Mathey Dearman Standard Rim Clamp Series User manual

STANDARD&MEGARIMCLAMP
OperationsandMaintenanceManual

4344SMaybelleAvenue
Tulsa,OK74107USA
Phone:(918)447‐1288
Fax:(918)447‐0188Email:
[email protected]
Revised:April22,2014,
MODEL#__________________
SERIAL#__________________

2
ALLWARNINGSPROVIDEDINTHISMANUALMUSTBEREADANDALLPROCEDURES
FOLLOWEDINANEFFORTTOPREVENTINJURYORDEATHTOPERSONNELAND/OR
DAMAGETOTHEEQUIPMENT.

ONLYQUALIFIEDAUTHORIZEDPERSONNELshouldoperateMatheyDearman
equipment.Thismanualincludessafetyinstructionsthroughouttheoperation
instructionsaswellasthosenotedonthisSafetyInstructionpage.Throughoutthis
manualthesewarningswillbenotedbytheseswarningsymbols.
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
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Operationofthisequipmentshouldbeinaccordancewiththeinstructionsprovidedin
thismanual.NoMatheyDearmanequipmentshouldeverbeusedinamannerother
thanasdescribedinthismanual.

OperatorsshouldwearapprovedPPEatalltimeswhileusingthisequipment.PPE
includeshardhat,ANSIapprovedeyeprotection,gloves,steeltoebootsand
protectiveclothing.Donotwearlooseclothingthatcanbecomeentangledinthe
equipment.
SAFETYINSTRUCTIONS
MatheyDearmanEquipment
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BESAFEATALLTIMES.WEARPPE.

3
INADDITIONTOTHEABOVEWARNINGSALLNATIONALANDINTERNATIONALSAFETY
RULESFORTHEUSEOFTHERIMCLAMPMUSTBEFOLLOWEDTOPREVENTANY
INJURIESORDEATHASARESULTOFIMPROPERCLAMPINGPROCEDURES.
TOREDUCETHERISKOFSERIOUSORINJURYDEATHTHESTANDARDORMEGARIM
CLAMPSHOULDNEVERBEUSEDTOLIFTTHEPIPEUNDERANYCIRCUMSTANCES.The
pipemusthaveanexternalsourceofsupportatalltimeswhentheStandardorMega
RimClampisbeinginstalledandduringuse.
ONLYQUALIFIED,TRAINEDANDAUTHORIZEDPERSONNELshouldoperateMathey
DearmanStandardandMegaRimClamp.OtherpersonnelshouldNOTbeallowedto
set‐up,operateormaintaintheRimClamp.
TheStandardorMegaRimClampshouldbeinspectedfordefectssuchascracks,nicks,
arcmarks,andabrasionspriortouseandduringscheduledmaintenance.
Maintenancepersonnelmustreadandunderstandthepartsandoperatingmanualof
theRimclamppriortoattemptingmaintenanceontheStandardorMegaRimClamp.
TheStandardorMegaRimClampshouldbetestedforproperfunctionpriortouse
includingthealignmentorreformingofpipeorpipefitting.
TheoperatorshouldinsurethattheareaaroundtheStandardorMegaRimClampis
clearofdebrisandotherhazardsthatmayposeatriphazardtopersonnelduring
operation.
ToavoidtheriskofelectricalshocktheoperatormustinsurethattheRimClampor
MegaRimClampiswithinasafedistancefrompowerlinesorotherelectricalsources.
NeverusetheStandardorMegaRimClampasagroundforanypurpose.
Makesurelooseclothing,tools,belts,etc.donotbecomeentangledintheRimclamp.
TheperiodicmaintenanceinstructionsmustbefollowedintheRimClamppartsand
operatingmanual.
Thepipemustbesecuredfromrotation,priortomountingtheRimClamponthepipe.
TheLevelandSupportDeviceshouldneverbeusedasthesolesupportofthepipe,
fittingorvalve.
MakesuretheRimClampisinfullcontactwiththematingpipe,fittingorvalve.
UseonlythewrenchprovidedwiththeRimClamptopreventovertorqueingof
jackscrews.
Neveruseacheaterbarwiththesuppliedwrench.
Thematingpipe,fittingorvalveshouldnothaveatapersurfaceofmorethan5
degreesatthepointwheretheFlipDownJackbarJackscrewpadwillcontactthepipe.
Toavoidtheriskofelectricalshockordeathkeeptheclampasfarawayaspossible
frompowerlines.
SAFETYINSTRUCTIONS
STANDARD/MEGARIMCLAMPOPERATION
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4
For Warranty Information visit www.mathey.com

5
TABLEOFCONTENTS
SAFETYINSTRUCTIONS2‐3
WARRANTYINFORMATION4
INTRODUCTION5
CHART1‐ClampReformingCapacity6
MAINCOMPONENTS7
OPERATIONINSTRUCTION8‐10
ClampLiftingandLatching8
ClampPositioning&Alignment9
PipeReformingInstructions10
Clampreleaseandremoval10
MAINTIANANCE11
STANDARD&MEGARIMCLAMPSIZES12
CHART2‐ClampSizes12
SPAREPARTSLIST12

6
INTRODUCTION
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TheMatheyDearmanRim‐TypeReformingClampisdesignedtoreformpipesizesfrom4”to72”.
Reformingcapabilitiesarebasedonpipediameterandwallthickness.Thebodyisdesignedtoallowafull
circumferenceweldand/orgrindwithouttheneedtoremovetheclamp.
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Therearetwotypesofreformingclampsavailable.ThefirstistheStandardRimClampwhichhasthe
capabilitytoreformpipewithamaximumtensilestrengthof45,000psi.ThesecondtypeistheMega
RimClampwhichhasthereformingcapabilitytoreformpipewithamaximumtensilestrengthof80,000
psi.
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Bothclampsaredesignedwithjackscrewsmountedontheinsideoftheclamp.Thesejackscrewsare
tightenedorloosenedtoshapethepipetomatchthematingpipeorfittingpriortotheweldingprocess.
Thereare4ormorestabilizerbarsthatareusedtopreventtoclampfrommovingonthepipe.Thereare
4ormoreflip‐upjackbarsthatcanbemovedtoallowaccesstothetwopipejointsforweldingand/or
grinding.
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Chart1‐Standard(STD)andMega(MEGA)RimClampReformingCapacity
Rim
Clamp
Type
PipeTensileStrengthMaximumRecommendedWallThickness
AccordingtoPipeDiameter
PSIMPA4"‐ 12"
DIA
14"‐ 24"
DIA
26"‐ 30"
DIA
32"‐ 48"
DIA
50"‐60"
DIA
62"‐72"
DIA
STD45,0003101/2"3/4"7/8”1”11/8”11/4"
MEGA
45,0003101/2"3/4"1”11/8”11/4"13/8”
65,0004487/16”5/8”3/4"1”11/8”13/8”
70,0004833/8”1/2"3/4"7/8”1”11/4"
80,0005523/8”1/2"5/8”3/4"1”11/8”
PipeWallThickness
Note:Asthetemperatureofthepipedecreasesbelow0°F(‐18°)theabilityofthe
RimClamporMegaRimClamptoreformthepipewallwillsharplydecrease.
WARNING:IFTHESTANDARDRIMCLAMPISUSEDTOREFORM
PIPEWITHATENSILESTRENGTHOFMORETHAN45,000POUNDS
PERSQUAREINCH,ITMAYRESULTINSERIOUSINJURYOR
DEATH.
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WARNING:USEOFTHERIMCLAMPBEYONDITSOPERATING
CAPACITYORDESIGNWILLVOIDTHERIMCLAMPWARRANTY.


7
MAINCOMPONENTS

WARNING:REDUCETHERISKOFSERIOUSINJURYORDEATH,
NEVERUSETHESTANDARDORMEGARIMCLAMPASALIFTING
DEVICEFORTHEPIPEUNDERANYCIRCUMSTANCES.


8
OPERATIONINSTRUCTIONS
PriortousingtheRimClampensurethattheliftingpressurehasbeen
releasedfromthechainliftingmechanismbyallowingtheclampto
lightlyrestonaflatsurface.Oncethepressurehasbeenreleased,the
operatormaythenunlatchtheredlatchhookbypullingonthehook
releasechain.Thiswillallowtheclamptoopensothatitcanbe
loweredontothepipe(Figure1).
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SmallerRimClamps,between4”and16”insize,maybeplacedover
thepipemanually.Largersizerimclampsmustbeconnectedtoa
liftingdevicebyusingthechainliftingmechanism.(Figure2).
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Figure1‐RedLatchHookattachedtochain.
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Figure2‐LiftingEyeandChain
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WARNING:TOREDUCETHERISKOFSERIOUSINJURY
ORDEATHNEVERSTANDUNDERNEATHTHECLAMP
DURINGTHELIFTINGPROCESS.
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WARNING:TOAVOIDTHERISKOFSERIOUSINJURY
ORDEATHALLPERSONNELSHOULDSTAYCLEAROF
RIMCLAMPDURINGTHELIFTINGPROCESSASWELL
ASDURINGTHEPOSITIONINGOFTHERIMCLAMP
ONTHEPIPE.

Theoperatormustloosenallofthereformingjackscrewswith
theexceptionofthetoptwo(2)priortoliftingtherimclamp
ontothepipe.Intheeventthatthereformingjackscrewsareleft
tighteneddown,theymaybedamagedbytheweightofthe
clamp,sothereforelooseningthemwillhelppreventdamageto
theclampaswellasallowtheredlatchhookroomtolatch
completelyshut.
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Figure3‐ReformingJackscrews

9
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Figure4‐RimClampclosingonpipe.
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Figure5‐RimClampsecuredonpipe.
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 
Figure6–Jackbar&JackbarLockPin

 
Figure7–MovableJackbar
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WARNING:TOREDUCETHERISKOFSERIOUS
INJURYORDEATHALLPERSONNELSHOULDKEEP
HANDSANDFINGERSCLEARFROMUNDERNEATH
THERIMCLAMPDURINGCLAMPPOSITIONING
ONTHEPIPE,WHILETIGHTENINGTHE
REFORMINGJACKSCREWSORWHENROTATING
THEMOVEABLEJACKBARANDTHEJACKBAR
MOUNTINGBRACKET.
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Oncetheclampisprepared,theoperatorshouldslowlylowerthe
rimclampontothepipesothatthejackbarsextendapproximately
two(2)inchesbeyondtheendofthepipe.(SeeFigure4)
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Astheclampisloweredontothepipe,itwillstarttoclose.Asthe
clampstartstoclose,theredlatchhookwillautomaticallylatch.Ifit
doesnotstarttolatchatthistime,theoperatorwillneedtopush
thetwo(2)separatesidesoftheclamptogetheruntiltheredlatch
hookissecurelyclosed.(SeeFigure5)
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Theoperatormustthenusethereformingjackscrewstocenterthe
clamponthepipe.Thisadjustmentmustbewithin+/‐1”(25mm)of
thepipecentertopreventtheswivelpadsfrombecoming
disengagedfromthejackscrews.Theclampshouldthenbeadjusted
sothatitisperpendiculartothepipecenterline.Thisisachievedby
tighteningorlooseningthejackscrewlocatedinthestabilizerbars.


TheoperatorshouldthenremovetheJackbarLockPinfromthetwo
(2)orthree(3)uppermovablejackbarsandthenrotatethe
moveablejackbarsoutofthewaysothatthejackbarlockpinscanbe
reinserted.Thematingpipesectionwillrestonthereforming
jackscrewslocatedonthetwo(2)orthree(3)lowermoveable
jackbars.Thiswillallowthematingpipeorpipefittingtobeinserted
intotheclampforwelding,buffingorgrinding.(SeeFigures6&7)

10
Whenthetwo(2)pipejointsorpipeandfittingarealignedascloselyas
possible,determinewhichreformingscrewscanbeusedtoreformthepipe
tothematingpipe.Adjustthereformingjackscrewsasneededtoreshape
thepipetomatchthepipejointorfittingthatisbeingaligned.The
reformingjackscrewsshouldonlybeusedwherehighspotsexist.



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Itwillbenecessarytoreducethepressureofsomeofthereforming
jackscrewsasyoutightenothers.Itmaybenecessarytorepeatthis
procedureseveraltimesbeforecompletingthefit‐up.Asmallamountof
pressureisallthatisneededwhenthereformingjackscrewsareusedonthe
highspots.
NOTE:Itisnotnecessarytouseallofthereformingjackscrewsat
thesametime.Onlytightenthereformingjackscrewsthatare
overthehighspotsaswellastheareaofthepipethatis180°from
thehighspot.

WARNING:Donotallowhandsorfingersto
becomecaughtunderneaththeRimClamp
whiletighteningthereformingjackscrews.

Atthispoint,theentireweldareawillbeexposedwhichwillallowtheweld
tobecompletedaswellasthegrindingorbuffingtheweldwithouttheneed
toreleasethereformingjackscrewsfromtheclamp.
Note:Inordertoachieveahighqualityweld,itisextremely
importantthattheclampoperatorfollowtheseprocedurestohelp
preventanychanceofaweldfractureduetolossofpressureona
partiallyiscompletedweld.
Oncetheentireweldprocedurehasbeencompleted,theclampcanthenbe
removed.Theclampshouldbeallowedtocooliftheweldpass
temperatureexceeds275°F(135°C)beforeattemptingtoremovetheclamp.

Thebeginremoval,theclampoperatorwillfirstloosenallofthestabilizers,
reformingjackscrewsandmoveablejackbarscrewswiththeexceptionof
thetopreformingjackscrews.Theoperatorwillleaveoneofthereforming
jackscrewsoneachsideofthehingingpointextended.Thesejackscrews
shouldextendapproximately½”ormorefurtherthanalloftheother
jackscrewstoallowtheclamptorestonthem.

Theredlatchhookcanbeunlatchedoncethepressureontheclamphas
beenreleased.Theoperatorwillpullupwardonthehooktoreleasethe
chainwhileliftingtheclamp.
