Equalizer TFA12TI, TFA15TI, TFA12TIRD37H, TFA15TIRD37H Operator's Instruction Manual
OPERATOR INSTRUCTION MANUAL
TFA12TI
TFA15TI
TFA12TIRD37H
TFA15TIRD37H
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
INTEGRAL
HYDRAULIC
FLANGE
ALIGNMENT
TOOLS
OPERATOR INSTRUCTION MANUAL
IM_TFA_TI_Rev01_A4
TFA INTEGRAL HYDRAULIC TOOLS
FLANGE ALIGNMENT TOOLS
2
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. TOOL OPERATION
3.1 GENERAL GUIDANCE
3.2 HANDLING
3.3 TOOL INSTALLATION
3.4 ADJUSTMENT LEG
3.5 WING EXTENSION
3.6 CYLINDER ADJUSTMENT SLEEVE
3.7 TOOL CHECKS
3.8 ALIGNMENT
3.9 SECURING THE FLANGE JOINT
4. TOOL MAINTENANCE
4.1 INSPECTION
4.2 CLEANING
4.3 SERVICING
4.4 LUBRICATION PROCEDURE
4.5 STORAGE & TRANSPORTATION
4.6 OPERATING CONDITIONS
4.7 SUB-SEA USAGE
5.
5.1 TOOL CAPABILITIES
5.2 TOOL FUNCTION
5.3 KIT CONTENTS
5.4 DIMENSIONS
6. TROUBLESHOOTING
7. REGULATORY INFORMATION
7.1 REGISTERED HEAD OFFICE
7.2 APPLICABLE PATENT NUMBERS
8. PARTS LISTS & SERVICE KITS
15/06/17
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2.
TOOL SAFETY
2.1
GENERAL SAFETY
These instructions cover the safe operation and
maintenance of THE EQUALIZER RANGE OF TFA
INTEGRAL HYDRAULIC FLANGE ALIGNMENT tools.
The use of any tools should be as part of a broader taskbased 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.
1.
INTRODUCTION
The Equalizer™ range of TFA integral hydraulic ange
alignment tools have been developed to assist in the
aligning of large anges on the inside of large pipes, for
example those which make up the tower sections of a
wind-turbine.
The tools have been designed to cope with the larger
loads and dimensions associated with these ange joints
while remaining relatively lightweight and user-friendly.
It is essential that the users familiarise themselves with
the contents of this manual prior to using the tool.
This manual contains information for the following tools:
• TFA12TI
Integral Hydraulic Flange Alignment Tool
• TFA15TI
Integral Hydraulic Flange Alignment Tool
• TFA12TIRD37H
Integral Hydraulic Flange Alignment Tool
• TFA15TIRD37H
Integral Hydraulic Flange Alignment Tool
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internal damage to hose wire strands. Protect
hoses from crush risks, such as heavy objects
or vehicles; crush damage can cause hose
failure.
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 containt unconnected couplers.
CAUTION: Do not lift hydraulic equipment by
the hoses or couplers. Use only the designated
carrying handles.
CAUTION: Lubricate tools as directed in this
manual prior to operation. Use only approved
lubricants of high quality, following the lubricant
manufacturers instructions.
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.
2.5
HAZARDS
WARNING: ensure all hydraulic components are
rated to a safe working pressure of 700 bar
(10 000 psi).
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
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FLANGE ALIGNMENT TOOLS
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3.2
HANDLING
The tool should be lifted and manouvered using its two
handles.
BACK HANDLE
FRONT HANDLE
3.3
TOOL INSTALLATION
Position the tool into the bolt-hole ensuring that the hook
is fully located into the bolt-hole and the base plate of the
tool is sitting at against the upper ange.
HOOK
BASE PLATE
WING
WING
ADJUSTMENT
ADJUSTMENT LEG
CYLINDER ADJUSTMENT
ALIGNMENT PISTON
3.
TOOL OPERATION
3.1
GENERAL GUIDANCE
Prior to alignment, an assessment should be carried out
to determine the most appropriate positioning of the tool
on the ange joint.
The TFA ange alignment tool should always be installed
in such a way that the lower ange is closer to the user
and the upper ange is further away. The tool is designed
to hook into the bolt-hole of the upper ange and push
the lower ange into alignment.
Prior to installation, ensure the Adjustment Leg and
Cylinder Adjustment Sleeve are fully retracted. Ensure
that the Alignment piston is fully retracted.
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3.6
CYLINDER ADJUSTMENT SLEEVE
The Alignment Piston has a 65 mm stroke. The Cylinder
Adjusment Sleeve extends the reach of the tool to t a
variety of ange sizes, without comprimising its maximum
alignment capacity.
Turn the Cylinder Adjustment Sleeve by the knurled ring
until the Alignment Foot is touching the lower ange.
3.4
ADJUSTMENT LEG
Extend the Adjustment Leg by turning the knurled foot
clockwise until it contacts the pipe wall. Ensure that the
tool is sitting squarely.
3.5
WING EXTENSION
The Alignment Piston is located on an adjustable wing
which can be extended to enable the tool to be used on a
variety of ange sizes.
Use the Wing Extension adjustment knob to lower the
wing until the foot of the Alignment piston is positioned
within the space between the upper and lower faces of
the lower ange.
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3.8
ALIGNMENT
Refer to section 5.2 for tool actuation instructions.
Actuating the tool will extend the Alignment Piston and
align the anges.
3.9
SECURING THE FLANGE JOINT
After the ange joint has been aligned it can be secured
by installing as many bolts as possible into the bolt holes.
It may be necessary to repeat the alignment process
several times while working around the ange joint.
3.7
TOOL CHECKS
Ensure that the tool is sitting square on the
ange, that the wing is parallel to the pipe wall
and that the Adjustment Leg is adjusted prior
to actuating the tool. Actuating the tool when it
is not correctly installed could cause injury or
equipment damage.
Do not allow ngers, hands or other body parts
to come into contact with the ange while
actuating the tool. Only hold the tool by its
designated handles.
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4.3
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.
Grease all moving parts by following the Lubrication
Procedure prior to usage, storage or transportation.
If topping up or replacing hydraulic oil as part of a service,
use only premium quality hydraulic oil of the grade 15 cSt.
4.4
LUBRICATION PROCEDURE
Apply grease following cleaning and servicing, prior to
usage, storage or transportation. Never assemble and
leave a tool without following the greasing procedure as
degradation or damage may occur.
Use only high pressure molybdenum disulphide grease.
Apply grease liberally to the following areas:
• the Adjustment Leg thread
• the Wing Extension thread
• the Cylinder Adjustment thread
ADJUSTMENT
LEG THREAD
CYLINDER
ADJUSTMENT
THREAD
WING
EXTENSION
THREAD
4.
TOOL MAINTENANCE
4.1
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
• visual inspection of the Alignment Piston (requiring
tool actuation). Damage to the Alignment Piston can
be indicative of tool over-load.
Cleaning and servicing should be undertaken as required
prior to the tool being used, stored or transported.
4.2
CLEANING
To lightly clean the tool, wipe gently with a damp cloth.
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 components thoroughly
Inspect, service and lubricate the tool immediately after
the cleaning process.
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4.5
STORAGE & 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.
4.6
OPERATING CONDITIONS
HYDRAULIC TOOLS:
Minimum Flange Contact Temperature: -30 °C (-22 °F)
Maximum Flange Contact Temperature: 70 °C (158 °F)
4.7
SUB-SEA USAGE
Using TFA integral hydraulic tools Sub-Sea
The TFA integral hydraulic tools are actuated by means of
a single-acting spring-return hydraulic cylinder and can be
used sub-sea providing the following actions are taken:
• The pump release valve is fully opened and remains
open until the tool has descended to the working
depth. This will allow the pressure to equalise.
• The tool is actuated via the hand pump by a diver.
• Upon completion of works the release valve is left in
the fully-open position until the tool has ascended to
the surface.
• The tool and pump are stripped-down, cleaned and
lubricated immediately to minimise corrosion.
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