Flanged Outlet Clamp

This instruction has been prepared for the correct and safe installation of flanged outlet clamps used for repairing leaks, cracks, and damages in potable water, wastewater, and industrial pipelines, while simultaneously enabling branch connections or valve installation via an integrated flange outlet.

1. Pre-Installation Preparation

• Correct Size Selection:
  Measure the pipe outer diameter (O.D.) using a caliper or circumference tape before installation.
  Ensure that the clamp size indicated on the label is suitable for the pipe diameter.
  Also verify that the selected flanged outlet size matches the intended equipment connection.
• Surface Cleaning:
  Clean mud, rust, loose coatings, and deposits from the pipe surface using a wire brush.
  A clean and smooth surface is essential for proper sealing performance.

2. Installation Steps

2.1 Lubrication

• Apply soapy water or a suitable lubricant to the pipe surface and gasket.
  This ensures smooth positioning and prevents gasket folding during tightening.
• Warning:
  Do not use petroleum-based oils or grease, as they may damage the gasket material.

2.2 Clamp Positioning

• Preparation of the Clamp:
  Fully loosen the nuts and open the clamp.
  Wrap the clamp around the damaged area or the intended branch connection point.
• Centering:
  Ensure that the damaged area or flange outlet location is centered within the clamp body.
  For repair applications, the clamp length should extend at least 50–100 mm beyond the damaged area on both sides.

2.3 Closing and Initial Tightening

• Bring the clamp lugs (ears) together.
• Ensure that the gasket lip is properly seated without folding.
• Insert the bolts into their slots and hand-tighten the nuts until snug.

2.4 Tightening Sequence

• Tighten the bolts gradually in a crosswise pattern, starting from the center and moving outward.
  This ensures even gasket compression and reliable sealing.

3. Equipment Installation (Flanged Connection)

• Once the clamp is fully secured to the pipe, connect the valve, air valve, flow meter, or other equipment to the flanged outlet.
• Place a suitable flange gasket between the mating flanges.
• Tighten flange bolts in a crosswise (star) pattern to ensure uniform load distribution.

4. Final Check and Commissioning

• Waiting Period:
  After installation, wait approximately 15–20 minutes and recheck bolt torque.
  The gasket may settle and slightly reduce bolt tension.
• Pressure Test:
  Gradually pressurize the pipeline and check for leaks.
  If leakage occurs, avoid overtightening—slightly loosen, reposition, and retighten the clamp.

5. Important Notes

• Axial Movement:
  Standard repair clamps are not designed to resist axial loads (pull-out resistance).
  If there is a risk of pipe movement, proper anchoring must be applied.
• Load Transfer:
  Heavy valves or pipeline extensions connected to the flanged outlet may create bending moments on the clamp.
  In such cases, additional supports (concrete or steel supports) must be installed.
• Sharp Edges:
  Use protective gloves during installation to prevent injury from metal edges.