VAG - Klamflex Product Training July 2013 - 3

Product Training
The Largest Manufacturer of

Pipe Couplings, Flange Adaptors, Stepped
Couplings,
and Dismantling Joints in the Southern
Hemisphere
COUPLE WITH CONFIDENCE
08.2013 2
2 2 VAG Gate Valves 09.10.2013
THE COMPANY
08.2013 3
The Company
• 1962 – Stewarts & Lloyds SA purchases the

controlling share of a small manufacturing
concern manufacturing Howell Couplings. Hall
Longmore (Pty) Ltd is the minority
shareholder and a new company “Pipe
Couplings (Pty) Ltd” is formed
08.2013 4
The Company
• 1967 – Pipe Couplings entered into an
agreement with Victaulic Co to manufacture
and market VJ Couplings in South Africa.
Victaulic held a 15% share in Pipe Couplings
• 1979 – British Steel (Victaulic was part of)
sold off their foreign holdings including the
15% in Pipe Couplings to Stewarts & Lloyds
• 1986 – Dorbyl Ltd purchases Stewarts &
Lloyds
• 1990 – Dorbyl purchases Hall Longmore’s
shares and Pipe Couplings is now 100%
owned by Dorbyl

The Company
• 1967 – Pipe Couplings entered into an

agreement with Victaulic Co to manufacture
and market VJ Couplings in South Africa.
Victaulic held a 15% share in Pipe Couplings
• 1979 – British Steel (Victaulic was part of)
sold off their foreign holdings including the
15% in Pipe Couplings to Stewarts & Lloyds
• 1986 – Dorbyl Ltd purchases Stewarts &
Lloyds
• 1990 – Dorbyl purchases Hall Longmore’s
shares and Pipe Couplings is now 100%
owned by Dorbyl

The Company
• 1992 – Victaulic PLC terminated agreement with Pipe

Couplings, the Klamflex brand name is introduced and
the company starts exporting
• 1999 – Andy Lawrence, and equity partners in
Singapore purchase Pipe Couplings (Pty) Ltd from
Dorbyl and the company is renamed “Klamflex Pipe
Couplings (Pty) Ltd”
• 2002 – Company is awarded “Exporter of the Year” by
the Johannesburg Chamber of Commerce and the
“Business Achievers” award from Krugersdorp
Chamber of Commerce
• 2003 – Export sales are 60% of total production

The Company
• 2007 – Company continues to grow and is a
finalist in the “Business Achievers” award
for exports from the Mogale City Chamber of
Commerce

The Company
• 2008 – Company grows turnover by 37% from

the previous year and profits before tax by
79%
• 2009 – Company achieves its best ever year,
turnover increases by 52% and profits
increase by 78%. Changes made to the
companies shareholding and most of the
equity partners are bought out
• 2011 – Company adds Stainless Steel Repair
Clamps and Shouldered Couplings to its
product range

The Company
2012
Klamflex celebrates its 50th anniversary
and remains the largest manufacturer
and supplier of Pipe Couplings, Flange
Adaptors, Dismantling Joints and
related products in the Southern
Hemisphere

The Company
2013
Klamflex Pipe Couplings
Becomes Part of the
Group

The Company
Andy Lawrence
Managing
Director
Gordon Harris Steve Channing Wayne Poisson

Financial Production Marketing
Accountant Manager Manager
Quality/R&D Sales
Debtors
Purchasing Internal Sales
Creditors
Dispatch Marketing
12 12 VAG Gate Valves Rienmüller 07.2013 09.10.2013

The Company

The Company

The Company

PRODUCT GROUPS
• Couplings
• Flange Adaptors
• Dismantling Joints
• Repair Clamps
Rienmüller 07.2013
08.2013 16
• Couplings
- Ranger Coupling
- Dedicated Coupling

• Couplings
- Ranger Coupling - Dedicated Coupling
Wide range of pipe diameter Small range of pipe diameter

Couplings
- Ranger Coupling
- Ranger Step Coupling
- Dedicated Coupling
- Dedicated Step Coupling
08.2013 19
Ranger Coupling Dedicated Coupling

Ranger Coupling
• Connect straight ended pipe

to straight ended pipe
• Join pipes which are in
published range
• Join different OD pipes
• Max working pressure 16bar
• Pipe NB 50-600mm

Materials of Construction
• Sleeve: 50-300NB Rolled Steel

• Sleeve: 350-600NB DI GGG40
• End Rings: 50-600NB DI GGG40
• Gaskets: EPDM
• Fasteners: Electro Galvanized
• Alternative: 316 Stainless Steel
• Coating: Fusion Bonded Epoxy

Step Ranger Coupling
• Connect straight ended
pipe to straight ended pipe
• Join pipes which are in
published range
• Join different OD pipes
• Max working pressure
16bar

• End Rings: DI GGG40
• Gaskets: EPDM

Dedicated Coupling
• Connect straight ended pipe to

straight ended pipe
• Join pipes only with same OD
• Working pressure 16bar
• For pressures over 16 bar and
sizes over 2000mm please
contact Klamflex

Dedicated Coupling Options
Harness Couplings

Anchored Couplings

Centre Registers


• End Rings: 300-2000NB Rolled Steel
• Gaskets: EPDM
• Coating: 50-1400NB Fusion Bonded
Epoxy
• Coating: 1500+ Sigma Guard 720

Dedicated Stepped Coupling
• Where pipe ends of different outside

diameters must be connected
• For pressures over 16 bar and sizes
over 2000mm please contact
Klamflex


• End Rings: 300-2000NB Rolled Steel
• Profile Plate: Steel Plate
• Gaskets: EPDM
• Fasteners Bolts: Electro Galvanized
• Fasteners Studs: 304 Stainless Steel

Materials of Construction Cont.

• Coating: 50-1400 NB Fusion Bonded
Epoxy

Gripper Coupling
• Designed to resist end pull-
out on PE and PVC pipes
• It is the fastening action of
the Gripper Ring that
secures the Coupling onto
the pipe resisting end pull-
out
16bar

• Sleeve: DI GGG40
• End Rings: DI GGG40
• Gripper Ring: Brass
• Gaskets: EPDM

FLANGE ADAPTORS
08.2013 35
Ranger Adaptor
• Straight ended pipe to

flanged equipment
• Join pipes and drilling tables
which are in published range
• Max working pressure 16bar

• End Ring: DI GGG40
• Flange: DI GGG40
• Gasket: EPDM

Dedicated Adaptor
• Straight pipe to flanged

equipment
• For pressures over 16 bar
and sizes over 2000mm
please contact Klamflex

Dedicated Adaptor Options
Stepped Adaptor

Dedicated Adaptor Options
Restrained Adaptor


• End Ring: 50-300NB DI GGG40
• End Ring: 350-2000NB Rolled Steel
• Flange: Steel Plate
• Gasket: EPDM
• Fastener Studs: 304 Stainless Steel

• Coating:50-1400NB Fusion Bonded

Epoxy

Gripper Adaptor
• Klamflex Gripper Flange
Adaptors are designed to
resist end pull-out on PE
and PVC pipes
• It is the fastening action of
the Gripper Ring that
secures the Flange Adaptor
onto the pipe resisting end
pull-out
16bar

• End Ring: DI GGG40
• Flange: DI GGG40
• Gasket: EPDM

DISMANTLING JOINTS
08.2013 45
Dismantling Joints
• Composite fitting featuring a

telescopic action designed to provide
longitudinal adjustment between a
flanged pipe and flanged equipment
• For pressures over 16 bar and sizes
over 2000mm please contact
Klamflex


• Flange: Steel Plate
• Spigot: Steel Plate & Rolled Steel
• Gasket: EPDM
• Fastener Studs: 304 Stainless Steel

Materials of Construction Cont.
• Fastener Tie Rods: Electro Galvanized

• Coating: 50-1400NB Fusion Bonded
Epoxy

PRODUCT FEATURES
08.2013 49
FEATURES
HOTROLLED ASYMMETRIC STEEL T

1 SECTION
BS EN 10025 : 2004
PROFILED ROLLED STEEL SLEEVE
2
BS EN 10025 : 2004
EPDM Gasket with SELF CENTERING LIP

3
BS EN 681-1:1996
5
D Cup Head low Carbon Steel Bolts

4 ISO 898-1:2009
1
NON TOXIC WRAS APPROVED COATINGS AND
5 GASKETS WITH BS 6920 CERTIFICATION

FEATURES

1 SECTION
BS EN 10025 : 2004
2
BS EN 10025 : 2004

3
BS EN 681-1:1996
5

4 ISO 898-1:2009
2

FEATURES

1 SECTION
BS EN 10025 : 2004
2
BS EN 10025 : 2004

3
BS EN 681-1:1996
5

3 4 ISO 898-1:2009


FEATURES

1 SECTION
BS EN 10025 : 2004
2
BS EN 10025 : 2004

3
BS EN 681-1:1996
5

4 ISO 898-1:2009

4 5 GASKETS WITH BS 6920 CERTIFICATION

FEATURES

1 SECTION
BS EN 10025 : 2004
2
BS EN 10025 : 2004

3
BS EN 681-1:1996

5 4 ISO 898-1:2009


MANUFACTURING
PROCESS
08.2013 55
Manufacturing Process
CAD Systems
End Ring Raw Material
CNC Programing for End Ring Rolling
End Ring Rolling
Completed End Rings
Automated D Sleeve Rolling
Sleeve Rolling
Completed Sleeves
Spigot Rolling
Butt-Welding
Grinding
Grinding
Sizing to AWWA C219
Sizing to AWWA C219
Sizing to AWWA C219
Sizing to AWWA C219
Flange Welding
Flange Welding
Flange Welding
Stud Welding
Stud Welding
Shot Blasting to SA 2.5 - 3.0
Shot Blasting Completed
FBE Coating to 300 microns
FBE Coating to 300 microns
Rubber Gaskets
Coupling Assembly
Coupling Assembly
Repair Clamp Assembly
Warehouse and Stock
Despatch
Despatch
Despatch
Despatch
COUPLING
APPLICATIONS
08.2013 90
Applications
08.2013 91
Applications
08.2013 92
Applications
08.2013 93
Applications
08.2013 94
Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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Applications
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109 109 VAG Gate Valves 09.10.2013
FLANGE ADAPTOR
APPLICATIONS
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Applications
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Applications
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112 112 VAG Gate Valves 09.10.2013
Applications
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Applications
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Applications
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115 115 VAG Gate Valves 09.10.2013
Applications
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116 116 VAG Gate Valves 09.10.2013
Applications
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Applications
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Applications
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DISMANTLING JOINT
APPLICATIONS
Rienmüller 07.2013
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120 120 VAG Gate Valves 09.10.2013
Applications
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121 121 VAG Gate Valves 09.10.2013
Applications
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122 122 VAG Gate Valves 09.10.2013
Applications
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Applications
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Applications
08.2013 125
125 125 VAG Gate Valves 09.10.2013
Repair Clamps
• Unique 2 stage sealing
arrangement to provide a
repair means for small
leaks in Steel, PVC, HDPE,
DI & AC pipelines
• Working pressure of 16bar
for pipe outside diameters
48-234mm
• Working pressure of 12bar
for pipe outside diameters
from 239-380mm
126 126 VAG Gate Valves 09.10.2013

• Outer Strap: 304 Stainless Steel
• Rubber Strap: EPDM
• Clamp Ends: DI GGG40
127 127 VAG Gate Valves 09.10.2013

Coupling Installation
Standard Pipe Laying
Procedures and Practices
to apply
• Trench and Backfilling

• Thrust blocks or anchoring
where required
• Joints exposed for pressure
testing
• Pressures, temperatures and
tolerances must not be
exceeded
Note: Klamflex Couplings are not
designed to resist end load
128 128 VAG Gate Valves 09.10.2013

Principles of Operation
• When the bolts are tightened,

the gasket is compressed into
the ‘throat’ of the sleeve, forcing
the gasket to seal onto the pipe
surface
• The profile of the sleeve and the
flexible gasket allow angular
movement of the pipe
129 129 VAG Gate Valves 09.10.2013

Pipe Tolerances
DI Nom Bore DI Pipe OD Tolerance on OD
100mm 118mm +1.0mm -3.0mm
•A close fit between pipe and 150mm 170mm +1.0mm -3.0mm
Klamflex Couplings will result in 200mm 222mm +1.0mm -3.5mm
optimum performance 300mm 326mm +1.0mm -3.5mm
•Undersized pipes may mean a 400mm 429mm +1.0mm -4.0mm
loss in pressure rating on a 500mm 532mm +1.0mm -4.0mm
possible leak 600mm 635mm +1.0mm -4.5mm
•Klamflex catalogues specify the 800mm 842mm +1.0mm -4.5mm

1000mm 1048mm +1.0mm -5.0mm
pipe OD tolerances which should
1200mm 1255mm +1.0mm -6.0mm
be adhered to
1400mm 1462mm +1.0mm -6.0mm
1600mm 1668mm +1.0mm -6.0mm
1800mm 1875mm +1.0mm -6.0mm
2000mm 2082mm +1.0mm -6.0mm
130 130 VAG Gate Valves 09.10.2013

Pipe Tolerances cont.
• Pipe manufacturers have

different tolerances on the pipe
ends compared to the centre of
the pipe
• Measure the pipe by using a tape
around the circumference and
dividing the result by 3.142 or
use a diameter tape
131 131 VAG Gate Valves 09.10.2013

Pipe Ovality
• If a pipe is considerably ‘out of

round’ then there is a possibility of
leakage. Precise circularity is
essential if Klamflex Couplings are
to be fitted successfully. To check
ovality measure the pipe as follows
and compare measurements
• 12-6 position
• 3-9 position
• 2-8 position
• 10-4 position
132 132 VAG Gate Valves 09.10.2013

Pipe End Preparation
• For pipes larger than 326mm

in diameter, 150mm of the
pipe end must be free from
loose surface deposits, weld
beads, dents, flat spots etc.
This will enable the coupling
to operate at optimum levels
• Thick pipe wrapping should
also be removed
133 133 VAG Gate Valves 09.10.2013

Setting Gaps
• Adjacent pipe ends should not

x
make contact with each other. The
pipeline will tend to buckle as
temperature increases
• At the opposite end the pipe end

gap must not be too large at
installation, as there will be a risk
that the pipe may pull out of the
coupling
134 134 VAG Gate Valves 09.10.2013

Setting Gaps Cont.
135 135 VAG Gate Valves 09.10.2013

Handling and Storage
• Couplings should be stored in the

flat position
• Storing couplings on their end
position could cause large
diameter couplings to go ‘out of
round’ Couplings obviously
should not be rolled off trucks,
ramps etc
• Rubber gaskets should be stored
in a cool dark environment.
Always store in an unstressed
condition
136 136 VAG Gate Valves 09.10.2013

Lubrication Deformed rubber profile
• Klamflex strongly recommends that

gaskets are well lubricated prior to
fitting, especially Ranger gaskets
• Use a non toxic soapy lubricant
such as dish washing liquid, or non
toxic silicone paste
• Non lubrication can cause difficulty
Normal rubber profile
in fitting and could also result in
gasket creep under load (change of
shape)
137 137 VAG Gate Valves 09.10.2013

Assembly
• Pipe ends prepared

• Reference marks made on the
pipes to get the correct setting
gap
• End rings and lubricated gaskets
to be placed on the pipe ends
• Centre sleeve to be placed on
one pipe end
• Align pipe ends leaving setting
gap.
138 138 VAG Gate Valves 09.10.2013

Assembly Cont.
• Move sleeve over pipe ends to

the reference marks
139 139 VAG Gate Valves 09.10.2013

Assembly Cont.
• Move gaskets into place

x
ensuring that the gasket is
introduced into the sleeve
uniformly all the way around
• On large diameter couplings it
may be necessary to lift the
sleeve so that it does not
‘hang’ on the pipe
• Move end rings into place
140 140 VAG Gate Valves 09.10.2013

Assembly Cont.
Special lip
• Klamflex Gaskets have a special lip
on the rear end allowing the end ring
to easily centralize.
• As the coupling is tightened the end Special lip with end ring
ring ‘rides’ up the lip
141 141 VAG Gate Valves 09.10.2013

Assembly Cont.
• Tighten the bolts in pairs, at

DIAMETRICALLY OPPOSITE
positions in a CIRCULAR
SEQUENCE.
• Tighten evenly giving nuts a few
turns at a time
• A uniform length of exposed bolt
thread should always be seen
• Tighten to the prescribed torque
rating of 80 – 120 Nm (M16 Bolt)
• If effective sealing is not obtained
then loosen the coupling, check
x
gaskets, re-align and re-torque
142 142 VAG Gate Valves 09.10.2013

Hints and Tips
• After pressure testing the line and before backfilling Klamflex

recommends that the bolt torques are checked again as some
pipe movement may have occurred during the pressurization
and depressurization process
• Should a gasket need to be renewed and it is not possible to
remove the Klamflex Coupling from the pipe, cut a length of the
correct profile gasket extrusion (available from Klamflex) to
about 5mm longer than the pipe circumference
143 143 VAG Gate Valves 09.10.2013

Hints and Tips Cont.
• Wrap the gasket around the pipe and glue the ends together using
quickset super glue (Cyanoacrylate). Keep the join at the top of the
pipe and re-assemble the coupling as normal
• Do not forget to lubricate the gasket.
144 144 VAG Gate Valves 09.10.2013

Hints and Tips Cont.
• If a situation arises where a pipe is extremely undersize and the

coupling is not leak tight as a result of the large tolerance, please
note that Klamflex does have different thickness rubber profiles
and it may be possible to solve the problem by using a thicker
rubber gasket which will take up the excessive tolerance
• Should the pipe end gap be too big for the standard Klamflex
sleeve, longer sleeve couplings and flange adaptors can be
supplied
145 145 VAG Gate Valves 09.10.2013

Coatings
• Klamflex products are coated with Klamflex LAK Fusion Bonded

Epoxy or Sigma Guard 720 which offers excellent corrosion
protection and resistance to a wide range of organic and inorganic
chemicals
• Site repair of localized surface damage through careless handling
is possible using our special touch up epoxy paint
146 146 VAG Gate Valves 09.10.2013

Offer Process
If the products are not found on Configurator the

following must be sent to vag@klamflex.com
• Product required
• Pipe OD
• Pipe material
• Working pressure
• Flange Drilling
• Special material and fastener requirements
Order Process
Order must be sent to vag@klamflex.com

• Order will be referenced against offer submitted
• Order will be entered into system under country
account
• Order confirmation will be sent back for signature
• Production will commence
• Changes in delivery will be communicated
• Despatch as per customer instructions
Market Survey
• What are the main brands in your market and who is the market
leader?
• What authority approvals are necessary in your market?
• What product approvals are necessary in your market?
• What typical pipe materials are found in your market?
• What is the market size per product family in your country?
(Couplings, Flange Adaptors, Dismantling Joints)
• What annual stock availability is required?
• Any additional requirements/comments pertaining to your
markets
Thank You
150 150 VAG Gate Valves 09.10.2013

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Product Training

The Largest Manufacturer of

• 1962 – Stewarts & Lloyds SA purchases the

5 5 VAG Gate Valves 09.10.2013

• 1967 – Pipe Couplings entered into an

6 6 VAG Gate Valves 09.10.2013

• 1992 – Victaulic PLC terminated agreement with Pipe

7 7 VAG Gate Valves 09.10.2013

8 8 VAG Gate Valves 09.10.2013

• 2008 – Company grows turnover by 37% from

9 9 VAG Gate Valves 09.10.2013

10 10 VAG Gate Valves 09.10.2013

11 11 VAG Gate Valves 09.10.2013

Gordon Harris Steve Channing Wayne Poisson

12 12 VAG Gate Valves Rienmüller 07.2013 09.10.2013

13 13 VAG Gate Valves Rienmüller 07.2013 09.10.2013

14 14 VAG Gate Valves Rienmüller 07.2013 09.10.2013

15 15 VAG Gate Valves Rienmüller 07.2013 09.10.2013

17 17 VAG Gate Valves 09.10.2013

18 18 VAG Gate Valves 09.10.2013

20 20 VAG Gate Valves 09.10.2013

• Connect straight ended pipe

21 21 VAG Gate Valves 09.10.2013

• Sleeve: 50-300NB Rolled Steel

22 22 VAG Gate Valves 09.10.2013

23 23 VAG Gate Valves 09.10.2013

24 24 VAG Gate Valves 09.10.2013

• Connect straight ended pipe to

25 25 VAG Gate Valves 09.10.2013

26 26 VAG Gate Valves 09.10.2013

27 27 VAG Gate Valves 09.10.2013

28 28 VAG Gate Valves 09.10.2013

• Sleeve: 50-125NB DI GGG40

29 29 VAG Gate Valves 09.10.2013

• Where pipe ends of different outside

30 30 VAG Gate Valves 09.10.2013

• Sleeve: 50-125NB DI GGG40

31 31 VAG Gate Valves 09.10.2013

• Alternative: 316 Stainless Steel

32 32 VAG Gate Valves 09.10.2013

33 33 VAG Gate Valves 09.10.2013

34 34 VAG Gate Valves 09.10.2013

• Straight ended pipe to

36 36 VAG Gate Valves 09.10.2013

37 37 VAG Gate Valves 09.10.2013

• Straight pipe to flanged

38 38 VAG Gate Valves 09.10.2013

39 39 VAG Gate Valves 09.10.2013

40 40 VAG Gate Valves 09.10.2013

• Sleeve: 50-125NB DI GGG40

41 41 VAG Gate Valves 09.10.2013

• Coating:50-1400NB Fusion Bonded

42 42 VAG Gate Valves 09.10.2013

43 43 VAG Gate Valves 09.10.2013

44 44 VAG Gate Valves 09.10.2013

• Composite fitting featuring a

46 46 VAG Gate Valves 09.10.2013

• Sleeve: 50-200NB DI GGG40

47 47 VAG Gate Valves 09.10.2013

• Fastener Tie Rods: Electro Galvanized

48 48 VAG Gate Valves 09.10.2013

HOTROLLED ASYMMETRIC STEEL T

EPDM Gasket with SELF CENTERING LIP