JCM INDUSTRIES 132 (01) PDF Document

Before beginning the installation, you must read the instructions and review the “Tricks of the Trade”.

1. Clean and scrape the pipe. Remove any scale, pipe wrap, debris, or dirt that may interfere with the complete sealing of the gasket.

2. Inspect the pipe for integrity, size, outside diameter, and surface irregularities.

3. Confirm you have the proper size and range of repair clamp for your pipe.

4. Inspect the fitting to ensure all parts are included.

Lubricate the pipe and the fitting gasket with soapy water. It is important that you do not use an oil-based pipe lubricant. Loosen the nuts of the bolts and back the nuts to the end of the bolt; complete removal of the bolts is not necessary. Release the oval-necked bolts from the lug ears and open the clamp.

The JCM INDUSTRIES 132 is a multi-band clamp with multi-lug segments. One section has “closed ears” (A) and another has “open ears” (B) for bolt engagement.

1. Locate the lug segment with the open “ear” to loosen bolts. Loosen the bolts of other lug segments. Do not remove the bolts.

2. Open the clamp at the open ear lug segment and place it on the pipe so that the gasket flap is on top, facing you.

3. Bring the back half of the clamp around the pipe.

4. Feed the tapered gasket end into place, mesh the top lug fingers into the “open ears,” and engage the bolts.

5. Rotate the clamp in the direction of the arrow to smooth the tapered gasket flaps.

6. Finger tighten the bolts to hold the clamp in place.

7. Begin tightening the bolts to the proper torque values, continuing around the pipe at each lug segment. Avoid tightening lugs to the point of being metal-bound at any one segment; gaps between lugs should be approximately even on both sides.

8. Continue the bolting sequence to proper torque values.

Tighten all bolts evenly to the following torque values. Ensure you use a calibrated field torque wrench to confirm the values.

After completing the initial installation, you should return after approximately 15 minutes and confirm that the minimum bolt torque levels have been maintained. For tapped clamps (Model 134), proceed with the tapping process.

Stainless steel fasteners can gall and freeze (seize up) if not handled properly. To ensure a trouble-free installation:

1. The nuts and bolts are made from materials of different hardness to give them different strengths.

2. The standard 5/8″ and 3/4″ nuts are coated with a special blue or green (antiseize) coating. If you have uncoated hardware, a Molybdenum-Base lubricant is recommended.

3. Each nut is assembled by hand at the factory to ensure it goes on the bolt freely.

4. The bolts and nuts are handled carefully to avoid damage to the threads.

5. The hardware is made to exacting specifications for material and thread form.

To prevent galling, the bolt threads must be kept clean, free from nicks, and not pitched or thrown into a tool bucket during installation. Use of the JCM 901 Master Wrench or JCM 905 Torque Wrench with Deep Socket is highly recommended. The use of a pneumatic wrench is not recommended as it could cause the hardware to seize.

For maximum performance under adverse conditions, take advantage of the following tips:

• Always clean and lubricate the pipe with water or soapy water. This helps overcome friction when rotating the clamp to smooth the gasket. Do not use an oil-based pipe lubricant. A water solvent lubricant should be used. A mirror can assist with inspection of the backside of the pipe or a pipe in a cramped space.

• Place a reference mark on the pipe back from the damaged area to help in centering the clamp over the break. Clamps provide maximum performance when centered over the damage area.

• For installation on a pipe under pressure: lubricate the clamp gasket with a soap/water mixture, assemble the clamp on the pipe beside the damaged area, lightly engage the bolts, slide the clamp over the damaged area, ensure the tapered gasket lays flat without curling or folding, and then proceed with the installation steps.

• Breaks involving deflected pipe require a wider clamp. JCM lugs will articulate, permitting the clamp to better conform to the pipe.

• For damage involving large holes or massive pitted areas, use a stainless steel plate over the large holes (under the repair clamp) to provide the gasket a surface to seal against.

• Drill holes in the ends of splits or cracks to relieve forces which could cause the splits to continue.

• Clamp performance drops when the gap between pipe ends is larger than 1/2″. Use a stainless steel spacer to fill or to place over the gap.

• Leave sufficient pressure on a broken line to prevent the intrusion of foreign matter and prevent excessive line contamination.

• With pressure reduced, spraying water will cease as soon as the water level rises above the break.

• Lubricating the clamp bolts will ease clamp installation and assure proper torquing of bolts.

To ensure the fitting is suitable for the application and to ensure a successful installation, you must consider the following:

• Confirm size, materials, pressure ratings, and line content, and ensure the fitting meets local governing and association standards.

• Be aware of pipeline operation forces, including pressure fluctuations, thermal expansion/contraction, and movement/shifting, as they will influence the success of the application.

• Provide proper anchorage, restraint, harnessing, thrust blocks, or other devices to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fitting.

• Inspection of the pipe integrity is the responsibility of the end user.

• It is recommended to use a calibrated torque wrench.