GTB 0466 Page 1 May 2009

Instructions for the Preservation, and

Use of Grayloc Clamp Connectors

Technical Bulletin GTB 0466

Western Hemisphere Headquarters: Eastern Hemisphere Headquarters: Middle East 11835 Charles Street Unit B Hydropark, Tern Place Unit No FZS1-BG04 Houston, Texas 77041-2411 Bridge of Don Jebel Ali Free Zone U.S.A. Aberdeen, Scotland, AB32 8JX Dubai, U.A.E Tel: 713-466-8853 Tel: +44 1224 222790 +971 (0) 4 886 1980 Fax: 731-937-2335 Fax: +44 1224 222780 +971 (0) 4 866 1766

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Index 1.0 Scope 2.0 Delivery and Storage 3.0 Welding 4.0 Painting 5.0 Assembly 6.0 Maintenance 7.0 Disassembly 8.0 Re-work/Repair

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1.0 Scope This procedure is intended to provide fabricators and end-users with detailed information on the proper storage, fabrication, painting, installation, maintenance disassembly and re-work of Grayloc Clamp Connectors. 2.0 Delivery and Storage All shipments from Grayloc are packed in suitable crates or secured to pallets depending on the method and length of transport. 2.1 Butt weld and blind hubs

All carbon and low alloy steel hubs are coated with a rust preventative to provide protection against corrosion during transport and storage. Stainless and nickel alloys are not coated. All hubs are provided with protective covers on the hubs face to protect against mechanical damage of the seal area.

Carbon and low alloy steel hubs can be provided with Electroless Nickel Plating. This will provide protection for the critical hub and sealing areas during storage, welding and assembly, and some degree of corrosion protection during operation. Electroless Nickel Plating is not applied to the butt weld end of the hub.

2.2 Clamps

Unless otherwise specified, all carbon and low alloy steel Grayloc clamps are supplied with a coat of primer or thin paint intended to provide protection against corrosion during transport and storage. Corrosion resistant alloy clamps are not coated unless otherwise specified.

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Note: On request clamps can be provided with a range of coatings, generally customer specified, for example PTFE, hot dip galvanising, zinc or nickel plated.

2.3 Bolting

The coating of the bolting is generally customer specified and will provide corrosion protection during transport and storage. Typical coatings include zinc, hot dip galvanising PTFE etc. Uncoated bolts are oiled. Standard bolting is supplied assembled with two nuts on each stud.

2.4 Seal rings

Seal rings are supplied in individual cardboard boxes to protect them during transportation and storage. It is recommended that the seal rings remain in these boxes prior to use.

Sealrings are provided with a dry lubricant coating, typically PTFE or MoS2 w/graphite. This coating is for lubrication of the seal ring during installation, but also provides some corrosion protection during shipment and storage.

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2.5 Receipt and storage on site

Clamp connectors should be stored in a clean and dry indoor environment. Carbon and low alloy steel parts, liable to corrosion, should be checked periodically and action taken if necessary. In particular the seal areas of the hubs and seal rings must not be allowed to corrode as this will affect the integrity of the seal.

3.0 Welding 3.1 Grayloc hubs may be fabricated to pipe or other component equipment by established

welding procedures. Normal procedures suitable for welding of pipe and flanges are suitable for the Grayloc hub. Initial fit-up and alignment tolerances normally used in the fabrication of ANSI flanges are also applicable for the Grayloc hub. Further information can obtained form Grayloc if required.

3.2 Prior to welding it may be necessary to remove the protective cover and any rust inhibitor. Hub seal areas must be protected from damage and weld spatter during welding. If the procedure requires stress reliving then anti-oxidation compounds can be used to prevent scaling during PWHT.

3.3 After welding, the surfaces of the hubs can be cleaned in-line with normal practices,

however hub seal areas must be protected from shot blasting and any other aggressive cleaning operations.

3.4 After welding, any corrosion protection (rust inhibitor) must be re-applied. It is

advisable to replace the protective cover to provide continued protection of the hub from mechanical damage

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4.0 Painting To ensure proper connection assembly, the following painting and masking guidelines shall be followed. 4.1 Hubs

The areas shown below shall not be painted.

After painting, inspect and, reapply any corrosion protection (rust inhibitor) to the unpainted areas. Replace the protective cover to provide continued protection of the hub from mechanical damage.

4.2 Seal rings and bolts

No additional coating should be applied to the seal rings or bolting.

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4.3 Clamps

Thick paint coatings such as epoxy paint systems must not be applied to the clamp inside profiles and clamp spherical radius areas. It is acceptable to apply thin coatings to these areas, for example inorganic zinc primers, typically 50-120μm (2 to 5mils) thick.

Clamps can be provided with a range of coatings, generally customer specified, for example PTFE, hot dip galvanising, zinc or nickel plated.

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5.0 Assembly No special tools are required to assemble the clamp connector other than standard tooling found on a typical fabrication and assembly site. Torque wrenches can be used to achieve the required bolt torque. The nuts used on the bolting are standard heavy hex nuts and will fit standard sockets. Bolt tensioners cannot be used on Grayloc clamps as the tensioner footprint area is not flat, extended length studs and special washers can be provided to accommodate bolt tensioner equipment if required. Please refer to the Installation and Maintenance of the Grayloc Connector bulletin (GLOC-106) for additional assembly, disassembly and maintenance recommendations.

5.1 The Grayloc seal ring does not seat until the connection is fully tightened; therefore a small clearance or standoff should be observed when the seal ring is placed into a mating hub. If no standoff is present use a new seal ring.

Applicable standoff figures for Grayloc seal rings are given in table 1

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GRAYLOC SEALRING

SIZE

MIN MAX GRAYLOC SEALRING

SIZE

MIN MAX

inches mm inches mm inches mm inches mm 4 0.003 0.08 0.019 0.48 72 0.035 0.89 0.085 2.16 5 0.003 0.08 0.019 0.48 76 0.033 0.84 0.091 2.31 7 0.005 0.13 0.021 0.53 82 0.036 0.91 0.095 2.41 11 0.006 0.15 0.021 0.53 84 0.038 0.97 0.096 2.44 13 0.008 0.20 0.024 0.61 87 0.036 0.91 0.102 2.59 14 0.008 0.20 0.022 0.56 91 0.055 1.40 0.121 3.07 16 0.007 0.18 0.021 0.53 94 0.040 1.02 0.106 2.69 20 0.006 0.15 0.027 0.69 97 0.042 1.07 0.108 2.74 23 0.008 0.20 0.028 0.71 102 0.044 1.12 0.109 2.77 25 0.008 0.20 0.031 0.79 106 0.068 1.73 0.134 3.40 27 0.009 0.23 0.032 0.81 112 0.046 1.17 0.119 3.02 31 0.008 0.20 0.034 0.86 114 0.033 0.84 0.099 2.51 34 0.011 0.28 0.036 0.91 120 0.050 1.27 0.122 3.10 40 0.011 0.28 0.038 0.97 122 0.048 1.22 0.128 3.25 42 0.021 0.53 0.050 1.27 125 0.036 0.91 0.107 2.72 46 0.014 0.36 0.040 1.02 130 0.051 1.30 0.132 3.35 50 0.013 0.33 0.045 1.14 134 0.055 1.40 0.135 3.43 52 0.014 0.36 0.046 1.17 137 0.057 1.45 0.137 3.48 56 0.016 0.41 0.049 1.24 140 0.053 1.35 0.134 3.40 62 0.029 0.74 0.080 2.03 144 0.061 1.55 0.141 3.58 64 0.044 1.12 0.095 2.41 152 0.061 1.55 0.148 3.76 67 0.025 0.64 0.076 1.93 160 0.097 2.46 0.184 4.67

Table 1 - Acceptable Standoff (inches)

5.2 Clean all lubricant and foreign matter from the hub sealing surfaces before

installation. Use a non-abrasive material to clean the sealrings of all foreign matter. Normally, all sealrings have a coating or plating (PTFE, MoS2 with graphite), which acts as a lubricant during make-up. In some applications where uncoated/un-plated sealrings are used, a light film of clean lubricant is recommended. When applying lubricant, take special care to insure that no

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solids or foreign particles are present in the lubricant. Also take care to prevent mechanical damage to the seal ring and the hub sealing surfaces.

5.3 Before assembly, the hubs must be aligned to allow engagement of the seal

ring lips to the hub sealing surfaces. This will ensure proper engagement of the hub and clamp segments for misaligning systems, it may be necessary to apply external loads to the mating piping (using jacks, come-a-longs, etc.) to align the hubs prior to assembly.

5.4 Align the hubs so that the seal ring can be installed.

5.5 Install the seal ring in the sealing surface of the hubs. The seal ring should

rock slightly; i.e., the seal ring rib should not be able to fully contact the hub face, If it does not rock, use a new seal ring.

5.6 Apply lubrication to the hub-clamp contact area to reduce friction during

assembly. Position the clamps around the hubs.

5.7 Lubrication of the bolting, the spherical faces of the nuts and clamp ears is recommended. Insert the stud bolts into the bolt holes of the clamp ears. The stud-bolts should be installed to ensure that the spherically face nuts fit into the spherical seats of the clamp ears

5.8 Tighten the bolting in a criss-cross pattern (i.e. bolt #1, #3, #2, #4) while

keeping the spacing between the clamp halves approximately equal.

5.9 Torque the bolting to the recommended vales. The clamp shall be jarred (i.e. a sound blow to the back of the clamp with a soft hammer) and the bolting retightened. This should be repeated until bolt torque does not change after jarring (torque, jar, torque, jar, etc)

5.10 After proper assembly the hub faces will fully contact the seal ring rib

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Table 2 - Torque Values

5.11 Grayloc recommend the use of lubricated bolting. Torque values given in Table 2 are based on lubricated bolting with a coefficient of friction of at least 0.15.

5.12 For extreme misalignment and/or extreme piping loads, torque values 1.5 to 2

times the table values are recommended. Do not exceed 2 times the recommended torque values, as this may result in permanent damage from distortion to the connector components.

5.13 For spools or pipework with more than one Grayloc connection, each

individual connector must be fully assembled and tightened prior to the make-up of the next connection.

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6.0 Maintenance

Special maintenance is not required for a Grayloc connector that has been properly assembled

7.0 Disassembly Important safety note: The following instructions shall be adhered to in order to prevent serious injury while disassembling the clamp connector

7.1 Vent and verify that all pressure has been removed form the line before disassembling the Grayloc connector.

7.2 The nuts should not be completely removed from the studs during the initial

disassembly of the clamp.

7.3 Loosen the bolting and all clamp segments to allow the safe release of any trapped pressure. If the clamp segments remain in place around the hubs, then both clamps segments must be loosened by jarring (i.e., a sound blow to the inside of the clamp ear with a soft hammer).

7.4 The bolting can then be removed after release of any trapped pressure.

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8.0 Re-work/Repair Re-work / refurbishment of Grayloc connectors is possible. The following instructions give a guide to the acceptance criteria.

8.1 Grayloc® Clamp Segments

1. Rust Clamp Inside Profile Wire brush, file & polish (no protrusions) Spherical Radius Wire brush, file & polish (no protrusions) Other Surfaces Wire brush & clean

2. Nicks & Dings Clamp Inside Profile Wire brush, file & polish (no protrusions)

Spherical Radius Wire brush, file & polish (no protrusions) Other Surfaces OK as is

3. Peeling Paint Clamp Inside Profile Wire brush & clean Spherical Radius Wire brush & clean Other Surfaces Wire brush & clean

4. Clamps Distorted / Clamp Ears Contact Replace

Clamp Inside Profile

Spherical Radius

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8.2 Grayloc® Butt Weld / Blind Hubs

1. Light Rust Seal Surface Remove with Scotch Brite & polish smooth** 25° Hub Profile Remove with Scotch Brite Other Surfaces (Neck, Face, O.D.) Remove with Scotch Brite

2. Heavy Rust Seal Surface Contact Grayloc Products for evaluation 25° Hub Profile Contact Grayloc Products for evaluation Other Surfaces (Neck, Face, O.D.) Contact Grayloc Products for evaluation

3. Marks Seal Surface Remove with Emery & polish smooth** 25° Hub Profile Remove with Emery Other Surfaces (Neck, Face, O.D.) Remove with Emery

4. Scratches Seal Surface Contact Grayloc Products for evaluation 25° Hub Profile Remove with Emery/Scotch Brite Other Surfaces (Neck, Face, O.D.) OK

5. Nicks / Dings Seal Surface Contact Grayloc Products for evaluation 25° Hub Profile File & polish smooth Other Surfaces (Neck, Face, O.D.) OK as is

6. Sandblasted Seal Surface Contact Grayloc Products for evaluation 25° Hub Profile File & polish smooth Other Surfaces (Neck, Face, O.D.) OK as is

7. Weld Spatter Seal Surface Contact Grayloc Products for evaluation 25° Hub Profile File, wire brush and polish smooth Other Surfaces (Neck, Face, O.D.) File, wire brush

8. Misc. Residues (Dirt, Grit, Grease, etc.) Seal Surface Clean with solvent 25° Hub Profile Clean with solvent Other Surfaces (Neck, Face, O.D.) Clean with solvent **The seal area surface finish is critical to achieving a good seal. Generally a seal surface roughness of 0.4μmAA (16μinAA) is required for sealring sizes 4 to 62 and 0.8μmAA (32μinAA) for sizes larger than 62. There shall only be circumferential machining/polishing marks; no axial scratches or marks are allowed. Any re-work or polishing of seal areas must be done in a circumferential direction taking wide sweeps around the seal area to avoid low spots and potential leak paths.

Seal Surface Seal Surface

25° Hub Profile 25° Hub Profile

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8.3 Grayloc® Seal Ring

1. Rust Seal Lips Replace Rib Remove with Scotch Brite & polish

3. Burnished Appearance Seal Lips OK as is (normal condition) Rib N/A

3. Scratches Seal Lips Replace Rib Remove with Scotch Brite & polish

4. Nick & Dings Seal Lips Replace Rib Replace

5. Misc. Residues (Dirt, Grit, Grease, etc.) Seal Lips Clean with solvent Rib Clean with solvent

6. Peeling Coating Seal Lips Scotch Brite, remove loose coating, apply light clean

lubricant Rib Scotch Brite, remove loose coating

7. No rock (standoff) observed Replace

Seal Lips

Seal Rib

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8.4 Grayloc® Bolting – Stud & Spherical Faced Nuts

1. Light Rust Stud Wire brush and clean Nut Wire brush and clean

2. Heavy Rust Stud Replace Nut Replace

3. Nicks & Dings (Thread Damage) Stud Replace Nut Replace

4. Distortion Stud Replace Nut Replace

5. Worn Threads Stud Replace Nut Replace

6. Misc. Residues (Dirt, Grit, Grease, etc.) Stud Wire brush & clean Nut Wire brush & clean

Nut Spherical Face