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OPERATOR INSTRUCTION MANUAL

IM_FA1TM_Rev08_A4

FA1TM

FLANGE ALIGNMENT TOOL 

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.

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, flame, 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 fit-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 fixing 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/s

2

.

Summary of Contents for FA1TM

Page 1: ...OPERATOR INSTRUCTION MANUAL E Q U A L I Z E R I N T E R N AT I O N A L LT D w w w e q u a l i z e r i n t e r n a t i o n a l c o m F L A N G E A L I G N M E N T T O O L FA1TM ...

Page 2: ...ATERAL MISALIGNMENT 4 FA1TM MECHANICAL FLANGE ALIGNMENT TOOL 4 1 TOOL CAPABILITIES 4 2 RANGE OF APPLICATION 4 3 TOOL FUNCTION 4 4 KIT CONTENTS 4 5 TOOL DIMENSIONS 4 6 TOOL MAINTENANCE 5 RANGE OF APPLICATION 5 1 BS10 API6BX API6B WELD NECK FLANGE TABLES 5 2 ASME B16 5 ASME B16 47 DIN WELD NECK FLANGE TABLES 5 3 SPO FLANGE TABLE 6 TROUBLESHOOTING 6 1 FA1TM TROUBLESHOOTING 7 REGULATORY INFORMATION 7 ...

Page 3: ...ols 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 ...

Page 4: ...re 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 Eq...

Page 5: ...ery second bolt around the flange Continue with this until misalignment occurs A flanged 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 maximum point of ...

Page 6: ...DIMENSION B 4 3 FA1TM TOOL FUNCTION FA1TM GENERAL GUIDANCE 1 The FA1TM is secured to the lower of the two flanges 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 firm 4 The ...

Page 7: ...own 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 DROP LEG RELEASE KNOB LIFT HOOK PARALLEL The drop leg release knob is then tightened until firm Rotate the crank handle clockwise until the driven wedge makes contact with the opposite flange CRA...

Page 8: ...o the circumference of the opposite flange bring the flange joint in alignment WARNING Do not exceed hand pressure on the crank handle 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 the previous steps Insert the last bolt and tighten WARNING Ca...

Page 9: ...e 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 component thoroughly Inspect service and lubricate the tool immediately after the cleaning process SERVICING Replace missing worn or damaged parts Use only genuine Equalizer parts from approved distributo...

Page 10: ...where not vacuum sealed as much air from bags as possible 6 Once bags have been closed and sealed DO NOT re open Any visual inspections must be done with closed and sealed bags If bags are opened the components will have to be dried re coated and re sealed in bags shrink wrap 7 Replace silica gel 100g EVERY TIME the case is opened NOTE depending on moisture content of air silica gel should be chan...

Page 11: ... 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...

Page 12: ...E OF APPLICATION CLASS 150 NPS 22 26 28 30 32 34 36 38 40 42 44 46 48 TOOL FA4TM FA9TE CLASS 300 NPS 22 26 28 30 32 34 36 38 40 42 44 46 48 TOOL FA4TM FA9TE CLASS 400 NPS 22 26 28 30 32 34 36 38 40 42 44 46 48 TOOL FA4TM FA9TE CLASS 600 NPS 22 26 28 30 32 34 36 38 40 42 44 46 48 TOOL FA4TM FA9TE CLASS 900 NPS 22 26 28 30 32 34 36 38 40 42 44 46 48 TOOL FA9TE DIN WELD NECK FLANGE RANGE OF APPLICATI...

Page 13: ... 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 TOOL FA4TM FA9TE CLASS 1500 NPS 2 1 2 3 3 1 2 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 TOOL FA4TM FA9TE CLASS 2500 NPS 2 1 2 3 3 1 2 4 5 6 8 10 12 14 16 18 20 22 24 TOOL FA4TM FA9TE CLASS 5000 NPS 2 1 2 3 3 1 2 4 5 6 8 10 12 14 16 18 20 22 24 TOOL FA4TM FA9TE CLASS 7500 NPS 2 1 2 3 3 1 2 4 5 6 8 10 12 1...

Page 14: ... S E There may be something restricting the joint from aligning R E C O M M E N D E D A C T I O N Check the area around the joint to establish if there is an obstruction to the joint P O S S I B L E C A U S E The joint may require more than 1 T 10 kN force to align R E C O M M E N D E D A C T I O N If the joint requires more force than that of the 1 T 10 kN tool attach a second tool or another met...

Page 15: ... MANUAL IM_FA1TM_Rev08_A4 FA1TM FLANGE ALIGNMENT TOOL 14 7 REGULATORY INFORMATION 7 1 REGISTERED HEAD OFFICE EQUALIZER INTERNATIONAL LTD Equalizer House Claymore Drive Aberdeen Scotland AB23 8GD 8 PARTS LISTS SERVICE KITS ...

Page 16: ...10100 01 211600 01 220800 01 BODY FRAME DRIVEN WEDGE DRIVE SCREW BASE PLATE 3 mm COVER PLATE 2 mm CRANK HANDLE TORSION SPRING NEEDLE BEARING BEARING SHAFT SPRING MANDREL M6 x 8 mm SOCKET FL BT SCREW DROP LEG M6 RELEASE KNOB LEG PIN 8 mm SPRING RING 8 mm SPRING PIN 2 x 16 mm BODY STICKER LEFT BODY STICKER RIGHT DRIVING WEDGE SPACER SHIM MINI RATCHET STRAP 01 01 01 01 01 01 01 04 04 01 12 01 01 01 0...

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Page 18: ...L LT D H e a d O f f i c e E q u a l i z e r H o u s e C l a y m o r e D r i v e A b e r d e e n S c o t l a n d U K A B 2 3 8 G D t 4 4 0 1 2 2 4 7 0 1 9 7 0 f 4 4 0 1 2 2 4 8 2 3 7 9 1 w w w e q u a l i z e r i n t e r n a t i o n a l c o m ...

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