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STOPPLE® II Plugging

System
3101C Isolation Introduction

STOPPLE® II Plugging Systems

Table of Contents
Overview .................................................................................................................................................................... 6
Simplified Agenda ................................................................................................................................................. 6
Learning Objectives .............................................................................................................................................. 6
Source Material .................................................................................................................................................... 7
Glossary of Terms ................................................................................................................................................. 7
Safety ..................................................................................................................................................................... 8
STOPPLE II Plugging System Overview..................................................................................................................... 9
Section Learning Objectives ................................................................................................................................. 9
Applications ........................................................................................................................................................... 9
STOPPLE Equipment Considerations ................................................................................................................... 9
Geometry & Forces ........................................................................................................................................... 9
Avoid Negative Pressure Differential ............................................................................................................ 10
Kinematics...................................................................................................................................................... 10
Video: “Hot Tapping and Plugging Transmission Lines” ................................................................................. 11
Video Activity .................................................................................................................................................. 11
Major Components............................................................................................................................................. 12
Sub Components................................................................................................................................................ 13
Hydraulic Cylinder (Actuator) ......................................................................................................................... 13
Housing ........................................................................................................................................................... 14
Plugging Head ................................................................................................................................................ 15
Nose Piece Padding ....................................................................................................................................... 17
Activity: Bad Examples of Nose Pads ............................................................................................................ 18
Specifications ..................................................................................................................................................... 19
STOPPLE Plugging Machine ......................................................................................................................... 19
Jackscrew Actuator ........................................................................................................................................ 20
Hydraulic Cylinder .......................................................................................................................................... 21
Plugging Head MAOP ..................................................................................................................................... 22
Plugging Head Retraction Rates ................................................................................................................... 23
Flow Rates ...................................................................................................................................................... 23
Flow Calculations ........................................................................................................................................... 23
Flow Rate Activity ........................................................................................................................................... 24
STOPPLE IIB vs. STOPPLE IIC............................................................................................................................. 25
Learning Checkpoint .......................................................................................................................................... 25
Section Summary ............................................................................................................................................... 25
STOPPLE II Plugging System Other Related Equipment & Accessories .............................................................. 26

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STOPPLE® II Plugging Systems

Section Learning Objectives .............................................................................................................................. 26
Other Related Equipment .................................................................................................................................. 26
Tapping Machines .......................................................................................................................................... 26
STOPPLE® Fittings ......................................................................................................................................... 26
SANDWICH® Valves ....................................................................................................................................... 28
Power Unit ...................................................................................................................................................... 28
STOPPLE® Cutters ......................................................................................................................................... 29
LOCK-O-RING® Plugging Technology ............................................................................................................ 29
Accessories......................................................................................................................................................... 29
Learning Checkpoint .......................................................................................................................................... 30
Section Summary ............................................................................................................................................... 30
AOCs Review ....................................................................................................................................................... 31
STOPPLE II Plugging System Pre/Post Job Equipment Servicing........................................................................ 32
Section Learning Objectives .............................................................................................................................. 32
Field Maintenance & Handling .......................................................................................................................... 32
Hydraulic Cylinder (Actuator) Maintenance ...................................................................................................... 32
Plugging Head Maintenance ............................................................................................................................. 33
Housing Maintenance ........................................................................................................................................ 34
Sealing Element Maintenance ...................................................................................................................... 34
Section Summary ............................................................................................................................................... 34
Learning Checkpoint .......................................................................................................................................... 35
Workshop Activity ............................................................................................................................................... 36
STOPPLE II Plugging System Setup ....................................................................................................................... 37
Section Learning Objectives .............................................................................................................................. 37
Tap the Line/Other Preparations ...................................................................................................................... 37
Prepare Plugging Machine ................................................................................................................................ 37
Take Measurement “D” ..................................................................................................................................... 38
Prepare Plugging Head ...................................................................................................................................... 38
Install the Sealing Element ............................................................................................................................... 39
Take Clearance Adjustment (Clearance B) Measurement ............................................................................. 39
Take Other Measurements .............................................................................................................................. 40
4”-6” Jackscrew Actuator Setup ....................................................................................................................... 41
Section Summary ............................................................................................................................................... 41
Learning Checkpoint .......................................................................................................................................... 42
AOCs Review ....................................................................................................................................................... 43
STOPPLE II Plugging System Operations .............................................................................................................. 44

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Revised MKP 04.07.2017 05_STOPPLE II_PG.docx

................................................................................................................ 50 Double Position Isolation ................................. 56 Frequently Asked Questions ........................................................................................................................................................... 55 Course Summary ...................................................................... 48 Section Summary ................................................. Do not distribute outside of TDW...................................................................................................................................................................................... 44 Install Plugging Equipment ......................................... 45 Verify Seal Integrity ........... 45 Set the Plugging Head ................................................................................................................................................................................................ 51 Double Position Isolation with Bypass Through 3-WAY™ Spool .............................................................. 52 Tandem Isolation Application ........................ 49 STOPPLE II Plugging Application Variations..................................................07................................................................................................................................................... 45 Perform Sweep Action...................................................................................................................................................................................................................................................................................................... 54 Section Summary .................................................................... 57 Control Bar Stalls ............................................................... 50 Section Learning Objectives ..................................................................................................................................................................................docx ............................................................... 57 Troubleshooting ............................. 44 Operations Summary ............................................................................................................. 46 Remove Plugging Equipment ..................................................................................................................... Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.......................................................................................................................................................................2017 05_STOPPLE II_PG......................................................................................................................................................................................................................................................................................................... Page 4 of 60 Revised MKP 04...................................................................................................................................................................................................................... 50 Single Position Isolation ....................... 53 Learning Checkpoint ........................................................... 58 Measurement Cards ..................... 56 Appendix ................................................................................................................................... 56 Document Control ............................................................................................................................................................................................................. 54 Workshop Activity ......................................................................................................................................................................................................................... 48 AOCs Review ......D................................................................................................................ 50 Various STOPPLE II Plugging Application Operations ...................... 48 Workshop Activity ............................................................................................................................................................................................................... 57 Nose Piece NCR ................................................................................................................................................................................................................................................... 46 Set Completion Plugs ..... 57 FPR Activity ...............................................................................................................STOPPLE® II Plugging Systems Section Learning Objectives ....................................................... 50 Applications Summary .............................. 52 Double-Double Isolation Application .......................... 58 T.................................. 51 Double Position Isolation with Separate Bypass...........................................................................

Do not distribute outside of TDW.STOPPLE® II Plugging Systems The following course was created by the HT&P Global Training Group.2017 05_STOPPLE II_PG. Contact the Global Central Services Group (GCSG) if you need a clarification or have any questions.docx . T. If you have any questions. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.D. Page 5 of 60 Revised MKP 04. please contact your local training team for assistance. Disclaimer •In the event of a conflict between this Participant Guide and any source materials. the most recent version of the published materials available on InfoWorld will control.07.

etc. the STOPPLE II b & c Plugging Systems will be covered.2017 05_STOPPLE II_PG..docx .D. Page 6 of 60 Revised MKP 04. The STOPPLE II Plugging System is designed to temporarily block flow in a pipeline by insertion of a STOPPLE IIb Plugging Head through a tapped hole into the line.STOPPLE® II Plugging Systems Overview Isolation equipment typically involves the STOPPLE® or SHORTSTOPP® Plugging Systems. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. relocation. In this participant guide. annually or as needed  Describe setup procedures for STOPPLE IIb/c Plugging Systems  Perform setup procedures for STOPPLE IIb/c Plugging Systems  Describe operational procedures for STOPPLE IIb/c Plugging Systems  Perform operational procedures for STOPPLE IIb/c Plugging Systems T. additions.07. without interruptions of service by using STOPPLE IIb equipment. A section of line can be isolated for repairs. the learner will be able to:  Describe the various applications of STOPPLE IIb/c Plugging Systems  Compare. •TDW introduced the STOPPLE plugging system in the early 1950s and today it remains the most reliable and widely-used method of isolating a section of pipeline. Do not distribute outside of TDW. contrast and recall specifications of STOPPLE IIb/c Plugging Systems  Identify major components of STOPPLE IIb/c Plugging Systems  Identify and compare various related equipment and accessories  Identify which maintenance items should be done after each job. Did You Know? Simplified Agenda •STOPPLE II Plugging System Overview •STOPPLE II Plugging System Other Related Equipment & Accessories •STOPPLE II Plugging System Pre/Post Job Equipment Servicing •STOPPLE II Plugging System Setup •STOPPLE II Plugging System Operations Learning Objectives Upon completing this course.

0 Standard Stopple II Dimensions and Retraction Rates o Section 12. HTP Services → HTP Tech Manual → o Section 06 0 Double STOPPLE Plugging Machine Application with Bypass o Section 08.0 Stopple II Plugging Head Specifications o Section 31 0 Torque and Torque Sequence o BULLETINS:  InfoWorld → Marketing Collateral → Hot-Tapping-and-Plugging → Plugging Bulletins → o STOPPLE Plugging Machine Glossary of Terms Term Definition A. 4–36in (ENGLISH) (00-3795-0326) o STOPPLE IIc → STOPPLE IIC Plugging Head (00-3795-0240) HTP TECH MANUAL:  InfoWorld → Quality Management System (Icon) → Level III Services → 5.0 Maximum Flow Rates for HTP Applications o Section 11.2017 05_STOPPLE II_PG.O. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.C. Page 7 of 60 Revised MKP 04. Do not distribute outside of TDW.docx .0 Stopple II Components and Data o Section 10. Abnormal Operating Conditions CFM Cubic Feet per Minute CSG Central Services Group HT&P Hot Tapping and Plugging JIS Job Information Sheet MAOP Maximum Allowable Operating Pressure MOP Maximum Operating Pressure NS/S Non Size on Size PSI Pressure per Square Inch S/S Size on Size SE Sealing Element SS275 SHORTSTOPP 275 SS500 SHORTSTOPP 500 STP STOPPLE STV SANDWICH Tapping Valve T.STOPPLE® II Plugging Systems Source Material PRODUCT MANUALS:  InfoWorld → Product Manuals → STOPPLE → o STOPPLE Large Diameter Applications (00-3795-0127) o STOPPLE IIb → to 36 in → STOPPLE IIB Plugging Head.D.07.0 Equipment Specifications o Section 09.

caught in moving parts. safety manual is to call the operator’s attention to possible glasses.07. safety shoes and hard hat are MANDATORY danger of injury to personnel and/or damage to whenever working around machinery.docx . Always know which commodity you are working in and how to best protect yourself and those around you.2017 05_STOPPLE II_PG. Refer to Appendix III Hot Tapping and STOPPLE Plugging Operations in Specific Commodities Notes: T. injury to personnel or injury to personnel or major damage to minor damage to equipment equipment Sometimes Always Required Required TDW Safety Safety Toe Ear Gas Monitor/ Breathing Gloves Hard Hat Coveralls Glasses Shoes Protection Detector Apparatus Take 5 for Safety Always take a few minutes to ensure that all work activities are given a final check to identify potential hazards and mitigate them prior to starting your task. gloves.D. Do not wear equipment. Do not distribute outside of TDW. Page 8 of 60 Revised MKP 04. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Commodity Safety Certain commodities require extra safety precautions. and deserve attention and loose clothing. jewelry or other clothing that can get understanding.STOPPLE® II Plugging Systems Safety Warnings and Cautions Protective Clothing The purpose of Warnings and Cautions in this Proper PPE such as FR coverall. A 4 gas Warnings Cautions monitor/detector is required when working in toxic atmosphere and May result in major May result in minor breathing apparatus if necessary.

it is sometimes necessary to isolate a section of pipe without interrupting the service to a customer. STOPPLE Plugging Equipment has been developed by T. the learner will be able to:  List various applications of the STOPPLE II Plugging System  Recall specifications related to the STOPPLE II Plugging System  Describe flow limitations  List major components and describe their respective uses Applications Equipment in the STOPPLE II Plugging System will perform a few basic operations: Repair of plant piping without interruption of flow 1 Temporarily stops flow in a pipeline 2 Lateral tie-ins 3 • Valve replacement • Line repair • Line relocation • Unit turn around STOPPLE Equipment Considerations Geometry & Forces This is the equation to calculate for forces to set a STOPPLE® plugging head..D. Section Learning Objectives Upon completing this section.07.2017 05_STOPPLE II_PG. T. The same necessity may also arise in a refinery or a petrochemical plant where it is desirable to avoid the shutdown of an entire unit.D. whether that customer is a large user such as a steel mill or a private homeowner. Inc. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Do not distribute outside of TDW.docx . Page 9 of 60 Revised MKP 04.STOPPLE® II Plugging Systems STOPPLE II Plugging System Overview In the pipeline industry. Williamson. to safely meet these requirements.

1 Reduce pumping rates if possible. 2 Use as large a bypass as possible. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.07. Page 10 of 60 Revised MKP 04. lower slowly into line to facilitate equalization process. Kinematics Kinematics refers to how the equipment moves. it is important to avoid a negative pressure differential. Operational decision with many factors involved. STOPPLE Large Diameter Applications Positive Differential P-2 is greater than P-1 Negative Differential P-1 is greater than P-2 When working with plugging heads. It is important to understand what exactly is happening during plugging and isolation. 3 Use large equalization line.D.STOPPLE® II Plugging Systems Avoid Negative Pressure Differential Refer to Product Manual 00-3795-0127. The photos and subsequent video will demonstrate how the plugging head pivots/moves once in the pipeline. Do not distribute outside of TDW.docx . 5 •Observe pressure gauges. 4 Install pressure gauges on equalization line and STOPPLE housing When setting downstream plugging head.2017 05_STOPPLE II_PG. A plugging head being lowered into the line Notes: T.

“Hot Tapping and Plugging for HPI” and point out the incorrect procedure.docx .07.D. What should have been done differently? T.STOPPLE® II Plugging Systems Video: “Hot Tapping and Plugging Transmission Lines” Notes: Video Activity Now. Do not distribute outside of TDW. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Page 11 of 60 Revised MKP 04.2017 05_STOPPLE II_PG. watch this video.

Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. a plugging head housing and a plugging head. Housing  Connects the cylinder to the valve. 2.D.  Has connections for bleeder valve and Equalization line.docx . Component Description Photo  Actuator to extend or retract the plugging heads 1. It is available for pipe sizes 4” (DN 100) and larger.  Houses the plugging heads when they are fully retracted so the set up can be pressurized. Page 12 of 60 Revised MKP 04. then pivots into 3. Notes: T.  Lowered through tapped hole.STOPPLE® II Plugging Systems Major Components The STOPPLE Plugging Machine consists of three major sections: a hydraulic cylinder or jackscrew. Its maximum operating temperature is 180°F (82°C). Head  Takes the place of a block valve in that it completely stops flow.07. Hydraulic in the pipe.2017 05_STOPPLE II_PG. Plugging line. Cylinder  Has increments on the control bar. Do not distribute outside of TDW.

•6-12" •14-20" Sizes for STOPPLE II •22-34" •36-48" Component Description Notes Photo  Exterior casing A. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Control Valve control bar by using hydraulic power unit  Near bottom of cylinder  Locks plugging head in place  May be one. T.2017 05_STOPPLE II_PG.docx .07. Control Bar  Connects to plugging head  Controls plugging head  Used to extend/retract C. Page 13 of 60 Revised MKP 04. Bar Lock extending or retracting control Clamp bar  Retighten after plugging head is set in line. Do not distribute outside of TDW. two or three bar lock clamps depending on size of cylinder  Turn clockwise with Allen wrench to torque to appropriate value per Section 31 0 Torque and Torque Sequence. counterclockwise to loosen  Always loosen clamp before D. There is also a jackscrew cylinder option (see accessories section in next section).D.STOPPLE® II Plugging Systems Sub Components Hydraulic Cylinder (Actuator) Each size of hydraulic cylinder operates the same manner. Cylinder  Houses control bar  Linear movement B.

4. Actuator should connect to housing Component Description Notes Photo  Near top of housing A. Choose the housing based on the SANDWICH® valve ANSI Class rating. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. It has O-ring seal (not a groove) 2. Adapter T-203 Adapter Housing T. Typically. Housing vs. 300 and 600#. This helps in retracting the sealing element without damaging it. This is not always the case. 2. Equalization pressure Fitting across plugging head when retracting/exte nding. housings are longer than adapters. Page 14 of 60 Revised MKP 04. Housings have an O-ring groove at the top 3. Do not distribute outside of TDW. Adapters have an RTJ groove at the top  Exception: The T-203 Tapping Machine does NOT have an RTJ groove.docx . 3. Housings typically come in ANSI classes of 150. Bleeder  Used to purge Valve air and bleed Connection off pressure before removing machine  Near bottom of housing  Used to equalize B.STOPPLE® II Plugging Systems Housing 1.2017 05_STOPPLE II_PG.07.D. In most cases. the entrance of housings may also be machined at an angle. Adapter What is the difference between a housing and an adapter? 1.

it’s located in the taped hole and gives the head support when depressurizing. Do not distribute outside of TDW. F.2017 05_STOPPLE II_PG. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.  From top of nose pad to center of nose piece should be half of Pipe ID T.D.  Connected to D. Force is transferred to the pipe.STOPPLE® II Plugging Systems Plugging Head NOTE: The LOAD RING is located on the top on the control bar head. When the plugging head is set. Connection  Attaches plugging Bolts head to control bar  Helps and guides the plugging head 1480 Plugging Head G. Yoke  seals sealing element to face of yoke. Guide Wheel move in correct direction when entering pipe  Only with new generation 1480 psi plugging heads H.  Attaches sealing element to plugging head C. Yoke Pin  Makes whole plugging head pivot into pipe  Holds pressure B. Rings  Matched with nose pads  Pipe ID sensitive  Loads against top inside wall of pipe when isolated section is I. Nose Piece  keeps sealing element centered in pipe while in set position.07.docx . Nose pads depressurized. (see page 9) Component Description Notes Photo  Connection between control bar head and yoke A. Sealing Element from line to isolated part. Page 15 of 60 Revised MKP 04. Control Bar Head control bar of cylinder  Used as pivot point E.

3 Red Dot Nitrile (Buna N)  A STOPPLE sealing element is a fabric reinforced compound Yellow Dot Viton designed specifically for the STOPPLE Plugging System applications.g. Component Description Notes Photo A.188" or thinner: On 4" & 6" . Does Green Neoprene Dot not apply to fluorowhite.STOPPLE® II Plugging Systems Sealing Element Refer to Product Manual.docx . Page 16 of 60 Revised MKP 04.pipe ID + 1/8".07. STOPPLE IIB Plugging Head. Do not distribute outside of TDW. White (Whole) Fluorowhite (formerly Fluorogreen)  For pipe wall . 18” Pipe. Paragraph 4. Trailing  Flexible to seal against inside of Edge pipe  Fabric reinforced  Rigid for support against line B.D. A damaged sealing element can result in fluid leaks during plugging operations. 0. Element is damaged when withdrawn through tapped hole.375” W. 4–36in (ENGLISH). Section I.313  Seals bolt holes on plugging head C.T 17. Leading pressure Edge  Sized to pipe ID + 1/16”/-0 for max pressure retention (e.  There are a few different materials used to make STOPPLE White Dot EPDM sealing elements.  For some jobs. Notes: T.2017 05_STOPPLE II_PG. On 8".10" & 12" - Sealing Element leading edge -pipe ID +1/4" & grind 15- 20 deg. Sealing as compressed against face of Ring yoke WARNING: Use sealing element one time only and discard after each plugging operation.Sealing Element leading edge . at 3 & 9 O’clock to within 1/8" of where fabric stops. super-neoprene Blue Dot Super-neoprene Fluorowhite Sealing Element and fluorowhite may be used with CSG approval. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.

STOPPLE® II Plugging Systems

Nose Piece Padding

NOTE: Contact CSG prior to any modifications.

 The top surface of nose pad must be built up to keep nose, sealing element and yoke centered in line.
 If there is a weld seam in the area of the load pad, must contact CSG.
Best Method Second Best Method Third Best Method

 Form an adequately thick piece of bar or
 Build up nose pad with weld over
plate to nose pad and weld it in place on
entire surface, then grind smooth nose pad.
to desired pipe radius
 Plate should cover at least 80% of existing
 Nose pad made with  Difficult to do in field when nose pad
radius matched to considering precision needed.
 Leading edge should have continuous fillet
Pipe ID  Best done in shop with MIG or TIG weld equal to thickness of added pad.
 Std. plugging heads, welding with lathe to turn nose
 Toe of weld should reach leading edge of
4”-12” have two or pad to size
original pad.
more nose pieces to  Leading edge should be rounded
 All corners should:
keep variation of to prevent snagging
plugging head  Be rounded with radii equal to two times
centerline within thickness.
0.0625” of pipe  Have continuous fillet weld that extends a
centerline. distance of 2 radii along each adjoining edge.
 Many times not  Remaining edges may be welded with fillet
feasible welds distributed to cover at least 50% of
remaining length edges.
 Leading edge (and associated welds),
corners and trailing edge welds should be
Welded Nose Pad Machined After smoothed and/or rounded.
Welding

Refer to Product Manual -0112, STOPPLE IIB Plugging Machines, Section I, Paragraph 2.1 or page 21 of this
Participant Guide for working pressures.

Good Examples of Nose Pads

Plugging head modified for Extreme example of modifying Note length of pad in Note rounded edges, etc.
thin wall application. Note plugging heads. Note additional axial direction, full fillet
corner of pad has been reactions rings over standard welds and how edge of
deformed. Probably caught reaction rings. pad has been ground.
during insertion.

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Revised MKP 04.07.2017 05_STOPPLE II_PG.docx

STOPPLE® II Plugging Systems

Activity: Bad Examples of Nose Pads

Each of these photos below depict a bad example of nose padding. Answer the questions after each
photo.
1. After contacting CSG, which steps still need
to be done to complete this nose piece
modification?

Nose pad built up with weld (second best method).

2. The welds on these nose pads are not
smooth. What may happen if this is not
corrected?

3. Fill in the blank: Modifications should have
added pad to cover ____% of the existing
pad. Why?

4. What will a moderate amount of pressure do
this pad? Why is it a problem?

T.D. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Do not distribute outside of TDW. Page 18 of 60
Revised MKP 04.07.2017 05_STOPPLE II_PG.docx

STOPPLE® II Plugging Systems

Specifications
Refer to Product Manual, STOPPLE IIB Plugging Head, 4–36in (ENGLISH), Section I, Paragraph 2.0 & 3.0

STOPPLE Plugging Machine

Refer to HTP Tech Manual, Section 08.0 Equipment Specifications

Notes:

T.D. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Do not distribute outside of TDW. Page 19 of 60
Revised MKP 04.07.2017 05_STOPPLE II_PG.docx

D.STOPPLE® II Plugging Systems Refer to HTP Tech Manual.0 Stopple II Components and Data. 62 bar Maximum Operating Temperature •180°F.2017 05_STOPPLE II_PG.2 STOPPLE II Data Jackscrew Actuator Maximum Operating Pressure •900 psi. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.07. Page 20 of 60 Revised MKP 04. Section 09. 9. 82°C Notes: T.docx . Do not distribute outside of TDW.

STOPPLE® II Plugging Systems Hydraulic Cylinder Maximum Operating Pressure •1480 psi. Do not distribute outside of TDW.07. Page 21 of 60 Revised MKP 04.D.2017 05_STOPPLE II_PG.docx . 82°C Notes: T. 102 bar Maximum Operating Temperature •180°F. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.

docx . 700 psi to 900 psi). to pipe I. gap back to standard. Maximum Working Pressure WARNING: Pressures shown in this table represent maximum possible working pressure for standard plugging heads Manufactured at TMP. The two nose pieces cover the pipeline ID range at the maximum working pressure.0 Stopple II Components and Data.e. Section 09. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.3 STOPPLE IIb Plugging Head. one for standard wall. NOTE 2: TDW is now offering two nose pieces. NOTE 1: For special applications where this working pressure must be increased to standard (I. Notes: T. the addition of a special aluminum backup plate can be used to bring the nose O. Paragraph 9. Do not distribute outside of TDW. Page 22 of 60 Revised MKP 04.07.D. This procedure applies also to thinner wall pipe. and one for thin wall for most sizes.D.STOPPLE® II Plugging Systems Plugging Head MAOP Refer to HTP Tech Manual.2017 05_STOPPLE II_PG. For new applications the Central Services Group (CSG) should be consulted.D. NOTE 3: 1/8” longer nose bolts should be used when using aluminum backup plate.

0 Maximum Flow Rates for HTP Applications. Do not distribute outside of TDW. please review HTP Tech Manual. Notes: T. Section 14. Should not be exceeded without review and approval by Technical Services Approval may require additional procedural steps Flow Calculations For this section.docx . 1.0 Flow Through Pipelines and Forces in its entirety and return to the participant guide to complete the exercises on the next page. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.D. Flow rates were determined based upon past experience in the field using TDW equipment 2. Page 23 of 60 Revised MKP 04.STOPPLE® II Plugging Systems Plugging Head Retraction Rates Size Retraction Rate (Seconds Per Inch) Retract Distance 4" 4 2. to view flow rates.07. Section 10.5" 6" 4 4" 8" 4 5" 10" 4 6" 12" 4 8" 14" 4 9" 16" 4 11" 18" 4 12" 20" 4 13" 24" 5 15" 26" 5 17" 30" 6 21" 36" 8 21" Flow Rates Refer to HTP Tech Manual.2017 05_STOPPLE II_PG. Used by TDW Technicians on TDW Service jobs as guidelines 3.

STOPPLE® II Plugging Systems Flow Rate Activity Example: If the flow in a 20” Pipeline is 5 Mph. Page 24 of 60 Revised MKP 04. what is the flow in the 10” Bypass? Pipeline size ÷ Bypass size = “X” 20 ÷ 10 = 2 X2 = “Y” 22 = 4 Y * Flow in Mainline = Flow in Bypass 4 x 5 = 20 Mph Above is an example of a 20” pipeline.D.2017 05_STOPPLE II_PG.docx .07. assuming the pipeline is 24” and the flow is 7 Mph? T. What would the flow of a 12” bypass be. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Do not distribute outside of TDW.

STOPPLE® II Plugging Systems STOPPLE IIB vs.D. most are for lower pressure and IIB’s are not NACE compatible.2017 05_STOPPLE II_PG. Do not distribute outside of TDW. Page 25 of 60 Revised MKP 04.07. Why is the trailing edge of a sealing element flexible? 4. What is a negative pressure differential? 2. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Which ANSI classes are available for housings? 5.docx . BONUS: Explain how to calculate flow in a gas line. Section Summary The learner should now be able to:  List various applications of the STOPPLE® II Plugging System  Recall specifications related to the STOPPLE® II Plugging System  Describe flow limitations  List major components and describe their respective uses T. Although some STOPPLE IIB’s are 1480 psi working pressure. What is the retraction rate for a 16” plugging head? 3. Learning Checkpoint 1. STOPPLE IIC The main difference between the STOPPLE IIB and IIC is that the IIC designed for full 600lb class (1480 psi) working pressure and is NACE compatible.

equipment used in conjunction with STOPPLE II equipment will be covered. Always look up specifications on the version of the particular machine being used. Section Learning Objectives Upon completing this section. to 152 760c: 3” to 1067 mm) 1. 2400 T-101 360 (B) 660/760 (C) 1200 (M) Series 1.docx . It is built not only to withstand the internal pressure of the pipeline. the learner will be able to:  Select ideal tapping machine(s) based on given job specifications  Describe how to determine proper fitting locations  List other related equipment and accessories used to complete a STOPPLE II application Other Related Equipment Tapping Machines Below are commonly used tapping machines when working with STOPPLE® II equipment.D.524 mm) ization mm) 16” (76 mm to 406 mm) STOPPLE® Fittings A STOPPLE® fitting is a fitting which has been developed for a specific purpose.STOPPLE® II Plugging Systems STOPPLE II Plugging System Other Related Equipment & Accessories In this section.2017 05_STOPPLE II_PG. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.480 psi @ 100°F (102 bar at 38°C) bar at 93°C) 660c: 3” to NOTE: 4” to 6” 12” (76 mm 12” to 42” 30” to 60” Tapping Only for (102 mm to 305 mm) (305 mm to (760 mm to Range equal.07. but also to take the forces developed by the STOPPLE® Plugging Head. Do not distribute outside of TDW.200 psi @ 200°F (83 MAOP 1. Page 26 of 60 Revised MKP 04. T.

but only Fitting Installation under special circumstances (subsea.07. Page 27 of 60 Revised MKP 04. etc. Flat Face or RTJ Standard Flange.STOPPLE® II Plugging Systems Description Types Available Flanges ANSI Class 150#.4. LOCK-O-RING® Flange Type Plus Flange Sleeve Types Reducing Branch Split Tee. LOCK-O-RING® Flange. SHORTSTOPP® Flange. Spherical 3-way. weld-on designs. Size on Size Split Tee Special Application Full Encirclement 3-way tee. Mechanical bolt-on for no weld installations can be used. High Temperature Designs Typically. CAM Flange. Fitting Design ANSI B31. B31. Do not distribute outside of TDW. 600# & 900# Flange Finish Raise Face.D. Equalization and Gas Bags T. Fitting Location with by-pass and equalization Fitting Location with Bypass.).8.3. B31. and Others Fitting Location Refer to HTP-CSGS-076 Fitting Location See the drawing and chart in this section for details on minimum fitting spacing and location on the line.2017 05_STOPPLE II_PG. encased.docx . Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. 300#.

Can be used for (de)-pressurizing the isolated pipe section. Positioned in front of the STOPPLE fitting on the side to be isolated.STOPPLE® II Plugging Systems Fitting Location Dimensions Equalization Considerations Equalization is critical for all STOPPLE and plugging operations. SANDWICH® Valves  Provides access to the pressurized pipe. Size depends on product and size of the pipe  Most common size is 2” THREAD-O-RING™ Completion Plug 5. Page 28 of 60 Revised MKP 04. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Must be connected with the STOPPLE housing when setting and retracting the plugging heads 4.07.docx .D. Power Unit  Typically.2017 05_STOPPLE II_PG.  Hydraulically operated for bigger sizes 24” and above. 1.  Manually operated for smaller sizes 4” thru 22”. 1200 TM power unit is recommended NOTE: Consult CSG for special situations or if uncertain T. Do not distribute outside of TDW. Prevents pressure differential on both sides of plugging heads or completion plug 2. use a 660/760 TM power unit  For 14” or larger. 3.

2 33-1/4 844.docx .6 15-1/4 387.2 23-1/4 590.2 4-1/16 103. Valve ID-Vert.55 26” 5-388-26 5-329-12 5-002-12 25 635 25-1/4 641.8 17-1/4 438.20 10” 5-388-10 5-329-4 5-002-4 9-7/8 250.35 38” 5-388-38 5-329-31 5-002-31 36-7/8 936.35 18” 5-388-18 5-329-8 5-002-8 17 431.55 36” 5-388-36 5-329-25 5-002-25 35 889 35-1/4 895.15 20” 5-388-20 5-329-9 5-002-9 19 482.55 16” 5-388-16 5-329-7 5-002-7 15-1/16 382.D. Referred to as “Standard LOCK-O-RING LOCK-O-RING” Plug Completion Plug 2.9 5” X 5-002-6 X 4-15/16 125. Completion Plug 4.6 19-1/4 488. Has been the standard plug for a long time 3.95 42” 5-388-42 5-329-33 5-002-33 40-7/8 1038.75 24” 5-388-24 5-329-11 5-002-11 23 584.2 LOCK-O-RING® Plugging Technology Equipment Description Notes Photo 1.95 22” 5-388-22 5-329-10 5-002-10 21 533.) Inch mm Inch mm 3” X 5-002-18 X 2-7/8 73 X X 4” 5-329-4 5-329-4 5-002-1 3-15/16 100. Do not distribute outside of TDW.07.15 30” 5-388-30 5-329-13 5-002-13 29 736.2017 05_STOPPLE II_PG.8 13-1/4 336.6 37-1/4 946. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Tap Size Last few of Part No.4 39-1/4 996. 2 leaf system (3 leaves on 22”& above) Accessories Accessory Description Jackscrew Operated Cylinder Optional use for 4” and 6” Safety Harness For fall protection Notes: T.4 21-1/4 539.STOPPLE® II Plugging Systems STOPPLE® Cutters STOPPLE operations requires STOPPLE cutters (painted red) For dimensions refer to charts below OD” OD mm Min.4 31-1/4 793.00 12” 5-388-12 5-329-5 5-002-5 11-13/16 300 12 304.6 29-1/4 742.15 40” 5-388-40 5-329-29 5-002-29 38-7/8 987.8 10 254.99 8” 5-329-8 5-329-3 5-002-3 7-7/8 200 8 203.8 27-1/4 692.75 34” 5-388-34 5-329-24 5-002-24 33 838. (Dernier No.8 6-1/16 159.35 28” 5-388-28 5-329-16 5-002-16 27 685. No leak paths through LOCK-O-RING Plus segment assembly.80 14” 5-388-14 5-329-6 5-002-6 13-1/16 331.95 32” 5-388-32 5-329-28 5-002-28 31 787. Page 29 of 60 Revised MKP 04.4 X X 6” 5-329-6 5-329-6 5-002-2 5-15/16 150.

07. Which tapping machine(s) could be used to make 24” hot taps on a STOPPLE II job? 3.STOPPLE® II Plugging Systems Learning Checkpoint 1.docx . Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Page 30 of 60 Revised MKP 04. Do not distribute outside of TDW. Why is fitting spacing important? 4.D. Which power unit would typically be used for an 8” hot tap? Section Summary The learner should now be able to:  Select ideal tapping machine(s) based on given job specifications  Describe how to determine proper fitting locations  List other related equipment and accessories used to complete a STOPPLE II application Notes: T. What is the cutter OD of a 30” STOPPLE cutter? 2.2017 05_STOPPLE II_PG.

a cylinder before 2. Do not proceed until AOC has been corrected. 1. 3. 5. Do not proceed until AOC has been corrected.2017 05_STOPPLE II_PG. 1. q Negative pressure differential 4. Confirm flow rate is within allowable velocity. Contact your supervisor and CSG. Contact your supervisor and CSG. 2. 6. If the control bar does not move easily. above plugging head. q A standard cutter was mistakenly  It may require replacing the fitting. reduce pumping rates if possible. Contact your supervisor. Tactfully inform customer that TDW uses only new q Customer would like to use sealing elements each time. Stop operation. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. contact supervisor and CSG. use to make the tap for plugging. Confirm bypass is open and operating properly. 900 psi. Page 31 of 60 Revised MKP 04. range. When activating control valve to extend or retract q Bar lock clamp is left tightened on control bar. Always pay special attention to warnings and cautions for your safety and the safety of those around you. 3.STOPPLE® II Plugging Systems AOCs Review NOTE: Some warnings and cautions (in product manuals. 2. etc. be exceeded without review and approval by CSG. check to see if extending/retracting control bar. Confirm equalization line is adequately sized for develops while setting a 30” and application. If negative differential still exists. Reduce insertion rate of plugging head. Do not distribute outside of TDW. 2. If so. Important AOC’s by Category Abnormal Operating Condition Solution 1.07. control bar clamp has been loosened. T. Do not proceed until AOC has been corrected. Do not allow sealing element to be used a second time. NOTE: Any modification should be consulted by CSG. 7.D. Confirm equalization line is open and operating properly. 1. under working pressures of 700 to  1/8” longer nose bolts must be used with plate. HTP Tech Manual. 1. 2. sealing element a second time 2. Contact your supervisor and CSG. listen for a grinding noise. q Customer would like to use a  CSG may recommend a special aluminum backup standard plugging head while plate. Do not proceed until the appropriate equipment is provided and CSG has approved. 1.docx . Contact your supervisor and CSG.) are AOC’s. 1. 2.  May need to add/remove padding q Nose pad is undersize for pipe ID. q Flow rate in pipeline exceeds  Rates are based on past experience and should not limitations for type of plugging.

07. Page 32 of 60 Revised MKP 04.docx .3 T. Section Learning Objectives Upon completing this section. Paragraph 1. Paragraph 1.D. the learner will be able to:  Describe pre/post equipment checks to be done by the TDW technician in the field/shop  Cite where to find job inspection lists for hydraulic actuators and plugging heads  Explain how to store STOPPLE II Plugging System compatible sealing elements Field Maintenance & Handling Refer to Product Manual: 1. 00-3795-0326 (STOPPLE IIb). Section 22 .2017 05_STOPPLE II_PG.Equipment Checklist and Servicing.0 Hydraulic Cylinder (Actuator) Maintenance Refer to HTP Tech Manual. Section III. Section 22 Equipment Checklist and Servicing and the respective product manual being used in class.0 2. Do not distribute outside of TDW. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Paragraph 1. Section IV.STOPPLE® II Plugging Systems STOPPLE II Plugging System Pre/Post Job Equipment Servicing For this section. 00-3795-0240 (STOPPLE IIc).11. please refer to HTP Tech Manual.

Do not distribute outside of TDW.Equipment Checklist and Servicing. Page 33 of 60 Revised MKP 04.07. Section 22 .STOPPLE® II Plugging Systems Plugging Head Maintenance Refer to HTP Tech Manual.docx .2017 05_STOPPLE II_PG.10.D.1 Notes: T. Paragraph 1. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.

A damaged sealing element can result in fluid leaks during plugging operations. Section Summary The learner should now be able to:  Describe pre/post equipment checks to be done by the TDW technician in the field/shop  Cite where to find job inspection lists for hydraulic actuators and plugging heads  Explain how to store STOPPLE II Plugging System compatible sealing elements T. Max number of stacked elements shall be four (4) WARNING: Use sealing element one time only and discard after each plugging operation. etc Keep in a box or a dark bag—preferably both Storage temperature should be between 40°F and 100°F Lay the elements on a flat surface. The element is damaged when withdrawn through the tapped hole. leading edge down to prevent deformation during storage Keep cardboard dividers between stacked elements.docx .4.1 Sealing Element Maintenance Sealing elements are made from a rubber compound and are subject to decomposition. Paragraph 1.STOPPLE® II Plugging Systems Housing Maintenance Refer to HTP Tech Manual.D. Proper storage and handling is required to maintain the usefulness of sealing elements. Page 34 of 60 Revised MKP 04. Do not distribute outside of TDW.07. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Keep out of direct sunlight Keep away from ozone producing equipment such as welding machines and electric pumps and generators.2017 05_STOPPLE II_PG. Section 22 .Equipment Checklist and Servicing.

D.2017 05_STOPPLE II_PG.07.STOPPLE® II Plugging Systems Learning Checkpoint 1.docx . What type of thread gauge would be used on a 20” housing? Notes: T. What is an example of irregular movement on the control bar? 3. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Page 35 of 60 Revised MKP 04. Between what temperatures should STOPPLE II sealing elements be stored? 2. Do not distribute outside of TDW.

Do not distribute outside of TDW.STOPPLE® II Plugging Systems Workshop Activity Description of Activity ____________________________________________________________________________________ ____________________________________________________________________________________ Equipment List q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ Lessons Learned/Debrief T.D. Page 36 of 60 Revised MKP 04.07.2017 05_STOPPLE II_PG.docx . Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.

Connect power unit 3.  Support on level surface with adequate support 5. Zero should appear in observation hole.2017 05_STOPPLE II_PG. Paragraph 2.STOPPLE® II Plugging Systems STOPPLE II Plugging System Setup This section will cover the steps needed in order to set up equipment involved in a STOPPLE II application. discuss and note the reasons for the above steps T.docx . Extend control bar & attach plugging head with special bolts and nuts. As a group.1 1.D. Page 37 of 60 Revised MKP 04.07. Mount cylinder on housing  Ensure equalization and control valve face same direction 2. Release bar lock clamp 4. Do not distribute outside of TDW. Section III. Inspect O-rings 1. discuss and note the reasons for the above steps Prepare Plugging Machine Refer to Product Manual -0326 (STOPPLE IIb). Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.  Check bolts and control bar for straightness. Section Learning Objectives Upon completing this section. the learner will be able to:  Describe setup procedures for the STOPPLE II Plugging System  Perform setup procedures for the STOPPLE II Plugging System Tap the Line/Other Preparations  Verify pipeline condition  Perform hot tap operation  Install bypass (if required)  Select proper sealing element As a group. Retract plugging head fully by moving lever to “up” position.

Visually check face of yoke As a group.STOPPLE® II Plugging Systems Take Measurement “D” Refer to Product Manual -0326 (STOPPLE IIb).2017 05_STOPPLE II_PG. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.1. NOTE: Always take measurement “D” before the sealing element is installed. NOTE: These instructions are for 4-36” plugging heads 1. – J. discuss and note the reasons for the above steps Prepare Plugging Head Refer to Product Manual -0326 (STOPPLE IIb). Section III. Lightly lubricate internal threads and yoke pin 5. I.  Provide support for weight if necessary 2. Save measurement for later. Page 38 of 60 Revised MKP 04. Section III.07. discuss and note the reasons for the above steps T. Face of STOPPLE housing flange to bottom of D control bar head. Remove nose bolts & nose piece from yoke by extending control bar. Do not distribute outside of TDW. Paragraph 2.D. Clean plugging head parts of dirt and debris 4.3. Paragraph 2. Inspect all parts & service/replace as necessary 3.docx . As a group.

torque nose bolts as required 6. Carefully retract plugging head using screwdrivers to guide. Start bolts by hand. discuss and note the reasons for the above steps T. Position element evenly so that bolt holes align.07. Adjust Clearance “B” to the dimension shown in the chart above As a group. Verify nose wheels move freely 8.2017 05_STOPPLE II_PG. Do not distribute outside of TDW. Install the sealing element and the nosepiece as required 2. If element installed correctly.docx .STOPPLE® II Plugging Systems Install the Sealing Element Refer to Product Manual -0326 (STOPPLE IIb).  Ensure element is pressed flat 3. Page 39 of 60 Revised MKP 04.3. D. 4. then torque according to Section 31 0 Torque and Torque Sequence 5.  Element lip must not pull inside-out WARNING: Failure to install the sealing element properly could result in property damage and possible personal injury from fluid leaks during plugging operation. NOTE: Double check sealing element size before installing. Paragraph 2. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Section III. Type of Plugging Size Clearance “B” Head 4” through 12” ¼” to ½” STOPPLE II 14” and larger 3/8” to 9/16” 1. Apply heavy coat of grease to seal ring of sealing element 2. Must be adjusted Clear- ance B correctly to allow clearance going through tapped hole and allow yoke to pivot into pipe. Install nose piece on element. 1.D. As a group. discuss and note the reasons for the above steps Take Clearance Adjustment (Clearance B) Measurement Plugging head clearance. Coat element lip thoroughly with heavy grease 7.

including thickness of B gasket. Section III. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. To know Ref2 when wheel touches botom of pipe. discuss and note the reasons for the above steps T.1WT 2.D.STOPPLE® II Plugging Systems Take Other Measurements Refer to Product Manual -0326 (STOPPLE IIb). Travel for plugging B D E head to be fully seated Summary of Measurements/Calculations Below is a list of the measurements needed.docx . tells when roller is to centerline of pipe.07.  Tapping Distance  Cut Out Distance  Twist Drill Calculations  RPM  Time Calculations  Flow in Bypass As a group. Top of tapping valve. Do not distribute outside of TDW. to top of pipe being plugged. Take Ref2 dimensions with sealing element installed and plugging head fully retracted.2017 05_STOPPLE II_PG. Paragraph 2. Also.3 1. D Face of housing to bottom of control bar head E Pipe OD . Page 40 of 60 Revised MKP 04. Nose wheel to face of plugging housing. Record the following measurements on the measurement card to obtain total travel for the plugging head.

0. Section II.D.docx . As a group. discuss and note the reasons for the above steps Section Summary The learner should now be able to:  Describe setup procedures for the STOPPLE II Plugging System  Perform setup procedures for the STOPPLE II Plugging System Notes: T. Paragraph 1. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.STOPPLE® II Plugging Systems 4”-6” Jackscrew Actuator Setup It is possible with STOPPLE IIb Plugging System equipment to use a 4” or 6” jackscrew plugging machine. For instructions. refer to Product Manual 00-3795-0326 (STOPPLE IIb).2017 05_STOPPLE II_PG. Do not distribute outside of TDW.07. Page 41 of 60 Revised MKP 04.

07. Page 42 of 60 Revised MKP 04. What size jackscrew actuator can be used in conjunction with the STOPPLE II Plugging System? 8.2017 05_STOPPLE II_PG. What can happen if the plugging head is not supported when extended outside the housing? 6. What is the torque value range for a 10” plugging head? 4.docx .STOPPLE® II Plugging Systems Learning Checkpoint 1.D. How many times can a sealing element be used? 3. When is a Ref2 dimension recorded? 9. Describe how to take Measurement “E” 2. Do not distribute outside of TDW. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. How do you extend the control bar? 7. Describe how to find the travel distance for the plugging head to be fully seated T. What should be applied to bolt holes to reduce friction? 5.

Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.D. q Sealing Element was improperly installed. Do not proceed until AOC has been corrected.) are AOC’s. Do not distribute outside of TDW.docx . Always pay special attention to warnings and cautions for your safety and the safety of those around you.07. pipe. 1. 3. installed evenly on the yoke.STOPPLE® II Plugging Systems AOCs Review NOTE: Some warnings and cautions (in product manuals. HTP Tech Manual. Page 43 of 60 Revised MKP 04. correctly tightened with no lip pulled inside-out. Important AOC’s by Category Abnormal Operating Condition Solution 1. Adjust clearance “B” per HTP Tech Manual specifications. Failure to do so may cause property damage and personal injury due to fluid leaks. 2. Notes: T.2017 05_STOPPLE II_PG.  A “B” clearance that is too long may cause plugging head to catch on the tapped hole and try to pivot prematurely. Sealing element must be greased on sealing ring.  A “B” clearance that is too short may cause the plugging head to try to pivot q Clearance B is not adjusted according to HTP backwards after hitting the bottom of the Tech Manual requirements. etc.

Section Learning Objectives Upon completing this section. Verify seal 4. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Install plugging equipment 2. it is possible to use the new section for a bypass while the old section is being removed. If a new section of line is being installed. or one plugging machine and an existing in-line valve. serving as a block valve. a section of pipe can be isolated and drained.docx . T. Proceed to repairs/remedial 5. the learner will be able to:  Describe standard operational procedures for the STOPPLE II Plugging System  Perform standard operational procedures for the STOPPLE II Plugging System Operations Summary Below is a very basic summary of STOPPLE II b or c operations. Set Completion Plug(s) work Next. we’ll cover operations in greater detail assuming the use of a hydraulic cylinder in an on-stream. 1. Set plugging head 3. Remove plugging equipment 6. Do not distribute outside of TDW. The plugging head. a STOPPLE Plugging Machine is installed on the valve and a plugging head inserted into the line.07. We will use Product Manual STOPPLE IIB Plugging Head.D. seals the line and retains pipeline pressure. double position STOPPLE without a bypass application. Page 44 of 60 Revised MKP 04. 4–36in (ENGLISH) as an example.STOPPLE® II Plugging Systems STOPPLE II Plugging System Operations After the tap is made. A bypass can be installed around the isolated section. If two plugging machines are used. keeping the line in service.2017 05_STOPPLE II_PG. The following “Application Variations” section will outline in more detail various job equipment setups. making possible necessary repairs or modifications in the isolated section.

Paragraph 3. •Set downstream plugging head WARNING: Vent pressure away from work area and first personnel. Open valves and on equalization line Important 5. discuss and note the reasons for the above steps Set the Plugging Head Refer to Section III.docx .07.4 1. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Personal injury may result from blowing material.D. Consider the total length and weight of the STOPPLE cylinder and housing. Make sure weight handling equipment has the capacity to lift it. All on-stream applications will use a “sweeping” sealing element to rid the inside of the pipe of chips and debris prior to plugging. Open internal bypass on SANDWICH Tapping Valve or open external bypass. Leave internal bypass on SANDWICH Valve open to equalize Tee pressure on both sides of the valve disc.2017 05_STOPPLE II_PG. Install bleeder valve on STOPPLE housing. Stand clear of vent when bleeder valve opened. Paragraph 2. In position when number in observation hole matches calculation c. 3.2 1. 2. As a group. 2. Open SANDWICH Valve.STOPPLE® II Plugging Systems Install Plugging Equipment Refer to Section III. When fully opened. close internal bypass. The Ref2 and “D” measurements will be used in sweeping calculations. Purge air from STOPPLE Plugging Head housing through bleeder valve. Do not distribute outside of TDW. 4. 6. •Unless using bypass with 3-WAY 3. Return lever to neutral position once plugging head set T. Move control lever down to extend plugging head b. Make up piping connection for refilling and pressure equalization 4. Support pipe under fitting with timbers or pipe supports Perform Sweep Action On-stream applications are those with flow present. Set downstream plugging head first a. Center machine on SANDWICH Valve and install with equalization connection facing the section to be isolated. Page 45 of 60 Revised MKP 04. Close bleeder valve when purge complete.

NOTE: While repeating steps to set heads. Move head back and forth only inside pipe. 10. Page 46 of 60 Revised MKP 04. If this decreases the leak. or fraction thereof. Paragraph 4. If isolated section of the line is to be cut. Close equalization valves 8. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. discuss and note the reasons for the above steps Verify Seal Integrity 1.D. b. a. it is crucial to not retract through tapped hole. Reset clamp and continue. but does not resolve. Exact number.07. Do not distribute outside of TDW. a. Tighten cap screw on bar lock clamp to appropriate torque. If leakage continues. However. connect hydraulic hoses. If number has moved UP in observation hole. recheck number (calculated distance) in observation hole of each plugging machine. If there is any leakage. Disconnect hydraulic hoses. Vent and drain isolated section of pipe completely As a group. install a new sealing element. TDW recommends cold-cutting methods.STOPPLE® II Plugging Systems 7. discuss and note the reasons for the above steps Remove Plugging Equipment Refer to Section III. Close valves on equalization lines. loosen clamps. Disconnect Supply Hose First (Small Hose) b. 1. Do not over tighten. Verify seal of plugging head through a valve connection before starting work on isolated section.1 T. make sure the cut is no closer to the fitting than three pipe diameters. 3. Customer may now proceed to repairs/remedial work As a group. if flame cutting is used. and lower plugging head until measured distance is reached. After both plugging heads are positioned in line.2017 05_STOPPLE II_PG. and reset plugging head. Install dust caps on hydraulic fittings. Disconnect Return Hose Second (Large Hose) 11. and a minimum of 2 feet 4. must be in same position as originally viewed before pressure in isolated section can be relieved. it must be replaced.docx . do again until a workable seal is achieved. 2. equalize isolated section and repeat plugging head setting procedures and re-verify seal. Should sealing element be retracted through tapped hole. remove plugging machine. and when welding in the new section is planned. 12. 13. Set upstream plugging head following the same sequence of steps with valves and head 9.

thoroughly clean and inspect all components of the STOPPLE Plugging head. 8 Remove plugging machine.D. Equalize pressure from side with highest static pressure. If a line pressure differential exists. Attempts to retract will result in damage to machine.2017 05_STOPPLE II_PG. This is necessary prior to proceeding to the next job or returning to storage. Retract plugging head by moving control valve up slowly. equalize from the upstream side and retract upstream machine first.STOPPLE® II Plugging Systems 1.docx . Make sure all pipeline product is removed. plugging head will remain locked in line. Upon removal. 5 Close SANDWICH Tapping Valve. Retract high pressure side plugging machine first  For an on stream operation. As a group. 2. 7 Open bleeder valve and bleed all pressure from housing to a safe area. CAUTION: Pressure must be equalized across plugging head before head can be withdrawn. Continue retracting until zero appears in the 4 observation hole. discuss and note the reasons for the above steps T. Do not distribute outside of TDW. 6 Close equalization valve.07. Drain housing before removal. the 9 plugging housing and the STOPPLE Cylinder. and keep it equalized. Page 47 of 60 Revised MKP 04. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. 1 Equalize pressure on both sides of plugging head. Equalize pressure before retracting. 3 Release bar-lock clamps. 2 Connect hydraulic hoses.

and timbers or pipe supports could be used.STOPPLE® II Plugging Systems Set Completion Plugs Set completion plugs per Product Manual of plug in use. q Isolated section is not 2. Important AOC’s by Category Abnormal Operating Condition Solution 1. filled from upstream or 3. 1. 2. 3. Contact your supervisor. Always pay special attention to warnings and cautions for your safety and the safety of those around you. 1. T. provided. Do not proceed until AOC has been corrected. Check pressure gauges on both up and downstream housings. HTP Tech Manual.2017 05_STOPPLE II_PG. Concrete plates. Do not proceed until AOC has been corrected. 4.07. discuss and note the reasons for the above steps Section Summary The learner should now be able to:  Describe standard operational procedures for the STOPPLE II Plugging System  Perform standard operational procedures for the STOPPLE II Plugging System AOCs Review NOTE: Some warnings and cautions (in product manuals.D. confirm pressure is the same on high pressure side after front and back side of plugging head before retracting plugging tie-in. As a group. Stop the job. Do not distribute outside of TDW.) are AOC’s. There may be a differential of pressure. Pipeline may move down after cutting pipe under a weight of an properly supported. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. q Equalization fitting not 3. q STOPPLE fitting not 2. If there is a high pressure side. 4. Page 48 of 60 Revised MKP 04. Weld on equalization fitting before setting plugging head. equipment installed on a fitting. Do not proceed until AOC has been corrected. blocks. etc. head.  Equalization should always be used during plugging operation.docx .

Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.D.STOPPLE® II Plugging Systems Workshop Activity Description of Activity ____________________________________________________________________________________ ____________________________________________________________________________________ Equipment List q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ Lessons Learned/Debrief T. Page 49 of 60 Revised MKP 04. Do not distribute outside of TDW.2017 05_STOPPLE II_PG.07.docx .

Double Position Isolation 5. Describe uses for various STOPPLE® II applications 2.STOPPLE® II Plugging Systems STOPPLE II Plugging Application Variations There are many applications for the STOPPLE II Plugging System. the learner will be able to: 1. To isolate one section of the pipeline. To isolate the end of a pipeline 3. Uses two sets of plugging equipment. maintaining pressure differential between the two STOPPLES 16. To isolate two separate sections of the pipeline Double-Double Isolation 11. Uses four sets of plugging equipment. STOPPLE® Train is available to replace this application 14. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. the customer must sign the measurement card. Adds a temporary line around isolated section. Here we will cover some of the most common applications. To isolate a section of pipe with a block valve 4. Extend plugging head 1/3 of “Sweep” dimension 4. Retract plugging head roller to bottom of the pipe 5. The purpose is to contain higher pressures than a single plugging machine could Tandem Isolation Application control. Uses two plugging machines set facing the same direction. 8.2017 05_STOPPLE II_PG.07. To isolate a section of a pipe 6. To gain entry without tapping in order to isolate section of pipe Re-Entry Isolation Application 18. Pages 48-49 Application Name Description 1. Extend plugging head roller to bottom of pipe 3. Uses existing fittings Various STOPPLE II Plugging Application Operations Single Position Isolation Prior to setting the plugging head. To isolate two sections of pipe where a continuous flow is required Application 12. Page 50 of 60 Revised MKP 04. To isolate a section where a continuous flow is not required Double Position Isolation with Separate Bypass 7. Extend plugging head 2/3 of “Sweep” dimension T.docx . The plugging heads share the load. 10. Used to isolate a section of a pipe and maintain the continuous flow of Double Position Isolation with product. Before setting the plugging head. Bypass Through 3-WAY™ Spool 9. Uses one set of plugging equipment. establish a “no-flow” line condition by either closing a main line block valve upstream or downstream. Operations Sequence 1. To establish a double block and bleed 17. To make it possible to use one section for a bypass while the other section is being removed 13. Determine difference between the SET dimension & roller to bottom of pipe = “Sweep” dimension 2. Section Learning Objectives Upon completing this section. 15. Distinguish when to use various applications based on given job specifications Applications Summary Refer to TDW High Pressure Product Catalog . Single Position Isolation 2.D. keeping line in service. Do not distribute outside of TDW.

keeping line in service. Do not distribute outside of TDW. Release locking device and slowly retract plugging head. 3. Equalize pressure on both sides of plugging head. 14. Confirm seal in isolated section of pipe 11. 8.07.D. Retract downstream plugging head from the line. Double Position Isolation with Separate Bypass A Double Plugging Operation with Bypass adds a temporary line around the isolated section. ask customer location of largest consumer. Lower and set downstream plugging head into line. Retract upstream plugging head from the line. Retract upstream plugging head from the line. Double Position Isolation Operations Sequence 1. T. 13. Purge air and load isolated section 6. Continue retracting plugging head until fully retracted. 4.STOPPLE® II Plugging Systems 6. Customer performs repair/service to line 5. 2.  This will establish upstream & downstream direction. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Lower and set upstream plugging head into line. Purge air  Always fill from Upstream or High Pressure Side 7. 15. 12. Purge and equalize isolated section. establish direction of flow in line. Lower and set upstream plugging head into line. Open bypass before lowering plugging head into line 2. Page 51 of 60 Revised MKP 04. customer must sign measurement card. When work is complete on isolated section of pipe. 7. Confirm total set dimension 9. Tighten locking device 10. 5. 3. Customer performs repair/service to line 6. Retract downstream plugging head from the line. Lower and set downstream plugging head into line. Retract plugging head roller to bottom of pipe 7. 4.docx .2017 05_STOPPLE II_PG. Operations Sequence 1. Extend plugging head to “set" position 8. Prior to setting plugging heads on bi-directional flow lines. To establish direction.  The downstream direction will be the end with largest consumer.

then upstream fully. next down-stream STOPPLE. 1. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Retract upstream plugging head from the line to zero. Do not distribute outside of TDW. For bypass through spool/housing. Purge air 7. Open bypass before lowering plugging head into line 2. Lower and set downstream plugging head into line. 9. 4.07. perform as if it’s one large double STOPPLE operation. As a double-double isolation consists of 2 separate double STOPPLE operations. Retract downstream plugging head from the line to zero. keeping line in service. Every double-double isolation operation should be handled as two separate double operations. Retract upstream plugging head to centerline of pipe. Extend upstream plugging head to “roller to center line” of pipe and tighten bar lock device. next downstream fully . retract upstream STOPPLE first. 3. Lower and set upstream plugging head into line. 2. 3. retract upstream STOPPLE until the roller is in the pipe centerline.docx . T. This type of application uses fewer fittings while continually maintaining the flow or service of product. Page 52 of 60 Revised MKP 04. Customer performs repair/service to line 6. 5. Double-Double Isolation Application A Double-Double Plugging Operation uses four sets of plugging equipment to:  Makes it possible to use the section to be replaced as a bypass while new line is established  Can be performed with separate bypass or with bypass through spool/adapter 1.STOPPLE® II Plugging Systems Double Position Isolation with Bypass Through 3-WAY™ Spool A Double Plugging Operation with Bypass adds a temporary line around the isolated section. For example: 1.2017 05_STOPPLE II_PG. For separate bypass.D. 2. 8. When retracting plugging heads from the line.

3 Typical Tandem STOPPLE Application T. NOTE 2: CSG must give approval for 3-WAY Tee/housing connections. the external equalization on the STOPPLE housing must be opened before and closed after the movement of the plugging head. Page 53 of 60 Revised MKP 04. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. STOPPLE Train is TDW’s latest solution to obtaining a double block and bleed. A Tandem STOPPLE Plugging operation uses two plugging machines set facing the same direction. Tandem Isolation Application While tandem isolation applications are still done. Operations Sequence Refer to HTP Tech Manual.2017 05_STOPPLE II_PG.D. Do not distribute outside of TDW.07.docx .STOPPLE® II Plugging Systems NOTE 1: Each time a plugging head is lowered or retracted. Section 6. The purpose is to contain higher pressures than a single plugging machine could control.

2017 05_STOPPLE II_PG.STOPPLE® II Plugging Systems Learning Checkpoint 1. How many sets of STOPPLE equipment will there be in a double-double isolation application? 2. Tandem STOPPLE applications have been improved by what technology? Section Summary The learner should now be able to:  Describe uses for various STOPPLE II applications  Distinguish when to use various applications based on given job specifications Notes: T. When might a single position application occur? 4.D. Page 54 of 60 Revised MKP 04. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Before setting the plugging head.docx . Do not distribute outside of TDW. the customer must sign what? 3.07.

docx .2017 05_STOPPLE II_PG.STOPPLE® II Plugging Systems Workshop Activity Description of Activity ____________________________________________________________________________________ ____________________________________________________________________________________ Equipment List q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ q ______________________ Lessons Learned/Debrief T. Do not distribute outside of TDW.07.D. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Page 55 of 60 Revised MKP 04.

Page 56 of 60 Revised MKP 04. Do not distribute outside of TDW.2017 05_STOPPLE II_PG.” 3 T. added housing machined at angle info. M.STOPPLE® II Plugging Systems Course Summary Frequently Asked Questions Question Answer 1. 14. Peruskie 09/30/2016 Removed metric control bar bullet. Document Control HT&P Training Department Document Title STOPPLE® II Participant Guide (PG) Course Code 3101C Isolation Introduction Origination Date Rev. 4/7/2017 15 & 16 T. Peruskie.07. added fluorowhite clarification. removed. Giles “grease back of sealing element” and replaced with “grease sealing rings. 3.D. 2 pads. 4. added info on rings and nose 12.docx . Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. 2. # Reason for Change Page Reviewer(s) Date Revised 0 New Document Finalized All Mm/dd/yyyy 1 Updated formatting All M.

Nose Piece NCR NOTE: FPR’s are now called NCR’s.that it was too big. Do not force the plugging head as you may bend the control bar or damage the plugging head.” When the plugging head is set: 1.docx . plugging head and Jackscrew were removed as one piece. valve. when plugging head was pulled up. When the technician activated the jackscrew and the plugging head moved to sealing position but the nose piece couldn’t get through the hot tap hole. Page 57 of 60 Revised MKP 04. Torque the cap screws per Section 31 of HTP Tech manual. The seal was ideal for carrying out the next operation. Read the FPR for full details. FPR – EAM-0009-010 Background A 5” plug was set in the pipeline even though it took a bit of more time than usual. You may be able to raise the control bar one or two inches and then slowly try to reach the set dimension. (the real cause was identified as miss-adjustment on clearance B on plugging head.D. three bolts on the nose broke and the disc fell off. The fitting. the pipeline was shut down and the fitting was cut off. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Check the measurement in the observation hole to make sure it corresponds with the calculated distance required to set the plugging head. Miss-adjustment clearance B Adjustment correct on the Plugging Head T. it got stuck in the tapping hole. However. 3.STOPPLE® II Plugging Systems Appendix Troubleshooting Control Bar Stalls If control bar stalls before reaching total set dimension. check the measurement card to determine what the plugging head has come into contact with. This assembly was sent back to the Service Center with a note that the nose piece was the wrong size .2017 05_STOPPLE II_PG. removed and replaced by another piece of pipe. 2. When maximum force was applied on the Jackscrew. Do not distribute outside of TDW. After many failed attempts. Tighten the cap screws on the bar-lock clamp.07.

2017 05_STOPPLE II_PG. Note: Please do not refer to catalogue or any other document to verify its dimensional conformities. Page 58 of 60 Revised MKP 04. Do not distribute outside of TDW. Measurement Cards T. each dimension can be checked against the drawings.D.docx .07. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.STOPPLE® II Plugging Systems The reinforcement plate was deformed when it passed through the tapping hole FPR Activity Look up the FPR associated with the above mishap: EAM-0003-010 Answer the following questions: The answer is each nose piece is designed for a specific working range and tested before put it in service – there are detailed fabrication drawings and as such.

2017 05_STOPPLE II_PG. Page 59 of 60 Revised MKP 04.07. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only.docx . Do not distribute outside of TDW.STOPPLE® II Plugging Systems Notes: T.D.

D.07. Page 60 of 60 Revised MKP 04.2017 05_STOPPLE II_PG.docx .STOPPLE® II Plugging Systems T. Williamson – PROPRIETARY & CONFIDENTIAL ║ For internal use only. Do not distribute outside of TDW.