass, oil, mold or any other material that can prevent solid contact between the pipe plug and pipe wall.

A clean contact surface of pipeline increases the pipe plug quality in sealing as well as in holding more back pressure.

Warning!! Failure to clean the pipe properly may result in pipe plug dislodgement or pipe plug failure causing death, serious bodily injury or property damage!

• The inflation hose must be of enough length to inflate or deflate the pipe plug from outside the Danger Zone.

• Insert the plug into the pipeline

Before inflating the pipe plug, position it correctly in the pipeline. The shortest allowable distance from the beginning of the pipeline to the pipe plug is equal to the pipeline diameter. (Figure 16)

The pipe plug must be positioned horizontally and it must be centralized in the middle of pipe’s cross-section (Figure -17 /18)

If the pipe plug is inserted incorrectly, this could cause incorrect distribution of forces inside the plug and also not homogeneous sealing between pipe plug and pipe wall and consequently permanent damage of the pipe plug as well as lower back pressure held. Plugco recommend to use the Plugco Centralizer to a safe and easy centerizing of the plug (Figure -19).

4.3 Dangerous Zone

Never allow a person to enter the test area (DANGER ZONE) when pipe plug is inflated in the pipe (Figure – 20-21)

WARNING! All inflatable products have a risk of suddenly rupturing. Pipe plug failure for any reason may result in deat h, serious bodily injury and/or property damage! Do not enter the Danger Zone when the pipe plug is under pressure!

Dangerous Zone is the most critical subject for plug usage. Therefore, all workers should be informed about the Dangerous Zone in the application. Project safety person should take necessary action to avoid the workers enter the Dangerous Zone.

4.4 Connection of Accessories on the Plug

• Attach the air hose to inflation connection, the anchor hook(s) to eyebolt(s) and the water hose to its connection for filling the test area with water. All hoses have universal quick release connection.

• Check the air hose, water hose, chain, rope and their connections to make sure that they are not damaged or leaking before the operation. (Figure – 22 ® 23)

4. 5 Supporting The Pipe Plug

• Proper support or bracing must be mounted to secure the pipe plug in place. Bracing support should contact the front face of the plug and the contact surface should be smooth to distribute forces equally on the pipe plug. Sharp points of contact may damage the pipe plug. (Figure – 24 ® 25)

• The end user should calculate the back forces and design suitable supports to prevent sliding of the plug.

Warning!! Pipe Plugs under pressure must be braced. Always brace the pipe plug securely!

Warning!! Never use eyebolts or handles on pneumatic plugs for fixing, of safety supports, since these are intended solely for lowering and lifting pipe plugs.

4.6 Inflation of the Pipe Plug

• ALWAYS inflate the pipe plug up to the max. allowable inflation pressure (working pressure) marked at the technical data sheet and on the pipe plug (Figure 26).During pipe plug inflation, monitor the pressure closely on the control device.

WARNING!! NEVER exceed the inflating pressure value outlined in the PlugCo Catalog and marked on the pipe plug. Also do not apply less inflation pressure than the Max. Inflation Pressure. Always inflate exactly Max. Inflation Pressure.

Recommendation: Since air is compressible, it is often advisable to inflate larger diameter pipe plugs with water.

• The inflation should be done from a location outside of the Danger Zone using an inflation hose, a proper pressure source and a calibrated control device to monitor the working pressure.
• Check the inflation pressure on the control device regularly. A small volume of inflation air leaks through the elastomeric body of every inflatable pipe plug. This lost air must be replaced periodically.

The control device should be connected to the plug throughout the inflation of the pneumatic plug and also during the period under the pressure. If the permissible working pressure is exceeded, safety valve is activated and begin to reduce the pressure in the pipe plug.

When activated, the flow volume of the safety relief valve is limited. In the case of air source with high flow capacit y, it can happen that the activated safety valve does not completely interrupt inflation of pipe plug but only slows it down.

The activated safety valve has a characteristic of loud sound. Upon activation of safety relief valve the operator must immediately close the supply valve on the controller to interrupt inflation of the pipe plug.

For advance pressure monitoring we recommend to use PlugCo Pressure Monitoring and Alarm System. (Figure 29)

The conditions where plug should not be inflated;
• Never inflate the pipe plug outside of the pipe (Figure – 30 ® 31).

• Never inflate the pipe plug over or near sharp objects (Figure 32). Remove all sharp objects, stones and any foreign material from the pipe before inserting the pipe plug.

• Never allow the pipe plug to protrude from the end of the pipeline during inflation or use. Always completely insert the plug into the pipe line. (Figure – 33)

• Never inflate the pipe plug over laterals or other openings. (Figure – 34)

5. Procedure of After Testing

• After completing the test/application, release the back pressure (head pressure) completely. Then open the discharge valve and deflate the pipe plug. Release the air in the pipe plug from outside the Danger Zone through the inflation hose until the pipe plug is completely deflated.

How to release the back pressure

• By pumping the water behind the plug
• Open the safety valve/discharge valve on the controller to release the working pressure until pressure gauge shows zero

• Never remove the pipe plug from the pipeline until all pipeline back pressure is released and the pipe plug is deflated.

• Never use the air inflating hose to remove the pipe plug from the pipe. Use chain or cable to install and remove the pipe plug. (Figure – 35)

• After using the inflatable pipe plug, clean it with detergent/water and inspect the plug for damage, tears or any other defect.

6. Storage

• Store the cleaned pipe plug in a clean dry place at room temperature and away from direct sunlight as per IS02230.

IS02230 list of instructions:
– Store at temperature between 15-25-degree Celcius
– Store in dry storage space
– Screen it from direct (sun) light
– Screen it from circulating air.
– As far as possible, ensure that pipe plug is not subjected to pressure while stored.
– Avoid long-term contact with liquid during storage.
– Avoid long-term contact with metals during storage.
– Avoid long-term contact with other rubber during storage.
– After long-term storage, the pipe plug can be cleaned with soap and water. Once cleaned, it should be left to dry at room temperature.

• Pipe plug must be stored suspended vertically or placed horizontally.

7. Warranty

Manufacturer warrants that all pneumatic plugs manufactured by it and shown in this manual will be free from defects in material and workmanship for one

(1) year following the date of manufacture. If any of the goods are found to be defective, such goods will, at manufacturer’s option be replaced or repaired at manufacturer’s cost. The parties hereto expressly agree that buyer’s sole and exclusive remedy against the manufacturer shall be for the repair and/or replacement of defective goods as provided herein. (The sole purpose of the stipulated exclusive remedy shall be to provide the buyer with free repair and replacement of defective goods in the manner provided herein. The exclusive remedy shall not be deemed to have failed of its essential purpose so long as the manufacturer is willing and able to repair or replace defective goods in the prescribed manner.) Goods which may be sold by manufacturer but are not manufactured by it are not warranted by manufacturer, but are sold only with the warranties, if any, of the original manufacturers thereof.

(This warranty does not cover labor or other costs or expenses to remove or install any defective, repaired or replaced goods.) Manufacturer’s warranty does

not apply to any goods which have been subjected to misuse, mishandling, misapplication, neglect (including but not limited to use of unauthorized parts or attachments), or adjustment or repair performed by anyone other than manufacturer or one of manufacturer’s authorized agents.

Any claim by buyer with reference to the goods sold hereunder shall be deemed waived by the buyer unless submitted in writing to manufacturer within the earlier of (1) thirty (30) days following the date buyer discovered or by reasonable inspection should have discovered, any claimed breach of the foregoing warranty, or (2) twenty-five (25) months following the date of manufacture. Any cause of action for breach of the foregoing warranty shall be brought within one year from the date the alleged breach was discovered or should have been discovered, whichever comes first. LIMITATION OF LIABILITY. Manufacturer’s liability (whether under the theories of breach of contract or warranty, negligence, or strict liability) for its goods shall be limited to repairing or replacing parts found by the manufacturer to be defective, or at manufacturer’s option, to refunding the purchase price of such goods or parts thereof.

DISCLAIMER OF CONSEQUENTIAL DAMAGES. In no event shall manufacturer be liable for consequential damages arising out of or in connection with this agreement, including without limitation breach of any obligation imposed on manufacturer hereunder or in connection herewith. Consequential damages for purposes hereof shall include, without limitation (including death) to any person, or loss or damage to property (including without limitation property handled or processed by the use of the goods). Buyer shall indemnify manufacturer against all liability, cost or expense which may be sustained by manufacturer on account of any such loss, damage or injury.
DEFECTIVE PRODUCTS POLICY. To obtain performance under this warranty, any product suspected of having a manufacturing defect in materials or workmanship at manufacturers request must be returned to PLUGCO INDUSTRIES INCORPORATED, freight prepaid, for inspection. A returned goods authorization (RGA) must be obtained before shipping any product back to PLUGCO. Contact (sales@plugco.net)

CUSTOMER TRANSPORTATION REIMBURSEMENT. Whenever PLUGCO repairs or replaces a product at PLUGCO’S expense, PLUGCO will reimburse the distributor by credit memo, the same surface freight amount it cost PLUGCO to return the warranty items.

The foregoing warranty is in lieu of all other warranties express or implied, including those of merchantability or fitness for any purpose not expressly set forth herein. No affirmation of manufacturer, by words or action, other than as set forth in this language shall constitute a warranty.

8. Application Drawings of the Pipe Plug/Pipe Test Plug

The End User must read and understand this PlugCo Safety Manual before using the plug. The failure of a plug for any reason including improper maintenance, installation or use can result in bodily injury, death and/or property damage!

1-BEFORE USING THE PLUG

[1.1]Read and understand this PlugCo Safety Instruction Manual before using the plug. Use the plug only as shown in the PlugCo User Manual which must also be read and understood by the user.

CAUTION!!! The pipe plugs should be used by a trained and experienced team. If your team has not been trained in the proper use, care and application of pipe plugs, DO NOT USE PlugCo Plugs. Usage by an untrained team may cause death or serious injuries. PlugCo can provide training and supervision for your team.

[1.2]Applying and following proper safety measures are the responsibility of the end-user.

[1.3]Follow and use proper confined space safety rules and equipment during installation and operation of the plug.

[1.4]Follow all applicable safety rules of international and local authorities.

[1.5]Use all required safety equipment including safety glasses, hard hat, hearing protection, protective footwear and all other necessary protective clothing and equipment. Safety equipment and clothing required will depend upon the environment in which the product is used.

[1.6]Carefully inspect the plug and all related equipment for damage and indications of wear or deterioration before and after each use. The plug may be inflated slightly to aid in the inspection process. After inflation, apply a solution of water and detergent to the equipment or submerge the product completely under water to help locate leaks. Bubbles will form at the site of any air leakage.

[1.7]Check the pressure gauge and control device for damage and leakage. Be sure that there is no air leakage at joints and connections. Always use a calibrated pressure gauge (Figure 1).

[1.8]Connect an extension hose to the plug, so it can be inflated and deflated from outside the danger zone.

[1.9]Do not use an air source (compressor) that does not have a pressure gauge.

[1.10]Inspect the air hose and water hose (for PTP model) for leakage. Check the connection points of both hoses for leakage (Figures 2-3).

[1.11]Measure the internal pipe diameter and choose the pipe plug size according to the internal pipe diameter (Figure 4). Never use a plug different in diameter than that recommended by PlugCo.

[1.12]Clean the external surface of the plug and internal surface of the pipe to remove stones, protrusions, and any other material from the location where the plug is to be positioned in the piping (Figure 7 and 8).

CAUTION!! Failure to remove dirt, stones or sharp objects in the pipeline can cause poor sealing and damage to the pipe plug.

[1.13]Position the plug in the pipeline. Use a Kevlar or other protective sleeve to protect the plug if there is debris which cannot be removed from the pipeline.

[1.14] Center the plug in the pipe. The centerline of the plug should be parallel to the centerline of the pipe. (Figure 9)

[1.15]Insert the plug seal surface completely so it is fully supported by the pipeline.

[1.16]Do not inflate the plug outside of the pipe (Figure 10.)

2-OPERATION OF THE PLUG

[2.1]Always read the information tag on the plug (Figure 11). If any value does not suit the site conditions DO NOT USE OR OPERATE the plug.

[2.2]Stop the pipeline flow before installing any type of plug.

[2.3]Use a bleeding type pressure regulator and a relief valve to maintain the correct pressure with changing temperature and head pressure. A relieving style pressure regulator and/or pressure relief valve must compensate for these factors and prevent over-inflation that could rupture the plug.

[2.4]Do not exceed the recommended maximum allowable inflation pressure (working pressure) as outlined in the PlugCo Catalog and on the technical information tag on the pipe plug. (Figure 11)

[2.5]Do not exceed the maximum allowable back pressure (Figure 16-17), as outlined in the PlugCo Catalog and on the technical information tag on the pipe plug (Figure 11).

[2.6]PlugCo recommends that water should be used for inflating the plug for model PP5001000 and larger sizes. As a minimum the deflated size of the plug should be filled with water.

[2.7]Always provide support or bracing to prevent sliding or other movement of the plug whenever back pressure is present (Figure 12 ).

[2.8]Stay clear of the plug when under pressure. Do not enter the Danger Zone area when the plug is in use (Figure 13).

CAUTION!!! Never enter the Danger Zone. Serious injuries or death may result.

[2.9]Do not stand in front of, to the side of or above a plug when in use.

[2.10]Never remove the inflation hose until all back pressure is released and the plug is deflated.

[2.11]Release the back pressure from the pipe first before deflating the pressure in the plug.

[2.12]Do not lift or pull the plug by the air or water hose (Figure 14). Attach a rope or chain to the lifting brace intended for moving or hoisting the plug (Figure 15).

Back Pressure:
The pressure which pushes against the plug and may cause sliding or other movement (Figures 16-17).

PIPE TEST PLUG APPLICATION-LEAK TEST BY WATER

PIPE TEST PLUG APPLICATION-DEWATERING BY PUMP

PIPE TEST PLUG APPLICATION- LEAK TEST BY AIR

PIPE TEST PLUG APPLICATION- BYPASS THE FLOW WITHOUT PUMP

JOINT TEST PLUG APPLICATION-LEAK TESING BY WATER

PROFESSIONAL PIPE TEST PLUG

What is the Back Pressure

What is the Back PressurE-2

MANHOLE TEST PLUG APPLICATION