MINI-GAP FLANGE SPREADER
Contents
1. 1 _ 2500 Small Bar Small Bar Small Bar Small Large Bar Large Bar Large Bar Small Bar Small Bar Small Bar Small Large Bar Large Bar Large Bar Small Small Bar Small Bar Small Bar Large Bar Large Bar Large Bar Small Bar Small Bar Small Bar Small Large Bar Large Bar Large Bar Small Bar Large Bar Large Large Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large LargeBar Large Bar Large Bar Small Bar Large Bar LargeBar Large Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Large Bar LargeBar Large Bar Large Bar Small Bar Large Bar LargeBar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar ASME B16 5 Socket welded flange 1500 Small Bar Small Bar Small Bar Large Bar Small Bar Small Bar Small Large Bar Small Bar Small Bar Small Bar Large Bar Small Bar Small Bar Small Bar Large Bar Small Bar Small Bar Small Bar Large Bar Small Bar Small Bar Small Bar Large Bar Small B2. 2617 2617 5 5 jews ews abe a Jeg awe Jeg e Jeg a Jeg a abe Jeg Jeg a Jeg a Jeg Jeg Jeg deg 1 5 deg 5 deg 1 5 deg jews deg jews deg 5 deg 5 Jeg ews deg 1 5 deg jews 2617 2617 Jeg Jeg 2617 Jeg 2617 Jeg Jeg ews Jeg euis ews euis ews euis Jeg euis aw aw Jeg a seg aw Jeg seg a aw aw Jeg eDue seg a aw aw Jeg Jeg a seg a aw aw
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4. Is lightweight and easy to use FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL IM MG REV07 A4 21 11 12 PAGE 1 2 SAFETY INFORMATION The operator MUST read this manual 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 instructions warnings and cautions carefully Follow all safety precautions to avoid personal injury or property damage during system operation Equalizer International Ltd cannot be responsible for damage or injury resulting from unsafe product use lack of maintenance or incorrect product and or system operation Contact Equalizer International Ltd when in doubt as to the safety precautions and applications 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 These instructions are only to cover the safe operation of THE EQUALIZER MG7TM MINI GAP MECHANI CAL TOOLS during normal maintenance installation operations All other safety aspects must be controlled by the operation supervisor FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 2 A CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage to or destruction of equ
5. without lubricating all moving parts Use only high pressure molybdenum disulphide grease FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL Spreading Force 6 8 T 68 kN per tool It is recommended that tools are used in pairs giving MG7TMSTD 2 x 6 8 13 6 T 136 kN The tool achieves a spreading distance of 27mm from a 2mm gap At a 7mm gap the tool steps down the spreading force applied from 6 8 tonnes to 3 9 tonnes 1 Select tool configuration 2 Tool assembly 3 Flange spreading The operator MUST read this manual prior to using the tools FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL 5 EXAMINATION MAINTENANCE AND STORAGE Before and after using any Equalizer tool ensure the full kit is available and check for any damage or wear Any missing or damaged items are to be replaced as soon as possible prior to the tool being used again Store in a cool dry place and ensure all machined surfaces are greased Grease all moving parts prior to use 6 MG7TM MINI GAP FLANGE SPREADER 6 1 KIT COMPONENTS 1 MG7TM Tool 1x4 16mm 0 63 Spreading Bar 1 x 20mm 0 79 Spreading Bar 1 x Instruction Manual Product Code MG7TMSTD FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 5 6 2 INSTALLATION AND OPERATION Before attaching the tool ensure at least two flange bolts remain in place 180 degrees apart with nuts loosened sufficiently enough for flange wo
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7. EADING WEDGES OPERATOR INSTRUCTION MANUAL 12 6 4 WEIGHTS AND DIMENSIONS MG7TM MI NI GAP FLANGE SPREADER 5 kg 11 05 Ibs GROSS KIT WEIGHT 5 5 kg 12 13 Ibs Packaging Dimensions 60 x 270 x 300 mm 7 48 x 7 09 x 12 60 Large 20mm 0 79 spreading bar TOOL CONFIGURATION 1 TOOL CONFI GURATI ON 2 OPEN CLOSED um Small 616mm 0 63 spreading bar TOOL CONFI GURATI ON 1 TOOL CONFI GURATI ON 2 OPEN CLOSED 14 37 365 mm 1 97 8 94 227 mm FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 13 7 RANGE OF APPLICATION CHARTS Use the charts on the following pages to determine which spreading bar is suitable for a particular flange The charts are categorised as per flange type ASME 16 5 Weldneck Threaded Slip on and Blind flanges see page 15 B16 5 Socket welded see page 15 B16 5 Long welding neck flange see page 16 B16 5 Lapped flange see page 16 B16 47 Weldneck and Blind flanges see page 17 ANSI Reducing see page 17 Orifice Weldneck flange see page 18 Orifice Slip on and Threaded flanges see page 18 BS 10 see page 19 Large Small Spreading bar Spreading bar 55758 Tool Configuration 1 Tool Configuration 2 FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL 14 EQUALIZER ASME B16 5 Weldneck threaded slip on and blind flanges Class
8. G WEDGES OPERATOR INSTRUCTION MANUAL 6 It is strongly recommended that two MG7TM Tools are used on the flange joint positioned 180 degrees apart Flange separation Flange spreading and seal removal 7 Turn each opposing tool a half turn at a time until the desired gap is achieved Care must be taken to ensure the force is applied evenly The maximum spreading distance for the MG7TM is 27mm FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 8 6 3 MAINTENANCE AND LUBRICATION Before and after each job the Equalizer Mini Gap mechanical tool kit must be checked to establish that they are complete and all items must be examined to ensure that they are serviceable At regular intervals and specifically after being exposed to salt water Mini Gap mechanical tools should be dismantled and lubricated as follows 1 Lay the tool on a bench or flat surface with the right hand side face down 2 the spreading bar out of the tool 3 To Remove the left hand cast leg from the tool Pull the spring loaded plunger to release the leg 4 Remove the right hand cast leg from the tool FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 9 5 Drive the handle so that the splitter wedge moves down Then remove the Splitter wedge and Thrust bearing from the tool _ 6 Fully unscrew the drive screw Remove the main body and the outer sleeve from
9. MG 7TM MINI GAP FLANGE SPREADER Operator Instruction Manual EQUALIZER m Pull for Small Spreader Bar p info equalizerinternational com www equalizerinternational com INNOVATION IN ITS MOST FUNCTIONAL FORM INDEX SECTI ON A W N CONTENTS INTRODUCTION SAFETY INFORMATION TECHNICAL DATA HOW THE FLANGE SPREADING WEDGES WORK EXAMINATION MAINTENANCE AND STORAGE MG7TM MINI GAP FLANGE SPREADER 6 1 KIT COMPONENTS 6 2 INSTALLATION AND OPERATION 6 3 MAINTENANCE AND LUBRICATION 6 3 PARTS LIST 6 4 WEIGHTS AND DIMENSIONS RANGE OF APPLICATION CHARTS 1 INTRODUCTION PAGE NO 1 2 3 9 11 12 13 14 19 The Equalizer MG7TM MINI GAP FLANGE SPREADER is designed to aid the safe separation of flange faces This system has a unique ability to break flange joints with a 2mm gap between the flange faces The tool is designed to separate flanges while applying an immense amount of force to the correct point of separation To extend the service life of the tool and to ensure the tool is used safely operators must read this instruction manual carefully before using the equipment Following these instructions will ensure maintenance and or installation procedures are carried out in a reliable and safe manner The Equalizer MG7TM Mini Gap Flange Spreader Offers a safe and reliable working method Provides 6 8 tonnes of spreading force Separates flange faces with a gap of 2mm or greater
10. ar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 15 ASME B16 5 Long welding neck flange Small Bar Small Bar Small Bar Large Bar Small Bar Small Bar Small Bar Large Small Small Bar Small Bar Large Bar Small Bar Small Bar Small Bar Large Bar Small Bar Small Bar Small Bar Large Bar Small Bar Small Bar Small Bar Large Bar Small Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Large Bar Large Bar Large Bar Large Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar ASME B16 5 Lapped flange 150 CNN 900 1500 2500 Small Small Bar Small Bar Small Bar Large Large Bar Large Small Bar Small Small Small Bar Large Bar Large Bar Large Bar Small Bar Small Small Bar Small Large Bar Large Bar Large Bar Small Bar Small Small Small Large Bar Large Bar Large Bar Small Bar Small Small Small Large Bar Large Bar Large Bar Small Bar Smal
11. eg lt jews lt lt Jeg lt Jeg lt FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL
12. ge Large Bar Large Bar LargeBar Large Bar Large Bar Large Bar Large Bar LargeBar Large Bar Large Bar Large Bar Large Bar LargeBar Large Bar Large Large Bar LargeBar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL 17 ANSI Orifice Weldneck flange Class 1500 2500 Small Bar Small Bar Small Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar LargeBar Large Bar Large Bar Small Bar Small Small Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar ANSI Orifice Slip on and Threaded flanges Small Bar Large Bar Small Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL 18 261
13. ipment or other property A WARNI NG 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 1 E if IMPORTANT Operator must be competent in the use of mechanical equipment The operator must have read and understood all instructions safety issues cautions and warnings before starting to operate the Equalizer equipment WARNING Do not overload equipment Overloading causes equipment failure and possible personal injury CAUTI ON Make surethatall system components are protected from external sources of damage such as excessive heat flame moving machine parts sharp edges and corrosive chemicals WARNING Immediately replace worn damaged parts with genuine Equalizer parts Equalizer parts are designed to fit properly and withstand rated loads For repair or maintenance service contact your Equalizer distributor or service centre gt gt gt DANGER To avoid personal injury keep hands and feet away from the tool and workpiece during operation WARNI NG Always wear suitable clothing and Personal Protective Equipment PPE WARNI NG Never place fingers in a joint held by an activated tool CAUTI ON Never hammer nor force the tool into a bolt hole if it does not fit easily you are using the wrong size of tool CAUTI ON Do not operate the equipment
14. l Small Bar Small Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Large Bar Large Bar Small Bar Large Bar Large Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL 16 ASME B16 47 Weldneck and blind flanges Class Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar Large Bar ANSI Reducing Class UC RN NN NENNEN RNC 1500 2500 Small Small Small Bar Small Bar Large Bar Large Bar Large Bar Small Small Small Bar Small Large Bar Large Bar Large Bar Small Bar Small Bar Small Bar Small Bar Large Bar Large Bar Large Bar Small Bar Small Bar Small Bar Small Bar Large Bar Large Bar Large Bar Small Bar Small Bar Small Bar Small Bar Large Bar Large Bar Large Bar Small Bar Small Bar Small Bar Small Bar Large Bar Large Bar Large Bar Small Bar Large Bar Large Bar Large Bar LargeBar LargeBar Large Small Bar Large Bar Large Bar LargeBar LargeBar LargeBar Large Bar Small Bar Large Bar Large LargeBar LargeBar Large Bar Small Bar Large Bar Large Bar LargeBar LargeBar Large Bar Lar
15. rk to be carried out These bolts will reduce lateral flange movement during flange spreading and will help support the unit Do not extend the handle or use the smaller spreading bar as an extension bar Be aware of the dangers of breaking sealed flange joints Ensure that relevant risk assessments have been carried out for the task and your company procedures must be followed at all times Large Small 9 20mm 0 79 9 16mm 0 63 Spreading bar Spreading bar i Tool Configuration 1 Tool Configuration 2 2 Choose the suitable configuration for the size and class of flange joint you wish to separate See the application charts found on page 14 19 of this manual The spreading bars are designed to only fit the correct flange specification No two spreading bars can fit the same stud hole FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 6 The flange bolting should be disassembled as per your company s procedures and risk assessment 3 Place the tool over the flange joint and align with the desired stud hole 4 Engage the spreading bar through the leg of the tool and the flange stud hole Do not hammer or use excessive force to fit the spreading bar The bar should be fitted by hand 5 Take care to ensure the spreading bar is correctly fitted through the second leg of the tool Check the wedge is positioned in the gap between the flange faces FLANGE SPREADIN
16. the tool 5 FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL PAGE 10 7 Apply grease to the drive screw Clean all components and inspect for wear anddamage Replace all worn and damaged components with genuine Equalizer spares 8 Reassemble by reversing the disassembly procedure steps 2 to 7 Note it is recommended that the tool is wiped down with a clean rag and WD40 or similar 1 Cleaning fluid to remove any dirt or grit and then liberally greased with a high load bearing grease Rocol sapphire high load 2 or similar FLANGE SPREADING WEDGES OPERATOR INSTRUCTION MANUAL 11 6 3 5 115 ps PART NO DESCRIPTION 01 READ INST STICKER 01 each QC SEALED STICKER 01 each MG7TM WRAP STI CKER 01 each 301301 01 M6X12 GRUB SCREW 01 each 313401 01 THRUST WASHER 01 set of 2 313501 01 THRUST RACE 01 each 403102 01 SPLIT RING 1 1 4 01 each 632001 01 M8 SPRING PLUNGER 01 set of 2 740101 01 CAST LEG LEFT HAND 01 each 740201 01 CAST LEG RI GHT HAND 01 each 740301 01 MAIN BODY 01 each 740401 01 SPLITTER WEDGE 01 each 740501 01 LARGE SPREADI NG BAR 01 each 740601 01 SMALL SPREADI NG BAR 01 each 740701 01 DRIVE SCREW 01 each 740901 01 OUTER SLEEVE 01 each 741101 01 8 MM PLUNGER 01 set of 2 741802 01 HANDLE ASSEMBLY 01 each 742001 01 BEARING WASHER 01 each 742101 01 7 MM PLUNGER 01 set of 2 743101 01 COILED SPRING PIN 01 each FLANGE SPR
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