How it works
PLUG’s modular isolation system features an inline isolation tool designed for precision and reliability in live pipeline environments. This advanced system includes three essential isolation tool 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 halted, the tool is precisely 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 that the tool remains immovable—even during pressure spikes—delivering robust, fail-safe isolation during demanding pipeline isolation procedures.
Isolation Tool Setting Procedure
✅ Pre-Set Verification
Once the isolation tool has been pigged to its predetermined SET location within the modular isolation system, the following sequence is initiated to ensure proper functionality and secure isolation: The isolation tool components are halted using flow control mechanisms. A detailed checklist and step-by-step operational procedure are completed to verify tool integrity and readiness as part of the pipeline isolation procedure.
🔧 Plug 2 Setting Sequence
Activate Plug Module 2 (PM2) as part of the modular isolation system. The control module begins feeding hydraulic oil to PM2, which is one of the key isolation tool components. The onboard computer continuously monitors the pipeline isolation procedure 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 of the modular isolation system 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, a key component of the isolation tool components.
Equalize LP Side to Ambient
Once PM1 is verified as SET, the LP side is lowered to ambient pressure, ensuring compliance with the pipeline isolation procedure.
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.