Enerpac Atm-4 User manual

L4063 Rev. B 09/19

Instruction Sheet

Hydraulic Flange Alignment Tool

Model ATM-4

Paragraph page

1.0 .Receiving instructions ..............................................2

2.0 .Safety Issues .................................................................2

3.0 .Product Description...................................................2

4.0 .Safety Information - ATM-4 ....................................3

5.0 .Misalignment Determination Procedure...........3

6.0 .Installation and Operation......................................4

7.0 .Rotational or Twist Misalignment ........................5

8.0 .Vertical Operation ......................................................6

9.0 .Dismantling the ATM-4 ............................................6

10.0 .Inspection and Examination...................................6

11.0 . Storage ...........................................................................6

12.0 .Lubrication and Maintenance................................6

13.0 .Troubleshooting .........................................................7

14.0 .Application Dimensions...........................................7

15.0 .Range of Application Tables ...............................8-10

16.0 .Weights and Dimensions....................................... 11

1.0 RECEIVING INSTRUCTIONS

Visually inspect all components for shipping damage.

Shipping damage is not covered by warranty. If

shipping damage is found notify carrier at once. The

carrier is responsible for all repair and replacement

costs resulting from damage in shipment.

safety first

Read all instructions, warnings and cautions carefully.

Follow all safety precautions to avoid personal

injury or property damage during system operation.

Enerpac cannot be responsible for damage or

injury resulting from unsafe product use, lack of

maintenance or incorrect product and/or system

operation. Contact Enerpac when in doubt as to the

safety precautions and applications.

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.

2.0 SAFETY ISSUES

Failure to comply with the

following cautions and warnings

could cause equipment damage

and personal injury.

IMPORTANT: Minimum age of the

operator must be 18 years. The operator

must have read and understood all

instructions, safety issues, cautions and warnings

before starting to operate the Enerpac equipment.

The operator is responsible for this activity towards

other persons.

CAUTION: Make sure that all system

components are protected from external

sources of damage, such as excessive

heat, flame, moving machine parts, sharp edges and

corrosive chemicals.

WARNING: Immediately replace worn or

damaged parts with genuine Enerpac

parts. Enerpac parts are designed to fit

properly and withstand rated loads.

WARNING: Always wear safety glasses.

The operator must take precaution

against injury due to failure of the tool or

workpiece

We recommend the use of special

loosening liquids or sprays. Enerpac

hydraulic torque wrenches offer both

square and hexagon drive units to loosen or tighten

bolts and nuts. Enerpac offers nut splitters in case a

nut can not be removed.

3.0 PRODUCT DESCRIPTION

The ATM-4 Alignment Tool is intended for use in

typical maintenance and installation procedures. It

allows the realignment of misaligned flanges within

a 4 ton [40 kN] physical capacity. It may be used

to assist in the replacement of ring and other type

joints.

The use of these instructions will promote the safe

use and maximum service life of the tool. All sections

of this instruction sheet should be read prior to using

the tool.

3.1 Applications

The ATM-4 Alignment Tool can be used for:

Flange change outs, repair of pipe lines, replacing

bolts, gaskets and seals and for aligning parts for

fabricating.

3.2 Major Features and Components

See Fig. 1. for an overview of ATM-4 major features

and components.

LIFT HOOK

TORQUE WRENCH

AND 22 mm SOCKET

DROP LEG

Fig. 1

SCREW BOLT

WING RETAINING KNOB

DROP

LEG

KNOB

SWIVEL

3.3 Capacity Information

Maximum Load

Wing Fully Retracted: Wing Fully Extended:

3.0 T [30 kN] from 50

ft-lbs [68 Nm] of torque.

4.0 T [40 kN] from 50

ft-lbs [68 Nm] of torque.

4.0 SAFETY INFORMATION  ATM4

IMPORTANT: In all installations the site safety

requirements must be adhered to and that safety

of the operator and, when present, any assisting

personnel is of paramount importance along with the

safety of others including, when present, the general

public.

These instructions are only to cover the safe

operation of ATM-4 during a normal maintenance /

installation operation. All other safety aspects must

be controlled by the operation supervisor.

CAUTION: The ATM-4 must not be attached

to pressure vessel nozzles.

WARNING: Never attach the ATM-4 to a

joint until after the flange bolts have been

loosened and removed. Overloading may

occur if bolts are removed while the tool is installed,

and the resulting force is greater than the safe

working load of the tool.

5.0 MISALIGNMENT DETERMINATION

PROCEDURE

• The ATM-4 MUST NOT be attached to a flanged

joint prior to the misalignment determination

procedure being carried out. Refer to warning

statement in section 4.0.

• Every second bolt should be loosened and

removed around the flange. Continue with this

procedure. Misalignment may not occur until only

a few bolts remain. At this point the direction of

any misalignment should become obvious.

• The ATM-4, once attached, will directly push

against the misalignment, bringing the joint back

into alignment.

Fig. 2

The ATM-4 should be attached at the maximum

point of misalignment.

Fig. 3

The point of attachment is determined by the

direction of misalignment at its maximum point, i.e.,

X or Y.

Fig. 4

Each of the examples here show where the ATM-4

should be attached.

MAX 45°

Fig. 5

If for some reason attachment at X,Y is obstructed,

two ATM-4’s can be used as illustrated. (see Fig. 5)

but must not be placed more than 45° apart.

6.0 INSTALLATION AND OPERATION

POINT OF MAX.

MISALIGNMENT

POINT OF MAX.

MISALIGNMENT

Fig. 6

1. Determine the maximum points of

misalignment. In the example shown in Fig. 6

example, the maximum points are on the top or

bottom of the joint, as illustrated by the arrows.

2. Guide the lift hook of the tool into the bolt hole at

the maximum point of misalignment. Then, adjust

the drop leg down onto the pipe by turning the

adjusting knob in the clockwise direction (see

Fig.7).

LIFT

HOOK

DROP LEG KNOB

PARALLEL

Fig. 7

Note: The tool should be held up level within the

bolt hole during adjustment. The tool must remain

parallel to the pipe at all times.

Fig. 8

WING RETAINING KNOB

SCREW

BOLT

SWIVEL

3. Loosen the wing retaining knob and extend the

wing over to the opposite flange. Then, rotate the

screw bolt onto the surface of the opposite flange

(See Fig.8).

Ensure that tool is sitting level and that the friction

pad on the base of the swivel is in full and even

contact with the surface of the opposite flange.

Fig. 9

BUCKLE

STRAP

RATCHET

4. Attach the hook of the strap through one of the

slots on the buckle (located above the drop leg

pad). Place the hook of the ratchet through the

other slot on the opposite side of the buckle.

Feed the end of the strap through the ratchet and

tighten. (see Fig.9).

Fig. 10

SCREW

BOLT

TORQUE WRENCH

5. Using the supplied torque wrench and 22 mm

socket, tighten the screw bolt in a clockwise

direction until the flanges come into alignment,

and bolts can be inserted. (see Fig.10).

Note: The torque wrench and 22 mm socket supplied

with the tool is preset to apply a maximum force of

50 ft. lbs. [68 Nm].

CAUTION: Only use torque wrench

supplied with ATM-4.

CAUTION: Do not exceed maximum

force rating. Maximum force on screw

bolt is 50 ft. lbs. [68 Nm]. Damage to tool

will result if maximum force rating is exceeded.

CAUTION: Do not use impact tool on

screw bolt. Severe damage to the tool will

result if impact tool is used.

7.0 ROTATIONAL OR TWIST MISALIGNMENT

This is a common problem on both onshore and

offshore pipeline installations (see Fig. 11). Quite

often the flanges are in alignment but the operator is

unable to fit the bolt into any two corresponding bolt

holes on the joint’s circumference.

Fig. 11

Rotational or Twist Misalignment

The ATM-4, within its 4 Ton [40 kN] maximum

capacity, has the ability to manipulate the flanges

in various directions. The setting-up procedure is

the same as before with one possible exception.

The ATM-4 can be attached to the most accessible

point on the joint’s circumference because the

misalignment occurs at all bolt-holes to the same

degree.

The recommended operating procedures are:

1. Select the most convenient or accessible point on

the joint’s circumference and attach the tool there.

(Follow steps 1 thru 4 in paragraph 6.0)

Fig. 12

2. In this situation when both flanges are aligned but

rotational misalignment is present, the ATM-4 is

used to push the flanges out of alignment until

one pair of bolt holes become parallel (see point

A, Fig.12).

Fig. 13

3. Insert the bolt into the bolt-hole at Point A (see

Fig. 13) and then release the ATM-4. The load will

transfer onto the inserted bolt.

4. The ATM-4 can then be attached at another point

on the joint’s circumference (see Fig. 14) pushing

against the inserted bolt. Advance the screw bolt

until another, or all of the bolt-holes are parallel.

Once the remaining bolts are inserted, the ATM-4

can be removed.

Fig. 14

Please note that in some situations the operator may

have to ‘chase’ the misalignment around the joint’s

circumference and attach the ATM-4 at several

different positions to rectify the misalignment. On

each occasion the procedures outlined in steps 1 to

5 in paragraph 6.0 should be followed.

8.0 VERTICAL OPERATION

The set-up and operation of ATM-4 in the vertical

position remains the same as steps 1 thru 5 in

section 6.0 (see Fig. 15).

Fig. 15

USING THE ATM-4 ON A

VERTICAL LINE

9.0 DISMANTLING THE ATM4

• Once alignment is achieved, all work on the joint

finished, and bolt-up completed (apart from the

bolt hole in which the ATM-4 is housed), the tool

can be dismantled by reversing steps 1 thru 5 in

paragraph 6.0.

• Care should be taken not to drop any of the

component parts when removing them from the

aligned joint. This action will prevent injuries to

either the operator’s lower limbs, or to passers-

by.

10.0 INSPECTION AND EXAMINATION

• After finishing the job and before the ATM-4 is

placed back into service,the completeness of the

tool must be established and items examined to

ensure that they are serviceable.

• Any missing or damaged items are to be replaced

as soon as possible and prior to the tool being

used again.

• Grease all moving parts regularly Refer to section

12.0, Lubrication and Maintenance.

• Ensure rollers and pins remain grit free.

• Return all items to the carrying case when not in

use.

11.0 STORAGE

• The ATM-4 should be stored in a cool dry place.

• Machined surfaces are to be smeared with

Mobilgrease XHP ™ 222 Special grease or an

equivalent good quality high load bearing grease.

12.0 LUBRICATION AND MAINTENANCE

Use Mobilgrease XHP ™ 222 Special grease or an

equivalent

good quality high load bearing grease

Maintaining the Tool

Always ensure the screw bolt is lubricated before use.

This will enhance the tool’s performance and lifetime.

On the base of the screw bolt within the swivel

is housed a thrust bearing which should be free

running and lubricated regularly.

Set the torque wrench to the lowest setting after

each use and for storage.

Cleaning and lubrication of internal parts

(see Fig. 16)

STEP 1. Place tool upright on a work bench

STEP 2. Using a flat blade screwdriver, lever out

the end of each spiral clip. Then, rotate

them counter clockwise to remove.

STEP 3. Slide the roller shafts out in order to remove

the rollers and bearings for examination.

STEP 4. Inspect the roller shafts, rollers and bearings

for damage. If there is no damage present,

they can then be cleaned, greased and

reassembled (reverse steps 1 through 3).

Fig. 16

SPIRAL

CLIPS

ROLLER

SHAFT

ROLLER

NEEDLE

BEARING

ROLLER

NEEDLE

BEARING

13.0 TROUBLESHOOTING

PROBLEM 1: THE SCREW BOLT FEELS TIGHT TO

ROTATE.

SOLUTION: Ensure there is grease present on

screw bolt.

PROBLEM 2: THE FRICTION PAD ON THE SWIVEL,

AT THE BASE OF THE SCREW BOLT,

IS ROTATING ON THE FLANGE

CIRCUMFERENCE.

Note: The tool should not be used

if the friction pad is rotating on the

flange circumference.

CAUSE: The swivel bearing is dirty or seized.

SOLUTION: The swivel should be stripped down,

cleaned, greased and reassembled.

If the problem still occurs replace

the swivel assembly (see repair parts

sheet).

PROBLEM 3: THE FRICTION PAD IS SLIDING ON

THE FLANGE CIRCUMFERENCE AS

THE JOINT IS ALIGNING.

CAUSE: Grit or dirt on wing, roller bearings

require greasing. The tool has reached

full extension.

SOLUTION: Ensure the rollers are rotating freely

on the wing of the tool as it extends

out. If they are not, strip tool, clean

and grease rollers and wing. (see

paragraph 12.0, Lubrication and

Maintenance).

If tool has reached full extension, the

joint will most likely be outside of the

ATM-4 range.

PROBLEM 4: THE TOOL IS ATTACHED AND

APPEARS TO BE FUNCTIONING

PROPERLY, BUT THE JOINT WILL

NOT ALIGN.

CAUSE: Hidden obstruction on the joint or

surrounding pipe, the load required to

align the joint is greater than that of

the ATM-4 (i.e. 4 Ton [40 kN]).

SOLUTION: a. Check the area around the joint for

obstructions.

b. It may be that the required pressure

to align the joint is greater that the

4 ton [40 kN] capacity of the tool.

In this instance another method to

align the joint should be adopted.

14.0 APPLICATION DIMENSIONS

Fig. 17

Min. bolt hole size

0.95 inch [24 mm]

Min. distance 1.18 inch [30 mm]

Max. distance 5.23 inch [133 mm]

Hook into this

bolt hole

15.0 RANGE OF APPLICATION TABLES

CLASS A

NPS 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"

TOOL ATM-2 ATM-2

ATM-2

ATM-4 ATM-4

CLASS D

NPS 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"

TOOL ATM-2 ATM-4 ATM-9

CLASS E

NPS 1

1/4"

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS F

NPS 1

1/4"

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS H

NPS 1

1/4"

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"

TOOL ATM-2 ATM-4

CLASS J

NPS 1

1/4"

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS K

NPS 1" 1

1/4"

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS R

NPS 1" 1

1/4"

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS S

NPS 1/2" 3/4" 1" 1

1/4"

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS T

NPS 1/2" 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 3

1/2" 4" 4

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

TOOL ATM-2 ATM-4 ATM-9

CLASS

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS

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"

TOOL ATM-4 ATM-9

CLASS

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"

TOOL ATM-2 ATM-4

CLASS

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"

TOOL ATM-2 ATM-4 ATM-9

CLASS

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"

TOOL ATM-2 ATM-4 ATM-9

BS10 Flange Range of Application

API6BX Weld Neck Flange Range of Application API6B Weld Neck Flange Range of Application

SUITABLE FOR ENERPAC ATM-2 TOOL

SUITABLE FOR ENERPAC ATM-4 TOOL

SUITABLE FOR ENERPAC ATM-9 TOOL

NOT SUITABLE FOR ANY ENERPAC ATM TOOL

Note: Models ATM-2 and ATM-9 shown for reference purposes only.

15.1

15.2 15.3

CLASS

150

NPS 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 3

1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"

TOOL ATM-2 ATM-4

CLASS

300

NPS 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 3

1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"

TOOL ATM-2 ATM-4

CLASS

400

NPS 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 3

1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"

TOOL ATM-2 ATM-4 ATM-9

CLASS

600

NPS 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 3

1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"

TOOL ATM-2 ATM-4 ATM-9

CLASS

900

NPS 1/2" 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"

TOOL ATM-2 ATM-4 ATM-9

CLASS

1500

NPS 1/2" 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"

TOOL ATM-2 ATM-4 ATM-9

CLASS

2500

NPS 1/2" 3/4" 1" 1

1/4"

1/2" 2" 2

1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"

TOOL ATM-2 ATM-4 ATM-9

ASME B16.5 Flange Range of Application

DIN Weld Neck Flange Range of Application

CLASS

150