Equalizer ELPTP50 Assembly instructions

OPERATOR INSTRUCTION MANUAL
TFA15TI
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
INTEGRAL
HYDRAULIC
FLANGE
ALIGNMENT
TOOL

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
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. TFA15TI
5.1 TOOL CAPABILITIES
5.2 TOOL FUNCTION
5.3 KIT CONTENTS
5.4 DIMENSIONS
6. TROUBLESHOOTING
6.1 TFA15TI TROUBLESHOOTING
7. REGULATORY INFORMATION
7.1 REGISTERED HEAD OFFICE
7.2 APPLICABLE PATENT NUMBERS
8. PARTS LISTS & SERVICE KITS
03/07/14

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
3
2.
TOOL SAFETY
2.1
GENERAL SAFETY
These instructions cover the safe operation and
maintenance of THE EQUALIZER TFA15TI 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
Onlypersonneldeemedcompetentintheuseofmechanical
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-freindly.
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:
• TFA15TI Integral Hydraulic Flange Alignment Tool

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
4
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 700bar
(10,000psi).
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

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
5
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 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.

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
6
3.6
CYLINDER ADJUSTMENT SLEEVE
The Alignment Piston has a 65mm 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.

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
7
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.

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
8
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 15cSt.
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.

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
9
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: -30ºC (-22ºF)
Maximum Flange Contact Temperature: 70ºC (158ºF)
4.7
SUB-SEA USAGE
Using TFA15TI Sub-Sea
The TFA15TI is actuated by means of 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.

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
10
RANGE OF APPLICATION
DIMENSION MINIMUM MAXIMUM
B Bolt Hole Diameter 45mm 51mm
M Misalignment 0mm 65mm
R Rise 150mm 250mm
D Pipe Leg Drop 83mm 123mm
W Wing Reach 120mm 160mm
H Reaction Spacing 200mm 200mm
MINIMUM EXTENSION
MAXIMUM EXTENSION
Wmin
H
Dmin
Mmax
Rmin
Wmax
H
Dmax
Rmax
Bmin
5.
TFA15TI
INTEGRAL HYDRAULIC
FLANGE ALIGNMENT
TOOL
The TFA15TI ange alignment tool uses an integral
hydraulic cylinder to advance the alignment foot and align
the anges.
5.1
TFA15TI TOOL CAPABILITIES
ALIGNMENT FORCE
With the maximum integral pump pressure applied,
the tool can apply 15T of alignment force through the
alignment foot. Depending on the extension of the wing,
the reaction forces may be as high as:
9T
15T
24T
12T
15T
27T

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
11
ACTUATING THE TFA15TI
Follow the Tool Operation instructions (see Section 3),
using the following instructions to actuate the TFA15TI
tool.
When advance (+) is selected, pumping the handle will
advance the Alignment Piston.
RETRACTING THE TFA15TI
Selecting retract (-) 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.
5.2
TFA15TI TOOL FUNCTION
HYDRAULIC TOOL OPERATION
Prior to operation, ensure the air-vent in the integral hand
pump is not obstructed. Any obstruction in the air-vent
can cause a vacuum in the system which can limit the
cylinder’s travel.
AIR-VENTS
The TFA15TI uses a hydraulic cylinder to advance the
Alignment Piston and align the anges. The hydraulic
pressure is applied using the integrated hand pump,
enabling accurate control of the force applied.
The integral hand pump has a control lever which allows
the user to select advance (+) or retract (-).

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
12
5.4
TFA15TI DIMENSIONS
Tool Weight: 21.5kg (47.4lb)
Box Dimensions:
585.0mm (23.0”)
900.0mm (35.4”)
160.0mm (11.8”)
430mm
(16.9”)
104mm
(4.1”) 635mm
(25.0”)
5.3
TFA15TI KIT CONTENTS
STANDARD KIT
1 x TFA15TI Tool
1 x Instruction Manual
1 x Hard Case
Product Code: TFA15TISTD

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
13
possibly indicative of a perished bladder. Refer to an
approved Equalizer distributor for repair.
THE ALIGNMENT PISTON MOVES AS
INTENDED, BUT DOESN’T SEEM TO BE
ACHIEVING FULL PRESSURE WHEN UNDER
LOAD
POSSIBLE CAUSE:
Intermediate valve not seating / relief valve leaking.
RECOMMENDED ACTION:
Refer to an approved Equalizer distributor for further
instruction.
HYDRAULIC PRESSURE SLOWLY DIMINISHES
AND THE PUMP HANDLE RISES
POSSIBLE CAUSE:
The outlet check valve is leaking.
RECOMMENDED ACTION:
Refer to an approved Equalizer distributor for further
instruction.
HYDRAULIC PRESSURE SLOWLY DIMINISHES
AND THE PUMP HANDLE DOES NOT RISE
POSSIBLE CAUSE:
The release valve is leaking.
RECOMMENDED ACTION:
Refer to an approved Equalizer distributor for further
instructions.
POSSIBLE CAUSE:
The piston seal is leaking.
RECOMMENDED ACTION:
Inspect the tool for oil leaks, possibly indicative
of a perished seal or loose blanking plug. Refer
to an approved Equalizer distributor for further
instructions.
TOOL ACTUATION FEELS SOFT AND
UNRESPONSIVE
POSSIBLE CAUSE:
There is air in the hydraulic system.
RECOMMENDED ACTION:
Refer to an approved Equalizer distributor for further
instruction.
6.
TROUBLESHOOTING
6.1
TFA15TI TROUBLESHOOTING
THE ALIGNMENT PISTON ADVANCES
SOME OF THE WAY AND THEN STOPS
PROGRESSING
POSSIBLE CAUSE:
The air-vent is obstructed by dirt or debris.
The tool has reached its maximum load.
RECOMMENDED ACTION:
Carefully unblock the air-vent using a small blunt
object.
THE ALIGNMENT PISTON DOESN’T MOVE
POSSIBLE CAUSE:
There is an air-lock within the hydraulic system.
RECOMMENDED ACTION:
Select Retract (-) and prime pump to circulate oil
around the system.
POSSIBLE CAUSE:
Insufcient oil in the hydraulic system.
RECOMMENDED ACTION:
Refer to an approved Equalizer distributor for further
instruction.
POSSIBLE CAUSE:
Retract (-) is selected.
RECOMMENDED ACTION:
Select Advance (+) and pump the handle.
POSSIBLE CAUSE:
Air has accumulated around pump inlet when used
upside down.
RECOMMENDED ACTION:
Inspect the tool for oil leaks on the reservoir,

OPERATOR INSTRUCTION MANUAL IM_TFA_REV03_A4
TFA15TI FLANGE ALIGNMENT TOOL
14
8.
PARTS LISTS
& SERVICE KITS
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 are applicable to EQUALIZER
INTERNATIONAL LTD TFA15TE and TFA15TI tools:
REGISTERED PATENTS
• 5832582
• AU690191
• NO319697
• 6327763
• 318535
• 0916051B

10
8
3
16
97
9
8
6
26
18
5
25
17
23
24 19
20 24
22
21
26
2
115
4
11
13
14
14
ITEM
NO.
PART NO DESCRIPTION
1 270100-01 WING ARM_WELDED ASSEMBLY
2 270200-01 BODY ASSEMBLY - WELDED
3 270300-01 STRUT ASSEMBLY
4 270500-01 CYLINDER ASSEMBLY
5 271300-01 HANDLE ASSEMBLY
6 270400-01 ADJUSTABLE LEG ASS
7 270900-01 ADJUSTMENT LEG FIXING SHAFT
8 272000-01 SIDE SPACER BUSH
9 270800-01 SPIRAL CLIP
10 070393-01 RHS STICKER
11 070392-01 LHS STICKER
13
KIT
271400-01
PROTECTION PAD
14 M6 CSK HEX SCREW
15 FOOT CAP FLANGE
16 FOOT CAP TOWER
17
KIT
271500-01
ADJUSTMENT ROD
18 ADJUSTER BOSS
19 ADJUSTMENT BUSH
20 ADJUSTMENT BUSH WASHER
21 WING ADJUST DECAL_TFA15TI
22 RELEASE KNOB
23 10MM EXTERNAL CIRCLIP
24 WASHER 10mm ID
25 M5 SCKT SET SCREW
26 M5x12mm SCKT HEAD CPSCREW
TFA15TI PARTS LIST
270000-01 REV.01

3
1
5
2
3
6
4
77
7
7
ITEM
NO.
PART NO DESCRIPTION
QTY/ASS
1 840300-01 H.CYLINDER & PUMP TI ASSEMBLY
1
2 270600-01 CYLINDER FOOT ASSEMBLY
1
3 270701-01 CYLINDER ADJUSTING RING
2
4 270501-01 TI CYLINDER SLEEVE
1
5
KIT
271900-01
SPIRAL RETAINING RING
2
6 M6 SCKT SET SCREW
1
7 M5 SCKT SET SCREW
4
TFA15TI CYLINDER ASSEMBLY PARTS LIST
270500-01 REV.01

25
421
21 23 24
3
119 26
22
23
24
4742 465
31
27
42464835
6
36
37
36
40
38
39
7
8
9
11
10
12
13
41
16
18
18
14
15
33 32 34
45 44 43 42
27
28
29
27
30
20
17
ITEM NO. PART NO DESCRIPTION QTY.
16
KIT
840160-01
HANDLE CLEVIS 1
17 CLEVIS PIN 2
18 RETAINING RING 4
19
KIT
840110-01
WIPER SEAL 1
20 TENSION DIE SPRING 1
21 SPRING LOCK 2
22 M6 CAPSCREW 1
23 O-RING 2
24 BACK-UP RING 2
25 SCREW 1
26 M6 GASKET SEAL 1
27
KIT
840120-01
O-RING 3
28 RELIEF VALVE SCREW 1
29 RELIEF VALVE KNOB 1
30 FIXING SCREW 1
31 OIL FILL SCREW 1
32 OVERLOAD COVER SCREW 1
33 CAP 1
34 O-RING 1
35 WASHER 1
36 O-RING 2
37 BACK UP RING 1
38 RESERVOIR BLADDER 1
39 O-RING 1
40 O-RING 1
41 PUMP PISTON ROD 1
42 STEEL BALL 1
43
KIT
375020-01
STEEL BALL 2
44 CONE SEAT 1
45 CONE 1
46 LONG SEPARATOR SPRING 1
47 SPRING 2
48 SCREW 1
49 SPRING LOCK 1
ITEM NO. PART NO DESCRIPTION QTY.
1 830301-01 CYLINDER BODY 1
2 830310-01 CYL VENT PLUG 2
3 830302-01 PISTON 1
4 840100-01 NUT 1
5 840301-01 CYLINDER BASE 1
6 376901-01 PUMP PISTON HOUSING 1
7 840302-01 BLADDER HOUSING 1
8 372401-01 PISTON HOUSING CAP 1
9 372501-01 SWIVEL CLEVIS 1
10 373201-01 CLEVIS SCREW 1
11 373301-01 ANTI-LOOSEN NUT 1
12 373101-01 LINK CONNECTOR 1
13 372601-01 RETAINING NUT 1
14 373401-01 HANDLE ROD 1
15 306502-01 HANDLE GRIP 1
TI CYLINDER PARTS LIST
840300-01 REV.02

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
KIT
271600-01
M8 BUTTON HEX SCREW
4
4 FOAM GRIP - 34MM X 135MM
1
5 6MM ROLL PIN
2
STRUT ASSEMBLY PARTS LIST
270300-01 REV.01

ITEM
NO.
PART NO DESCRIPTION QTY/ASS
1 270800-01 SAFETY BOND ASSEMBLY 1
SAFETY BOND ASSEMBLY PARTS LIST
270800-01 REV.01

6
6
5
3
1
4
2
5 6
6
5
6
6
5
7
7
ITEM
NO.
PART NO DESCRIPTION QTY/ASS
1 501301-01 HANDLE BAR 1
2 501101-01 HANDLE LEFT 1
3 501201-01 HANDLE RIGHT 1
4
KIT
271800-01
BLUE HANDLE SLEEVE 1
5 WASHER (0.8MM) 6
6 SCREW FOR HANDLE 6
7 SPACER 2
HANDLE ASSEMBLY PARTS LIST
271300-01 REV.01