SWi Operating Manual - Equalizer International Ltd
Contents
1. m e C A a A I c tion 4 4 4 1 TI nt fd n a Y H TE r a DN R P N A A gt 12 14 20 25TE 20 2511 nt E LI INT li 4 r a 7 U J o KA FAL e U SW SW SW OPERATOR INSTRUCTION MANUAL W W W IZER OPERATOR INSTRUCTION MANUAL SWi REVO7 A4 English CONTENTS 1 INTRODUCTION 2 TOOL SAFETY 2 1 GENERAL SAFETY 2 2 PERSONNEL COMPETENCY 2 9 DISCLAI MER 2 4 DEFINITION OF TERMS 2 5 HAZARDS di GENERAL SPREADING WEDGE TOOL OPERATION dall GENERAL GUIDANCE 2 4 FLANGE SPREADING 552 FLANGE WORK 3 4 FLANGE CLOSURE 3 9 SAFETY BLOCKS 5 6 STEPPED BLOCKS 3 7 HANDLE 3 8 LANYARD 2 0 STEP DIMENSIONS amp SPREADING DISTANCES 4 TOOL MAINTENANCE 4 1 INSPECTION 4 2 CLEANING 4 3 MAINTENANCE 4 4 LUBRICATION 4 5 STORAGE amp TRANSPORTATION 4 6 OPERATING CONDITIONS 4 7 SUB SEA USAGE B SWi12 14TM Dal TOOL CAPABILITIES 5 2 TOOL FUNCTION 9 9 KIT CONTENTS 5 4 DIMENSIONS 6 SWi20 25TI 6 1 TOOL CAPABILITIES 6 2 TOOL FUNCTION 6 3 KIT CONTENTS 6 4 DIMENSIONS Zh SWi20 25TE 7 1 TOOL CAPABILITIES 7 2 TOOL FUNCTION 7 3 KIT CONTENTS 7 4 DIMENSIONS 8 TROUBLESHOOTING 8 1 SWi GENERAL TROUBLESHOOTING 8 2 SWi12 14TM TROUBLESHOOTING 9 4 SWi20 25TI TROUBLESHOOTING 8 2 SWi20 25TE TROUBLESHOOTING 9 REGULATORY INFORMATION 9 1 REGISTERED HEAD OFFICE2. 01 REV 01 DESCRIPTION QTY RETAINING WASHER M6 CSK HEX SCREW WASHER 0 8MM M5 SCKT SET SCREW M6 GRUB SCREW M6 GRUB SCREW 4 MM ALLEN KEY N ND N IQ SWi DECAL SERVICE KIT 840150 01 REV O1 ITEM NO DESCRIPTION QTY ASS 1 DECAL TI PUMP WRAP 1 2 DECAL WEDGE SML 2 3 DECAL WEDGE LRG 2 MECHANICAL CYLINDER SERVICE KIT 850110 01 REV 02 DESCRIPTION QTY THRUST WASHER 2 1 THRUST RACE 1 2 DOWEL PIN 1 3 M6 CSK HEX SCREW 1 4 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 5 FIXING SCREW 1 6 OIL FILL SCREW 1 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 1 INTEGRAL MANIFOLD SERVICE KIT 840130 01 REV 03 AGM DESCRIPTION QTY 4 1 STEEL BALL 2 2 CONE SEAT 1 3 CONE 1 4 LONG SEPARATOR SPRING 1 5 SPRING 2 6 SCREW 1 7 1 SPRING LOCK CLEVIS SERVICE KIT 840160 01 REV 01 DESCRIPTION HANDLE CLEVIS CLEVIS PIN 2 RETAINING RING 4 WIN CYLINDER SERVICE KIT 840110 01 REV 02 ITEM NO DESCRIPTION QTY 1 WIPER SEAL TENSION DIE SPRING
3. 9 2 APPLICABLE PATENT NUMBERS 10 PARTS LISTS amp SERVICE KITS 29 08 14 Wi12 14TM SWi20 25TE SWi20 25TI 2 FLANGE SPREADING WEDGES INTRODUCTI ON The Equalizer SWi Innovative Range of Flange Spreading Wedge tools has been developed to assist in the spreading of all flange joint types with a minimum access gap of 6 0mm 0 24 The tools can be used during pipework construction commissioning or during routine maintenance The SWi tools have less moving parts and no finger pinch points The tools have been developed to increase the spreading distance on each step while gaining easier access between any remaining stud bolts within the flange joint The tools provide a much higher spreading force than the existing SW flange spreading tools The SWi tools are supplied with a swivel handle safety lanyard and stepped block attachment as standard 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 e SWI12 14TM Mechanical Flange Spreading Wedge e SWI20 25TI Integral Hydraulic Flange Spreading Wedge e SWI20 25TE External Hydraulic Flange Spreading Wedge Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 3 IM SWi REVO7 4 English m TOOL SAFETY 2 1 GENERAL SAFETY These instructions cover the safe operation and maintenance of THE EQUALIZER SWi12 14TM SWi20 25TE and SWi2
4. 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 FLANGE SPREADING WEDGES AU LIZ OPERATOR INSTRUCTION MANUAL IM SWi REV07 A4 English TOOL ACTUATI ON FEELS SOFT AND UNRESPONSI VE POSSIBLE CAUSE There is air in the hydraulic system RECOMMENDED ACTION Bleed the hydraulic system Refer to an approved Equalizer distributor for further instruction 8 2 SWi20 25 TROUBLESHOOTING THE WEDGE IS ADVANCI NG BUT DOES NOT REACH FULL PRESSURE POSSIBLE CAUSE There is air in the hydraulic system RECOMMENDED ACTION Follow the Airlock Relief instructions SWi12 14TM SWi20 25TE SWi20 25TI 20 FLANGE SPREADING WEDGES 4 EQUALIZER OPERATOR INSTRUCTION MANUAL IM SWi REVO7 A4 English REGULATORY INFORMATION 9 1 REGISTERED HEAD OFFICE EQUALIZER INTERNATIONAL LTD Equalizer House Claymore Drive Aberdeen Scotland AB23 8GD 9 2 APPLICABLE PATENT NUMBERS The following list of Patents are applicable to EQUALIZER INTERNATIONAL LTD SWil2 14TM SWI20 25TI and SWi20 25TE tools REGI STERED DESIGNS 002224980 0001 002224980 0002 002224980 0003 002224980 0004 84204 353180 256685 2L201330454407 8 REGI STERED PATENTS WO01 66191 1259293B 6880809 WO98 47809 2328671B 219545 70630 98 316596 6267354 1012105B Wi12 14TM SWi20 25TE SWi20 25TI 21 FLANGE SPREADING WEDGES EQ
5. ON 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 The SWi20 25TI Spreading Wedge uses a hydraulic cylinder to advance the wedge and spread the jaws The hydraulic pressure is applied using the integrated hand pump enabling accurate control of the force applied The integral hand pump has a control lever which allows the user to select advance or retract ACTUATING THE SWi20 25 Follow the SWi Spreading Wedge Tool Operation instructions using the following instructions to actuate the SWi20 25TI tool in particular When advance is selected pumping the handle will advance the cylinder and spread the jaws RETRACTI NG THE SWi20 25 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 When using multiple tools exercise caution while retracting to keep the spreading force balanced as the gap is closed FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL IM SWi REVO7 AA English AI R RELI EF I NSTRUCTI ONS In the event of air build up within the cylinder pump subassembly the following procedure should be executed Select advance and pump the handle to extend the piston around 30mm 1 2 Remo
6. 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
7. SWi REVO7 4 English 5 3 SWi12 14TM KIT CONTENTS STANDARD KIT Product Code SWI1214TMSTDSPB 1 SWi12 14TM Mechanical Flange Spreader Wedgehead x Mechanical Cylinder x Torque Wrench with 22mm Socket 1 x Set of Safety Blocks x Pair of Stepped Blocks 1 x Lanyard 1 x Hex Key 1 x Instruction Manual x Plastic Carry Case 580mm x 330mm x 165mm 22 8 x 13 0 x 6 5 Gross kit weight Tool only weight 13 0kg 28 6 6 2kg 13 710 5 4 SWi12 14TM DIMENSIONS TOOL DIMENSIONS CLOSED FLANGE SPREADINC WEDGES SWI20 25TI INTEGRAL HYDRAULIC FLANGE SPREADI NG WEDGE SWI20 25TI Spreading Wedge uses an integral hydraulic cylinder to advance the wedge and spread the jaws 6 1 SWi20 2511 TOOL CAPABILITIES SPREADI NG FORCE With the maximum hydraulic pressure of 700bar 10 000psi applied the tool can apply 20T 200kN spreading force on the lst step up to 24T 240kN spreading force on the 4th step SPREADI NG GAP SEE SECTI ON 3 9 Using only the 1st step the tool can spread from 6 0mm to 40 0mm 0 24 1 6 Using all 4 steps but without the stepped blocks the tool can spread from 6 0mm to 87 5mm 0 24 3 4 Using both steps on the stepped blocks the tool can spread 48 5mm 103 5mm 1 9 4 1 Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 14 IM SWi REVO7 4 English 6 2 SWi20 2511 TOOL FUNCTI
8. reservoir body is held down when removing the refilling plug as pulling up on the reservoir body will release the bladder within and oil may spill out Fill the reservoir to the top with a premium quality hydraulic oil of the grade 15 cSt Reinsert the refilling plug wipe away any oil and reassemble by reversing the disassembly process 7 3 SWi20 25TE KIT CONTENTS MI NI KIT Product Code SWi2025TEMIN 1 x SWi20 25TE Flange Spreader Wedgehead 1 x 10 000psi 700bar Hydraulic Cylinder 1 x Set of Safety Blocks 1 x Pair of Stepped Blocks 1 x Hex Key 1 x Lanyard 1 x Instruction Manual x Plastic Carry Case Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 17 IM SWi REVO7 4 English 580mm x 330mm x 165mm 22 8 x 13 0 x 6 5 Gross kit Weight Tool only weight 11 6kg 25 6lb 6 4kg 14 116 STANDARD KIT Product Code SWI2025TESTDSPB 1 x SWi20 25TE Flange Spreader Wedgehead 1 10 000psi 700bar Hydraulic Cylinder 1 10 000psi 700bar Hydraulic Hose 2m 78 75 with 90 degree elbow 1 x 10 000psi 700bar HP350S Sealed Hand Pump with Gauge 1 x Set of Safety Blocks x Pair of Stepped Blocks 1 x Hex Key 1 x Lanyard 1 x Set of Instruction Manuals x Plastic Carry Case 920mm x 500mm x 205mm 36 2 x 19 7 x 8 1 Gross kit Weight Tool only weight 20 7kg 45 6 6 4kg 14 10 FLANGE SPREADINC WEDGES MM JEQUALIZERT OPERATOR INSTRUCTION MANUAL n swi REVO7 A4
9. torque has been achieved Do not continue to apply force after the Torque Wrench has clicked Special care should be taken when using low torque settings FLANGE SPREADING WEDGES ER ER EQUALIZ INTERNATI Gi TORQUE WRENCH CARE Prior to storing the Torque Wrench and between use leave the Torque Wrench with its lowest torque setting selected To clean the Torque Wrench wipe gently with a damp cloth Avoid using any detergent or solvent as this may detrimentally affect the factory fitted internal lubrication of the mechanism ACTUATI NG THE SWi12 14TM Follow the SWi Spreading Wedge Tool Operation instructions using the following instructions to actuate the SWi12 14TM tool in particular Actuate the tool by manually applying force to the torque wrench in the clockwise direction see Torque Wrench Usage Gradually increase the torque setting of the Torque Wrench over several steps for example 30Nm or 20ft lb each time Do not exceed the maximum SWL torque of 175N m 1308 16 When using multiple tools ensure that the torque settings of all wrenches correspond to keep the spreading force balanced RETRACTI NG THE SWi12 14TM Retract the tool by manually applying force to the torque wrench in the anti clockwise direction When using multiple tools work around all wrenches to keep the spreading force balanced as the gap is closed Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 13 IM
10. 0 25 FLANGE SPREADING WEDGE 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 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 SPREADINC WEDGES risks such as heavy objects or vehicles crush damage can cause hose failure 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 practice
11. 0313 01 SPIRAL RETAINING RING 830100 01 SWi JAW SOLD IN PAIRS 10 RETAINING WASHER 11 M6 CSK HEX SCREW 12 WASHER 0 8MM 13 M5 SCKT SET SCREW 14 M6 GRUB SCREW 15 DECAL TI PUMP WRAP 16 San DECAL WEDGE LRG 17 DECAL WEDGE SML 18 ON REQUEST DECAL TI CYLINDER WRAP TI CYLINDER PARTS LIST 840300 01 REV 02 ITEM NO PART NO 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 3 6901 01 PUMP PISTON HOUSING 1 840302 01 BLADDER HOUSING 1 8 3 2401 01 PISTON HOUSING CAP 1 9 3 2501 01 SWIVEL CLEVIS 1 10 3 3201 01 CLEVIS SCREW 1 11 373301 01 ANTI LOOSEN NUT 1 12 373101 01 1 13 372601 01 RETAINING NUT 1 14 373401 01 1 15 306502 01 HANDLE GRIP 1 PART NO DESCRIPTION lt HANDLE CLEVIS KIT 840160 01 CLEVIS PIN RETAINING RING WIPER SEAL TENSION DIE SPRING SPRING LOCK KIT 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
12. 0psi of hydraulic pressure applied the tool can apply 20T 200kN spreading force on the 1st step up to 24T 240kN spreading force on the 4th step SPREADI NG GAP SEE SECTI ON 3 9 Using only the 1st step the tool can spread from 6 0mm to 40 0mm 0 24 1 6 Using all 4 steps but without the stepped blocks the tool can spread from 6 0mm to 87 5mm 0 24 3 4 Using both steps on the stepped blocks the tool can spread 48 5mm 103 5mm 1 9 4 1 Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 16 IM SWi REVO7 4 English 7 2 SWi20 25TE TOOL FUNCTI ON HYDRAULI C TOOL OPERATI ON The SWi20 25TE Spreading Wedge uses a hydraulic cylinder to advance the wedge and spread the jaws The hydraulic pressure is applied using an external hand pump enabling accurate control of the force applied HAND PUMP OPERATI ON Consult the Instruction Manual for the Equalizer HP Hand Pump supplied in the kit ACTUATING THE SWi20 25TE Follow the SWi Spreading Wedge Tool Operation instructions using the following instructions to actuate the SWi20 25TE tool in particular When the Hand Pump release valve is closed pumping the Hand Pump handle will advance the cylinder and spread the jaws When using multiple tools ensure that the spread of all tools correspond to keep the spreading force balanced The Maxi kit includes a twin port hand pump which can be used to actuate two tools simultaneously R
13. A Do not rely upon hydraulic systems for supporting the access gap during flange work Do not allow fingers hands or other body parts into the space created between the flanges 3 4 FLANGE CLOSURE Allow the flanges to return to their closed position by gradually retracting the tool Consult the relevant section of the manual for tool specific instructions on how to retract each tool Before the tool has fully retracted insert the Safety Blocks into the flange joint Ensure the full breadth of the selected Safety Block step is fully inserted before gradually retracting the tool until the flange load has been applied to them To use the next smallest step actuate the wedges to around 75 prior to inserting back into the joint Place the tool in the gap and actuate enough to relieve the load on the Safety Blocks In this way the flange joint can be progressively closed As the flange approaches its fully closed position support the tool to avoid it dropping out of the joint Ensure that care is taken to prevent objects being dropped Dropped objects pose a risk of personal injury or equipment damage Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 6 IM SWi REVO7 4 English 3 5 SAFETY BLOCKS Each tool is supplied with a set of 2 Safety Blocks The Safety Blocks have been designed with steps that match the spreading distance of the SWI tools 3 6 STEPPED BLOCKS The SWi Range of Flange Spre
14. ETRACTI NG THE SWi20 25TE Opening the release valve 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 When using multiple tools exercise caution while retracting to keep the spreading force balanced as the gap is closed AI R LOCK RELI EF If full pressure is not achieved an air lock may be present in the hydraulic system The following procedure can be executed to relieve any air locks Connect the hand pump to the tool with the hydraulic hose Close the release valve on the pump and prime the pump until the hydraulic cylinder is fully extended and a small pressure is achieved FLANGE SPREADING WEDGES ER ER EQUALIZ INTERNATI With the hand pump elevated above the level of the tool and the tool in an upright position open the hand pump release valve causing any air that is within the system to be forced up through the pump and vented into the oil reservoir Repeat this process three further times to ensure that all air is removed from the system The tool should now reach full working pressure Disconnect the hand pump from the hydraulic hose grip the baseplate of the hand pump body in a vice with the pump body vertical and the main handle at the top Remove the four nuts holding the main handle and lift off Grip the refilling plug with pliers and extract it by pulling and twisting simultaneously Ensure the
15. English ER MAXI KIT Product Code SWi2025TEMAXSPB 2 X SWi20 25TE Flange Spreader Wedgeheads 2 x 10 000psi 700bar Hydraulic Cylinders 2 x 10 000psi 700bar Hydraulic Hoses 2m 78 75 with 90 degree elbow 1 10 000psi 700bar HP550D Sealed Hand Pump with Gauges 2 x Sets of Safety Blocks 2 X Pairs of Stepped Blocks 2 X Hex Keys 2 x Lanyards 1 x Set of Instruction Manuals 1 Plastic Carry Case 920mm x 500mm x 205mm 36 2 x 19 7 x 8 1 Gross kit Weight 33 0kg 72 8lb Tool only weight 6 4kg 14 10 SWi20 25TE DIMENSIONS TOOL DIMENSIONS 312mm CLOSED i Wi12 14TM SWi20 25TE SWi20 25TI 18 FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL IM SWi REVO7 4 English TROUBLESHOOTING 8 1 SWi20 2511 TROUBLESHOOTING THE WEDGE ADVANCES SOME OF THE WAY AND THEN STOPS PROGRESSI NG POSSIBLE CAUSE The air vent is obstructed by dirt or debris RECOMMENDED ACTION Carefully unblock the air vent using a small blunt object THE WEDGE 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 Refill with clean oil and bleed the hydraulic system POSSIBLE CAUSE Retract is selected RECOMMENDED ACTION Select Advance and pump the handl
16. FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL IM SWi REVO7 4 English 4 6 OPERATI NG CONDI TI ONS GREASE LI MI TATI ONS 59C 239F 409C 1049F Minimum Temperature Maximum Temperature MECHANI CAL TOOLS 302C 220F 1509C 3029F Minimum Jaw Contact Temperature Maximum aw Contact Temperature HYDRAULI C TOOLS 309C 229F 709C 1589F Minimum Jaw Contact Temperature Maximum aw Contact Temperature 4 7 SUB SEA USAGE The Equalizer range of HP hydraulic hand pumps are fitted with a sealed bladder type reservoir system that allows for sub sea operation Using SWi12 14TM Sub Sea The SWi20 25TM is actuated mechanically and can be used sub sea providing the following actions are taken e The tool is actuated via the torque wrench by a diver e he tool and pump are stripped down cleaned and lubricated immediately to minimise corrosion Using SWi20 25TI Sub Sea SWi20 25TI is actuated by means of single acting spring return hydraulic cylinder and can be used sub sea providing the following actions are taken e he 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 the surface e The tool and pump are stripped down
17. I ONS STEP DIMENSIONS amp SPREADING N DISTANCES Sb LARGE SAFETV BLOCK O N EN RA IS BO AD SMALL SAFETY BLOCK lt lt CN GA LEN EN lt lt lt N oo OES Y EN HEN lt lt aon O eS DO KY TOOL OPEN TOOL CLOSED Wi12 14TM SWi20 25TE SWi20 25TI 9 FLANGE SPREADING WEDGES TOOL MAI NTENANCE 4 1 I NSPECTI ON A thorough inspection should be carried out prior to usage storage or transportation to ensure the completeness and condition of the tool Inspection should include visual inspection of the outer parts of the tool checking for obvious damage degradation or missing parts visual inspection of the wedge tip requiring tool actuation or jaw removal Damage to the wedge tip is indicative of tool over load Cleaning and servicing should be undertaken as required prior to the tool being used stored or transported 4 2 CLEANI NG 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 strip the tool down observing the schematics in section 10 clean the components using detergent following the manufacturer s guidelines rinse the components to remove traces of detergent dry the components thoroughly Inspect service and lubricate the tool immediately after the cleaning pro
18. STEEL BALL STEEL BALL CONE SEAT CONE KIT 375020 01 LONG SEPARATOR SPRING SPRING SCREW SPRING LOCK SWi20 25TE PARTS LIST 830000 01 REV 02 PART NO DESCRIPTION QTY EDGE 2 830202 01 WEDGE TIP 1 3 830300 01 HYDRAULIC CYLINDER 10 000 PSI 1 4 830313 01 SPIRAL RETAINING RING 2 5 830400 01 HANDLE 1 6 830500 01 CAPTIVE FASTENER 2 7 830600 01 LUGS 1 8 830800 01 ANCHOR POINT 1 9 830100 01 SWi JAW SOLD IN PAIRS 2 10 RETAINING WASHER 4 M6 CSK HEX SCREW 2 PUN WASHER 0 8MM 6 M6 SCKT SET SCREW 1 M5 SCKT SET SCREW 4 DECAL WEDGE LRG 2 ES DECAL WEDGE SML 2 DECAL TI PUMP SURPLUS FOR TE amp TM 1 ON REQUEST SW TE CYLINDER WRAP 1 TE HYDRAULIC CYLINDER PARTS LIST 830300 01 REV 04 ITEM NO 1 830301 01 CYLINDER BODY 830302 01 PISTON 830303 01 CYL END CAP 771110 01 3 8 COUPLER 10kPST 1 TENSION DIE SPRING SPRING LOCK M6 CAPSCREW PART NO DESCRIPTION e M N gt KIT 840110 01 N BACK UP RING M6X25 SCKT H SCREW M6 GASKET SEAL N SAFETY BLOCK SMALL 830021 01 REV 02 x N SAFETY BLOCK LARGE 830020 01 REV 02 STEP BLOCK PAIR 830050 01 REV 02 SAFETY BOND 830080 01 REV 01 SWi FASTENER SERVICE KIT 840140
19. UALIZER OPERATOR INSTRUCTION MANUAL Swi REVO7 A4 English INE ET INTA TT PON FASE 10 PARTS LISTS amp SERVI CE KI TS Wi12 14TM SWi20 25TE SWi20 25TI 22 FLANGE SPREADING WEDGES SWi12 14TM PARTS LIST 850000 01 REV 02 MEM PART NO DESCRIPTION QTY 1 830201 01 WEDGE I 2 830202 01 WEDGE TIP I 3 830400 01 HANDLE I 4 830500 01 CAPTIVE FASTENER 2 LUGS 830800 01 ANCHOR POINT I 830313 01 SPIRAL RETAINING RING I 850300 01 MECHANICAL CYLINDER I SWi JAW SOLD IN PAIRS 2 10 RETAINING WASHER 2 11 M6 CSK HEX SCREW 3 12 Bi ann WASHER 0 8MM 2 13 M5 SCKT SET SCREW I 14 M6 GRUB SCREW 2 15 DECAL WEDGE LRG 2 TN T DECAL WEDGE SML 2 17 DECAL TI PUMP SURPLUS IN TE amp TM 1 18 ON REQUEST DECAL TM CYLINDER WRAP I MECHANICAL CYLINDER PARTS LIST 850300 01 REV 03 PART DESCRIPTION QTY 1 850301 01 CYLINDER BASE I 2 850302 01 DRIVE ROD I 3 850303 01 CYL CAP I 4 850304 01 PUSH ROD I 5 850305 01 DRIVE HEX I 6 850306 01 THREAD STOP I 7 THRUST WASHER 2 8 KIT THRUST RACE I 9 850110 01 DOWEL PIN 1 10 M6 CSK HEX SCREW I SWi20 25TI PARTS LIST 840000 01 REV 03 PART NO DESCRIPTION QTY 830201 01 WEDGE 830202 01 WEDGE TIP 840300 01 H CYLINDER amp PUMP TI ASSEMBLY 830500 01 CAPTIVE FASTENER 830600 01 LUGS 830800 01 ANCHOR POINT 83
20. ader tools are supplied as standard with a pair of Stepped Blocks These can be fixed to the jaws individually or in pairs to increase the effective jaw thickness and therefore the maximum spreading distance Use of the Stepped Blocks also enables the SWi Flange Spreaders to be used in a joint with a larger access gap Wedge protrusion can be minimised by the use of Stepped Blocks reducing the penetration into the joint This enables for example spectacle blinds to be changed Attach the stepped block to the tool using the M6 counter sunk screw Use the hex key supplied to tighten the screw into the threaded hole in the jaw of the tool Repeat for second Stepped Block to further increase the effective jaw thickness if required e Ea Ea FLANGE SPREADING WEDGES UAL ER OPERATOR INSTRUCTION MANUAL IM SWi REVO7 A4 English To remove the Stepped Blocks unscrew the M6 counter sunk screw Do not force the screw out of the Stepped Block it is deliberately retained to prevent it becoming misplaced Use the tool as per the Tool Operation instructions Ensure that there is a minimum hold of 15mm 0 59 and that the full width of the block is used 15 0mm 0 59 MINIMUM HOLD 3 7 HANDLE The handle can be swivelled around the central axis of the tool to improve access to the Flange and allow the tool to be easily held in the vertical or horizontal orientation If the tool is being used in an appli
21. cation where access space is very limited the handle can be removed temporarily Unclip the spiral ring and remove the anchor point and handle Special caution should be exercised when working with a tool in this configuration Replace the handle immediately following the task HANDLE SPIRAL RING ANCHOR POINT Wi12 14TM SWi20 25TE SWi20 25TI 7 3 8 LANYARD The SWi tools are supplied with a secure anchor point and a lanyard The lanyard should be used to minimise the risks associated with the tool dropping Attach one end of the lanyard to the tool using the supplied shackle The other end of the lanyard should be fixed to a secure point close to the work site using an appropriate shackle Avoid using the lanyard as a means for picking up or carrying the tool Do not fix the lanyard to the handle The anchor point and lanyard have been engineered to safely sustain a drop over the full lanyard length It is recommended that all parts are inspected following a drop incident as damage may compromise the safety of the tool ZA A 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 FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL IM SWi REVO7 A4 English Wi12 14TM SWi20 25TE SWi20 25TI 8 FLANGE SPREADING WEDGES 3 9 SAFETY BLOCK DI MENS
22. cess Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 10 IM SWi REVO7 4 English 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 Do not exceed 5 0N m 3 68ft lb of torque when tightening the J aw retaining screws The jaws have been engineered to have a small degree of movement when correctly tightened If topping up or replacing hydraulic oil as part of a service use only premium quality hydraulic oil of the grade 15cSt 4 4 LUBRI CATI ON PROCEDURE Apply grease 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 Remove the jaws as per the dissassembly instructions Apply grease liberally to the following areas the large flat surface on the underside of the jaws the internal flat surfaces in the square cut out in the Jaws 4 5 STORAGE amp TRANSPORTATION 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
23. cleaned and lubricated immediately to minimise corrosion Wi12 14TM SWi20 25TE SWi20 25TI 11 Using SWi20 25TE Sub Sea The SWi20 25TE is actuated by means of single acting spring return hydraulic cylinder and can be used sub sea providing the following actions are taken e he gauge and manifold are removed from the Equalizer HP350S D hydraulic hand pump and the coupler is fitted directly to the pump outlet tools in this configuration can be requested from Equalizer e tool is connected to the Equalizer HP350S D pump whilst still top side e he 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 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 the surface e The tool and pump are stripped down cleaned and lubricated immediately to minimise corrosion Please note that a sub sea SWI20 25TE tool cannot be operated from top side by use of a down line The return springs in the hydraulic cylinders do not have sufficient force to close the tool if used with a down line from a top side pump therefore the standard hydraulic tools will not function correctly and may jam in place if used in this configuration FLANGE SPREADINC WEDGES SWI12 14TM MECHANI CAL FLANGE SPREADI NG WEDGE The SWi12 14TM Spreadi
24. e POSSIBLE CAUSE Air has accumulated around pump inlet when used upside down RECOMMENDED ACTION Bleed any air from the hydraulic reservoir Inspect the tool for oil leaks on the reservoir possibly indicative of a perished bladder Refer to an approved Equalizer Wi12 14TM SWi20 25TE SWi20 25TI 19 distributor for repair POSSIBLE CAUSE The inlet check valve or intermediate valve ball has become stuck RECOMMENDED ACTION Dismantle the check valve free and clean the valve balls Refer to an approved Equalizer distributor for repair THE WEDGE MOVES AS I NTENDED 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 Check cleanliness of valve ball Re seat using a hammer and punch 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 Check cleanliness of valve ball Re seat using a hammer and punch Refer to an approved Equalizer distributor for further instruction HYDRAULI C PRESSURE SLOWLY DI MI NI SHES AND THE PUMP HANDLE DOES NOT RI SE POSSIBLE CAUSE The release valve is leaking RECOMMENDED ACTION Refer to an approved Equalizer distributor for further instructions POSSIBLE CAUSE The piston seal is leaking RECOMMENDED ACTION
25. izer 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 containt 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 FLANGE SPREADING WEDGES ALIZERI OPERATOR INSTRUCTION MANUAL im_Swi_REV07_A4 English AMIE SWI SPREADI NG WEDGE TOOL OPERATION 3 1 GENERAL GUI DANCE Before attaching the tool ensure at least two flange bolts remain in place These should be 180 degrees apart with 3 2 their nuts loosened sufficiently to enable flange work to FLANGE SPREADI NG be carried out Lea
26. ng Wedge uses mechanical torque to advance the wedge and spread the jaws 5 1 SWi12 14TM TOOL CAPABILITIES SPREADI NG FORCE Maximum SWL torque of 175N m 130 0 will generate 12T 120kN spreading force on the 1st step and 14T 140kN spreading force on the 4th step Wi12 14TM SWi20 25TE SWi20 25TI OPERATOR INSTRUCTION MANUAL 12 IM SWi REVO7 4 English 5 2 SWi12 14TM TOOL FUNCTI ON MECHANI CAL TOOL OPERATI ON The SWi12 14TM Spreading Wedge uses mechanical torque to advance the wedge and spread the jaws The torque is applied using the supplied Torque Wrench enabling accurate control of the force applied TORQUE WRENCH USAGE Holding the Torque Wrench in one hand unlock the knurled handle by turning the locking knob anti clockwise Select the torque setting by turning the knurled handle until the required torque value is indicated For example to set the Torque Wrench to 46Nm turn the knurled handle until the O on the fine scale aligns with 40Nm on base scale now turn slightly further until the 6 on the fine scale aligns with the central line Setting an imperial torque in ft lb is done in exactly the same Way Lock the handle by turning the locking knob clockwise Install the supplied socket onto the Torque Wrench and attach to the tool Slowly and smoothly pull the handle gradually applying more force until you feel or hear the Torque Wrench click indicating that the selected
27. s 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 N A 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 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 Wi12 14TM SWi20 25TE SWi20 25TI 4 PP gt gt 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 Equal
28. ve the Oil Fill Screw using an appropriate hex key ensuring the tool is on its side with the Oil Fill facing upwards top photo ee p w Replenish any missing hydraulic oil by pouring into the Oil Fill hole until excess spills over middle photo Sit the tool with the wedge facing uphill and the open Oil Fill hole still facing upwards on a gentle slope around 30 degrees from horizontal Very slowly move the selector from advance to retract and wait for the tool to fully retract lower photo Replace the Oil Fill Screw Repeat this procedure 3 times Wi12 14TM SWi20 25TE SWi20 25TI 15 6 3 SWi20 25TI KIT CONTENTS STANDARD KIT Product Code SWI2025TISTDSPB 1 x SWi20 25TI Flange Spreader Wedgehead 1 x 10 000psi 700bar Integral Hydraulic Pump Cylinder 1 x Set of Safety Blocks 1 x Pair of Stepped Blocks 1 x Lanyard 1 x Hex Key 1 x Carry Strap 1 x Instruction Manual 1 x Carry Case 580mm x 330mm x 165mm 22 8 x 13 0 x 6 5 Gross kit Weight Tool only weight 13 8kg 30 4lb 8 5kg 18 71 6 4 SWi20 25TI DIMENSI ONS TOOL DIMENSIONS CLOSED 4 FLANGE SPREADING WEDGES SWI20 25TE HYDRAULI C FLANGE SPREADI NG WEDGE The SWi20 25TE Spreading Wedge uses an external hydraulic pump to drive the cylinder to advance the wedge and spread the jaws 7 1 SWi20 25TE TOOL CAPABILITIES SPREADI NG FORCE With 700bar 10 00
29. ving these bolts in place will help to reduce unwanted lateral flange movement during flange Spread the flanges apart by actuating the tool Consult spreading the relevant section of the manual for tool specific instructions on how to actuate each tool Once the joint has been opened to the desired distance or if the tool has reached its maximum travel insert the Safety Blocks into the flange joint Ensure the full width of the selected Safety Block step is fully inserted before gradually retracting the tool until the flange load has been applied to them Prior to spreading an assesment should be carried out to determine the most appropriate positioning of the tools around the joint A minimum of 2 tools should always be used Determine the flange joint access gap a minimum access gap of 6 mm 0 24 is required for the SWi tools The access gap is the clearance between the surfaces onto which the wedge will apply its spreading force EN MINIMUM ACCESS GAP The wedges can then be retracted fully and inserted again using the next step In this way the flange joint can be iteratively opened further until the required spread Place the tool into the access gap with the full width of is reached the selected step fully inserted up to the heel Wi12 14TM SWi20 25TE SWi20 25TI 5 FLANGE SPREADING WEDGES EQUALIZER INTERNS ER 3 3 FLANGE WORK Z
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