Where thee’s Pipe There’s Mathey Mathey Dearman, Inc. 4344 South Maybelle Ave. Tulsa, OK 74107 Phone: 800-725-7311 • 918-447-1288 • Fax: 918-447-0188 Model ______________ Serial Number _______ Double Chain Clamp Parts and Operating Manual Shipping & Mailing Address: 4344 S. Maybelle Ave., Tulsa, OK 74107 USA Phone: 918-447-1288 or 1-800-725-7311 Fax: 918-447-0188 Email: [email protected] Revised: February 28, 1914 1.0 – SAFETY. Proper safety precautions should be taken when using the D251 Double Chain Clamp as with all heavy alignment equipment. A little common sense goes a long way towards preventing accidents involving your Mathey Dearman Double Chain Clamp. • • • • • • • • • • • • • • The operator and maintenance person shall read and understand the Double Chain Clamp parts and operating manual prior to attempting operation of the equipment. The maintenance person shall read and understand the parts and operating manual prior to attempting maintenance of the Double Chain Clamp. Eye protection, steel toed shoes and gloves and other protective clothing shall be worn to protect the operator when using the Double Chain Clamp. Make sure loose clothing, tools, belts, etc. do not become entangled in the Double Chain Clamp. The periodic maintenance instructions must be followed in the Double Chain Clamp parts and operating manual. Never use the Double Chain Clamp for other than its intended purpose. Clear the general area where the Double Chain Clamp will be used of all trip hazards. Never use the Double Chain Clamp as a ground for a plasma or welding systems Always check the Double Chain Clamp for defects such as arc marks, abrasions and nicks and repair as needed prior to operation. Make sure that the Double Chain Clamp will function properly prior to attempting the alignment or reforming of pipes or fittings. When using the Double Chain Clamp, basic safety precautions must always be followed to reduce the risk of personal injury. Always operate the Double Chain Clamp in accordance with the operating instructions. The pipe must be secured from rotation, prior to mounting the Double Chain Clamp on the pipe. The Level and Support Device or Come-A-Long should never be used as the sole support of the pipe, fitting or valve. • Make sure the Double Chain Clamp is in full contact with the mating pipe, fitting or valve. • Use only the wrench provided with the Double Chain Clamp. • The supplied wrench is not designed to be used with a cheater bar. • A pneumatic impact wrench should not be used to tighten the jackscrew on the pipe. • Always inspect the Double Chain Clamp prior to use. • The mating pipe, fitting or valve should not have a taper surface of more than 5 degrees at the point where the Double Chain Clamp Jackscrew pad will contact the pipe. • To avoid the risk of electrical shock or death keep the Double Chain Clamp as far away as possible from power lines. IN ADDITION TO THE ABOVE PROCEDURES, ALL SHOP, NATIONAL AND INTERNATIONAL SAFETY RULES CONCERNING THE DOUBLE CHAIN CLAMP SHOULD BE FOLLOWED. ALL CLAMPING OPERATIONS SHOULD BE CONDUCTED IN THE BEST OF SAFETY CONDITIONS. 2 WARNING: THE DOUBLE CHAIN CLAMP SHOULD NEVER BE USED TO LIFT THE PIPE AS IT MAY RESULT IN SERIOUS INJURY OR DEATH. WARNING: THE DOUBLE CHAIN CLAMP SHOULD NEVER BE USED AS THE ONLY SUPPORT OF THE PIPE OR FITTING. WARNING: THE DOUBLE CHAIN CLAMP SHOULD NEVER BE USED AS A GROUND FOR A WELDING POWER SOURCE 3 Table 1 – D251 Double Chain Clamp Sizes Part Number Pipe Clamping Range Estimated Weight Inches MM lbs kg D251-1036 10 – 36 254 – 914 220 100 D251-1036SS 10 – 36 254 – 914 220 100 D251-1048 10 – 48 254 – 1219 278 126 D251-1048SS 10 – 48 254 – 1219 278 126 D251-1054 10 – 54 254 – 1372 300 136 D251-1054SS 10 – 54 254 – 1372 300 136 D251-1060 10 – 60 254 – 1524 328 149 D251-1060SS 10 – 60 254 – 1524 328 149 D251-1072 10 – 72 254 – 1829 387 176 D251-1072SS 10 – 72 254 – 1829 387 176 D251-1084 10 – 84 254 – 2134 442 200 D251-1084SS 10 – 84 254 – 2134 442 200 D251-1096 10 – 96 254 – 2438 498 226 D251-1096SS 10 – 96 254 – 2438 498 226 D251-10108 10 – 108 254 – 2743 554 251 D251-10108SS 10 – 108 254 – 2743 554 251 D251-10120 10 – 120 254 – 3048 610 277 D251-10120SS 10 – 120 254 – 3048 610 277 D251-1011F 10 – 132 254 – 3353 660 299 D251-1011FSS 10 – 132 254 – 3353 660 299 D251-1012F 10 – 144 254 – 3715 710 322 D251-1012FSS 10 – 144 254 – 3715 710 322 D251-1014F 10 – 168 254 – 4267 810 367 D251-1014FSS 10 – 168 254 – 4267 810 367 D251-1016F 10 – 192 254 – 4877 910 410 D251-1016FSS 10 – 192 254 – 4877 910 410 D251-1018F 10 – 216 254 – 5486 1010 455 D251-1018FSS 10 – 216 254 – 5486 1010 455 D251-1020F 10 – 240 254 – 6096 1110 500 D251-1020FSS 10 – 240 254 – 6096 1110 500 4 Table 2 – Chain Clamp Components Qty of Main Blocks Main Block Part Number Qty. of fine Adjustment Fine Adjustment Part Number Qty of Jackbars Jackbar Part Number Chain Length Chain Part Number Qty of Conn Links Conn Link Part Number D251-1036 1 DD-100 2 DC-200 9 DD-500SS 20 DC-300 VARIES DC-301 D251-1036SS 1 DD-100SS 2 DC-200 9 DD-500SS 20 DC-300S VARIES DC-301S D251-1048 1 DD-100 2 DC-200 12 DD-500SS 26 DC-300 VARIES DC-301 D251-1048SS 1 DD-100SS 2 DC-200 12 DD-500SS 26 DC-300S VARIES DC-301S D251-1054 1 DD-100 2 DC-200 14 DD-500SS 30 DC-300 VARIES DC-301 D251-1054SS 1 DD-100SS 2 DC-200 14 DD-500SS 30 DC-300S VARIES DC-301S D251-1060 1 DD-100 2 DC-200 16 DD-500SS 33 DC-300 VARIES DC-301 D251-1060SS 1 DD-100SS 2 DC-200 16 DD-500SS 33 DC-300S VARIES DC-301S D251-1072 1 DD-100 2 DC-200 20 DD-500SS 40 DC-300 VARIES DC-301 D251-1072SS 1 DD-100SS 2 DC-200 20 DD-500SS 40 DC-300S VARIES DC-301S D251-1084 1 DD-100 2 DC-200 24 DD-500SS 46 DC-300 VARIES DC-301 D251-1084SS 1 DD-100SS 2 DC-200 24 DD-500SS 46 DC-300S VARIES DC-301S D251-1096 2 DD-100 4 DC-200 28 DD-500SS 52 DC-300 VARIES DC-301 D251-1096SS 2 DD-100SS 4 DC-200 28 DD-500SS 52 DC-300S VARIES DC-301S D251-10108 2 DD-100 4 DC-200 32 DD-500SS 59 DC-300 VARIES DC-301 D251-10108SS 2 DD-100SS 4 DC-200 32 DD-500SS 59 DC-300S VARIES DC-301S D251-10120 2 DD-100 4 DC-200 36 DD-500SS 66 DC-300 VARIES DC-301 D251-10120SS 2 DD-100SS 4 DC-200 36 DD-500SS 66 DC-300S VARIES DC-301S D251-1011F 2 DD-100 4 DC-200 39 DD-500SS 73 DC-300 VARIES DC-301 D251-1011FSS 2 DD-100SS 4 DC-200 39 DD-500SS 73 DC-300S VARIES DC-301S D251-1012F 2 DD-100 4 DC-200 42 DD-500SS 80 DC-300 VARIES DC-301 D251-1012FSS 2 DD-100SS 4 DC-200 42 DD-500SS 80 DC-300S VARIES DC-301S D251-1014F 3 DD-100 6 DC-200 48 DD-500SS 92 DC-300 VARIES DC-301 D251-1014FSS 3 DD-100SS 6 DC-200 48 DD-500SS 92 DC-300S VARIES DC-301S D251-1016F 3 DD-100 6 DC-200 54 DD-500SS 106 DC-300 VARIES DC-301 D251-1016FSS 3 DD-100SS 6 DC-200 54 DD-500SS 106 DC-300S VARIES DC-301S D251-1018F 3 DD-100 6 DC-200 60 DD-500SS 120 DC-300 VARIES DC-301 D251-1018FSS 3 DD-100SS 6 DC-200 60 DD-500SS 120 DC-300S VARIES DC-301S D251-1020F 3 DD-100 6 DC-200 66 DD-500SS 128 DC-300 VARIES DC-301 D251-1020FSS 3 DD-100SS 6 DC-200 66 DD-500SS 128 DC-300S VARIES DC-301S Part Number 5 Figure 1 – JACKBAR ASSEMBLY Description Complete Jackbar Ass’y Jackbar Jackscrew Thumbscrew Chain Lock Part Number DD-500SS DD-500C DC-501 22-38TS-114 DB-507 Item Number 1 2 3 4 5 Qty. 1 1 2 2 2 Figure 2 – MAIN BLOCK – Part number: DD-100 Main Block Spring Chain Dog Chain Dog Retainer Chain Lock 5/8”-11 SHCS 5/8”- 11 Lock Nut Jackscre w DD-100 DB-103 DC-102 DC-120 DC-131 11-58C0-312 1l-58C0-000 DC-501 Item 1 2 3 4 5 6 7 QTY. 2 2 2 2 2 2 1 6 Figure 3 – FINE ADJUSTMENT – Part Number: DC-200 Model Crank Housing Piston Crank Handle Stud (Not Shown) Collar (Not Shown) Flat Washer Item C1 C2 C3 C4 C6 C7 DC-200 DC-201 DC-202 DC-205 DC-202 12-0100-F00 DC-203 Figure 4 – CHAIN END Item Description Chain* Part Number Qty. DC-300 Varies F Shaft Collar 01-0185-004 4 G Lock Nut 1L-38C0-000 2 E SHCS, 3/8-16 x 2 1/2 lg. 11-38C0-212 2 7 GENERAL The Double Chain Clamp is heavy-duty vessel clamp designed for the alignment large diameter having wall thickness no greater than schedule 120. The Double Chain Clamp will reform schedule 80 pipe and vessels having a tensile strength up to 45,000psi (310megapascal). The extra heavy-duty Jackbars and Main Block provide the brute strength to accomplish almost any reforming job. Models of the Clamp are available to align and reform pipe or vessels up to 20 foot (6 meters) in diameter. The 10” to 84” Double Chain Clamp and larger will have multiple Main Block Assemblies, dependent on the clamps pipe clamping range. Multiple Main Blocks and Fine Adjustments are included with large pipe or vessels Clamps to enable the operator to remove the slack in sections of the chain (Table-2). The use of multiple Main Blocks and Fine Adjustments greatly aids in the installation, application and function of the clamp. A. Installing the Clamp on Pipe without Cable Puller 1. Lay out the clamp on the floor or table with Jackscrews (Figure 1) facing downward. Make sure all Jackscrews are lightly touching the floor and the Jackbars are not elevated. (See Figure 5) Figure 5 WARNING: Due to the weight of the Double Chain Clamp, precaution should be taken when lifting the clamp to avoid injuries to the back, hands and feet. The Double Chain Clamp will have 1 or more Double Main Blocks (Figure 2) containing 2 or more Chain Dogs, Chain Dog Retainers and chain Locks. A Jackbar protrudes out of one side of the Main Block to assist with the alignment and reforming processes. The attachment point of the Main Block (Figure 2) is used as an attachment point for the hook of a Cable Puller or crane. The Main Block and all parts attached to the Main Block are made from carbon steel. A 3/16” x 3/16” stainless steel square bar is welded to the bottom of the Main Block for stainless steel and specialty alloy applications. The parts of the Jackbar that contact the pipe are made of stainless steel. 2. Evenly space the Jackbars (Figure 1) along the Chain as shown in Figure 5 and tighten both Chain Locks (Figure 1 Item 5) with the Thumbscrews (Figure 1 item 4) located on the Jackbar (See Figure 1) to secure the Jackbars in position on the Chain. Adjust all Jackscrews (Figure 1 item 3) to make sure they are lightly touching the floor and the Jackbar (Figure 1) is not elevated. (See Figure 5) WARNING: If the Thumbscrews do not adequately tightened the Chain Lock against the Chain, the Jackbar will slip on the chain resulting serious injury or loss of a body member. 3. Take the Chain Dog Retainers (Figure 2 Item 3) and Chain Locks (Figure 2 Item 4) that are located on both WARNING: When spacing the Jackbars, use caution to not to place hands or fingers side of the Main Block out of the support holes and leave dangling from the Main Block until it is time to under jackbar or where the chain enters and leaves the Jackbar as it may cause serious lock the Chain in position. 8 4. With an overhead crane lower the clamp over each side of the pipe. If crane is not available or there is not enough clearance above the pipe, pull the clamp over the pipe 5. NOTE: Instructions for making a “spread bar” to assist in lowering the clamp on the pipe or vessel with a crane is located in the back of this manual. WARNING: When using a crane do not stand under the Double Chain Clamp as it may disengaged from the crane resulting in serious injury or death. WARNING: To avoid injury some method should be used to maintain the clamp on the pipe to avoid serious injury to the operator 5. Fit the clamp on pipe so the Jackscrew (Figure 1 Item 3) of the Jackbar (Figure 1 Item 1) protrudes past the pipe end approximately 1” (25mm). 6. Adjust the clamp so the Main Block (Figure 2) is at a convenient height (Waist high for most persons) to lift the Fine Adjustment, Chain and Jackbars. WARNING: To avoid a back injury, do the appropriate exercises to stretch your back prior to lifting the fine adjustments. 7. Figure 6 Place the ears of the Fine Adjustments (Figure 5) into the notches of the Main Block. See Figure 6 WARNING: Do not place hands under Jackbar or Chain as it will result in serious injury. 8. Install the Chain Locks (Figure 2 Item 4) into the large hole in the Main Block (Figure 2), over the chain into the inner hole in the Main Block See Figure 7 Figure 7 WARNING: Failure to install the Chain Locks may cause the Fine Adjustment to become separated from the Main Block causing serious injury or death. 9. Pull both Chains through the Chain Dogs (Figure 2 Item 2) of the Main Block until both chains are tight against the side of the pipe or vessel. The lengths of each chain should be even with each other. See Figure 8 Figure 8 9 10. Install Chain Dog Retainers (Figure 2 Item 3) back into the hole in the Main Block slots. (See Figure 9) Figure 9 11. Move the 2nd section of the pipe forward until pipe rest on the Jackscrews (Figure 1 Item 3) of the Jackbar Assembly. If too much HI-LO exists, it may be necessary to remove some of the out-of-roundness of the mating pipe to fit the pipe in the clamp. When aligning fabricated out-of-round pipes or shells, it may be necessary to place a brace, about 1” (25mm) smaller than the inside diameter, into the shell to remove a majority of the out-of- round condition). The brace(s) can be easily removed after the fit-up is complete. WARNING: Do not place body, hands or feet under pipe or fitting being placed in clamp as it may result in serious injury or death. NOTE: It will never be necessary to tighten all Jackscrews (Figure 1 Item 3). Tighten only those Jackscrews (Figure 1 Item 3) where the HIGHS between the 2 pipes exist. When adjusting the pipe diameters to match up to each other with the Jackscrews, it may be necessary to loosen some Jackscrews (Figure 1 Item 3) opposite those that were tightened previously. NOTE: Do not attempt to adjust all Jackscrews at the same to time to remove the high points. 12. Tighten each Jackscrew (Figure 1 Item 3) a little at a time. Go around the Vessel as many times as necessary until you have a good fit-up. Caution: Do not tack weld the vessels before a good fit-up is achieved all the way around the vessel. 13. When possible, completely weld the weld joint on inside of the vessel before removing the clamp. This will eliminate the need to tack the weld joint on the outside pipe or vessel. When inside welding of the weld joint is not possible, the Jackbars should be arranged to obtain an 80% completed weld joint on the outside of the vessel prior to removing the clamp. 14. Raise the jackscrews above the surface of the vessel surface before removing the clamp. WARNING: Failure to make sure the clamp is cool prior to removal of the clamp, may result in serious injury. 15. Reverse the procedure used to install the clamp to remove the clamp. C. Mounting Instructions using a Cable Puller (Come-A-Long) Figure 10: Cable Puller Detail 10 Figure 11 1. With the Dearman Double Chain Clamp resting over the pipe, wrap the chains just above one of Jackbars with a strap. Attach 1 of the 2 hooks (Figure 10 Items A & B) of the Heavy-Duty Cable Puller to the strap that is attached just above one of the Jackbars. Bring the strap attached Cable of the Cable Puller to center between the 2 Jackscrews. Figure 12 2. Place the Hook (Figure 10 Item A) on the end of the Cable Puller attachment point in the center of the Main Block. (see Figure 2) Figure 13 3. Ratchet the handle (C) of Cable Puller (see Figure 10) to move the Main Block (Figure 2) into position on the pipe. (See Figure 2 below & Figure 12) WARNING: Keep hands, finger and arm from under Chain and Jackbars when ratcheting the Cable Puller as it may result in serious injury. 11 Figure 14 4. Place the ears of the Fine Adjustment (Figure 3) into the notches of the Main Block. (As Illustrated in Figure 6) 5. Pull the excess chain through the Chain Dog (Figure 2 Item 2) and put the Chain Lock (Figure 2 Item 3) of the Main Block. Both Chains should be as close to the same length as possible. (As illustrated in Figure 8) 6. Install the Chain Dog Retainers (Figure 2 Item 3). (Installation shown in Figure 9) 7. The Cable Puller is now ready for removal. Figure 15 8. Move Latch (Figure 10 Item D) of the Cable Puller to the down position. Pull back on the latch (Figure 10 Item E) of the cable puller and with the other hand pull the cable downward to obtain slack in the cable. (See Figure 10) Figure 16 9. Unhook Hook (Figure 10 Item A or B) of Cable Puller from attachment point of the Main Block (Figure 10 Item B). 10. Remove hook (Figure 10 Item A or B) from the Double Chains of the Clamp. 12 11. If a Hi-Lo of more than 1” (25mm) exists, it will be necessary to remove some of the out-of-roundness of the pipe in order fit the pipe into the clamp. When aligning fabricated shells with an out of round condition, a brace about 1” (25mm) smaller than the inside diameter can be inserted into the shell to remove some of the out of round condition). The brace can be easily removed after making the fit-up. WARNING: Before attempting step 10, the process for removing the out of round condition should be discussed with the appropriate safety personnel due to the risk the personal injury. 12. Move the fitting or other section of the pipe forward until pipe rest on the Jackscrews (Figure 1 Item 3). NOTE: Tighten only those jackscrews (Figure 1 Item 3) where the HIGHS exist. It may be necessary to loosen some jackscrews that were tightened previously when adjusting the pipe diameters to match. WARNING: Due to the risk of severe injury and death, hand, fingers or other extremities should not be placed between the 2 pipes or pipe and fitting being moved into clamp. NOTE: Do not attempt to adjust all Jackscrews at the same to time to remove the high points. 13. Tighten only the 2 Jackscrews (Figure 1 Item 3) over the high spot and 2 jackscrews 180 degrees to the first 2 jackscrews a little at a time Tighten 4 Jackscrews as many times as necessary until good fit-up is achieved. NOTE: Do not tack weld joint together before a good fit-up has been achieved all the way around the vessel. 14. When possible, weld the inside of the weld joint before removing the clamp to eliminate tacking the outside of the weld joint. When welding the inside weld joint is not possible, Jackbars should be arranged to weld 80% weld of the weld joint. Note: If it is not possible to weld the inside first, it is suggested that all unrestricted areas of the weld joint be welded before removing the clamp to help prevent cracking of the skip-welds. 15. Before removing the clamp, raise the jackscrews about surface of the vessel surface. WARNING: When removing the clamp, there is a risk of a severe burn, due to the heat generated during the welding process. 16. To remove the clamp, reverse the procedure used to install the clamp. To loosen the Roller Chain 1. 2. 3. 4. Rotate the Crank Handle (Figure 3 Item C1) on the Fine Adjustment (Figure 3) until the piston (Figure 3 Item C2) is at its outer most point if additional slack in the Chain is needed. Warning: Do not extend the piston past the hole in the Fine Adjustment Housing. Position the Fine Adjustment ears in the recess of the Main Block as shown in Figure 6. Remove the Chain Dog Retainers (Figure 2 Item 3) from the Main Block (Figure 2) as shown in Figure 9. Lift the Chain Dogs (Figure 2 Item 2) and pull the chains through the Main Block as shown in Figure 8. WARNING: When lifting the Chain Dog, there is a potential risk of serious injury. The weight of the Jackbars and chains can cause the chain to be rapidly released through the chain bog. 13 Note: The length of the Chains protruding out of the Chain Dogs should be as even as possible. To Tighten the Roller Chain 1. Remove the Chain Dog retainers (Figure 2 Item 3) from Main Block (Figure 2) as shown in Figure 9. 2. Pull the Chain through the Chain Dog (Figure 2 Item 2) to take up the slack in the Roller Chain as show in Figure 8 keeping them as even as possible. 3. The Chain Dog (Figure 2 Item 2) is spring-loaded to clamp the Roller Chain automatically when the handle is released. Lift the trigger on the Chain Dog to let the chain go through the Main Block if the chain needs to be released. WARNING: When lifting the Chain Dog, there is a potential risk of serious injury. The weight of the Jackbars and chains can cause the chain to be rapidly released through the chain bog. Note: The length of the Chains protruding out of the Chain Dogs (Figure 2 Item 2) should be as even as possible. 4. Replace the Chain Dog Retainers (Figure 2 Item 3). 5. Rotate the Crank Handle of the Fine Adjustment to tension the Chain. D. Removing the Jackbars from the Clamp Figure 17 1. Remove Lock Nut (Figure 4 Item G), Collar (Figure 4 Item F) and Hex Head Cap Screw (Figure 4 Item E) from the both chain ends. Save these Items as they will be needed later. (See Figure 4) 2. Remove the both Chain Dog Retainers (Figure 2 Item 3) if installed. 3. Lift up the Chain Dog Handle (Figure 2 Item 2). 4. While holding the Chain Dog Handle upward, pull the roller Chains through the bottom of the Main Block. 5. Remove the number of Jackbar required. See Table 2 for the number of Jackbars required for a particular pipe or vessel diameter. 6. Reinstall the Chain through the Main Block as illustrated in Figure 16) 7. Reinstall Lock Nuts (Figure 4 Item G), Collars (Figure 4 Item F) and Hex Head Cap Screws (Figure 4 Item E) on the end of the chains. 14 E. Double Chain Clamp Spreader bar design Figure 18: Approximate dimensions of the spreader bar cable for use on 15’ diameter vessel: center cable 2’ long, end cables 9’6” long. When hooking to the clamp, space hook at 11’7” from center of hook. F. Maintenance 1. All Jackscrews should be inspected after each clamping operation for splatter and other foreign debris. Any slag, splatter and other foreign debris should be removed prior to the next clamping operation. 2. Check all Jackscrews for damaged threads. If the threads are damaged, they should be filed smooth so that the Jackscrew will rotate smoothly in and out of the Jackscrew Nut. 3. If play between the threaded hole and the Jackscrew exceeds .020” (.5mm) the Jackscrew and/or Jackbar should be replaced. 4. When the Clamp is used daily, a Copper based Anti-seize compound should be applied to all Jackscrews daily. 5. Check Segments of the Chain for welding arc marks. If chain exhibits arc marks replace the chain. WARNING: Use of any other chain that the Mathey Dearman Chain will cause the chain dog to work improperly resulting in failure of the clamp and serious injury and possibly death. WARNING: To avoid serious injury or death, the clamp should be inspected prior to each use and repaired as necessary, regardless of the application. G. Warranty For warranty details see Mathey Dearman’s website at www.mathey.com 15
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