How it works
PLUG’s inline isolation tool is a modular system engineered for precision and reliability in live pipeline environments. It consists of three integrated components:
- Plug Modules (PM) – create the physical seal.
- Control Module (CM) – manages activation, monitoring and tracking.
- Pigging Module – enables transport through the pipeline.
During operation, the tool is pigged down the line using normal product flow to a predetermined location. Once flow is stopped, the tool is located, and two-way, through-wall communication is established with the control module.
Upon command, the control module injects fluid into a piston housed within the working head. This piston compresses the tool, drawing the ends of the working head together. As the tool compresses:
- Specialized grips travel up internal ramps and expand outward, anchoring securely to the pipe wall.
- Continued compression forces the rubber packer element outward, forming a vapor-tight seal against the pipe interior.
Any differential pressure across the tool further compresses the assembly, enhancing both the seal integrity and the anchoring force.
This self-reinforcing design ensures the tool remains immovable—even during pressure spikes—delivering robust, fail-safe isolation in demanding conditions.
Isolation Tool Setting Procedure
✅ Pre-Set Verification
Once the isolation tool has been pigged to its predetermined SET location, the following sequence is initiated to ensure proper functionality and secure isolation:
- The tool is halted using flow control mechanisms.
- A detailed checklist and step-by-step operational procedure are completed to verify tool integrity and readiness.
🔧 Plug 2 Setting Sequence
Activate Plug Module 2 (PM2)
- The control module begins feeding hydraulic oil to PM2.
- The onboard computer continuously monitors the process to ensure accurate execution.
- Once the required hydraulic pressure is achieved, the system confirms that PM2 is successfully SET.
🔧 Plug 1 Setting Sequence
Adjust Pressure Levels
- The low-pressure (LP) side is reduced by bleeding off pressure until it reaches approximately 50% of the high-pressure (HP) side.
Set Plug Module 1 (PM1)
- After pressure stabilization is confirmed, the PLUG supervisor initiates the setting of PM1.
Equalize LP Side to Ambient
- Once PM1 is verified as SET, the LP side is lowered to ambient pressure.
Final Monitoring & Certification
- The tool is monitored for a customer-specified duration to ensure no leaks are present.
- Upon successful inspection, an Isolation Certificate is issued, allowing the customer to begin work on the pipeline.