Installation Manual for Flange Adaptors
Detailed manual for installing Klamflex Flange Adaptors. Covers installation, storage, troubleshooting, and important practices to avoid incorrect use.
Installation Manual for Flange Adaptors
Detailed manual for installing Klamflex Flange Adaptors. Covers installation, storage, troubleshooting, and important practices to avoid incorrect use.
Installation
- Ensure the pipe end is correctly prepared. Thoroughly clean all surfaces that come into contact with the gaskets immediately before installing the flange adaptor, allowing the gaskets to seal effectively. Prepare a distance of one centre sleeve length plus 50 mm to remove all loose rust, dirt and foreign matter. Pipe ends must be smooth, concentric and within the specified tolerances (SABS 719-1971 Section 5, BS 534-1990 Section 14). Weld beads must be ground flush while maintaining the correct surface profile.
- Place reference marks on the pipe to facilitate centring the flange adaptor over the gap between the pipes, in accordance with the Klamflex setting gaps specified for each flange adaptor.
- 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 assembly of the flange adaptor.
- 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 that the gaskets are clean.
- Place the gasket onto the pipe end with the bevelled faces directed towards the centre sleeve.
- Attach the flange and sleeve to the mating flange.
- Align the pipe end, 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.
- Tighten the studs to the Klamflex recommended torque. To ensure correct end-ring seating and gasket compression, tighten the studs 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 sizes up to 300 NB and 80–120 Nm for sizes over 300 NB.
- The tightening sequence ensures that the end ring is pulled evenly, compressing the gasket uniformly and maintaining the appropriate gap. Repeat the bolt-tightening process as many times as necessary to bring all fasteners to the required torque and provide a leak-proof installation at the specified test pressure. If effective sealing is not achieved at the recommended torque, loosen the flange adaptor, 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.
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.