Equalizer FA1TM Operator's Instruction Manual

OPERATOR INSTRUCTION MANUAL

FA1TM

FLANGE
ALIGNMENT
TOOL

EQUALIZER INTERNATIONAL LTD

www.equalizerinternational.com

OPERATOR INSTRUCTION MANUAL

CONTENTS

1. INTRODUCTION

2. TOOL SAFETY

2.1 GENERAL SAFETY

2.2 PERSONNEL COMPETENCY

2.3 DISCLAIMER

2.4 DEFINITION OF TERMS

2.5 HAZARDS

3. FLANGE MISALIGNMENT DETERMINATION PROCEDURE

3.1 LATERAL MISALIGNMENT

4. FA1TM MECHANICAL FLANGE ALIGNMENT TOOL

4.1 TOOL CAPABILITIES

4.2 RANGE OF APPLICATION

4.3 TOOL FUNCTION

4.4 KIT CONTENTS

4.5 TOOL DIMENSIONS

4.6 TOOL MAINTENANCE

5. RANGE OF APPLICATION

5.1

5.2 ASME B16.5, ASME B16.47, DIN WELD NECK
FLANGE TABLES

5.3 SPO FLANGE TABLE

BS10, API6BX, API6B WELD NECK FLANGE TABLES

IM_FA1TM_Rev08_A4

6. TROUBLESHOOTING

6.1 FA1TM TROUBLESHOOTING

7. REGULATORY INFORMATION

7.1 REGISTERED HEAD OFFICE

8. PARTS LISTS & SERVICE KITS

31/10/2018

FA1TM

1

FLANGE ALIGNMENT TOOL

OPERATOR INSTRUCTION MANUAL

IM_FA1TM_Rev08_A4

1.

INTRODUCTION

The Equalizer FA1TM TOOL is an aid of use in
normal maintenance and installation procedures to

enable the realignment of misaligned anges within
respective working capacities. For example, the tool

can be used to assist in the replacement of ring and

other types of ange joint.

The use of these instructions will promote safe use,
and maximise the service life of the tools.

It is essential that the user familiarises themselves

with the contents of this manual prior to using the

tool.

This manual contains information for the following

tools:

• FA1TM Flange Alignment Tool

2.

SAFETY INFORMATION

2.1

GENERAL SAFETY

These instructions cover the safe operation and
maintenance of THE EQUALIZER FA1TM FLANGE
ALIGNMENT tools. The use of these tools should be as

part of a broader task-based risk assessment, which

should be carried out by the operation supervisor or
other competent person.

Failure to comply with the safety information
contained within this manual could result in personal
injury or equipment damage. Read all instructions,
warnings and cautions carefully, and follow all safety

precautions.
The safety of the operator, any assisting personnel

and the general public is of paramount importance.

Always work in accordance with applicable national,
local, site & company-wide safety procedures.

2.2

PERSONNEL COMPETENCY

Only personnel deemed competent in the use of
mechanical and hydraulic equipment should use
these tools.

2.3

DISCLAIMER

Equalizer cannot be held responsible for injury or
damage resulting from unsafe product use, lack of

maintenance or incorrect product and/or system
operation. If in doubt as to the safety precautions
and applications, contact Equalizer using the contact

details at the back of this manual.

FA1TM

2

FLANGE ALIGNMENT TOOL

OPERATOR INSTRUCTION MANUAL

IM_FA1TM_Rev08_A4

2.4

DEFINITION OF TERMS

A CAUTION is used to indicate correct operating or
maintenance procedures and practices to prevent damage
to, or destruction of equipment or other property.

A WARNING indicates a potential danger that requires

correct procedures or practices to avoid personal injury.

A DANGER is only used when your action or lack of action

may cause serious injury or even death.

DO: an illustration showing how the tool should

be used.

DON’T: an illustration showing an incorrect way

to use a tool.

WARNING: Applying pressure to a damaged
hose may cause it to rupture.

WARNING: Immediately replace worn or

damaged parts. Use only genuine Equalizer parts
from approved distributors or service centres.
Equalizer parts have been engineered and

manufactured to be t-for-purpose.

DANGER: To minimise risk of personal injury keep
hands and feet away from the tool and workpiece

during operation.

WARNING: Always wear suitable clothing and

Personal Protective Equipment (PPE). Do not

handle pressurised hoses; escaping oil under
pressure can penetrate the skin, causing serious
injury. Seek medical attention immediately if oil

penetration is suspected.

WARNING: Only pressurize complete and fully
connected hydraulic systems. Do not pressurize
systems that contain unconnected couplers.

2.5

HAZARDS

WARNING: ensure all hydraulic components are

rated to a safe working pressure of 700

000 psi

(10

WARNING: Do not overload equipment. The risk

of hydraulic overloading can be minimised by using

the Equalizer Hand Pump, which has a factory-set
safety valve preventing the safe working pressure
being exceeded.

If alternative hydraulic pumps are used, ensure
that there are adequate systems to limit the the

working pressure to 700 bar (10,000 psi).

CAUTION: ensure components are protected

from external sources of damage, such as excessive
heat, ame, moving machine parts, sharp edges

and corrosive chemicals.

CAUTION: Take care to avoid sharp bends and
kinks in hydraulic hoses. Bends and kinks can
cause severe back-up pressure and cause hose
failure. Protect hoses from dropped objects; a

sharp impact may cause internal damage to hose

wire strands. Protect hoses from crush risks, such
as heavy objects or vehicles; crush damage can

cause hose failure.

CAUTION: Do not lift hydraulic equipment by the
hoses or couplers. Use only the designated carrying
handles.

bar

).

CAUTION: Lubricate tools as directed in this
manual prior to operation. Use only approved

lubricants of high quality, following the lubricant

manufacturers instructions.

CAUTION: Only use the designated anchor point

for xing the lanyard. Do not attach the lanyard to

the plastic handle.

DANGER: Care should be taken when using the
lanyard to avoid entanglement with body parts.

The vibration total value to which this tool is

subjected does not exceed 2.5 m/s

2

.

FA1TM

3

FLANGE ALIGNMENT TOOL

OPERATOR INSTRUCTION MANUAL

3.

FLANGE MISALIGNMENT
DETERMINATION
PROCEDURE

The tool being used must not be attached to a

anged joint prior to the misalignment procedure

being carried out.

3.1

LATERAL MISALIGNMENT

1. Loosen and remove every second bolt around

the ange. Continue with this until misalignment

occurs.

IM_FA1TM_Rev08_A4

A anged joint, once broken down, may spring

out of alignment at any point or in any direction
around its circumference. Misalignment may not

occur until only a few bolts remain.

2. At this point the direction of any misalignment
should become obvious. The alignment tool

being used should be attached at the maximum

point of misalignment (point A or B in the

examples shown below).

POINT A

POINT B

POINT A

POINT B

FA1TM

4

FLANGE ALIGNMENT TOOL

OPERATOR INSTRUCTION MANUAL

4.

FA1TM

MECHANICAL FLANGE
ALIGNMENT TOOL

The FA1TM Flange Alignment Tool uses mechanical torque

to advance the screw bolt and align the anges.

4.1

TOOL CAPABILITIES

Maximum aligning force of tool = 1 T (10 kN)

4.2

IM_FA1TM_Rev08_A4

4.3

FA1TM TOOL FUNCTION

FA1TM GENERAL GUIDANCE

1. The FA1TM is secured to the lower of the

two anges by fully inserting the lift hool
into the bolt-hole at the point of greatest

misalignment.

2. The drop leg release knob is slackened and

the drop leg is adjusted down to the pipe
while the tool is held level in the bolt-hole.

3. The drop leg release knob is then tightened

until rm.

4. The strap and buckle are attached to the drop
leg and around the pipe for added
security.

5. The crank handle is then turned clockwise

until the driven wedge comes into contact

with the circumference of the opposite ange.

RANGE OF APPLICATION

MINIMUM AND MAXIMUM FLANGE SIZES

Dimension A: must be between 14 mm and

82 mm (0.55” and 3.23”).

Dimension B: bolt-hole diameter must be 16 mm

(0.63”) or greater

DIMENSION

A

DIMENSION

B

CRANK

HANDLE

RELEASE

KNOB

MINI

RATCHET &

STRAP

DRIVEN
WEDGE

FA1TM

5

FLANGE ALIGNMENT TOOL