M19-Pipework REV

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Module ZADCO AHRT TRAINING

M19
ZIRKU

MECHANICAL

PIPEWORK

M19 PIPEWORK PAGE 1 OF 45


DATE OF ISSUE 20/07/01 REVIEW DATE GB/08/05/03
ZADCO - AHRT

TABLE OF CONTENTS
Paragraph Page

2.0 OBJECTIVES

2.1 INTRODUCTION

2.2 PIPING SYSTEM

2.3 TYPES OF PIPE

2.4 METHODS OF JOINING PIPEWORK

2.4.1 Flanges

2.5 PIPE DIMENSIONS

2.6 METHODS OF MANUFACTURING PIPE

2.7 PIPE FITTINGS

2.7.1 Blinds

2.8 FABRICATING A PIPE SYSTEM

2.9 PIPE LEAKAGE

2.10 PIPE HANGERS AND SUPPORTS

2.11 TUBING

2.12 CUTTING AND FORMING PIPEWORK

2.12.1 Cutting and joining tubing

2.12.2 Bending and forming tube

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2.0 OBJECTIVES

The trainee will be able to:

 List parts of a pipe system.

 Demonstrate how pipe is dimensioned.

 Describe methods of manufacturing pipe.

 List types of common pipefittings and state their use.

 List types of common pipe hangers and state their use.

 Describe methods of forming pipework.

2.1 INTRODUCTION

There are many different types of pipework used throughout a large plant.
It is important that mechanical technicians are familiar with different piping
specifications.

2.2 PIPING SYSTEM

Refineries have large piping systems. All fluids and gases are moved
from place to place through piping systems. A piping system will include
the following:

 Pipework. To carry the fluid from place to place.

 Pipe fittings. Fittings are used to join sections of pipework and control
the direction of flow.

 Valves. Valves control the amount and direction of flow, and shut off
the supply.

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 Flanges. Flanges join lengths of pipework together, and connect


pipework to valves and fittings.

 Gaskets. Gaskets seal the joints in the system.

The size and material used for the pipework and fittings depends on the
amount and type of fluid to be moved in the system. The piping system
can carry hot or cold water, crude oil, refined products, chemicals, gases
etc. These fluids can be at various temperatures, pressures, and flow
rates. All parts of the pipework system must be correctly maintained.

2.3 TYPES OF PIPE

Although pipe is normally made of steel, it can also be found in may other
different materials. The material is selected because of the product it has
to carry and the conditions it will be used in.

Types and uses of pipework.

 Glass pipe. Glass pipe is not often used because it is brittle. It is


sometimes used, however, for corrosive materials or food products. It
is joined together by compression type fittings or by special welding
techniques.

 Plastic and fibreglass pipe. This type of pipe is used for water or
other corrosive products. It can be joined together using various
methods, such as glue, welding, fusion or threading.

 Brass and copper pipe. This type of pipe is used in some chemical
processes, but is mostly used for pneumatic instrumentation. It is
never used for processes where the temperature is higher than
232°C. It can be joined by threading, soldering, or with flanges or
compression fittings.

 Aluminium pipe. This type of pipe is used in chemical processes


where steel cannot be used. It is light and easy to handle. It can be
joined by threads, flanges or welds. Aluminium is very resistant to
corrosion from atmospheric conditions.

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 Cast iron pipe. This type of pipe is used for water, sewers and some
chemical processes. It must not be used where temperatures go
above 232°C. It is very brittle and should not be used where there is
excessive vibration or shock loads. Cast iron can be joined by
threading, compression, bell and spigot, and flanged fittings.

 Malleable iron pipe. This type of pipe is used in many different


operations. It is very useful where there is expansion, contraction or
shock loads. It is mostly used in small size pipework and is joined by
screwed fittings.

 Steel pipe. Steel is the most common type of pipe. It can be joined
by welding, threading, or by flanged joints. It has good resistance to
vibration, shock, low temperatures and fire.

 Stainless steel pipe. This type of pipe is used in the same way as
normal steel pipe. The advantage of using stainless instead of normal
steel pipe is, it is stronger, lighter and more resistant to corrosion.

2.4 METHODS OF JOINING PIPEWORK

The method of joining pipework is very important. There are many


different methods. The method used will depend on the work it has to do.
Some common ones are as follows:

 Threaded joint (see figure 2.1).

Figure 2-1.

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 Compression joint (see figure 2.2).

Figure 2-2

 Welded joint (see figure 2.3).

BUTT OR BEVEL WELD

FLAT TYPE

ME-1 42 2

BACKING RING

Figure 2-3.

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 Tubing fitting (see figure 2.4).

ME-1 4 2 4

Figure 2-4

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 Flanged joint (see figure 2.5).

Figure 2-5

 Bell and spigot joint (see figure 2.6).

Figure 2-6

 Fused or glued joint (see figure 2.7).

Figure 2-7

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 Mechanical joint (see figure 2.8).

Figure 2-8

2.4.1 Flanges

Flanged pipe is used in high pressure and hazardous chemical


operations. There are three main methods of joining flanges to pipework:

 Glued

 Welded

 Threaded

Flanged joints are required where pipelines and piping components need
to be disassembled for maintenance. No matter how the flanges are
attached to the pipe, the two flanges faces are bolted together. Gaskets
are placed between the flange faces to make sure there is no leakage.

For permanent joints, welding is used to join the two sections of pipe
together. If the pipework has to be separated it must be cut.

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Some of the standard types of flange faces are as follows:

 Welding neck (see figure 2.9).

Figure 2-9

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 Lap joint (see figure 2.10).

Figure 2-10

 Slip-on (see figure 2.11).

Figure 2-11

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 Threaded (see figure 2.12).

Figure 2-12

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 Socket (see figure 2.13).

Figure 2-13

 Blind (see figure 2.14).

Figure 2-14

Flange faces are also different. The shape of the face depends on how it
is linked together. If the two faces do not match then the joint will leak.
Common flanged faces are as follows:

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 Raised face (see figure 2.15).

Figure 2-15

 Tongue and grooved (see figure 2.16).

Figure 2-16

 Large male and female (see figure 2.17).

Figure 2-17

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 Flat face (see figure 2.18).

Figure 2-18

 Lapped face (see figure 2.19).

Figure 2-19

 Ring joint (see figure 2.20).

Figure 2-20

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2.5 PIPE DIMENSIONS

There are four dimensions that are used to show the size of pipework,
they are:

 Length.

 Wall thickness.

 Inside diameter (ID).

 Outside diameter (OD) (see figure 2.21).

Figure 2-21

The most common measurements on a piece of pipe are the outside and
inside diameters (OD and ID), and the nominal size.

Wall thickness is usually given as a schedule number. A schedule


number is the classification given to the thickness. The numbers range
from 10 to 160. The lower the number the thinner the wall thickness.
Common schedule numbers are 40, 80, 120 and 160.

Besides the OD, ID and wall thickness, the length of the pipe is also
important. A normal length of pipe is usually about 10 metres long.

The nominal size is a very important dimension. The nominal size is the
approximate size of the pipe.

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 Under 300 mm (12") diameter the ID is used for the nominal size.

 over 300 mm (12") the OD is used.

It is usually the nearest standard size. Normally the size of the pipe is
referred to using the nominal size and the schedule number.

The weight of a piece of pipe will vary according to the wall thickness and
material it is made from. Its weight is given for a 12" length.

2.6 METHODS OF MANUFACTURING PIPE

There are five main methods of manufacturing pipe, they are:

 Wrought pipe. This type of pipe is made from a single block of metal
which is heated and is either drilled or bored. The block is then rolled
and shaped to the final size. Pipe up to 65 mm (2 1/2") diameter can be
made this way. (see figure 2.22).

Figure 2-22

 Forged pipe. This type of pipe is made from a block of metal that is
heated, lengthened and shaped, using forging hammers. This is done
to approximately 25 mm of its final size. Then it is machined to the
finished size. This method is used for large pipe with heavy wall
thickness.

 Cast pipe. To make cast pipe, molten metal is poured into a mould
and allowed to cool. The pipe is then removed from the mould and
checked for faults. Its accuracy is limited to the quality of the mould.

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 Welded pipe. Welded pipe is made from a flat strip of metal that is
rolled or shaped into a tube. The seam where the edges meet is then
welded. This is known as lap welding. Any size of pipe can be made
this way (see figure 2.23).

Figure 2-23

 Spiral welded pipe. Spiral-welded pipe is made by winding coils of


narrow strip steel into cylinders with touching or overlapping edges.
The edges are fused together using electric arc welding. This method
is used for making lightweight pipe in 6 m (20') lengths (see figure
2.24).

Figure 2-24

2.7 PIPE FITTINGS

Pipe fittings are used to join sections of pipe together, or to change the
direction of flow. They can be made of the following materials:

 Steel
 Cast iron
 Bronze
 Copper
 Plastic
 Glass

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Most fittings are available in screw or welded types although the flanged
type is also common. Welded fittings are classed as permanent.

The main function of a pipe fitting is:

 To join sections of pipe (Coupling, union or nipple).

 To change the direction of flow (Elbow or "Y").

 To change the size of pipe (Reducer or bushing).

 To branch the line (Tee or cross).

To close the ends of pipe (Plug or cap).

The most common types of fitting are as follows:

 Elbows. They allow pipework to change direction at either a 90° or a


45° angle (see figure 2.25 and 2.26).

Figure 2-25

 A 45° elbow (see figure 2.26).

Figure 2-26
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 Tee. Allows pipe to branch in two directions. It can also be


considered as the joining of three pipes (see figure 2.27).

Figure 2-27

 Cross. A cross allows pipe to branch in three directions, or the joining


of four different pipes (see figure 2.28).

Figure 2-28

 Bushing. Bushing is threaded inside and outside to allow large pipe


to be connected to smaller pipe. The inside and outside thread
dimensions come in different sizes (see figure 2.29).

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Figure 2-29

 Cap. A cap is a threaded fitting that screws directly onto a pipe to


close it off (see figure 2.30).

Figure 2-30

 Plug. A plug is a solid threaded fitting which screws into another


fitting to plug an opening (see figure 2.31).

Figure 2-31

 Coupling/sockets. They are used to join two sections of pipe (see


figure 2.32).

Figure 2-32

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 Nipple. A nipple is a short section of threaded pipe which usually fits


between two different pipe fittings. They can vary from 5 to 25 mm in
length (see figure 2.33).

Figure 2-33

 Reducer (concentric and eccentric). The function of a reducer is to


change the diameter from a larger pipe size to a smaller pipe size..
This is done to reduce the volume, or to increase the pressure in the
pipe. They come in various sizes (see figure 2.34).

Figure 2-34

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 Union. A union is a coupling which comes apart into two sections. It


allows two sections of pipe to be disconnected (see figure 2.35).

Figure 2-35

 "Y" fitting. A "Y" fitting allows two branches to go off at 45° to each
other (see figure 2.36).

Figure 2.36

 Return bend. A return bend allows a pipe to return parallel to itself


(see figure 2.37).

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Figure 2.37

2.7.1 Blinds

A blind is a circular metal plate that can be placed between two flanges to
stop the flow. It is used to isolate a section of the plant, usually for
maintenance work. A spacer is placed between the flanges to allow for
the thickness of the blind. It is removed when the blind is to be used.

There are three types of blind.

 Blank blind (see figure 2.38).

Figure 2-38

 Spectacle blind (see figure 2.39).

Figure 2-39

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 Blind flange (see figure 2.40).

Figure 2-40

To insert a blind.

Remove the spacer from between the flanges. Place the blind between
the circle of the flange bolts, then insert the gasket. The flange bolts are
tightened to make a leakproof seal (see figure 2.41).

Figure 2-41

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2.8 FABRICATING A PIPE SYSTEM.

To fabricate a pipe system it is necessary to know the dimensions of the


fitting and valve, and the thread engagement length. Figure 2.42 shows
an example of a pipe system using various common fittings (see figure
2.42).

Figure 2-42

The normal thread engagement length is the amount of threaded pipe


turned into the fitting to make a tight joint. A mechanical technician must
be able to accurately decide the length of pipe that is needed. When he
calculates the length, he must measure between the fittings, plus the
thread engagement at both sides. In figure 2.43 the total length of pipe
required (L), is the thread engagement length (Y), plus the length
between the fittings (X) (see figure 2-43).

Figure 2-43
Examples:

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Nominal pipe/fitting size. Thread engagement size.


1 3
/4" /8"
3 3
/8" /8"
1 1
/2" /2"
3 9
/4" /16"
11
1" /16"

1 1/4" 11
/16"

1 1/2" 11
/16"
3
2" /4"

2.9 PIPE LEAKAGE

Unrepaired pipe leaks can cause very serious problems in petrochemical


plants and refineries. There are many common causes of leaks. They
are:

 Vibration.

 Improper alignment of flanges.

 Pipe stress.

 Corrosion.

If the leaks go unrepaired they can lead to:

 Corrosion to other lines.

 Toxic contamination to humans.

 Serious skin burns.

 Explosions.

 Fires.

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Repairing leaks

Temporary repair of leaks is often done without taking the pipeline out of
service. The most common piece of equipment used to repair leaks is
the pipe sleeve. A pipe sleeve must fit nicely over the outside diameter of
the pipe. If repairs are carried out whilst the line in still in operation, make
sure all safety precautions are taken. Wear all the proper safety
equipment.

Pressure must be taken off the line before the sleeve is installed. Then
the area around where the sleeve is to installed must be cleaned. A
chipping hammer and wire brush are used to clean the pipe. Assemble
the pipe sleeve a metre from the leak. When the bolts are in place, slide
the sleeve over the leak. Align the gasket correctly, then tighten the bolts.
Tighten, firstly by hand, and then with the correct size spanner (see figure
2.44).

Figure 2-44

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Any gasket material used must be suitable for the product in the line.

A pipe clamp is another piece of equipment used to repair leaks. The


installation procedure is similar to the pipe sleeve (see figure 2.45).

Figure 2-45

2.10 PIPE HANGERS AND SUPPORTS

Pipe must be supported to keep it in a straight line and prevent it from


sagging. Sagging pipes put strain on the fittings, causing them to leak. A
pipe support must hold the pipe, but allow it some freedom for thermal
expansion. Pipe can be supported and fastened to the floor, walls, ceiling
or to pillars.

There are many different types of pipe support, each one is used for a
particular job. Some common ones are as follows:

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 Spring hangers. This type absorbs vibration (see figure 2.46).

Figure 2-46

 Adjustable swivel pipe roll. Roll type supports allow the pipe to
move as it expands and contracts due to heat (see figure 2.47).

Figure 2-47

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 Single hook (see figure 2.48).

Figure 2-48

 Ring and bolt hanger (see figure 2.49).

Figure 2-49

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 Adjustable clevis and band hanger (see figure 2.50).

Figure 2-50

 Adjustable pipe roll stand (see figure 2.52).

Figure 2-52

The spacing of pipe hangers is very important. Although the space varies
according to the size and weight of the pipe, 3 metres is correct for simple
pipe hangers.

Pipe hangers and supports must be included in any preventative


maintenance programme. This is important because of the possibility of
vibration or corrosion.

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2.11 TUBING.

Tube has many advantages over pipe. They are as follows:

 It can be used in small or confined spaces.

 It is flexible and can absorb shock or vibration.

 It requires less fittings or supports and is bent quite easily.

 It is light in weight, so it puts less strain on the fittings due to sagging.


Therefore, there is less wear in the fittings.

 It is easier and quicker to install.

 Its smooth inner surface reduces turbulence in the flow.

Tube does, however, have some disadvantages.

 It is small in diameter.

 The wall thickness is thin.

 Threading the tube weakens it.

Tubing materials and uses.

Tubing can be made from a range of materials. The material it is made of


will depend on its use. Some common materials are as follows:

 Copper. Copper pipe is used for plumbing, cooling, heating, gas,


steam and oil.

 Aluminium. Aluminium pipe is seamless and can be bent or even


flared at the ends. It is used on cryogenic lines (they become stronger
at low temperatures), and on sanitary applications.

 Steel and stainless steel. These pipes are used for high pressure
hydraulic systems, cooling units, evaporators, and process lines.

 Plastic and nylon. It is used for low temperatures and pressures,


pneumatics, chemicals and for insulating electric lines.

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2.12 CUTTING AND FORMING PIPEWORK.

2.12.1 Cutting and joining tubing

Tubing can be cut to length using a tubing cutter or hacksaw. A hacksaw


cannot make as smooth or as straight a cut as a tubing cutter (see figure
2.53).

Figure 2-53

Any rough edges are removed with a de-burring tool. When the tubing is
cut to length it can be joined to another piece.

Joining tubing.

Common fittings used for joining tube are as follows:

 Soldered fittings.

 Compression fittings.

 Flared fittings.

2.12.2 Bending and forming tube

One of the main advantages of tube is that we can bend it. This reduces
the number of fittings that are required.

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There are two common types of benders, they are:

 Hand bender. This is used for small size tubing (see figure 2.54).

Figure 2-54

 Hydraulic bender. This is used for heavier or larger diameter tube


(see figure 2.55).

Figure 2-55

A bending exercise with a hand bender.

A hand bender is for light gauge copper pipe up to 25 mm (1") bore, or


carbon steel pipe up to 12 mm ( 1/2") bore. The pipe is bent around
formers. Formers vary in size to suit the wall thickness and bore of the
pipe. The width of the groove in the former must be the same as the
diameter of the pipe.

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The depth of the groove depends on the type of back guide or sleeve
used (see figure 2.56).

Figure 2-56

To set up the bender, firstly, lock the selected former in position. This is
done by passing a pin through the bending arm and the body of the
machine (see figure 2.57).

Figure 2.57

Fit the back stop to the stop bar of the machine, this holds the pipe in
position while it is being bent round the former (see figure 2.58).

Figure 2.58

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Place the pipe in the machine by passing it through the bending arm.
Make sure the pipe is sat in the groove of the former and against the back
stop (see figure 2.59).

Figure 2-59

Fit the back guide or sleeve over the back of the pipe. Then hand tighten
the bending arm adjusting screw until the bending arm roller contacts the
sleeve. This will hold it in position.

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Then tighten the bending arm lock nut using the correct size spanner (see
figure 2.60).

Figure 2-60

Take up a comfortable position with one foot in front of the other. This
will make sure the body is properly balanced. Then bend the pipe by
pulling the bending arm towards the body (see figure 2.61).

Figure 2-61

The sleeve bends the pipe round the former as the bending arm is pulled
forward.

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The back stop holds the tail of the pipe in position during the bending
operation (see figure 2.62).

Figure 2-62

To avoid faulty bends, always make sure to use the correct size former
and sleeve to suit the dimensions of the pipe (see figure 2.63).

Figure 2-63

A bending exercise with a hydraulic bender.

A hydraulic bending machine is used for bending larger cold pipes.

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To carry out a bending exercise with a hydraulic bender, screw the


forming head onto the hydraulic cylinder (see figure 2.64).

Figure 2-64

Place the machine on the ground. The forming head has holes that are
marked to show the nominal bore sizes of pipes (see figure 2.65).

Figure 2-65

Select the correct size former to suit the outside diameter of the pipe.

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Formers are available for standard pipe from 12 mm ( 1/2") to 50 mm (2")


bore (see figure 2.66).

Figure 2-66

Fit the former onto the cylinder ram (see figure 2.67).

Figure 2-67

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Place the pipe between the forming head plates and against the former
(see figure 2.68).

Figure 2-68

Support the pipe while fitting the dollies (or rollers) between the upper
and lower plates of the forming heads. Then secure them in position by
passing the pins through the plates and the dollies. The dollies
themselves fit into holes in the plates that suit the size of pipe (see figure
2.69).

Figure 2-69

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Close the pressure release valve on the pump body (see figure 2.70).

Figure 2-70

Start pumping to push the former against the pipe (see figure 2.71).

Figure 2-71

Stop pumping when the pipe has been bent to the required angle. Then
turn the pressure release valve anti-clockwise to release the pressure in
the hydraulic cylinder. When the ram has moved back about 6 mm ( 1/4")
to 10 mm (3/8") close the pressure release valve to hold the ram steady.

Check the accuracy of the bend. Then open the pressure release valve
to allow the ram to return to the start position. The machine can now be
disassembled and stored away in the correct place.

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Cutting pipe threads.

A mechanical technician must know how to cut pipe threads. This is


because pipes are required with threads in a variety of lengths. It would,
therefore, be impossible for the manufacturer to standardise the sizes.

A ratchet and die stock is a common tool used for cutting threads. It is
adjustable so that threads can be cut on pipe from 1/2" to 9" diameter (see
figure 2.72).

Figure 2-72

A ratchet diestock has a set of four dies for each size of standard pipe.
Each die is clearly marked with the thread type, the range of pipe it is
suitable for, and an identification number (see figure 2.73).

Figure 2-73

PIPEWORK PAGE 44 OF 45
DATE OF ISSUE 20/07/01 REVIEW DATE GB/09/05/03
ZADCO - AHRT

These types of dies must always be stored as a set. If dies get mixed up
the thread will be ruined.

Assembling the diestock.

Slacken off the tightening nut and turn the face of the diestock anti-
clockwise until it is fully open. There are four slots inside the diestock that
are numbered 1 to 4. Fit each die into the slot with the corresponding
number, with the numbered face upwards (see figure 2.74).

Figure 2-74

PIPEWORK PAGE 45 OF 45
DATE OF ISSUE 20/07/01 REVIEW DATE GB/09/05/03

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