JCM INDUSTRIES 133 (01) PDF Document

1. Clean and scrape the pipe. Remove any scale, pipe wrap, debris, or dirt that may interfere with the complete sealing of the gasket. Inspect the pipe for integrity, size, outside diameter, and surface irregularities. Confirm you have the proper size and range of repair clamp and that all parts are included.

2. Lubricate the pipe and the fitting gasket with soapy water. Do not use oil base 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 installation procedure for the JCM INDUSTRIES 133 is as follows:

1. Place the clamp on the pipe and center it over the damaged area.

2. Tuck the tapered gasket in place.

3. Mesh the finger lugs and rotate the clamp in the direction of the arrow to smooth the tapered gasket flap.

4. Position the bolting lug for easy access for continued bolt tightening.

5. Engage the bolts in the receiver lugs and finger tighten to hold the clamp in place.

6. Begin the bolt tightening sequence as specified.

For multi-band clamps (Models 132, 134) with multi lug segments, follow these steps:

1. One section has “closed ears” (A) and “open ears” (B) for bolt engagement. 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 on top is 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 proper torque values, continuing around the pipe at each lug segment. Avoid tightening lugs to metal bound at any one segment; gaps between lugs should be approximately even on both sides.

8. Continue the bolting sequence to the proper torque values.

Tighten all bolts evenly to the following torque values using a calibrated field torque wrench:

5/8″ Bolts to 70 Foot Pounds

3/4″ Bolts to 90 Foot Pounds

After completing the installation of the fitting, return after approximately 15 minutes and confirm that the minimum bolt torque levels have been maintained. For JCM 133 Tapped Clamps, proceed with the tapping process.

Yes, 18-8 stainless steel fasteners can gall and freeze (seize up). To prevent this, several measures are taken and precautions are necessary:

1. The nuts and bolts are made from materials of different hardness.

2. Standard 5/8″ and 3/4″ nuts are coated with a special blue or green (antiseize) coating. A Molybdenum-Base lubricant is recommended if additional lubrication is needed.

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

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

5. The bolts and nuts are made to exacting specifications for material and thread form.

It is crucial to keep the bolt threads clean, free from nicks, and not pitched or thrown into a tool bucket during installation. Use of a pneumatic wrench is not recommended as it could cause the hardware to seize.

For maximum performance under adverse conditions, consider 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 oil base pipe lubricant as it does not disperse, leaves residue, and prevents the gasket from sealing. 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. Clamps provide maximum performance when centered over the damaged 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, and then slide the clamp over the damaged area. Ensure the tapered gasket lays flat without a curl or fold, then proceed with installation.

• 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 avoid 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.

Ensure the fitting is suitable for the application by confirming size, materials, pressure ratings, line content, and that it meets local governing and association standards. Pipeline operation forces, including pressure fluctuations, thermal expansion/contraction, and movement/shifting, will influence the success of the application. Proper anchorage, restraint, harnessing, thrust blocks, or other devices must be provided to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fitting. The end user is responsible for inspecting the pipe’s integrity. It is also recommended to use a calibrated torque wrench.