Nowadays, in the world of pipe plugs and testing plugs, there are small problems that can lead to serious injury or even death.
In general, the pipe plug, by definition, is a pneumatic rubber tool designed to temporarily seal pipes in sewage and/or water systems to repair or to test the pipes. However, the pipe plug is also considered as a dangerous tool, as it operates by compressed air, especially big size plug which can cause serious damages, if not treated and used as per the manufacturer’s safety instructions and user manual. Therefore, the end user must be well trained and take into consideration the control and the monitoring of plugs pressure during and after the application, more so if the plug is to remain in the pipe for a long period of time.
Pressure Monitoring of Plugs is a Necessity
The first control that needs to be carried out is the inflation pressure control during the plug inflation, which is done by using the air control devices. But what if the plug is to remain in the pipe for a long time? What can the end user do to ensure that the pressure is as it should be?
Although we, as a leading company in the field of pipe plugs and packers in Turkey, do not recommend our customers to use the plugs for a long period of time in a pipe, there are some applications that oblige the customer to keep the plug for months inside the pipe. However, to avoid any risk, we have developed a solution that can handle this kind of situation, which is our PRESSURE MONITORING AND ALARM SYSTEM.
Pressure and its Impact on Applications
What makes the plug dangerous in the first place is the inflation pressure. The inflation pressure changes according to the environmental temperature if the plug remains in the pipe for a long time, and if this pressure changes, the plug will explode, which is very risky, especially if there are people close to the dangerous zone. Therefore, it is necessary to be monitored.
In many cases, the pressure to be checked is not only the inflation pressure, but also the back pressure, as this can increase and cause serious consequences. This type of unwanted change occurs especially in sea applications.
Normally, it is recommended to check the pressure at least once every 4 hours to be sure that everything is going alright. But, thanks to our intelligent and developed solution, we succeeded to make a PLC, Programable Logic Controller, monitoring device that checks the inflation pressure instantaneously and records all the information collected, as well as alarming and warning the user of any change in pressure.
PlugCo’s Pressure Monitoring and Alarm System
As we have already mentioned, pressure control requires commitment and awareness of the seriousness of the situation, either during the application or afterwards. For this reason, we, the PlugCo Team, have developed an intelligent system called Pressure Monitoring and Alarm System.
This system is intended to control and monitor both inflation pressure and back pressure. It will be connected directly to the plug and monitor it. All that the user has to do is to set the real back pressure that the plug can withstand, as well as the required pressure to inflate the plug. Our system is in charge to display the current inflation and back pressures at all times and inform the user through buzzers and LEDs whether everything is OK or there is a dangerous situation. In addition, the client will also be able to visualize all the data on a graph and save it in a file for further review.
Utilities of the Pressure Monitoring and Alarm System
Besides avoiding problems caused by inflation pressure and back pressure, the monitoring and Alarm System is also well recommended for the use of big-size and high-pressure plugs. As known, plugs that require high pressure have a high possibility of bursting. Therefore, our system offers the safety of using the plugs by carefully following all the instructions.
It is true that there are cases where the user is obliged to repair manholes and pipes, which requires his access near or around the dangerous zone, and it is also true that our New System is the appropriate and adequate solution to reduce the risks during application. But it is still forbidden and not recommended to get into the danger zone during the application.
The latest and the most interesting utility of our system is PlugCo’s patented Smart Plug, which has solved the most critical problem, which is plug sliding inside the pipe.
Smart Plug and the Pressure Monitoring and Alarm System
All manufacturers of pipe plugs seem to inform the end user of the back pressure that the plug can withstand. However, this value is always given for a specific type of pipes such as a clean, dry concrete pipe or a ductile iron pipe… Thus, when the plug is used in another pipe or under other conditions, the plug will not be able to withstand the same back pressure as the one given. This will cause the plug to slide, which may burst, resulting in financial loss, serious or fatal accidents.
Before starting using the plug, the end-user must first know the exact back pressure the plug can hold inside that pipe, which may be full of debris or foreign materials such as grass, oil, mold, or others; which reduce the back pressure holding capacity inside the pipe. At this stage, our patented Smart Plug product will be the right solution to solve the problem. It will be connected to the plug by a force measurement sensor. And then the actual back pressure will be calculated by a platform we provide on our website using the forces obtained by the Smart Plug.
Eventually, our monitoring and Alarm System will be connected to the plug, to help control and monitor the pressure, and make sure that the pressure obtained by the Smart Plug is the same as the one the plug holds. In this case, the application will be done in a professional and well-organized way, without any risk.
Sum up: Advantages of Pressure Monitoring and Alarm System
- Solving Plug Sliding Problem in The Pipeline Industry, by using the Smart Plug System.
- Reducing the risks if the plug should stay inside the pipe for a long time.
- Control and monitor the back pressure to ensure the safe use of the plugs.
- Monitor the inflation pressure to avoid any problems due to changes in environmental temperature.
- Alarming and warning the user of imminent danger
- Ensure the safe use of high-pressure and big size plugs.
Selecting the most Suitable Air Control Device
| Model | Pressure Control System | Over Pressure Relief System | Pressure Monitoring System | Pressure Maintaining System |
|---|---|---|---|---|
Pressure Control Device 
|
Manual Control by Ball Valves | Manual Relief by Ball Valves | Analog Pressure Gauge | N/A |
Air Control Device with Pressure Relief Valve  |
Manual Control by Ball Valves | Automatically by Pressure Relief Valves | Analog Pressure Gauge | N/A |
Air Control Device with Pressure Regulator 
|
Manual Control by Ball Valves | Manually Setting the required pressure by regulator. Then, automatically not allowing the over pressure. | Analog Pressure Gauge | N/A |
Pressure Maintaining Device 
|
Automatic | Automatically by Pressure Relief Valves. | Analog Pressure Gauge | Mechanically Automatic. Pressure maintaining system by Pressure Relief Valve and Solenoid Valve |
Pressure Monitoring System, PLC 
|
N/A | N/A | Monitoring via the display of the PLC, and Warning Alarm System for over pressure and pressure loss | N/A |
Pressure Maintaining & Monitoring Device 
|
Automatic | Automatically by Pressure Relief Valves. | Analog Pressure Gauge, monitoring via the display of the PLC, and Warning Alarm System for over pressure and pressure loss | Mechanically Automatic. Pressure maintaining system by Pressure Relief Valve and Solenoid Valve |
PlugCo at your Disposal
If you need an effective solution for any of the problems we have listed in this article, or if you face any other problems during your project, do not hesitate to contact us sales@plugco.net . Our team is always at your disposal to solve and find solutions for you, dear customers.