Series 440 Fabricated Line Stop Sleeve Types T2, T12, T3, T13, T5, T15
Testing of Fitting Prior to Tap/Stop Procedure
JCM Quality Fitting Equipped With 18-8 Stainless Steel Bolts and Nuts When not properly handled it is the nature of stainless steel fasteners to gall and freeze (seize up). This is due to the inherent properties of the stainless material. Galling and freezing is often triggered by the presence of metal chips, burrs and grains of sand on the threads of the bolts and nuts. Extra care has been taken by JCM prior to assembly and packing of this fi tting to assure a trouble-free installation. 1. The nuts and bolts are made from material of di ff erent hardness so that they have di ff erent strengths. 2. Nuts are coated with a special anti-seize coating. Additional lubricant may be needed. A Molybdenum-Base lubricant is recommended. The test is performed using the test port (typically) in the neck of the line stop fi tting. A standard test tree, wrapped with Te fl on tape and using a 300lb. liquid fi lled guage is screwed into the test port. A hydrostatic test is conducted by attaching a water hose to the barbed end of the test tree and using a hand pump, the technican achieves the desired pressure. Line Stop fi ttings are available with two types of completion plugs, threaded or push-pin. Threaded plugs: loosen the plug to remove the air and then tighten using the completion tool. Push Plug: all cap screws should be removed, wrapped in Te fl on tape and then tightened. The Blind/Blank fl ange will be installed and after the air is out, it should be bolted down with the provided blind fl ange bolts until the pressure test is performed successfully. Once the test is veri fi ed by the inspecting authority, the test tree can be removed, the test plug wrapped in Te fl on tape installed and tightened. Encasement of the line stop fi tting in concrete is recommended. Test speci fi cs (i.e. PSI, time duration, etc.) is set forth by the Authorizing Inspector. JCM remands adherence to the AWWA Standard C223, Section 4.6. Tests ensure the proper installation of the fi tting and con fi ms all seals are water tight prior to the technician wet/hot tapping the main. JCM does not recommend hydrostatic testing above the mainline pressure.
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 speci fi cations to assure that the correct material is used and that the thread form is correct. Stainless hardware is especially susceptible to galling. JCM supplies specially coated nuts to eliminate the galling caused by over- torquing, but 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 pneumatic wrench for installation could cause hardware to seize and is not recommended. T o ensure a successful, trouble free installation of this JCM Tapping Sleeve, the following Tips/Tricks are o ff ered: Lubricate the pipe with soap-water or water. Oil based pipe lubricants produce a fi lm between the gasket and pipe surface that is not water soluble and can interfere with the gasket/pipe water tight seal. Do not rotate the sleeve on the pipe. Rotation of the sleeve on the pipe can result in the gasket being ripped from the groove and damaging the gasket beyond repair. Some manufacturers recommend rotation - JCM does not. Tighten the bolts in the sequence provided in the instructions. Fittings are engineered to “load” the gasket in a certain fashion. Instructions provide the “sequence” of tightening bolts. Ensure the gap between sleeve halves is equal on both sides Con fi rm bolt torques with a torque wrench. Proper compression of the gasket is critical to the success of the tapping sleeve installation. A torque wrench should be used to ensure recommended levels are achieved. Most fi eld problems are directly related to lack of proper torque levels.
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