Petersen® Hot Tap Pipe Plug Insertion Systems

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Time and cost can be reduced considerably by using a Petersen® Hot Tap Pipe Plug Insertion System to stop the flow in a pressurized pipeline. There are basically two systems for plug insertion through a hot tap.  Contact us to discuss how this system may be adapted to your project.

Inflation controllers, gauges, hoses, etc. on our accessories page

For Hot Tapping Tools

Hot Tap Plugging Video Click Here

Hot Tap Plugging Slide Show Click Here

128-Series Hot Tap Plug Installation System Instruction Summary for Air & Water Inflation

129-Series Hot Tap Line Stop Plug Installation System Instruction Summary for Air & Water Side of Plug Inflation

129-Series Hot Tap Line Stop Plug Installation System Instruction Summary for Air inflation

 

The 128-Series Hot Tap Pipe Plug Insertion System uses the 128-Series Multi-Flex™ Plugs and requires and directs the plug down stream from the tap. The hot tap may also be used as a by-pass or for purging up stream of the plug. The top hole is smaller than for the 129-Series system, the head pressures that may be stopped somewhat lower, and the launch cylinder a little longer. General 128-Series system instructions are available to be adapted for your project.

For Detailed Drawing Click Here

 

hot tap plugging
 
The 129-Series Hot Tap Pipe Plug Insertion System uses the 129-Series Multi-Flex™ Plug and can be customized for higher pressures than the 128-Series system. This plug inserts a little easier since the plug is inflated just below the hot tap. The 129-Series system requires a larger tap hole, but can be inserted with a shorter launch cylinder. The 129-Series Plug may also be installed through a riser with an end inflation port when the plug is installed down stream of the riser. General 129-Series system instructions are available to be adapted for your project.
 
Compact Plug Diameter Allows Insertion Through Small Hot (Live) Tap

Launch cylinder with inflation ram and packing seal allows insertion of Petersen® Plugs into pressurized pipeline.
Typically used for plugging of pipelines through a hot tap in the side of the pipe or through a valve on the end of a pipe. A variety of Petersen® Multi-Flex™ plugs are available for most chemical, pressure, and temperature requirements. A 36" plug as an example may be installed through an 8" Tap with the pipeline pressurized.

Pipe Plug Insertion Plug Launch Cylinder AssemblySystem
The Launch Cylinder and Inflation Ram is used for positioning and inflating the plug. Configurations are available to allow removal of the Launch Cylinder and Inflation Ram after inflation.
Plug Launch CylinderPlug Launch Cylinder
The plug may be inserted into the Launch Cylinder before or after it is attached to a tapping valve.

Packing Gland
The packing gland provides a seal that allows the inflation ram to push the plug into position.
Inflation RamInflation Ram

The plug is pushed into position with the Inflation Ram after opening the valve and equalizing the pressure in the Launch Tube. An In-Line Swivel on the end of the Ram allows the plug to navigate the bend. Very large plugs may require a winch to pull the handle and plug into position.

Multi-FlexT Hot Tap Plugging Launch Cylinder Assembly

Hot Tap Plugging Video Click Here

Hot Tap Plugging Slide Show Click Here

 

Directional Shoe and Bow Stiffener Directional Shoe and Bow Stiffener
The Directional Shoe accessory on the plug helps guide the plug in the desired direction into the pipeline. There is also an internal Bow Stiffener to act as a spring bending the plug into the pipeline.

In-Line Swivels
The In-Line Swivel provides a flexible connection between the inflation ram and plug.

 

Hot Tap Pipe Plug Insertion Systems

Shpg

Wt

lbs

Item

Number

2" mnpt x 24" long launch cylinder with 1/2" dia x 36" long inflation ram with 2" fnpt packing seal
12
PET.939-8020-24
3" mnpt x 24" long  launch cylinder with 1/2" dia x 36" long inflation ram with 3" fnpt packing seal
21
PET.939-8030-24
4" x 150 lb flange x 36" long launch cylinder with 3/4" dia x 48" long inflation ram with 4" x 150 lb flange packing seal
89
PET.939-9040-36
6" x 150 lb flange x 48" long launch cylinder with 1 1/2" dia x 60" long inflation ram with 6" x 150 lb flange packing seal
185
PET.939-9060-48
8" x 150 lb flange x 60" long launch cylinder with 2" dia x 72" long inflation ram with 8" x 150 lb flange packing seal
334
PET.939-9080-60
12" x 150 lb flange x 72" long launch cylinder with 2 1/2" dia x 84" long inflation ram with 12" x 150 lb flange packing seal
609
PET.939-9120-72
System Includes: Launch cylinder, inflation packing gland (seal), inflation ram, centering guide, and drain/fill valve 
Other sizes and custom configurations also available
           
Launch Cylinders
   
2" mnpt x 24" long
8
PET.939-2020-24
3" mnpt x 24" long
16
PET.939-2030-24
4" x 150 lb flange x 36" long
66
PET.939-1040-36
6" x 150 lb flange x 48" long
128
PET.939-1060-48
8" x 150 lb flange x 60" long
227
PET.939-1080-60
12" x 150 lb flange x 72" long
404
PET.939-1120-72
           
Inflation Rams    
2" fnpt x 1/2" diameter x 36" long
4
PET.939-4020-0536
3" fnpt x 1/2" diameter x 36" long
5
PET.939-4030-0536
4" x 150 lb flange x 3/4" diameter x 48" long
23
PET.939-3040-0748
6" x 150 lb flange x 1 1/2" diameter x 60" long
57
PET.939-3060-1560
8" x 150 lb flange x 2" diameter x 72" long
107
PET.939-3080-2072
12" x 150 lb flange x 2 1/2" diameter x 84" long
205
PET.939-3120-2584
     
Swivels, In-Line
   
1.875" OD x 3/4" fnpt, steel
1
PET.936-8007-1
1.875" OD x 1 1/4" fnpt, steel
5
PET.936-8012-1
2.88" OD x 2" fnpt, steel
10
PET.936-8020-1
3.88" OD x 3" mnpt, steel
16
PET.936-8030-1
(Flange adaptors available)

 

**Inflatable Plug Warning: Maximum head pressures that a pipe plug may restrain can only be estimated. Slippage is influenced by many factors including fluid in the pipe, coefficient of pipeline friction, pressure required to inflate the plug, and accuracy of pressure gauges. Generally, a Multi-Flex™ Inflatable Plug inserted fully into pipeline will begin slipping between 50% and 80% of the inflation pressure if it has an inflated pipe contact length of 1 ½ to 2 times the diameter, but even a head of 50% of the inflation pressure may cause slippage with some liquids. The inflation pressure is also subject to temperature change and debris or protrusions in the pipeline that could rupture the plug. The inflation pressure should be monitored and plugs anchored and/or mechanically blocked when slippage may cause property damage or injury.  NEVER use a test pressure greater than the capacity of the weakest pipe or component in the system. NEVER use an inflatable plug when its failure would cause injury.Price subject to change without notice Petersen Terms & Conditions Apply Products covered by one or more of the following patents: 4,565,222; 5,353,842; 5,901,752; 6,446,669; 6,568,429; 6,899,138 and other applications pending.

 

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