Caution

Read carefully the safety precaution included in this manual before
using this equipment. Make sure to check this manual for the reference in the future.
For inquiry,
call +82-31-454-4111 (Rep), Daewon Industrial Co., Ltd.

Contents

• Safety Precaution
• General Information
• Entering a Closed Space
• Risk Areas
• Preparation before Using
  • Selection of a Plug
  • Gauging the Back Pressure
  • Selection of the Plug Size
  • Pipe Design
  • Corrected Gauge
  • Cleaning and Testing
  • Clean Pipes
  • Plug Rupture
  • backup System
  • Blocking the Plug
• Operation
  • Risk Areas
  • Temperature Range
  • Plug Placement
  • Monitoring Pressure
  • Limitation to Restricted Media
  • Expansive Media
  • Excessive Expansion
  • Insufficient Expansion
• Maintenance and Storage

Safety Precaution

DANGEROnce the plug is disrupted for any reason, it could incur death, physical injury and damage to the property. Unsafe practice may lead to death or serious injury. Information provided as follows. Always comply with the instruction in "General Information", "Risk Areas", "Operation" and "Maintenance and Storage". Take good care of the safety information emphatically indicated with this sign.

General Information

Make sure to reference the instruction in the safety and health guidelines of Korea Occupational Safety and
Health Agency of the Ministry of Employment and Labor. Do not use the plugs in a condition that may threaten the safety of human life and properties.

Entering the Closed Space

Since there are no separate user guidelines for the purpose of entering the closed space in which to use the plugs, follow the safety and health guidelines of Korea Occupational Safety and Health Agency of the Ministry of Employment and Labor, and the requirement of the Company.

Entering the Closed Space

Follow the safety and health guidelines of Korea Occupational Safety and Health Agency of the Ministry of Employment and Labor,
and the requirement of the Company. (The recommendation of Daewon Industrial Co., Ltd. is to start works only after the safety conditions are confirmed after the
safety check done before any work starts.

Danger Zone

There is a danger zone which expands outwards in the shape of a cone when the plug is under usage. Do not get into the danger zone
when the plug is under usage.

DANGER

Preparation before Usage

1. Selection of a Plug

Select the appropriate plug and relevant equipment. The functional specifications of all the pipe plugs are shown in the table of specification.

2. Gauging the Back Pressure

Determine the maximum back pressure the plugs should endure. Back pressure should be limited by the pressures (of air or fluid) in front of or at the back of the plug.

Back pressure grades of the plugs should not be surpassed. The listed grades of maximum back pressures are based on the plugs installed into a clean and dry pipe of standard size. Usage of plugs in a pipe layer with these changing conditions may reduce the maximally allowed back pressure figure.

3. Selection of the Size of a Plug

Each pipe plug has ranges of minimum and maximum sealing sizes. Check if the internal diameter of the pipes are within the sealing range (usable range) of the plug.

4. Corrected (Inspection Certified) Gauge

Not using the corrected gauge may lead to the loss of plugs. Plugs may be destroyed due to excessive pressure or insufficient expansion. Monitor the expansion and back pressure only by the corrected gauges. After monitoring the pressures using corrected gauge and appropriate hoses, expand and recoil the plugs outside of the danger zone.

5. Cleaning and Testing

Plugs should be clean and be tested before and after the usage. In case of traces of abrasion or thermal burn being observed or shown, do not use the plug. All the natural rubber products will develop deterioration with time even though it is seldom used, stored in good conditions, or not indicated outwardly.

Traces of damage. For this reason, Daewon recommends the abolition of the plug within 3 years of the date of manufacturing
which is indicated in the main body of the plug in case of the product being unknowingly damaged for its serial number tag,
month of manufacturing, or date of sales. For inquiries due to not being able to find the date of manufacturing or other
questions, call 031-454-4111(Rep).
Plugs are released for sale after sufficient testing before the release, but returning of the product due to problems from manufacturing is possible.

Testing includes but not limited to the following :
1. Excessive scratch on the surface
2. Traces of abrasion
3. Puncture
4. Traces of expansion
5. Fissure
6. Corrosion
7. Loosened or damaged components of parts
8. Leakage

6. Clean Pipes

Remove debris before fitting the plugs. Dirty pipes may reduce the back pressure endurance capacity of the plugs and may cause damage to the plugs at the time of placement or expansion.

7. Plug Rupture

The plug may rupture if it expands against the sharp materials or insufficiently expanded.

8. Backup System

To prevent any injury or property damage during the plug disruption, an additional backup system should be taken into account. Never use eye-bolt, expansion hose or other attachment to the plugs as a means to constrain the movement of plugs under back pressure situation.

9. Blocking the Plug

Not appropriately blocking the plug or not using the bracket tools (or bracket) may lead to fatal results.
The power behind the plug could be tremendous. Well-designed blocking equipment or bracket equipment should be used to control the movement of plugs.

Operation

Danger Zone

While the plug is under usage,
Never get into the danger zone while the plug is being used since there comes into being a risk area to which cone type expansion occurs to the outside.

Temperature Range

Pipe plug is designed to be used between the range of 0° C ~ + 50°C temperature. Using the plug outside the range of standard temperature range may lead to the damage to the plug. For using below or above the above temperature limits, please inquire to Daewon Industrial Co., Ltd.

Plug Placement

Not sufficiently inserting into pipes in the first insertion may lead to inability because the pneumatic plug is enlarged with the plug protruding while expansion. Place the plug into the pipe at least at the same distance as the diameter of the pipe.

Monitoring Pressure

Expansion pressure and back pressure should be monitored more than once per every 4 hours and maintained to the standard plug specification. For specific application program, more frequent monitoring may be required. During the operation, a pressure source could adhere to the plug.

Limitation to Restricted Media

Using the plug along with the chemical materials including carbon dioxide can create a severe damage to the plug. Plug made of natural rubber is designed to endure air, water or sewage waters. Plug blockage could be the cause of deaths or serious injuries.

Expansion Media

Daewon's plug is liable for expansion with air, water or inert gases such as nitrogen. Air and other inert gasses are more dangerous than water when plugs are damaged.

1. Either block plugs or pipes, or place the plug to test or other plug at least at the same distance to the diameters to operate and inside the pipe or operation.
2. Connect one end of expanding hose to the plug expansion fitting (e.g. Schrader Valve, 1/4 ", 3/8", 1/2 " port and etc.). For the other end of expanding hose, use line pressure, pump or other air-supply pressure equipment. Always discharge pressure by an appropriate method after the application.
3. You should connect to the corrected gauge.
4. Plugs should be blocked with brackets or reinforced. Before usage, plugs should be inflated with appropriate methods.
5. Plug should be pressurized through expansive hose. Plug should be expanded with standard expansion pressure indicated in the plug. (Reference is made to the specification table.)
6. Please have the plugs stabilized for the moment. Put pressure to maintain standard expansion pressure when needed.
   Excessive expansion : Do not exceed the needed expansion pressure. Plug may be ruptured to derail with extreme speed.
   Insufficient expansion : Let the plug and media not separated from the pipe because of excessive expansion.
7. Test the pipe, application program or other usage of plugs. After the test application or plug usage is completed, clear all the reverse pressure aft the plugs at outside of the danger zone.
8. When all the back pressure is cleared, release the plug pressure from the outside. Clear the danger zone and constant back pressure till the plugs are completely shrunken.
   Before shrinking the plugs, if the shrinkage occurs before clearing back pressure, plug may be derailed with extreme speed.
9. Remove bracket materials and brackets for safety. Remove plugs from the pipe and follow the instruction of storage (regulation of the concerned company).

Maintenance and Storage

Plugs can be cleaned by soft soap
and water, too (other cleaning agent may create damage.).

Expand the plugs by 0.2psi for testing the plug during every usage.
It may not be used showing the trace of abrasion.
Plugs deteriorated and damaged shall not be reused because they’re not safe.
Do not expand the plugs more than 0.2psi in the following cases.

When the plugs are outside of pipes,
keep it in a dry place with no exposure to ultra violet ray and ozone. Plugs should be kept indoor with less than 30 degree Celsius temperature and may be kept either vertically or horizontally.