test plug user manual (1)

Test Plug
User Manual
Pipeline Solutions
Tel：+971-65354507 Email: info@crystalrbr.com Web: www.crystalrbr.com
Page Table of Content:
3-3 1. Introduction
3 1.1 Purpose of the Test Plug
3 1.2 Important Safety Information.
4-6 2. Data Sheet
4 2.1 Technical Specifications
5 2.2 Metal Specifications
5 2.3 Rubber Specifications
6 2.4 Sizes, Dimensions and Weight.
7-7 3. Safety Guidelines
7 3.1 Personal Protective Equipment (PPE)
7 3.2 Work Area Safety
7 3.3 Emergency Procedures
8-10 4. User Instructions
8 4.1 Pre-Use Inspection
9 4.2 Air Test - Testing Procedure
10 4.3 Water Test - Testing Procedure
11-11 5. Storage Guidelines

11 5.1 Storage Guideline
11 5.2 Handling and Transportation
12-12 6. Environmental Considerations

12 6.1 Material Compatibility
12 6.2 Temperature and Pressure Limits
12 6.3 Eco-Friendly Practices
13-14 7. More Information

13 7.1 Warranty
14 7.2 Customer Support
14 7.3 Manufacturer Information 2
Pipeline Solutions
1. Introduction
1.1 Purpose of the Test Plug

Steel Test Plugs are designed for testing leaks, pressure and to seal
off sections of pipelines.
The Test Plugs are developed with a vent tube for venting excess
back pressure, suitable to test pressure in sewage, waste, and
stormwater pipes. Before selecting a test plug the maximum allowed
back pressure should be pre-determined.
1.2 Important Safety Information

• Only trained and qualified personnel should operate the Test
Plug.
• Follow all safety precautions outlined in this manual.
• Never exceed the maximum pressure rating specified.
Pipeline Solutions
2. Data Sheet
2.1 Technical Specifications

I. Standard: BS8301, BS8005 & EN1610.
II. Material Composition:
a. Durable Steel Construction: The mechanical Test Plugs are

crafted with durable steel, ensuring strength and corrosion
resistance.
b. Rubber: EPDM Rubber (Ethylene Propylene Diene Monomer

Rubber)
III. Corrosion Resistance: Enhanced Protection: Coated with

corrosion-resistant materials, such as zinc, ensuring longevity and
performance in corrosive environments.
IV. Identification Markings: Clear Information: Marked with clear

indications of size, and CRYSTAL Logo.
V. Temperature Limits: - 50°C to 125°C.
D NR/SBR
CR
EPDM
40mm to Back Pressure Material -50/+125 C Corrosion Safe Light

600mm 0,2 to 2 Bar Choice Resistant Operation Weight
Pipeline Solutions
2. Data Sheet
2.2 Metal Specifications
UNIT OF
TYPE OF TEST SPECIFICATION REQUIREMENTS
MEASUREMENT
Density Kg/m3 7870
Melting point °C 1375 – 1400
Elastic modulus (Min) GPa 205
Ultimate tensile strength (Max) Mpa 420
Hardness rockwell B HB 71
2.3 Rubber Specifications

TEST PLUG SPECIFICATION
TYPE OF TEST TEST METHOD
SIZES REQUIREMENTS
Original physical properties
Hardness shore A (°) 1.5" to 24" ASTM D 2240 60 ± 10
1.5" to 3" 10 to 15
Tensile strength. MPa 3.5 to 4.5" ASTM D 412 15 to 20
5 to 24" 20 to 25
Compression Set at the test
ISO 1414 ,
conditions 22 hours @ 100°C 1.5" to 24" 20% Max
ASTM D395
Solid (25 % compressed)
Heat Ageing 70 hours @ 70°C

Hardness, Shore A (°) max 1.5" to 24" +10
Tensile change % max 1.5" to 24" ASTM D 573 -20%
Elongation change % max 1.5" to 24" -20%
Pipeline Solutions
2. Data Sheet
2.4 Sizes, Dimensions and Weight.

Pipe Size Internal Plug Will Fit Pipes
Minimum Overall Diameter Maximum
Nominal With Approx
Part No Insertion Length of Water Allowable
Diameter Internal Diameter Weight
Into Pipe Of Plug way Back Pressure
Metric Imperial Minimum Maximum
TP2001 40mm 1 1/2” 38mm 50mm 45mm 94mm 1/2 30p.s.i 0.17kg
TP2002 50mm 2” 49mm 62mm 43mm 90mm 1/2 30p.s.i 0.22kg
TP2010 175mm 7” 175mm 200mm 64mm 100mm 1 7p.s.i 1.92kg
TP2013 250mm 10” 245mm 370mm 73mm 178mm 1 7p.s.i 2.TP2kg
Pipeline Solutions
3. Safety Guidelines
3.1 Personal Protective Equipment (PPE)

Always wear appropriate PPE, including safety
glasses and gloves, when handling the Test Plug.
3.2 Work Area Safety

Ensure the work area is clear of obstacles, and follow
industry safety standards during use.
3.3 Emergency Procedures

Have emergency procedures in place, including first
aid kits, fire extinguishers, and emergency contact
information. Train personnel on emergency response
protocols.
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4. User Instructions
4.1 Pre-Use Inspection
GENERAL PROCEDURE FOR AIR AND WATER TESTS - The following

procedure should be adopted before testing.
1. Inspect the pipeline for possible damage sustained during or after

laying.
2. Clear the pipeline of any debris and flush it out.
3. Check that all pipe joints have been correctly made.
4. If any cement mortar joints have been used, leave for at least 24 hours
before testing to allow the mortar to set and reach adequate strength.
5. Thoroughly check all plugs and equipment. Make sure that any rubber
tubing used in connections is in good condition and not perished.
6. Fit expanding plugs into the ends of the pipeline and all branches.
Make sure that the surface of the pipes where plugs fit is also clean and
free from any extraneous material such as grit.
➢ N.B. Concrete pipes may require the installation point areas cleaned of
any irregular surfaces to ensure a good seal. If necessary, due to some
concrete surfaces being porous, the area should be painted to create a
good seal.
• 1 inch (25.4mm) head of water gauge is equivalent to 0.036Ib. per
square inch.
• 1ft. head of water is equivalent to 0.432Ib. per square inch.
• 1Ib. per square inch is equivalent to 2.3ft head of water.
• 1 bar is equivalent to 14.7Ib. per square inch.
• 1 bar is equivalent to 33.35ft. head of water
Pipeline Solutions
4.2 Air Test - Testing Procedure
• Seal pipe section with appropriate size drain test plug.
• Fit the test nipple to one of the drain test plugs.
• Connect rubber hose via ‘Y’ piece to the nipple, ‘U’ gauge, and hand
bellows.
• Fill the ‘U’ gauge with water to ‘zero’.
• Squeeze the hand bellows gently until the level reaches 100mm on the
open side of the gauge and the lower limit below zero on the closed
side. The level should not fall to less than 75mm during a period of 5
minutes without further pumping, after allowing a suitable time for
stabilization of air temperature. If it drops below 75mm within the
specified time the pipe section is leaking.
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4.3 Water Test - Testing Procedure
• Fit an expanding plug, suitably strutted to resist the full hydrostatic

head, at the lower end of the pipeline. Also plug any branches. The
pipes may need strutting to prevent movement.
• Provide a means of applying the test head of water at the top end of
the line, preferably using a 90° bend and a straight pipe of the same
diameter as the line. Ensure that the standpipe and plug are suitably
strutted to resist the applied hydrostatic head. Provide a means of
filling the pipeline
• with water.
• Fill the system with water keeping pockets of trapped air to a
minimum. Fill the standpipe to the requisite level.
• Leave for at least two hours to enable the pipes to become saturated,
topping up as necessary.
• After the absorption period measure the loss of water from the system
by noting the amount needed to maintain the level in the standpipe
over a further period of 30 minutes. In carrying out the test to the
requirements of BS8005, the standpipe should be topped up at regular
intervals of 5 minutes and the amounts measured.
Fill water here

Sewer/Drain pipe
Stand pipe
Plug
Branch pipe Plug

10
Pipeline Solutions
5. Storage Guidelines
5.1 Storage Guideline
1. Temperature: The storage temperature should be around 25˚C,

and products should be stored away from direct sources of
heat.
2. Humidity: The storage should be in a dry area.
3. Light: The products should be protected from direct sunlight,
UV and artificial light that has a high UV content.
4. Radiation: Products should be protected from all sources of
ionizing radiation.
5. Ozone: Storage rooms should not contain any equipment
capable of generating ozone.
6. Deformation: Rubber should be stored free from superimposed
tensions and compressive stresses or other causes of
deformation. Do not hang sealing rings!
7. Contact with liquid or semi-liquid materials: Rubber should
not come into contact with liquid or semi-liquid materials or
their vapours at any time during storage.
5.2 Handling and Transportation

Use proper lifting equipment and follow safe handling procedures when
moving the plug. Secure the plug during transportation to prevent
damage.
11
Pipeline Solutions
6. Environmental Considerations
CRYSTAL's test plug: 100% recyclable, eco-friendly, and committed to a

sustainable future.
6.1 Material Compatibility

Ensure the Test Plug is compatible with the materials it will come into
contact with during use.
6.2 Temperature and Pressure Limits

Adhere to specified temperature and pressure limits to prevent damage
to the plug and surrounding equipment.
6.3 Eco-Friendly Practices

Dispose of the Test Plug and associated materials in an environmentally
responsible manner.
12
Pipeline Solutions
7.1 Warranty
• Limited Warranty Coverage:
CRYSTAL Ind. Factory, hereinafter referred to as "the Manufacturer," warrants that each
CRYSTAL steel test plug is free from defects in material and workmanship under normal
use and service. This limited warranty is subject to the terms and conditions outlined
herein.
• Warranty Duration:
The Manufacturer provides a limited warranty period of 1 year from the date of
purchase for CRYSTAL steel test plugs.
Coverage Details:
This limited warranty covers defects in materials and workmanship under normal use
and service. The warranty does not cover damage resulting from misuse, accidents,
improper installation, improper storage or unauthorized modifications.
• Remedies under Warranty:
During the 1-year warranty period, the Manufacturer will, at its discretion, either repair
or replace any CRYSTAL steel test plug found to be defective in materials or
workmanship.
• Conditions for Warranty Validity:
To be eligible for warranty service, the following conditions must be met:
1.The CRYSTAL steel test plug must have been installed, used, and maintained in
accordance with the Manufacturer's instructions.
2.The purchaser must provide proof of purchase or a valid warranty registration.
• Exclusions:
This warranty does not cover:
1.Normal wear and tear.
2.Damage caused by accident, misuse, negligence, or improper installation.
3.Modifications or repairs carried out by unauthorized personnel.
• Transferability:
This warranty is transferable within the original 1-year warranty period, provided the
product changes ownership. The new owner must notify the Manufacturer to validate
the transfer.
• Claims Procedure:
In the event of a warranty claim, the purchaser must:
1.Contact CRYSTAL Ind. Factory's Customer Service Department.
2.Provide proof of purchase or a valid warranty registration.
3.Follow the Manufacturer's instructions for returning the product.
• Response Time:
The Manufacturer will make reasonable efforts to process warranty claims within 15
business days of receiving the required documentation.
• Disclaimer:
This warranty is in lieu of all other warranties, expressed or implied, including but not
limited to the implied warranties of merchantability and fitness for a particular purpose.
13
Pipeline Solutions
7.2 Customer Support
For any questions, concerns, or assistance, contact our customer
support team at customer-service@crystalrbr.com
7.3 Manufacturer Information

• Name: Crystal Ind. Factory.
• Address: Sajaa Industrial area - Sharjah - UAE.
• Phone: +971-65354507
• Fax: +971-65354506
• Email: info@crystalrbr.com
• Website: www.crystalrbr.com
Our documents aim to inform and advise our customers. The information
provided herein is correct to the best of CRYSTAL Group‘s knowledge. No
liability for any errors, facts, or opinions is accepted. Customers must satisfy
themselves as to the suitability of this product for their application. No
responsibility for any loss as a result of any person placing reliance on any
material contained herein will be accepted. Our technical documents aim 14
Pipeline Solutions

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Test Plug

3 1.1 Purpose of the Test Plug

3 1.2 Important Safety Information.

4-6 2. Data Sheet

4 2.1 Technical Specifications

5 2.2 Metal Specifications

5 2.3 Rubber Specifications

6 2.4 Sizes, Dimensions and Weight.

7-7 3. Safety Guidelines

7 3.1 Personal Protective Equipment (PPE)

7 3.2 Work Area Safety

7 3.3 Emergency Procedures

8-10 4. User Instructions

8 4.1 Pre-Use Inspection

9 4.2 Air Test - Testing Procedure

10 4.3 Water Test - Testing Procedure

11-11 5. Storage Guidelines

11 5.2 Handling and Transportation

12-12 6. Environmental Considerations

12 6.2 Temperature and Pressure Limits

12 6.3 Eco-Friendly Practices

13-14 7. More Information

14 7.2 Customer Support

14 7.3 Manufacturer Information 2

1.1 Purpose of the Test Plug

1.2 Important Safety Information

2.1 Technical Specifications

II. Material Composition:

a. Durable Steel Construction: The mechanical Test Plugs are

b. Rubber: EPDM Rubber (Ethylene Propylene Diene Monomer

III. Corrosion Resistance: Enhanced Protection: Coated with

IV. Identification Markings: Clear Information: Marked with clear

V. Temperature Limits: - 50°C to 125°C.

40mm to Back Pressure Material -50/+125 C Corrosion Safe Light

2.3 Rubber Specifications

Heat Ageing 70 hours @ 70°C

2.4 Sizes, Dimensions and Weight.

3.1 Personal Protective Equipment (PPE)

3.2 Work Area Safety

3.3 Emergency Procedures

4.1 Pre-Use Inspection

GENERAL PROCEDURE FOR AIR AND WATER TESTS - The following

1. Inspect the pipeline for possible damage sustained during or after

• Fit an expanding plug, suitably strutted to resist the full hydrostatic

Fill water here

Branch pipe Plug

5.1 Storage Guideline

1. Temperature: The storage temperature should be around 25˚C,

5.2 Handling and Transportation

CRYSTAL's test plug: 100% recyclable, eco-friendly, and committed to a

6.1 Material Compatibility

6.2 Temperature and Pressure Limits

6.3 Eco-Friendly Practices

7.3 Manufacturer Information

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