Pneumatic Plug
Safety & Instruction Manual
Bouchon pneumatique
Manuel de sécurité et d’instructions
Tapón neumático
Manual de instrucciones y seguridad
Notice: Before using this equipment, carefully read SAFETY PRECAUTIONS contained in this
manual. Keep this manual for future reference. Additional free copies of this manual can be
obtained by contacting Cherne Industries. Contact Cherne Industries at 1-800-843-7584 or
Oatey.com/Cherne for questions or recommendations.
Avis : Avant d’utiliser cet équipement, lisez attentivement les MISES EN GARDE de ce manuel.
Gardez ce manuel pour référence future. Vous pouvez obtenir des copies supplémentaires
gratuites de ce manuel en contactant Cherne Industries. Contactez Cherne Industries au
1-800-843-7584 ou visitez Oatey.com/Cherne pour les questions ou recommandations.
Aviso: Antes de utilizar este aparato, es importante leer las PRECAUCIONES DE SEGURIDAD
contenidas en este manual. Guarde este manual para referencia futura. Se pueden obtener copias
gratuitas adicionales de este manual a través de Cherne Industries. Contáctese con Cherne
Industries al 1-800-843-7584 o visite Oatey.com/Cherne por preguntas o recomendaciones.
Cherne Industries Incorporated | 5700 Lincoln Drive | Minneapolis, MN 55436
Phone: 1-800-843-7584 | Fax: 1-800-843-7585 | Email: [email protected] | Oatey.com/Cherne
Cherne Industries Incorporated is part of the Oatey family of companies
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Safety Precautions .........................4
General Information ........................ 4
Conned Space Entry .................................4
Danger Zone ..............................................4
Preparation Before Use ...................4
Plug Selection ............................................4
Back Pressure Determination ......................4
Plug Size Selection .....................................4
Pipe Design ...............................................4
Calibrated Gauges ......................................4
Cleaning and Inspection..............................4
Clean Pipe .................................................5
Plug Rupture ..............................................5
Mises en garde .................................7
Informations générales ....................7
Application dans un espace restreint ..............7
Zone de danger ............................................7
Préparation avant l’utilisation .......... 7
Sélection du bouchon ....................................7
Détermination de la surpression .....................7
Sélection de la taille du bouchon .....................7
Conception du tuyau ......................................7
Jauges étalonnées ........................................8
Nettoyage et inspection .................................8
Nettoyage du tuyau ........................................8
Rupture du bouchon .....................................8
Precauciones de seguridad ...........11
Información general .......................11
Ingreso a espacios limitados .........................11
Zona de peligro ..........................................11
Preparación antes del uso .............. 11
Selección del tapón .....................................11
Determinación de la contrapresión ...............11
Selección del tamaño del tapón ...................11
Diseño de la tubería .....................................11
Manómetros calibrados ...............................12
Limpieza e Inspección ..................................12
Limpieza de la tubería .................................12
Ruptura del tapón .......................................12
Backup System ..........................................5
Plug Blocking .............................................5
Operation ........................................5
Danger Zone ..............................................5
Temperature Range ....................................5
Plug Placement ..........................................5
Monitor Pressure ........................................5
Restrain Media Restrictions .........................5
Ination Media ...........................................5
Over-Ination .............................................6
Under-Ination ...........................................6
Maintenance and Storage ...............6
Système de reux ..........................................8
Blocage du bouchon ......................................8
Opération ...........................................9
Zone de danger .............................................9
Plage de température .....................................9
Pose du bouchon ...........................................9
Surveillance de la pression .............................9
Restrictions des substances de retenue .........9
Substances de gonement .............................9
Gonage excessif ........................................10
Gonage insufsant ....................................10
Entretien et entreposage .................10
Sistema de respaldo ...................................12
Bloqueo del tapón .......................................12
Operación ........................................13
Zona de peligro ..........................................13
Gama de temperatura .................................13
Colocación del tapón ...................................13
Monitoreo de la presión ...............................13
Restricciones de las sustancias a refrenar .....13
Medios de inación .....................................13
Demasiada inación ....................................14
Poca inación .............................................14
Mantenimiento y Almacenamiento .. 14
Table of Contents
Table des matières
Índice
4
Safety Precautions
Death, bodily injury and/or
property damage could result if plug fails
for any reason. Unsafe practices can also
result in death or severe injury.
The following information provided
under “General Information,”
“Preparation Before Use,” “Operation,”
and “Maintenance and Storage” must
always be followed. Pay careful attention
to safety information highlighted by this
symbol:
General Information
Follow all safety instructions contained in
OSHA and federal, state, and local regulations.
Do not use the plug if any conditions exist that
could jeopardize the safety of personnel or
property.
Conned Space Entry: Follow Federal,
State, local and/or company requirements for
entry into conned spaces.
Danger Zone: When a plug is in use, a
danger zone exists that expands outwardly
in a cone shape. NEVER enter the danger
zone when a plug is in use.
Preparation Before Use
1. Plug Selection: Select the proper
plug and related equipment. Every pipe
plug has performance specs listed
on the plug and /or in the literature.
Contact Cherne Industries or dealer for
recommendations.
2. Back Pressure Determination:
Determine maximum back pressure the
plug must withstand. Back pressure is
the pressure (air or liquid) in front or
back of the plug that it must restrain.
Never exceed the plug’s back
pressure rating. Maximum back
pressure ratings listed are for
plugs installed in clean, dry pipe
of nominal size. Usage of plugs
in pipeline that varies from these
conditions could reduce maximum
allowable back pressure.
3. Plug Size Selection: Pipe plugs have
a minimum and maximum sealing size
range. Verify the pipe inside diameter is
within the plug’s sealing (usage) range.
4. Pipe Design: Plug performance
could vary depending on pipe types.
For example, in corrugated pipe, plug
back pressure rating drops by 50%.
Contact Cherne Industries or dealer for
recommendations.
5.
Calibrated gauges: Failure to use
calibrated gauges could result in plug
over-ination or under-ination which
could lead to plug failure.
Monitor ination and back pressure
with calibrated pressure gauges only.
Use calibrated gauges and proper hoses
to monitor pressure, inate, and deate
the plug from outside of danger zone.
Contact Cherne Industries or dealer for
recommendations.
6. Cleaning and Inspection: Plugs must
be clean and inspected before and after
every use. Do not use a plug if it
has or shows any signs of wear
or deterioration. All natural rubber
products degrade over time, even if
they are used infrequently, stored
properly, and show no external
5
signs of damage. Because of this,
Cherne recommends that this plug
be retired from service no later
than 17 years after the date of
manufacture, which can be found
on the serial number tag, ination
end, non-ination end, or on the
plug body. If you cannot nd
the date of manufacture or have
questions, call 1-800-843-7584.
The inspection should include but not be
limited to looking for:
1. Cuts
2. Abrasions
3. Punctures
4. Bulges
5. Cracks
6. Corrosion
7. Loose or damaged ttings
& components
8. Leaks
7. Clean Pipe: Clean any debris or foreign
substances before placing plug. An
unclean pipe could reduce plug’s back
pressure holding capability and could
damage plug during placement or upon
ination.
Plug Rupture: Improper ination
or ination against a sharp object
could result in plug rupture.
8. Backup System: An additional backup
system should be considered to prevent
injury or property damage in case of
plug failure. Never use eye bolts, ination
hoses, or other attachments of the
plug as a means to restrain the plug
movement under back pressure.
9.
Plug Blocking: Failure to use
proper blocking/bracing could result
in a fatality.
Forces behind the plug could be
tremendous. A properly designed
blocking or bracing device must be
used to restrain any plug movement.
Operation
Danger Zone:
When a plug is in use,
a danger zone exists that expands
outwardly in a cone shape. NEVER enter
the danger zone when a plug is in use.
Temperature Range:
Pipe plugs
are designed for use at temperatures from
0°F to +125°F. Plug use outside of its
rated temperature range could cause plug
failure.
Plug Placement:
Pneumatic plugs
can elongate upon ination, causing the
plug to protrude and resulting in failure
if not initially placed far enough into
the pipe. Position the plug into the pipe
at a distance at least equal to the pipe
diameter.
Monitor Pressure:
Ination pressure
and back pressure should be monitored
and maintained to the rated plug
specications at least once per 4 hours.
More frequent monitoring may be required
for certain applications. A regulated
pressure source may be attached to the
plug during operation.
Restrained Media Restrictions:
Use of plugs with chemicals including
hydrocarbons may cause severe damage
to the plug. Plugs made of natural rubber
are designed to hold air, water or sewage.
Plug failure could result in death, serious
bodily injury and/or property damage.
Ination Media:
Cherne plugs can
be inated with air, water or inert gasses
such as nitrogen. Air and other inert gases
pose more danger than water in the case
of a plug failure.
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1. Place the plug in the pipe or application
to be blocked or tested making sure it is
positioned inside the pipe or application
a distance at least equal to the pipe or
application diameter.
2. Connect one end of ination hose
to the plug ination tting (such as
Schrader valve, 1/4", 3/8", 1/2" port
etc.). The other end of the ination hose
is connected to line pressure, pump or
another supply pressure device. Always
use an appropriate method to dump the
pressure after application.
3. If another tting (such as Schrader valve,
1/4", 3/8", 1/2" port etc.) is available,
connect a second hose to the tting.
The other end of the second hose
should be connected to a calibrated
gauge. This second hose is a pressure
read back hose.
4. Make sure to block/brace the plug
using appropriate method before
inating the plug.
5. Introduce pressure to the plug through
the ination hose. Inate the plug to the
rated ination pressure listed on the
plug. Contact Cherne Industries or
dealer for recommendations.
6. Let the plug stabilize for a few moments.
Add pressure if needed to maintain rated
ination pressure.
Over-Ination:
Do not exceed
required ination pressure. Over ination
could cause the plug to rupture and
dislodge at extreme velocity.
Under-Ination:
Inate plug to
required ination pressure. Under-ination
could cause the plug and the media
restrained to dislodge from the pipe.
7. Proceed with testing pipe, application, or
other use of plug. After test, application,
or use of the plug is complete, release
all back pressure behind the plug from
outside the danger zone.
8. When all back pressure is released,
relieve plug pressure from outside
the danger zone until the plug is
completely deated.
Always release the back pressure
from the pipe before deating the plug.
Plug deation before releasing back
pressure could cause the plug to dislodge
at extreme velocity.
9. Remove blocking/bracing system.
Remove plug from pipe and follow
storage instruction.
Maintenance and Storage
The plug may be cleaned with mild soap
and water (other cleaning agents may
cause damage).
Inate plug with 1 psig to inspect the plug
after every use. Plug should not be
used if it shows any signs of cut, wear
or deterioration. A damaged plug is
unsafe and should not be used again.
Never inate plug more than 1 psig when
the plug is outside of a pipe. Plug damage
and failure could occur.
Store the plug in a dry place away from
sunlight or other sources of ultra-violet light
and ozone. Plugs must be stored below 110°F
and can be stored suspended vertically or
placed horizontally.
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dans d''autres langues
- English: CHERNE 041394 Installation guide
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