In this article, we will take the testing of infrastructural pipes as an example. The inflatable plugs are used either to stop the flow of a liquid or gas into the pipe or to test the pipe for leaks. For these tests to be successful, the plugs must withstand the back pressure applied by the fluid inside the pipe.

Usually, all manufacturers of this type of plugs inform their customers or end-users about the back pressure, or the height of water, that the plug can withstand. But unfortunately, this back pressure is always given for a specific type of pipes, as clean & dry concrete pipe or ductile iron pipe… So, when the plug is used in different pipe or for a different usage, the plug will not be able to withstand the same indicated back pressure. This will cause the plug to slide, which may lead to bursting, resulting in financial loss, serious injury or even death.

What is a SmartPlug?

Before starting the use of a plug, it is necessary to know the actual/exact back pressure of the pipe plug in the line that may be filled with debris or foreign materials such as grass, oil, mold, or others; which reduce the back pressure holding capacity inside the pipeline for pipe plug. At this point, PlugCo’s patented Smart Plug product will be the right solution to solve this problem by providing the real status of back pressure of the pipe.

As shown in the picture below, SmartPlug, is a logical measurement device equipped of a Pressure Monitoring and Alarm System, a Loading Mechanism and a Software to Calculate the Back Pressure.

How to use a SmartPlug?

Once the plug is placed in the pipe, the loading mechanism ensures that it is well centered. The user then starts to inflate the plug by the compressor, as normal, to the optimum inflation pressure according to the technical specifications. The loading mechanism, pulls the plug backwards to see at what load it will move. After continuously pulling the plug for several times, the user should note all the force values acquired.

Based on the values obtained in the previous steps, all required data can be submitted to the back pressure calculation Software, which is Available in PlugCo Website, to get the exact back pressure of the pipe plug.

To accomplish all the work, PlugCo has also programmed a Monitoring System, that will be connected to the plug, to help the user to control and monitor the pressure; So, after obtaining the back pressure that the plug can withstand, it is now enough to set it on the Pressure Monitoring and Alarm System, which is also manufactured by PlugCo. This System will display the current back pressure at all times and inform the user with a green LED if everything is OK and warns with a buzzer and a red LED if there is a dangerous situation. This process will help to avoid the damages that may occur during the applications.

SPCS is a master control device. PlugCo certainly recommends to use it for long-term operations. This device allows to inflate the plug automatically up to its inflation pressure. If its pressure drops 0,1 bar from inflation pressure, it starts to inflate and once the pressure arrives to the required inflation pressure, it automatically stops. The main advantage of this device is that, nobody must check its inflation pressure manually. Open the valve and continue to do your other works with no worries. This device should be connected to an air compressor while using.

Smart Pressure Control System (SPCS) provides automatic inflation for inflatable products, such as pipe plugs, to the required pressure. Thus, it controls the inflation pressure as per the specified pressure value. In other words, it doesn’t allow the inflation pressure to go above or below the set pressure value. For example, if there is a change in pressure due to external factors such as the environment temperature, it supplies or release air to keep the pressure at the specified value.

The Smart Pressure Control System is mechanically set to the required pressure. Then, it operates via the On/Off switch button. The analog pressure gauge placed on the box is used to monitor the inflation pressure.

The device has a single air supply connection and two accesses to the pressurized area. It is equipped with a solenoid valve and a pressure relief valve, which are used to maintain and control the pressure. Smart Pressure Control System can be used for maintaining the pressure of different media, such as air, gas or water.

By watching the above video, you will get to know more details about SPCS

PlugCo offers different models for controlling/monitoring the pressure which you can review from this link. PlugCo team is always ready to assist you for all your inquiries and you can reach us anytime by e-mail or WhatsApp.

This project has been carried out in Muscat, Oman. It is the Muscat Desalination project. Our client requested a High-Pressure Pipe Plug for 1700mm Pipe Dia., and we offered them HPP1700/8,0 with 8,0 bar inflation pressure and 2,5 bar Back Pressure. As known 2,5 back pressure refers to 25 meters waterhead which is a high pressure for this Pipe Size.

Our client didn’t only request the supply of the pipe plug, but needed an on-site training service as well. Thus, PlugCo technical team organized the training and one of our engineers took part in the project; gave the instructions and ion supervised the installation process.

As PlugCo, our goal is to offer our customers the most suitable product in line with their needs and requirements and to be with them whenever they need our support, either remotely or on site.

You can check in our Products Page our standard sizes for PP and PTP Models.

All Pipe Leak Test performed by PlugCo plugs are compliant with EN1610.

If you would like to make a similar test, you can choose the suitable models of Pipe Test Plug with Bypass from our PTP Page and the suitable model of Inflatable Plug without bypass from our PP Page. In case of any confusion, you can contact us directly to provide you the suitable models.

As per your conclusion of your need, you may choose the size required from the single size model from our MPP Page or the Size Range required from our PP Page.

All Pipe Leak Test performed by PlugCo plugs are compliant with the European Standard EN1610.

Please note that all PlugCo products meet the requirements of the European standard EN1610 and the American Standard ASTM C969M.

Leakage Tests

The leakage test can be either Air Leak Test or Water Leak Test.

As for the Air Leak Test, it had to be carried out according to the manufacturer’s specified method, taking into account that the air test can be dangerous for the enduser.

After applying the Air Leak Test, if it is well done, the results can be relied upon. However, in case of a single or continuous failure of the air leak test, a step towards the Water Leak Test is allowed to get decisive results.

According to the EN1610 standard, the maximum test pressure for the Air Leak Test is 0,2 Bar, above this test Pressure, it will be dangerous to apply the test.

Concerning the Water Leak Test, it can be applied with or without a manhole. As illustrated in the following chart.

Note: According to the EN1610 standard, test pressure for the water leak test is 0.5 bar and for air leak test is 0.2 bar.

What are the steps to pressure test a sewer line?

In order to carry out a successful leak test, it is necessary to follow specific steps, so as not to cause problems related to the safety of operators and the sewer line to be tested as well. PlugCo has explained the required steps to be followed in the video above.

This video explains how to carry out a pipe leak test by filling the test area with water through the plug and without using the manhole.

Steps for the water leak test

• 1st Step: Connect the air Discharge adapter with the Pipe Test Plug.
• 2nd step: Place the Pipe Plug and the Pipe Test Plug, which is connected with the air discharge adapter, in the pipeline that should be tested
• 3rd step: Fill the water through the Bypass connection, and discharge the air by using the ADA (Air Discharge Adaptor); This air discharge adaptor has two ends, the first one is connected with the pipe plug and through it the compressed air is released. The second end provides connection with the water pipe, so that the water lines will be filled.
• 4th step: After receiving continous flow water from the end of Air Discharge Adaptor the water hose can be connected to the manual pressure test pump. If you will make water leak test by using Water Hose, consult plugCo website to know how to operate this method correctly.
• 5th step: Make sure that X; the pressure created by the manual pressure test pump. plus H/10 ; the static pressure devided by 10, should be 0,5 bar; X+H/10=0,5 bar.
• 6th step: Remove the manual pressure test pump and connect the pressure gauge to monitor the pressure drops. As per EN1610 wait 30minutes to check if the test pressure is 0,5bar. If it is the case, the test is considered as successfully complete.

For more information on the steps required to test the pressure of a sewer pipe, you can watch the following video https://www.youtube.com/watch?v=ndcooFgCZ10.

Are there any safety Hazard to pressure testing a water line?

Before operating a pipe plug, the PlugCo safety manual must be read and understood carefully. For example, during a pressure test on a water pipe, the pipe plugs must be supported against sliding. Always brace the pipe plugs securely! Operators should be far away from the water lines, which is why PlugCo offers accessories such as long air hoses for monitoring from outside the pipe.

Qhat are the requirements of the water test pressure?

As per EN1610, the pipe plugs must be inflated to the maximum permissible inflation pressure. then fill the test section with water up to 5 metres and monitor the water level; this means 0.5 bar because a water level of 5 metres is equal to 0.5 bar (50 kPa).

Conclusion

Our entire team is at your disposal to meet your specific needs. Please do not hesitate to send us your enquiry. Our engineers look forward to working with you on your specific needs.

PlugCo is wholesaler that deliver its products all over the world, thanks to our logistics department, which ensures fast delivery to our customers all over the world. This means that customers receive their products on time at their front door.

The above video is kind of live streaming from the WWETT Show where PlugCo exhibited its products. The WWETT Show is where professionals in the wastewater and environmental come together. You can check all our news by visiting our page.

The above video explains in a simple way how to use the pipe plugs along with the different accessories of PlugCo. You can check all our Pipe Plugs Models by visiting our PP Page.