FA1TM FLANGE ALIGNMENT TOOL. Operator Instruction Manual INNOVATION IN ITS MOST FUNCTIONAL FORM

Transcription

1 FA1TM FLANGE ALIGNMENT TOOL Operator Instruction Manual INNOVATION IN ITS MOST FUNCTIONAL FORM

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3 INDEX SECTION CONTENTS PAGE NO. 1 INTRODUCTION 2 2 SAFETY INFORMATION TECHNICAL DATA KIT COMPONENTS HOW THE FA1TM WORKS 4 FLANGE MISALIGNMENT DETERMINATION PROCEDURE LATERAL MISALIGNMENT 5 5 FA1TM MECHANICAL FIXED FLANGE & ROTATIONAL ALIGNMENT TOOL 5.1 INSTALLATION & OPERATION EXAMINATION & STORAGE MAINTAINANCE PARTS LIST WEIGHTS & DIMENSIONS TROUBLESHOOTING APPLICATION DIMENSIONS 11 6 RANGE OF APPLICATION 6.1 BS10, API6BX UND API6B FLANGE TABLES ASME B16.5, B16.47 AND DIN WELD NECK FLANGE TABLES SPO FLANGE TABLE 14 FA1TM IM_REV 04_29/10/2012 PAGE 1

4 1. INTRODUCTION 2. SAFETY INFORMATION The operator MUST read this maual prior to using the tools. Failure to comply with the following cautions and warnings could cause equipment damage and personal injury; read the manual fully! Read all the following instruction, warnings and cautions carefully. Follow all safety precautions The Equalizer FA1TM TOOL is an aid of use in normal maintenance and installation proce- For example, the tool can be used to assist in the replacement of ring and other types of life of the tools. izer International Ltd when in doubt as to the safety precautions and applications. Only people competent in the use of mechanical and hydraulic equipment should use these tools. In all installations the site safety requirements must be adhered to. ALSO the safety of the operator, and when present, any assisting personnel, is of paramount importance along with the safety of others including, when present, the general public. ALIGNMENT TOOL, during normal maintenance/installation operations. PAGE 2

5 A CAUTION is used to indicate correct operating or maintenance procedures and practices to A WARNING A DANGER IMPORTANT: Operator must be competent in the use of hydraulic equipment. The operator safety issues, cautions and warnings before stating to operate the Equalizer equipment. WARNING: - sure of 700bar (10,000psi) WARNING:loading causes equipment failure and possible (10,000psi) CAUTION: nents are protected from external sources of - chemicals. CAUTION: impact may cause internal damage to hose wire strands; applying pressure to a damaged hose mature hose failure. WARNING: Immediately replace worn or damaged parts with genuine Equalizer parts. Equalizer parts are designed to DANGER: hands and feet away from the tool and WARNING: Always wear suitable clothing DANGER: Do not handle pressurised hoses. Escaping oil under pressure can pene- tion immediately. WARNING: couplers. Only use hydraulic equipment in a connected system. IMPORTANT: Do not lift hydraulic equipment by the hoses or couplers. Use the carrying handle or other means of safe transport. CAUTION: Do not operate the equipment section 5.4, 6.4 & 7.4. Use only high pressure molybdenum disulphide grease. PAGE 3

6 3. TECHNICAL DATA FA1TM Tool Description Mechanical Fixed Flange Alignment Tool Aligning Force 3.1 KIT COMPONENTS 1 x FA1TM Tool 1 x Ratchet & Strap 1 x Instruction Manual Product Code: FA1TMSTD 3.2 HOW THE FA1TM WORKS 1. into the bolt-hole at the point of greatest misalignment The strap and ratchet are attached to the drop leg and around the pipe for added security. 5. SCREW HANDLE THUMB SCREW DRIVEN WEDGE BUCKLE & STRAP PAGE 4

7 4. FLANGE MISALIGNMENT DETERMINATION procedure being carried out. 4.1 LATERAL MISALIGNMENT 1. alignment occurs. direction around its circumference. Misalignment may not occur until only a few bolts remain. 2. tool being used should be attached at the maximum point misalignment (point A or point B in the examples shown below) as shown in sections 5.3, 6.3 & 7.3. POINT A POINT B POINT B POINT A PAGE 5

8 5. FA1TM MECHANICAL FIXED FLANGE ALIGNMENT TOOL 5.1 INSTALLATION AND OPERATION 1. Carry out the Flange Misalignment Determination Procedure (see section 4) to determine the points of maximum misalignment. POINT OF MAXIMUM MISALIGNMENT In this example, the points of maximum misalignment are at the top POINT OF MAXIMUM MISALIGNMENT 2. the point of maximum misalignment. NB: The tool must be parallel to pipe during operation. PARALLEL LIFT HOOK THUMB SCREW DROP LEG 3. SCREW HANDLE DRIVEN WEDGE OPPOSITE FLANGE 4. Thread the strap through the aperture on the base of the drop leg as shown. STRAP APERTURE STRAP PAGE 6

9 5. Close the clasp to secure strap. FEED THROUGH STRAP 6. alignment. Do not exceed hand pressure on the screw 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 operator s lower limbs, or to passers-by. PAGE 7

10 5.2 EXAMINATION & STORAGE 1 2 Any missing or damaged items are to be replaced as soon as possible and prior to the tool being used again. 3 Store the FA1TM in a cool, dry place and ensure all machined surfaces are greased MAINTENANCE 1 Secure the tool upright on a bench Inspect components for wear and damage, replace if necessary! If there is no damage Recommended grease COVER PLATE DRIVING WEDGE HEX SCREW CIRCLIP DRIVEN WEDGE NEEDLE BEARINGS PAGE 8

11 5.4 PARTS LIST NO. PART NO DESCRIPTION QTY BODY PLATE STICKER LEFT BODY PLATE STICKER RIGHT DRIVING WEDGE BODY FRAME DRIVEN WEDGE DRIVE SCREW COVER PLATE LEFT COVER PLATE RIGHT CRANK HANDLE SPRING PIN TORSION SPRING NEEDLE BEARING BEARING SHAFT SPRING MANDREL DISTANCE PLATE DROP LEG LEG PIN 8mm SPRING RING 8mm LEG PLASTIC INSERT M6 RELEASE KNOB M6 HEX NUT RATCHET STRAP 1 PAGE 9

12 5.5 WEIGHTS & DIMENSIONS WEIGHTS DIMENSIONS MINIMUM EXTENSION 151 mm (5.94 ) 37 mm (1.46 ) 38 mm (1.50 ) 50 mm (1.99 ) 54 mm (2.13 ) MAXIMUM EXTENSION 37 mm (1.46 ) 11 mm (0.43 ) 82 mm (3.23 ) 35 mm (1.38 ) 50 mm (1.99 ) 91 mm (3.58 ) 21 mm (0.83 ) 72 mm (2.83 ) PAGE 10

13 5.6 TROUBLESHOOTING There may be something restricting tach a second too or another method of aligning should be adapted. 5.7 APPLICATION DIMENSIONS Dimension A: must be between 14 and 82mm (0.55 and 3.29 ). Dimension B: bolt-hole diameter must be 16mm (0.63 ) or greater DIMENSION B DIMENSION A PAGE 11

14 20K 5K NPS " " " 3 1-8" " 5 1-8" " 9" 11" " " NPS " " 3 1-8" " 5 1-8" " 9" 11" " " " 15K 3K NPS " " " 3 1-8" " 5 1-8" " 9" 11" " " NPS " " 3 1-8" " 5 1-8" " 9" 11" " " " 10K 2K TOOL FA1TM FA4TM NPS " " " 3 1-8" " 5 1-8" " 9" 11" " " NPS " " 3 1-8" " 5 1-8" " 9" 11" " " " API6BX WELD NECK FLANGE RANGE OF APPLICATION API6B WELD NECK FLANGE RANGE OF APPLICATION T NOT SUITABLE FOR TOOLS 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" SUITABLE FOR FA9TE TOOL S SUITABLE FOR FA4TM TOOL 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 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" K 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" J NPS 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" 21" 22" 23" 24" H TOOL FA1TM FA4TM NPS 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" 21" 22" 23" 24" F NPS 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" 21" 22" 23" 24" 27" 29" 30" 33" 35" 36" 39" 42" 45" 48" E NPS 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" 21" 22" 23" 24" 27" 29" 30" 33" 35" 36" 39" 42" 45" 48" D NPS 4" 5" 6" 7" 8" 9" 10" 12" 13" 14" 15" 16" 17" 18" 19" 20" 21" 22" 23" 24" 29" 30" 33" 35" 36" 39" 42" 45" 48" 54" 60" 66" 72" 78" 84" 96" 108" 120" A TOOL FA1TM FA1TM FA4TM FA4TM NPS 3 1/2" 4" 5" 6" 7" 8" 9" 10" 12" 13" 14" 15" 16" 17" 18" 19" 20" 21" 22" 23" 24" 26" 27" 29" 30" 33" 35" 36" 39" 42" 45" 48" 54" 60" 66" 72" 6.1 BS10 FLANGE RANGE OF APPLICATION 6. RANGE OF APPLICATION PAGE 12

15 PN160 NOT SUITABLE FOR TOOLS NPS 3/8" 1/2" 3/4" 1" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" SUITABLE FOR FA9TE TOOL PN100 SUITABLE FOR FA4TM TOOL NPS 1/2" 3/4" 1" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" SUITABLE FOR FA1TM TOOL PN64 TOOL FA1TM FA4TM NPS 3/4" 1" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16" PN40 TOOL FA1TM FA4TM NPS 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16" 18" 20" PN25 TOOL FA1TM FA4TM NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16" 18" 20" 24" 28" 32" 36" 40" PN16 NPS 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 7" 8" 10" 12" 14" 16" 18" 20" 24" 28" 32" 36" 40" 48" 56" 72" 80" DIN WELD NECK FLANGE RANGE OF APPLICATION 2500 NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 1500 NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" TOOL FA9TE NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48" NPS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48" NPS 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48" NPS 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" NPS 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48" 150 TOOL FA1TM FA4TM 150 NPS 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" NPS 22" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48" 6.2 ASME B16.5 FLANGE RANGE OF APPLICATION ASME B16.47 FLANGE RANGE OF APPLICATION PAGE 13

16 15000 NOT SUITABLE FOR TOOLS NPS 2 1/ / SUITABLE FOR FA9TE TOOL SUITABLE FOR FA4TM TOOL NPS 2 1/ / SUITABLE FOR FA1TM TOOL 7500 NPS 2 1/ / NPS 2 1/ / NPS 2 1/ / NPS 2 1/ / NPS 2 1/ / NPS 2 1/ / NPS 2 1/ / TOOL FA1TM FA4TM NPS 2 1/ / SPO FLANGE RANGE OF APPLICATION PAGE 14