You must always enlist the pros when it comes to pneumatic plugs. This is an incredibly dangerous job that when done incorrectly can cause injury or plug failure.
Here, we will discuss the dangers of pneumatic plugs and why it is always imperative to enlist the pros.
They know all about the danger zone
The first and most important thing to remember with pneumatic plugs is to never enter the danger zone when in use. This is an area stemming from the manhole opening that expands outwardly in a cone shape. The total force created on a pipeline plug is proportional to the pipeline area and pressure. It can create a massive force that is incredibly dangerous for operators and this is the first reason why you need experts for the job.
They know how to prepare pneumatic plugs
Before they start any test, your experts will be sure to follow the correct guidelines to prepare your pneumatic plugs – this is essential to pipeline testing services as it can be an incredibly hazardous job.
First, they will choose the correct pneumatic plug and necessary technology. Each plug has different specifications attributed to the plug that is found on the plug itself and in the provided guidebook.
They will start by determining the back pressure. They will ensure that the maximum plug back pressure is able to withstand the pressure in the back or front of the plug as it must restrain this pressure. This is because you should never allow the back pressure rating to be exceeded.
Next, they will choose the right plug size. Pneumatic plugs comprise a maximum and minimum size range and the experts will choose the right size for the job.
They understand correct pipe design
Plug performance can vary depending on the type of plug you use. Corrugated pipes, for example, contain a plug back pressure rating that falls by 50%.
Your experts will always calibrate gauges as without them the operation could incur plug under or over-inflation and this will cause a failure. They will then continue to monitor back pressure and inflation with calibrated pressure gauges and nothing else.
Furthermore, they would absolutely never deflate a pneumatic plug whilst the line still contains back pressure. The experts will always deflate your pneumatic plug remotely using an extension hose to ensure its safe deflation.
Once this is done, they can provide proper inspection and clean your pneumatic plugs. They should be inspected and cleaned before and after every operation and you should never use a plug that shows signs of wear and tear. This inspection will include checks for bulges, corrosion, cuts, abrasions, damaged or loose fittings or leaks.
They will ensure that the pipe is properly inspected and remove any dust, debris or unwanted substances before conducting any testing. Any inflation of foreign objects could rupture the pipe and cause failure. What’s more, a dirty pneumatic pipe could cause its pressure-holding capacity to drop and damage the unit during placement or inflation.
You must also enlist a trained and experienced engineer to determine if a backup system is necessary. They must also design a blocking device and produce said backup device to prevent unit failure or injury. The blocking device exists to retrain any pneumatic plug movement as the force behind them can be extreme.
They will always avoid the use of inflation hoses, eye bolts or other attachments on the plug in order to restrain plug movement under back pressure – this is why the blocking device exists.
So, it’s imperative that you enlist the pros for this imperative service. They will ensure that the job is done safely and efficiently.
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