TFA15TI Operating Manual
Contents
1. www equalizerinternational com 4 OPERATOR INSTRUCTION MANUAL _ IM TFA REVO3 A4 CONTENTS INTRODUCTION 3 1 TFA15TI 2 TOOL SAFETY GENERAL SAFETY PERSONNEL COMPETENCY DISCLAI MER DEFINITION OF TERMS HAZARDS TOOL OPERATION GENERAL GUIDANCE HANDLING TOOL INSTALLATION ADJUSTMENT LEG WING EXTENSION CYLINDER ADJUSTMENT SLEEVE TOOL CHECKS ALIGNMENT SECURING THE FLANGE J OINT TOOL MAINTENANCE TFA15TI INSPECTION CLEANING SERVICING LUBRICATION PROCEDURE STORAGE amp TRANSPORTATION OPERATING CONDITIONS SUB SEA USAGE TOOL CAPABILITIES TOOL FUNCTION KIT CONTENTS DIMENSIONS TROUBLESHOOTING 15 TROUBLESHOOTING REGULATORY INFORMATION REGISTERED HEAD OFFICE APPLICABLE PATENT NUMBERS PARTS LISTS amp SERVICE KITS 03 07 14 FLANGE ALIGNMENT TOOL M INTRODUCTION Equalizer TFA hydraulic flange alignment tool has been developed to assist in the aligning of large flanges 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 flange 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 to2. 4 4 4 4 4 e e e e e e e e e e o o o o 4 4 4 ee 4 ee 4 ee e 4 es e e e e e e e e e e e e e 9999909509999 s s ee 09090909 4 4 1 e e e e 1 4 e e e e e e e e e Oa o o o 4 1 1 1 1 1 1 Nu e e 9 o o o a o a o a a o e ese 1 1 1 1 1 1 s s sS a a eee ye e o e e 9 9 9 e e e ee FLANGE ALIGNMENT TOOL e e e e e e 9 9
3. the flange joint 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 flat against the upper flange The TFA flange alignment tool should always be installed in such a way that the lower flange is closer to the user and the upper flange is further away The tool is designed to hook into the bolt hole of the upper flange and push the lower flange into alignment ADJUSTMENT LEG WING ADJUSTMENT HOOK Prior to installation ensure the Adjustment Leg and BASE PLATE Cylinder Adjustment Sleeve are fully retracted Ensure WING that the Alignment piston is fully retracted ALIGNMENT PISTON CYLINDER ADJUSTMENT TFATSTI 5 FLANGE ALIGNMENT TOOL PN T E N A NAL 3 4 ADJ USTMENT 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 WI NG EXTENSI ON The Alignment Piston is located on an adjustable wing which can be extended to enable the tool to be used on a variety of flange 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 flange TFATSTI 2 OPERATOR INSTRUCTION MANUAL IM TFA REVO3 A4 3 6 CYLI NDER ADJ USTMENT SLEEVE The Alignm
4. the surface e tool and pump are stripped down cleaned and lubricated immediately to minimise corrosion TFATSTI FLANGE ALIGNMENT TOOL WJEQUALIZER OPERATOR INSTRUCTION MANUAL IM_TFA_REVO3_A4 RANGE OF APPLI CATI ON DIMENSION MINIMUM MAXIMUM B Bolt Hole Diameter 45mm 51mm M Misalignment Omm 65mm TFALSTI PR Rise 150mm 250mm D Pipe Leg Drop 83mm 123mm INTEGRAL HYDRAULI C FLANGE ALI GNMENT TOOL The TFA15TI flange alignment tool uses an integral hydraulic cylinder to advance the alignment foot and align the flanges MINIMUM EXTENSION 5 1 15 TOOL CAPABILITIES ALI GNMENT 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 15 15 1 10 FLANGE ALIGNMENT TOOL EQ EQU LI N A ONAL 5 2 TFA15TI TOOL FUNCTION HYDRAULI C TOOL OPERATI ON 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 15 uses a hydraulic cylinder to advance the Alignment Piston and align the flanges The hydraulic pressure is applied using the integrated hand pump enabling accurate control o
5. 1 CYLINDER SERVICE KIT 840110 01 REV 02 ITEM NO DESCRIPTION QTY 1 WIPER SEAL TENSION DIE SPRING SPRING LOCK M6 CAPSCREW O RING BACK UP RING SCREW M6 GASKET SEAL EQUALIZER INTERNATIONAL LTD Head Office Equalizer House Claymore Drive Aberdeen Scotland UK AB23 8GD t 44 0 1224 701970 f 44 0 1224 823791 Houston Office 1330 Yale Street Houston TX 77008 USA t 1 713 927 1840 www equalizerinternational com
6. 01 KIT 271500 01 PROTECTION PAD M6 CSK HEX SCREW FOOT CAP FLANGE FOOT CAP TOWER ADJUSTMENT ROD ADJUSTER BOSS ADJUSTMENT BUSH ADJUSTMENT BUSH WASHER WING ADJUST DECAL_TFA15TI RELEASE KNOB 10MM EXTERNAL CIRCLIP WASHER 10mm ID M5 SCKT SET SCREW M5x12mm SCKT HEAD CPSCREW TFA15TI CYLINDER ASSEMBLY PARTS LIST 270500 01 REV 01 NG PART NO DESCRIPTION QTY ASS 1 840300 01 H CYLINDER amp PUMP TI ASSEMBLY 2 270600 01 CYLINDER FOOT ASSEMBLY 3 270701 01 CYLINDER ADJUSTING RING 2 270501 01 TI CYLINDER SLEEVE SPIRAL RETAINING RING 2 KIT M6 SCKT SET SCREW 4 M5 SCKT SET SCREW TI CYLINDER PARTS LIST 840300 01 REV 02 ITEM PART 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 PART NO DESCRIPTION O lt HANDLE CLEVIS KIT 840160 01 CLEVIS PIN RETAINING RING WIPER SEAL TENSION DIE SPRING SPRING LOCK KIT
7. EVIS WELDED ASSEMBLY 1 2 270402 01 ADJUSTMENT FOOT 1 3 ADJUSTMENT FOOT PAD 1 KIT 4 271700 01 SPIRAL CLIP 1 5 M6 CSK HEX SCREW 2 PROTECTIVE PAD SERVICE KIT 271400 01 REV 01 na DESCRIPTION QTY ASS 1 M6 CSK HEX SCREW 2 2 FOOT CAP TOWER 1 3 FOOT CAP FLANGE 1 4 PROTECTION PAD 1 WING ADJUSTMENT SERVICE KIT 271500 01 REV 01 ae DESCRIPTION QTY ASS lt gt ADJUSTMENT ROD ADJUSTER BOSS ADJUSTMENT BUSH ADJUSTMENT BUSH WASHER WING ADJUST DECAL TFA15TI RELEASE KNOB 10MM EXTERNAL CIRCLIP WASHER 10mm ID M5 SCKT SET SCREW M5x12mm SCKT HEAD CPSCREW Im QA 2 CO N N I N P P m CLEVIS SERVICE KIT 840160 01 REV 01 DESCRIPTION HANDLE CLEVIS CLEVIS PIN 2 RETAINING RING 4 W N INTEGRAL MANIFOLD SERVICE KIT 375020 01 REV 01 1 DESCRIPTION QTY 4 1 STEEL BALL 2 2 SEAT 1 3 CONE 1 4 LONG SEPARATOR SPRING 1 5 SPRING 2 6 SCREW 1 7 1 SPRING LOCK INTEGRAL BLADDER SERVICE KIT 840120 01 REV 02 ITEM NO DESCRIPTION QTY 1 STEEL BALL 1 2 O RING 3 3 RELIEF VALVE SCREW 1 4 RELIEF VALVE KNOB 1 D FIXING SCREW 1 6 OIL FILL SCREW 1 7 OVERLOAD COVER SCREW 1 8 CAP 1 9 O RING 1 10 WASHER 1 11 O RING 2 12 BACK UP RING 1 13 O RING 1 14 PUMP PISTON ROD 1 15 RESERVOIR BLADDER 1 16 O RING
8. M6 CAPSCREW 840110 01 O RING BACK UP RING SCREW M6 GASKET SEAL O RING RELIEF VALVE SCREW RELIEF VALVE KNOB FIXING SCREW OIL FILL SCREW OVERLOAD COVER SCREW CAP KIT O RING 840120 01 WASHER O RING BACK UP RING RESERVOIR BLADDER O RING O RING PUMP PISTON ROD STEEL BALL STEEL BALL CONE SEAT CONE KIT 375020 01 LONG SEPARATOR SPRING SPRING SCREW SPRING LOCK IN N N ele N IN EF N F IN STRUT ASSEMBLY PARTS LIST 270300 01 REV 01 ned PART NO DESCRIPTION QTY ASS 1 270301 09 STRUT TUBE 2 270302 09 CLEVIS 2 3 M8 BUTTON HEX SCREW 4 KIT 4 FOAM GRIP 34MM X 135MM 5 6MM ROLL PIN 2 SAFETY BOND ASSEMBLY PARTS LIST 270800 01 REV 01 MEM PART DESCRIPTION QTY ASS 1 270800 01 SAFETY BOND ASSEMBLY 1 HANDLE ASSEMBLY PARTS LIST 271300 01 REV 01 PART NO DESCRIPTION QTY ASS 1 501301 01 HANDLE BAR 1 501101 01 HANDLE LEFT 501201 01 HANDLE RIGHT BLUE HANDLE SLEEVE KIT WASHER 0 8MM 271800 01 SCREW FOR HANDLE B N NI OY O SPACER ADJUSTMENT LEG ASSEMBLY PARTS LIST 270400 01 REV 01 ITEM NO PART NO DESCRIPTION QTY ASS 1 270401 01 CL
9. OPERATOR INSTRUCTION MANUAL e e e oo o o a eee ee e e e e e e e e e e e e ao 0 0 e e e e e e e e e e eee e 9 9 e e e e e e e e e e 4 99 e e e 0 0 0 0 0 D 0 0 e e 4 4 4 4 e on e O O O O O O O O O O O O O O O O O O O O O O O O O 4 4 i e e e e e e e e e e e e e e e e e e e 909090509099 0
10. bject THE ALI GNMENT PI STON 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 Insufficient 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 TFATSTI possibly indicative of a perished bladder Refer to an approved Equalizer distributor for repair THE ALI GNMENT PI STON MOVES AS INTENDED BUT DOESN T SEEM TO BE ACHI EVI NG 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 HYDRAULI C PRESSURE SLOWLY DI MI NI SHES AND THE PUMP HANDLE RI SES POSSIBLE CAUSE The outlet check valve is leaking RECOMMENDED ACTION Refer to an approved Equalizer distributor for further instruction HYDRAULI C PRESSURE SLOWLY DI MI NI SHES 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 pisto
11. ent Piston has a 65mm stroke The Cylinder Adjusment Sleeve extends the reach of the tool to fit a variety of flange sizes without comprimising its maximum alignment capacity Turn the Cylinder Adjustment Sleeve by the knurled ring until the Alignment Foot is touching the lower flange 6 FLANGE ALIGNMENT TOOL OPERATOR INSTRUCTION MANUAL IM_TFA_REVO3_A4 3 7 TOOL CHECKS Ensure that the tool is sitting square on the flange 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 fingers hands or other body parts to come into contact with the flange while actuating the tool Only hold the tool by its designated handles TFA15TI 3 8 ALI GNMENT Refer to section 5 2 for tool actuation instructions Actuating the tool will extend the Alignment Piston and align the flanges C 3 9 SECURING THE FLANGE JOINT After the flange 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 flange joint FLANGE ALIGNMENT TOOL 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
12. f the force applied The integral hand pump has a control lever which allows the user to select advance or retract TFATSTI OPERATOR INSTRUCTION MANUAL IM TFA REVO3 A4 ACTUATI NG THE 15 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 NG THE 15 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 FLANGE ALIGNMENT TOOL OPERATOR INSTRUCTION MANUAL IM TFA REVO3 4 15 KIT CONTENTS TFA15TI DIMENSIONS STANDARD KIT Tool Weight 21 5kg 47 41 1 x TFA15TI Tool Box Dimensions 1x Instruction Manual x Hard Case 585 0mm 23 0 900 0mm 35 4 Product Code TFAL5TISTD 160 0mm 11 8 635mm 430mm TFATSTI 12 FLANGE ALIGNMENT TOOL Q UAL ZER OPERATOR INSTRUCTION MANUAL IM TFA REVO3 A4 NURSE N TROUBLESHOOTI NG 6 1 TFA15TI TROUBLESHOOTI NG THE ALI GNMENT PI STON ADVANCES SOME OF THE WAY AND THEN STOPS PROGRESSI NG 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 o
13. n 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 ACTUATI ON FEELS SOFT AND UNRESPONSI VE POSSIBLE CAUSE There is air in the hydraulic system RECOMMENDED ACTION Refer to an approved Equalizer distributor for further instruction FLANGE ALIGNMENT TOOL PY JEQUALIZ OPERATOR INSTRUCTION MANUAL IM_TFA_REVO3_A4 7 8 REGULATORY PARTS LI STS INFORMATION amp SERVICE KITS 7 1 REGISTERED HEAD OFFICE EQUALIZER INTERNATIONAL LTD Equalizer House Claymore Drive Aberdeen Scotland AB23 8GD 7 2 APPLI CABLE PATENT NUMBERS The following list of Patents are applicable to EQUALIZER INTERNATIONAL LTD TFA15TE and 15 tools REGI STERED PATENTS 5032582 AU690191 NO319697 6327763 318535 0916051B TFATSTI 14 FLANGE ALIGNMENT TOOL TFA15TI PARTS LIST 270000 01 REV 01 PART NO DESCRIPTION 270100 01 WING ARM WELDED ASSEMBLY 270200 01 BODY ASSEMBLY WELDED 270300 01 STRUT ASSEMBLY 270500 01 CYLINDER ASSEMBLY 271300 01 HANDLE ASSEMBLY 270400 01 ADJUSTABLE LEG ASS 270900 01 ADJUSTMENT LEG FIXING SHAFT 272000 01 SIDE SPACER BUSH 270800 01 SPIRAL CLIP 070393 01 RHS STICKER 070392 01 LHS STICKER 4 15 O N N NI IN N N N P gt j e 1 22 KIT 271400
14. ndicate 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 ZA ZA 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 flame moving machine parts sharp edges and corrosive chemicals gt CAUTION Take care to avold 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 TFATSTI risks such as heavy objects or vehicles cru
15. ols e 15 Integral Hydraulic Flange Alignment Tool TFA15TI OPERATOR INSTRUCTION MANUAL IM TFA REVO3 4 m 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 amp 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 DI SCLAI MER 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 TOOL IUALIZER OPERATOR INSTRUCTION MANUAL IM TFA REVO3 A4 INTERNATIONAL 2 4 DEFINITION OF TERMS A CAUTION is used to i
16. se 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 e the Adjustment Leg thread e the Wing Extension thread e the Cylinder Adjustment thread WING EXTENSION THREAD ADJUSTMENT LEG THREAD CYLINDER ADJUSTMENT THREAD FLANGE ALIGNMENT TOOL OPERATOR INSTRUCTION MANUAL IM TFA REVO3 4 4 5 STORAGE amp TRANSPORTATI ON 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 OPERATI NG CONDI TI ONS HYDRAULI C TOOLS Minimum Flange Contact Temperature 309C 229F Maximum Flange Contact Temperature 709C 1589F 4 7 SUB SEA USAGE Using 15 Sub Sea The 15 is actuated by means of single acting spring return hydraulic cylinder and can be used sub sea providing the following actions are taken e 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 e The tool is actuated via the hand pump by a diver e Upon completion of works the release valve is left in the fully open position until the tool has ascended to
17. sh damage can cause hose failure WARNING Applying pressure to a damaged hose may cause it to rupture WARNING Immediately replace worn 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 gt gt WARNING Only pressurize complete and fully connected hydraulic systems Do not pressurize systems that containt unconnected couplers gt CAUTION Do not lift hydraulic equioment 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 gt gt FLANGE ALIGNMENT TOOL 3 2 HANDLI NG TOOL OPERATION 3 1 GENERAL GUIDANCE The tool should be lifted and manouvered using its two handles BACK HANDLE FRONT HANDLE Prior to alignment an assesment should be carried out to determine the most appropriate positioning of the tool on
18. tool Inspection should include e visual inspection of the outer parts of the tool checking for obvious damage degradation or missing parts e 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 e strip the tool down observing the schematics in section 8 e clean the components using detergent following the manufacturer s guidelines e rinse the components to remove traces of detergent e dry the components thoroughly Inspect service and lubricate the tool immediately after the cleaning process TFATSTI OPERATOR INSTRUCTION MANUAL IM TFA REVO3 A4 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 fit 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 grea
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