In sewer repair or maintenance work, keeping wastewater moving is critical. We often can not afford to shut off flow entirely, especially in live systems. That is where using a pipe test plug with a bypass comes in handy. When combined with a pump and the right setup, it lets us reroute flow safely and keep the job moving without risking backups or overflows.
What is a Bypass Plug?
A bypass plug is basically a pipe plug with a hole through the center. Sounds simple, but it is pretty effective. You inflate the plug to block off the pipe while the central port lets water flow through. It is really useful when you need to isolate a section of the line but still keep things running. They have been used on several jobs where full shutdowns were not an option.
What You will Need on Site?
Here is a rough checklist of the needed material in such applications:
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Bypass Pipe Test Plug
Make sure it fits the pipe you are working on. They come in different sizes of bypass (2”, 4”, etc.). If you have doubts about which model is suitable for your application, consult PlugCo team.
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Pump
Submersible or centrifugal both work, depending on the setup. Choose one that can handle the expected flow and any solids in the line.
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Hoses or Piping
You will need to route water from the upstream manhole to the pump, and from the pump discharge to the downstream section. Flexible hoses are generally prefered for tight spaces.
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Inflation Source
A compressor or manual pump does the trick. Always use a long inflation hose so you are not right next to the plug during inflation.
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Safety & Monitoring Tools
Do not skip these: pressure gauge, rope or chain to retrieve the plug, and all the accessories Recommended by PlugCo in the Safety Manual. Trust us, checking flow early saves headaches later.
How to Install the Pipe Test Plug with Bypass?
1. Preparing the Site
Inspect the pipe and clean it from debris. In addition, confirm your pump and plug are rated for the job, especially for larger flows.
2. Install the Plug
Slide the plug into the upstream section and inflate it. Always follow the PlugCo’s pressure specifications.
3. Connect the Bypass
Hook up the inlet hose to the plug’s bypass port, and connect the outlet to your discharge point. Double-check fittings, as one loose clamp can flood your site fast.
4. Start the Bypass
Fire up the pump and make sure everything is running smoothly. Monitor the pressure and check for leaks or unusual noise. A second plug downstream can help isolate the repair zone completely.
Things to Watch Out For
- Never enter a manhole alone or without gas monitoring. It is not worth the risk.
- Keep a spare pump or generator ready: For unexpected pump failures in mid-job as it is stressful if you are not prepared.
- Monitor flow during storms: a sudden downpour can double the flow.
Post-completion of the Job
Once the repair or inspection is done:
- Shut down the pump.
- Deflate and remove the plug (slowly and carefully).
- Flush and disconnect all hoses.
- Restore the normal flow.