Professional Documents
Culture Documents
DC2685 08/05
REV 6 03/13
PAGE 1 OF 6
Monitor connection: Connect pressure gauge, leak tight, to this connection to monitor upstream pressure
(See Figure 1). Alternatively, upstream vapors may be vented by attaching a long hose (ie: 50 ft.) to the port and
locating the end of the hose well downwind from the weld area. If upstream vapors are to be vented a tee fitting may
be used such that the hose and the pressure gauge are both connected to the monitor connection
(See Figures 2 & 3).
6.2
Pressure connection: Connect pressure source to pressurize between seals for isolation and/or test purposes.
7. Install the plug so both seals are inside the pipe. When using the plug as an isolation and/or welding plug position the plug
so that the seals are at least 12 (305 mm) from the weld location. During welding, the pipe at the plug 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. When testing the weld position the plug so that the seals straddle the weld or area to be tested.
8. If the residual air between the seals must be removed, the following technique may be implemented.
8.1.
Ensure the port between the seals is at the six oclock position.
8.2.
Tighten the hex nut(s) on the plug until the plug is just snug in the pipe. At this point, the plug should barely be able to
slide within the pipe. Then apply slight pressure of the test medium until a small amount of medium escapes past the
seals. This technique will push the majority of the residual air out from between the seals.
EST GROUP
DC2685 08/05
REV 6 03/13
PAGE 2 OF 6
During pressurization there may be some settling of the plug. If at any time during pressurization or testing the test
plug moves more than a total of .125 (3mm) the test must be halted and the pressure released immediately. The
test plug and pipe ID should be inspected for damage, and the installation procedure should be reviewed prior to
reinstalling the plug and retesting. If the situation continues please contact EST Customer Service for technical
assistance.
12.2
During pressurization and testing all personnel should remain clear of the test plug and immediate test area.
EST GROUP
DC2685 08/05
REV 6 03/13
PAGE 3 OF 6
PLUG REMOVAL
14. After isolation or testing application is complete, insure all back pressure is released from pipe.
15. Relax the seal by loosening the hex nut(s). Ensure to loosen hex nut(s) until the top of the nut is at the top of the threads.
This will prevent permanent seal deformation. When removing plugs with multiple shafts loosen the hex nuts incrementally,
using the standard bolting pattern so that the load continues to be distributed over all of the shafts.
16. Withdraw the plug from the tube end.
INSPECT PLUG AFTER EACH USE
17. Inspect the plug for wear and replace any worn components. 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.
18. Prior to storing, clean and dry the plug. Re-lubricate the shaft threads and between the hex nut and mating surface as
previously described.
19. Store plug in an area out of contact with sun or UV light. UV light will damage and prematurely age the seal elements.
EST GROUP
DC2685 08/05
REV 6 03/13
PAGE 4 OF 6
Table 1. Double Block & Bleed Installation Torque Specifications, Sizes 3/4" to 3
Sales Part
Number
DBB-75P80
DBB-75P10
DBB-1PXXS /
75P160
DBB-1P160 /
75P40
DBB-1P80
DBB-1P40
DBB-1P10
DBB-125P160
DBB-125P80
DBB-125P40
DBB-125P10
DBB-15P160
DBB-15P40
DBB-2PXXS /
15P80
DBB-2P160 /
15P10
DBB-2P80
DBB-2P40
DBB-2P10
DBB-25P160
DBB-25P40
DBB-3PXXS /
25P80
DBB-3P160
25P10
DBB-3P80
DBB-3P40
DBB-3P10
Note:
Nominal
Plug
SCH
Size
3/4"
3/4"
1
3/4"
1
3/4"
1
1
1
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/2
1-1/2
2
1-1/2
2
1-1/2
2
2
2
2-1/2"
2-1/2"
3
2-1/2
3
2-1/2
3
3
3
80
10
XXS
160
160
40
80
40
10
160
80
40
10
160
40
XXS
80
160
10
80
40
10
160
40
XXS
80
160
10
80
40
10
Clearance
Normal
Distance
Between
Install.
Plug OD
Length
Between
Plug &
Torque
[in (mm)]
[in (mm)]
Seals
Pipe
[ft-lbs
[in (mm)]
[in (mm)]
(N-m)]
0.65 (16.5) 0.09 (2.3) 23-1/2 (597) 1.50 (38) 2.5 (3.4)
0.78 (19.8) 0.10 (2.5) 23-1/2 (597) 1.50 (38) 4.0 (5.4)
0.06 (1.5)
0.54 (13.7)
21-1/2 (546) 1.25 (32) 1.5 (2.0)
0.07 (1.8)
Maximum
Install.
Torque
[ft-lbs
(N-m)]
5.0 (6.8)
7.0 (9.5)
7/16
7/16
Maximum
Maximum
Pressure
Upstream
Between
Pressure
Seals
[psi (Bar)]
[psi (Bar)]
2250 (155)
10 (0.7)
2250 (155)
10 (0.7)
3.0 (4.1)
7/16
2250 (155)
10 (0.7)
Crowfoot
Size
(in)
0.72 (18.3)
0.10 (2.5)
23-1/2 (597)
1.50 (38)
3.5 (4.7)
6.5 (8.8)
7/16
2250 (155)
10 (0.7)
0.84 (21.3)
0.93 (23.6)
0.98 (24.9)
1.01 (25.7)
1.13 (28.7)
1.23 (31.2)
1.29 (32.8)
1.19 (30.2)
1.46 (37.1)
0.12 (3.0)
0.12 (3.0)
0.12 (3.0)
0.15 (3.8)
0.15 (3.8)
0.15 (3.8)
0.15 (3.8)
0.15 (3.8)
0.15 (3.8)
23-1/2 (597)
23-1/2 (597)
23-1/2 (597)
24-3/4 (629)
24-3/4 (629)
24-3/4 (629)
24-3/4 (629)
27 (686)
27 (686)
1.50 (38)
1.50 (38)
1.50 (38)
1.50 (38)
1.50 (38)
1.50 (38)
1.50 (38)
2.50 (64)
2.50 (64)
4.0 (5.4)
7.0 (9.5)
5.0 (6.8)
7.0 (9.5)
5.0 (6.8) 7.5 (10.2)
8.0 (10.8) 12 (16.3)
10 (13.6) 13 (17.6)
11 (14.9) 14 (19.0)
12 (16.3) 14 (19.0)
15 (20)
20 (27)
15 (20)
20 (27)
7/16
7/16
7/16
1/2
1/2
1/2
1/2
3/4
3/4
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
1.35 (34.3)
0.15 (3.8)
27 (686)
2.50 (64)
15 (20)
20 (27)
3/4
2250 (155)
10 (0.7)
27 (686)
2.50 (64)
20 (27)
30 (41)
3/4
2250 (155)
10 (0.7)
28-1/2 (724)
28-1/2 (724)
28-1/2 (724)
28-1/2 (724)
29 (737)
2.50 (64)
2.50 (64)
2.50 (64)
2.50 (64)
2.50 (64)
30 (41)
30 (41)
35 (47)
35 (47)
60 (81)
50 (68)
50 (68)
60 (81)
60 (81)
90 (122)
7/8
7/8
7/8
7/8
1-1/4
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
29 (737)
2.50 (64)
60 (81)
90 (122)
1-1/4
2250 (155)
10 (0.7)
33-5/8 (854)
10 (0.7)
33-5/8 (854)
33-5/8 (854)
33-5/8 (854)
10 (0.7)
10 (0.7)
10 (0.7)
1.53 (38.9)
1.76 (44.7)
1.89 (48.0)
1.98 (50.3)
1.95 (49.5)
2.29 (58.2)
2.13 (54.1)
2.46 (62.5)
2.69 (68.3)
2.86 (72.6)
3.04 (77.2)
0.16 (4.1)
0.15 (3.8)
0.18 (4.6)
0.18 (4.6)
0.18 (4.6)
0.18 (4.6)
0.18 (4.6)
0.17 (4.3)
0.19 (4.8)
0.17 (4.3)
0.18 (4.6)
0.21 (5.3)
0.21 (5.3)
0.22 (5.6)
For plugs that require torques greater than 91 ft-lbs a high strength crowfoot may be required. EST Group does offer
high strength crowfoot wrenches. Please contact the factory with any inquires.
EST GROUP
DC2685 08/05
REV 6 03/13
PAGE 5 OF 6
Table 2. Double Block & Bleed Installation Torque Specifications, Sizes 4 to 24
Sales Part
Number
DBB-4PXXS
DBB-4P160
DBB-4P120
DBB-4P80
DBB-4P40
DBB-4P10
DBB-6P160
DBB-6P120
DBB-6P80
DBB-6P40
DBB-6P10
DBB-8P160
DBB-8PXXS
DBB-8P140
DBB-8P120
DBB-8P100
DBB-8P80
DBB-8P60
DBB-8P40
DBB-8P20
DBB-8P10
DBB-10P100
DBB-10P80
DBB-10PXS
DBB-10P40
DBB-10P10
DBB-12P80
DBB-12P40 /
12PSTD
DBB-14P80
DBB-14P40
DBB-14PSTD
DBB-16P80
DBB-16P40
DBB-16PSTD
DBB-18P80
DBB-18P40
DBB-18PSTD
DBB-20P80
DBB-20P40
DBB-20PSTD
DBB-24P80
DBB-24P40
DBB-24PSTD
Nominal
Plug
Size
4
4
4
4
4
4
6
6
6
6
6
8
8
8
8
8
8
8
8
8
8
10
10
10
10
10
12
12
14
14
14
16
16
16
18
18
18
20
20
20
24
24
24
SCH
XXS
160
120
80
40
10
160
120
80
40
10
160
XXS
140
120
100
80
60
40/STD
20
10
100
80
60/XS
40/STD
10
80
40
STD
80
40
30/STD
80
40/XS
30/STD
80
40
STD
80
40
20/STD
80
40
20/STD
Plug OD
[in (mm)]
3.00 (76.2)
3.29 (83.6)
3.48 (88.4)
3.63 (92.2)
3.83 (97.3)
4.06 (103.1)
4.99 (126.7)
5.30 (134.6)
5.56 (141.2)
5.87 (149.1)
6.16 (156.5)
6.56 (167)
6.63 (168)
6.75 (171)
6.94 (176)
7.19 (183)
7.38 (187)
7.56 (192)
7.73 (196)
7.88 (200)
8.08 (205)
9.06 (230)
9.31 (236)
9.50 (241)
9.77 (248)
10.17 (258)
11.00 (279)
11.62 (295)
12.12 (308)
12.74 (324)
12.87 (327)
13.93 (354)
14.62 (371)
14.87 (378)
15.74 (400)
16.50 (419)
16.87 (428)
17.56 (446)
18.43 (468)
18.87 (479)
21.18 (538)
22.24 (565)
22.87 (581)
Clearance
Between
Plug &
Pipe
[in (mm)]
0.15 (3.8)
0.15 (3.8)
0.15 (3.8)
0.20 (5.1)
0.20 (5.1)
0.20 (5.1)
0.20 (5.1)
0.20 (5.1)
0.20 (5.1)
0.20 (5.1)
0.20 (5.1)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.25 (6.4)
0.38 (9.7)
0.32 (8.1)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
0.38 (9.7)
Length
[in (mm)]
Distance
Between
Seals
[in (mm)]
6-1/2 (165)
6-1/2 (165)
6-1/2 (165)
6-1/2 (165)
6-1/2 (165)
6-1/2 (165)
9 (229)
9 (229)
9 (229)
9 (229)
9 (229)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
9-3/4 (248)
3-1/2 (89)
3-1/2 (89)
3-1/2 (89)
3-1/2 (89)
3-1/2 (89)
3-1/2 (89)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
9-3/4 (248)
4 (102)
10-1/4(260)
10-1/4(260)
10-1/4(260)
10-1/4(260)
10-1/4(260)
10-1/4(260)
10-1/4(260)
10-1/4(260)
10-1/4(260)
10-3/4(273)
10-3/4(273)
10-3/4(273)
10-3/4(273)
10-3/4(273)
10-3/4(273)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
4-1/2 (114)
Normal
Install.
Torque
[ft-lbs
(N-m)]
10 (14)
15 (20)
20 (27)
20 (27)
20 (27)
20 (27)
70 (95)
80 (109)
80 (109)
90 (122)
90 (122)
125 (169)
125 (169)
125 (169)
125 (169)
125 (169)
150 (203)
175 (237)
175 (237)
175 (237)
175 (237)
200 (271)
200 (271)
200 (271)
225 (305)
225 (305)
200 (271)
Maximum
Maximum
Deep
Maximum
Install.
Pressure
Socket
Upstream
Torque
Between
Size
Pressure
[ft-lbs
Seals
[in]
[psi (Bar)]
(N-m)]
[psi (Bar)]
15 (20)
9/16 2250 (155) 10 (0.7)
25 (34)
9/16 2250 (155) 10 (0.7)
30 (41)
9/16 2250 (155) 10 (0.7)
30 (41)
11/16 2250 (155) 10 (0.7)
30 (41)
11/16 2250 (155) 10 (0.7)
30 (41)
11/16 2250 (155) 10 (0.7)
110 (149) 1-1/16 2250 (155) 10 (0.7)
120 (163) 1-1/16 2250 (155) 10 (0.7)
130 (176) 1-1/16 2250 (155) 10 (0.7)
140 (190) 1-1/16 2250 (155) 10 (0.7)
140 (190) 1-1/16 2250 (155) 10 (0.7)
200 (271) 1-7/16 2250 (155) 10 (0.7)
200 (271) 1-7/16 2250 (155) 10 (0.7)
200 (271) 1-7/16 2250 (155) 10 (0.7)
200 (271) 1-7/16 2250 (155) 10 (0.7)
200 (271) 1-7/16 2250 (155) 10 (0.7)
225 (305) 1-5/8 2250 (155) 10 (0.7)
250 (339) 1-5/8 2250 (155) 10 (0.7)
250 (339) 1-5/8 2250 (155) 10 (0.7)
250 (339) 1-5/8 2250 (155) 10 (0.7)
250 (339) 1-5/8 2250 (155) 10 (0.7)
275 (373) 1-5/8 2250 (155) 10 (0.7)
275 (373) 1-5/8 2250 (155) 10 (0.7)
275 (373) 1-5/8 2250 (155) 10 (0.7)
300 (407) 1-5/8 2250 (155) 10 (0.7)
300 (407) 1-5/8 2250 (155) 10 (0.7)
250 (339) 1-5/8 2250 (155) 10 (0.7)
1-5/8
2250 (155)
10 (0.7)
225 (305)
225 (305)
225 (305)
200 (271)
225 (305)
250 (339)
250 (339)
250 (339)
275 (373)
225 (305)
175 (237)
225 (305)
275 (373)
300 (407)
275 (373)
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
2250 (155)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
10 (0.7)
275 (373)
275 (373)
275 (373)
250 (339)
275 (373)
300 (407)
300 (407)
300 (407)
325 (441)
275 (373)
225 (305)
275 (373)
325 (441)
350 (475)
325 (441)
EST GROUP
DC2685 08/05
REV 6 03/13
PAGE 6 OF 6