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Installation Instructions

GS-Retain Ring Flange System

GS-RR

GS-RETAIN RING FLANGE SYSTEM | Installation Instructions

Table of contents


Introduction 3
Selection of the pipe

Cutting of the pipe 5


Prefabrication of the pipe

Cleaning and protection of pipes

Assembling of parts 8
Connecting the joint 9
During installation 10
Reassembly 11

Appendix 1. Bolt torques (Gleitmo 805)

12

Appendix 2. Bolt torques (Molykote)

13

GS-Hydro | GS-Retain Ring Flange System

Introduction
These are GS-Hydros guidelines for the manufacture and
assembly of the GS-Hydro retain ring system. In the case
of special applications (special sealing arrangements, nonconductive connections, dynamic impulses, high operating
pressures, special materials, etc.) please contact GS-Hydro for
further instructions.In order to achieve the integrity required
in any piping system it is imperative that operators are fully
trained and conversant with the tools and machines to be
used. GS-Hydro can provide training and instruction as well
as installation supervision if required.

Refer to the relevant health and


safety instructions for protective
measures.
Protect yourself always by using
the required personal protective
equipments.

The GS-Hydro retain ring system is primary used for piping


with pressure up to 420 bar. In special applications, the retain
ring system can be used with working pressures as high as 690
bar. Extensive test programs including rigorous vibration
testing have proven the suitability of the retain ring system
for a wide range of different materials and applications.
GS-Hydro solutions are approved by many Classification companies for a wide range of materials and applications.

GS-Retain Ring Flange System (technical data):


SAE 3000

SAE 6000

ISO 6164

pressure, bar

210350

420

210690

size, pipe

26x697x12

26x666x8.5

60.3x11.04355.6x41.4

1/2 3

1/2 2

2 12

size, flange
material, pipe

carbon steel, stainless steel, duplex, super duplex, titanium (materials having elongation above 20 %)

material, flange

electric zinced carbon steel, hot dip galvanized carbon steel, stainless steel or titanium

material, seal

NBR, Viton

material, retain ring

stainless steel AISI 302

GS-Hydro | GS-Retain Ring Flange System

GS-RETAIN RING FLANGE SYSTEM | Installation Instructions

Selection of the pipe


GS-Hydro recommends the use of cold drawn pipes & tubes
due to the inherent quality, (precision dimensions and shape)
and cleanliness (no scale) characteristics. As a comparison, hot
rolled tubes will always have scale both inside and outside
due to the manufacturing process and may not be exactly
round.
GS-Hydros cold forming process ensures there will not be any
scale inside the cold drawn tube after the manufacturing.
Original GS-Hydro high-pressure piping can be recognised
from the marking GS-PIPING along the tube length.
GS-Hydro maintains a large stock of carbon and stainless steel pipes & tubes to be utilised in hydraulic and other
piping systems:
Carbon Steel
Material Specification
Manufacturing Tolerances
Technical Terms of Delivery
Material Specification
Manufacturing Tolerances

DIN 1630

DIN 2391-1

EN 10305-4

DIN 2391-2/C

EN 10305-4

Stainless Steel (mm)

Stainless Steel (sch)

ASTM A269/A213 (A.W.)

ASTM A312

ASTM A269

ASTM A530

All precision steel pipes are supplied with trace numbers.

Always keep the tubes stored indoors away from rain and
moisture. Make sure all the tubes are fitted with plastic plugs
in the ends.

GS-Hydro | GS-Retain Ring Flange System

Cutting of the pipe


Cut tubes squarely by using cold saw. Do not use roller cutter
or grinder.
After cutting the tube, make sure to put a plastic plug in the
tube you do not use.

GS-Hydro | GS-Retain Ring Flange System

GS-RETAIN RING FLANGE SYSTEM | Installation Instructions

Prefabrication of pipes
Always use prefabricated pipes grooved and pipe end
machined in accordance with GS-Hydros procedures.

DAndrea machining head for workshop grooving

GS-Hydro provides various machines for retain ring grooving


operations. GS-Hydro uses GSG-350 special lathe or DAndrea
machining head together with appropriate lathe in order to
guarantee required machining quality and tolerances.

It is not possible to machine


GS-Hydro connections using
a standard lathe.
GSG-350 Special lathe for mass production

Also portable grooving machines are available for on-site


work.

TTS-Portable grooving machine

GS-Hydro | GS-Retain Ring Flange System

Cleaning and protection of pipes


Piping modules are cleaned with a steam wash and...

...protected with oil in order to prevent corrosion during


transportation and storing.
Especially with small size pipes (below 60 mm) it is
recommended also to shoot foam projectiles by means of
compressed air through pipes use Jet Clean, Compri Tube
Clean or respective method.

Prior to shipping the pipe end is carefully plugged.

GS-Hydro | GS-Retain Ring Flange System

GS-RETAIN RING FLANGE SYSTEM | Installation Instructions

Assembling of parts
The cover is removed from the pipe end and the pipe is
cleaned with a doth.

Install the flanges with the retain ring groove facing towards
the end of the pipe.
The original GS-flange has a GS-PIPING -text, marking of
flange type and a charge number for traceability.

Install the retain ring onto the pipe.

Lubricate the bonded seal (dowty seal) with Gleitmo 805


-paste or equivalent.
Control that pipe ends fit together and are aligned for
sealing.
Control that the bolts run free through bolt holes, and
that the flanges are parallel before starting the tightening
sequence.

GS-Hydro | GS-Retain Ring Flange System

Connecting the joint


Verify that you are using the right type and size of bolt.
Always use calibrated torque tools.
For bolt dimensions exceeding M20 we recommend use of
hydraulic torque tool.
Please note that there are two values shown for each bolt
type, one for Gleitmo 805 (Appendix 1, page 10) and one
for MOLYKOTE G-Rapid Plus (Appendix 2, page 11). Torque
tables are only valid for these two lubrication agents.

Inspect the bolts and nuts to ensure no damage.


Lubricate bolt threads amply according to illustration.
Spread evenly with a brush.
Tightening must be done from the bolt side. If in special
case nut is tightened, then the bolt torque values must be
engreased with 5%.

Tighten bolts in diagonal sequence in small increments to

Manual tightening/One hydraulic tool

appropriate torque level. See illustrated example.


1. Tightening of the bolts should start immediately after
greasing of threads
2. Tighten lightly with a wrench.
3. Tighten crosswise with 30% of the recommended torque.
4. Tighten crosswise with 70% of the recommended torque.
5. Tighten crosswise with 100% of the recommended torque.
Repeat this step until all bolts stand still with full torque
applied. Minimum 2 full cycles.

Two hydraulic tools

GS-Hydro | GS-Retain Ring Flange System

GS-RETAIN RING FLANGE SYSTEM | Installation Instructions

Tighten bolts in diagonal sequence in small increments to


appropriate torque level. See illustrated example.
1. Tightening of the bolts should start immediately after
greasing of threads
2. Tighten lightly with a wrench.
3. Tighten crosswise with 50% of the recommended torque.
4. Tighten crosswise with 100% of the recommended torque.
Repeat this step until all bolts stand still with full torque
applied. Minimum 2 full cycles.

We recommend that all bolt torques are checked immediately


after pressure test at least 10%
of connections must be verified.
We also recommend that after
1 - 2 weeks of system operation,
bolt torques of all connections
are verified.

During installation
After each tightening sequence ensure that flanges are at
90 degrees to the pipe and that the gap between flanges is
equal to (x=y) 1 mm.
Also, verify that the bolts protrude 12 threads from the nut.

10

GS-Hydro | GS-Retain Ring Flange System

Four hydraulic tools

Reassembly
Ensure that all pressure is bled out from the system.

DO NOT take for granted that


there is no pressure in the
system, all connections must be
disassembled with great caution.
Please check that all relevant HSE
regulations are followed.
Loosen bolts a quarter of a turn in a crosswise pattern similar
to assembly. Repeat until all pretension of bolts is released.
Continue disassembly until the flange can be moved. Ensure
that no pressure is left in the system and the clamping of
bonded seal is released. Take out the bolts and carefully take
the connection apart.
Check all sealing surfaces and ensure no damages.
Seal all parts that are not to be reassembled immediately.
If temporary storage is required, make sure parts are protected
from environmental influences.
We recommend that all soft seals are replaced before
reassembly.
If the time in operation have been short, and no damage can
be seen on the seals, they might be used again.
When the connection is to be assembled again please follow
procedure for connecting the joint step by step. Use the
correct bolt torque from tables in appendix 1.

GS-Hydro | GS-Retain Ring Flange System

11

GS-RETAIN RING FLANGE SYSTEM | Installation Instructions

Appendix 1. Bolt Torques for Gleitmo 805 -grease


Metric connections
SAE 50 bar
Size

Flange Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

HDG 8.8bolts

1 1/2

124

M12x70

x40

36 Nm

43 Nm

132

M12x70

x40

36 Nm

43 Nm

2 1/2

140

M12x70

x40

36 Nm

43 Nm

148

M16x80

x50

50 Nm

60 Nm

3 1/2

156

M16x90

x50

50 Nm

60 Nm

164

M16x90

x50

63 Nm

76 Nm

180

M16x120

x60

92 Nm

76 Nm

196

M16x110

x60

81 Nm

97 Nm

228

M20x120

x70

118 Nm

142 Nm

10

260

M20x140

x80

166 Nm

199 Nm

SAE 3000 psi


Size

Flange Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

ANSI 36.19 connections


SAE 3000 psi
Size

Flange Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

1/2

308

M8x60

x35

22 Nm

27 Nm

1/2

308/21.3

M8x60

x35

22 Nm

27 Nm

3/4

312

M10x60

x35

23 Nm

28 Nm

3/4

312/26.7

M10x60

x35

23 Nm

30 Nm

316

M10x60

x35

31 Nm

37 Nm

316/33.4

M10x60

x35

31 Nm

37 Nm

1 1/4

320

M10x70

x35

40 Nm

48 Nm

1 1/4

320/42.2

M10x70

x35

40 Nm

48 Nm
54 Nm

1 1/2

324

M12x80

x45

45 Nm

54 Nm

1 1/2

324/48.3

M12x80

x45

45 Nm

332

M12x90

x50

53 Nm

64 Nm

332/60.3

M12x90

x50

53 Nm

64 Nm

2 1/2

340

M12x110

x60

69 Nm

83 Nm

2 1/2

340/73.0

M12x110

x60

69 Nm

83 Nm

348

M16x140

x80

137 Nm

165 Nm

348/88.9

M16x140

x80

137 Nm

165 Nm

SAE 6000 psi


Size

Flange Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

SAE 6000 psi


Size

Flange Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

1/2

608

M8x60

x35

22 Nm

27 Nm

1/2

608/21.3

M8x60

x35

22 Nm

27 Nm

3/4

612

M10x70

x40

28 Nm

30 Nm

3/4

612/26.7

M10x70

x40

25 Nm

30 Nm

616

M12x70

x45

41 Nm

49 Nm

616/33.4

M12x70

x45

41 Nm

49 Nm

1 1/4

620

M14x90

x50

59 Nm

70,8 Nm

1 1/4

620/42.2

M14x90

x50

59 Nm

70,8 Nm

1 1/2

624

M16x100

x60

95 Nm

106 Nm

1 1/2

624/48.3

M16x100

x60

88 Nm

106 Nm

632

M20x110

x70

114 Nm

137 Nm

632/60.3

M20x110

x70

114 Nm

137 Nm

2 1/2

640

M24x140

x90

227 Nm

272 Nm

2 1/2

640/73

M24x140

x90

169 Nm

203 Nm

648

M30x160

x100

359 Nm

426 Nm

648/88.9

M30x160

x100

311 Nm

370 Nm

DIN 350400 bar

Bolt DIN 912, 8.8

Size

Flange Type

Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

DIN 350400 bar

Bolt DIN 912, 8.8

Size

Flange Type

Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

432

M16x110

x60

95 Nm

107 Nm

432/60.3

M16x110

x60

95 Nm

107 Nm

2 1/2

440

M20x120

x70

158 Nm

190 Nm

2 1/2

440/73.0

M20x120

x70

140 Nm

168 Nm

448

M24x140

x80

311 Nm

373 Nm

448/88.9

M24x140

x80

287 Nm

345 Nm

456

M30x160

x100

511 Nm

614 Nm

456/114.3

M30x160

x100

511 Nm

614 Nm

4 1/2

860

M20x140

x80

183Nm

220 Nm

864/141.3

M24x160

x100

340 Nm

408 Nm

864

M24x160

x100

362 Nm

435 Nm

864/139.7

M24x160

x100

340 Nm

408 Nm

880

M30x220

x130

590 Nm

644 Nm

880/168.3

M30x220

x130

590 Nm

644 Nm

896

M36x210

x130

1247 Nm

1360 Nm

888/219.1

M30x220

x130

886 Nm

966 Nm

10

8160

M36x280

x180

977 Nm

1066 Nm

10

8160

M36x280

x180

977 Nm

1066 Nm

12

8192/323.9

M36x320

x180

1280 Nm

1396 Nm

14

8224/355.6

M39x360

x220

1249 Nm

1362 Nm

ELZ = Zinc electroplated coating


HDG = Hot dip galvanised coating
Torque values are with a tolerance of 0...5% .
(Note! The torque values of 340-flanges shall not be exceeded).

12

Bolt Torque
ELZ 8.8bolts

GS-Hydro | GS-Retain Ring Flange System

Appendix 2. Bolt Torques for MOLYKOTE G-Rapid Plus -grease


Metric connections
SAE 50 bar
Size

Flange
Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

SS A4-80 bolts

1 1/2

124

M12x70

x40

33 Nm

36 Nm

50 Nm

132

M12x70

x40

33 Nm

36 Nm

50 Nm

2 1/2

140

M12x70

x40

33 Nm

36 Nm

50 Nm

148

M16x80

x50

45 Nm

50 Nm

58 Nm

3 1/2

156

M16x90

x50

45 Nm

50 Nm

68 Nm

164

M16x90

x50

57 Nm

63 Nm

72 Nm
106 Nm

180

M16x120

x60

83 Nm

92 Nm

196

M16x110

x60

73 Nm

81 Nm

94 Nm

228

M20x120

x70

107 Nm

118 Nm

136 Nm

10

260

M20x140

x80

150 Nm

166 Nm

238 Nm

SAE 3000 psi


Size

Flange
Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

ANSI 36.19 connections


SAE 3000 psi

SS A4-80 bolts

Size

Flange
Type

Bolt DIN 912, 8.8

Bolt Torque

Flange to
flange

Flange to
block

ELZ 8.8bolts

HDG 8.8bolts

SS A4-80 bolts

1/2

308

M8x60

x35

20 Nm

22 Nm

20 Nm

1/2

308/21.3

M8x60

x35

22 Nm

17 Nm

20 Nm

3/4

312

M10x60

x35

21 Nm

23 Nm

28 Nm

3/4

312/26.7

M10x60

x35

25 Nm

25 Nm

30 Nm

316

M10x60

x35

28 Nm

31 Nm

38 Nm

316/33.4

M10x60

x35

31 Nm

31 Nm

38 Nm

1 1/4

320

M10x70

x35

36 Nm

40 Nm

49 Nm

1 1/4

320/42.2

M10x70

x35

40 Nm

40 Nm

49 Nm

1 1/2

324

M12x80

x45

41 Nm

45 Nm

61 Nm

1 1/2

324/48.3

M12x80

x45

45 Nm

49 Nm

61 Nm

332

M12x90

x50

48 Nm

53 Nm

72 Nm

332/60.3

M12x90

x50

53 Nm

57 Nm

72 Nm

2 1/2

340

M12x110

x60

63 Nm

69 Nm

87 Nm

2 1/2

340/73.0

M12x110

x60

63 Nm

69 Nm

87 Nm

348

M16x140

x80

124 Nm

137 Nm

158 Nm

348/88.9

M16x140

x80

137 Nm

115 Nm

158 Nm

SS A4-80 bolts

Size

Flange
Type

SAE 6000 psi


Size

Flange
Type

Bolt DIN 912, 8.8


Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

SAE 6000 psi

Bolt DIN 912, 8.8

Bolt Torque

Flange to
flange

Flange to
block

ELZ 8.8bolts

HDG 8.8bolts

SS A4-80 bolts

1/2

608

M8x60

x35

20 Nm

22 Nm

20 Nm

1/2

608/21.3

M8x60

x35

22 Nm

17 Nm

20 Nm

3/4

612

M10x70

x40

26 Nm

28 Nm

35 Nm

3/4

612/26.7

M10x70

x40

25 Nm

25 Nm

30 Nm

616

M12x70

x45

37 Nm

41 Nm

55 Nm

616/33.4

M12x70

x45

41 Nm

44 Nm

55 Nm

1 1/4

620

M14x90

x50

54 Nm

59 Nm

84 Nm

1 1/4

620/42.2

M14x90

x50

59 Nm

59 Nm

84 Nm

1 1/2

624

M16x100

x60

86 Nm

95 Nm

111Nm

1 1/2

624/48.3

M16x100

x60

88 Nm

74 Nm

102 Nm

632

M20x110

x70

103 Nm

114 Nm

160 Nm

632/60.3

M20x110

x70

114 Nm

112 Nm

160 Nm

2 1/2

640

M24x140

x90

204 Nm

288 Nm

288 Nm

2 1/2

640/73

M24x140

x90

152 Nm

215 Nm

215 Nm

648

M30x160

x100

326 Nm

359 Nm

471 Nm

648/88.9

M30x160

x100

282 Nm

311 Nm

409 Nm

DIN 350400 bar

Bolt DIN 912, 8.8

Size

Flange
Type

Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

DIN 350400 bar

HDG 8.8bolts

SS A4-80 bolts

Bolt DIN 912, 8.8

Size

Flange
Type

Flange to
flange

Flange to
block

Bolt Torque
ELZ 8.8bolts

HDG 8.8bolts

SS A4-80 bolts

432

M16x110

x60

87 Nm

95 Nm

130 Nm

432/60.3

M16x110

x60

87 Nm

95 Nm

130 Nm

2 1/2

440

M20x120

x70

143 Nm

158 Nm

226 Nm

2 1/2

440/73.0

M20x120

x70

126 Nm

140 Nm

197 Nm

448

M24x140

x80

280 Nm

311 Nm

392 Nm

448/88.9

M24x140

x80

259 Nm

287 Nm

362 Nm

456

M30x160

x100

460 Nm

511 Nm

667 Nm

456/114.3

M30x160

x100

460 Nm

511 Nm

667 Nm

4 1/2

860

M20x140

x80

165 Nm

183Nm

194 Nm

864/141.3

M24x160

x100

306 Nm

340 Nm

405 Nm

864

M24x160

x100

326 Nm

362 Nm

431 Nm

864/139.7

M24x160

x100

306 Nm

340 Nm

405 Nm

880

M30x220

x130

536 Nm

536 Nm

700 Nm

880/168.3

M30x220

x130

536 Nm

536 Nm

700 Nm

896

M36x210

x130

1133 Nm

1133 Nm

1577 Nm

888/219.1

M30x220

x130

805 Nm

805 Nm

1117 Nm

10

8160

M36x280

x180

888 Nm

888 Nm

1162 Nm

10

8160

M36x280

x180

888 Nm

888 Nm

1162 Nm

12

8192/323.9 M36x320

x180

1163 Nm

1163 Nm

1613 Nm

14

8224/355.6 M39x360

x220

1135 Nm

1135 Nm

1704 Nm

ELZ = Zinc electroplated coating


HDG = Hot dip galvanised coating
SS = Stainless steel
Torque values are with a tolerance of 0...5% .
(Note! The torque values of 340-flanges shall not be exceeded).

GS-Hydro | GS-Retain Ring Flange System

13

GS-RETAIN RING FLANGE SYSTEM | Installation Instructions

Notes

14

GS-Hydro | GS-Retain Ring Flange System

Notes

GS-Hydro | GS-Retain Ring Flange System

15

GS-Hydro is the worlds leading supplier of complete non-welded piping solutions, with numerous benefits for a wide range of demanding applications.

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MED 96/98/EC
PED 97/23/EC

RR

37

90

Headquarters in Finland: GS-Hydro Oy, Lautatarhankatu 4, FI-13110 Hmeenlinna, FINLAND


tel. +358 3 65 641, fax +358 3 653 2768, e-mail sales@gshydro.com
Please view our web site to find GS-Hydro in Your region www.gshydro.com
leak-free reliable highest level of cleanliness small space requirement prefabrication fast and easy on-site installation zero-fire hazard

8990306501 GS-Retain Ring Installation Instructions, EN-2 March 2015

GS-Hydro is the worlds leading supplier of innovative, non-welded piping solutions for hydraulic, and other both low and
high pressure applications with high demands on quality, reliability and cleanliness. Global GS-Hydro network helps customers
to grow their business by offering high quality products and comprehensive services.