Equalizer FC10TE Instrucciones de montaje
OPERATOR INSTRUCTION MANUAL
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
HYDRAULIC
FLANGE CLOSING
TOOL
FC10TE
OPERATOR INSTRUCTION MANUAL IM_FC10TE_Rev09_A4
FC10TE HYDRAULIC FLANGE CLOSING TOOL
1
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. FC10TE HYDRAULIC FLANGE CLOSING TOOL
3.1 TOOL CAPABILITIES
3.2 TOOL FUNCTION
3.3 KIT CONTENTS
3.4 TOOL DIMENSIONS
3.5 TOOL MAINTENANCE
4. REGULATORY INFORMATION
4.1 REGISTERED HEAD OFFICE
5. PARTS LISTS & SERVICE KITS
15/02/2019
OPERATOR INSTRUCTION MANUAL IM_FC10TE_Rev09_A4
FC10TE HYDRAULIC FLANGE CLOSING TOOL
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1.
INTRODUCTION
The Equalizer FC10TE Hydraulic Flange Pulling Tools
are tools designed to assist in the maintenance and
installation of pipeline ange assemblies.
The FC10TE Hydraulic Flange Pulling Tools are used to
close any ange joint made up of anges with a bolt
hole of 22mm (7/8”) or greater producing a pulling force
of up to 20T when used as recomended in pairs. The
FC10TE can close from a distance of 600mm.
The use of these instructions will promote safe use, and
maximise the service life of the tool.
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:
• FC10TE Flange Closing Tool
2.
SAFETY INFORMATION
2.1
GENERAL SAFETY
These instructions cover the safe operation and
maintenance of THE EQUALIZER FC10TE HYDRAULIC
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
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.
OPERATOR INSTRUCTION MANUAL IM_FC10TE_Rev09_A4
FC10TE HYDRAULIC FLANGE CLOSING TOOL
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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
(10000 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).
DANGER: 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
hosesor couplers.Useonly thedesignated 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.
WARNING: Never place ngers in a joint held by
an activated tool
CAUTION: Never hammer or force the tool into a
bolt hole; if it does not t easily you are using the
wrong size of tool.
OPERATOR INSTRUCTION MANUAL IM_FC10TE_Rev09_A4
FC10TE HYDRAULIC FLANGE CLOSING TOOL
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3.
FC10TE
HYDRAULIC FLANGE
CLOSING TOOL
3.1
TOOL CAPABILITIES
CLOSING FORCE
Closing force = 10 tonnes per tool
It is recommended that tools are used in pairs, giving 2
x 10 = 20 tonnes
If using the Equalizer HP550S/D Hand Pump (or if a
hydraulic pressure gauge is tted), the spreading force
per tool can be determined by taking a reading from the
gauge.
Gauge pressures will produce spreading forces as set out
below.
Pressure Bar 69 207 345 483 690
psi 1000 3000 5000 7000 10000
Spreading
force T135710
RANGE OF APPLICATION
Closing distance = 600mm - 0mm (23.5” - 0”)
Can be used on any ange joint with ange bolt holes of
22mm (7/8”) or greater.
Hydraulic oil grade: 15 centistokes(cSt) @ 40°C tested
by ASTM D 445
The FC10TE has not been designed or certied
as lifting equipment. If the tool is being used
to close ange joints with a Vertical Axis the
FC10TE must be used in conjuction with
certied lifting equipment.
3.2
FC10TE TOOL FUNCTION
FC10TE GENERAL GUIDANCE
1. The Pull Rod is inserted through the coresponding
bolt holes in the anges.
PULL ROD
2. The FC10TE Tool is slid over the pull rod untill the face
of the tool comes into contact with the ange.
FC10TE TOOL
3. The ratchet nut is slid over the pull rod and locked
into the tool.
REACTION NUT
4. The hydraulic hand pump and hoses are connected
HAND PUMP
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FC10TE HYDRAULIC FLANGE CLOSING TOOL
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5. The Hand Pump is actuated untill the cylinders reach
full stroke.
6. The Hydraulic pressure is released and the cylinders
are allowed to fully retract.
RELEASE VALVE
7. The Hand Pump is actuated until the cylinders reach
full stroke.
8. Steps 6 and 7 are repeated untill the ange joint is
closed.
INSTALLATION AND OPERATION
Note: Prior to attaching the FCT10TE it is
important that the location of the tools around
the ange joint is considered. the tools should
be attached to the bolt holes at the points
where the highest load is expected.
Consideration should also be given to the
ange Gasket/Seal ring, it may be neccesary
toinsertthe Gasket/SealringPrior toattaching
the tools.
1. The anges are placed with a gap of no more than
600mm between the backs of the anges and within
reasonable alignment.
2. Having determined the best location for the tools
insert both pull rods through the bolt holes in one
ange and into the corresponding bolt holes of the
mating ange.
SHORT
THREADED
SECTION
LONG THREADED SECTION
CAUTION: The Pull Rod has a long threaded
section and a short threaded section. The
threads on both sections are different!, The
short threaded end of the Pull Rod must be
passed through the anges to mate with the
pull nut.
OPERATOR INSTRUCTION MANUAL IM_FC10TE_Rev09_A4
FC10TE HYDRAULIC FLANGE CLOSING TOOL
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6. The Secondary Ratchet Nuts are then slid up the pull
rods until the nut retaining pins engage in the key
holes in the FC10TE’s rear plate.
RETAINING
PIN KEY HOLE
SECONDARY
RATCHET
NUT
PULL ON THE
RELEASE SLEEVE
TO RETRACT
THE NUT
PULL ON THE
MAIN BODY TO
ADVANCE THE
NUT
ADVANCE
RETRACT
LOCK
LOAD ON THIS
FACE WILL
LOCK THE NUT
3. The Rod washers are slid over the Pull Rod and rotated
to align with the curvature of the ange.
4. The Pull Nuts are threaded on to the pull rod.
5. The FC10TE tools are slid on to the Pull Rods until the
face of the tools are in contact with the back of the
flange. You will feel / hear a clicking as the Primary
Ratchet nut slides along the Pull Rod.
OPERATOR INSTRUCTION MANUAL IM_FC10TE_Rev09_A4
FC10TE HYDRAULIC FLANGE CLOSING TOOL
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RELEASE
VALVE
PRESSURE
GAUGE
HP550S
RELEASE
VALVE
PRESSURE
GAUGE
HP550D
9. The Pumps can now be connected to the tools using
the Hoses supplied. ensure all couplers are fully
tightened.
HP550D
HP550S
Note: The Ratchet Nut is designed to move
freely when advanced along the pull rod
(indicated by the green arrow).
The nut can only be advanced by gripping
on the nut body.
The nut will lock on to the pull rod when a
force is applied to the load face of the nut.
It is not possible to move the nut until the
load is removed from the load face of the
nut.
The nut can only be retracted by pulling on
the release sleeve in the retract direction
(indicated by the yellow arrow).
7. Rotate the secondary ratchet nuts clockwise 30
degrees to lock them on to the rear plate.
REAR PLATE
8. Check that the release valves on the hand pumps are
open by rotating fully anti-clockwise and then connect
the Pressure gauges to the pump ensuring all the
couplers are fully hand tight.
RELEASE
VALVE
OPERATOR INSTRUCTION MANUAL IM_FC10TE_Rev09_A4
FC10TE HYDRAULIC FLANGE CLOSING TOOL
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12. Release the hydraulic pressure from the system. This
will allow the Actuators to retract and the secondary
ratchetnutto advancealongthepull rodautomatically.
13. Once the Actuators have fully retracted close the
release valve and continue priming the hand pump
until the actuators have reached full stroke.
14. Repeat steps 12 and 13 to continue closing the gap
between ange faces. Adjust the pressure on each
tool as neccesary to maintain an even gap around
the joint.
Note: If you are experiencing misalignment
of the anges during the nal stages of
closing the joint Equalizer International’s
Flange Alignment tools can be used in
conjuction with the FC10TE. For information
on these tools please vist “www.
equalizerinternational.com”
Note: Prior to operating the Equalizer
Hydraulic Hand Pumps please read the
Hydraulic Hand Pump Manual. This is
included in all tool kits and is also available
for download from
www.equalizerinternational.com
10. Close the release valve on the pump by turning
clockwise. To commence flange closing gently prime
the pump(s) adjusting the pressure on each tool as
neccessary to maintain parrallelism between flange
faces. If the pressure increases to 10,000 PSI with no
movement of the flanges then a greater number of
tools will be required to close the joint.
RELEASE
VALVE
11. Continue priming the Hand Pump untill the actuators
have reached full stroke 100mm (4”).
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FC10TE HYDRAULIC FLANGE CLOSING TOOL
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17. Now that the pressure has been released from
the system the hydraulic Pump and Hoses can be
detached.
18. Now that the load has been released from the tools,
the secondary ratchet nut can be removed. Rotate the
nut anticlock wise through 30 degrees to disengage it
from the rear plate then slide the nut off by gripping
and pulling on the pull sleeve section of the nut.
PULL
SLEEVE
SECONDARY
RATCHET
NUT
15. Once the ange joint has been fully closed insert and
tighten as many bolts as possible with the FC10TE still
in position.
FLANGE
BOLTS
CAUTION: The FC10TE Ratchet Nuts will not
release until they are fully unloaded, this is
achieved by tightening the ange bolts until all
the load has been transferred onto them.
16. Once the ange bolts have been tightened sufciently
to remove any load from the FC10TE turn the release
valves on the pump(s) anticlockwise to release the
pressure from the hydraulic system.
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