Equalizer international Equalizer fa1tm Assembly instructions

FA1TM

FLANGE ALIGNMENT

TOOL

Operator Instruction Manual

[email protected]

www.equalizerinternational.com

INNOVATION IN ITS MOST FUNCTIONAL FORM

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 1

SECTION CONTENTS PAGE NO.

1 INTRODUCTION 2

2 SAFETY INFORMATION 2 - 3

3 TECHNICAL DATA 4

3.1 KIT COMPONENTS 4

3.2 HOW THE FA1TM WORKS

4 FLANGE MISALIGNMENT DETERMINATION PROCEDURE 5

4.1 LATERAL MISALIGNMENT 5

5FA1TM MECHANICAL FIXED FLANGE & ROTATIONAL ALIGNMENT TOOL

5.1 INSTALLATION & OPERATION 6 - 7

5.2 EXAMINATION & STORAGE 8

5.3 MAINTAINANCE 8

5.4 PARTS LIST 9

5.5 WEIGHTS & DIMENSIONS 10

5.6 TROUBLESHOOTING 11

5.7 APPLICATION DIMENSIONS 11

6 RANGE OF APPLICATION

6.1 BS10, API6BX UND API6B FLANGE TABLES 12

6.2 ASME B16.5, B16.47 AND DIN WELD NECK FLANGE TABLES 13

6.3 SPO FLANGE TABLE 14

INDEX

FA1TM IM_REV 04_29/10/2012

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 2

The Equalizer FA1TM TOOL is an aid of use in normal maintenance and installation proce-

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For example, the tool can be used to assist in the replacement of ring and other types of

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life of the tools.

1. INTRODUCTION

2. SAFETY INFORMATION

The operator MUST read this maual prior to using the tools.

Failure to comply with the following cautions and warnings could cause equipment

damage and personal injury; read the manual fully!

Read all the following instruction, warnings and cautions carefully. Follow all safety precautions

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SURGXFWXVHODFNRIPDLQWHQDQFHRULQFRUUHFWSURGXFWDQGRUV\VWHPRSHUDWLRQ&RQWDFW(TXDO-

izer International Ltd when in doubt as to the safety precautions and applications.

Only people competent in the use of mechanical and hydraulic equipment should use these

tools.

In all installations the site safety requirements must be adhered to. ALSO the 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.

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ALIGNMENT TOOL, during normal maintenance/installation operations.

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FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 3

ACAUTION is used to indicate correct operating or maintenance procedures and practices to

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A WARNINGLQGLFDWHVDSRWHQWLDOGDQJHUWKDWUHTXLUHVFRUUHFWSURFHGXUHVRUSUDFWLFHVWRDYRLG

SHUVRQDOLQMXU\

A DANGERLVRQO\XVHGZKHQ\RXUDFWLRQRUODFNRIDFWLRQPD\FDXVHVHULRXVLQMXU\RIHYHQGHDWK

IMPORTANT: Operator must be competent in

the use of hydraulic equipment. The operator

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safety issues, cautions and warnings before stat-

ing to operate the Equalizer equipment.

WARNING: 7RDYRLGSHUVRQDOLQMXU\DQGSRVVL-

EOHHTXLSPHQWGDPDJHPDNHVXUHDOOK\GUDXOLF

FRPSRQHQWV DUH UDWHG WR D VDIH ZRUNLQJ SUHV-

sure of 700bar (10,000psi)

WARNING:'RQRWRYHUORDGHTXLSPHQW2YHU-

loading causes equipment failure and possible

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WKH\DUHUDWHGDWDVDIHZRUNLQJSUHVVXUHEDU

(10,000psi)

CAUTION: 0DNHVXUHWKDWDOOV\VWHPFRPSR-

nents are protected from external sources of

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LQJ PDFKLQH SDUWV VKDUS HGJHV DQG FRUURVLYH

chemicals.

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ZLOO FDXVH VHYHUH EDFNXS SUHVVXUH LQ KRVHV

%HQGVDQGNLQNVOHDGWRSUHPDWXUHKRVHIDLOXUH

'RQRWGURSKHDY\REMHFWVRQWRKRVHV$VKDUS

impact may cause internal damage to hose wire

strands; applying pressure to a damaged hose

PD\ FDXVH LW WR UXSWXUH 'R QRW SODFH KHDY\

ZHLJKWV RQ WKH KRVHV RU DOORZ YHKLFOH WR UROO

RYHUWKHKRVHVFUXVKGDPDJHZLOOOHDGWRSUH-

mature hose failure.

WARNING: Immediately replace worn

or damaged parts with genuine Equal-

izer parts. Equalizer parts are designed to

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(TXDOL]HUGLVWULEXWRURUVHUYLFHFHQWUH

DANGER: 7R DYRLG SHUVRQDO LQMXU\ NHHS

hands and feet away from the tool and

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WARNING: Always wear suitable clothing

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DANGER: Do not handle pressurised hos-

es. Escaping oil under pressure can pene-

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LQMHFWHGXQGHUWKHVNLQVHHNPHGLFDODWWHQ-

tion immediately.

WARNING:1HYHUSUHVVXUL]HXQFRQQHFWHG

couplers. Only use hydraulic equipment in

a connected system.

IMPORTANT: Do not lift hydraulic equip-

ment by the hoses or couplers. Use the car-

rying handle or other means of safe trans-

port.

CAUTION: Do not operate the equipment

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section 5.4, 6.4 & 7.4. Use only high pres-

sure molybdenum disulphide grease.

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 4

3. TECHNICAL DATA

Tool Description Aligning Force

FA1TM Mechanical

Fixed Flange Alignment Tool 7N1

3.1 KIT COMPONENTS

1 x FA1TM Tool

1 x Ratchet & Strap

1 x Instruction Manual

Product Code: FA1TMSTD

3.2 HOW THE FA1TM WORKS

1. 7KH)$70LVVHFXUHGWRWKHORZHURIWKHWZRÀDQJHVE\IXOO\LQVHUWLQJWKHOLIWKRRN

into the bolt-hole at the point of greatest misalignment.

2. 7KHGURSOHJWKXPEVFUHZLVVODFNHQHGDQGWKHGURSOHJLVDGMXVWHGGRZQWRWKHSLSH

 ZKLOHWKHWRROLVKHOGOHYHOLQWKHEROWKROH

3. 7KHGURSOHJWKXPEVFUHZLVWKHQWLJKWHQHGXQWLO¿UP

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

security.

5. 7KHVFUHZKDQGOHLVWKHQWXUQHGFORFNZLVHXQWLOWKHGULYHQZHGJHFRPHVLQWRFRQWDFW

 ZLWKWKHFLUFXPIHUHQFHRIWKHRSSRVLWHÀDQJH

DRIVEN

WEDGE

SCREW HANDLE

THUMB SCREW

BUCKLE & STRAP

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 5

4. FLANGE MISALIGNMENT DETERMINATION

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procedure being carried out.

4.1 LATERAL MISALIGNMENT

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alignment occurs.

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direction around its circumference. Misalignment may not occur until only a few bolts

remain.

2. $WWKLVSRLQWWKHGLUHFWLRQRIDQ\PLVDOLJQPHQWVKRXOGEHFRPHREYLRXV7KHDOLJQPHQW

tool being used should be attached at the maximum point misalignment (point A or

point B in the examples shown below) as shown in sections 5.3, 6.3 & 7.3.

POINT A

POINT B POINT A

POINT B

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 6

1. Carry out the Flange Misalignment

Determination Procedure

(see section 4) to determine the points

of maximum misalignment.

In this example, the points of

maximum misalignment are at the top

 DQGERWWRPRIWKHMRLQW

2. *XLGHWKHOLIWKRRNLQWRWKHEROWKROHDW

the point of maximum misalignment.

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 E\VODFNHQLQJWKHWKXPEVFUHZLQDQ

 DQWLFORFNZLVHGLUHFWLRQ

 7KHWRROVKRXOGEHKHOGXSOHYHOZLWKLQ

 WKHEROWKROHGXULQJDGMXVWPHQW

NB: The tool must be parallel to pipe

during operation.

3. 5RWDWHWKHVFUHZKDQGOHFORFNZLVHXQWLO

 WKHGULYHQZHGJHPDNHVFRQWDFWZLWK

 WKHRSSRVLWHÀDQJH

4. Thread the strap through the aperture

on the base of the drop leg as shown.

POINT OF MAXIMUM

MISALIGNMENT

DROP LEG

SCREW

HANDLE

THUMB SCREW

5.1 INSTALLATION AND OPERATION

LIFT HOOK

DRIVEN

WEDGE

OPPOSITE FLANGE

STRAP

APERTURE

5. FA1TM MECHANICAL FIXED FLANGE ALIGNMENT TOOL

PARALLEL

POINT OF MAXIMUM

MISALIGNMENT

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 7

5. )HHGWKHRSHQHQGRIWKHVWUDSWKURXJKWKHEXFNOHPHFKDQLVPDVVKRZQ

Close the clasp to secure strap.

6. 1RZWKDWHYHU\WKLQJLVVHFXUHGURWDWHWKHKDQGOHFORFNZLVHWRDSSO\SUHVVXUH

 WRWKHFLUFXPIHUHQFHRIWKHRSSRVLWHÀDQJHEULQJWKHÀDQJHMRLQWLQ

alignment.

FEED THROUGH

STRAP

Do not exceed hand pres-

sure on the screw handle

7. 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

 ORFDWHGUHPRYHWKHWRROE\UHYHUVLQJVWHSV,QVHUWWKHODVWEROWDQGWLJKWHQ

&DUHVKRXOGEHWDNHQQRWWRGURSDQ\RIWKHFRPSRQHQWSDUWVZKHQUHPRYLQJ

WKHPIURPWKHÀDQJHMRLQW7KLVDFWLRQZLOOSUHYHQWLQMXULHVWRHLWKHUWKH

operator’s lower limbs, or to passers-by.

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 8

1 2QUHWXUQIURRPHDFKMREEHIRUHDOORFDWLRQDJDLQVWVXEVHTXHQWZRUNWKH

 FRPSOHWHQHVVRIWKH(TXDOL]HU)$70NLWPXVWEHHVWDEOLVKHGDQGLWHPVH[DPLQHGWR

 HQVXUHWKDWWKH\DUHVHUYLFHDEOH

2Any missing or damaged items are to be replaced as soon as possible and prior to the

tool being used again.

3Store the FA1TM in a cool, dry place and ensure all machined surfaces are greased.

4 (QVXUHZHGJHVSLQVDQGOHJVUHPDLQJULWIUHHDQGWKDWSDUWVPRYHIUHHO\

5.2 EXAMINATION & STORAGE

5.3 MAINTENANCE

1Secure the tool upright on a bench.

28VLQJDVPDOOÀDWVFUHZGULYHUOHYHURXWRQHFLUFOLSDQGXQVFUHZ[PPKH[VFUHZV

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4Inspect components for wear and damage, replace if necessary! If there is no damage

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Recommended grease –

5RFRO6DSSKLUH+L/RDGRUHTXLYDOHQWJRRGTXDOLW\KLORDGEHDULQJJUHDVH

CIRCLIP

NEEDLE

BEARINGS

COVER PLATE

HEX SCREW

DRIVING

WEDGE

DRIVEN

WEDGE

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 9

NO. PART NO DESCRIPTION QTY.

1 070280-01 BODY PLATE STICKER LEFT 1

2 070281-01 BODY PLATE STICKER RIGHT 1

3 210100-01 DRIVING WEDGE 1

4 210200-01 BODY FRAME 1

5 210300-01 DRIVEN WEDGE 1

6 210400-01 DRIVE SCREW 1

7 210500-01 COVER PLATE LEFT 1

8 210501-01 COVER PLATE RIGHT 1

9 210600-01 CRANK HANDLE 1

10 210700-01 SPRING PIN 1

11 210800-01 TORSION SPRING 1

12 210900-01 NEEDLE BEARING 4

13 211100-01 BEARING SHAFT 4

14 211200-01 SPRING MANDREL 1

  0[PP6RFNHW)O6FUHZ  

16 211600-01 DISTANCE PLATE 1

17 211800-01 DROP LEG 1

18 211900-01 LEG PIN 8mm 1

19 212000-01 SPRING RING 8mm 2

20 212200-01 LEG PLASTIC INSERT 1

21 230203-01 M6 RELEASE KNOB 1

22 771801-01 M6 HEX NUT 1

23 220800-01 RATCHET STRAP 1

5.4 PARTS LIST

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 10

5.5 WEIGHTS & DIMENSIONS

WEIGHTS

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5DWFKHWVWUDS NJOEV

 *5266.,7:(,*+7     NJOEV

DIMENSIONS

MINIMUM EXTENSION

MAXIMUM EXTENSION

37 mm

(1.46”)

38 mm

(1.50”)

54 mm

(2.13”)

50 mm

(1.99”)

151 mm

(5.94”)

72 mm

(2.83”)

21 mm

(0.83”)

91 mm

(3.58”)

50 mm

(1.99”)

35 mm

(1.38”)

37 mm

(1.46”) 11 mm

(0.43”)

82 mm

(3.23”)

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 11

0,1,080$1'0$;,080)/$1*(6,=(6

Dimension A: must be between 14 and 82mm (0.55” and 3.29”).

Dimension B: bolt-hole diameter must be 16mm (0.63”) or greater

5.6 TROUBLESHOOTING

3UREOHP7KHWRROLVDWWDFKHGDQGDSSHDUVWREHIXQFWLRQLQJSURSHUO\EXWWKHMRLQWZLOOQRWDOLJQ

There may be something restricting

WKHMRLQJIURPDOLJQLQJ

&KHFNWKHDUHDDURXQGWKHMRLQWWRHVWDEOLVKLIWKHUHLVDQREVWUXFWLRQ

WRWKHMRLQW

7KHMRLQWPD\UHTXLUHPRUHWKDQ

WN1IRUFHWRDOLJQ

,IWKHMRLQWUHTXLUHVPRUHIRUFHWKDQWKDWRIWKH7N1WRRODW-

tach a second too or another method of aligning should be adapted.

5.7 APPLICATION DIMENSIONS

DIMENSION

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 12

6.1 BS10 FLANGE RANGE OF APPLICATION

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 FA1TM FA1TM FA4TM FA4TM

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 FA1TM FA4TM FA9TE

CLASS E

NPS 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"

TOOL FA1TM FA4TM FA9TE

CLASS F

NPS 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"

TOOL FA1TM FA4TM FA9TE

CLASS H

NPS 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"

TOOL FA1TM FA4TM

CLASS J

NPS 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"

TOOL FA1TM FA4TM FA9TE

CLASS K

NPS 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"

TOOL FA1TM FA4TM FA9TE

CLASS R

NPS 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"

TOOL FA1TM FA4TM FA9TE

CLASS S

NPS 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" SUITABLE FOR FA1TM TOOL

TOOL FA1TM FA4TM FA9TE SUITABLE FOR FA4TM TOOL

CLASS T

NPS 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" SUITABLE FOR FA9TE TOOL

TOOL FA1TM FA4TM FA9TE NOT SUITABLE FOR TOOLS

API6BX WELD NECK FLANGE RANGE OF APPLICATION

CLASS

10K

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 FA1TM FA4TM FA9TE

CLASS

15K

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 FA1TM FA4TM FA9TE

CLASS

20K

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 FA4TM FA9TE

API6B WELD NECK FLANGE RANGE OF APPLICATION

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 FA1TM FA4TM

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 FA1TM FA4TM FA9TE

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 FA1TM FA4TM FA9TE

6. RANGE OF APPLICATION

FLANGE ALIGNMENT TOOLS

OPERATOR INSTRUCTION MANUAL PAGE 13

6.2 ASME B16.5 FLANGE RANGE OF APPLICATION

CLASS

150

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" 18" 20" 24"

TOOL FA1TM FA4TM

CLASS

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" 18" 20" 24"

TOOL FA1TM FA4TM FA9TE

CLASS

400

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" 18" 20" 24"

TOOL FA1TM FA4TM FA9TE

CLASS

600

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" 18" 20" 24"

TOOL FA1TM FA4TM FA9TE

CLASS

900

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" 18" 20" 24"

TOOL FA1TM FA4TM FA9TE

CLASS

1500

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" 18" 20" 24"

TOOL FA1TM FA4TM FA9TE

CLASS

2500

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" 18" 20" 24"

TOOL FA1TM FA4TM FA9TE

ASME B16.47 FLANGE RANGE OF APPLICATION

CLASS

150