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2014-1 KaMOS Gasket & Test Equipment - Operating Manual
2014-1 KaMOS Gasket & Test Equipment - Operating Manual
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Operating Manual
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
Contents
1.0 Gasket information
1.1 KaMOS Patented Gaskets...................................................................................4
1.2 Gasket Quality....................................................................................................4
1.3 Flange Surfaces.................................................................................................4
1.4 Fasteners............................................................................................................4
1.5 Assembly............................................................................................................5
2.0 Preparation
2.1 Clean and check................................................................................................6
2.2 Inspection and repair.........................................................................................6
2.3 Check for stand-off............................................................................................7
2.4 Lubricate.............................................................................................................7
2.5 Alignment............................................................................................................7
2.6 Ready for testing................................................................................................7
3.0 Installation
3.1 Bolt up sequence...............................................................................................8
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Surface finish
Flatness
Parallelism
Waviness
Allowable imperfections
For optimum gasket performance KaMOS recommends that the flange surface finishes
specified for the respective gasket selected is to be used.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
The condition of flange surfaces, as well as the proper flange material selection play
an important part in achieving a leak- free joint assembly. Assure that flanges have the
acceptable:
1.4 Fasteners
It is important that the proper stud/bolts and nuts are selected to assure joint integrity.
Improper selection of these may compromise the entire joint assembly. The following list
is to be considered when selecting fasteners:
Type
Grade
Class
Proper material
Appropriate coating or plating
Correct stud/ bolt length
1.5 Assembly
Install a new gasket on the gasket seating surface and bring the mating flange in
contact with the gasket.
Do not apply any compounds on the gasket or gasket seating surfaces
Install all bolts, making sure that they are free of any foreign matter, and well
lubricated. Lubricate nut bearing surfaces as well. (Lubrication will not be required
for PTFE coated fasteners)
Run- up all nuts finger tight
Develop the required bolt stress or torque incrementally in a minimum of four steps
in a crisscross pattern. The initial pre- stress should be no more than 30% of the
final required bolt stress. After following this sequence, a final tightening should be
performed bolt to bolt to ensure that all bolts have been evenly stressed.
Note: The use of hardened washers will enhance the joint assembly.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
In an effort to achieve a high degree of success in attaining a leak- free joint several steps
are required. It is imperative that a regimented bolt up procedure is applied. As a minimum
the following is offered:
Ensure use of skilled workmen and correct equipment. Final preload tools should be well
maintained and should have accuracy within +/- 2% of the torque or tension to be applied.
For critical applications a more sophisticated method for bolt up may be considered such
as heating rods, bolt tensioners, or ultrasonic extensometer.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 5
2.0 Preparation
before installing KaMOS Patented Gaskets
2.1 Clean and check
Use a nonabrasive soft cloth to clean all components with solvent to remove grease,
preservation and dirt. Special care should be taken on sealing faces and contact areas.
Check that all components are of correct material and size.
2.2 Inspection and repair
Remedy
Grind with fine emery paper to the required depth. Finish with emery
paper grade 240.
Scratch or dent at the heel, Grind with fine emery paper to the required depth. Finish with emery
covering or more of the paper grade 240. The depth after grinding should be maximum 0,1
heel width.
mm. Repair with Loctite 510.
Small damage in seal ring
seat location
Grind with fine emery paper. Finish with emery paper grade 240.
Outer wedge
Inspect bolt threads and nut bearing area to verify that there is no evidence of galling or
other damage. The surface shall be completely intact. If any sign of damage discard and
replace.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Damage location
Specifications and images are subject to change without notice. Not responsible for typographical errors.
Examine all sealing surfaces for mechanical damage and rust. The sealing faces
relies on a good surface finish. These surfaces should therefore be free from leak path
scratches, damage marks and other surface
irregularities. Use a suitable light source
Grind smooth
and run the finger tip over seal surfaces to
detect dents and gouges. Polish off any small
Grind smooth with
max depth of 0.1mm
scratches on the heel, seal ring and seal ring
Repair with Loctite 510
seat with fine emery cloth in the circumferential
direction only. Polish at least on third of the
circumference to ensure a uniform blending
of the re-work area. Lateral polishing is
unacceptable. Larger flange damages may
require flange face remachining. Consult
Flange manufacturer for remachining advice.
2.4 Lubricate
Prior to assembly, lubricate the flange heel and
seating surfaces on the flange with recommended
lubricator. Take care that no foreign matters (such
as grit) is present in the lubricant. The nut thread
and nut bearing surfaces on the flange should be
lubricated in accordance to the qualified procedure
when torque is used to achieve the final preload.
Lubrication
2.5 Alignment
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Once above is accomplished, the bare test tube of the KaMOS Gasket should be fitted
with a KaMOS Test Plug ready for the end Quick Connect of the test hose. Continue to
page 8 for KaMOS Hydraulic Test Equipment or page 10 for KaMOS Pneumatic Test
Equipment set up.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 7
3.0 Installation
KaMOS Patented Gaskets
1. Torque bolts up to approximately 30% of final torque value following the diametrically
opposed sequence.
2. Repeat Stage 1, increasing the torque value to approximately 60% of the final
torque value.
3. Repeat Stage 2, increasing the torque value to the final required torque value.
4. A final tightening should be performed following an adjacent bolt to bolt sequence to
ensure that all bolt have been evenly stressed.
The gasket should NOT be fitted with the blind plug prior to installation of the gasket
in the flange tightening of flange bolts. Blind plug should only be installed after gasket
has been installed, hydrotight performed on the flange bolts and tested.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
1. Standard procedure for installation of gaskets is to be used. Make sure that the
injection tube for testing the gasket is placed between the bolt holes.
2. Bolt up.
1. Connect the quick release coupling (6) to the pump and the KaMOS testplug.
Pos Description
Hydraulic Pump
200800-01
10,000 Psi
200800-01
Protection frame
200800-15
Manometers
200800-11
0-400 bar
200810-07
0-1000 bar
Valve
200800-04
400 bar
200810-04
10 K
200500-05*
400 bar
200810-09
10 K
200500-06*
600 bar
200810-10
10 K
Test hose
200500-07*
630 bar
200810-13
700 bar
10,000 Psi
Alu 700 mm
3
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 9
Specifications and images are subject to change without notice. Not responsible for typographical errors.
Important When using KaMOS Hydraulic Test Equipment and a long hose, it
can take some time to stabilize the pressure, this is because of the oil viscosity and
compressibility.
It can be necessary to bring the test pressure up to final rest pressure several times
until the pressure is stabilize.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Type
Description
200500-01
200500-02
200500-03
Adapter
200500-04
T-Coupling/valve
200500-05
200500-06
200500-07
2
6
3
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Pos
5
4
7
6
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 11
12
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
1.
2.
3.
4.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
1.
2.
3.
4.
5.
6.
7.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 13
5.3 Instructions
for R21 Cylinder pressure regulator
These instructions must be kept permanently at hand in the workshop
1. Operation
1.1 Cylinder pressure regulator use in accordance with current regulations.
Cylinder pressure regulators are designed to reduce the respective cylinder
pressure and to ensure a constant outlet working pressure. They are
used with compressed gasses, pressurized dissolved gases in cylinder
and liquid gases having a filling pressure of up to a maximum of 200 bar.
1.2 Cylinder pressure regulator use contrary to current regulations. Cylinder
pressure regulators must not be used for gases in a liquid state. Cylinder
pressure regulators must not be operated under temperatures of -30C or
above +60C. Cylinder pressure regulators must not be used for corrosive
gases such as ethylamine, dimethylamine, ammonia etc.
2. Safety instructions
14
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2.1 Cylinder pressure regulators comply with all current relevant technical
regulations and meet all existing standards.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
3. Operating Instructions
3.1 Keep hands and tools clean. Oil and grease can cause an explosion on
contact with oxygen.
3.2 The operator should be fully familiar with these operating instructions prior
to use of his equipment. All instructions should be adhered to when in use.
3.3 Check that the cylinder pressure regulator is suitable for the gas to be used
(see label 3).
3.4 Check that the cylinder valve connection is clean and undamaged:
if not, you must not connect the cylinder pressure regulator.
3.5 Before connecting the cylinder pressure regulator, the cylinder valve should
be swiftly opened and closed to dislodge water or foreign matter from the
valve.
Do not stand in front of the cylinder valve.
Do not hold your hand before the cylinder valve.
3.6 Connect the cylinder pressure regulator to the valve by means of the inlet
nut (1) on the inlet stern.
3.7 Connect the hose to the cylinder pressure regulator outlet (6).
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Slowly open the cylinder valve. Ensure that the cylinder pressure is showing
on the contents gauge (2), open the downstream valve (5) and with the
pressure adjusting knob (7) rotate clockwise to set the required working
pressure using the outlet gauge (4).
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 15
16
The flow set by the outlet valve may be read at the flowmeter scale.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
6. Repairs
References
for KaMOS products
SALES/ TECHNICAL
NORWAY
VIETNAM
KARMSUND MARITIME
OFFSHORE SUPPLY AS
Post address:
P.O.Box 484
N-4291 Kopervik
NORWAY
KARMSUND MARITIME
VIETNAM CO.,LTD
Visiting and delivery address:
Lot E11, Suoi Dau Industrial Zone
Cam Lam district,
Khanh Hoa province,
VIETNAM
Visit/delivery address:
Austre Karmyveg 76
N-4250 Kopervik
NORWAY
Tel:
Fax:
E-mail:
Web:
+47 52 84 43 40
+47 52 84 43 41
offshore@kamos.no
www.kamos.no
ASIA - SINGAPORE
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
PRODUCTION
KARMSUND MARITIME
SINGAPORE PTE LTD
Visiting and delivery address:
1 Tanglin Road #04-19,
Orchard Parade Hotel,
SINGAPORE 247905
Tel:
Fax:
E-mail:
Web:
Tel:
Fax:
+84 58 37 44 207
+84 58 37 44 209
KARMSUND MARITIME
OFFSHORE PRODUCTION AS
Post address:
P.O.Box 484
N-4291 Kopervik
NORWAY
Sales office
Fabrikkveien
N-4033 Stavanger
NORWAY
Tel sales office: +47 47 46 78 42
E-mail:
sales@kamop.no
Web:
www.kamop.no
Workshop
Delivery address:
Vollsytoppen 4
N-4180 Kvitsy
NORWAY
Tel workshop:
Fax workshop:
E-mail:
+47 51 73 64 00
+47 51 73 64 01
production@kamop.no
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 17
18
-time, cost and safety efficient solution for sealing and surveillance of flanged connections
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Specifications and images are subject to change without notice. Not responsible for typographical errors.
Notes
-time, cost and safety efficient solution for sealing and surveillance of flanged connections 19
Specifications and images are subject to change without notice. Not responsible for typographical errors.
2014-1 KaMOS Patented Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
-time,
-time,cost
costand
andsafety
safetyefficient
efficientsolution
solutionfor
forsealing
sealingand
andsurveillance
surveillanceofofflanged
flangedconnections
connections
2014-1 KaMOS Gasket & Test Equipment - Operating Manual - Karmsund Maritime Offshore Supply AS. All rights reserved.
Specifications and images are subject to change without notice. Not responsible for typographical errors.