Equalizer International Equalizer FA1TM Montageanleitung
OPERATOR INSTRUCTION MANUAL
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
FA1TM
FLANGE
ALIGNMENT
TOOL
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
4 FLANGE MISALIGNMENT DETERMINATION PROCEDURE 5
4.1 LATERAL MISALIGNMENT 5
5FA1TM MECHANICAL FLANGE ALIGNMENT TOOL 6 - 11
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 12 - 14
6.1 BS10, API6BX AND 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
IM_FA1TM_Rev07_A4 | ECN0003 | 27/04/17
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 2
The Equalizer FA1TM TOOL is an aid of use in normal maintenance and installation proce-
dures to enable the realignment of misaligned anges within respective working capacities.
For example, the tool can be used to assist in the replacement of ring and other types of
ange joint. The use of these instructions will promote safe use, and maximise the service
life of the tools.
1. INTRODUCTION
2. TOOL SAFETY
2.1 GENERAL SAFETY
These instructions cover the safe operation and maintenance of THE EQUALIZER FA1TM
FLANGE ALIGNMENT tools. The use of these 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.
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 3
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 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 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.
CAUTION: Only use the designated anchor
point for xing the lanyard. Do not attach the
lanyard to the plastic handle.
DANGER: Care should be taken when using
the lanyard to avoid entanglement with body
parts.
The vibration total value to which this tool is
subjected does not exceed 2.5 m/s2.
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 4
DRIVEN
WEDGE
CRANK HANDLE
RELEASE KNOB
MINI RATCHET &
STRAP
3. TECHNICAL DATA
Tool Description Aligning Force
FA1TM Mechanical Flange Alignment Tool 1.0 T (10 kN)
3.1 KIT CONTENTS
1 x FA1TM Tool
1 x Mini Ratchet Strap
1 x Instruction Manual
Product Code: FA1TM
3.2 HOW THE FA1TM WORKS
1. The FA1TM is secured to the lower of the two anges by fully inserting the lift hool into
the bolt-hole at the point of greatest misalignment.
2. The drop leg release knob is slackened and the drop leg is adjusted down to the pipe
while the tool is held level in the bolt-hole.
3. The drop leg release knob is then tightened until rm.
4. The strap and buckle are attached to the drop leg and around the pipe for added
security.
5. The crank handle is then turned clockwise until the driven wedge comes into contact
with the circumference of the opposite ange.
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 5
4. FLANGE MISALIGNMENT DETERMINATION PROCEDURE
The tool being used must not be attached to a anged joint prior to the misalignment
procedure being carried out.
4.1 LATERAL MISALIGNMENT
1. Loosen and remove every second bolt around the flange, continue with this until mis-
alignment occurs.
A flange joint, once broken down, may spring out of alignment at any point, or in any
direction around its circumference. Misalignment may not occur until only a few bolts
remain.
2. At this point the direction of any misalignment should become obvious. The alignment
tool being used should be attached at the point of maximum misalignment (point A or
point B in the examples shown below) as shown in sections 3.2 & 5.1.
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
and bottom of the joint.
2. Guide the lift hook into the bolt-hole at
the point of maximum misalignment.
Adjust the drop leg down onto the pipe
by slackening the release knob in an
anticlockwise direction.
The tool should be held up level within
the bolt-hole during adjustment.
NB: The tool must be parallel to pipe
during operation.
3. Rotate the crank handle clockwise until
the driven wedge makes contact with
the opposite ange.
4. Thread the strap through the aperture
on the base of the drop leg as shown.
POINT OF MAXIMUM
MISALIGNMENT
5.1 INSTALLATION AND OPERATION
5. FA1TM MECHANICAL FLANGE ALIGNMENT TOOL
POINT OF MAXIMUM
MISALIGNMENT
DROP LEG
RELEASE
KNOB
LIFT HOOK
PARALLEL
CRANK
HANDLE
DRIVEN
WEDGE
OPPOSITE FLANGE
STRAP
STRAP
APERTURE
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 7
5. Feed the open end of the strap through the buckle mechanism as shown.
Close the clasp to secure strap.
6. Now that everything is secured, rotate the handle clockwise to apply pressure
to the circumference of the opposite ange & bring the ange joint in
alignment.
Do not exceed hand pres-
sure on the crank 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
located) remove the tool by reversing steps 2-6. Insert the last bolt and tighten.
Care should be taken not to drop any of the component parts when removing
them from the ange joint. This action will prevent injuries to either the
operator’s lower limbs, or to passers-by.
FEED THROUGH
STRAP
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 8
5.2 EXAMINATION & STORAGE
5.3 MAINTENANCE
1. Secure the tool upright on a bench.
2. Using a small at screwdriver, lever out one circlip and unscrew 6 x 6mm hex screws.
3. Remove cover plate and remove any dirt or corrosion from moving parts.
4. Inspect components for wear and damage, replace if necessary! If there’s no damage
present, then they can be greased and re-assembled by reversing steps 1-4.
Recommended grease –
Rocol Sapphire Hi-Load or equivalent good quality hi load bearing grease.
1. On return from each job before allocation against subsequent work, the completeness
of the Equalizer FA1TM kit must be established and items examined to ensure that they
are serviceable.
2. Any missing or damaged items are to be replaced as soon as possible and prior to the
tools being used again.
3. Store the FA1TM in a cool, dry place and ensure all machined surfaces are greased.
4. Ensure wedges, pins and legs remain grit free and that parts move freely.
CIRCLIP
HEX SCREW
COVER PLATE
DRIVEN
WEDGE
NEEDLE
BEARINGS
DRIVING
WEDGE
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