High Lift Flange Weld/Test Plug (3/4"-8") - Technical Specifications

Transcription

1 EXPANSION SEAL TECHNOLOGIES DC /98 REV 4 03/05 High Lift Flange Weld/Test Plug (3/4"-8") - Technical Specifications Flange Size Ansi Flange Class Pipe Schedule Part Number Plug OD Seal to Pipe Pipe Clearance Shaft OD Shaft ID Vent & Fill Port Size Upstream Monitor Size L1A Welding Plug L1B Test Plug ESTIMATED SHIPPING WEIGHT 300 LB ESTIMATED SHIPPING WEIGHT 600 LB (in) (mm) (in) (mm) (in) (mm) (in) (mm) NPT (3) NPT (3) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (in) (lb) (kg) (lb) (kg) (lb) (kg) 160 HLZ-075P /4" DN HLZ-075P / / /8 F 1/8 F / / / n/a (4) 9/ HLZ-075P xxs HLZ-1PXXS HLZ-1P " DN / / /8 F 1/8 F / / / n/a (4) 9/ HLZ-1P HLZ-1P HLZ-125P /4" DN HLZ-125P / / /8 F 1/4 M / / / /2 15/ HLZ-125P HLZ-15P /2" DN HLZ-15P / / /4 F 1/4 M / / / / /2 15/ HLZ-15P xxs HLZ-2PXXS HLZ-2P " DN / / /4 F 1/4 M / / / / /2 15/ HLZ-2P HLZ-2P HLZ-25P /2" DN HLZ-25P / / /4 F 3/8 F / / / HLZ-25P xxs HLZ-3PXXS HLZ-3P " DN / / /4 F 3/8 F / / / HLZ-3P HLZ-3P xxs HLZ-4PXXS HLZ-4P " DN HLZ-4P / / /4 F 3/8 F / / / HLZ-4P HLZ-4P HLZ-6P HLZ-6P " DN / /4 F 3/4 F / / /8 3 1/ HLZ-6P HLZ-6P HLZ-8P xxs HLZ-8PXXS HLZ-8P HLZ-8P " DN / /4 F 3/4 F / /8 3 1/ HLZ-8P HLZ-8P HLZ-8P HLZ-8P L2 Max L3 L4 Shaft Hex Wrench Size Hex Nut Wrench Size ESTIMATED SHIPPING WEIGHT 150 LB Notes: (1) Standard Seal Material = Urethane (2) Standard Operating Pressures: Z = A = 150 lb = 450 psi, Z = B = 300 lb = 1125 psi, and Z = D = 600 lb = 1125 psi (3) Male NPT = M, Female NPT = F (4) 3/4"-1" has round section for use of pipe wrench info@expansionseal.com

2 EXPANSION SEAL TECHNOLOGIES DC /98 REV 4 03/05 HIGH LIFT FLANGE WELD TEST PLUG (10"-16") - TECHNICAL SPECIFICATIONS ESTIMATED ESTIMATED ESTIMATED BOTTOM SEAL/WASHER ANSI FLANGE PLUG OD (3) (4) DIM TO SEAL O/A LENGTH SEAL O-RING SHIPPING WEIGHT SHIPPING WEIGHT SHIPPING WEIGHT FLANGE SIZE PIPE SCHEDULE PART NUMBER WASHER OD (4) SHAFT QTY LENGTH CLASS (2) DASH NO. (5) 150 LB 300 LB 600 LB (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lbs) (kg) (lbs) (kg) (lbs) (kg) sch 100 (4) HLZ-10P / sch 80 HLZ-10P sch 60/xs HLZ-10PXS sch 40/std HLZ-10P " DN / / sch 30 HLZ-10P sch 20 HLZ-10P sch 10s HLZ-10P10S sch 5 HLZ-10P sch 80 (4) HLZ-12P / sch 60 HLZ-12P xs HLZ-12PXS " DN sch40/std HLZ-12P / / sch 30 HLZ-12P sch 20 HLZ-12P sch 10s/5 HLZ-12P10S sch 140 (4) HLZ-14P / sch 120 HLZ-14P / sch 100 HLZ-14P / sch 80 HLZ-14P / sch 60 HLZ-14P / " DN / / N/A N/A xs HLZ-14Pxs / sch 40 HLZ-14P / sch 30/std HLZ-14PSTD / sch 20 HLZ-14P / sch 10/10s/5 HLZ-14P / sch 120 (4) HLZ-16P / sch 100 HLZ-16P / sch 80 HLZ-16P / sch 60 HLZ-16P / " DN / / N/A N/A sch 40/xs HLZ-16P / sch 30/std HLZ-16PSTD / sch 20 HLZ-16P / sch 10/10s/5 HLZ-16P / Notes: (1) Standard Seal Material = Urethane (2) Standard Operating Pressure: Z = A = 150 lb = 450 psi; Z = B = 300 lb = 1125 psi; and Z = D = 600 lb = 2250 psi (10" & 12" only) (3) Seal to pipe clearance is appoximately 1/2", clearance may be slightly smaller on plugs that accommodate more than one schedule size. (4) Replacement washers are required on all schedule sizes except for the smallest one for each pipe size (5) 10" & 12" Seals include an external o-ring info@expansionseal.com

3 EXPANSION SEAL TECHNOLOGIES DC /98 REV 4 03/05 HIGH LIFT FLANGE TEST/WELD PLUG (18"-24") - TECHNICAL SPECIFICATIONS BOTTOM WASHER ESTIMATED SHIPPING ESTIMATED SHIPPING ANSI FLANGE PLUG OD (3) (4) DIM TO SEAL O/A LENGTH SEAL/WASHER LENGTH SEAL O-RING DASH FLANGE SIZE PIPE SCHEDULE PART NUMBER OD (4) SHAFT QTY WEIGHT 150 LB WEIGHT 300 LB CLASS (2) NO. (5) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lbs) (kg) (lbs) (kg) sch 120 (4) HLZ-18P120 4 sch 100 HLZ-18P / sch 80 HLZ-18P / sch 60 HLZ-18P / sch 40 HLZ-18P / " DN / / N/A xs HLZ-18PXS / sch 30 HLZ-18P / std HLZ-18PSTD / sch 20 HLZ-18P / sch 10/10s/s HLZ-18P / sch 100 (4) HLZ-20P / sch 80 HLZ-20P / sch 60 HLZ-20P / " DN / / sch 40 HLZ-20P / N/A sch 30/xs HLZ-20PXS / sch 20/std HLZ-20PSTD / sch 10/10s/5 HLZ-20P / sch 120 (4) HLZ-24P sch 100 HLZ-24P / sch 80 HLZ-24P / sch 60 HLZ-24P / sch 40 HLZ-24P / " DN / / N/A sch 30 HLZ-24P / xs HLZ-24PXS / sch 20/std HLZ-24PSTD / sch 10/5 HLZ-24P / Notes: (1) Standard Seal Material = Urethane (2) Standard Operating Pressure: Z = A = 150 lb = 450 psi; Z = B = 300 lb = 1125 psi; Z = D = 600 lb = 2250 psi (10" & 12" only) (3) Clearance may be slightly smaller (less than 1/2") on plugs that accommodate more than one schedule size (4) Replacement washers are required on all schedule sizes except for the smallest one for each pipe size (5) 10" & 12" Seals include an external o-ring (6) Seal to Pipe clearance is approximately 1/2" info@expansionseal.com

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16 EXPANSION SEAL TECHNOLOGIES DC /00 PAGE 1 OF 4 STANDARD HIGH LIFT FLANGE WELD TEST PLUG OPERATING INSTRUCTIONS These operating instructions give step by step instructions on the use of the High Lift Flange Weld Test Plug. These plugs can be used in two different configurations as a testing plug and a welding plug. The test plug configuration allows the flange to pipe weld to be tested after welding. The weld plug configuration aids in the welding of the flange to pipe while monitoring upstream pressure and also allows the weld to be tested after welding. Follow steps labeled TP for test plug configuration, WP for weld plug configuration and TP WP for both. WARNING! PRESSURE TESTING IS INHERENTLY DANGEROUS. STRICT ADHERENCE TO THESE OPERATION INSTRUCTIONS AND INDUSTRY SAFETY PRACTICES COULD PREVENT INJURY TO PERSONNEL. ALL PERSONNEL MUST BE CLEAR OF TEST PLUG WHEN PRESSURE TESTING. FOR SAFETY, AN INCOMPRESSIBLE LIQUID SUCH AS WATER SHOULD BE USED AS THE TEST MEDIUM, RESIDUAL AIR OR GAS IS TO BE EVACUATED FROM THE PIPE PRIOR TO TESTING. PRIOR TO USE: Verify marking on seal with o-ring and replacement washer is equivalent to the pipe size being tested. They should be marked with the flange size and pipe schedule. The seal and the washer OD is sized approximately ½ smaller than the pipe ID. Replacement washers are required on all sizes except the smallest schedule available. The following sizes do NOT have replacement washers. 10 schedule 100, 12 schedule 80, 14 schedule schedule 120, 18 schedule 120, 20 schedule 100 & 24 schedule 120 Inspect the raised face (gasket surface) of the Flange Plug and mating flange to be tested. Damage or surface imperfections may result in leakage and should be repaired prior to testing. Clean and dry the pipe ID. Remove all moisture, debris and excessive scale. STEP 1 TP ATTACHMENT OF TEST PLUG TO MATING FLANGE Any weld droop or spatter that protrudes into pipe id more than the clearance listed in table 1 must be removed to allow plug installation. Apply gasket to mating flange face and position Flange Plug against mating flange. Rotate plug as required locating purge vent at highest point and installing flange bolts. Tighten bolts in a cross-like pattern to properly seal the flange gasket. WP ATTACHMENT OF WELDING PLUG SET-UP TO MATING FLANGE Locate the flange to be welded on the pipe using an alignment tool (The Flange Test & Welding Plug is not designed to support or position flange to be welded). Apply gasket to mating flange face and insert the Flange plug into the flange and pipe with the inert gas purge ports oriented at the top and bottom of the flange. Tighten bolts in a cross-like pattern to properly seal the flange gasket. STEP 2 TP WP TIGHTENING AND EXPANSION OF SEAL ELEMENT Correct Tightness of hex nut is critical to the operation of the Flange Test & Welding Plug, a leak of the seal is usually an indication the hex nuts were not adequately tightened. The normal torque listed in table 1 should be adequate for most installations, however due to variations within pipe ID finishes the torque may need to be increased up to the maximum torque value listed in table 1. If at the maximum torque the plug still leaks, verify the correct seal and washers are being used. Verify that the seal O-ring is seated correctly in the groove on seal and that the O-ring is not damaged, (10 and 12 plugs only). Tighten hex nuts in a cross-like pattern in approx. 100 ft/lbs increments using an impact wrench until torque specified in Table 1 has been reached. Verify this torque with a calibrated torque wrench. Remove the purge plug closest to highest point. Connect hydropump to fill port on Flange. Slowly begin to fill the plug until water flows from the vent. Discontinue water input and install plug leak tight. STEP 3 WP PREPARATION FOR WELDING Make connection to upstream monitor port that will clearly indicate an increase of pressure or the presence of dangerous gases. In addition upstream vapors may be vented by attaching approximately 50 ft. of hose to the vent port and locating the end of the hose downwind from the weld area. For normal conditions where Inert Gas Purge is not required: Remove pipe plugs from fill and vent plugs on the flange or make connections to fill and vent ports as required by welding safety procedures. If Inert gas purge is required:

17 EXPANSION SEAL TECHNOLOGIES DC /00 PAGE 2 OF 4 Remove pipe plugs from the fill and vent ports on the flange. Connect Inert gas supply to fill port. Make connections to vent port as required to monitor or regulate the flow of inert gas. Initiate Inert gas purge and adjust Inert gas pressure regulator as required to maintain a slight positive pressure during welding. As welding proceeds, adjust Inert gas flow as needed to insure weld quality. STEP 4 WP Welding NOTE: do not let the weld protrude into the pipe ID by more than the values listed in Table 1 or grinding of the pipe ID may be required for plug removal. Begin welding the flange to the pipe while monitoring upstream pressure. Stop welding immediately if the upstream pressure increases which indicates flow in the line. During welding the pipe at the seal location must not become too hot to touch by hand. Should the pipe in the seal location become too hot to touch by hand, discontinue welding and allow pipe too cool. STEP 5 TP WP HYDROSTATIC PRESSURE TEST WARNING! NEVER ATTEMPT TO ADJUST THE FLANGE TEST & WELDING PLUG WHILE UNDER PRESSURE. NEVER EXCEED THE TEST PRESSURES IN TABLE 2 Remove the vent plug. Connect hydropump to fill port on Flange. Slowly begin to fill the plug until water flows from the vent. Discontinue water input and install the vent plug leak tight. Refer to Table 2 for the maximum test pressure for the Flange Test Plug. The test pressure must never exceed the strength of the weakest component in the system being tested. Slowly introduce the test pressure. If a pressure decay test will be conducted, hold at desired pressure with pump for a minimum of 5 minutes prior to closing isolation valve. This will allow parts to settle. Continue holding the desired pressure to meet testing requirements. If pressure drops off a large amount or a leak between seal and tube id is detected, tighten the hex nut until leak is sealed. (Do not exceed max. installation torque). After the test is completed, release all pressure. Remove the fill and vent plugs to drain water. Remove all testing equipment. Loosen the hex nuts to fully relax seal. Loosen and remove hex nuts and flange mounting bolts. Withdraw the Flange Test Plug from the pipe. INSPECT PLUG AFTER EACH USE Surface imperfections on the flange face should be fixed prior to further testing. Replace worn or damaged seals and o-rings. Clean and dry prior to storage. Store these instructions with plug. TABLE 1 High Lift Flange Weld Test Plug Clearance and Suggested Installation Torque Values FLANGE TEST PLUG SIZE (IN) CLEARANCE BETWEEN SEAL OD & PIPE ID NORMAL INSTALLATION TORQUE (FT-LBS) MAX INSTALLATION TORQUE (FT-LBS) lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½ lb ½

18 EXPANSION SEAL TECHNOLOGIES DC /00 PAGE 3 OF 4 TABLE 2. High Lift Flange Weld Test Plug Maximum Test Pressures FLANGE CLASS MAXIMUM TEST PRESSURE (PSI) 150 LB LB LB 2250 REPLACEMENT SEAL & WASHER PROCEDURE 1. Remove hex nuts, hardened washers & compression tubes, if present, from Flange Test Plug. 2. Remove the flange assembly from the inner tube assembly. 3. The seal may now be removed from the inner tube assembly. (The 10 and 12 size seals have o-rings) 4. Verify marking on seal and replacement washer is equivalent to the pipe size being tested. They should be marked with the flange size and pipe schedule. Replacement washers are required on all sizes except the smallest schedule available. The following sizes do NOT have replacement washers. 10 schedule 100, 12 schedule 80, 14 schedule schedule 120, 18 schedule 120, 20 schedule 100 & 24 schedule Install the replacement washer so the radius on outside edge is towards the seal. The replacement washer has an internal chamfer for weld clearance. Ensure this is installed correctly. Install the seal. 6. Place the flange assembly back onto the inner tube assembly 7. Install the compression tubes, if present, the hardened washers and the hex nuts. 8. The Flange Test Plug is ready for testing. QUESTIONS? Contact EST Customer Service at any of the following locations with questions. In USA and Canada: tel: , fax: , info@expansionseal.com In Europe: tel: , fax: ; info@estgrp.nl In Asia: tel: , fax: , estasia@singnet.com.sg On the Internet: Expansion Seal Technologies is part of the EST Group of companies. EST Group provides a complete range of repair products, services and replacement parts covering the life cycle of tubular heat exchangers and condensers; additionally EST provides products and services to facilitate pressure testing pipe, piping systems, pressure vessels and their components. Visit EST Group on the internet at

19 EXPANSION SEAL TECHNOLOGIES DC /00 PAGE 4 OF 4 REPLACEMENT PART LIST REPLACEMENT PART LIST REPLACEMENT O-RING REPLACEMENT REPLACEMENT O-RING REPLACEMENT PIPE PIPE SEAL DASH SEAL & WASHER PIPE PIPE SEAL DASH SEAL & WASHER SIZE SCHEDULE PART NUMBER NUMBER SET PART NUMBER SIZE SCHEDULE PART NUMBER NUMBER SET PART NUMBER 10 sch 100 HL-10P100-RS -445 N/A 18 sch 120 HL-18P120-RS N/A N/A 10 sch 80 HL-10P80-RS -446 HL-10P80-SW 18 sch 100 HL-18P100-RS N/A HL-18P100-SW 10 sch 60/xs HL-10PXSRS -446 HL-10PXSSW 18 sch 80 HL-18P80-RS N/A HL-18P80-SW 10 sch 40/std HL-10P40-RS -447 HL-10P40-SW 18 sch 60 HL-18P60-RS N/A HL-18P60-SW 10 sch 30 HL-10P30-RS -447 HL-10P30-SW 18 sch 40 HL-18P40-RS N/A HL-18P40-SW 10 sch 20 HL-10P20-RS -447 HL-10P20-SW 18 xs HL-18PXS-RS N/A HL-18PXS-SW 10 sch 10s HL-10P10S-RS -448 HL-10P10S-SW 18 sch 30 HL-18P30-RS N/A HL-18P30-SW 10 sch 5 HL-10P5-RS -448 HL-10P5-SW 18 std HL-18PSTD-RS N/A HL-18PSTD-SW 12 sch 80 HL-12P80-RS -449 N/A 18 sch 20 HL-18P20-RS N/A HL-18P20-SW 12 sch 60 HL-12P60-RS -450 HL-12P60-SW 18 sch 10/10s/5 HL-18P10-RS N/A HL-18P10-SW 12 xs HL-12PXS-RS -450 HL-12PXS-SW 20 sch 100 HL-20P100-RS N/A N/A 12 sch40/std HL-12P40-RS -451 HL-12P40-SW 20 sch 80 HL-20P80-RS N/A HL-20P80-SW 12 sch 30 HL-12P30-RS -451 HL-12P30-SW 20 sch 60 HL-20P60-RS N/A HL-20P60-SW 12 sch 20 HL-12P20-RS -451 HL-12P20-SW 20 sch 40 HL-20P40-RS N/A HL-20P40-SW 12 sch10s/ 5 HL-12P10S-RS -452 HL-12P10S-SW 20 sch 30/xs HL-20PXS-RS N/A HL-20PXS-SW 14 sch 140 HL-14P140-RS N/A N/A 20 sch 20/std HL-20PSTD-RS N/A HL-20PSTD-SW 14 sch 120 HL-14P120-RS N/A HL-14P120-SW 20 sch 10 HL-20P10-RS N/A HL-20P10-SW 14 sch 100 HL-14P100-RS N/A HL-14P100-SW 24 sch 120 HL-24P120-RS N/A N/A 14 sch 80 HL-14P80-RS N/A HL-14P80-SW 24 sch 100 HL-24P100-RS N/A HL-24P100-SW 14 sch 60 HL-14P60-RS N/A HL-14P60-SW 24 sch 80 HL-24P80-RS N/A HL-24P80-SW 14 xs HL-14PXS-RS N/A HL-14PXS-SW 24 sch 60 HL-24P60-RS N/A HL-24P60-SW 14 sch 40 HL-14P40-RS N/A HL-14P40-SW 24 sch 40 HL-24P40-RS N/A HL-24P40-SW 14 sch 30/std HL-14PSTD-RS N/A HL-14PSTD-SW 24 sch 30 HL-24P30-RS N/A HL-24P30-SW 14 sch 20 HL-14P20-RS N/A HL-14P140-SW 24 xs HL-24PXS-RS N/A HL-24PXS-SW 14 sch 10/10s/5 HL-14P10-RS N/A HL-14P140-SW 24 sch 20/std HL-24PSTD-RS N/A HL-24PSTD-SW 16 sch 120 HL-16P120-RS N/A N/A 24 sch 10/5 HL-24P10-RS N/A HL-24P10-SW 16 sch 100 HL-16P100-RS N/A HL-16P100-SW 16 sch 80 HL-16P80-RS N/A HL-16P80-SW 16 sch 60 HL-16P60-RS N/A HL-16P60-SW 16 sch 40/xs HL-16P40-RS N/A HL-16P40-SW 16 sch 30/std HL-16PSTD-RS N/A HL-16PSTD-SW 16 sch 20 HL-16P20-RS N/A HL-16P20-SW 16 sch 10/10s/5 HL-16P10-RS N/A HL-16P10-SW

20 EXPANSION SEAL TECHNOLOGIES DC /98 REV 3 07/99 PAGE 1 OF 6 HIGH LIFT FLANGE TEST & WELDING PLUG OPERATING INSTRUCTIONS These operating instructions give step-by-step instructions on the use of the high lift flange test & welding plug. This plug can be used in two different configurations as a test plug and a welding plug. The test plug configuration allows the flange to pipe weld to be tested after welding. The weld plug configuration aids in the welding of the flange to pipe while monitoring upstream pressure and also allows the weld to be tested after welding. Follow steps labeled TP for test plug configuration, WP for weld plug configuration and TP WP for both WARNING! PRESSURE TESTING IS INHERENTLY DANGEROUS. STRICT ADHERENCE TO THESE OPERATING INSTRUCTIONS AND INDUSTRY SAFETY PRACTICES COULD PREVENT INJURY TO PERSONNEL ALL PERSONNEL MUST BE CLEAR OF TEST PLUG WHEN PRESSURE TESTING FOR SAFETY, AN INCOMPRESSIBLE LIQUID SUCH AS WATER SHOULD BE USED AS THE TEST MEDIUM. RESIDUAL AIR OR GAS IS TO BE EVACUATED FROM THE PIPE PRIOR TO TESTING. PRIOR TO USE: Verify stamping on washer is equivalent to the pipe size being tested. The washer should be stamped with the flange size and pipe schedule. Example: The stamp 1P80 should be interpreted as 1 Sch 80 pipe sizes. The seal OD should be the same as the washer OD. Inspect the raised face (gasket surface) of the Flange Plug and mating flange to be tested. Damage or surface imperfections may result in leakage and should be repaired prior to testing. Clean and dry the pipe ID. Remove all moisture, debris and excessive scale. STEP 1 TP ATTACHMENT OF TEST PLUG TO MATING FLANGE Any weld droop or spatter that protrudes into pipe ID more than clearance listed in Table 1 must be removed to allow plug installation. If installation depth is limited in length of pipe one of the compression tubes between the flange and seal can be moved to the opposite side of the flange to reduce the distance between seal and flange. For ¾ 1 sizes the compression tube that is being repositioned must be placed between the Flange/Fill-Vent Port tube assembly and the Upstream monitor Port Tube. (See diagram on page 3) Apply gasket to mating flange face and position Flange Plug against mating flange. Rotate plug as required locating purge vent at highest point and installing flange bolts. Tighten bolts in a cross-like pattern to properly seal the flange gasket. WP ATTACHMENT OF WELDING PLUG SET-UP TO MATING FLANGE The distance between the flange and the washer and seal assembly should be approx. 12. If not check to see both compression tubes are installed between the flange and seal and washer assembly. Locate the flange to be welded on the pipe using an alignment tool (The Flange Test & Welding Plug is not designed to support or position flange to be welded). Apply gasket to mating flange face and insert the Flange plug into the flange and pipe with the inert gas purge ports oriented at the top and bottom of the flange. Tighten bolts in a cross-like pattern to properly seal the flange gasket. STEP 2 TP WP TIGHTENING AND EXPANSION OF SEAL ELEMENT Correct Tightness of hex nut is critical to the operation of the Flange Test & Welding Plug, a leak of the seal is usually an indication the hex nut(s) was not adequately tightened. The normal torque listed in Table 1 should be adequate for most installations, however due to variations within pipe id finishes the torque may need to be increased up to the maximum torque value listed in Table 1. If at the maximum torque the plug still leaks verify the correct seal and washers are being used. For Sizes 3/4 to 2-1/2 : Tighten hex nut to normal installation torque listed in Table 1 using a calibrated torque wrench. If shaft spins while hex nut is being tightened, a crowsfoot and a pipe wrench/opened end wrench must be used. (See Table 1 for crowsfoot sizes.) For Sizes 3-8 : For sizes 3 and larger, tighten the hex nut by hand to remove any slack from the parts. Then use a ¾ drive or larger impact wrench capable of producing the torque values listed in Table 1. A deep impact socket is required (See Table 1 for impact socket sizes.). The use of an impact wrench will prevent the shaft from spinning and enable the counting of turns listed in Table 1 to reach the required torque. If an impact wrench and deep socket are not available, two pipe wrenches may be used. The second is required to hold the shaft while turning the hex nut the required number of times.

21 EXPANSION SEAL TECHNOLOGIES DC /98 REV 3 07/99 PAGE 2 OF 6 The torque may be checked with a calibrated torque wrench and should be between the normal and maximum values listed in Table 1. NOTE: The torque required to seal plug sizes 3 to 8 is greater than the torque used to bolt up a 300lb flange when using a spiral wound metal gasket. STEP 3 WP PREPARATION FOR WELDING Make connection to upstream monitor port that will clearly indicate an increase of pressure or the presence of dangerous gases. In addition upstream vapors may be vented by attaching approximately 50 ft. of hose to the vent port and locating the end of the hose downwind from the weld area. For normal conditions where Inert Gas Purge is not required: Remove pipe plugs from fill and vent plugs on the flange or make connections to fill and vent ports as required by welding safety procedures. If Inert gas purge is required: Remove pipe plugs from the fill and vent ports on the flange. Connect Inert gas supply to fill port. Make connections to vent port as required to monitor or regulate the flow of inert gas. Initiate Inert gas purge and adjust Inert gas pressure regulator as required to maintain a slight positive pressure during welding. As welding proceeds, adjust Inert gas flow as needed to insure weld quality. STEP 4 WP WELDING NOTE: Do not let the weld protrude into the pipe ID by more than the values listed in Table 1 or grinding of the pipe ID may be required for plug removal. Begin welding the flange to the pipe while monitoring upstream pressure. Stop welding immediately if the upstream pressure increases which indicates flow in the line. During welding the pipe at the seal location must not become too hot to touch by hand. Should the pipe in the seal location become too hot to touch by hand, discontinue welding and allow pipe too cool. STEP 5 TP WP HYDROSTATIC PRESSURE TEST WARNING: NEVER ATTEMPT TO ADJUST THE FLANGE TEST & WELDING PLUG WHILE UNDER PRESSURE. NEVER EXCEED THE TEST PRESSURES IN TABLE 2. Remove the vent plug. Connect hydropump to fill port on Flange. Slowly begin to fill the plug until water flows from the vent. Discontinue water input and install the vent plug leak tight. Refer to Table 2 for the maximum test pressure for the Flange Test Plug. The test pressure must never exceed the strength of the weakest component in the system being tested. Slowly introduce the test pressure. If a pressure decay test will be conducted, hold at desired pressure with pump for a minimum of 5 minutes prior to closing isolation valve. This will allow parts to settle. Continue holding the desired pressure to meet testing requirements. If pressure drops off a large amount or a leak between seal and tube id is detected, tighten the hex nut until leak is sealed. (Do not exceed max. installation torque). After the test is completed, release all pressure. Remove the fill and vent plugs to drain water. Remove all testing equipment. Loosen the hex nut(s) to fully relax seal. Loosen and remove hex nuts and flange mounting bolts. Withdraw the Flange Test Plug from the pipe. INSPECT PLUG AFTER EACH USE Surface imperfections on the flange face should be fixed prior to further testing. Replace worn or damaged seals. Clean and dry plug prior to storage. Store these instructions with plug.

22 EXPANSION SEAL TECHNOLOGIES DC /98 REV 3 07/99 PAGE 3 OF 6 TABLE 1. High Lift Flange Weld Test Plug Clearance and Suggested Installation Torque Values Nom. Plug Size Nom. Plug Size Clearance Between Plug & Pipe (in) Normal Installation Torque Maximum Installation Torque Wrench Size to Hold Shaft (in) Crowsfoot Size (in) ¾ in-lbs. Do Not Exceed 9/16 9/16 Normal Torque in-lbs 200 in-lbs 9/16 9/16 1-1/ ft-lbs 40 ft-lbs 1 / 2 15/16 1-1/ ft-lbs 40 ft-lbs 1 / 2 15/ ft-lbs 50 ft-lbs 1 / 2 15/16 2-1/ ft-lbs 200 ft-lbs 7/8 2 Clearance Between Plug & Pipe (in) Normal Installation Torque (*) Maximum Installation Torque Estimated Number of Turns of Hex Nut Wrench Size to Hold Shaft (in) Deep Impact Socket Size (in) ft-lbs 400 ft-lbs 5 7/ ft-lbs 400 ft-lbs 5 7/ ft-lbs 900 ft-lbs 6 1-5/8 3-1/ ft-lbs 900 ft-lbs 6 1-5/8 3-1/8 Under normal conditions a 200lb. Man would require at least a 1ft. lever to achieve 200ft-lbs. The same man would require at least a 2ft. lever to achieve 400ft-lbs. TABLE 2. Flange Weld Test Plug Working Pressures CLASS MAXIMUM TEST PRESSURE (PSI) 150 LB LB LB 1125 REPLACEMENT SEAL & WASHER PROCEDURE ¾ 1 Plug Sizes (refer to Figure 1.) 1. Remove hex nut & jam nut from bottom of shaft. 2. Remove bottom washer, seal and washer from shaft.. 3. Install first washer, seal and second washer. 4. Install jam nut onto shaft as far as possible. Install hex nut and wrench tighten hex nut against jam nut. 5. Plug is ready for testing. 1-1/4 To 3 Plug Sizes (refer to Figure 2.) 1. Remove hex nut & jam nut from shaft. 2. Remove washer, seal and o-ring washer from shaft taking care not to damage o-ring in ID of washer. Inspect o-ring and replace if worn or damaged. 3. Lubricate o-ring in id of washer with grease and carefully install washer onto shaft. 4. Install seal and washer. 5. Install jam nut onto shaft as far as possible. Install hex nut and wrench tighten hex nut against jam nut. 6. Plug is ready for testing.

23 EXPANSION SEAL TECHNOLOGIES DC /98 REV 3 07/99 PAGE 4 OF 6 4 To 8 Plug Sizes (refer to Figure 3.) 1. Remove hex nut & jam nut from shaft. 2. Remove washer, seal and o-ring washer from shaft taking care not to damage o-ring in ID of washer. Inspect o-ring and replace if worn or damaged. 7. Lubricate o-ring in id of washer with grease and carefully install washer onto shaft so that tapered side will be positioned against seal. 3. Install seal and tapered washer, so that tapered side will be positioned against seal. 4. Install jam nut onto shaft threads first as far as possible. Install hex nut and wrench tighten hex nut against jam nut. 5. Plug is ready for testing. QUESTIONS? Contact EST Customer Service at any of the following locations with questions. In USA and Canada: tel: , fax: , info@expansionseal.com In Europe: tel: , fax: ; info@estgrp.nl In Asia: tel: , fax: , estasia@singnet.com.sg On the Internet: Expansion Seal Technologies is part of the EST Group of companies. EST Group provides a complete range of repair products, services and replacement parts covering the life cycle of tubular heat exchangers and condensers; additionally EST provides products and services to facilitate pressure testing pipe, piping systems, pressure vessels and their components. Visit EST Group on the internet at

24 EXPANSION SEAL TECHNOLOGIES DC /98 REV 3 07/99 PAGE 5 OF 6 Figure 1. High Lift Flange Weld Test Plug, ¾ and 1 Plug Sizes, Shown in WP Configuration Figure 2. High Lift Flange Weld Test Plug, 1-1/4 through 3 Plug Sizes, Shown in WP Configuration

25 EXPANSION SEAL TECHNOLOGIES DC /98 REV 3 07/99 PAGE 6 OF 6 Figure 3. High Lift Flange Weld Test Plug, 4 through 8 Plug Sizes, Shown in WP Configuration

26 EXPANSION SEAL TECHNOLOGIES DC /98 PAGE 1 OF 2 HIGH LIFT UPGRADE RETROFIT INSTRUCTIONS FOR FLANGE TEST & FLANGE WELD PLUGS This Instruction outlines how to retrofit High Lift Seals onto Flange Test and Flange Weld Plugs. The seal retrofit strictly increases the clearance between the plug and the pipe, it is not intended to change or modify the intended use of the Flange Test or Flange Weld Plug. Refer to DC2678 High Lift Flange Test Plug/Weld Plug Operating Procedures when using the upgraded product. Table 1. Maximum Pressure Ratings for Upgraded Flange Test & Flange Weld Plugs Class Maximum Test Pressure 150 lb. 450psi (31 Bar) 300 lb. 1125psi (77 Bar) 600 lb. 1125psi (77 Bar) 3/4 1 PLUG SIZES, HIGH LIFT SEAL AND WASHER UPGRADE 1. Remove Jamnuts, seal and washers from bottom of shaft. 2. Install one washer, urethane seal, second washer and Jamnuts onto shaft threads, threading on as far as possible. Wrench tighten Jamnuts together. 1-1/4 2 PLUG SIZES, HIGH LIFT SEAL AND WASHER UPGRADE 1. Remove Jamnuts, seal and washers from bottom of shaft. 2. Lubricate the o-ring in ID of the new washer. 3. Carefully install the washer with internal o-ring onto the shaft. 4. Install the urethane seal, washer and Jamnuts onto shaft threads, threading on as far as possible. Wrench tighten Jamnuts together. 2-1/2 3 PLUG SIZES, HIGH LIFT SEAL AND WASHER UPGRADE 1. Remove Jamnuts, seal and washers from bottom of shaft. 2. Install the 1 long compression tube, provided with upgrade kit, onto the shaft. 3. Lubricate the o-ring in ID of the new washer. 4. Carefully install the washer with internal o-ring onto the shaft. 5. Install the urethane seal, washer and Jamnuts onto shaft threads, threading on as far as possible. Wrench tighten Jamnuts together. 4 PLUG SIZE, HIGH LIFT SEAL AND WASHER UPGRADE 1. Remove Jamnuts, seal and washers from bottom of shaft. 2. Install the 1 long compression tube, provided with upgrade kit, onto the shaft. 3. Lubricate the o-ring in ID of the new tapered washer. 4. Carefully install the tapered washer with internal o-ring onto the shaft so that tapered side will be positioned against the seal. 5. Install the urethane seal, tapered washer so that tapered side will be positioned against the seal and Jamnuts onto shaft threads, threading on as far as possible. Wrench tighten Jamnuts together. 6-8 PLUG SZES, HIGH LIFT SEAL AND WASHER UPGRADE 1. Remove Jamnuts, seal and washers from bottom of shaft. 2. Lubricate the o-ring in ID of the new tapered washer. 3. Carefully install the tapered washer with internal o-ring onto the shaft so that tapered side will be positioned against the seal. 4. Install the urethane seal, tapered washer so that tapered side will be positioned against the seal and Jamnuts onto shaft threads, threading on as far as possible. Wrench tighten Jamnuts together. QUESTIONS? Contact EST Customer Service at any of the following locations with questions. In USA and Canada: tel: , fax: , info@expansionseal.com In Europe: tel: , fax: ; info@estgrp.nl In Asia: tel: , fax: , estasia@singnet.com.sg On the Internet: Expansion Seal Technologies is part of the EST Group of companies. EST Group provides a complete range of repair products, services and replacement parts covering the life cycle of tubular heat exchangers and condensers; additionally EST provides products and services to facilitate pressure testing pipe, piping systems, pressure vessels and their components. Visit EST Group on the internet at

27 EXPANSION SEAL TECHNOLOGIES DC /98 PAGE 2 OF 2 Figure 1. Flange Weld Test Plug and High Lift Seal and Washer Sets Table 1. High Lift Seal and Washer Upgrade Part Numbers UPGRADE KIT FLANGE SIZE FLANGE CLASS PIPE SCHEDULE OD LENGTH PART NUMBER HL-75P80-UG 3/4 150# /4 HL-75P40-UG 3/4 300# /4 HL-1P80-UG 1 600# /4 HL-1P40-UG /4 HL-125P80-UG 1-1/ /8 HL-125P40-UG 1-1/ /8 HL-15P80-UG 1-1/ /4 HL-15P40-UG 1-1/ /4 HL-2P80-UG /4 HL-2P40-UG /4 HL-25P80-UG 2-1/ HL-25P40-UG 2-1/ HL-3P80-UG HL-3P40-UG HL-4P80-UG HL-4P40-UG HL-6P80-UG /4 HL-6P40-UG /4 HL-8P80-UG HL-8P40-UG

28 EXPANSION SEAL TECHNOLOGIES DC /99 REV 1 07/99 PAGE 1 OF 5 CANADIAN HIGH LIFT FLANGE TEST & WELDING PLUG OPERATING INSTRUCTIONS These operating instructions give step by step instructions on the use of the high lift flange test & welding plug. This plug can be used in two different configurations as a test plug and a welding plug. The test plug configuration allows the flange to pipe weld to be tested after welding. The weld plug configuration aids in the welding of the flange to pipe while monitoring upstream pressure and also allows the weld to be tested after welding. Follow steps labeled TP for test plug configuration, WP for weld plug configuration and TP WP for both WARNING! PRESSURE TESTING IS INHERENTLY DANGEROUS. STRICT ADHERENCE TO THESE OPERATING INSTRUCTIONS AND INDUSTRY SAFETY PRACTICES COULD PREVENT INJURY TO PERSONNEL ALL PERSONNEL MUST BE CLEAR OF TEST PLUG WHEN PRESSURE TESTING FOR SAFETY, AN INCOMPRESSIBLE LIQUID SUCH AS WATER SHOULD BE USED AS THE TEST MEDIUM. RESIDUAL AIR OR GAS IS TO BE EVACUATED FROM THE PIPE PRIOR TO TESTING. PRIOR TO USE: Verify stamping on washer is equivalent to the pipe size being tested. The washer should be stamped with the flange size and pipe schedule. Example: The stamp 1P80 should be interpreted as 1 Sch 80 pipe sizes. The seal OD should be the same as the washer OD. Inspect the raised face (gasket surface) of the Flange Plug and mating flange to be tested. Damage or surface imperfections may result in leakage and should be repaired prior to testing. Clean and dry the pipe ID. Remove all moisture, debris and excessive scale. STEP 1 TP ATTACHMENT OF TEST PLUG TO MATING FLANGE Any weld droop or spatter that protrudes into pipe id more than clearance listed in table 1 must be removed to allow plug installation. If installation depth is limited in length of pipe one of the compression tubes between the flange and seal can be moved to the opposite side of the flange to reduce the distance between seal and flange. For ¾ 1 sizes the compression tube that is being repositioned must be placed between the Flange/Fill-Vent Port tube assembly and the Upstream monitor Port Tube. (See diagram on page 3) Apply gasket to mating flange face and position Flange Plug against mating flange. Rotate plug as required locating fill port at highest point and installing flange bolts. Tighten bolts in a cross-like pattern to properly seal the flange gasket. WP ATTACHMENT OF WELDING PLUG SET-UP TO MATING FLANGE The distance between the flange and the washer and seal assembly should be approx. 12. If not check to see both compression tubes are installed between the flange and seal and washer assembly. Locate the flange to be welded on the pipe using an alignment tool (The Flange Test & Welding Plug is not designed to support or position flange to be welded). Apply gasket to mating flange face and insert the Flange plug into the flange and pipe with the fill port oriented at the top of flange. Tighten bolts in a cross-like pattern to properly seal the flange gasket. STEP 2 TP WP TIGHTENING AND EXPANSION OF SEAL ELEMENT Correct Tightness of hex nut is critical to the operation of the Flange Test & Welding Plug, a leak of the seal is usually an indication the hex nut(s) was not adequately tightened. The normal torque listed in table 1 should be adequate for most installations, however due to variations within pipe id finishes the torque may need to be increased up to the maximum torque value listed in table 1. If at the maximum torque the plug still leaks verify the correct seal and washers are being used. For Sizes 3/4 to 2-1/2 PLUG SIZES Tighten hex nut to normal installation torque listed in Table 1 using a calibrated torque wrench. If shaft spins while hex nut is being tightened, a crowsfoot and a pipe wrench/opened end wrench must be used. (See table 1 for crowsfoot sizes.) For Sizes 3-8 PLUG SIZES: For sizes 3 and larger, tighten the hex nut by hand to remove any slack from the parts. Then use a ¾ drive or larger impact wrench capable of producing the torque values listed in Table 1. A deep impact socket is required (See table 1 for impact socket

29 EXPANSION SEAL TECHNOLOGIES DC /99 REV 1 07/99 PAGE 2 OF 5 sizes.). The use of an impact wrench will prevent the shaft from spinning and enable the counting of turns listed in Table 1 to reach the required torque. If an impact wrench and deep socket are not available, two pipe wrenches may be used. The second is required to hold the shaft while turning the hex nut the required number of times. The torque may be checked with a calibrated torque wrench and should be between the normal and maximum values listed in Table 1. NOTE: The torque required to seal plug sizes 3 to 8 is greater than the torque used to bolt up a 300lb flange when using a spiral wound metal gasket. STEP 3 WP PREPARATION FOR WELDING Make connection to upstream monitor port that will clearly indicate an increase of pressure or the presence of dangerous gases. In addition upstream vapors may be vented by attaching approximately 50 ft. of hose to the upstream monitor port and locating the end of the hose downwind from the weld area. For normal conditions where Inert Gas Purge is not required: Remove pipe plug from fill port on the flange and make connection to fill port as required by welding safety procedures. If Inert gas purge is required: Remove pipe plug from the fill port on the flange. Connect Inert gas supply to fill port. Initiate Inert gas purge and adjust Inert gas pressure regulator as required to maintain a slight positive pressure during welding. As welding proceeds, adjust Inert gas flow as needed to insure weld quality. STEP 4 WP WELDING NOTE: DO NOT LET THE WELD PROTRUDE INTO THE PIPE I.D. BY MORE THAN THE VALUES LISTED IN TABLE 1 OR GRINDING OF THE PIPE I.D. MAY BE REQUIRED FOR PLUG REMOVAL. Begin welding the flange to the pipe while monitoring upstream pressure. Stop welding immediately if the upstream pressure increases which indicates flow in the line. During welding the pipe at the seal location must not become too hot to touch by hand. Should the pipe in the seal location become too hot to touch by hand, discontinue welding and allow pipe too cool. STEP 5 TP WP HYDROSTATIC PRESSURE TEST WARNING! NEVER ATTEMPT TO ADJUST THE FLANGE TEST & WELDING PLUG WHILE UNDER PRESSURE. NEVER EXCEED THE TEST PRESSURES IN TABLE 2 WARNING! (DO NOT EXCEED MAX. INSTALLATION TORQUE WHEN INSTALLING PLUG. REFER TO TABLE 1. Remove air from test cavity: Attach a valve to the fill port on the flange face of the plug. Attach the water supply to this valve. Fill and pressurize test cavity to at least 150 psi. Close valve. Release pump pressure and remove fill line from pump to valve. Open the valve to release the trapped air. This process should be repeated at least once before applying test pressure. Refer to Table 2 for the maximum test pressure for the Flange Test Plug. The test pressure must never exceed the strength of the weakest component in the system being tested. Slowly introduce the test pressure. If a pressure decay test will be conducted, hold at desired pressure with pump for a minimum of 5 minutes prior to closing isolation valve. This will allow parts to settle. Continue holding the desired pressure to meet testing requirements. If pressure drops off a large amount or a leak between seal and tube id is detected, tighten the hex nut until leak is sealed. After the test is completed, bleed off all pressure and disconnect pressure pump from fill port. Loosen the hex nut(s) to fully relax seal. Loosen and remove hex nuts and flange mounting bolts. Withdraw the Flange Test Plug from the pipe.

30 EXPANSION SEAL TECHNOLOGIES DC /99 REV 1 07/99 PAGE 3 OF 5 INSPECT PLUG AFTER EACH USE Surface imperfections on the flange face should be fixed prior to further testing. Replace worn or damaged seals. Clean and dry plug thoroughly prior to storage. Store these instructions with plug. TABLE 1. Canadian High Lift Flange Weld Test Plug Installation Torques. Size Clearance Between Plug & Pipe (in) Normal Installation Torque Maximum Installation Torque Wrench Size to Hold Shaft (in) Crowsfoot Size (in) ¾ in-lbs. Do Not Exceed 9/16 9/16 Normal Torque in-lbs 200 in-lbs 9/16 9/16 1-1/ ft-lbs 40 ft-lbs 1 / 2 15/16 1-1/ ft-lbs 40 ft-lbs 1 / 2 15/ ft-lbs 50 ft-lbs 1 / 2 15/16 2-1/ ft-lbs 200 ft-lbs 7/8 2 Size Clearance Between Plug & Pipe (in) Normal Installation Torque (*) Maximum Installation Torque Estimated Number of Turns of Hex Nut Wrench Size to Hold Shaft (in) Deep Impact Socket Size (in) ft-lbs 400 ft-lbs 5 7/ ft-lbs 400 ft-lbs 5 7/ ft-lbs 900 ft-lbs 6 1-5/8 3-1/ ft-lbs 900 ft-lbs 6 1-5/8 3-1/8 Under normal conditions a 200lb. Man would require at least a 1ft. lever to achieve 200ft-lbs. The same man would require at least a 2ft. lever to achieve 400ft-lbs. TABLE 2. Canadian High Lift Flange Weld Test Plug Working Pressures. CLASS MAXIMUM TEST PRESSURE (PSI) 150 LB LB LB 1125 REPLACEMENT SEAL & WASHER PROCEDURE ¾ 1 PLUG SIZES, Refer to Figure Remove hex nut & jamnut from bottom of shaft. 2. Remove bottom washer, seal and washer from shaft. 3. Install first washer, seal and second washer. 4. Install jam nut onto shaft as far as possible. Install hex nut and wrench tighten hex nut against jamnut. 5. Plug is ready for testing.

31 EXPANSION SEAL TECHNOLOGIES DC /99 REV 1 07/99 PAGE 4 OF 5 1-1/4 To 3 PLUG SIZES, Refer to Figure Remove hex nut & jam nut from shaft. 2. Remove washer, seal and o-ring washer from shaft taking care not to damage o-ring in i.d. of washer. Inspect o-ring and replace if worn or damaged. 3. Lubricate o-ring in id of washer with grease and carefully install washer onto shaft. 4. Install seal and washer. 5. Install jam nut onto shaft as far as possible. Install hex nut and wrench tighten hex nut against jam nut. 6. Plug is ready for testing. 4 To 8 PLUG SIZES, Refer to Figure Remove hex nut & jam nut from shaft. 2. Remove washer, seal and o-ring washer from shaft taking care not to damage o-ring in i.d. of washer. Inspect o-ring and replace if worn or damaged. 7. Lubricate o-ring in id of washer with grease and carefully install washer onto shaft so that tapered side will be positioned against seal. 3. Install seal and tapered washer, so that tapered side will be positioned against seal. 4. Install jam nut onto shaft threads first as far as possible. Install hex nut and wrench tighten hex nut against jam nut. Plug is ready for testing. QUESTIONS? Contact EST Customer Service at any of the following locations with questions. In USA and Canada: tel: , fax: , info@expansionseal.com In Europe: tel: , fax: ; info@estgrp.nl In Asia: tel: , fax: , estasia@singnet.com.sg On the Internet: Expansion Seal Technologies is part of the EST Group of companies. EST Group provides a complete range of repair products, services and replacement parts covering the life cycle of tubular heat exchangers and condensers; additionally EST provides products and services to facilitate pressure testing pipe, piping systems, pressure vessels and their components. Visit EST Group on the internet at Figure 1. ¾ And 1 Canadian High Lift Flange Weld Test Plugs

32 EXPANSION SEAL TECHNOLOGIES DC /99 REV 1 07/99 PAGE 5 OF 5 Figure /4 through 3 Canadian High Lift Flange Weld Test Plugs Figure 3. 4 through 8 Canadian High Lift Flange Weld Test Plugs

33 EXPANSION SEAL TECHNOLOGIES DC /02 REV 1 06/03 PAGE 1 OF 4 ADDENDUM TO DC2678 OPERATING INSTRUCTIONS FOR HIGH LIFT FLANGE PLUGS USED AS WELD ISOLATION PLUGS WITHOUT FLANGE WARNING! PRESSURE TESTING IS INHERENTLY DANGEROUS. STRICT ADHERENCE TO THESE OPERATING INSTRUCTIONS AND INDUSTRY SAFETY PRACTICES COULD PREVENT INJURY TO PERSONNEL. ALL PERSONNEL MUST BE CLEAR OF TEST PLUG WHEN PRESSURE TESTING. FOR SAFETY, AN INCOMPRESSIBLE LIQUID SUCH AS WATER SHOULD BE USED AS THE TEST MEDIUM. RESIDUAL AIR OR GAS IS TO BE EVACUATED FROM THE PIPE PRIOR TO TESTING. CAUTION: THE SEAL ASSEMBLY, WHEN NOT ATTACHED TO A PROPERLY INSTALLED FLANGE, WILL NOT SEAL THE TEST PRESSURES PER ANSI B16.5. TO AVOID EXPULSION OF THE SHAFT AND SEAL ASSEMBLY FROM THE PIPE, DO NOT ALLOW UPSTREAM PRESSURE TO EXCEED THE VALUES SHOWN IN TABLE (2) AND INSTALL SAFETY GAG (SEE FIGURE 2). PRIOR TO INSTALLATION 1. To insure that all installation torque is transmitted to the seal, liberally spread antiseize over both sides of the hardened washer and onto the threads of the shaft. Use caution when applying the lubricant and handling the test plug after lubrication. The lubricant must not come in contact with the rubber seal or tube ID. WARNING! FAILURE TO USE ANTISEIZE MAY CAUSE AN INCOMPLETE TORQUE TRANSMITTAL WHICH WILL RESULT IN A DECREASE IN THE PRESSURE RATING. 2. Verify stamping on washer is equivalent to the pipe size being tested. The washer should be stamped with the flange size and pipe schedule. Example: The stamp 1P80 should be interpreted as 1 Sch 80 pipe sizes. The seal OD should be the same as the washer OD. 3. Complete Site safety standard checklist. NOTE: If the size of the seal/washer set is different than the pipe to be tested, contact Expansion Seal for the correctly sized set. 4. Prior to installing the flange welding/hydrostatic test plug, clean all debris from the pipe ID. For ¾ 1 Plug Sizes 5. Disassemble plug by removing jam nuts from end of plug. Remove all parts except hex nut and hardened washer. Install safety gag link, long tube and remaining parts as shown in Figure 2. Insert the plug into the pipe. Attach pipe restraint and tighten bolts on clamp to avoid slippage. Proceed with either step 8 9, or 10 below depending on plug size. For 1-1/2 8 Plug Sizes 6. Remove hex nut and hardened washer, compression tubes & flange. Install long tube and safety gag link as shown in Figure 2. Insert the plug into the pipe. Attach pipe restraint and tighten bolts on clamp to avoid slippage. Proceed with either step 8, 9 or 10 below depending on plug size. For Plug Sizes 7. Locate the flange on the pipe using an alignment tool (The Flange Test & Welding Plug is not designed to support or position flange to be welded). Apply gasket to mating flange face and insert the Flange plug into the flange and pipe with the inert gas purge ports oriented at the top and bottom of the flange. Tighten bolts in a cross-like pattern to properly seal the flange gasket. See figure 4. Proceed with either step 8, 9 or 10 below depending on plug size.

34 EXPANSION SEAL TECHNOLOGIES DC /02 REV 1 06/03 PAGE 2 OF 4 TIGHTENING AND EXPANSION OF SEAL ELEMENT For 3/4 to 2-1/2 Plug Sizes 8. Tighten hex nut to normal installation torque listed in Table 1 using a calibrated torque wrench. If shaft spins while hex nut is being tightened, a crowsfoot and a pipe wrench/opened end wrench must be used. (See Table 1 for crowsfoot sizes.) For 3-8 Plug Sizes 9. Tighten the hex nut by hand to remove any slack from the parts. Then use a ¾ drive or larger impact wrench capable of producing the torque values listed in Table 1. A deep impact socket is required (See Table 1 for impact socket sizes.). The use of an impact wrench will prevent the shaft from spinning and enable the counting of turns listed in Table 1 to reach the required torque. For Plug Sizes 10. Correct Tightness of hex nut is critical to the operation of the Flange Test & Welding Plug, a leak of the seal is usually an indication the hex nuts were not adequately tightened. The normal torque listed in Table 1 should be adequate for most installations, however due to variations within pipe ID finishes the torque may need to be increased up to the maximum torque value listed in Table 1. A deep impact socket is required (See Table 1 for impact socket sizes.) If at the maximum torque the plug still leaks, verify the correct seal and washers are being used. Verify that the seal O-ring is seated correctly in the groove on seal and that the O-ring is not damaged, (10 and 12 plugs only). Tighten hex nuts in a cross-like pattern in approx. 100 ft/lbs increments using an impact wrench until torque specified in Table 1 has been reached. Verify this torque with a calibrated torque wrench. Remove the purge plug closest to highest point. Connect hydropump to fill port on Flange. Slowly begin to fill the plug until water flows from the vent. Discontinue water input and install plug leak tight. 11. After isolation application is complete, insure all back pressure is released for pipe. 12. Relax the Seal by loosening the Compression Nut(s). Remove safety gag. Un-bolt the flange. (10 and larger) 13. Withdraw the plug from the tube end. 14. Inspect the plug for wear and replace any worn components. Re-lubricate the shaft threads and between the hexnut and mating surface as previously described. Any component, which is worn or damaged, must be replaced before attempting any further testing. Contact the factory for additional information on the replacement of worn or damaged parts. WARNING! FAILURE TO REPLACE WORN OR DAMAGED COMPONENTS MAY AFFECT THE ABILITY OF THE PLUG TO HOLD PRESSURE AND MAY CAUSE INJURY OR DAMAGE TO PERSONS OR PROPERTY IN THE TEST AREA. 15. Continue steps 8 through 14 for the number of pipes being tested. QUESTIONS? Contact EST Customer Service at any of the following locations with questions. In USA and Canada: tel: , fax: , info@expansionseal.com In Europe: tel: , fax: ; info@estgrp.nl In Asia: tel: , fax: , estasia@singnet.com.sg On the Internet: Expansion Seal Technologies is part of the EST Group of companies. EST Group provides a complete range of repair products, services and replacement parts covering the life cycle of tubular heat exchangers and condensers; additionally EST provides products and services to facilitate pressure testing pipe, piping systems, pressure vessels and their components. Visit EST Group on the internet at

35 EXPANSION SEAL TECHNOLOGIES DC /02 REV 1 06/03 PAGE 3 OF 4 Figure 1. Flange Test Plug With Flange Installed. Note: Above Figures are representative of ¾ to 8 sizes. Figure 2. Flange Test Plugs Installed as Isolation Plug, After Flange Has Been Removed. Note: Above Figures are representative of ¾ to 8 sizes. Figure 3. Flange Test Plug With Flange Installed. Note: Above Figures are representative of 10 to 24 sizes. Figure 4. Flange Test Plugs Installed as Isolation Plug, Note: Above Figures are representative of 10 to 24 sizes.

36 EXPANSION SEAL TECHNOLOGIES DC /02 REV 1 06/03 PAGE 4 OF 4 TABLE 1A. ¾ to 2-1/2 Plug Sizes High Lift Flange Weld Test Plug Clearance and Suggested Installation Torque Values Nom. Plug Size Clearance Between Plug & Pipe (in) Normal Installation Torque (*) Maximum Installation Torque (*) Wrench Size to Hold Shaft (in) Crowsfoot Size (in) Maximum Ambient Back Pressure of Shaft & Seal w/o Flange installed ¾ in-lbs. Do Not Exceed 9/16 9/16 10 psi (0.7Bar) Normal Torque in-lbs 200 in-lbs 9/16 9/16 10 psi (0.7Bar) 1-1/ ft-lbs 40 ft-lbs 1/2 15/16 10 psi (0.7Bar) 1-1/ ft-lbs 40 ft-lbs 1/2 15/16 10 psi (0.7Bar) ft-lbs 50 ft-lbs 1/2 15/16 10 psi (0.7Bar) 2-1/ ft-lbs 200 ft-lbs 7/ psi (0.7Bar) TABLE 1B. 3 to 8 Plug Sizes High Lift Flange Weld Test Plug Clearance and Suggested Installation Torque Values Nom. Plug Size Clearance Between Plug & Pipe (in) Normal Installation Torque (*) Maximum Installation Torque (*) Estimated Number of Turns of Hex Nut Wrench Size to Hold Shaft (in) Deep Impact Socket Size (in) Maximum Ambient Back Pressure of Shaft & Seal w/o Flange installed ft-lbs 400 ft-lbs 5 7/ psi (0.7Bar) ft-lbs 400 ft-lbs 5 7/8 2 5 psi (0.4Bar) ft-lbs 900 ft-lbs 6 1-5/8 3-1/8 5 psi (0.4Bar) ft-lbs 900 ft-lbs 6 1-5/8 3-1/8 5 psi (0.4Bar) Under normal conditions a 200lb. Man would require at least a 1ft. lever to achieve 200ft-lbs. The same man would require at least a 2ft. lever to achieve 400ft-lbs. TABLE 1C. 10 to 24 Plug Sizes High Lift Flange Weld Test Plug Clearance and Suggested Installation Torque Values Nom Plug Size Clearance Between Plug & Pipe (in) Normal Installation Torque Maximum Installation Torque Deep Impact Socket Size (in) Maximum Ambient Back Pressure of Shaft & Seal w/o Flange welded lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 5 psi (0.4Bar) lb ½ /8 3 psi (0.2 Bar) lb ½ /8 3 psi (0.2 Bar) lb ½ /8 3 psi (0.2 Bar) lb ½ /8 3 psi (0.2 Bar)

37 EXPANSION SEAL TECHNOLOGIES DC /03 PAGE 1 OF 2 REPLACEMENT FLANGE PROCEDURES FOR HIGH LIFT FLANGE TEST & WELDING PLUGS ¾ 1 Plug Sizes (refer to Figure 1.) 1. Remove hex nut & jam nut from bottom of shaft. 2. Remove bottom washer, seal and washer from shaft. 3. Remove the compression tubes. 4. Remove the Flange and the upstream monitor port 5. Remove the old o-rings from the upstream monitor port. Apply Parker O-ring Lube to o-ring grooves and the new o-rings and install into upstream monitor port. Install onto shaft taking care not to damage the o-rings on threads. 6. Apply Parker O-ring Lube to o-ring groove and the new o-ring and install into vent port, if not already pre-installed. Install onto shaft taking care not to damage the o-ring on threads. 7. Install the compression tubes. 8. Install first washer, seal and second washer. 9. Install jam nut onto shaft as far as possible. Install hex nut and wrench tighten hex nut against jam nut. 10. Plug is ready for testing. 1-1/4 To 3 Plug Sizes (refer to Figure 2.) 1. Remove hex nut & jam nut from shaft. 2. Remove the plain washer, seal and o-ring washer from shaft. 3. Remove the compression tubes. 4. Remove the flange. 5. Apply Parker O-ring Lube to o-ring groove and the new o-ring and install into new flange, if not already pre-installed. Install flange onto shaft taking care not to damage the o-ring on threads. 6. Install the compression tubes. 7. Remove the old o-ring from the o-ring washer. Apply Parker O-ring Lube to o-ring groove and the new o-ring and install into washer. Install washer onto shaft taking care not to damage the o-ring on threads. 8. Install seal and the plain washer. 9. Install jam nut onto shaft as far as possible. Install hex nut and wrench tighten hex nut against jam nut. 10. Plug is ready for testing. 4 To 8 Plug Sizes (refer to Figure 3.) 1. Remove hex nut & jam nut from shaft. 2. Remove plain washer, seal and o-ring washer 3. Remove the compression tubes 4. Remove the flange. 5. Apply Parker O-ring Lube to o-ring groove and the new o-ring and install into new flange, if not already pre-installed. Install flange onto shaft taking care not to damage the o-ring on threads. 6. Install the compression tubes. 7. Remove the old o-ring from the o-ring washer. Apply Parker O-ring Lube to o-ring groove and the new o-ring and install into washer. Install washer onto shaft taking care not to damage the o-ring on threads. The tapered side of the washer should be against the seal. 8. Install seal and the plain tapered washer ith the taper side against the seal. 9. Install jam nut onto shaft as far as possible. Install hex nut and wrench tighten hex nut against jam nut. 10. Plug is ready for testing. O-RING CHART FLANGE SIZE DASH NUMBER 3/4" - 1" /4" TO 2" /2" - 4" " - 8" -329 QUESTIONS? Contact EST Customer Service at any of the following locations with questions. In USA and Canada: tel: , fax: , info@expansionseal.com In Europe: tel: , fax: ; info@estgrp.nl In Asia: tel: , fax: , estasia@singnet.com.sg On the Internet:

38 EXPANSION SEAL TECHNOLOGIES DC /03 PAGE 2 OF 2 Expansion Seal Technologies is part of the EST Group of companies. EST Group provides a complete range of repair products, services and replacement parts covering the life cycle of tubular heat exchangers and condensers; additionally EST provides products and services to facilitate pressure testing pipe, piping systems, pressure vessels and their components. Visit EST Group on the internet at Figure 1. High Lift Flange Weld Test Plug, ¾ and 1 Plug Sizes, Shown in WP Configuration Figure 2. High Lift Flange Weld Test Plug, 1-1/4 through 3 Plug Sizes, Shown in WP Configuration Figure 3. High Lift Flange Weld Test Plug, 4 through 8 Plug Sizes, Shown in WP Configuration

39 High Lift Flange Weld Test Plug NOW AVAILABLE IN SIZES TO 42 High Lift Flange Test Plug GripTight Test Plug AutoSquat Test Systems Hydrostatic Test Pumps Purge, Weld and Test All With The Same Plug. A radically new and improved High Lift seal design permits greater seal expansion, allowing larger seal-to-pipe clearance. This means the plug will easily pass over weld penetration. Grinding out excess root penetration is eliminated! EST reduces the cost, downtime delays, and waste water disposal associated with conventional flange testing. Our new High Lift Flange Weld Test Plug lets you monitor conditions upstream of the seal, isolate and purge the weld area, complete the weld, and hydro test to Code requirements 1 with one tool. The test plug isolates just the weld area so there s no need to fill the entire line or vessel. Each test utilizes a minimum amount of water. No line blinds, no vacuum trucks or dehydration services; reduced NDE; and reduced water and environmental waste. Just a simple rock-solid tool that saves time and money every time you use it. One of our refinery customers reports that the High Lift Flange Test plug paid for itself onequarter of the way through its first use! Fast, easy installation and testing. Faster pipe repairs and retrofits. Reduces NDE Minimal water use, less handling and waste. Minimum 1.5:1 safety factor. Rugged, heavy duty construction. Versatile: Seal and washer sets easily change to change to accommodate different pipe schedules. Center Port: Permits monitoring or venting pressure upstream of the seal. Super Stock available: Standard sizes and flange rating available for same or next day shipment. New split compression tube allows you to vary the length between the flange and seal. Maximum Test Pressures ANSI Max psig Flange Class psi Bar & up 1125* 77.2* *Consult Factory 1. Meets ASME BPV section I, V & VII, ASME piping Code B21.1 and B31.3, API-510 and National Board Inspection code. (Ref. National Board Interpretation dated February 2,2002) World Headquarters Expansion Seal Technologies 2701 Township Line Road Hatfield, PA Tel: Fax: Toll-Free: SPECIALISTS IN TUBE TESTING, SLEEVING AND PLUGGING TECHNOLOGY Expansion Seal Technologies-Europe Utrechthaven 11e 3433 PN Nieuwegein, The Netherlands Tel: Fax: Expansion Seal Technologies Asia Pte Ltd. 35 Tannery Rd, #11-10 Tannery Block Ruby Industrial Complex Singapore Tel: Fax: AN ISO-9001 REGISTERED COMPANY DC8005 Rev 2 08/05 Web Address: info@estgrp.com