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CHERNE Test-Ball User Manual

CHERNE Test-Ball
62 pages
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1
CHERNE INDUSTRIES INCORPORATED
5700 LINCOLN DRIVE
MINNEAPOLIS, MINNESOTA 55436-1695
PHONE: 1-800-843-7584
FAX: 1-800-843-7585
SAFETY &
INSTRUCTION
MANUAL
A Guide to
the safe and
proper use of
Cherne
Pneumatic
Pipe Plugs
KEEP THIS MANUAL WITH PLUG FOR FUTURE REFERENCE
WA R N I N G
MUST
READ THIS
MANUAL BEFORE
USING CHERNE
PNEUMATIC
PIPE PLUGS
This manual covers Cherne
Pneumatic Plugs as follows:
Single Size Test-Ball® Plugs (8” & larger)
Multi-Size Test-Ball® Plugs (6” & larger)
Muni-Ball® Plugs
i-Series® Plugs
REMO® Plugs
BIG MOUTH® Plugs
AIR-LOC® Plugs
Factory Replaceable Sleeve
Large Pillow-Style Test Ball® Plugs
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CHERNE Test-Ball Specifications

General IconGeneral
Nominal SizeVaries by model
DiameterVaries by model
TypeInflatable Test Ball
MaterialRubber
ApplicationPipeline testing
Pressure RatingVaries by model
UsagePipeline testing

Summary

Introduction and General Safety

Manual Overview and Purpose

Introduces the safety instruction manual and its application to all Cherne pneumatic plugs.

Back Pressure Management

Maximum Allowable Back Pressure

Outlines maximum back pressure ratings for Cherne pneumatic pipeline plugs.

Danger Zone Safety Precautions

Details the danger zone and critical safety warnings regarding its use.

Plug Usage Conditions

Temperature and Media Limitations

Specifies operating temperature range and media compatibility for Cherne plugs.

Pipe Measurement and Plug Selection

Pipe Measurement and Plug Sizing

How to measure pipe diameter and select the correct plug size.

Pneumatic vs. Mechanical Plug Comparison

Compares the advantages and disadvantages of pneumatic and mechanical plugs.

Plug Cleaning and Inspection

Pre-Use Cleaning Procedures

Instructions for cleaning and inspecting plugs and related equipment before use.

Detailed Pre-Use Inspection Checklist

Lists items to inspect for wear, damage, or missing components.

Safety Equipment and Procedures

Required Personal Protective Equipment

Lists essential safety gear like glasses, hard hat, ear protection, and footwear.

Confined Space Entry Protocols

Safety procedures for entering manholes and other confined spaces.

Plug Installation and Inflation

Proper Plug Placement in Pipe

Correct positioning of plugs in the pipe, including minimum insertion depth.

Safe Inflation Procedures

Guidelines for safe plug inflation using calibrated gauges and proper sources.

Operational Safety and Support

Backup System and Bracing Requirements

Emphasizes the necessity of backup systems and proper bracing for safety.

Proper Plug Removal Procedures

Step-by-step instructions for safely deflating and removing plugs.

Product Usage Data and Special Applications

Cherne Plug Specifications Tables

Technical data for various Cherne pneumatic plug models.

Gravity Flow Bypass Application Guide

Special instructions for using plugs in gravity flow bypass applications.

Warranty and Policy Information

Limited Warranty Terms and Conditions

Details the manufacturer's warranty period, coverage, and exclusions.