SAFETY & INSTRUCTION MANUAL
Contents
1.2. 10 1 INTRODUCTION CAREFULLY READ UNDERSTAND AND FOLLOW THE USAGE INSTRUCTIONS OUTLINED IN THIS BOOKLET The safety recommendations principles and guidelines outlined in this manual apply to the use of all Cherne pneumatic pipe plugs All Cherne products are designed engineered and inspected with safety in mind Cherne cannot control or predict the unlimited work place variables that can affect safety and usage conditions Therefore safety must be your responsibility too THINK AND PRACTICE SAFETY WHENEVER YOU USE A PIPE PLUG THANK YOU FOR PURCHASING AND USING CHERNE PNEUMATIC PLUGS AND ACCESSORIES The instructions and warnings in this manual are provided to assist you our customer to receive maximum benefit from the safe use of our products This manual may be freely copied and distributed Additional copies are available at no charge upon request If you need additional copies or have questions call Cherne toll free at 1 800 843 7584 or fax toll free at 1 800 843 7585 Emergency assistance and emergency product shipment surcharge applies to emergency after hours shipments is also available through the toll free 1 800 843 7584 phone number 24 hours per
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4. GRAVITY OR PUMPING BACK PRESSURE B RELEASE THE AIR THE PNEUMATIC PLUG from outside the Danger Zone through the inflation extension hose until the plug is completely deflated Full plug deflation minimizes possibility of plug damage during the removal process NOTE A vacuum pump may be used to speed the deflation of larger plugs The suction hose of a water pump may be needed to aid deflation of any plug inflated with water These deflation aids may require fabrication of special inflation extension hose assemblies Consult with a registered professional engineer for the design and construction of such assemblies C REMOVE THE PLUG FROM TEE PIPE Fully deflate small plugs and simply pull on the attached chain and ring assembly to remove the plug Fully deflate larger plugs and pull on the attached Poly Lift Line or tether device to remove the plug If unexpected resistance is encountered stop pulling and carefully inspect the plug installation Prevent damage to the plug and or accessories by eliminating any obstructions before proceeding N WARNING DO NOT ATTEMPT TO USE AN EXTENSION HOSE AS ALIFTING OR CARRYING HANDLE OR AS A TETHER TO REMOVE THE PLUG FROM THE PIPELINE This may weaken or damage the inflation line or the plug itself and result in a damaged or unsafe plug THE DAMAGED PLUG MAY LATER FAIL WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE WARNING DEFLATING A PNEUMA
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7. SINGLE HOSE POLY LIFT INFLATION LINE UN SELECT PROPERLY ATTACH ANCHOR HOOK CALIBRATED GAUGE d f USE INFLATION EXTENSION HOSE FOR SMALL PNEUMATIC PLUGS SMALLER HOSE IS GAUGE LINE HOSE i Na LARGER HOSE IS INFLATION LINE 26 INSPECT INFLATOR ASSEMBLY OF PLUG AND EXTENSION HOSE OR POLY LIFT LINE BEFORE USE AND REPLACE PROTECTIVE INFLATOR CAP AFTER USE Ensure that there is no dirt or debris lodged in the inflator valve or other connections Dirt or debris may prevent positive sealing of the inflator valve core Carefully inspect inflation extension hoses to ensure that end fittings are properly crimped that sealing washers are in place and that the hose is not worn or damaged Ensure that the inflation valve core is in position and properly tightened Such defects left uncorrected may cause a Slow leak resulting in under inflation and plug dislodgement To ensure secure attachment to the plug make sure the Poly Lift Line is not worn or abraded and that the end fittings are properly attached If any damage is found to any component repair or replace the equipment before use INSPECT INFLATOR DEFLATOR AND EXTENSION HOSE POLY LIFT LINE BEFORE USING PLUG t INSPECT INFLATOR FOR DIRT REPLACE N CAP AFTER USAGE INSPECT DEFLATOR FOR DIRT EE MAKE SURE CONNECTIONS ARE AIR TIGHT INSPECT HOSE AND CRIMPS FOR DEFECTS Z NWARNING DO NOT ATTEMPT TO USE AN EXTENSION HOSE AS ALIFTING OR CARRYING HANDLE
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9. Confined Space Ventilation Equipment Protective Clothing Safety Ladders Any Other Recommended or Required Equipment ENSURE THAT EQUIPMENT MEETS OR EXCEEDS MINIMUM REQUIREMENTS of all applicable regulatory guidelines All equipment should be properly maintained stored calibrated if necessary and inspected prior to each use in compliance with applicable regulations and equipment manufacturer s recommendations THOROUGHLY CHECK FOR HAZARDOUS GASSES AND PROPER OXYGEN LEVELS oxygen 20 minimum at all levels before entering a confined space Continuously monitor these levels when workers are in a confined space VENTILATE CONFINED SPACE before entry and continuously ventilate when anyone is in the confined space USE PROPER RETRIEVAL EQUIPMENT AND CO WORKER ASSISTANCE All personnel must be properly trained in the safety requirements for access to confined spaces IF YOU ENCOUNTER OR OBSERVE ANY CONDITIONS THAT ARE NOT EXPLAINED HERE OR ARE NOT FULLY UNDERSTOOD BY YOU NOTIFY YOUR SUPERVISOR OR SAFETY DIRECTOR BEFORE PROCEEDING 24 Z NWARNING THESE RECOMMENDATIONS ARE TO BE USED AS GENERAL GUIDELINE ONLY Although Cherne recommends these guidelines it does not warrant represent or assume any responsibility that these recommendations will fulfill all applicable Federal State or Local requirements Cherne assumes no liability for either personal injury or consequential damages resulting from the rel
10. which will prevent a permanent crease from forming in the plug body A crease may cause a weakened area resulting in premature failure upon plug inflation or use N WARNING DO NOT INFLATE PLUG IN EXCESS OF ONE 1 PSIG WHEN PLUG IS NOT IN A PIPE Plugs are designed only to be fully inflated when properly positioned inside a pipe THE PLUG MAY RUPTURE RESULTING IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE WARNING EXCESSIVE COATING OF PRESERVATIVE ON ELASTOMER MAY RESULT IN A SLIPPERY PLUG SURFACE AND REDUCE THE BACK PRESSURE HOLDING CAPABILITIES DO NOT COAT A PLUG IMMEDIATELY BEFORE USE AS THE COATING MAY REDUCE THE BACK PRESSURE HOLDING CAPABILITIES OF THE PLUG If plug use is required and the plug has an excessive coating of preservative the plug should be washed with solution of water and mild detergent flushed with clean water and then allowed to air dry before use USE OF SOME PRODUCTS SUCH AS PETROLEUM OR SOLVENT BASED COMPOUNDS MAY CAUSE SEVERE DAMAGE TO THE PLUG The damage may be below the plug surface and not be obvious during inspection but failure may result upon plug inflation or use PLUG FAILURE MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 38 15 SPECIAL CAUTION TO EMPLOYERS AND CONTRACTORS A ENSURE THIS MANUAL IS KEPT FOR REFERENCE BY CURRENT FUTURE PLUG USERS Employer must ensure that this manual is kept for reference by the user of Cherne products For example this booklet s
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12. NEVER inflate a pneumatic plug over lateral openings The plug may rupture upon inflation in the non supported body area Note Cherne Long Test Balls and 52 Long Test Balls amp are designed for use in wye pipeline sections where the plug body is not completely supported Clean Seal plugs are designed for use in blocking test tees that have unsupported area on each branch of the tee NEVER allow a pneumatic plug to protrude from the end of a pipeline during inflation or use The plug may rupture upon inflation or dislodge when back pressure is applied NEVER inflate a pneumatic plug outside of a pipeline in excess of one 1 PSIG The plug may rupture catastrophically 30 NEVER INFLATE NEVER INFLATE NEAR SHARP OVER LATERALS OBJECTS OR OTHER OPENINGS NO N NO NEVER ALLOW PLUG NEVER INFLATE TO PROTRUDE PLUG OUTSIDE FROM PIPE OF THE PIPE J ABOVE 1 PSIG q NO Z NWARNING FAILURE TO PROPERLY PLACE A PLUG BEFORE INFLATION MAY CAUSE PLUG FAILURE OR DISLODGEMENT WHICH RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY WARNING NEVER ALLOW A PERSON THE ISOLATED TEST AREA SUCH AS A PIPE OR MANHOLE WHEN A PRESSURE ORA VACUUM TEST IS BEING PERFORMED ALLOWING SOMEONE IN THE TEST AREA MAY RESULT IN DEATH OR SERIOUS BODILY INJURY 31 11 PROVIDE A BACKUP SYSTEM FOR SAFETY NEVER RELY ON PIPELINE PLUGSAS THE ONLY MEANS TO PREVENTINJURY OR
13. PROPERTY DAMAGE NEVER ENTER THE DANGER ZONE DURING USE 7 PREVENT INJURY OR PROPERTY DAMAGE ADDITIONAL PLUGS MAY BE PLACED ALWAYS PROVIDE A BACKUP SYSTEM 3 UPSTREAM TO PREVENT LEAKAGE No DANGER PLUGS MAY NEVER enter me DANGER ZONE BE BRACED To PREVENT THE DANGER ZONE exists IN FRONT DISLODGEMENT OF THE PLUGGED PIPE OPENING IN AN AREA WHICH EXPANDS OUTWARDLY IN A CONE SHAPE BRACING CONSULT A REGISTERED ENGINEER BRACING CONSTRUCTION WARNING NEVER ATTEMPT TO USE THE EYE BOLTS INFLATION HOSE OR CARRYING HANDLE OF A PNEUMATIC PLUG AS ASAFETY TETHER OR AS AMEANS TO RESTRAIN THE PLUG IF IT IS DEFLATED WHILE HOLDING BACK PRESSURE Safety bracing properly designed and constructed to withstand the tremendous forces involved is required Eye bolts and carrying handles on most pneumatic plugs are designed only for carrying lifting and lowering pneumatic plugs They are NOT designed to withstand the large forces encountered when pugs are deflated when restraining back pressure The carrying handles eye bolts or their attachment to the pneumatic fail thereby damaging the 119 itself may result unsafe conditions THIS MAY CAUSE PLUG FAILURE WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY PROPERTY DANGER A FULLY OPERATIONAL BACKUP SYSTEM MUST BE USED IF THE PLUG IS USED INANY ENVIRONMENT WHERE PLUG LEAKAGE F
14. Pneumatic pipeline plugs are to be used only for the few hours that are necessary to perform a task If a pneumatic plug must be used for extended periods the inflation pressure must be CHECKED AND ADJUSTED IF NECESSARY EVERY FOUR HOURS Over time a small volume of air will leak through the elastomeric rubber body of every pneumatic plug The lost air must be replaced or under inflation may result allowing the plug and any media restrained to dislodge from the pipe A regulated pressure source may be permanently attached to the plug s inflation inlet port as an alternative to periodically checking and adjusting the inflation pressure Consult with a registered professional engineer for the construction and maintenance of such a pressure regulated inflation source refer to description of panel and warnings in Section 12 of this manual if you are constructing a regulated pressure source For long term or permanent usage a Cherne mechanical plug is recommended Call Cherne toll free at 1 800 843 7584 for recommendations PNEUMATIC PLUGS VERSUS MECHANICAL PLUGS Pneumatic plugs have many advantages over mechanical plugs They normally have a much wider sealing range than mechanical plugs Some pneumatic plugs may even be used in multiple sizes of pipes Pneumatic plugs easily seal minor imperfections in pipe and can seal non circular pipe shapes Pneumatic plugs normally have a long contact area with the pipe which minimizes leakage in rough or p
15. Poly Lift Line s with internal inflation hose of proper length to allow plug inflation and deflation from outside the Danger Zone Attach the Poly Lift Line s to the plug s ATTACH A BYPASS HOSE ADAPTER USING PIPE SEALANT ATTACH A PROPER LENGTH BYPASS HOSE BY PUSHING HANDLES DOWN LOCKING lt FITTING TO ADAPTER ATTACH A POLY LIFT LINE OF PROPER LENGTH TO THE EYEBOLT AND INFLATION VALVE B PLUG PLACEMENT a Place the plugs into the pipeline a minimum distance of one pipeline diameter refer to Section 10 of this manual b Construct a backup system as required for the installation refer to Section 11 of this manual 58 Inflate the plug from outside the Danger Zone as fully described Section 12 of this manual to the pressure shown on the plug the proper inflation pressure is also outlined in the chart on page 46 d Proceed with the planned maintenance or other selected task Make sure that no one enters into the Danger Zone during plug use even if the plug is not restraining back pressure TYPICAL BIG MOUTH FLOW THROUGH PLUG INSTALLATION C PLUG REMOVAL a Totally deflate the plug s through the inflation extension hose of the attached Poly Lift Line s Deflate the downstream plug first b Remove the plugs from the pipe by pulling on the woven of the Poly Lift Line s c Clean inspect and properly store the plugs for future use
16. Y ENTIENDA ESTA MANUAL DE INSTRUCCIONES DE SEGURIDAD DEBE USAR GAFAS DE SEGURIDAD Y CASCO DURO NO ENTRE EN LA ZONA DE PELIGRO CUANDO ESTE EN USO EL TAPON MIDA EL DIAMETRO DE LA TUBERIA ANTES DE SELECCIONAR EL TAPON INSPECCIONE SI HAY DA OS EN EL TAPON ANTES Y DESPUES DE USARLO NUNCA USE UN TAPON EN UN TAMA O DE TUBERIA DIFERENTE DEL MARGEN DE USO RECOMENDADO CONSULTE ESTE MANUAL DE INSTRUCCIONES DE SEGURIDAD SIEMPRE INSTALE UNA MANGUERA DE EXTENSION DE INFLACION DE MANERA QUE EL TAPON PUEDA INFLARSE Y DESINFLARSE DESDE FUERA DE LA ZONA DE PELIGRO NUNCA RETIRE LA MANGUERA DE INFLACION HASTA QUE SE LIBERE TODA LA PRESION ACUMULADA Y EL TAPON ESTE DESINFLADO DEBE INFLAR EL TAPON LA PRESION ILUSTRADA EN EL TAPON SIEMPRE USE MEDIDORES DE PRESION CALIBRADOS EN FORMA CORRECTA NO SOBREPASE LA PRESION ACUMULADA PERMITIDA MAXIMA RECOMENDADA CONSULTE ESTE MANUAL DE INSTRUCCIONES DE SEGURIDAD SIEMPRE LIBERE LA PRESION ACUMULADA DESDE LA TUBERIA PRIMERO ANTES DE DESINFLAR EL TAPON iNUNCA ENTRE EN LA ZONA DE PELIGRO EXISTE UNA ZONA DE PELIGR0 EN LA PARTE DELANTERA DE LA APERTURA DE L TUBERIA TAPADA EN UN AREA QUE SE EXPANDA HACIA AFUERA EN FORMA DE CONO INO 10 11 12 13
17. at 1 800 843 7584 for recommendations USE OF PLUGS WITH CHEMICALS If a plug is to be used in chemical environments call Cherne toll free at 1 800 843 7584 for recommendations Z NWARNING MOST STANDARD CHERNE PNEUMATIC PLUGS ARE DESIGNED TO HOLD AIR OR WATER BACK PRESSURE ONLY AND MUST ONLY BE USED WITHIN THE DESIGNATED TEMPERATURE RANGE Use with other media or at temperatures outside of designated range may cause the plug to fail PLUG FAILURE MAY RESULT DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 16 4 MEASURE THE PIPE AND SELECT THE PROPER PLUG AND RELATED EQUIPMENT EVERY PIPELINE PLUG HAS A MINIMUM AND MAXIMUM SEALING SIZE RANGE AND A MAXIMUM ALLOWABLE BACK PRESSURE RATING The allowable sealing size usage range and maximum allowable back pressure are outlined in the data section of this manual Cherne catalogs and specification sheets Nominal plug size is clearly marked on the product However certain types and classes of pipe may have actual inside diameters that vary considerably from nominal diameters and may therefore be larger or smaller than the plug s sealing size usage range MEASURE THE INSIDE DIAMETER OF THE PIPE VERIFY THE DIAMETER IS WITHIN THE PLUG S RECOMMENDED SEALING SIZE USAGE RANGE NEVER EXCEED MAXIMUM ALLOWABLE BACK PRESSURE VERIFY THAT THE PROJECTED BACK PRESSURE IS WITHIN THE PLUG S MAXIMUM ALLOWABLE BACK PRESSURE RATING PNEUMATIC PLUGS ARE ONLY RECOMMENDED FOR TEMPORARY SEALING
18. employer or contractor is aware of Such instruction is the contractor s or employer s duty Should the employer or contractor be aware of such misuse Cherne should be so informed F INFORM ALL WORKERS OF THE COMPANY REPRESENTATIVE WHO IS RESPONSIBLE FOR SAFETY ON THE JOB The employer or contractor must inform all workers who is responsible for safety on the job and for consultation regarding questions relating to Cherne product use and other safety considerations 39 sn ui 9 p 3eiq eq 3snuu s6n d 9NINHVM WV 21 sc 8 sc 20 LL vov 5 81 EZZ S OL 05 00 81 8 1 t l 0c 8 sc 20 LL LLE 9 1 841 00 00 002 ZL 8 8805 SE ZL Ov ZL 012 sc 8 ObL ZS 002 051 8 9 8505 10 0 ZL Ov ZL 661 529 6 SLE OSL 001 9 8b0SZZ Salas SZZ suone3ilddv sBnid glleg 3591 8ZIS HINW 154 IN 3293 4eq ISd ww 55 29 1 ww s ubul 8 1111 16 zis uonejuil pasinbay 1111 11111 peg ejqemo ry 2215 44 lt lt ZL Ov ZL ZL LLE SZZL 9 S 0L 008 ZL 8071 0 74 SZ ZL Ov cl ZL 092 GZ0L 622 6 052 01 v6tlvo U sc ZL Ov c1 ZL 015 SC8 841 002 8 985190 56 14 2 3591
19. 10 Feet of Water x 0 43 PSIG Foot 4 3 PSIG PIPE AREA 2 827 square inches x PRESSURE 4 3 PSIG FORCE 12 157 pounds 14 CONVERSION TABLE FEET OF WATER HEAD TO PSIG Pounds Per Square Inch Gauge FT OF FT OF FT OF FT OF HEAD 80 J HERD TEND 05 1 043 46 19 92 2 0 87 47 2035 3 1 30 48 2078 4 1 73 49 21 22 5 2 16 50 21 65 6 2 60 51 22 08 7 3 03 52 22 52 8 346 53 22 95 9 3 90 54 23 38 10 433 55 23 82 11 4 73 56 24 25 12 5 20 57 24 68 13 5 63 58 25 11 14 6 06 59 25 5 15 6 49 60 25 96 TABLE 1 Z NWARNING NEVER EXCEED THE PLUG S BACK PRESSURE RATING Maximum recommended back pressure ratings listed are for plugs installed in clean dry pipe Other pipe conditions such as a pipe with debris or foreign substances on its surface may significantly reduce back pressure holding capabilities Harmful foreign substances may include grease mold algae sand and or any other material that prevents solid contact between the plug and the pipe wall Pipe made from material having a low coefficient of friction such as polyethylene or new pipe having traces of release agent used as part of the manufacturing process may also reduce the back pressure holding capabilities Corrugated piping will also reduce back pressure holding capabilities by
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21. 50 see page 18 IF SUCH CONDITIONS EXIST IMMEDIATELY NOTIFY YOUR SUPERVISOR OR SAFETY DIRECTOR AND TAKE APPROPRIATE CORRECTIVE ACTION SUCH AS CLEANING BEFORE PROCEEDING FAILURE TO HEED THIS WARNING MAY CAUSE PLUG DISLODGEMENT WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE Z NWARNING TREMENDOUS FORCES MAY BE RESTRAINED INSIDE OF AND BY PIPELINE PLUGS WHEN THE PLUGS ARE INFLATED AND USED Total force exerted on a pipeline plug is directly proportional to both the pressure and the pipeline area refer to formula and example page 14 ANY BARRIER OR BLOCKING DEVICE USED TO RESTRAIN THE PLUG IN A PIPELINE MUST PROPERLY DESIGNED AND CONSTRUCTED TO SAFELY WITHSTAND THE HIGH FORCES INVOLVED FAILURE TO USE PROPER BRACING MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY SEE PAGE 32 15 3 DETERMINE THE USAGE TEMPERATURE AND THE MEDIA THE PLUG MUST WITHHOLD TEMPERATURE RATING Most standard Cherne natural rubber pneumatic plugs are designed for use at temperatures from 0 to 125 DEGREES F 18 to 52 DEGREES C Using a plug at a temperature below this minimum may cause the plug to stiffen resulting in incomplete pipe contact and the plug may dislodge when back pressure is applied Usage at temperatures above this maximum may damage the plug body and the plug may rupture during inflation and or use If the application requires temperatures outside of these limits call Cherne toll free
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24. 80 1 S S 81 650 8 LLLL EY sbol Clv 0011 ZY 160992 60 L 1 9 02 190 28 56 968 006 9 70997 6 0 L L 9 0 190 78 048 9 618 098 E 550992 6 8L 9 sc 9 0 LL F62 SC1E 42 6 054 0 70997 435 0 14 sBnid elle unW 215 eq 54 s1939W 1994 154 Et EYDECEYRI 8215 uonegul peeH WNWIUIN leuIWON peg SIdEAOIIV abuey 5215 56 esn ui e IuM eq s6n d 59NINHVM W 550 8 08 be 0 S E 1 89 v9L 9 0041 99 LEZZ Z0 OL p EL i 0 95 6 61 Z9 v6vL 885 0051 09 EC Z0 OL p EL 0 95 1 9S 1 6 5 00 1 vS 612472 680 ZL b EL 70 95 0 21 0S 5611 0021 8t LOCLLE 8 0 ZL 81 550 8 1111 5901 0011 561476 60 g 129 0 190 28 56 S Z 968 E SE 006 9 981 6 0 L 0 9 OZ 190 8 0 8 618 EZE 098 1 6 81 94 sc 970 LL 67 SC1 24 6c 09 0 691447 be l 81 97 sc 9 0 LL ZIZ 8 29 lt 9 00 42 061 7 bz l 81 92 sc 9 0 LL
25. AILURE OR DISLODGEMENT FOR ANY REASON COULD RESULT IN LIFE ENDANGERMENT BODILY INJURY OR PROPERTY DAMAGE The backup system must be designed to safely stop a dislodged plu and the pipeline media that will discharge upon plug failure Consult registere p engineer for proper construction and maintenance of such a system AILURE TO PROVIDE BACKUP SYSTEM MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 32 12 PROPER PNEUMATIC PLUG INFLATION PLACEMENT OF PLUGS BEFORE INFLATION In most applications plugs can simply be placed into proper position refer to Section 10 of this manual and then inflated to the proper inflation pressure The inflation is performed from outside the Danger Zone using an inflation hose and a proper pressure source NOTE Other applications may require a plug to be held in position until the plug body fully contacts the pipe eg attachment of fittings which cause the plug to tip during inflation From a location outside the immediate Danger Zone the user may employ a device such as a pole with attached hook to position the plug The plug is inflated using an inflation extension hose or Poly Lift Line until it expands to make pipe wall contact After initial pipe contact the user moves to a new position well outside the Danger Zone and continues inflation until the recommended pressure is reached USE PROPERLY CALIBRATED PRESSURE GAUGES to monitor inflation pressure and back pressure U
26. BWEICHT WIR VERWEISEN AUF DIESES SICHERHEITSHANDBUCH BEFESTIGEN SIE IMMER EINEN VERLANGERUNGSSCHLAUCH AM ST PSEL UM VON AUSSERHALB DER GEFAHRENZONE DEN DRUCK ERHOHEN BZW SENKEN ZU KONNEN ENTFERNEN SIE DEN VERLANGERUNGSSCHLAUCH AUF KEINEN FALL WENN NICHT SAMTLICHER RUCKSTAU FREIGESETZT UND DER STOPSEL ENTLEERT IST DER STOPSEL MUSS AUF DEN AM STOPSEL ANGEGEBENEN WERT AUFGEBLASEN WERDEN BENUTZEN SIE IMMER ORDNUNGSGEMASS KALIBRIERTE MESSGERATE BERSCHREITEN SIE NICHT DEN EMPFOHLENEN MAXIMAL GESTATTETEN RUCKSTAU WIR VERWEISEN AUF DIESES SICHERHEITSHANDBUCH SETZEN SIE IMMER ZUERST DEN R CKSTAU AUS DEM ROHR FREI BEVOR SIE DEN STOPSEL ENTLEEREN DIE GEFAHRENZONE DARF AUF KEINEN FALL BETRETEN WERDEN EINE GEFAHRENZONE EXISTIERT VOR DER VERSTOPSELTEN ROHROFFNUNG IN EINEM BEREICH DER SICH KEGELFORMIG NACH AUSSEN ERWEITERT S CURIT G N RALES ET INSTRUCTIONS D UTILISATION 1 DES BLESSURES PHYSIQUES OU MORTELLES ET DOMMAGES LA PROPRI T PEUVENT TRE CAUSES SI LE BOUCHON FAIT D FAUT POUR TOUTE RAISON 2 LIRE ET COMPRENDRE CE MANUEL D INSTRUCTION SUR LA S CURIT AVANT L UTILISATION DU BOUCHON 3 TOUJOURS PORTOR DES LUNETTES DE S CURIT ET UN CASQUE PROTECTEUR 4 PAS P N TRER DANS LA ZONE DE DANGER LORSQUE LE BOUCHON EST EN USAGE 5 MESURER LE DIAMETRE DU TUYAU AVANT DE CHOISIR LE BOUCHON 6 V RIFIER SI LE BOUCHON N EST PAS ENDOMMAG aVANT ET APR S L UTILISATION 7 NE
27. CESSORIES Cherne sells inflation extension hoses and lifting inflation hoses Poly Lift Lines Many of Cherne s larger pneumatic plugs are supplied with a second access port into the plug inflation area contact Cherne toll free at 1 800 843 7584 for a list of plugs equipped with read back ports This additional port allows attachment of a calibrated pressure gauge which provides continuous and accurate measurement of inflation pressure The length and type of inflation hose needed will vary depending upon job site conditions but it must be of sufficient length to allow plug operation from outside the Danger Zone When using a larger pneumatic plug always secure a line to the plug s eyebolt s or other attachment point s before use This will assist safe plug placement and plug removal It also helps prevent inadvertent loss of the plug in a pipeline A Poly Lift Line with rope and anchor hooks is designed for this purpose Ensure that any other inflation hose selected has sufficient strength to safely support the weight of the plug and accessories Extension hoses and Poly Lift Lines can be interchanged between various sizes and styles of pneumatic pipe plugs or linked together to allow operation from greater distances Additional optional accessories allow plugs to be optimized for specific job requirements Call Cherne toll free at 1 800 843 7584 for recommendations SELECT AN INFLATION EXTENSION HOSE POLY LIFT LINE AND OTHER PLUG ACCESSORIES
28. ING IF YOU ENCOUNTER OR OBSERVE ANY UNUSUAL CONDITIONS THAT ARE NOT EXPLAINED HERE REMOVE THE PLUG OR EQUIPMENT FROM SERVICE AND NOTIFY YOUR SUPERVISOR OR SAFETY DIRECTOR INSPECT PLUG FOR DAMAGE BEFORE AND AFTER USAGE AN WARNING NEVER ATTEMPT TO CLEAN A PNEUMATIC PLUG WITH SOLVENTS OR PETROLEUM PRODUCTS This may cause severe damage to the plug The damage may be below the plug surface and not be obvious during inspection THE PLUG MAY FAIL UPON INFLATION OR USE RESULTING IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE N WARNING DO NOT INFLATE PLUG IN EXCESS OF ONE 1 PSIG WHEN PLUG IS NOT IN A PIPE Plugs are designed only to be fully inflated when properly positioned in a pipe THE PLUG MAY FAIL RESULTING IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE N WARNING FAILURE TO CAREFULLY INSPECT EQUIPMENT BEFORE USE MAY CAUSE PLUG RUPTURE OR DISLODGEMENT WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 21 6 SELECT AND USE PROPER SAFETY AND PROTECTIVE EQUIPMENT NOTE When plug use requires entry into a manhole or other confined Space it is important to refer to Section 7 of this manual SECURE THE JOB SITE Each job site must be evaluated to determine proper safety procedures and equipment It is extremely important to allow only experienced personnel to function in this decision making capacity If necessary place barriers such as traffic cones to reroute pedestrian and v
29. ITHSTAND FOR THE JOB OR 2 1 1 nnn 12 3 THE USAGE THE MEDIA THE PLUG MUST WITHHOLD PAGE 16 4 MEASURE THE PIPE AND SELECT THE PROPER PLUG AND RELATED EQUIPMENT PAGE 17 5 CLEAN PLUG AND RELATED EQUIPMENT BEFORE EVERY USE AND INSPECT FOR DAMAGE PAGE 20 6 SELECT AND USE PROPER SAFETY AND PROTECTIVE EQUIPMENT PAGE 22 7 RECOMMENDED SAFETY PROCEDURES FOR ENTRANCE INTO MANHOLES AND OTHER CONFINED SPACES sy o 666666 voee PAGE 24 8 CLEAN PIPE BEFORE PLACING PLUG PAGE 25 9 ATTACH INFLATION HOSE TO ENABLE PLUG INFLATION AND DEFLATION FROM OUTSIDE DANGER ZONE 4 3 lt 121 26 10 PROPER PLUG PLACEMENT IN PIPE PAGE 28 11 PROVIDE A BACKUP SYSTEM FOR SAFETY PAGE 32 12 PROPER PNEUMATIC PLUG INFLATION PAGE 33 13 PROPER PNEUMATIC PLUG REMOVAL PAGE 36 14 CLEAN AND INSPECT PLUG AFTER EVERY USE AND STORE PROPERLY 606 sena a tet Porno PAGE 38 15 SPECIAL CAUTION TO EMPLOYERS AND 8 2 2 39 16 PRODUCT USAGE 40 17 SPECIA
30. JAMAIS UTILISER UN BOUCHON POUR UN TUYAU DE GROSSEUR DIFFERENTE DU CHOIX RECOMMANDE SE REFERER AU MANUEL D INSTRUCTION SUR LA SECURITE 8 TOUJOURS FIXER UN BOYAU DE RALLONGE DE GONFLEMENT DE FACON CE QUE LE BOUCHON PUISSE TRE GONFL ET D GONFL L EXT RIEUR DE LA ZONE DE DANGER 9 JAMAIS RETIRER BOYAU DE GONFLEMENT TANT QUE TOUTE LA CONTRE PRESSION NE SERA PAS D GAG E ET QUE LE BOUCHON NE SERA PAS D GONFL 10 GONFLER LE BOUCHON SELON LA PRESSION INDIQU E SUR CELUI CI 11 TOUJOURS UTILISER DE FACON APPROPRI E LES MANOM CALIBR S 12 NE PAS D PASSER LA CONTRE PRESSION MAXIMALE PERMISE ET RECOMMAND E SE R F R AU MANUEL D INSTRUCTION SUR LA S CURITE 13 TOUJOURS D GAGER LA CONTRE PRESSION DU TUYAU EN PREMIER AVANT DE DEGONFLER LE BOUCHON NE JAMAIS P N TRER DANS LA ZONEMDE DANGER LA ZONE DE DANGER SE TROUVE DEVANT L OUVERTURE DU TUYAU POURVU DU BOUCHON ET S ETEND EN FORME DE CONE VERS L EXTERIEUR NON ZONE DE DANGER IV 10 11 12 13 ISTRUZIONI GENERALI SULLA SICUREZZA E L USO DECESSO LESIONI ALLE PERSONE E O DANNI ALLE COSE POSSONO VERIFICARSI SE PER UN MOTIVO QUALSIASI IL TAPPO PNEUMATICO NON FUNZIONASSE CORRETTAMENTE LEGGERE E COMPRENDERE A FONDO IL PRESENTE MANUALE DI ISTRUZIONI SULLA SICUREZZA PRIMA DI USARE IL TAPPO PNEUMATICO OBBLIGATORIO INDOSSARE OCCHIALI DI PROTEZIONE ED ELMETTO NON INTRODURSI NELLA ZONA DI PERICOLO MENTRE IL TAPPO PNEU
31. L USAGE INSTRUCTIONS FOR GRAVITY FLOW BYPASS APPLICATIONS PAGE 52 18 LIMITED WARRANTY PAGE 54 The Cherne products described in this manual may be covered by one or more of the following Patents and trademarks US Patent Numbers 3 834 422 3 951 173 4 096 977 4 274 206 4 493 344 4 588 110 4 614 206 4 763 511 4 817 671 5 035 266 5 076 328 5 209 266 5 234 034 5 329 646 5 353 841 DES 300 350 DES 339 405 DES 350 704 DES 351 013 DES 358 871 DES 362 713 DES 369 652 DES 370 055 DES 370 715 additional patents pending Trademark Numbers 625 158 717 948 718 126 718 373 737 860 816 386 930 319 906 675 912 238 1 138 344 1 145 721 1 163 062 1 276 011 1 360 285 1 428 285 1 574 687 1 559 813 1 937 973 additional trademarks pending Additional foreign trademarks are not listed Copyright 1991 1992 1998 2000 2007 All Rights Reserved Cherne Industries Incorporated Nou ew 10 11 12 13 GENERAL SAFETY amp USAGE INSTRUCTIONS DEATH BODILY INJURY AND OR PROPERTY DAMAGE MAY RESULT IF PLUG FAILS FOR ANY REASON READ AND UNDERSTAND THIS SAFETY INSTRUCTION MANUAL BEFORE USING PLUG MUST WEAR SAFETY GLASSES AND A HARD HAT DO NOT ENTER DANGER ZONE WHEN PLUG IS IN USE MEASURE PIPE DIAMETER BEFORE SELECTING PLUG INSPECT PLUG FOR DAMAGE BEFORE AND AFTER USE NEVER USE A PLUG IN A PIPE SIZE DIFFERENT FROM RECOMMENDED USAGE RANGE REFER TO THIS SAFETY INSTRUCTIO
32. LL 97 sc 9 0 LL 6 0 6 0 gl 6 0 60 L ZL Ov c1 ZL 4MO 9q Wey 6 lt 0 94 sc 9 0 LL 94 sc 9 0 LL 6 0g 60 6 0 60 L ZL Ov ZL 4MO 9q uey 29S S44 5 0 2sig ainjdny M N sBnjd ell g8 unW 51838 3954 eq 154 s nsse d ay s ubul 8 11 116 eunsseJd Yeg uinuuixelN 896 898 9 1 8 111 116 WNWIUIN 05 0 3e 009 3e SZS 1 3 0 lt 8135 6 6 61 ae 0S7 40 51 057 0 3e 009 3e SZS 1 3 05 81 1e 6 6 61 18 OSZ 5 1 ninw s ubul 9215 ZIS TI LT Y 80 0 806 07 44 esn ui al aq snw sBnjd 5NINHVM V 19 oz 90 6251 091e 6 0 60 EL 6221 871e 0501 0001 LL SE 01 SL L 9 9 0 6 0501 CY 1e 6 0 6 0 L 05 Iq 0E 32 LL SE 01 SL 009 pz 3 45 sn ui e IuM p 3eiq eq snu s6n d 9NINHVM WV 0 ez 20 01 Szz1 0 8 ZO OL 5 gvie sz 9 0 LL 0501 78 ez 80 zi 006 9 1e re 0 60 067 01 LU se 0 1 51 009 vz 1 61 zz Viva 335 0421 0S UZS S 0Z 889555 U
33. MATICO E IN USO MISURARE IL DIAMETRO DELLA TUBATURA PRIMA DI SELEZIONARE IL TAPPO PNEUMATICO ADATTO ESAMINARE IL TAPPO PNEUMATICO PRIMA E DOPO L USO PER RILEVARE GLI EVENTUALI DANNI DA ESSO SUBITI NON USARE MAI UN TAPPO PNEUMATICO SU UNA TUBATURA DI DIMENSIONI NON ELENCATE TRA QUELLE CONSIGLIATE CONSULTARE IL PRESENTE MANUALE DI ISTRUZIONI SULLA SICUREZZA COLLEGARE SEMPRE UN TUBO DI GONFIAMENTO DI PROLUNGA IN MODO CHE IL TAPPO PNEUMATICO POSSA ESSERE GONFIATO E SGONFIATO DALL ESTERNO DELLA ZONA DI PERICOLO NON RIMUOVERE MAI IL TUBO DI GONFIAMENTO PRIMA DI AVER ELIMINATO TUTTA LA CONTROPRESSIONE E DI AVER SGONFIATO COMPLETAMENTE IL TAPPO PNEUMATICO NECESSARIO GONFIARE IL TAPPO PNEUMATICO ALLA PRESSIONE MOSTRATA SUL TAPPO STESSO UTILIZZARE SEMPRE MANOMETRI CORRETTAMENTE CALIBRATI NON ECCEDERE LA CONTROPRESSIONE MASSIMA CONSENTITA CONSULTARE IL PRESENTE MANUALE DI ISTRUZIONI SULLA SICUREZZA RILASCIARE SEMPRE LA CONTROPRESSIONE DALLA TUBATURA PER PRIMA PRIMA DI SGONFIARE IL TAPPO PNEUMATICO NON INTRODURSI MAI NELLA ZONA DI PERICOLO LA ZONA DI PERICOLO E UN AREA CONICA CHE PARTE DALLAPERTURA DELLA TUBATURA DOTATA DI TAPPO PNEUMATICO E SI ESTENDE VERSO L ESTERNO NO V N num 10 11 12 13 INSTRUCCIONES DE SEGURIDAD GENERAL 050 SI EL TAPON FALLA POR CUALQUIER RAZON PUEDE PROVOCAR MUERTE LESIONES CORPORALES Y O DANOS LA PROPIEDAD ANTES DE USAR EL TAPON LEA
34. N MANUAL ALWAYS ATTACH AN INFLATION EXTENSION HOSE SO PLUG CAN BE INFLATED AND DEFLATED FROM OUTSIDE THE DANGER ZONE NEVER REMOVE THE INFLATION HOSE UNTIL ALL BACK PRESSURE IS RELEASED AND THE PLUG IS DEFLATED MUST INFLATE PLUG TO THE PRESSURE SHOWN ON PLUG ALWAYS USE PROPERLY CALIBRATED PRESSURE GAUGES DO NOT EXCEED RECOMMENDED MAXIMUM ALLOWABLE BACK PRESSURE REFER TO THIS SAFETY INSTRUCTION MANUAL ALWAYS RELEASE BACK PRESSURE FROM THE PIPE FIRST BEFORE DEFLATING PLUG CALL 1 800 THE PLUG OR 1 952 933 5501 IF ADDITIONAL CLARIFICATION IS REQUIRED NEVER ENTER THE DANGER ZONE THE DANGER ZONE EXISTS IN FRONT OF THE PLUGGED PIPE OPENING IN AN AREA WHICH EXPANDS N G E OUTWARDLY IN A CONE SHAPE NO II ALLGEMEINE SICHERHEITS UND BEDIENUNGSANLEITUNGEN 1 10 11 12 13 FALLS DER ST PSEL AUS IRGENDEINEM GRUND VERSAGT KANN DIES ZUM TOD ZU VERLETZUNGEN UND ODER ZU SACHSCHADEN FUHREN LESEN SIE DIESES SICHERHEITSHANDBUCH DURCH UND MACHEN SIE SICH MIT SEINEM INHALT VERTRAUT BEVOR SIE DEN STOPSEL BENUTZEN ICHERHEITSBRILLE UND SCHUTZHELM M SSEN GETRAGEN WERDEN DIE GEFAHRENZONE DARF NICHT BETRETEN WERDEN WENN DER STOPSEL BENUTZT WIRD MESSEN SIE DEN ROHRDURCHMESSER BEVOR SIE DEN STOPSEL WAHLEN INSPIZIEREN SIE DEN STOPSEL VOR UND NACH DEM GEBRAUCH AUF BESCHADIGUNGEN BENUTZEN SIE AUF KEINEN FALL EINEN STOPSEL IN EINER ROHRGROSSE DIE VOM EMPFOHLENEN EINSATZBEREICH A
35. OR AS A MEANS TO REMOVE THE PLUG FROM THE PIPELINE This may weaken or damage the inflation line or the plug and result in a damaged or unsafe plug Poly Lift Lines which are anchored to the plug are designed for such use THE DAMAGE MAY CAUSE PLUG FAILURE OR PLUG DISLODGEMENT WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE A WARNING ALWAYS ATTACH AN EXTENSION HOSE or Poly Lift Line to enable plug inflation and deflation from outside the Danger Zone NEVER REMOVE THE INFLATION HOSE or Poly Lift Line until all back pressure is released and the plug is completely deflated FAILURE TO HEED THIS WARNING MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 27 10 PROPER PLUG PLACEMENT IN PIPE POSITION THE PLUG INTO PIPE A MINIMUM DISTANCE OF ONE PIPE DIAMETER Pneumatic plugs may elongate upon inflation forcing the plug to protrude from pipeline and resulting in failure if not initially placed far enough into the pipe PLACE PLUG INTO PIPELINE A MINIMUM DISTANCE OF ONE PIPELINE DIAMETER PLUGS MAY ELONGATE UPON INFLATION DIAMETER D PLUGS USED FOR VACUUM TESTING OF MANHOLES When plugs are used to seal the pipes entering a manhole for a vacuum test the plugs must be placed well into the pipe beyond the manhole s sealing boot areas Failure to properly position the plugs will prevent the sealing boot areas from being adequately tested and leaks or bad seals may not b
36. OT OVER INFLATE OR UNDER INFLATE A PNEUMATIC PLUG OVER INFLATION of a pneumatic plug exceeding the required inflation pressure may cause the plug to rupture and dislodge at extreme velocity UNDER INFLATION of a pneumatic plug inflation to pressure less than that required may cause the plug and the media restrained to dislodge from the pipe A plug that is over inflated or under inflated may not fail immediately However such failure may occur at any time without warning IMPROPER INFLATION MAY CAUSE PLUG FAILURE OR DISLODGEMENT WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 35 13 PROPER PNEUMATIC PLUG REMOVAL A RELEASE ALL RESTRAINED MEDIA back pressure from a pneumatic plug before deflatiing the plug PLUGS PROPERLY BLOCKED OR SUPPORTED BY BRACING MAY BE DEFLATED TO RELEASE THE MEDIA RESTRAINED BY THE PLUG BACK PRESSURE Gradual plug deflation can control th rate of media discharge Use extreme caution to ensure that such bracing is properly designed to withstand the full force of the plug and any restrained media nsure that any media released does not result in injury or property amage SOME PRODUCTS ARE DESIGNED TO SAFELY RELEASE BACK PRESSURE WITHOUT THE USE OF BRACING This includes MS2 Long Test Ball amp plugs Clean Seal plugs which ar simply deflated to release back pressure Other plugs such as most sizes pillow type Muni Ball and Test Ball plugs ha
37. SAFETY amp INSTRUCTION MANUAL A Guide to the safe and proper use of Cherne Pneumatic Pipe Plugs This manual covers Cherne Pneumatic Plugs as follows Single Size Test Ball amp Plugs 8 amp larger Multi Size Test Ball amp Plugs 6 amp larger Muni Ball Plugs i Series Plugs REMO Plugs BIG MOUTH Plugs AIR LOC Plugs Factory Replaceable Sleeve Large Pillow Style Test Ball amp Plugs CHERNE INDUSTRIES CHERNE INDUSTRIES INCORPORATED 5700 LINCOLN DRIVE MINNEAPOLIS MINNESOTA 55436 1695 PHONE 1 800 843 7584 FAX 1 800 843 7585 KEEP THIS MANUAL WITH PLUG FOR FUTURE REFERENCE PANTS Plugs must be braced while in use Dedicated to the memory of Allen D Mathison 1946 1996 SAFETY INSTRUCTION MANUAL INDEX REV 12 GENERAL SAFETY AND USAGE INSTRUCTIONS ENGLISH cesse PAGE 5 lI ALLGEMEINE SICHERHEITS UND BEDIENUNGSANLEITUNGEN GERMAN PAGE 6 III S CURIT G N RALES ET INSTRUCTIONS UTILISATION FRENCH PAGE 7 ISTRUZIONI GENERALI SULLA SICUREZZA E L USO ITALIAN PAGE 8 V INSTRUCCIONES DE SEGURIDAD GENERAL Y USO SPANISH PAGE 9 VI JAPANESE PAGE 10 1 PAGE 11 2 DETERAINE THE AMOUNT OF BACK PRESSURE THE PLUG AUST W
38. SOME APPLICATIONS ALLOW DIRECT A CALIBRATED PRESSURE MEASUREMENT GAUGE CAN REMOTELY OF WATER HEIGHT PROVIDE ACCURATE AIR BACK PRESSURE MEASUREMENT WATER WILL ACCUMULATE BEHIND ANY PLUG BLOCKING A FLOWING LINE The flow will gradually increase the water column height behind the plug Prior to installing a plug the user must determine the maximum water height that may accumulate during plug use DETERMINE MAXIMUM WATER HEIGHT THAT MAY ACCUMULATE ABOVE PIPE CENTER HOW TO CALCULATE PIPELINE FORCES AND PRESSURES A MEASURE THE INSIDE DIAMETER OF THE PIPELINE IN INCHES B DETERMINE THE MAXIMUM BACK PRESSURE Air pressure is measured in PSIG Pounds Per Square Inch Gauge Water pressure is calculated by determining the height of water column in feet above the center line of the pipe Water height is multiplied by 0 43 to yield water pressure in PSIG A FEET OF WATER HEAD TO PSIG conversion table is also provided see Table 1 next page C CALCULATE THE PIPE AREA IN SQUARE INCHES Area of a circle square inches Diameter in inches x Diameter in inches x 3 1416 pi 14 D CALCULATE THE FORCE THE PLUG MUST WITHSTAND FORCE AREA in square inches x PRESSURE PSIG EXAMPLE A plug must hold a 10 foot column of water above the centerline of a 60 diameter pipe PIPE AREA 60 dia x 60 dia x 3 1416 pi 4 2 827 square inches PRESSURE
39. TIC PLUG BEFORE ALL BACK PRESSURE IS RELEASED MAY CAUSE THE PLUG AND THE MEDIA RESTRAINED TO EJECT FROM THE PIPE AT HIGH VELOCITY THIS MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE AND DAMAGE TO THE PLUG AND ACCESSORIES 37 14 CLEAN AND INSPECT PLUG AFTER EVERY USE AND STORE PROPERLY A CLEAN AND INSPECT PLUG as outlined in Section 5 of this manual B STORE THE PLUG IN A CLEAN DRY PLACE away from sunlight or other sources of ultra violet light and away from sources of ozone such as electrical equipment Ozone and ultra violet light may cause the elastomer rubber to weaken and fail prematurely C STORE PLUGS BELOW 110 DEGREES F 43 degrees C Exposure to excessive temperatures may cause damage to the elastomer of pneumatic plugs NOTE Storage of plugs in non ventilated structures such as metal buildings may expose the plugs to excessive temperatures which may damage the plugs and possibly result in a plug failure D ARMOR ALLG MAY BE USED AS A PRESERVATIVE on elastomeric rubber surfaces for extended storage Apply only a light coating to the plug Other water or silicone based preservatives may also be used see warning below ARMOR ALL is a Registered Trademark of Armor All Products Corp Allso Vlejo CA USA 92656 E PLUGS MAY BE STORED SUSPENDED VERTICALLY OR PLACED HORIZONTALLY When storing a plug it is recommended that the plug be partially inflated to 1 PSIG only see inflation warning below
40. Z 0 68 0 6 0 g 919 982 SLI o gbesse UZ 0 Le 0 6 0 EL 8291 961 Ar 891555 L Z 0 L 6 0 6 0 L OLE 9 1 StL SZ S 821556 UZ 0 Le 0 6 0 012 S6 SLE 880955 s6n d olleg UNW w 5 44 5 1 ISd 5 1994 eq 154 ww s u ul aanssodd Teyoureiq EI TI LIL V uonegul peeH unu xew 84 55344 Yeg SIdEAOIIV abuey ezis 46 esn e IuM paresq aq 1Snuu snid NINYYM WV Sz 0 LL EV vl 9 055 sc96 0001 S po 2 896595 z o OL 0051 09 1e 8 0 6 0 EL 10 812 LU se 01 s 0501 LL SE 01 SL 0S2 0 12 6 lt lt 62 0 L Z 0 L Z 0 L Z 0 eq 154 55 pasinbay esn ui 9jJIUM peoeaq eq ysn s5nld DNINHVW N L 6 0 L 6 0 11 SE LL SE 11 SE 335 0 2 92 sc 68 8c L 6 0 11 SE M0739 335 16 0 126 0 16 0 L 6 0 CHO ETT 3994 57 6 0 g 60 01 SL 01 SL 01 SL M0739 335 70 OL 70 OL 9470 LL 580 ZL 60 L 01 51 M0739 Viva 335 60 L 919 S
41. as inflation pressure is increased as back pressure builds and by possible ricochet effects from pipes walls or other objects in the Danger Zone The area of foreseeable Danger Zone may be reduced by the use of a backup system refer to Section 11 of this manual 12 DANGER ANGER NEVER ENTER INTO THE FORESEEABLE DANGER NA PNEUMATIC PLUG IS INFLATED EVEN IF NO BACK ZONE WHE PRESSURE EXISTS IN THE PIPE IF YOU OR ANYONE ELSE IS IN TH ONE AND THE PLUG FAILS OR DISLODGES FOR ANY E DANGER Z REASON FAILURE TO HEED THIS WARNING MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE MONITOR BACK PRESSURE DURING PLUG USE Monitor water back ressure by attaching a calibrated pressure gauge or a vertical sight tube o the bypass of a Muni Ball amp plug A gauge must be located at pipe centerline to accurately measure water pressure Other applications may allow direct measurement of the water column height restrained by the plug Air back pressure can be monitored by attachment of a calibrated pressure gauge to the plug bypass port using an extention hose This allows accurate back pressure readings from a remote location outside of the Danger Zone WATER HEIGHT ATTACH CALIBRATED ATTACH A CLEAR 7 PRESSURE GAUGE TO SIGHT TUBE TO MUNI BALL PLUG MUNI BALL PLUG BYPASS TUBE BYPASS TUBE IGAUGE PORT READING MUST BE CORRECTED FOR HEIGHT ABOVE PLUG CENTERLINE
42. as outlined in this manual Ensure a copy of this Safety Instruction Manual is kept with the plug for future use 59 18 LIMITED WARRANTY Manufacturer warrants all pneumatic plugs manufactured by it and shown in this manual will be free from defects in material and workmanship for two 2 years following the date of manufacture If any of the goods are found to be defective such goods will at manufacturer s option be replaced or repaired at manufacturer s cost The parties hereto expressly agree that buyer s sole and exclusive remedy against the manufacturer shall be for the repair and or replacement of defective goods as provided herein The sole purpose of the stipulated exclusive remedy shall be to provide the buyer with free repair and replacement of defective goods in the manner provided herein The exclusive remedy shall not be deemed to have failed of its essential purpose so long as the manufacturer is willing and able to repair or replace defective goods in the prescribed manner Goods which may be sold by manufacturer but are not manufactured by it are not warranted by manufacturer but are sold only with the warranties if any of the original manufacturers thereof This warranty does not cover labor or other costs or expenses to remove or install any defective repaired or replaced goods Manufacturer s warranty does not apply to any goods which have been subjected to misuse mishandling misapplication neglect including but
43. ation source INFLATION PRESSURE VERSUS TEMPERATURE Any temperature increase or decrease will cause a corresponding change in inflation pressure Monitor and adjust plug inflation pressure as necessary to compensate for temperature changes NOTE Temperatures in pipelines may vary widely from outside ambient temperatures Monitor inflation pressure closely and adjust as necessary to maintain recommended pressure INFLATION OF PLUGS WITH MEDIA OTHER THAN AIR Many Cherne pneumatic plugs may also be inflated with water or with inert gasses such as nitrogen as long as all pressure sources are regulated Consult with a registered professional engineer or call Cherne toll free at 1 800 843 7584 for recommendations refer to following warnings N WARNING ANY PNEUMATIC PLUG INFLATION SOURCE MUST BE EQUIPPED WITH A PRESSURE REGULATED OUTPUT MONITORED BY A PROPERLY CALIBRATED PRESSURE GAUGE Lack of such components may result in a condition of over inflation or under inflation Consult with a registered professional engineer for the proper Specification and design of such an inflation source NEVER attempt to inflate a pneumatic plug using a non regulated high pressure source eg Nitrogen tank Scuba tank non regulated air compressor etc Catastrophic plug failure may result USE OF AN IMPROPER INFLATION SOURCE MAY CAUSE PLUG FAILURE OR DISLODGEMENT WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 34 Z NWARNING DO N
44. c vc 622 L1 6 0 g ELp SC91 981 6 0 g OLE SZZI SI 5 76 60 L 012 sc8 c6 9 5 ofl amp 9 3S2L wSeles 7661 S 09 9 99 0 1 0S 125 0 eq 54 uunuu u W 84 55944 258 wnwixew 86 5 9215 6221 0 8 35 SZZ L 0901 3 006 9 32 05 0 001 002 09 0 S ZL Id 81 6221 8 38 0901 1e 006 9 1e 052 0 3e 009 0021 009 St vc 009 006 1 005 002 91 8 00 061 21 9 002 001 8 7 525 809SZE 88966 8vcS6t 891565 8 1565 880565 48 sn eq 358 s6n d 9NINHVM W 10 0 L s 6 91 s 0 919 scvc 647 LL 009 006 ZL 8 58 L Z 0 L s 6 91 50 5 91 981 007 002 91 8 891586 5 4 elleg 1S L 1 iSd 3594 ISd CETT 2 91155914 9215 uonegu De 3IdEAOIIV 9215 9 0 LL
45. day CHERNE WISHES TO EXPRESS THANKS TO THOSE WHO HAVE CONTRIBUTED TO THIS MANUAL If you have suggestions on how we can improve this manual or have additional data you think would be pertinent that should be added please call Cherne toll free at 1 800 843 7584 CHERNE PROVIDES TRAINING ASSISTANCE If your organization eg Union School Tech School Sewage District Trade Organization etc provides training on a topic such as testing product safety or a related topic please contact us for help Cherne will provide free training materials eg copies of testing standards product catalogs Safety Instruction Manuals specification sheets safety tags etc to assist your presentation Upon request a company representative may assist in the presentation Call Cherne toll free at 1 800 843 7584 to further discuss this assistance A WARNING AN INHERENT DANGER EXISTS WITH ALL INFLATABLE PRODUCTS ANY PRESSURIZED PIPELINE OR OTHER PRESSURE CONTAINMENT SYSTEMS Every pneumatic plug like tires will eventually wear out and fail from continued use Abuse and misuse will greatly accelerate this failure Always protect against the eventuality of plug failure to prevent injury and property damage If any conditions exist with equipment that may jeopardize the safety of yourself or others or if you are unsure about proper use DO NOT USE THE EQUIPMENT If you have any questions or think any unusual conditions exist that are not described in this bookl
46. e discovered When a manhole is vacuum tested before being backfilled the incoming pipes and plugs must be properly braced or blocked to prevent the pipes from being pulled into the manhole during the test SEALING BOOTS WHEN USING PLUGS FOR VACUUM TESTING PLACE PLUGS BEYOND SEALING BOOTS TO INSURE THE BOOT AREA 5 PROPERLY TESTED 28 PLACING PLUG THROUGH RESTRICTED ACCESS When plug placement requires installation through a restricted access air may be forced from the plug to provide a minimum cross section The inflation valve core or inflation fitting may be temporarily removed to aid deflation The valve core or inflation fitting must be properly replaced and leak free using pipe sealant or teflon tape and the fitting s protective cap must be replaced The plug body may be temporarily lashed with a rope to provide the minimum possible cross section for placement The lashed plug is inserted into the pipe the plug body is then untied and the plug is properly positioned and then inflated normally Use caution as the restricted access may cause the plug to be significantly more difficult to remove than to install A vacuum pump may be used to extract air from larger pipeline plugs Vacuum pump use may require fabrication of special inflation extension hose assemblies Consult with a registered professional engineer for the design and construction of such assemblies BENDING FLEXIBLE PLUGS If installation re
47. e pipe such as clay or non reinforced concrete if a plug is used before the pipe is properly backfilled 19 5 CLEAN PLUG AND RELATED EQUIPMENT BEFORE EVERY USE AND INSPECT FOR DAMAGE CLEAN PLUG Pneumatic plugs may be cleaned with a solution of mild detergent and water After cleaning flush the plug with clean water and allow it to air dry thoroughly before use INSPECT PLUG AND RELATED EQUIPMENT inspect the pneumatic plug and all related equipment for indications of wear or deterioration prior to each use The plug may be inflated slightly 1 PSIG refer to warning on following pago to aid in the inspection process After inflation apply a solution of water and detergent to the equipment or submerge the product completely under water as an aid locating leaks Bubbles will form at the site of any air loss Look very carefully for evidence that any material of the plug assembly and related equipment has been damaged weakened or is missing The inspection should include but not be limited to looking for Cuts Abrasions Punctures Presence of a proper inflation source refer to Section 12 of this manual Bulges Cracked castings Softening of elastomer rubber Cracks in elastomer rubber Corrosion Loose corroded or damaged fittings Leaks from or damage to inflator assembly Leaks from or damage to inflation extension hoses Dirt or debris lodged in the inflator valve which may cause a slow inf
48. ehicle traffic and to prevent entry into work area NEVER allow unauthorized or untrained individuals inside the work perimeter NEVER leave a pneumatic plug unattended in a unsecured location Pedestrians or curiosity seekers may inadvertently enter into the Danger Zone Vandalism or tampering with a pneumatic plug and accessories may result in plug failure or dislodgement SECURE THE JOB SITE NEVER LEAVE A PLUG UNATTENDED WEAR NECESSARY SAFETY EQUIPMENT This includes safety glasses a hard hat ear protection protective footwear and all other necessary protective clothing and equipment Safety equipment and clothing required will depend upon the environment in which the product is used 22 HEARING PROTECTION N WARNING FAILURE TO USE PROPER SAFETY EQUIPMENT OR TO SECURE THE JOB SITE MAY RESULT IN DEATH OR SERIOUS BODILY INJURY 23 Ph dy 7 RECOMMENDED SAFETY PROCEDURES FOR ENTRY INTO MANHOLES AND OTHER CONFINED SPACES COMPLETE THE PROPER CONFINED SPACE ENTRY PERMIT EQUIP YOURSELF WITH THE NECESSARY SAFETY EQUIPMENT for entrance into the manhole or confined space This may include but not be limited to the following recommended equipment Safety Hat Safety Glasses Respirator With Self Contained Air Source Safety Harness Cables and Safety Winching System Safety Shoes or Boots Protective Gloves Ear Protection Hazardous Gas Detector and Oxygen Monitor
49. et consult your supervisor or safety director before proceeding FAILURE TO COMPLY WITH THESE SAFETY INSTRUCTIONS OR THOSE OF OSHAAND YOUR FEDERAL STATE OR LOCAL GOVERNMENTS MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 11 2 DETERMINE THE AMOUNT OF BACK PRESSURE THE PLUG MUST WITHSTAND FOR THE JOB OR APPLICATION DETERMINE THE MAXIMUM BACK PRESSURE the differential fluid either air or liquid restrained by the plug the plug must withstand efore selecting a plug WATER BACK PRESSURE nydrostatic back pressure is measured in either feet of head ud height above centerline of the plug or PSIG Pounds Per Square Inch Gau IR BACK PRESSURE pneumatic back pressure is measured in PSIG Pounds Per Square Inch Gauge See Conversion Table on page 15 WATER BACK PRESSURE 5 AIR BACK PRESSURE PSIG P z WATER COLUMN IN FEET reo ABOVE PIPE CENTERLINE Z pressure DANGER ZONE N MAXIMUM ALLOWABLE BACK PRESSURE for each Cherne pneumatic pipeline plug is clearly outlined in the data section of this manual Cherne catalogs and product specification sheets Maximum back pressure ratings listed for plugs installed in clean dry pipe of nominal size Usage of ugs in pipeline that varies from these conditions may reduce maximum allowable back pressure MAXIMUM BACK PRESSURE RATING AIR VERSUS WATER Pipeline plugs
50. he pipe may need to be coated with sealant to prevent such leakage Other concrete pipe has a cast in place plastic liner and leakage may occur under the liner The edges of the plastic liner may require caulking to provide a leak free seal Other pipe with sharp 90 corners longitudinal seams or defects may provide a leakage path past the plug DO NOT attempt to prevent the leakage described above by over inflation of the plug Over inflation will not provide a better seal and the plug may rupture catastrophically and dislodge at high velocity Such leakage may only be minimized or eliminated by mechanically blocking the leakage path with material such as caulk or cement grout PIPE SHAPES OTHER PIPE SHAPES Pneumatic plugs may also be used to block pipes that have non circular cross sections eg elliptical arch or rectangular Measure the pipe and call Cherne toll free at 1 800 843 7584 for recommendations for your application A standard plug or fabrication of a custom sized product may be recommended Cherne can quickly determine what plug will best meet your performance requirements 18 DETERMINE THE TYPE OF PNEUMATIC PLUG REQUIRED Cherne offers wide variety of plug types including a Blocking type pneumatic plugs Test Ball plugs b Plugs for sealing wyes Long Test Ball amp plugs and MS2 Long Test Ball amp plugs c Plugs for sealing test tees Clean Seal plugs d Plugs with a bypass through the plug M
51. hould be placed in the tool box of the plumber or user This manual may be freely copied and distributed or additional copies may be obtained free upon request from Cherne by calling toll free at 1 800 843 7584 B INSTRUCT EMPLOYEES WITH THIS MANUAL ON THE PROPER USE OF PLUGS AND ALL RELATED EQUIPMENT The employer or contractor has a duty to provide all necessary training on equipment usage In addition the employer or contractor must provide all necessary safety equipment and training familiarize users with this manual and the purchased equipment and provide copies of this SAFETY INSTRUCTION MANUAL for use on the job C INSTRUCT EMPLOYEES AND WORKERS IN PROPER SAFETY PROCEDURES The employer or contractor has a duty to properly instruct and ensure compliance with safety procedures and all applicable OSHA Federal State and Local rules D INSTRUCT ALL EMPLOYEES AND WORKERS AS TO POSSIBLE HAZARDS The employer or contractor has a duty to instruct as to possible hazards that may be encountered on the job including the magnitude of the risk The employer or contractor must inform employees of the proper methods for safe use of all the equipment including Cherne products and working in the job environment E INSTRUCT ALL EMPLOYEES AND WORKERS REGARDING THE DANGERS OF ANY REASONABLY FORESEEABLE MISUSE OF THE PRODUCT The employer or contractor has a duty to provide such information as set forth in this manual as well as anything else the
52. iance on these recommendations IT IS THE PRODUCT USER S RESPONSIBILITY TO READ AND COMPLY WITH ALL APPLICABLE REGULATIONS Refer to Code Of Federal Regulations CFR Part 1926 and all other pertinent Federal State and Local regulations FAILURE COMPLY WITH ALL REQUIREMENTS MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR SUBSTANTIAL FINANCIAL PENALTIES 8 CLEAN PIPE BEFORE PLACING PNEUMATIC PLUG PROPERLY CLEAN THE PIPELINE BEFORE INSTALLING A PNEUMATIC PLUG Clean any debris or foreign substances which may reduce back pressure holding capability from the pipe before the plug is installed Such foreign substances may include grease mold algae sediment seashells coral sand and or any other material that prevents solid contact between the plug and the pipe wall Cleaning methods may include using a high pressure cleaner or by using a wire brush followed with a water flush Remove any sharp objects that may puncture plug upon inflation If any debris remains in the pipe it may cause the plug to seal improperly or cause damage to the plug upon inflation CLEAN PIPE BEFORE INSTALLING PLUG BRUSH AND WATER FLUSH MAY BE USED Z NWARNING FAILURE TO PROPERLY CLEAN PIPE MAY CAUSE PLUG DISLODGEMENT OR PLUG FAILURE WHICH MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 25 9 ATTACH INFLATION HOSE TO ENABLE PLUG INFLATION AND DEFLATION FROM OUTSIDE THE DANGER ZONE SELECT AN INFLATION HOSE AND OTHER AC
53. lation leak Protective inflator cap in place An orange warning tag attached to the plug Replacement tags are available at no charge upon request Call Cherne toll free at 1 800 843 7584 and ask for a Warning Tag A copy of this Safety Instruction Manual to accompany plug for user reference NOTE Call Cherne toll free at 1 800 843 7584 to request the most current revision of the Safety Instruction Manual Additional application information instructions and warnings are periodically added as Cherne becomes aware of such information Additional Manual copies are available from Cherne at no charge upon request Q Loose or damaged banding clamps r Eye bolts chain and ring or tether attachment in location s t 023 TD Inflator valve core in place properly tightened and leak free in the inflation fitting Presence of a properly calibrated inflation pressure gauge to accurately determine inflation pressure refer to Section 12 of this manual IF ANY EVIDENCE OF DAMAGE DETERIORATION MISSING COMPONENTS WARNING TAG MANUAL LOSS OR EXCESS WEAR IS OBSERVED CONSULT YOUR LOCAL CHERNE DEALER OR REPRESENTATIVE AND MAKE ARRANGEMENTS TO RETURN THE PRODUCT FOR INSPECTION OR DESTROY 20 THE PRODUCT cut puncture otherwise disable the discarded product to prevent any inadvertent use and subsequent failure AND REPLACE IT WITH A NEW PLUG OR RELATED PLUG EQUIPMENT BEFORE PROCEED
54. not limited to use of unauthorized parts or attachments or adjustment or repair performed by anyone other than manufacturer or one of manufacturer s authorized agents Any claim by buyer with reference to the goods sold hereunder shall be deemed waived by the buyer unless submitted in writing to manufacturer within the earlier of 1 thirty 30 days following the date buyer discovered or by reasonable inspection should have discovered any claimed breach of the foregoing warranty or 2 twenty five 25 months following the date of manufacture Any cause of action for breach of the foregoing warranty shall be brought within one year from the date the a eged breach was discovered or should have been discovered whichever comes first LIMITATION OF LIABILITY Manufacturer s liability whether under the theories of breach of contract or warranty negligence or strict liability for its goods shall be limited to repairing or replacing parts found by the manufacturer to be defective or at manufacturer s option to refunding the purchase price of such goods or parts thereof DISCLAIMER OF CONSEQUENTIAL DAMAGES In no event shall manufacturer be liable for consequential damages arising out of or in connection with this agreement including without limitation breach of any obligation imposed on manufacturer hereunder or in connection herewith Consequential damages for purposes hereof shall include without limitation including death to any pers
55. on or loss or damage to property including without limitation property handled or processed by the use of the goods Buyer shall indemnify manufacturer against all liability cost or expense which may be sustained by manufacturer on account of any such loss damage or injury 60 DEFECTIVE PRODUCTS POLICY obtain performance under this warranty any product suspected of having a manufacturing defect in materials or workmanship at manufacturers request must be returned to CHERNE INDUSTRIES INCORPORATED freight prepaid for inspection A returned goods authorization RGA must be obtained before shipping any product back to CHERNE Call 1 800 843 7584 and ask for customer service CUSTOMER TRANSPORTATION REIMBURSEMENT Whenever CHERNE repairs or replaces a product at CHERNE S expense CHERNE will reimburse the distributor by credit memo the same surface freight amount it cost CHERNE to return the warranty items The foregoing warranty is in lieu of all other warranties express or implied including those of merchantability or fitness for any purpose not expressly set forth herein No affirmation of manufacturer by words or action other than as set forth in this language shall constitute a warranty 61 CHERNE INDUSTRIES INCORPORATED 5700 LINCOLN DRIVE MINNEAPOLIS MINNESOTA 55436 1695 U S A Phone 1 800 THE PLUG 843 7584 Fax 1 800 843 7585 Form 103586E 3 07 Printed in U S A WC 62
56. orous pipe They also can be inflated and deflated from a remote location out of the Danger Zone and can be positioned in many areas that are not accessible to mechanical plug use Mechanical plugs have the advantage of not relying on inflation pressure to provide proper sealing and are a better choice for long term or permanent usage When the plugging application requires a minimum sealing length a narrow mechanical plug may be the only viable option as proper installation of a long pneumatic plug may not be possible Mechanical plugs generally have a much shorter sealing length requirement 17 CORRUGATED Pneumatic plugs may be used corrugated pipe However the plug will not fully fill the pipe corrugations resulting in reduced contact area Maximum allowable back pressure therefore must be reduced by 50 eg a plug normally rated for 30 feet of back pressure must be derated to 15 feet Minor media leakage may still result along the longitudinal pipe construction seams When a plug is used in spiral type corrugated pipe a section of corrugations must be filled with a material such as cement grout to prevent major leakage around the spirals PLUGS MAY NOT TOTALLY SEAL SOME TYPES OF PIPE When pipes have rough or very uneven surfaces such as brick lined pipe the plug may allow minor leakage of the restrained media Some concrete pipe is very porous and media may leak past the plug through the pipe itself The surface of t
57. quires a flexible plug to be bent to reach proper position temporary removal of the inflation valve core or inflation fitting will make the bending process easier The valve core inflation fitting and the fitting s protective cap must be properly replaced and be leak free using pipe sealant or teflon tape NOTE To prevent damage to or collapse of the bypass hose assembly of a flexible Muni Ball amp plug DO NOT bend the plug body in excess of 90 degrees or attempt to exceed the maximum allowable bend radius of the bypass hose REA NS FLEXIBLE PLUGS Exp INFLATOR MAY BE REMOVED TEMPORARILY TO AID BENDING FLEXIBLE PLUGS USE PIPE SEALANT OR TEFLON TAPE WHEN REPLACING 29 PLACEMENT OF PLUGS UNDER WATER When installation requires a plug to be submerged remove the inflation fitting and partially fill the plug with water to create neutral buoyancy Properly replace the inflation fitting using pipe sealant or teflon tape correctly position the plug in the pipe and then inflate the plug normally with air through an inflation extension hose THE INFLATOR CAN BE REMOVED TEMPORARILY TO FILL PLUG WITH WATER TO PROVIDE NEUTRAL BUOYANCY USE PIPE SEALANT OR TEFLON TAPE WHEN REPLACING INFLATOR FITTING PLACEMENT OF PLUGS UNDER WATER NEVER inflate a pneumatic plug over or near a sharp object or obstruction Puncture of the plug body and failure may result upon plug inflation and use
58. se of non calibrated gauges may result in a condition of over inflation or under inflation refer to following warnings NOTE Rough handling contamination or a sharp impact can quickly cause any pressure gauge to fall out of calibration Other pressure gauges eg some inexpensive tire type gauges are extremely inaccurate and should not be used The user must select and maintain properly calibrated pressure gauges for use with pneumatic plugs INFLATE PLUG TO RECOMMENDED PRESSURE Do not exceed this pressure Proper inflation pressure is clearly marked on each product outlined in this booklet and included in Cherne product catalogs and product specification sheets refer to following warnings INFLATE PLUGS USING A PROPER PRESSURE SOURCE A Cherne Test Pump equipped with a pressure gauge or a regulated air source with pressure gauge is required 33 CHECK THE INFLATION PRESSURE AT LEAST EVERY FOUR 4 HOURS A small volume of inflation air over time may will leak through the elastomeric rubber body of every pneumatic plug This lost air must be replaced or under inflation may result allowing the plug and any media restrained to dislodge from the pipe A regulated pressure source may be permanently attached to the plug s inflation inlet port as an alternative to periodically checking and adjusting the inflation pressure Consult with a registered professional engineer for the construction and maintenance of Such a pressure regulated infl
59. uni Ball amp plugs e Plugs with maximum bypass size for gravity flow bypass applications Big Mouth Flow Through plugs f Plugs for remote placement REMO plugs 9 Plugs large diameter capable of fitting through small diameter openings Urethane Test Ball amp and Muni Ball amp Plugs h Plugs for air testing sewer lines AIR LOC plugs NOTE Refer to Section 13 of this manual to determine what method will be used to remove back pressure before plug deflation Then select the necessary plug s and related equipment Many sizes of plugs are available in several product configurations optimized for specific applications Consult your catalog Cherne dealer or call Cherne toll free at 1 800 843 7584 for recommendations Z N WARNING NEVER ATTEMPT TO USE A PLUG PRODUCT IN A PIPE SMALLER OR LARGER THAN THE RECOMMENDED SEALING SIZE USAGE RANGE Media leakage product failure and or plug dislodgement may result PLUG FAILURE OR DISLODGEMENT MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE Z N CAUTION CHECK THE PRESSURE RATING OF THE PIPE TO BE SEALED The pipe s internal pressure rating must exceed the inflation pressure for the pneumatic plug selected for use A plug body may exert a force on the pipe wall nearly equal to the inflation pressure Damage to the pipe such as breakage may occur if the pipe has a lower pressure rating than the plug s inflation pressure Special caution should be used with brittl
60. ve tether attachment points of sufficient strength to allow attachment of an anchor cable that can withstand full rated back pressure Call Cherne toll free at 1 800 843 7584 for specific recommendations A HOSE AND SHUT OFF VALVE MAY BE ATTACHED TO THE BY PASS OF A MUNI BALL PLUG The valve is opened from outside the Danger Zone to release back pressure The back pressure may be released by gravity flow or the hose may be attached to the inlet of a water pump THE SUCTION HOSE OF A PUMP MAY BE INSERTED BEHIND A PLUG Some applications allow direct access to the restrained media Back pressure is relieved by activating the pump to remove the media THE BY PASS OF A MUNI BALL PLUG MAY BE TEMPORARILY BLOCKED USING A SMALL PNEUMATIC PLUG The small plu connected to an inflation extension hose is deflated from outside the Danger Zone to allow release of back pressure air or water through the Muni Ball bypass NOTE Damage to the small plug and extension hose ay occur as the plug is ejected from the bypass area Inspect the plug and hose carefully before attempting further use PLUGS PROPERLY BRACED MAY BE DEFLATED TO RELEASE BACK PRESSURE BRACING WATER MAY BE PUMPED FROM CONSULT A REGISTERED ENGINEER BEHIND PLUG TO RELEASE ON BRACING CONSTRUCTION BACK PRESSURE A SMALL PLUG CAN BLOCK A MUNI BALL PLUG BY PASS THE BY PASS ON MUNI BALLG PLUG MAY 2 Ta PLUG TO RELIEVE
61. will normally hold withstand nearly equal back pressure for water pressure hydrostatic pressure or air pressure pneumatic pressure owever extra caution must given when using a plug in an air pressure A pressure is more likely to cause pipeline plug to dislodge at Igh velocity EQUAL BACK PRESSURE MAY BE RESTRAINED FROM EITHER THE FRONT OR THE BACK OF THE PLUG VACUUM IS NEGATIVE PRESSURE A plug maximum allowable back pressure rating is independent of the direction the back pressure is applied This also includes pressure caused by a vacuum which is equivalent to a negative pressure in the direction of the vacuum Each 1 Hg Mercury of vacuum is approximately 0 5 PSIG of pressure If pressure exists on one side of the puq and vacuum on the other side the forces must be added to calculate otal back pressure vacuum may be created by pumping water from either side of the plug and not venting the evacuated area NEVER ENTER THE DANGER ZONE The approximate Danger Zone exists in front of the plugged pipe opening an area which expands outwardly in a cone shape The Danger Zone includes the entire area where a pipeline plug any portions fragments thereof and or any media back pressure restrained by the pipeline plug may be ejected from the pipeline should the plug rupture or dislodge for any reason Although the Danger Zone described applies to normal usag conditions the foreseeable Danger Zone increases
62. winwixey jeunuovN 84 55544 258 3IdEAOIIV unuixew 41 sn e IuM p 3eiq eq snu s6n d 9NINHVM WV 10 0 16 0 6 0 1 098 5 81 ez lt 01 10 0 1 6 0 6 0 gl LLE SZZL 841 10 0 L 6 0 6 0 L 092 SZ0L 0 S S Jeq 164 s1i y IW 1 43 15 s u3zul mss ld 5594 5594 Jeyoueig 8 1 1111 16 uoneyul pasinbay uunuutu W 84 55944 258 lqemolilV uunuiixeW abuey Besn 5215 74 SZ L 6 0 6 0 L v 1881 EZZ 9 0 74 sc ZL Ov ZL LLE lt 271 840 10 0 ZL Ov ZL ZL 092 5 01 841 4 0 SE 1 0 uU ZL 210 668 EEL S S SE ZL Ov ZL 1 6SL 5 9 96 SLE xS5nld elIed unMW 2215 eq 5 3994 1e 154 s ubul ww P 8711111116 Teyauleiq ed lqemolilV uinuuixelW sbuey 2215 05 008 81 21 00 002 21 8 052 061 01 9 05 006 81 21 00 002 21 8 052 000 01 8 002 061 8 9 051 001 9 s ubul zIS JUIWON 89 6 8 5 8 5 8 199 86059 8 059 89099
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