Installation Manual for Gripper Block Type
Detailed manual for installing Klamflex Gripper Block Types. Covers installation, storage, troubleshooting, and important practices to avoid incorrect use.
Installation Manual for Gripper Block Type
Detailed manual for installing Klamflex Gripper Block Types. Covers installation, storage, troubleshooting, and important practices to avoid incorrect use.
Installation
- Ensure the pipe end is correctly prepared (HDPE pipe to be bevelled). 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. Weld beads must be ground flush while maintaining the correct surface profile.
- Place reference marks on the pipe to facilitate centring the flange adaptor/coupling over the gap between the pipes, in accordance with the Klamflex setting gaps specified for each flange adaptor/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 assembly of the flange adaptor/coupling.
- Place the end ring containing the gripper blocks 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.
- Align and push the pipe end into position, 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.
- Pull the end ring back up the sleeve.
- Tighten the bolts to the Klamflex recommended torque.
- Tighten the restraining block bolts. These bolts are only for gripping action and do not affect sealing. The required tightening force of the gripper bolts will depend on the pipe material being gripped, as different pipe materials require different forces.
- Consult Klamflex for torque recommendations.
- 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.