trouble shooting how to recognize improper installation may 2009 the ford meter box company, inc....
TRANSCRIPT
Trouble ShootingHow to Recognize Improper Installation
May 2009
The Ford Meter Box Company, Inc.
Table of Contents
Valves and Corp Stops Pages 1 - 20
Tubing and fitting problems Pages 21 - 27
Repair Clamp and FAST Pages 28 - 41
Backup Ring Pages 42 - 44
NOTE: Do not take apart and inspect - return items to the Ford Quality Assurance Staff in the exact condition that it is received from the field.
1. Iron teeth easily distort brass material
2. Increased torque on wrench handle squeezes jaws more tightly against the valve or fitting.
3. Typical pipe wrench jaws are 5 to 7 degrees from parallel
Why pipe wrenches should not be used.
Valve leaks at valve body. Pipe wrench distortions break the machined seal between the valve body and the outlet assembly.
Outlet assembly
Valve body
Teeth marks from pipe wrench
Should locate smooth jaw
wrench on the flat area here
Valve leaks after backfill. A dye test shows a key style corp stop with an arched body.
No dye = lack of seal because of
no key contact
Incorrect!Vertical key
placement can distort or “arch” the valve when
backfilled
Correct!Valve installed on its side will absorb higher backfill force
Valve leaks during pressure test. The grooves (scars) on the key are caused by operating the valve against stones or shavings. This valve was not properly flushed after installation.
The key port is distorted from a drilling operation that was done with the key not completely open. View 1 of 3
The key port is distorted from a drilling operation that was done with the key not completely open. View 2 of 3
Valve leaks / hard to operate. The key is bulged from the expansion of frozen water. The key was in the closed position when frozen. View 1 of 2
Valve leaks / hard to operate. The key is bulged from the expansion of frozen water. The key was in the closed position when frozen. View 2 of 2
Valve appears to be closed but allows water flow. A ball valve not fully closed when the tee-head is in a fully closed position. View 1 of 3
Valve appears to be closed but allows water flow. Note the twisted tee-head spade due to valve operation while frozen. View 2 of 3
Valve appears to be closed but allows water flow. The distortion of the ball slot is the result of operating the valve while frozen. View 3 of 3
Leaking compression fitting. Out-of-round copper tubing can cause a poor gasket seal. View 1 of 2
Copper Rounding Tool3/4” - CRT-31” - CRT-4
1-1/4” - CRT-51-1/2” - CRT-6
2” - CRT-7
Leaks after in service for weeks or months. Deflected copper can cause a poor gasket seal. View 1 of 3
Leaks after weeks or months - deflected / out of round. The narrowing of the shiny band shows an uneven gasket seal. The leak usually occurs at the most narrow part of the shiny area. View 2 of 3
Leak. Classic erosion pattern is from water escaping from between the gasket and the copper. View 3 of 3
Leak. An incomplete insertion of the copper tube into the fitting allows too much deflection. View 1 of 2
Leak. Part of the gasket was compressed over the end of the tube causing a poor gasket seal. View 2 of 2
Equal torque must be applied to all bolts/nuts to prevent leak. The wavy side bar shows over-torque. An over-torque can break the weld between the side bar and the band.
Protrusions on the band show that the finger lugs were placed under the band. Most commonly found on the underside of pipe. View 1 of 2
This repair clamp was used where a coupling should be installed. The indentations on the band show the end of the pipe. See Catalog Section L for proper applications. View 1 of 2
This repair clamp was used as a coupling. The indentations on the band show the end of the pipe. Close-up view of band. View 2 of 2
A repair clamp as a "transition" coupling. View 1 of 3
PVC pipe sidePVC pipe side11.10" (smaller) diameter11.10" (smaller) diameter
Cast iron pipe side Cast iron pipe side likely 11.60" (larger) diameterlikely 11.60" (larger) diameter
Additional stress on Additional stress on the band-to-sidebar the band-to-sidebar weld at the pipe weld at the pipe diameter transition diameter transition areaarea
SidebarSidebar
A repair clamp as a "transition" coupling. View 2 of 3
PVC pipe sidePVC pipe side11.10" (smaller) diameter11.10" (smaller) diameter
Cast iron pipe side Cast iron pipe side likely 11.60" (larger) diameterlikely 11.60" (larger) diameter
Broken band-to-sidebar weldBroken band-to-sidebar weld
A repair clamp as a "transition" coupling. View 3 of 3
PVC pipe sidePVC pipe side Cast iron pipe sideCast iron pipe side
Lifter BarLifter Bar
StudStud
Set of Set of finger finger lugslugs
SidebarsSidebars
WasherWasherLubricantLubricant
This 3-piece tapping sleeve leaked because the bottom row of bolts was not torqued.
Unequal gap - no gap on left, large gap on right and
bottom nuts not torqued.
During installation, tighten so the torque and gap are equal. This will prevent
leaking.