TECHLOK ASSEMBLY /
DIS-ASSEMBLY PROCEDURE
Document No. VI/AB/02-013-01
REV. DESCRIPTION PREPARED CHECKED / DATE
BY: APPROVED BY:
O ISSUED FOR USE M.Stanton D.Robertson 26/02/03
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TECHLOK ASSEMBLY /
DIS-ASSEMBLY PROCEDURE
Document No. VI/AB/02-013-01
CONTENTS
1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. EQUIPMENT
6. ASSEMBLY ACTIONS
7. DIS-ASEMBLY ACTIONS
8. ASSEMBLY ACCEPTANCE CRITERIA
9. SAFETY PRECAUTIONS
APPENDIX A – Techlok assembly and dis-assembly instruction card.
APPENDIX B – Techlok joint assembly form.
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TECHLOK ASSEMBLY /
DIS-ASSEMBLY PROCEDURE
Document No. VI/AB/02-013-01
1.0 PURPOSE
1.1 The purpose of this procedure is to define the actions and equipment required to safely
assemble and dis-assemble Techlok clamp type connectors.
2.0 SCOPE
2.1 The scope of this procedure covers the normal requirements and equipment to carry out the
above purpose.
3.0 REFERENCES
3.1 Techlok assembly/disassembly cards. See Appendix A.
3.2 UKOOA Guidelines for the Management of Integrity of Bolted Pipe Joints. Issue No. 1 June
2002
3.3 Joint Assembly Report Form. See Appendix B.
3.4 Easilift, Techlok blind hub and clamp lifting frame Operating Instructions: VI/AB/01-008.
4.0 RESPONSIBILITIES
4.1 It is the responsibility of the operator to ensure that all personnel involved in the assembly /
dis-assembly of Techlok connectors are suitably trained.
4.2 It is the responsibility of the operative to follow the procedure.
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DIS-ASSEMBLY PROCEDURE
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5.0 EQUIPMENT
Table 1: Equipment (5.0).
ITEM DESCRIPTION QUANTITY COMMENT
5.1 GREASE AS REQUIRED SUITABLE FOR CLAMP
COATING
5.2 LIGHT HYRAULIC OIL OR MoS2 AS REQUIRED FOR HUBS ONLY WHEN
SPRAY RE-USING SEALRINGS
5.3 CLEAN CLOTHS AS REQUIRED
5.4 CLEANING SOLVENT AS REQUIRED TO DE-GREASE NEW
HUBS
5.5 GRIT PAPER (180 MAXIMUM AS REQUIRED FOR DRESSING HUB
ROUGHNESS) SEATS.
5.6 FEELER TYPE GAUGES 1 OPTIONAL
5.7 TORCH 1
5.8 TWIN TORQUE KIT C/W 1 *
SUITABLE SOCKETS
5.9 PNEMATIC TORQUE WRENCH 1 *
C/W SUITABLE SOCKETS
5.10 LOW PROFILE HYDRAULIC 1 MIN. *
TORQUE WRENCH C/W
SUITABLE SOCKET
5.11 HYDRAULIC TENSIONER C/W 1 MIN. * (REQUIRES NON-
SUITABLE SOCKET STANDARD BOLTING)
5.12 HAND TORQUE WRENCH C/W 1 *
SUITABLE SOCKET
5.13 SOFT FACED HAMMER (SIZE TO 1
SUIT)
5.14 SUITABLE SPANNER / STOP TO 1
FIT OVER SECOND NUT
5.15 JOINT ASSEMBLY FORM 1 SEE APPENDIX 1
5.16 HYDRAULIC NUT-SPLITTER OPTIONAL TO REMOVE SEIZED
NUTS ON DIS-ASSEMBLY
5.17 EASILIFT – TECHLOK CLAMP & OPTIONAL LIFTING AID FOR
BLIND HUB LIFTING FRAME TECHLOK BLIND HUB
AND CLAMP SEGMENTS.
* Select one of these calibrated tightening methods.
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TECHLOK ASSEMBLY /
DIS-ASSEMBLY PROCEDURE
Document No. VI/AB/02-013-01
6.0 ACTIONS - ASSEMBLY
6.1 Precautions before and during assembly:
6.1.1 USE THE CORRECT TOOLS.
6.1.2 PROTECT THE SEALING SURFACES AT ALL TIMES.
6.1.3 CLEANLINESS AT ALL TIMES.
6.1.4 PREVENT DAMAGE DURING ASSEMBLY.
6.1.5 KNOW THE CORRECT TORQUE AND APPLY IT.
6.1.6 IF THE SEALRING IS DAMAGED, IT MUST BE REPLACED.
6.1.7 IF HUB DAMAGE IS EXCESSIVE, THEN A PROFESSIONAL REPAIR WILL BE
NECESSARY BEFORE ASSEMBLY
6.2 Component Check
6.2.1 Visually check the hub surfaces for damage, especially the sealing surfaces. The
sealing surfaces must have NO scratches or blemishes on the surface.
6.2.2 If the sealing surfaces have blemishes, they must be polished out by hand using a
maximum of 180 grit wet or dry paper.
6.2.3 If hand polishing is not effective in terms of time or the depth of damage then an
alternative means of repair should be considered.
6.2.4 The clamps should be visually examined for damage. Any sharp edges shall be de-
burred. If considered to be too heavily damaged then the segments shall be replaced.
6.2.5 The stud and nut sets should also be visually examined for
damage. The nuts should be free to spin along the operational
length of the stud.
Figure 1: Visual
6.2.6 The sealring should be visually checked for damage. If
inspection (6.2).
damage to the sealing surfaces exists, it must be replaced.
NOTE: Use of a damaged sealring
may cause damage to the hub seat.
6.2.7 The sealring should be checked for rock or
“standoff” within the hub seats (see Figure 2).
Remember to check both sides in both seats. The
“standoff” should be approximately as per Table 2.
Figure 2: Check
standoff (6.2.7).
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TECHLOK ASSEMBLY /
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Document No. VI/AB/02-013-01
Table 2: Recommended standoff (6.2.7).
6.3 Lubrication
Figure 3:
6.3.1 The clamp segments are to be lightly lubricated along Lubrication
the inner angled faces to aid assembly. Ensure the (6.3).
lubricant is compatible with the materials and any
paint/coating.
6.3.2 Where possible, the studs are to be lubricated along the
working length of the threads and the nuts need to be
lubricated on the spherical face with a lubricant, which
is compatible with the materials and any paint/coating.
(Not required if PTFE coated).
6.3.3 If a sealring is being reused or there is no coating on the sealring then a light oil or
MoS2 coating can be applied to the hub seats, NOT THE SEALRING.
6.4 Alignment
6.4.1 Ensure the spools are correctly aligned.
6.4.2 Although the clamps may assist in “pulling in” some mis-alignment, they are not
designed for this purpose and therefore the hubs are required to be properly aligned
before assembly.
6.5 Handling Components
6.5.1 Ensure the necessary rigging equipment is available for the job in hand and that all
local regulations are adhered to.
6.5.2 Due to the weight and shape of the components when assembling blind hubs, the use
of the ‘Easilift’ blind hub and clamp lifting frame is recommended for connection
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Document No. VI/AB/02-013-01
sizes 8inch and above. ‘Easilift’ will enable safer and better management of the
clamps, blind hub and sealring for assembly. The ‘Easilift’ lift frame itself will
require rigging.
N.B. When using the ‘Easilift’ lifting frame Operating Instructions
VI/AB/01/008, this Techlok assembly and dis-assembly procedure
MUST still be adhered to and under no circumstances overridden.
6.6 Assemble Components
6.6.1 Care is required during assembly to ensure that sealing surfaces on the hubs and on
the sealring are not damaged.
6.6.2 Separate hubs far enough to insert sealring in between the seats.
6.6.3 Close hubs and place clamps segments over the hub lips.
6.6.4 Insert studs and nuts ensuring the spherical face is
inwards towards the spherical seat in the clamps
segments as shown in Figure 4.
6.7 Tighten Bolts
6.7.1 The nuts shall be tightened in a uniform manner
(clockwise, anti-clockwise or figure of 8) as shown in
Figure 5.
6.7.2 The gap between the clamp segments to be approximately Figure 4: Nut
equal as shown in Figure 6. orientation (6.6.4).
6.7.3 Torque and tension values to be taken from Table 3 below.
6.7.4 The clamps are to be shocked using a soft-faced hammer to aid assembly as shown in
Figure 6.
6.7.5 ALWAYS re-tighten bolts after shocking by repeating the operations in sections 6.7.1
to 6.7.4.
Figure 5: Nut tightening sequence (6.7.1).
Figure 6: Ensure gaps are equal
(6.7.2) and shock clamps (6.7.4).
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Table 3: Minimum Bolt tightening torque values (6.7.3).
6.8 Joint Verification
6.8.1 After tightening to the recommended value, the hubs must be face to face with the rib
of the sealring (or the hubs face to face if in a recessed hub configuration). Check
using feeler type gauges if necessary or if visual examination is not possible.
6.8.2 If a gap is still present then the studs and nuts can be re-tightened up to 2 times the
minimum value. A value of 1.5 times the minimum required is normal for most
piping systems.
6.8.3 If the gap is still not closed then there is a fit up problem that has to be resolved.
Disassembling the connection and reassessing the situation is the most likely course
of action.
6.8.4 If both the hubs and sealring rib are face to face (or both the hubs are face to face for
recessed hubs) and the correct tightening value has been used, then, and only then can
the connection be deemed correctly assembled.
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7.0 ACTIONS - DISASSEMBLY
7.1 ALWAYS PROCEED WITH CAUTION!
7.2 Carry out local assessment of the joint area. Check on potential for
movement, lifting and handling points, access to connector etc.
7.3 Consider presence of compressive loads and spring loads from the
system and the presence and effects of corrosion and rust.
Figure 7: De-pressurise
7.4 Ensure the system has been de-pressurised in accordance with the the system (7.4).
standing instructions of the installation (Figure 7).
7.5 Always check, never take it for granted that the line has been de-pressurised, since re-
pressurisation can occur for many reasons, even during the dis-assembly itself.
7.6 Crack the nuts on all four studs, but DO NOT REMOVE (Figure 8).
7.7 Shock the clamps to aid release from the hubs as shown in Figure 9.
7.8 Loosen the nuts on each stud 1 or 2 turns and re-shock the clamps.
Figure 8: Crack nuts
Figure 9: Shock clamps to aid
(7.6).
release (7.7).
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7.9 Continue to loosen the nuts until the safe maximum nut travel is achieved as defined in Table 4
and Figure 10. Note that this distance assumes that the clamps do not move while this stage is
in progress.
Table 4: Safe maximum nut travel (7.9). See also Figure 10.
Figure 10: Safe maximum
nut travel showing
distances referred to in
Table 4 (7.9)
7.10 It is imperative that the studs, nuts and clamps are not removed until the seal is broken.
7.11 Ensure that ALL of the components are loose and free to
move independently indicating that the SEAL IS BROKEN.
This is the only verification that the seal is broken. See
Figure 11.
7.12 Once the seal has been broken, then remove the clamps. Take
care handling the studs and clamp segments and observe the
additional precautions listed below in section 7.13.
7.13 Dis-assembly – Additional precautions:
Figure 11: Ensure all
components are loose (7.11).
7.13.1 Internal Pressure.
7.13.1.1 Clamps being difficult to move off the hub shoulders during dis-assembly
can be an indication of pressure remaining in the system.
7.13.1.2 Contents leaking during dis-assembly can be an indication of pressure
remaining in the system.
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7.13.1.3 Please note that even if any leaking of contents stops, internal pressure could
still remain.
7.13.1.4 If at any point during the dis-assembly procedure, it becomes evident
that internal pressure is still present, it is essential that you stop
immediately, make the area as safe as possible and notify the relevant
personnel.
7.13.2 Compression in a line.
7.13.2.1 Where a line is in compression, and although the clamps may be loose, there
is still the potential for pressure in the line.
7.13.2.2 It is essential that an assessment is carried out to ascertain the most
appropriate method of allowing enough flexure to ensure the seal can be
broken.
7.13.2.3 It is essential that verification of the seal being broken is achieved before the
studs are removed.
7.13.3 Spring Loads.
7.13.3.1 Where spring loads are acting on the pipe and connection, the clamp may be
bound onto the hubs.
7.13.3.2 Suitable rigging should be used to control the spring and allow the connector
components to become loose.
7.13.4 Corrosion and Rust.
7.13.4.1 Corrosion and rust may bind the clamps to the hubs
7.13.4.2 Corrosion must be dealt with to ensure that all components become free
before the studs are removed.
7.13.4.3 Use of a ‘nut-splitter’ on badly corroded or bound bolting:
7.13.4.3.1 Use a ‘nut-splitter’ only as a last resort. An approved procedure
must be followed for using a ‘nut-splitter’.
7.13.4.3.2 Attempt to wind back the nut at least to the point where a broken
seal can be verified, before carrying out the nut-splitting operation.
7.13.4.3.3 If a broken seal cannot be verified then an over-clamp or ‘Hot
Bolting Replacement’ Clamp must be used while the nut-splitting
operation is in progress. An approved procedure must be followed
for using an over-clamp.
7.13.4.3.4 Each bolt removed must be replaced with a new bolt immediately as
described in the approved over-clamp procedure.
7.13.4.3.5 Remove the over-clamp on completion of the bolt replacement and
re-start the dis-assembly procedure.
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7.13.5 Handling Components.
7.13.5.1 Ensure the necessary rigging equipment is available for the job in hand and
that all local regulations are adhered to.
7.13.5.2 Due to the weight and shape of the components when dis-assembling blind
hubs, the use of the ‘Easilift’ blind hub and clamp lifting frame is
recommended for connection sizes 8inch and above. ‘Easilift’ will enable
safer and better management of the clamps and blind hub for dis-assembly.
The ‘Easilift’ lift frame itself will require rigging.
N.B. When using the ‘Easilift’ lifting frame Operating
Instructions VI/AB/01/008, this Techlok assembly and dis-
assembly procedure MUST still be adhered to and under no
circumstances overridden.
8.0 ASSEMBLY ACCEPTANCE CRITERIOR
8.1 Sealring and hub seats free from damage.
8.2 Clamps and bolting in good repair and burr free.
8.3 Application of the correct torque.
8.4 Ensure the hubs come face to face with the rib of the sealring OR if both hubs are recessed,
then the hubs themselves must come face to face.
8.5 BE SURE OF BOTH 8.3 AND 8.4 BEFORE ACCEPTING THAT THE CONNECTION
IS CORRECTLY ASSEMBLED.
9.0 SAFETY PRECAUTIONS
9.1 ADHERE TO THE PROCEDURES.
9.2 STATUTORY HEALTH AND SAFETY REQUIREMENTS TO BE ADHERED TO.
9.3 NEVER ASSUME THAT THERE IS NO PRESSURE RETAINED WHEN
DISMANTLING.
9.4 CLEAR THE AREA IF DURING DIS-ASSEMBLY YOU SUSPECT INTERNAL
PRESSURE.
9.5 NEVER TAKE THE STUDS OUT UNTIL YOU ARE SURE THE SEAL IS BROKEN.
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APPENDIX – A: Techlok assembly and dis-assembly instruction card.
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APPENDIX – B: Techlok joint assembly form.
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