JCM INDUSTRIES 134 (01) PDF Document

Read the installation instructions and review the “Tricks of the Trade” section to assist with installation. For purposes other than water, you should seek application and product assistance.

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 the proper size and range of the repair clamp.

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

Lubricate the pipe and the fitting gasket with soapy water. Do not use oil base pipe lubricant. Loosen the nuts on 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 134 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 the clamp on the pipe so that the gasket flap is on top and 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 bolts to the proper torque values, continuing around the pipe at each lug segment.

8. Avoid tightening lugs to metal bound at any one segment; gaps between lugs should be approximately even on both sides.

9. Continue the bolting sequence to proper torque values.

Tighten all bolts evenly to the following torque values, ensuring the values with a calibrated field torque wrench:

5/8″ Bolts: 70 Foot Pounds

3/4″ Bolts: 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 134 Tapped Clamps, you can then proceed with the tapping process.

You must 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. Inspection of the pipe integrity is the responsibility of the end user.

The JCM INDUSTRIES 134 is equipped with 18-8 stainless steel bolts and nuts. Stainless steel fasteners can gall and freeze (seize up). To assure a trouble-free installation, note the following:

1. The nuts and bolts are made from material of different hardness so that they have different strengths.

2. Standard 5/8″ and 3/4″ nuts are coated with a special blue or green (antiseize) coating. Additional lubricant may be needed. Uncoated stainless steel hardware is provided without lubrication to prevent a build up of dirt, sand or grit during shipment. A Molybdenum-Base lubricant is recommended.

3. Each nut is assembled by hand to be sure that it went 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 to assure that the correct material is used and that the thread form is correct.

The bolt threads must be kept clean, free from nicks and not pitched or thrown into the tool bucket during the installation process. Use of a pneumatic wrench for installation could cause hardware to seize and is not recommended.

For installation on a pipe under pressure:

1. Lubricate the clamp gasket with a soap/water mixture.

2. Assemble the clamp on the pipe beside the damaged area.

3. Lightly engage the bolts and slide the clamp over the damaged area.

4. Ensure the tapered gasket lays flat without a curl or fold.

5. Proceed with the standard installation steps.

• 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. Use of a mirror will assist inspection of the backside of the pipe or pipe in cramped, limited 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.

• Breaks involving deflected pipe require a wider clamp. The 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 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 intrusion of foreign matter to prevent excessive line contamination.

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

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