Opening remarks, introduction and review of objectives  (8.00-810 am)

History of mechanical pipe joining methods: (8:10-8:30)

  Screwed and Coupled
  Lead Joints and Leadite
  Flanged Joints
  Gasket-less joints (Trenton’s “universal” pipe)
  Dresser Couplings
  Pushon, Tyton etc joints
  Hymax Couplings

Pipe Types:  History and Characteristic Traits.  Joining methods (8:30-8:45)

  Steel
  Wrought Iron
  Cast iron Billet Pipe
  Pit Cast Iron
  Centrifugally cast or Spun Cast (DeLavaud process)
  Asbestos-Cement
  Ductile Iron
  PVC
  HDPE

Gasket Theory:                         (8:45-9:15)
   Mechanical considerations
   Durometer scale and reading 
   Geometric shapes vs sealing ability-wedge vs ball vs flat vs O-ring style
   Compostion with respect to chemical resistance
   Composition with respect to leaching of compounds into the water	
   Example comparison of 4 different types of hydrant ball discs
   Calculation of sealing/clamping force from pressure in a hydrant valve
   Cold-flow of gaskets and the importance of proper clamping pressure
   The bell curve of sealing pressure vs cold flow to support the above
   Lubrication…When, where and with what.

Torque:                                  (9:15-9:45)
 Clamping pressure in water distribution is usually related to torque on bolts
 Nut and Bolt theory, and the 50-40-10 rule of torque
 Rolled versus cut threads and their effect on torque
 Platings and coatings and their effect on torque
 Galling in aluminum and stainless nut/bolt systems and how to prevent it
 Lubricants in nut/bolt systems
 The impact of all of the above on proper installation and sealing of joints 
 Torque wrenches and Torque limiting socket extensions
 Try your hand at “guessing the torque”
  
Break Time                 (9:45-10:00)

Stainless steel-         (10:00-10:15)
 History and composition
 Review of galling, 
 Type 304 vs 316 and their applications
 Effect of deoxygenation and the presence of chlorides on stainless

Review of the Dresser Style Coupling  (10:15-10:30)
  Principle and importance of torque and tightening order
  When and with what to lubricate
  Review of manufactures installation instructions
  Size on Size Coupling
  Variable Gland Rings and Gaskets based on OD chart
  Materials 
  Cathodic Protection
  Unbalanced forces that require restraint, with sample calculations

Review of the Hymax Style Coupling    (10:30-10:45)
  A different principle than dresser type couplings
  Principle of operation and gasket geometry
  Torque and bolts on the Hymax
  Review of manufacturers installation instructions
  Deflection limits, and flexiblity
  Unbalanced forces in reducers/transition couplings that need restraint

Stainless Steel Repair Clamps:  (10:45-11:15)

Principle of operation
Mechanical limitations
Gauge of Metal
Welded vs non-welded types
Mat gaskets vs finger joints
Flat gaskets vs Waffle type gaskets
Gasket thickness and durometer rating
Gasket geometry-ridges/surface area/reinforcing materials
Torquing of nuts/studs on band clamps and tightening order
Continuity across ring breaks
Importance of careful handling w/r to passivation of the stainless steel

	
Hands-on demonstrations of couplings and clamps 11:15-11:30

Quiz and evaluation-  11:30-11:45

Total contact time exclusive of break - 3.5 hours

Metallic piping

Steel Pipe –typically 1.2% or less carbon by weight.

Cast Iron-More carbon is added to make the iron flow much easier, and melt at a lower temperature.   This allows more complex shapes to be formed, or cast in moulds.   Carbon content is twice (or more) that of steel.  When the cast iron cools, the carbon tends to collect in a flake structure.   These flakes can make the metal brittle, as they in effect form fault lines in the metal.  When and if the metal fractures, the crack surface is grey in colour.   This is why cast is sometimes referred to as grey iron.  It tends to be quite strong in compression and less so in tension.

Pit cast iron tended to have flaws such as air bubble, diametric differences, and inclusions (impurities) that weaken the pipe.   In addition the flake structure was different in that the graphite flakes were larger, tending to  make the pipe more brittle.

Spun cast iron pipes had fewer defects in general than pit cast pipes, but were still subject to thickness variations, and inclusions from dirty moulds.

See Failures in Gray Cast Iron Distribution  pipes (NRC)

Learning  Objectives  for  this  Course

After this introductory course, the participant should be able to:

1)	Describe the differences between the various types of pipe joining methods used in repair of broken mains
2)	Describe the importance of gasket design and shape in making the seal
3)	Describe the importance of torque in relation to the engineered aspects of modern clamps and couplings
4)	Describe the other factors that affect the making of a proper seal, ie proper selection of lubricants, thread cleanliness, deflection.
5)	Describe the differences in modern repair clamps (bandaids), as opposed to couplings
6)	Demonstrate the ability to properly lubricate, install, and torque down both couplings and clamps.
7)  Corrosion effects with respect to stainless steel, 304 and 316.