Equalizer FA1TM Operator's Instruction Manual

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OPERATOR INSTRUCTION MANUAL

FA1TM

FLANGE ALIGNMENT TOOL

EQUALIZER INTERNATIONAL LTD

www.equalizerinternational.com

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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

FLANGE ALIGNMENT TOOL

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OPERATOR INSTRUCTION MANUAL

IM_FA1TM_Rev08_A4

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

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

FLANGE ALIGNMENT TOOL

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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

FA1TM

FLANGE ALIGNMENT TOOL

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OPERATOR INSTRUCTION MANUAL

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

FLANGE ALIGNMENT TOOL

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OPERATOR INSTRUCTION MANUAL

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

CRANK

HANDLE

RELEASE

KNOB

MINI

RATCHET &

STRAP

DRIVEN WEDGE

FA1TM

FLANGE ALIGNMENT TOOL

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ACTUATING THE FA1TM

OPERATOR INSTRUCTION MANUAL

Rotate the crank handle clockwise until the driven wedge makes contact with the opposite ange.

IM_FA1TM_Rev08_A4

Carry out the Flange Misalignment Determination Procedure (see Section 3) to determine the points of

maximum misalignment.

In this example the points of maximum misalignment are the top and bottom of the joint.

POINT OF MAX. MISALIGNMENT

POINT OF MAX.

MISALIGNMENT

CRANK

HANDLE

DRIVEN WEDGE

OPPOSITE FLANGE

Thread the strap through the aperture on the base

of the drop leg as shown.

STRAP

APERTURE

Guide the lift hook into the bolt-hole at the point of maximum misalignment.

Adjust the drop leg down onto the pipe by slackening the release knob in an anticlockwise direction.

The tool should be held up level within the bolt-hole during adjustment. NB: The tool must be parallel to

pipe during operation.

LIFT HOOK

RELEASE

PARALLEL

KNOB

DROP LEG

The drop leg release knob is then tightened until rm.

STRAP

Feed the open end of the strap through the buckle mechanism as shown.

Close the clasp to secure strap.

FEED THROUGH

STRAP

FA1TM

FLANGE ALIGNMENT TOOL

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OPERATOR INSTRUCTION MANUAL

IM_FA1TM_Rev08_A4

Now that everything is secured, rotate the handle clockwise to apply pressure to the circumference of the opposite ange & bring the ange joint in

alignment.

WARNING: Do not exceed hand pressure on

the crank handle

Once in alignment the bolts may be inserted and tightened. After replacing all of the bolts (apart from

the bolt which will go into the bolt-hole in which the

FA1TM is located) remove the tool by reversing the previous steps. Insert the last bolt and tighten.

4.4

FA1TM KIT CONTENTS

Product Code: FA1TMSTD

1 x FA1TM Tool 1 x Mini Ratchet Strap 1 x Instruction Manual

Box Dimensions:

180.0mm x 330.0mm x 220.0mm

(7.1” x 13.0” x 8.7”)

Tool only Weight: 2.1 kg (4.63 lb) Gross Kit Weight: 2.3 kg (5.07 lb)

WARNING: Care should be taken not to drop

any of the component parts when removing them from the ange joint. This action will prevent injuries to either the operator’s lower

limbs, or to passers-by.

FA1TM

FLANGE ALIGNMENT TOOL

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OPERATOR INSTRUCTION MANUAL

IM_FA1TM_Rev08_A4

4.5

FA1TM TOOL DIMENSIONS

MINIMUM EXTENSION

151 mm

(5.94”)

50 mm (1.97”)

MAXIMUM EXTENSION

54 mm (2.13”)

31 mm (1.22”)

38 mm (1.50”)

4.6

FA1TM TOOL MAINTENANCE

INSPECTION

A thorough inspection should be carried out prior to usage, storage or transportation to ensure the completeness and condition of the tool.

Inspection should include:

• visual inspection of the outer parts of the tool,

checking for obvious damage, degradation or

missing parts.

Cleaning and servicing should be undertaken as

required prior to the tool being used, stored or transported.

CLEANING

To lightly clean the tool, wipe gently with a damp

cloth.

194 mm

(7.64”)

50 mm (1.97”)

89 mm

(3.50”)

21 mm (0.83”)

72 mm (2.83”)

5 mm (0.2”)

82 mm (3.23”)

If more thorough cleaning is required (for example following immersion in water) carry out the following

cleaning procedure:

• strip the tool down, observing the schematics in

section 8

• clean the components using detergent, following

the manufacturer’s guidelines

• rinse the components to remove traces of

detergent

• dry the component thoroughly

Inspect, service and lubricate the tool immediately after the cleaning process.

SERVICING

Replace missing, 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.

FA1TM

35 mm (1.38”)

Grease all moving parts by following the Lubrication

Procedure prior to usage, storage or transportation.

Ensure wedges, pins and legs remain grit free and

that parts move freely.

FLANGE ALIGNMENT TOOL

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OPERATOR INSTRUCTION MANUAL

Secure the tool upright on a bench.

Using a small at screwdriver, lever out one circlip and unscrew 6 x 6mm hex screws.

Remove cover plate and remov e any dirt or corrosion from moving parts.

Inspect components for wear and damage, replace if

necessary! If there’s no damage present, then they

can be greased and re-assembled by reversing the

previous steps. Recommended grease –

Rocol Sapphire Hi-Load or equivalent good quality hi

load bearing grease.

COVER

PLATE

HEX

SCREW

DRIVEN

WEDGE

CIRCLIP

DRIVING

WEDGE

NEEDLE

BEARINGS

IM_FA1TM_Rev08_A4

STORAGE AND TRANSPORTATION

Equalizer tools should be stored in a cool, dry

place. Tools should always be cleaned, serviced and

lubricated prior to storage. Ensure that tools are

stored in their designated packing cases.

LONG-TERM STORAGE - MAINTENANCE PLAN

1. Rub components down with a dry cloth to remove

moisture.

2. Coat EVERY surface and contact point with a corrosion

inhibitor. Where necessary, coat inside and outside of component

3. Nuts and threads must also be coated with a corrosion

inhibitor.

4. Once surfaces have been coated, seal individual

components in clear plastic bags or clear vacuum

bags or clear shrink wrap. NOTE: bags/shrink wrap must be clear for visibility. Take care when using shrink wrap that the tool is/

components are still easy to see.

5. Remove all or, where not vacuum sealed, as much air

from bags as possible.

6. Once bags have been closed and sealed DO NOT re-

open. Any visual inspections must be done with closed

and sealed bags. If bags are opened the components

will have to be dried, re-coated and re-sealed in bags/ shrink wrap.

7. Replace silica gel (100g) EVERY TIME the case is

opened. NOTE: depending on moisture content of air, silica gel

should be changed weekly.

8. Visually inspect kits after 30-days and every 30-days

thereafter. Remember to replace silica gel before closing case.

FA1TM

FLANGE ALIGNMENT TOOL

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CLASS

20K

TOOL FA4TM FA9TE

NPS 1 13-16" 2 1-16" 2 9-16" 3 1-8" 4 1-16" 5 1-8" 7 1-16" 9" 11" 13 5-8" 16 3-4"

CLASS

15K

TOOL FA1TM FA4TM FA9TE

NPS 1 13-16" 2 1-16" 2 9-16" 3 1-8" 4 1-16" 5 1-8" 7 1-16" 9" 11" 13 5-8" 16 3-4"

CLASS

10K

TOOL FA1TM FA4TM FA9TE

OPERATOR INSTRUCTION MANUAL

API6BX WELD NECK FLANGE RANGE OF APPLICATION

NPS 1 13-16" 2 1-16" 2 9-16" 3 1-8" 4 1-16" 5 1-8" 7 1-16" 9" 11" 13 5-8" 16 3-4"

CLASS T TOOL FA1TM FA4TM FA9TE NOT SUITABLE FOR TOOLS

NPS

CLASS S TOOL FA1TM FA4TM FA9TE SUITABLE FOR FA4TM TOOL

NPS

CLASS R

TOOL FA1TM FA4TM FA9TE

NPS

CLASS K TOOL FA1TM FA4TM FA9TE

NPS

CLASS J TOOL FA1TM FA4TM FA9TE

NPS

CLASS H

TOOL FA1TM FA4TM

NPS

CLASS F TOOL FA1TM FA4TM FA9TE

NPS

CLASS E TOOL FA1TM FA4TM FA9TE

NPS

CLASS D

TOOL FA1TM FA4TM FA9TE

IM_FA1TM_Rev08_A4

5.1 BS10 FLANGE RANGE OF APPLICATION

CLASS A TOOL FA1TM FA1TM FA4TM FA4TM

NPS

5. RANGE OF APPLICATION

1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 4 1/2" 5" 6" 7" 8" 9" 10" 11" 12" 13"

1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 4 1/2" 5" 6" 7" 8" 9" 10" 11" 12" 13" 14" 15" 16"

1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 7" 8" 9" 10" 12" 13" 14" 15" 16" 17" 18" 19" 20"

1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 7" 8" 9" 10" 12" 13" 14" 15" 16" 17" 18" 19" 20" 21" 22" 23" 24"

1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 7" 8" 9" 10" 12" 13" 14" 15" 16" 17" 18" 19" 20" 21" 22" 23" 24" 27" 29" 30" 33" 35" 36" 39" 42" 45" 48"

4" 5" 6" 7" 8" 9" 10" 12" 13" 14" 15" 16" 17" 18" 19" 20" 21" 22" 23" 24" 29" 30" 33" 35" 36" 39" 42" 45" 48" 54" 60" 66" 72" 78" 84" 96" 108" 120"

3 1/2" 4" 5" 6" 7" 8" 9" 10" 12" 13" 14" 15" 16" 17" 18" 19" 20" 21" 22" 23" 24" 26" 27" 29" 30" 33" 35" 36" 39" 42" 45" 48" 54" 60" 66" 72"

CLASS

TOOL FA1TM FA4TM FA9TE

NPS 2 1-16" 2 9-16" 3 1-8" 4 1-16" 5 1-8" 7 1-16" 9" 11" 13 5-8" 16 3-4" 21 1-4"

CLASS

TOOL FA1TM FA4TM FA9TE

NPS 2 1-16" 2 9-16" 3 1-8" 4 1-16" 5 1-8" 7 1-16" 9" 11" 13 5-8" 16 3-4" 21 1-4"

CLASS

TOOL FA1TM FA4TM

API6B WELD NECK FLANGE RANGE OF APPLICATION

NPS 2 1-16" 2 9-16" 3 1-8" 4 1-16" 5 1-8" 7 1-16" 9" 11" 13 5-8" 16 3-4" 21 1-4"

SUITABLE FOR FA9TE TOOL

SUITABLE FOR FA1TM TOOL

FA1TM

FLANGE ALIGNMENT TOOL

Page 12

CLASS PN160

TOOL FA1TM FA4TM FA9TE NOT SUITABLE FOR TOOLS

NPS 3/8" 1/2" 3/4" 1" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" SUITABLE FOR FA9TE TOOL

CLASS

PN100

TOOL FA1TM FA4TM FA9TE SUITABLE FOR FA4TM TOOL

NPS 1/2" 3/4" 1" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" SUITABLE FOR FA1TM TOOL

CLASS

PN64

TOOL FA1TM FA4TM

NPS 3/4" 1" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16"

OPERATOR INSTRUCTION MANUAL

CLASS

PN40

TOOL FA1TM FA4TM

NPS 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16" 18" 20"

CLASS

PN25

TOOL FA1TM FA4TM

NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16" 18" 20" 24" 28" 32" 36" 40"

CLASS

PN16

TOOL FA1TM FA4TM FA9TE

DIN WELD NECK FLANGE RANGE OF APPLICATION

NPS 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16" 18" 20" 24" 28" 32" 36" 40" 48" 56" 72" 80"

CLASS

2500

TOOL FA1TM FA4TM FA9TE

NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16"

CLASS

1500

TOOL FA1TM FA4TM FA9TE

NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16"

CLASS

900

TOOL FA1TM FA4TM FA9TE

NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16"

CLASS

600

TOOL FA1TM FA4TM FA9TE

NPS 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 8" 10" 12" 14" 16"

CLASS

400

TOOL FA1TM FA4TM FA9TE

IM_FA1TM_Rev08_A4

300

NPS 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 8" 10" 12" 14" 16"

CLASS

150

TOOL FA1TM FA4TM

NPS 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 8" 10" 12" 14" 16"

CLASS

TOOL FA1TM FA4TM FA9TE

5.2 ASME B16.5 FLANGE RANGE OF APPLICATION

18" 20" 24"

CLASS

900

TOOL FA9TE

NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48"

18" 20" 24"

CLASS

600

TOOL FA4TM FA9TE

NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48"

18" 20" 24"

CLASS

400

TOOL FA4TM FA9TE

NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48"

18" 20" 24"

CLASS

300

TOOL FA4TM FA9TE

18" 20" 24"

NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48"

CLASS

150

TOOL FA4TM FA9TE

18" 20" 24"

ASME B16.47 FLANGE RANGE OF APPLICATION

NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48"

FA1TM

FLANGE ALIGNMENT TOOL

Page 13

OPERATOR INSTRUCTION MANUAL

IM_FA1TM_Rev08_A4

CLASS 15000

TOOL FA4TM FA9TE NOT SUITABLE FOR TOOLS

NPS 2 1/2” 3” 3 1/2” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24” SUITABLE FOR FA9TE TOOL

CLASS 10000

TOOL FA4TM FA9TE SUITABLE FOR FA4TM TOOL

NPS 2 1/2” 3” 3 1/2” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24” SUITABLE FOR FA1TM TOOL

CLASS

7500

TOOL FA4TM FA9TE

NPS 2 1/2” 3” 3 1/2” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24”

CLASS

5000

TOOL FA4TM FA9TE

NPS 2 1/2” 3” 3 1/2” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24”

CLASS

2500

TOOL FA4TM FA9TE

NPS 2 1/2” 3” 3 1/2” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24”

CLASS

1500

TOOL FA4TM FA9TE