Equalizer TFA12TE Assembly instructions

OPERATOR INSTRUCTION MANUAL
TFA12TE
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
EXTERNAL
HYDRAULIC
FLANGE
ALIGNMENT
TOOL

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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. TFA12TE
5.1 TOOL CAPABILITIES
5.2 TOOL FUNCTION
5.3 KIT CONTENTS
5.4 TOOL DIMENSIONS
6. TROUBLESHOOTING
6.1 TFA12TE TROUBLESHOOTING
7. REGULATORY INFORMATION
7.1 REGISTERED HEAD OFFICE
7.2 APPLICABLE PATENT NUMBERS
8. PARTS LISTS & SERVICE KITS
23/03/2017

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2.
TOOL SAFETY
2.1
GENERAL SAFETY
These instructions cover the safe operation and
maintenance of THE EQUALIZER TFA12TE FLANGE
ALIGNMENT tool. The use of any 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.
1.
INTRODUCTION
The Equalizer™ TFA hydraulic ange alignment tool has
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 tool has 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:
• TFA12TE External Hydraulic Flange Alignment Tool

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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.
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.
The vibration total value to which this tool is
subjected does not exceed 2.5 m/s2.
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
working pressure to 510 bar (7400 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.

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3.2
HANDLING
The tool should be lifted and manouvered using its two
handles.
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.
3.
TOOL OPERATION
3.1
GENERAL GUIDANCE
Prior to alignment, an assesment 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.
BACK HANDLE FRONT HANDLE
HOOK
BASE PLATE
WING
ADJUSTMENT LEG
CYLINDER ADJUSTMENT
ALIGNMENT PISTON
WING
ADJUSTMENT

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Fit the plastic cap onto the Foot Extension:
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.
NOTE:
The TFA12 is a longer reaching version of the TFA15 and
suitable for thicker anges that require a longer wing.
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.
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.
The TFA tools can be supplied with a Foot Extension that
can be xed to the adjustment leg to increase the effective
leg length and therefore the range of application.
See the Range of Application at the end of Section 5.1.
To t the Foot Extension, rst remove the plastic cap:
Screw in the Foot Extension fully until the screw-thread
is no longer taking load and the foot feels slightly loose:

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3.7
TOOL CHECKS
WARNING: 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.
WARNING: 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.
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 compromising its maximum
alignment capacity.
Turn the Cylinder Adjustment Sleeve by the knurled ring
until the Alignment Foot is touching 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.

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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
WING
EXTENSION
THREAD
ADJUSTMENT
LEG THREAD
CYLINDER
ADJUSTMENT
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 TFA12TE Sub-Sea
The TFA12TE is actuated by means of single-acting
spring-return hydraulic cylinder and can be used sub-sea
providing the following actions are taken:
• The gauge and manifold are removed from the
Equalizer HP hand-pump and the coupler is tted
directly to the pump outlet (tools in this conguration
can be requested from Equalizer).
• The tool is connected to the Equalizer HP hand-pump
whilst still top-side.
• 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.
Please note that a sub-sea TFA12TE tool cannot be
operated from top-side by use of a down-line. The return
springs in the hydraulic cylinders do not have sufcient
force to close the tool if used with a down-line from a
top-side pump, therefore the standard hydraulic tools will
not function correctly and may jam in place if used in this
conguration.

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5.
TFA12TE
EXTERNAL HYDRAULIC
FLANGE ALIGNMENT
TOOL
The TFA12TE ange alignment tool uses an external
hydraulic cylinder to advance the alignment foot and align
the anges.
5.1
TFA12TE TOOL CAPABILITIES
ALIGNMENT FORCE
With the maximum integral pump pressure applied,
the tool can apply 12 T of alignment force through the
alignment foot. Depending on the extension of the wing,
the reaction forces may be as high as:
10 T
12 T
22 T
12 T
12 T
24 T
RANGE OF APPLICATION
Without Extension Foot
DIMENSION MINIMUM MAXIMUM
B Bolt Hole Diameter 45 mm -
M Misalignment 0 mm 65 mm
R Rise 150 mm 250 mm
D Pipe Leg Drop 83 mm 123 mm
W Wing Reach 160 mm 203 mm
H Reaction Spacing 200 mm -
With Extension Foot (Optional)
DIMENSION MINIMUM MAXIMUM
B Bolt Hole Diameter 45 mm -
M Misalignment 0 mm 65 mm
R Rise 150 mm 250 mm
D Pipe Leg Drop 123 mm 163 mm
W Wing Reach 160 mm 203 mm
H Reaction Spacing 200 mm -
Note: By attaching the bush to the hook, the minimum
Bolt Hole Diameter (B) is increased to 65 mm.
MINIMUM EXTENSION
Wmin
H
Dmin
Mmax
Rmin
MAXIMUM EXTENSION
Wmax
H
Dmax
Rmax
Bmin

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HYDRAULIC MANIFOLD OPERATION
Up to 4 TFA12TE tools can be manifolded to a single
HP1000S hydraulic Hand-Pump using the Equalizer
manifold.
Each tool can be independently isolated by closing the
corresponding valve. It is not recommended to isolate
or engage alignment tools while under load as an over-
load might occur. See the document ‘Use of Equalizer
International tools with a Hydraulic Manifold’ for further
guidance.
5.2
TFA12TE TOOL FUNCTION
HYDRAULIC TOOL OPERATION
The TFA12TE uses a hydraulic cylinder to advance the
Alignment Piston and align the anges. The hydraulic
pressure is applied using an external hand pump, enabling
accurate control of the force applied. The maximum
working pressure of the tool is 510 bar (7400 psi).
HAND PUMP OPERATION
Consult the Instruction Manual for the Equalizer HP
Hand-Pump supplied in the kit. Only use the supplied
Hand-Pumps which have been regulated to 510 bar
(7400 psi) to suit this tool.
ACTUATING THE TFA12TE
Follow the Tool Operation instructions (see Section 3),
using the following instructions to actuate the TFA12TE
tool.
When the Hand-Pump release valve is closed, pumping
the Hand-Pump handle will advance the Alignment Piston.
When using multiple tools, ensure that the spread of all
tools correspond to keep the spreading force balanced.
RETRACTING THE TFA12TE
Opening the release valve will depressurise the cylinder
and cause it to retract under the force of its internal
spring. The handle does not need to be pumped to retract
the tool.
When using multiple tools, exercise caution while retracting
to keep the spreading force balanced as the gap is closed.

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PUMP KIT
1 x HP1000S74PMIN Hydraulic Hand Pump
1 x 4-Way Manifold
4 x 2.0 m Hydraulic Hoses
1 x Instruction Manual
1 x Carry-Case with foam inserts
Product Code: MAN_TE_STD
1200 mm x 540 x 170 mm (47.2” x 21.3” x 6.7”)
Gross kit weight: 35.0 kg (77.2 lb)
5.4
TOOL DIMENSIONS
Tool Weight: 21.1 kg (46.5 lb)
440 mm
(17.3”)
104 mm
(4.1”) 635 mm
(25.0”)
5.3
KIT CONTENTS
TOOL KIT
1 x TFA12TE Tool
1 x Safety Lanyard
1 x Instruction Manual
1 x Carry-Case with foam inserts
Product Code: TFA12TEMIN
640 mm x 540 x 170 mm (25.2” x 21.3” x 6.7”)
Gross kit weight: 30.0 kg (66.1 lb)
Tool only weight: 21.1 kg (46.5 lb)

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7.
REGULATORY
INFORMATION
7.1
REGISTERED HEAD OFFICE
EQUALIZER INTERNATIONAL LTD.
Equalizer House
Claymore Drive
Aberdeen
Scotland
AB23 8GD
7.2
APPLICABLE PATENT NUMBERS
The following list of Patents and Design Registrations are
applicable to EQUALIZER INTERNATIONAL LTD TFA tools:
REGISTERED PATENTS & DESIGN
REGISTRATIONS
• 5832582
• AU690191
• NO319697
• 6327763
• 318535
• 0916051B
• 0024229878
• 84481
• 95727
• 44142
• 45155
6.
TROUBLESHOOTING
6.1
TFA12TE TROUBLESHOOTING
THE ALIGNMENT PISTON IS ADVANCING
BUT DOES NOT REACH FULL PRESSURE
POSSIBLE CAUSE:
There is air in the hydraulic system.
RECOMMENDED ACTION:
Follow the Airlock Relief instructions.
AIR-LOCK RELIEF
Connect the hand pump to the tool with the hydraulic
hose. Close the release valve on the pump, and prime the
pump until the hydraulic cylinder is fully extended and a
small pressure is achieved.
With the hand pump elevated above the level of the tool,
and the tool in an upright position, open the hand pump
release valve causing any air that is within the system to
be forced up through the pump and vented into the oil
reservoir.
Repeat this process three further times to ensure that
all air is removed from the system. The tool should now
reach full working pressure.
Disconnect the hand pump from the hydraulic hose,
grip the baseplate of the hand pump body in a vice with
the pump body vertical and the main handle at the top.
Remove the four nuts holding the main handle and lift off.
Grip the relling plug with pliers and extract it by pulling
and twisting simultaneously. Ensure the reservoir body
is held down when removing the relling plug as pulling
up on the reservoir body will release the bladder within,
and oil may spill out. Fill the reservoir to the top with a
premium quality hydraulic oil of the grade 15 cSt. Reinsert
the relling plug, wipe away any oil, and reassemble by
reversing the disassembly process.

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8.
PARTS LISTS
& SERVICE KITS

19
20
23
21
22
18
17
22
15
5
24
16
24
2
12
13
13
4 11
10 8
6
8
9
7
9
6
3
1
14
ITEM NO. PART NO DESCRIPTION QTY
1 1210100-01 WING ARM WELDMENT 1
2 270200-01 BODY ASSEMBLY - WELDED 1
3 270300-01 STRUT ASSEMBLY 1
4 270500-01 CYLINDER SUB-ASSEMBLY 1
5 271300-01 HANDLE ASSEMBLY 1
6 1210400-01 EXTENSION LEG ASS 1
7 270900-01 ADJUSTMENT LEG FIXING SHAFT 1
8 272000-01 SIDE SPACER BUSH 2
9 273300-01 SPIRAL CLIP 2
10 070410-01 LHS STICKER 1
11 070411-01 RHS STICKER 1
12
KIT
1215000-01
PROTECTION PAD FINISHED 1
13 M6 CSK HEX SCREW 2
14 FOOT CAP TOWER 1
15
KIT
271500-01
ADJUSTMENT ROD 1
16 ADJUSTER BOSS 1
17 NYLON BUSH 1
18 NYLON WASHER 1
19 WING ADJUST DECAL_TFA15TI 1
20 RELEASE KNOB 1
21 EXTERNAL CIRCLIP 1
22 WASHER 10mm ID 2
23 M5 SCKT SET SCREW 1
24 M5x12mm SCKT HEAD CPSCREW 2
TFA12TE PARTS LIST
1210000-01 REV.01

3
2
3
5
4
1
5
3
2
3
ITEM
NO.
PART NO DESCRIPTION
QTY/ASS
1 270301-09 STRUT TUBE
1
2 270302-09 CLEVIS
2
3 270303-01 M8X12mm BUTTON HEAD HEX SCREW
4
4 273000-01 FOAM GRIP - 34MM X 135MM
1
5 273100-01 6MM ROLL PIN
2
STRUT ASSEMBLY PARTS LIST
270300-01 REV.01

1
4
3
7
7
2
6
ITEM NO. Part No DESCRIPTION QTY
1 830300-01 HYDRAULIC CYLINDER - 10,000 PSI 1
2 1320600-01 Cylinder Foot Assembly 1
3 270701-01 CYLINDER ADJUSTING RING 1
4 270501-01 TI CYLINDER SLEEVE 1
5 830313-01 SPIRAL RETAINING RING 1
6 301301-01 M6 SCKT SET SCREW 1
7 300401-01 M5 SCKT SET SCREW 2
TFA15TE CYLINDER ASSEMBLY PARTS LIST
1320500-01 REV.01

31
2
4
3
2
ITEM
NO.
PART NO DESCRIPTION QTY/ASS
1 270601-01 CYLINDER FOOT 1
2 270602-01 CYLINDER FOOT PAD 1
3 271800-01 M6 SET SCREW 2
4 501501-01 TFA15TE FOOT SCREW 1
CYLINDER FOOT PARTS LIST
1320600-01 REV.01

6
1
9
13
2
11
10
7
8
10
11
3
124
ITEM
NO.
PART NO DESCRIPTION QTY
1 830301-01 CYLINDER BODY 1
2 830302-01 PISTON 1
3 830303-01 CYL END CAP 1
4 771110-01 3/8" NPT COUPLER 10kPSI 1
6
KIT
840110-01
WIPER SEAL 1
7 TENSION DIE SPRING 1
8 SPRING LOCK 2
9 M6 CAPSCREW 1
10 O-RING 2
11 BACK-UP RING 2
12 M6X25 SCKT H. SCREW 1
13 M6 GASKET SEAL 1
TE HYDRAULIC CYLINDER PARTS LIST
830300-01 REV.04