In the Sharjah central route stormwater drainage system project in the UAE, we faced a special challenge: pressure testing a 2-meter existing GRP pipeline under 6.0 bar of water pressure. For pipelines larger than 1 meter, EN 1610 standards using joint testers instead of standard pipe plugs are possible. Testing joints individually is more economical, reduces water usage, and saves valuable time.

During the planning phase, the site engineers ensured a pipeline bend. After our production team did a 3D drawing and ran a simulation in our factory, we realized that our standard joint testers may be blocked from reaching the test area. So how did we solve this issue? our team designed a customized, three-part joint tester that could be assembled inside the restricted area, perfectly fitting the customer’s site conditions.

Here is the solution PlugCo proposed:

• For the 208 joints to be tested, we recommended using our joint tester, which is capable of handling over 100 joints, with spare rubber bladders suggested to ensure continuity if needed.

• Site engineers shared a table with us; it ensured that the 2000 mm pipeline had a deflection of 60 mm vertically and 40 mm horizontally, so we proposed a customized rubber joint tester that could adapt to this situation.
• The 2000 mm pipeline had a deflection of 60 mm vertically and 40 mm horizontally, so we proposed a customized rubber joint tester that could adapt to this situation.
• All specific requirements were addressed through PlugCo’s innovative engineering approach.

Bend in the 2000 mm pipeline.

Three-part joint tester

Why Choose PlugCo Joint Testers?

PlugCo manufactures a wide range of standard and customized joint testers along with all necessary accessories. Whatever your project requirements are—large pipelines, tight bends, or high-pressure tests—our solutions are designed for precision, efficiency, and reliability.

FAQ:

1. What sizes of joint testers does PlugCo offer?

We produce joint testers in a wide range of sizes, starting from 100 mm and going up to 2800 mm.

2. Does PlugCo provide on-site technical supervision?

Yes, our technical engineers can join you on site to guide and support the testing process when needed.

3. How can I get in touch with PlugCo’s sales team?

You can reach our sales team at sales@plugco.net.

UMM Al Quwain Independent Water 150MIGD Project is Located at a coastal site in the Emirate of Umm Al Quwain along the border of Emirate of Ras Al Khaimah. The mentioned project is part of the UAE’s effort to optimize water production and meet the increasing demand for water in the country.

Once commissioned, the Umm Al Quwain plant will be the largest desalination project in the Northern Emirates.

PlugCo completed training and installation work for Joint Testers which were supplied to the project in Ras Al Khaimah.

IMPLEMENTATION

PlugCo sold many variable sizes of Joint tester, between 1500mm up to 2500mm dia., for this project. Our client wanted to make water leakage test with 1,5 bar water pressure. PlugCo designed their products accordingly and dispatched all products after testing them in the factory. PlugCo also provided user manual and related videos about how to use it. Then, the materials were delivered on time. The contractor started to make leak test from 2000mm dia.

The contractor contacted us and they wanted us to go to site, because they tried to make test but they failed. They said that there was a leakage once they fill in 1,5 bar water to test area.

PlugCo always support their customer. So PlugCo team went to project site in Ras Al Khaimah. Firstly, we try to understand what is the problem of their usage. So, we just supervised their application at first. They were inflating the joint tester with 1-2 bar. Once the bladder touches the pipe, they were stopping to inflate it more and started to make 1,5 bar water tests. Therefore, it is not holding this pressure and the leakage was occurred as they did not inflate the Joint Tester with the correct pressure.

PlugCo designed all products with 4,0 bar inflation pressure. We marked it on the products as well. So, the end user should inflate it up to 4,0 bar and then they can make 1,5 bar water leakage tests successfully.

PlugCo also provided air filling hose, water hose and advanced control device to check both inflation pressure and test pressure

The test passed successfully once the joint tester was inflated up to the required inflation pressure. It was 4,0 bar for all the given models. PlugCo always mention the products inflation pressure on the technical label. The End user should follow it and they should inflate PlugCo products up to the mentioned inflation pressure.

During this training PlugCo presented and discussed the following points:

Presentation of PlugCo company profile and products in range

• How to use joint tester?
• How to use accessories?
• How to inflate the joint tester correctly and how to start test?
• Which safety precautions to take at the implementation?

PlugCo’s Engineer arrived at the project site in Dubai on April 6th to make water leakage test and train technicians for the ongoing pipe project.

IMPLEMENTATION: Their application is to make water leakage test for a new pipeline.

Firstly, the subcontractor contacted PlugCo to discuss details to complete the water leakage test for a new 1200mm dia. pipeline.

There is a new GRP pipe line in this project. The contractor needs to make leakage test to complete the project after the pipe is installed. It is a long pipeline and there are too many joint points because they used 12-meter pipes and joint them together. The consultant accepts only the water test. So, we recommended them to use PP model plugs and fill the water from manhole. However, consultant did not accept to fill water from manhole. Consultant insisted on filling the water in the line through the pipe test plug. They would like to make the test with less water so they did not want to fill it from manhole. So, we recommended our PTP model plugs. PTP model plugs have a bypass connection that allowed them to fill water easily from the bypass line.

PlugCo offers the best cost-effective solutions to the client.

In this project, there was elevation difference of 6-8 meters for each test area. We considered the height difference between upstream and downstream as 10 meters to be in safe side. So, PlugCo provided PTP model pipe test plug that can withstand 1 bar back pressure.

PlugCo dispatched the goods to Dubai end of March. PlugCo shipped the PTP6001200 model and all the necessary accessories for water test as well. The most important accessory is the “Air Discharge Adaptor” to make the water test; To close the line with Pipe test plugs and add water into the test area, they should discharge the compressed air from the area to make the test correctly. The unique option to perform it is to use the Air Discharge Adaptor (ADA). So, they used ADA on test plugs and they discharged the air from the test area successfully.

How to Use the Air Discharge Adaptor?

1. Float-Discharging the compressed air from inside of the pipeline to the outside.
2. Quick Coupling- To be connected to the hose to discharge the air to the outside. Once the air is discharged, the water flows out of the end of the hose. A pressure gauge can be connected to the end of the hose to monitor the water pressure. This end can also be used for pressurizing the pipeline.
3. Air Hose to discharge the compressed air.
4. Connection to Pipe Plug.
5. Connection for Water Hose to fill water to pipeline.

• Air Discharge Adaptor is connected to the Pipe Test Plug from the left (#4) and is connected to the water hose from the right (#5), as illustrated in the below picture.
• The air hose used for discharging is connected to the quick coupling and the pressure gauge is connected to the air hose.
• The pipe line is filled with water by the water hose.
• During the water filling, the compressed air in the pipe line is discharged by the float.
• The compressed air in the pipe will be discharged through the air hose.

Then, PlugCo gave its own suggestions on how can they centralize the plug and brace it against sliding.

PlugCo has a new accessory that called centralizer which is recommended to be used especially for big size plugs. We gave them more information about centralizing and we informed them that bracing is mandatory to prevent any sliding while using pipe plugs. And then, we saw the bracing and confirmed that is suitable to start testing.

In the meantime, you can read our article that was written about the consequences of not centralizing and supporting the plugs. https://www.plugco.net/why-pipe-plug-is-sliding

As a result, PlugCo has provided supervision, training service and attended the client’s project to help them with their project.

PlugCo completed training and installation work for high pressure plug (HPP model) which were supplied to the Muscat City Desalination Company SAOG Team in Oman.

PlugCo’s Engineer arrived in Oman on 20th January to test High pressure plug and train technicians for the ongoing pipe project.

IMPLEMENTATION: Their application is to repair penstock.

Firstly, MCDC Team contacted PlugCo. They sent the project design and explained their application very clearly.

There was a problem with their penstock; It was not working properly. Water was coming in although it was closed. They wanted to remove the penstock, so they had to block the sea-water intake pipeline temporarily until it is repaired or changed.

The pipe size is 1700mm and depth of water is 10 meters. However, the back pressure will reach 2,4 bar due to pig cleaning. They therefore need a pipe plug for 1700mm diameter that can withstand a back pressure of 2,4 bar. PlugCo worked on this project and offered the HPP1700 model which can provide a 100% sealing if they make a bracing to prevent the sliding. Then, PlugCo calculated the total force in the pipe line at 2,4 bar back pressure and informed MCDC team to make an appropriate bracing. As a result, MCDC confirmed the need of the product and PlugCo dispatched the goods in January 2020.

Secondly, PlugCo team visited the project site and attended the application to give a supervision service. At that time, PlugCo recommended a long-term pressure monitoring and alarm system to check back pressure.

What is the pressure monitoring and alarm system?

The monitoring system is used to check the inflation pressure or back pressure of the Plug.

MCDC asked to check the back pressure, which means that the wanted to check whether the back pressure is increasing, so that they will make dewatering to reduce back pressure to prevent the sliding.

MCDC has purchased the pressure monitoring and alarm device, and from our side we explained all procedures of how to use it.

As a result, PlugCo provided supervision, training service and joined the application.

During our training we presented and discussed the following points:

• How to put the pipe plug in right position
• How to inflate the pipe plug correctly
• How to use pressure monitoring system
• How to make suitable bracing
• How to remove the pipe plug after using
• What safety precautions to take during implementation

This good reputation started the day we received an enquiry from a Colombian Spanish speaker customer, who wondered about our high-quality products. The experienced PlugCo engineers contacted him, trying to understand his application and provide him with the suitable products and the correct quantity they need. Our engineers answered all customer’s questions quickly and precisely, so that the details were clearly understood by the end-users.

High Quality Products and Professional Service

Following the enquiry, we received, our customer wanted plugs to ensure air and water leaking test for sanitary pipelines between 6” and 36” (150mm to 900mm). Our engineers have proposed Three models of Pipe Plugs: PP100200 for pipelines from 4″ to 8″, PP200500 for pipelines from 8″ to 20″ and PP5001000 for pipelines from 20″ to 40″.

The customer also needed test plugs with bypass, as the leakage test was carried out with air and water. We therefore offered three models of Pipe Test Plugs with Bypass: PTP100200, PTP200500 and PTP5001000 as well as the accessories that are used to mount and ensure a well applied test. So, the accessories that we offered are the following: The Air Discharge Adaptor, ADA, with a female threaded Storz coupling, which is applicable for water testing and used to discharge the air from the test area. The Air Test Adapter, ATA, which has two ports; one port for the air supply of the test area and the other for monitoring the test pressure.

To clarify the steps required to use the products, PlugCo engineers have sent sketches as below and some informative videos such as : PlugCo | Pipeline Air Leak Test as Per EN1610 and PlugCo | Pipe Plug Application for Leak Test and PlugCo | How To Use the Inflatable Pipe Plugs.

After Sales Services

After a while the customer decided to buy all the mentioned products. He sent us the Purchase Order so that we could prepare our Performa Invoice. Once the payment was received, we sent the goods by Airfreight to Bogota airport on time, without any delay.

Our engineers didn’t stop there, they followed our customer step by step during his application. They were ready to provide training if necessary. The customer was very satisfied with the performance of the product. And also, by the technical and professional service given by the PlugCo team.

Following this Colombian enquiry, we have received several enquiries from our clients, but this time we haven’t received enquiries only from the same client, but we got also inquiries from other Colombian companies, who have reached us via recommendations, for all the other sizes and Models of Pipe Plugs we have.

PlugCo at your service

PlugCo wholesales plugs all over the world thanks to its dedicated and reliable shipping service. This means that our customers receive their products at their doorstep.

PlugCo wholesales plugs for its customers without defining a minimum order quantity. We always support our customers and help them get the products and the correct quantity they need. This makes us the leading supplier of pipe plugs for many retailers and end users.

We look forward to welcoming you to our family. Call us or contact us via our website.

Located in the capital city Muscat of Oman, The Oman Construction Co LLC (a.k.a. TOCO) contacted PlugCo for a special hydrocarbon fluid pipeline treatment.

Since it is a very special treatment TOCO demanded technical advice and assistance for every detail. Thus, experienced PlugCo engineers replied all their questions swiftly in a very clear manner so that the details would be understood thoroughly by the users. Following the inquiry correspondence, PlugCo suggested that Oil and Gas Pipe Plug should be used in this treatment, because hydrocarbon fluids require nitrile rubber plugs since other rubber types are not suitable for these kinds of fluids.

Implementation

As a first step, TOCO decided to purchase two units of Oil and Gas Pipe Plug for trial. After shipping the goods to their address, the PlugCo team visited TOCO premises in Oman. The purpose of the on-site visit was to train the TOCO team on how-to-use the product and assist them in their application.

We conducted a detailed meeting with the Purchasing Manager, 2 Purchase Engineers, Project Manager and Operators who will use the PlugCo product.

In the meeting, we presented and discussed the following points:

• Presentation of PlugCo company profile and products in range
• Gas and Oil Pipe Plug for the TOCO Project
• How to put the pipe plug in right position
• How to inflate the pipe plug correctly
• Which safety precautions to take at the implementation

Following the technical brief, we applied for a trial session. And then, we informed the TOCO team about the procedures and standards which they should follow.

After using the Oil and Gas Pipe Plug at this special hydrocarbon fluid pipeline project, TOCO was very satisfied with the performance of the product. And also by the technical service given by the PlugCo team. Consequently, TOCO placed an order for all diameters of the Oil and Gas Pipe Plug in the product range of PlugCo.

PlugCo, renowned for its pipe plugs and pipe joint testers, has gained popularity for pipe repair packers following an intense marketing activity in Gulf Countries.
Dubai and Abu Dhabi are tourism and trade hubs with their developed infrastructure and architecture. These two emirates always use latest high technology products. In the fast-paced Dubai, the services must be the fastest since the United Arab Emirates is a trade hub supplying goods both for domestic market and Gulf Countries. And the Emirates are one of the main markets of PlugCo.

Just-in-time Projects

In the recent months PlugCo had received an urgent demand from Jamal Al Sharouq Company, active in infrastructure pipeline rehabilitation works in Dubai. Our client specified that they needed pipe repair packers for the VIP Villa Project in downtown Dubai. The client stated that they would like to purchase PlugCo products. Because PlugCo manufactures pipe repair packers in various diameters from 25mm to 1200mm and length and from 1m to 5m.

The Delivery time was extremely important for Jamal Al Sharouq company. However, our client was at the right address for fast delivery, since PlugCo is capable of providing solutions for fast track projects.

PlugCo delivered the goods in various diameters and length to the warehouse of the client in Dubai. Delivery time was as short as 10 days.

Jamal Al Sharouq company received the products before the designated delivery date and was able to finish their Project in-time by applying the steps as in our article.

Door-to-Door Service in Dubai

PlugCo provides door-to-door service in Dubai. Our clients can get service from us as a local company. Door delivery is also available for emirates such as Abu Dhabi, Sharjah, Ras Al Khaimah.

Moreover, PlugCo engineers visit the region and provide site-supervision and training for using the products. This unique training service provided only by PlugCo is appreciated by our clients.

Contact PlugCo for your urgent pipe plug, joint tester and pipe repair packer inquiries.

PlugCo completed training and installation work for Joint Testers which were supplied to the Alghanim Team in Kuwait.

PlugCo’s Engineer arrived in Kuwait on 15th October to test Joint Testers and train technicans for the ongoing pipe project.

Kuwait New Refinery Project

The PlugCo Team provided training to technicans of the Alghanim Team between the 16th and 18th of October 2017.

These Joint Testers were purchased from the Alghanim Company for use in the Storm Pipe Line Project, with length of approximately 77 km. The Joint Testers’ diameters range between 600-2100mm, all of them were succesfully tested at the Project site.

PlugCo also provided a certificate of training to participants. We thank you for this opportunity to prove our commitment to global services and guarantees.

Jubail – Aramco

The pipe lines which carry process water from plant to sea, are available in Aramco Berri Gas Plant ongoing projects. On this line, DN400 two pipe lines were damaged and leakage occurred.

The lines, although damaged, were used as damaged for 3 month. Since an existing line was used, it was dulled temporarily for repair and was completed very quickly.Installation of the pipe plug to dull lines temporarily was provided by the PlugCo team within 2 days.

On the first day, the preparations (analysing the application area, selecting proper pipe plug, etc.) were made and applied by the PlugCo team while proper safety measures were provided by the contractor.

On the second day, dulling temporarily on existing line were provided by the PlugCo team by using 4 pcs. Pipe plug model- PP300600 in four different locations. for a DN400 pipe the technical information of the pipe plug is that the Inflation pressure is 2,5 bar and back pressure is 0,5 bar.

After successfully completing pipe line repairs, the pipe plugs were removed which completed the installation. PlugCo Team successfully completed the installation in two days.

Dammam – Aramco

It was necessary to add a new pipe line and manhole to the existing sewage pipe line an ongoing project belonging to the ARAMCO company. The manhole was inside of the Aramco community compound which all VIP ARAMCO managers live. That was the challenging part of the job.

We should be quick and don’t bother anyone inside the community. Because of this, any existing pipe line should be dulled temporarily. After providing proper safety measures, installation of a pipe plug to dull the pipeline was done by PlugCo.

The PlugCo Team has provided pipe plug Installation within three days. On the first day, the preparations were made and applied by the PlugCo team while proper safety measures were provided by the contractor.

On the second day, 4pcs. pipe plugs, model (PP300600), readied for installation DN500 mm pipe in 3 different locations. A new pipe line and manhole was added to the existing sewage pipe line.

On the last day, the pipe plugs were removed from the pipe line which completed the installation. PlugCo successfully completed the application of 4pcs. model PP300600 pipe plugs for a DN500 pipe in three days.