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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 Petersen to discuss how this system may be adapted to your project.

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

For Completion Plugs click here

For Hot Tapping Tools click here

For Hydraulic Heavy Duty Tapper click here

For Hot Tap Sleeves click here

Hot Tap Plugging Video click here

Hot Tap Plugging Slide Show click here

Petersen Inflatable Pipe Plugs Generic Operating Instruction Manual

128-Series Multi-Flex™ Plug Hot Tap Installation Instructions

129-Series Multi-Flex™ Line Stop Plug Hot Tap Installation Instructions

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 tap 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 (gland) 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 SystemPlug Launch Cylinder Assembly
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.

Launch CylinderPlug Launch Cylinder
The plug may be inserted into the Launch Cylinder before or after it is attached to a tapping valve.

Packing Seal (Gland)
The packing seal (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 Cylinder. A rotating elbow 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.

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.

Rotating Elbow
The Rotating Elbow provides a flexible connection between the inflation ram and plug.

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128-Series Hot Tap Pipe Plug Insertion Systems

Maximum Plug Diameter in

LAUNCH CYLINDERS

INFLATION RAMS

INSERTION SYSTEMS

(Includes Launch Cylinder

& Inflation Ram)

Diameter in Length in Approx Shpg Wt lbs

Item Number

 Unit Price Each Length in Approx Shpg Wt lbs

Item Number

 Unit Price Each Approx Shpg Wt lbs

Item Number

 Unit Price Each
2-3 2 npt 24 8 939-2020-24 US $84.00 48 16 939-4020-0748 US $1,080.00 24 939-8020-24 US $1,164.00
4 3 npt 36 23 939-2030-36 US $130.00 60 20 939-4030-0760 US $1,218.00 43 939-8030-36 US $1,358.00
6

4 npt

 36 32 939-2040-36 US $228.00 72 68 939-4040-1972 US $1,420.00 100 939-8040-36 US $1,648.00
8 4 npt 48 43 939-2040-48 US $303.00 84 74 939-4040-1984 US $1,620.00 117 939-8040-48 US $1,923.00
10 6 flanged 60 126 939-1060-60 US $600.00 96 114 939-3060-1996 US $1,780.00 240 939-9060-60 US $2,380.00
12 6 flanged 72 145 939-1060-72 US $720.00 108 207 939-3060-25108 US $1,830.00 352 939-9060-72 US $2,550.00
15-18 6 flanged 84 164 939-1060-84 US $780.00 120 218 939-3060-25120 US $1,940.00 382 939-9060-84 US $2,720.00
20 6 flanged 96 183 939-1060-96 US $820.00 132 Call 939-3060-40132 US $2,070.00 Call 939-9060-96 US $2,890.00
24 6 flanged 108 202 939-1060-108 US $925.00 144 Call 939-3060-40144 US $2,095.00 Call 939-9060-108 US $3,020.00
30

7 flanged

 120 395 939-1080-120 US $1,030.00 168 Call 939-3080-40168 US $2,250.00 Call 939-9080-120 US $3,280.00
33 7 flanged 132 423 939-1080-132 US $1,132.00 180 Call 939-3080-50180 US $2,278.00 Call 939-9080-132 US $3,410.00
36 8 flanged 144 452 939-1080-144 US $1,262.00 192 Call 939-3080-50192 US $2,448.00 Call 939-9080-144 US $3,710.00
42 8 flanged 168 509 939-1080-168 US $1,350.00 216 Call 939-3080-60216 US $2,620.00 Call 939-9080-168 US $3,970.00
48

10 flanged

 192 888 939-1100-192 US $1,551.00 252 Call 939-3100-60252 US $3,009.00 Call 939-9100-192 US $4,560.00
54 10 flanged 204 929 939-1100-204 US $1,595.00 264 Call 939-3100-60264 US $3,095.00 Call 939-9100-204 US $4,690.00
60 10 flanged 228 1010 939-1100-228 US $1,683.00 288 Call 939-3100-60288 US $3,267.00 Call 939-9100-228 US $4,950.00
66 10 flanged 240 1050 939-1100-240 US $1,772.00 312 Call 939-3100-70312 US $3,438.00 Call 939-9100-240 US $5,210.00
72 12 flanged 264 1671 939-1120-264 US $1,949.00 336 Call 939-3120-70336 US $3,782.00 Call 939-9120-264 US $5,731.00
84 12 flanged 300 1832 939-1120-300 US $2,082.00 372 Call 939-3120-70372 US $4,039.00 Call 939-9120-300 US $6,121.00
96 12 flanged 336 1992 939-1120-336 US $2,257.00 420 Call 939-3120-80420 US $4,384.00 Call 939-9120-336 US $6,641.00
The above lengths are calculated with estimated valve heights and may be adjusted for a specific job requirement.
150 lb. Flanges are standard but the system may be customized for a specific job requirement.
The above pricing does not include the Rotating Elbow.

129-Series Hot Tap Pipe Plug Insertion Systems

Maximum Plug Diameter in

LAUNCH CYLINDERS

INFLATION RAMS

INSERTION SYSTEMS

(Includes Launch Cylinder

& Inflation Ram)

Diameter in Length in Approx Shpg Wt lbs

Item Number

 Unit Price Each Length in Approx Shpg Wt lbs

Item Number

 Unit Price Each Approx Shpg Wt lbs

Item Number

 Unit Price Each
2 2 npt 12 4 939-2020-12 US $72.00 36 14 939-4020-0736 US $1,020.00 20 939-8020-12 US $1,092.00
3 3 npt 12 8 939-2030-12 US $74.00 36 15 939-4030-0736 US $1,120.00 23 939-8030-12 US $1,194.00
4 4 npt 12 11 939-2040-12 US $76.00 36 33 939-4040-1036 US $2,880.00 44 939-8040-12 US $1,309.00
6 4 npt 24 22 939-2040-24 US $152.00 48 34 939-4040-1048 US $1,170.00 56 939-8040-24 US $1,510.00
8-10 6 flanged 24 70 939-1060-24 US $240.00 60 67 939-3060-1060 US $1,330.00 137 939-9060-24 US $1,570.00
12-15 8 flanged 36 137 939-1080-36 US $516.00 72 152 939-3080-1972 US $1,485.00 289 939-9080-36 US $2,001.00
16-20 10 flanged 36 192 939-1100-36 US $619.00 72 204 939-3100-1972 US $1,575.00 396 939-9100-36 US $2,194.00
24 12 flanged 48 360 939-1120-48 US $1,108.00 84 325 939-3120-2584 US $2,056.00 635 939-9120-48 US $3,164.00
30 12 flanged 60 360 939-1120-60 US $1,200.00 96 325 939-3120-2596 US $2,099.00 685 939-9120-60 US $3,299.00
33-36 12 flanged 72 410 939-1120-72 US $1,440.00 108 338 939-3120-25108 US $2,361.00 748 939-9120-72 US $3,801.00
42 16 flanged 84 855 939-1160-84 US $2,100.00 120 459 939-3160-25120 US $2,938.00 1314 939-9160-84 US $5,038.00
48 16 flanged 96 918 939-1160-96 US $2,400.00 132 469 939-3160-25132 US $3,232.00 1387 939-9160-96 US $5,632.00
54 16 flanged 108 980 939-1160-108 US $2,700.00 156 488 939-3160-25156 US $3,819.00 1468 939-9160-108 US $6,519.00
60-66 18 flanged 120 1166 939-1180-120 US $3,360.00 168 581 939-3180-25168 US $4,607.00 1767 939-9180-120 US $7,967.00
72 24 flanged 132 1869 939-1240-132 US $4,620.00 180 1026 939-3240-25180 US $5,528.00 2895 939-9240-132 US $10,148.00
84 24 flanged 144 1964 939-1240-144 US $5,040.00 192 1036 939-3240-25192 US $5,265.00 3000 939-9240-144 US $10,305.00
96 36 flanged 168 4728 939-1360-168 US $6,035.00 216 1867 939-3360-25216 US $6,929.00 6595 939-9360-168 US $12,964.00
The above lengths are calculated with estimated valve heights, pipe IDs, and ODs and may be adjusted for a specific job requirement.
150 lb. Flanges are standard but the system may be customized for a specific job requirement.
The above pricing does not include the Rotating Elbow.
System Includes: Launch cylinder, inflation packing seal (gland), inflation ram, centering guide, and drain/fill valve.
Other sizes and custom configurations also available.

Rotating Elbows
Description Shpg Wt lbs

Item Number

 Unit Price Each
1.875" OD x 3/4" fnpt, steel
1
US $240.00
1.875" OD x 1 1/4" fnpt, steel
5
US $280.00
2.88" OD x 2" fnpt, steel
10
US $320.00
3.88" OD x 3" mnpt, steel
16
US $580.00
(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.