Installation Manual for Couplings
Detailed manual for installing Klamflex Couplings. Covers installation, storage, troubleshooting, and important practices to avoid incorrect use.
Installation Manual for Couplings
Detailed manual for installing Klamflex Couplings. Covers installation, storage, troubleshooting, and important practices to avoid incorrect use.
Installation
- Klamflex couplings are not designed to resist end loading or prevent lateral movement and/or angular displacement. Piping systems must be adequately supported and anchored to eliminate lateral movement and angular displacement.
- Ensure the pipe ends are correctly prepared. Thoroughly clean all surfaces that contact the gaskets immediately before installation. Prepare a distance of one centre sleeve length plus 50 mm on each pipe end, removing all loose rust, dirt and foreign matter. Pipe ends must be smooth, concentric and within the pipe manufacturer's specified tolerances. Weld beads must be ground flush while maintaining the correct surface profile.
- Place reference marks on the pipe to facilitate centring the coupling over the gap between the pipes, in accordance with the Klamflex setting gaps specified for each coupling.
- Larger-diameter pipes may become out of round during transportation and handling. It is therefore normal to use jacks, wedges, shims or other suitable means to facilitate coupling assembly.
- Place the end ring onto the pipe.
- Apply a suitable gasket lubricant, such as non-toxic silicone oil, to the pipe end and sealing ring. Ensure the gaskets are clean. Place the gasket onto the pipe end with the bevelled faces directed towards the centre sleeve.
- Place the centre sleeve onto one pipe end.
- Align the pipe ends, leaving the appropriate gap specified in the Setting Gaps section of the Technical Catalogue and Klamflex website. Adjustment of the trench bed may be necessary.
- Where locating plugs are used, increase the setting gap by 9.5 mm for pipe diameters DN300 and smaller, and by 12.5 mm for pipe diameters DN350 and larger, to avoid contact with the plugs.
- Move the centre sleeve into position, centring it over the gap using the reference marks made on the pipe to ensure a central installation.
- Once the centre sleeve is correctly positioned, ensure the gap between the outside diameter of the pipe and the inside diameter of the centre sleeve is evenly distributed. Move the gaskets into position with their bevelled faces against the centre sleeve ends. Position the end rings behind the gaskets. Install the bolts through the end-ring holes and tighten to the Klamflex recommended torque. To ensure correct end-ring seating and gasket compression, tighten the bolts in pairs at diametrically opposite positions in a circular sequence. Tighten evenly, giving the nuts one or two turns at a time, to the prescribed torque of 65–80 Nm for M12 fasteners and 80–120 Nm for M16 fasteners. If an effective seal is not achieved at the recommended torque, loosen the coupling, realign it and retorque the bolts.
- After pressure testing and depressurising the line, and before backfilling, Klamflex recommends checking the bolt torques again, as pipe movement may have occurred during the pressurisation and depressurisation process.
- If a gasket needs to be renewed and it is not possible to remove the Klamflex coupling from the pipe, cut a length of the correct-profile gasket extrusion, available from Klamflex, approximately 5 mm longer than the pipe circumference. Wrap the gasket around the pipe and glue the ends together using quick-setting super glue (cyanoacrylate). Keep the joint at the top of the pipe and reassemble the coupling as normal. Do not forget to lubricate the gasket.
- If a pipe is extremely undersize and the coupling is not leak-tight due to the large tolerance, Klamflex offers rubber gasket profiles in different thicknesses. A thicker rubber gasket may be used to accommodate the excessive tolerance.
- If the pipe-end gap is too large for the standard Klamflex sleeve, longer sleeve couplings and flange adaptors can be supplied.
Storage
- Store in a cool, dark place and, where possible, at temperatures below 65°C.
- Store away from direct sunlight, electrical discharges and sparking electric motors.
- Always store sealing rings in an unstressed condition; never hang them, even for a short period.
Trouble Shooting
- Check if the fitting is correct for the application. If not, replace it with the correct fitting.
- Check for any pipe movement. If movement has occurred, the pipes must be strapped or restrained and the fitting reinstalled.
- Check for angular deflection. If present, the pipes must be strapped or restrained and the fitting reinstalled.
- Check that the gasket is uniformly compressed and the end ring is evenly tightened. If not, loosen and retighten the bolts as specified in the installation instructions. In some cases, the fitting may need to be strapped or restrained, as excessive movement could also dislodge the gasket.
- Check the bolt torques. If they are not within the specified torque range, retighten them to the installation specifications. Ensure that the pipeline is depressurised before retightening.
- Check that the fittings are properly aligned. If not, loosen the bolts, align the fittings and retighten them according to the installation instructions.
- Ensure that the pipe is not oval or out of specification by measuring the pipe OD at the open end in at least four positions.
- Check that the rubber seal was installed correctly. If not, replace the rubber seal and follow the installation instructions.
- Check the setting gaps, if possible. If they are incorrect, reinstall the fitting using the correct setting gaps.
- Check whether lubricant was used on the rubber seal. If not, remove the fitting, apply lubricant to the outside of the rubber seal and reinstall it according to the installation instructions.
- Check the fitting ID. If it is incorrect, contact the supplier.
Don't
- Do not over-torque the bolts.
- Do not modify or alter any components of the flange adaptor.
- Do not exceed the design or test pressure.
- Do not overstretch the sealing rubbers or expose them to open flames.