AMEX GmbH

Rondenbarg 16
22525 Hamburg

MANUAL INSTALLATION OF AMEX®-10 Seals

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1.0 OBJECTIVES

To properly install AMEX®-10 internal pipe seals at specified joints and cracks
needing sealing.
The seals will prevent further degradation of piping joints, will maintain system
reliability and will be installed as a corrective/preventive measure. The AMEX®-10
seal consists of a rubber seal secured by metal retaining bands and wedges.

2.0 ACCEPTANCE CRITERIA

Acceptance of Installation and pressure tests is based upon inspection and approval
by the client. DOCUMENT all required inspection results on Form 1.

3.0 REFERENCES

3.1 AMEX GmbH Drawing No………..

3.2 AMEX GmbH Drawing No………..

4.0 SITE CONDITIONS

Note

The following site conditions do note have to be exist in the sequence listed

4.1 This procedure shall be performed while the pipe is out of service and
adequate safety barrier has been erected.

4.2 All supplied tools and equipment are available. All required pressure
gauges have been callbrated and verified by owner.

4.3 All approvals which cover the scope of work to be performed inside the
pipe have been processed.

4.4 All lines have been emptied and are at atmospheric pressure

4.5 Access to the lines has been provided

4.6 All consumables (i.e. hydraulic, oil, lubricants, thread sealers, markers etc.)
have been approved by the owner.

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 4.7 Verify the hydraulic expander has been provided for use in expanding the
retaining bands.

4.8 Continous forced air ventilation has been established and is sufficient to
maintain the confined space safe for entry.

_____________________________________
Signature / Supervisor

5.0 PRECAUTION

If any unanticipated or unexpected alarm, noise, vibration, odour or excessive

leakage is observed, personnel shall immediately exit and remain outside the
confined space until the reason is identified and rectified.

6.0 PROCEDURE

6.1 VERIFY all preconditions have been fulfilled and the necessary
precautions have been taken care of.

________________________________
Signature / Supervisor

6.2 PERFORM and inspection of pipe interior. Review all seal installation
locations, paying particular attention to those at bends, to verify that the
pipe/fitting geometry will allow AMEX®-10 seal installation. REPORT any
discrepancies to the client for decision.

6.3 REMOVE dirt, scale, and other debris from the pipe, walls in the area
where the seal is to be installed. These cleaning operations shall be
accomplished by hand brushing and scraping, pneumatic wire brushes,
and/or oil-free air jet.

6.4 MARK the locations of the lip seals on the pipe wall with an approved
marker to clearly define the seal installation position.

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6.5 ALL high/low surface unevenness (i.e., dirt, scale, and other debris)
running axially through or part way through the sealing surface must be
removed prior to installation of the seal.

6.6 VERIFY that the seating surface of the lip seal is free of dirt, scale, and
other debris.

6.7 LUBRICATE the prepared seal area with approved lubricant. The lubricant
supports the fitting of the AMEX-10 seal; it does not reduce the pressure to
the retaining bands.

6.8 POSITION the seal parallel to the joint gap with the pressure test valve
located at approximately either the 9 o’clock position or the 3 o’clock
position. The seal must be positioned accurately on the joint areas.

6.9 INSTALL shims underneath the wedge area in the seal grooves for each
band prior for installing the metal retaining bands in the seal. The shims
enable radial loads to be transmitted evenly to the AMEX®-10 seal as the
retaining bands are expanded.

6.10 POSITION the retaining bands in the seal grooves of the AMEX®-10
seal.

6.11 POSITION the AMEX® Hydraulic Expander in line with the retaining
band and ENSURE that the retaining band remains in the groove.
Install safety bar and screw tight.

6.12 EXPAND the retaining bands using the hydraulic expander,

6.13 INSTALL a wedge in the exposed gap between the expanded bands
ends. The wedge size shall be selected to fit exactly into the existing
space.

6.14 REPEAT steps 6.11 through 6.13 for the second retaining band on the
same seal.

6.15 PERFORM a second expansion of each of the retaining bands a

minimum of 30 minutes after the first expansion using the same pressure
range as the first expansion. Replace wedge place with larger size if
required to provide exact.

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6.16 PERFORM a pressure test on the seal sections after a minimum of 30
minutes has elapsed after final fitting of the seal to be tested. Pipeline
Verifier to verify minute minimum and document on Form 1.A
restraining device (the retaining band) called a “test band” is to be fitted
over the center of the seal. This will prevent excessive ballooning that
would otherwise occur during this test.

6.16.1 Install test band and press to 0,5 up to 0,8 bar through the seal
test valve and apply an approved liquid to the seal ends.

6.16.2 If the pressure test indicates leakage, determine cause and

repeat steps 6, 5 and higher. In the event of a second pressure
test failure, notify client for evaluation and direction before
additional work on the failed seal.

6.17 PERFORM a second test at a lower pressure with the test band
removed.

6.17.1 Remove test band and press to 0,3 up to 0,5 bar through test
valve. Apply and approved test liquid to entire surface of the
seal. This lower pressure leak test is primarily used to check for
seal defects such as seal punctures.

6.17.2 If the pressure test indicates leakage notify client. After receipt of
client approval, remove seal and replace with a now seal
beginning at Step 7,5, or as otherwise directed by the client.

6.18 DEPRESSURIZE seal and isolate test valve. The end cap has to be
fitted by using an approved sealing compound. All installation equipment
including the test band and pressure gauges have to be removed from the
pipe.

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 FORM 1
AMEX®-10 SEAL INSTALLATION VERIFICATION FORM

SEAL NUMBER Supervisor’s Signature DATE

ITEM TO BE VERIFIED
Seal surface of pipe has been smoothed
and is free of debris
The AMEX®-10 Seal is positioned lip
seals do not rest on pipe joint
Retaining Bands 1 and 2 Band 1 / Band 2
Record time of first expansion. Time / Time

Retaining Band 1 and 2 Band 1 / Band 2

Record time of second expansion and Time / Time
verify a minimum of 30 minutes has
elapsed since the first expansion.
Retaining Bands 1 and 2 Band 1 / Band 2
Was a larger wedge installed? (Yes/No / Yes/No)

Retaining Bands 1 and 2

Hydraulic expander pressure maintained
in correct range.
Verify that a minimum of 30 minutes has
elapsed since the second expansion.
Seal is pressurized to 0,5 – 1,0 bar
during leak test of seal ends.
No leakage as indicated by bubbling is
observed at seal ends.
Seal is pressurized 0,5 – 1,0 during leak
test of seal surface.
No leakage as indicated by bubbling is
observed at seal surface.
Seal is depressurized and test valve
threaded plug has been installed and
sealed.
All installation equipment testing band
and pressure gauges have been
removed.

Date: Signature / Supervisor:

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 Hydraulic expansion pressures

DN 500 – DN 600: 185 bar

DN 700 – DN 1100: 260 bar

DN 1200 – upwards: 275 bar

This calculation is based on the assumption, that the pipe and the retaining
bands have been lubricated and on an even load around the inner surface of
the pipe. Despite the size and the thickness of the material the hydraulic
expansion of the retaining bands required, because of the cold flow of the
seal, a slow expansion speed. The hydraulic pressure must be increased
slowly to take the cold flow of the seal into account.

Differences in temperature have the following effect to the expansion speed:

the colder the seal is the slower is the cold flow.

The expansion pressure has always to be increased slowly until the maximum
allowed gauge pressure has been reached.

Mark the pressure rating on two – pieced and three – pieced retaining bands.
The pressure rating should also been marked on the wedges.
 Checklist AMEX®-10

Check: GERNAL EQUIPMENT Check: DN – EQUIMENT

Electric aggregate 5 KVA Scrapers/pigs

Electric aggregate mobile Tail sheave
Electric fan Chain rotation head
Air fan Suction funnel
Water pump/hose Special grinder
Suction pump/suction hose Pressing device
Water separation container
Winch MATERIAL
Electric pipe trolley
Pipe trolley measuring wheel/measuring Seals retaining bands
tape Wedges
Air grinder Shims
Hydraulic expander and piston Valves
Box for wedges
Test instrument and hose CONSUMABLES
Pressure recorder and diagrams
Torch Intertol 1
Head torch Javel water
Knee- and elbow protection Cloth, paper, plastic sheeting
Protective mask Rubbish bags
Ladders Gloves
Tent/tarpaulin Grinding discs
Umbrella Knifes/blades
Water/diesel container Oil binder
Tool box, complete Scotch tape
Saw, shovel, broom Testing soap
Batteries/charging unit Marking spray/penetrating oil
Compressed air bottles Marking chalk
Soap towel
 AMEX-10@t-online.de
http://www.AMEX-10.de

MEASUREEMENT OF QUANITIES

Client

Order / Street

Line from to

Material

Length

Date

Signature Client
 “AMEX®-10- Report (Joint Chart)”

AMEX-10@t-online.de
http://www.AMEX-10.de

JOINT CHART
Site…………………………………………………………………………………………….
Line…………………………………………………………………………………………….
DN…………………………………………………………………………………………….
Length…………………………………………………………………………………………
Number of
joints……………………………………………………………………………………………
Process………………………………………………………………………………………
Plan

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26

27 28 29 30 31 32 33 34 35

36 37 38 39 40 41 42 43 44

45 46 47 48 49 50 51 52 53

54 55 56 57 58 59 60 61 62

63 64 65 66 67 68 69 70 71

Unusual feature

Date: Signature: