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Trouble Shooting How to Recognize Improper Installation May 2009. The Ford Meter Box Company, Inc. Table of Contents Valves and Corp Stops Pages 1 - 20 Tubing and fitting problems Pages 21 - 27 Repair Clamp and FAST Pages 28 - 41 Backup Ring Pages 42 - 44.

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trouble shooting how to recognize improper installation may 2009

Trouble ShootingHow to Recognize Improper InstallationMay 2009

The Ford Meter Box Company, Inc.

Table of Contents

Valves and Corp Stops Pages 1 - 20

Tubing and fitting problems Pages 21 - 27

Repair Clamp and FAST Pages 28 - 41

Backup Ring Pages 42 - 44

NOTE: Do not take apart and inspect - return items to the Ford Quality Assurance Staff in the exact condition that it is received from the field.

why pipe wrenches should not be used
Why pipe wrenches should not be used.

Iron teeth easily distort brass material

Increased torque on wrench handle squeezes jaws more tightly against the valve or fitting.

Typical pipe wrench jaws are 5 to 7 degrees from parallel

slide9
Valve leaks at valve body. Pipe wrench distortions break the machined seal between the valve body and the outlet assembly.

Outlet assembly

Teeth marks from pipe wrench

Should locate smooth jaw wrench on the flat area here

Valve body

valve leaks after backfill a dye test shows a key style corp stop with an arched body
Valve leaks after backfill. A dye test shows a key style corp stop with an arched body.

Incorrect!

Vertical key placement can distort or “arch” the valve when backfilled

No dye = lack of seal because of no key contact

Correct!

Valve installed on its side will absorb higher backfill force

slide11

Valve leaks during pressure test. The grooves (scars) on the key are caused by operating the valve against stones or shavings. This valve was not properly flushed after installation.

slide12
The key port is distorted from a drilling operation that was done with the key not completely open.View 1 of 3
slide13
The key port is distorted from a drilling operation that was done with the key not completely open.View 2 of 3
the machined surface of a key corp body is scored from turning a distorted key view 3 of 3
The machined surface of a key corp body is scored from turning a distorted key. View 3 of 3
slide16

Valve leaks / hard to operate. The key is bulged from the expansion of frozen water. The key was in the closed position when frozen. View 1 of 2

slide17

Valve leaks / hard to operate. The key is bulged from the expansion of frozen water. The key was in the closed position when frozen. View 2 of 2

slide18

Valve appears to be closed but allows water flow. A ball valve not fully closed when the tee-head is in a fully closed position. View 1 of 3

slide19
Valve appears to be closed but allows water flow. Note the twisted tee-head spade due to valve operation while frozen. View 2 of 3
slide20

Valve appears to be closed but allows water flow. The distortion of the ball slot is the result of operating the valve while frozen. View 3 of 3

leaking compression fitting out of round copper tubing can cause a poor gasket seal view 1 of 2
Leaking compression fitting. Out-of-round copper tubing can cause a poor gasket seal. View 1 of 2

Copper Rounding Tool

3/4” - CRT-3

1” - CRT-4

1-1/4” - CRT-5

1-1/2” - CRT-6

2” - CRT-7

leaking compression fitting out of round copper tube compared to a round fitting view 2 of 2
Leaking compression fitting. Out-of-round copper tube compared to a round fitting. View 2 of 2
slide23
Leaks after in service for weeks or months. Deflected copper can cause a poor gasket seal. View 1 of 3
slide24

Leaks after weeks or months - deflected / out of round. The narrowing of the shiny band shows an uneven gasket seal. The leak usually occurs at the most narrow part of the shiny area. View 2 of 3

slide25
Leak. Classic erosion pattern is from water escaping from between the gasket and the copper. View 3 of 3
slide26
Leak. An incomplete insertion of the copper tube into the fitting allows too much deflection. View 1 of 2
slide27
Leak. Part of the gasket was compressed over the end of the tube causing a poor gasket seal. View 2 of 2
slide28

Equal torque must be applied to all bolts/nuts to prevent leak. The wavy side bar shows over-torque. An over-torque can break the weld between the side bar and the band.

slide32
Protrusions on the band show that the finger lugs were placed under the band. Most commonly found on the underside of pipe. View 1 of 2
slide35

This repair clamp was used where a coupling should be installed. The indentations on the band show the end of the pipe. See Catalog Section L for proper applications. View 1 of 2

slide36
This repair clamp was used as a coupling. The indentations on the band show the end of the pipe. Close-up view of band. View 2 of 2
a repair clamp as a transition coupling view 1 of 3
A repair clamp as a "transition" coupling. View 1 of 3

Additional stress on the band-to-sidebar weld at the pipe diameter transition area

PVC pipe side

11.10" (smaller) diameter

Cast iron pipe side

likely 11.60" (larger) diameter

Sidebar

a repair clamp as a transition coupling view 2 of 3
A repair clamp as a "transition" coupling. View 2 of 3

Broken band-to-sidebar weld

PVC pipe side

11.10" (smaller) diameter

Cast iron pipe side

likely 11.60" (larger) diameter

a repair clamp as a transition coupling view 3 of 3
A repair clamp as a "transition" coupling. View 3 of 3

Stud

Lubricant

Lifter Bar

Washer

Sidebars

Set of finger lugs

PVC pipe side

Cast iron pipe side

this 3 piece tapping sleeve leaked because the bottom row of bolts was not torqued
This 3-piece tapping sleeve leaked because the bottom row of bolts was not torqued.

During installation, tighten so the torque and gap are equal. This will prevent leaking.

Unequal gap - no gap on left, large gap on right and bottom nuts not torqued.