Certain criteria should be considered for the correct plug selection. These are:

1. The Diameter of the Pipe Where the Plug Will Be Used

• If the plug to be selected will be used in more than one pipe diameter, a multi-size plug should be preferred.
• If the plug will be used in a single pipe diameter, a single-size plug should be selected.

https://www.youtube.com/watch?v=xuBP1BGwrH4

• Care should be taken to ensure that the internal diameter of the pipe where the plug will be used is within the usable diameter range of the plug.

Note: In cases where the plug will be used in critical applications, a higher model of the suitable plug should be preferred to stay on the safe side.

Example:

• Internal Pipe Diameter: 400-500–600 mm
• Working Pressure: 0.5 bar
• Suitable Plug Model: PP300600 (1.5 bar model)

If the application is critical and difficult, instead of the PP300600/1.5 bar plug, the PP300600/2.5 bar or PP375800/1.5 plug model should be used to stay on the safer side.

2. Back Pressure / Test Pressure

Back Pressure

Back Pressure: It refers to the maximum water head that the plug can withstand. In other words, it is the pressure generated by the water accumulating behind the plug.

Test Pressure: It is the pressure value applied during the leakage tests of newly constructed pipelines. This value is specified in the EN 1610 standard or defined in the project specifications.

For plug selection, back pressure and test pressure refer to the same information. This information is indicated on the plug’s label or specified in the data sheet of the purchased plug.
For more detailed information: https://www.plugco.net/pipe-plug-inflation-presure-and-back-pressure

3. Media Resistance

The type of fluid the plug will be exposed to is important in plug selection.

• When the plug is exposed to a non-chemical fluid, plugs produced from standard flow, SBR+NR rubber, and reinforced cord fabrics can be used.
• However, if the plug will be exposed to chemical fluids such as gas or oil, plugs manufactured from Nitrile (NBR) rubber with high chemical resistance must be preferred.
• To give another application example, if the pipeline is a potable (clean) water line, the plug should be manufactured with rubber that is not harmful to health.
• If the application involves high temperatures, the raw material of the plug should be selected from heat-resistant materials.
• Plugs can be manufactured to meet specific application requirements.

4. Requirements of the Application Where the Plug Will Be Used

Another critical piece of information in plug selection is the specific details of the application. Based on this information, the most suitable plug selection will be made.
Inflatable plugs are generally used for the following similar applications:

Repairing broken or faulty pipelines by temporarily blocking them: During the repair, actively flowing fluid is transferred from one location to another using a by-pass plug.
Use of by-pass plugs: In such applications, a by-pass plug must be used.
Water discharge: To ensure water is transferred more quickly and easily, or to prevent the pressure of the water accumulating behind the plug from exceeding the back-pressure limit, the water should be discharged with the help of a pump.

In leakage tests of newly constructed pipelines: If there is an opening such as a manhole to add water on the line to be tested, a non-bypass inflatable plug can be used.

Both ends of the pipe are blocked with PP model plugs, and the test is performed by filling water through the manhole.

Related Video:

In leakage tests without openings or manholes: If there is no opening or manhole on the line, 2 PTP model plugs or a combination of 1 PP model and 1 PTP model plug are used to fill the line with water or air.

Testing with PTP (By-pass) plugs: The leakage test is conducted by filling the test area with water or air through the bypass line of the PTP model plug.
Related Video:

Model PP or PTP plugs are used in the repair of faulty pipelines and manholes, depending on the specific characteristics of the application.

If a manhole is to be repaired: The temporary blocking of the pipe is performed using a PTP model plug.

Dewatering process: The accumulated water is discharged with the help of a motor (pump) by using the bypass line available on the PTP model.

Manhole Repair bu Using the PTP

In some applications, the access point diameter (manhole diameter) may be smaller than the pipe diameter.

Example: The manhole diameter may be 500 mm and the pipe diameter 1200 mm. In this application, the deflated diameter of the plug to be used must be smaller than 500 mm. The deflated diameter of the PP6001200 product recommended for a 1200 mm pipe is 586 mm, which is larger than the entrance.

In such special applications, a conical plug with foldable features is recommended. Because conical plugs are foldable, they are used as a solution in applications where the manhole diameter is smaller than the deflated diameter of the plug. A conical plug is used when the condition D_manhole > D_pipe plug is met.

Frequently Asked Questions About Pipeline Tests and Plug Selection

1. What are the basic criteria to consider when selecting a plug?
The pipe diameter, the back pressure (or test pressure) it will withstand, the type of fluid it will be exposed to, and the specific requirements of the application.

2. What is the difference between a multi-size plug and a single-size plug?
Multi-size plugs can be used in multiple pipe diameters, whereas single-size plugs are designed for only one specific, fixed pipe diameter.

3. What does “Back Pressure” mean?
It is the maximum water head that the plug can withstand; in other words, it is the pressure generated by the water accumulating behind the plug.

4. What type of rubber plug should be used in lines exposed to chemical fluids or oil?
Plugs manufactured from Nitrile (NBR) rubber with high chemical resistance must be preferred.

5. What should be the characteristics of plugs used in potable water lines?
The rubber used must not contain harmful substances and must be suitable for drinking water.

6. In which cases is a by-pass (PTP model) plug necessary?
It is used to transfer the flow in the line to another location (bypass), discharge the water accumulating behind the plug, or to fill test water/air in lines without manholes.

7. What solution should be applied if the manhole entrance is narrower than the pipe diameter?
Conical plugs with foldable features should be preferred.

8. How should plug selection be made for critical and difficult applications?
To stay on the safe side, a higher model (higher pressure resistance or suitable diameter range) of the appropriate plug should be preferred.

9. According to which standards are pipeline leakage tests performed?
They are generally performed according to the values specified in the EN 1610 standard or defined in the project specifications.

10. For which fluids are standard SBR+NR rubber plugs suitable?
They are suitable for non-chemical, standard flow fluids (generally domestic wastewater or rainwater).

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.

Pipe Plug Solutions in Iraq – Real Data from Field Tests

PlugCo has contributed to many projects across Iraq. Below are two case studies highlighting our expertise in action:

DORA 2 Station Project:

In 2025, we supplied our pipe plugs to the DORA 2 Station Project, located southwest of Baghdad, where sewage pipelines needed to be shut off for urgent repairs. With guidance from PlugCo engineers, the appropriate plugs were selected and installed quickly; allowing the repair team to work safely. This was a large-scale project including many pipelines of different sizes, ranging from 150 mm up to 2.8 meters in diameter. The applicable back pressure was 4.5 meters-0.45 bar. The project was successfully completed, and photos related to the project are shown below.

Inflated Pipe Plug in The Pipeline

Plug Access Shaft to Pipeline

Erbil Water and Sewage Project:

In 2024, PlugCo supplied high-quality pipe plugs for the Erbil Water and Sewage Project in Iraq. The project required water leak tests using two types of our pipe plugs: the PP (inflatable balloons) and the PTP model (test pipe plug with bypass), for 500 mm and 1000 mm pipelines. The leak test back pressure was 0.5 bar. PlugCo provided the air discharge adaptor for the discharge of entrapped air, which was preventing stable test pressure during the test. The project was fully supervised remotely by our expert team and completed successfully, with long pipelines tested efficiently and safely. This demonstrates PlugCo’s expertise in providing reliable pipe plug solutions for water and sewage projects across Iraq.

Water Leak Test Set

Why PlugCo Is the First Choice for Iraqi Customers

As PlugCo has established a strong presence in Iraq, we have observed that our inflatable plugs are consistently preferred and trusted by many industry experts. The following points highlight the strengths of PlugCo products and explain why they have earned such a solid reputation in the Iraqi market.

• Expert Guidance: Our engineers work side by side with project teams to ensure the right solution, avoiding any inappropriate or unsuitable product choices. When engineers on-site face urgent challenges, our team is there to guide them step by step, making sure they feel confident and supported throughout the project. Furthermore, PlugCo has a distributor in Iraq; if our customers prefer to deal with an Iraqi plug supplier, that option is also available.
• Wide Range of Options: PlugCo offers inflatable pipe plugs for a wide variety of applications, and we also provide customization to meet specific project needs.
• Short Delivery Times: Projects stay on schedule thanks to fast delivery.
• Durability: High-quality plugs can be used over 100 times when stored under proper conditions.
• Compliance: All plugs comply with EN1610 standards, giving project managers confidence in international safety and performance requirements.
• Supportive Team: Our knowledgeable team handles every project with care and expertise.

Looking for reliable pipe plugs in Iraq? PlugCo supplies inflatable and test pipe plugs for major projects; reach out to our sales team at sales@plugco.net to discuss your requirements.

Whether you are working on water, sewage, or industrial pipeline maintenance, you can keep your project on schedule and your deadlines safe with our stock pipe plugs.

Why Stock Availability Matters?

Construction and maintenance sites often face emergencies where pipeline sealing is required immediately. With local availability in the UAE, PlugCo ensures:

• No waiting for overseas shipments.
• Cost savings by avoiding project delays and meeting the project delivery time.
• Quick support from our UAE-based team.

What Sizes Are Available in the PlugCo Ajman Store?

PlugCo normally keeps multisized inflatable pipe plugs ranging from 150 mm to 1800 mm in Ajman store in UAE. Thanks to their multi-sized design, these plugs are highly cost-effective, as one plug can cover multiple pipe diameters.

What are the Technical Features of Available Pipe Plug Models in UAE?

• Inflation Pressure: 2.5 bar
• Back Pressure Resistance: 1.0 bar at the largest diameter
• Usable with: Air, Water, Sewage, and Nitrogen

Are the Plug Accessories Also Available in Stock?

To support your site operations, PlugCo also stocks:

• Air control devices
• Air hoses
• Other essential pipe plugs accessories

This ensures you receive a complete and ready-to-use solution directly from our Ajman warehouse.

What are the Delivery Terms offered by PlugCo?

All offers are prepared EXW-Ajman, allowing quick collection or flexible transport arrangements to your project site.

Need Urgent Pipe Plugs?

If you are closing a project or handling an urgent repair, don’t lose time waiting for international shipping. Contact PlugCo at sales@plugco.net and order directly from our Sharjah stock.

Where is PlugCo Store Location in UAE?

Jurf Industrial 2, Jurf Industrial 2 AJMAN Ajman, United

Arab Emirates AJMAN: Google Maps

Frequently Asked Questions (FAQ)

• Do PlugCo keep stock in the UAE? Yes, we keep a wide range of inflatable pipe plugs in stock.
• What sizes are available in PlugCo Ajman store? From 150 mm to 1800 mm.
• Where is the PlugCo store located? Ajman, UAE – see on Google Maps

Different Models for Diverse Needs

PlugCo provides a range of models produced to meet pipelines’ requirements.

• Multi-Size Models (GP Series): These plugs can accommodate multiple pipe diameters, offering flexibility and cost-effectiveness. For example, the GP6001200/1.5 model works with pipes ranging from 600 mm to 1,200 mm in diameter. It needs 1.5 bar of inflation pressure and can handle back pressures of 0.5 bar at 1,200 mm and 1.0 bar at 600 mm. Model
• Single-Size Models (MGP Series): Designed for specific pipe diameters, these plugs are ideal when precise sizing is requested.
• Flow-Through Models (GPB Series): Equipped with a bypass connection, these plugs allow for continuous flow during maintenance, making them invaluable when a complete shutdown is simply not possible.

Safety and Durability

Safety is the most important thing in pipeline operations. PlugCo’s Oil & Gas Pipe Plugs are reinforced with Kevlar® cording to enhance their strength and durability in high-pressure situations. These plugs are designed to withstand high back pressures and comply with relevant standards, ensuring reliable performance during pigging operations and other demanding tasks.

Real-World Applications and Global Reach

Thanks to PlugCo’s commitment to quality and innovation, over 65 countries around the world use these Oil & Gas Pipe Plugs. Our Oil & Gas Pipe Plugs have been successfully used for leak testing in Dubai and for high-pressure applications in Oman. Oil and Gas Pipe Plug for Oman | PlugCo | plugco.net

In the oil and gas industry, using the right materials for sealing and testing pipelines is non-negotiable. PlugCo’s Oil & Gas Pipe Plugs, which are made from high-quality nitrile rubber, offer the chemical resistance, durability and versatility needed for safe and efficient operations. Whether you’re carrying out maintenance, leak testing or flow diversion, these plugs offer a reliable, industry specific solution.

To find out more or to explore PlugCo’s range of Oil & Gas Pipe Plugs, visit our website. Oil & Gas Pipe Plug | PlugCo | plugco.net

What is Back Pressure?

Imagine you block one end of a pipe and start filling it with water. The water pushes against the blockage. That pushing force is what we call back pressure.

In pipeline testing, back pressure is the force pushing back on the pipe plug, the device that blocks the pipe during tests. If the pressure becomes too high and the plug isn’t strong enough, the plug can slip or even shoot out, and that’s dangerous.

Why is Back Pressure Important?

Here’s why you need to understand back pressure:

• Safety: Too much back pressure can cause a plug to fail or fly out. This puts workers and equipment at risk.
• Accurate Testing: If the plug doesn’t hold, your test results won’t be reliable.
• Proper Equipment Use: Every plug has a limit. If you don’t calculate back pressure correctly, you could damage the plug or the pipe.

In the photo above, you can see the damage caused to a pipe plug when the pressure limit was exceeded: The client used a the PP6001600/1.0 model and according to datasheet, this plug can handle 0.8bar back pressure at 1200mm:

However, the client used this plug in a 1200 mm pipe where the actual back pressure was 1.5 bar almost double the rated capacity.

This excessive pressure caused the plug to deform and fail, leading to potential safety hazards and equipment damage.

How to Calculate Back Pressure (The Easy Way)

PlugCo provides a clear formula to calculate back pressure. Here it is:

However, there is an easy way as well to consider for back pressure while giving an order.

Back Pressure (Bar) = Height of Water Column (meters) ÷ 10

Let’s say you want to block a pipe of 600mm inner diameter and the Height of water inside that pipe is up to 5 meters:

5 meters ÷ 10 = 0.5 bar of back pressure

So the plug to be used should resist 0.5bar at 600mm pipe.

But remember, real life isn’t always perfect. The pipe may not be smooth or dry. That’s why PlugCo always recommends using a safety margin and choosing plugs rated above your expected pressure.

Back Pressure of Pipe Plug | PlugCo | plugco.net

How PlugCo Helps You Manage Back Pressure

At PlugCo, we don’t just sell pipe plugs, we give you the tools and knowledge to use them safely.

Here’s how:

• Strong, tested products: Our pipe plugs are built to handle high back pressure, some up to 6 bar (that’s a lot!).
• Clear specifications: Every PlugCo product comes with details about how much back pressure it can hold and at which exact diameter.

• Back pressure calculator: On our website, you can find guides and examples to help you calculate the right plug and inflation pressure. (I need the link for calculation I couldn’t find it)
• Custom solutions: Need a plug for special conditions? We can help with that too, just Contact sale@plugco.com and we can select the right plug for your application together.

Want to Go Even Smarter? Use PlugCo’s Smart Plug

PlugCo’s Smart Plug is an advanced testing tool with:

• Real-time back pressure monitoring
• Pressure alarms for safety
• Accurate readings even in dirty, wet, or non-standard pipes

This takes the guesswork out and makes your pipeline testing much safer and more precise. How to Prevent Inflatable Plug Sliding in Real Pipeline Condition | PlugCo | plugco.net

So let’s talk about the 4 most important things to consider when selecting a pipe plug (and how to avoid costly mistakes).

Know Your Pipe Size (Not Just “About or Around 600 mm”)

This may seem obvious, but you would be surprised how often people guess or try to estimate it. Pipe plugs are designed to expand and seal properly based on the inner diameter (ID) of the pipe. Even being inaccurate by a few millimetres can result in poor sealing or, worse still, the plug sliding out

Tip: Get the accurate pipe specifications before you order. PlugCo offers both multi-size plugs (for flexibility) and single-size plugs (for exact fits), depending on what you need.

Don’t Forget About Back Pressure!

Imagine your plug is in place. Now consider what is inside the pipe. Is it water, air or oil pushing back on the plug with force? That is back pressure, and if your plug isn’t designed to withstand it, things can quickly go bad.

PlugCo clearly labels the maximum back pressure each plug can handle. For example, the PP6001200/1.5 model can manage 0.5 bar at the larger diameter and 1.0 bar at the smaller end.

Important Note: If you’re performing a leak test using two plugs (filling the section between them with water or air), the test pressure applied inside the pipe will act outward against both plugs. This test pressure is the same as back pressure. So always ensure that the test pressure does not exceed the plug’s rated back pressure.

Tip: Always check the exact back pressure of your system and match it with the plug’s rating, not the other way around. If you are not sure, we also have a Smart system that can tell the exact back pressure of your system, to know more about it you can check this blog: How to Prevent Inflatable Plug Sliding in Real Pipeline Condition | PlugCo | plugco.net

What is inside Your Pipeline? (Media Compatibility Matters)

Water, air, oil, chemicals… they all behave differently. And they don’t treat rubber the same way.

That’s why PlugCo uses different materials depending on the application:

• SBR+NR rubber for water and wastewater.
• Nitrile rubber (NBR) for oil, gas, and petrochemical pipelines.

Tip: If you’re working in oil & gas, don’t even think about using standard rubber plugs. Get the chemical-resistant like PlugCo’s Oil & Gas Series plugs.

The Flow During Maintenance? Use a Bypass Plug

Sometimes, you can’t shut down the whole line just to run a test or do a repair. That’s when a plug with a bypass connection becomes your option.

PlugCo’s PTP models and GPB models let the flow continue through the pipe while still sealing off the area you’re working on. It’s ideal for stormwater lines, sewer bypasses, or industrial systems that need to keep running.

Tip: If keeping flow uninterrupted is a must, look for models with bypass options.  PlugCo has several sizes available.

PlugCo Helps You Get It Right

A pipe plug might seem like a small part of a massive system, but picking the wrong one can lead to big problems: leaks, lost time, safety risks, and blown budgets.

At PlugCo, we’re not just selling rubber. We’re helping engineers, contractors, and field crews do the job safely and effectively.

If you still not sure which plug is right for your setup? Get in touch with PlugCo, and we’ll help you figure it out. sales@plugco.net

• What is a bypass connection?
• Why it’s important?
• Which PlugCo products have bypass options?
• A comparison table of plugs with and without bypass

What Is a Bypass Connection?

A bypass connection is a special feature on a pipe plug. It allows liquid or air to flow through the plug, even while the plug is inside the pipe.

Think of it like this: You want to block a pipe, but still need water or air to go from one side to the other. That’s when a bypass plug becomes a need!

Without a bypass, a plug simply stops all the flow. With a bypass, it blocks and allows the flow to keep going at the same time.

Why Use a Pipe Plug with a Bypass?

There are several situations where using a pipe plug with a bypass connection is not just helpful, it’s necessary. Let’s look at the most common reasons in more detail:

1. Water Leak Testing Without a Manhole

When you’re testing a new pipeline for leaks, you usually fill the pipe with water and apply pressure. But here’s the problem:

If there’s no manhole (or any opening in the Middle of the testing area), how do you get water inside the pipe?

That’s where the bypass connection comes in!

• You insert a pipe plug with a bypass into one end of the pipe and another normal pipe plug into the other end.
• Then, you pump water through the bypass to fill the pipe.
• Once filled, the same bypass can be used to apply pressure for the test.

Without a bypass, there’s no easy way to fill the pipe or run the test, especially in long pipelines or systems without manholes. So in these cases, the bypass is a must. If you need to know more about the water leak test process you can refer to this Video: https://www.youtube.com/watch?v=ndcooFgCZ10&t

2. Drainage and Maintenance – Letting Water Out Safely

This is about removing leftover water or liquids from the pipe after work or testing is done.

• Example: After doing a leak test, some water remains inside the pipe.
• You can use the bypass to slowly drain that water through a hose.
• This is especially useful when there’s no slope or gravity drain available.

Think of it as an answer of: “How do I empty the pipe safely?”

3. Air Release or Pressure Control – Managing Test Pressure

This is about controlling air or water pressure during the test, not after.

• Example: While you’re filling the pipe with water for testing, air pockets can get trapped.
• Those air pockets can cause false results or dangerous pressure spikes.
• The bypass lets you release air or connect a pressure gauge to monitor and adjust pressure.

Think of it as an answer of: “How do I make the test safe and accurate?”

PlugCo Products With and without Bypass

PlugCo has two main plug types for pipeline testing and blocking:

PP Model – Pipe Plug (Without Bypass)

This is a basic plug used to fully block a pipe. It does not include a bypass connection. It’s ideal when you need to stop the flow completely, like for maintenance or sealing off unused lines.

Example: PP5001000 → For pipes 500–1000 mm, no bypass connection.

PTP Model – Pipe Test Plug (With Bypass)

This plug is designed for leak testing and filling the pipeline through the plug itself. It has a built-in bypass connection, allowing you to fill, test, or drain the pipe without a need of manholes. Especially useful in long pipe sections where no access point exists.

Example: PTP5001000 → Same pipe size as the PP version, but with a bypass.

What If the Pipe Contains Chemicals, Gas, or Hydrocarbons?

Pipelines don’t always carry just water or air. In many industries, like oil & gas, chemical plants, or fuel Systems, pipes can be full of chemical fluids, gas, or hydrocarbons. These substances require special materials and more durable plug construction, like a nitril rubber that can resist all that.

To solve this, PlugCo has developed specialized models based on the same concept as the PP and PTP plugs. These are called GP and GTP models. Just like before, the GP is the version without a bypass, and the GTP includes a bypass connection.

What makes them special is the material: they are made from nitrile rubber, which is resistant to chemicals, oil, gas, and hydrocarbons. That makes them ideal for use in industrial pipelines where standard rubber would not last. You can learn more about these models by checking this blog: (publish the link of this article when it is accepted Why Nitrile Rubber Is Essential for Oil & Gas Applications)

Simple Rule to Remember:

• If the model is PP or GP → It’s a Pipe Plug, no bypass.
• If the model is PTP or GTP → It’s a Pipe Test Plug, and has a bypass.

This also makes PlugCo’s system very user-friendly, becasue you can choose the same size range, and just pick whether you need a bypass or not.

What Is Smart Pressure Control System?

PlugCo’s Smart Pressure Control System (SPCS) is more than just an air control device, it is a monitoring and regulating setup that helps you manage plug pressure in real-time. It is designed to work with inflatable and bypass plugs and can be connected to air compressors, hand pumps, or remote inflation lines.

It can include:

• Real-time pressure readouts
• Pressure regulators
• Alarm systems (visual or audible)

The system basically helps you avoid pressure-related surprises, and that is a huge deal in confined spaces or high-risk tests.

Why SPCS Makes a Difference on the Job?

1. Keeps You from Overinflating

Every plug has a max pressure limit. Go over, and you could rupture the plug, damage the pipe, or worse; injure someone. This system helps you stay within safe limits at all times.

2. Shows You Exactly What is Going On

Whether you are installing a plug, running a tightness test, or bypassing flow, knowing the real-time pressure makes a difference. The system shows exact numbers; no guesswork. It is especially helpful during EN 1610 or ASTM leak tests where consistency is everything.

3. Alerts You to Trouble

PlugCo can offer a version with built-in alarms. If the pressure spikes or suddenly drops, the system lets you know right away. That early warning can mean the difference between a controlled adjustment and an emergency fix.

4. Helps You Run a Clean, Accurate Test

Pressure fluctuation is one of the main reasons for failed tests. If you are testing to tight specs, especially on critical lines, the smart system holds the pressure steady. That means fewer re-tests and more reliable results.

5. Keeps Operators Safer

No one wants to stand next to an inflating plug. With long hose connections and remote monitoring, your team can stay out of the danger zone while still controlling and watching everything. This is key in deep manholes or tight access points.

Key Features of Smart Pressure Control System

• Precise calibrated Gauge
• Adjustable regulators to fine-tune pressure
• Alarms for high/low-pressure situations
• Works with all PlugCo plug models
• Built to take a beating on rough sites

When to Definitely Use the Smart Pressure Control System?

We are generally recommending our clients to use the SPCS for long-term Operations, for confined spaces where staying away from the danger zone is not an option, and for high pressure applications.

PlugCo’s Smart Pressure Control System might not seem essential at first glance, but once you have used it, you will wonder how you ever worked without it. It adds that extra layer of safety and accuracy we all need when the margin for error is small. Whether it is a high-stakes test or a basic maintenance job, it gives you:

• Confidence that pressure is right
• Protection against plug or pipe failure
• One less thing to worry about

When you are working with air or water pressure, things can go wrong fast if you don’t have full control. PlugCo’s Control Device makes sure you do.

So, What Exactly Is the Control Device for Joint Tester?

In simple terms, it is a pressure monitoring and regulation unit that connects directly to PlugCo Joint Testers. It controls everything from start to finish:

• Inflating the sealing bladders
• Regulating the test pressure between the bladders
• Monitoring pressure changes
• Safely discharging air or water after the test

Instead of juggling multiple valves, gauges, or hoses, you manage the entire process from a single, compact unit, built specifically for this job.

Why It is Worth Using the Control Device of Joint Tester Every Time?

1. It Lets You Inflate the Bladders Precisely

Each PlugCo Joint Tester has two inflatable bladders and both need to be inflated accurately.

Why this matters:

• Prevents leaking
• Ensures the test chamber is properly sealed
• Reduces wear and tear on the equipment

2. You Get Accurate Test Pressure Control

Once the bladders are sealed in place, you inject air or water into the chamber between them, and this is where precision matters most.

The Control Device helps you:

• Set the exact test pressure
• Keep an eye on it with real-time monitoring
• Spot leaks immediately based on any pressure drop

This is not just helpful, it is critical. A few seconds of pressure loss can tell you exactly where a joint is compromised.

3. It Makes Testing Safer for Everyone

Releasing pressure from a joint test can get messy, and dangerous, if not done carefully.

PlugCo’s Control Device guides you through the correct discharge sequence:

1. First, release the test pressure safely.
2. Then, deflate the bladders in a controlled way.
3. Avoid sudden blowouts, water sprays, or damaged equipment.

This also means no last-minute surprises when you are pulling equipment out of a manhole or trench.

4. It Works with Both Air and Water

Whether you are running air pressure tests or hydrostatic (water) tests, this Control Device handles both without needing any special conversion. Just hook up your compressor or water tank and go.

This flexibility makes it ideal for:

• Municipal inspections
• Utility contractors
• Trenchless rehab crews
• QA teams on new installs

A Few Features That Make the Control Device of Joint Tester Stand Out

• High-accuracy gauges
• Quick-connect ports for all hoses
• Rugged, portable design with legs and carrying handle
• Air-Water test compatiblity
• Compatibility with all PlugCo’s Models of Joint Tester