Accumulator Technology. E 3.000.14/03.16 1. HYDAC ACCUMULATOR TECHNOLOGY FLUID ENGINEERING EFFICIENCY VIA ENERGY MANAGEMENT.

HYDAC Accumulator Technology has over 50 years' experience in research & development, design and production of Hydac accumulators. Bladder, piston, diaphragm and metal bellows accumulators from HYDAC together form an unbeatable range and as components or units, support hydraulic systems in almost all sectors.

The main applications of our accumulators are: zzEnergy storage, zzEmergency and safety functions, zzDamping of vibrations, fluctuations, pulsations (pulsation damper), shocks (shock absorber) and noise (silencer), zzSuction flow stabilisation, zzMedia separation, zzVolume and leakage oil adjustment, zzWeight equalization, zzEnergy recovery.

Using accumulators improves the performance of the whole system and in detail this has the following benefits: zzImprovement in the functions zzIncrease in service life zzReduction in operating and maintenance costs zzReduction in pulsations and noise

On the one hand, this means greater safety and comfort for operator and machine. On the other hand, HYDAC accumulators enable efficient working in all applications. 2. QUALITY In conjunction with the customer service department at HYDAC's headquarters, Basic criteria, such as: Quality, safety and reliability are paramount service is possible worldwide. z for all HYDAC accumulator components. zDesign , HYDAC's worldwide distributor network zzDesign temperature, They comply with the current regulations means that trained staff are close at hand (or standards) for pressure vessels in the to help our customers. zzFluid displacement volume, individual countries of installation. zzDischarge / Charging velocity, In taking delivery of a HYDAC hydraulic zzFluid, accumulator therefore, the customer is This ensures that HYDAC customers have the support of an experienced workforce zzAcceptance specifications and also assured of a high-quality accumulator product which can be used in every both before and after sale. z zInstallation options country in the world, depending on the are important parameters required for certification. sizing the correct accumulator. For more details, please turn to Section 4. In addition the knowledge developed by our accumulator specialists will help to select the right type of accumulator. The All the processes involved, from comprehensive range of HYDAC development, engineering and production accessories simplifies installation and to approval and delivery are defined by maintenance according to the HYDAC's certified management system specification. and the relevant international accreditation for the manufacture of pressure vessels. E 3.000.14/03.16

2 Catalogue CONTENTS Page section

1. HYDAC ACCUMULATOR TECHNOLOGY 2 E 3.000

2. QUALITY 2

3. SAFETY INFORMATION 4

4. REGULATIONS 5

5. PRODUCT OVERVIEW 6 – 8

5.1. BLADDER ACCUMULATORS

5.1.1 Low pressure E 3.202

5.1.2 Standard E 3.201

5.1.3 High pressure E 3.203

5.2. PISTON ACCUMULATORS

5.2.1 Standard E 3.301

5.2.2 Series SK280 E 3.303

5.2.3 High pressure E 3.302

5.3. DIAPHRAGM ACCUMULATORS E 3.100

5.4. METAL BELLOWS ACCUMULATORS E 3.304

5.5. HYDRAULIC DAMPERS E 3.701

5.6. SPECIAL ACCUMULATORS

5.7. ACCUMULATOR STATIONS E 3.653

5.8. ACCUMULATOR ACCESSORIES

5.8.1 Hydraulic accumulators with back-up nitrogen bottles E 3.553

5.8.2 Universal charging and testing unit E 3.501

5.8.3 Safety and shut-off block E 3.551

5.8.4 Safety equipment for accumulators E 3.552

5.8.5 Supports for hydraulic accumulators E 3.502

5.8.6 ACCUSET SB E 3.503

6. INDUSTRIES AND APPLICATIONS 9 – 10

7. / 8. WEBSITE / SPECIFICATION FORMS 10 – 17

9. SIZING 18 – 19

10. NOTE 19 E 3.000.14/03.16

3 3. SAFETY INFORMATION Manufacturers of hydraulic accumulators 3.1. RISK OF EXCESSIVE and products must observe the following Accumulators are closed vessels which are principles: PRESSURE designed and built to hold pressurized Products: fluids. They are charged with nitrogen zzRemoval or reduction of risks, insofar as which is separated from the fluid section this is reasonably possible, Safety and shut-off block for the fluid side by a piston, bladder or diaphragm. zzApplication of appropriate protective in various sizes and versions. Hydraulic accumulators are exclusively measures against risks which cannot be See catalogue section: designed to store and then discharge eliminated, zzSafety and Shut-off Block SAF/DSV pressure fluids. zzIf required, training of the users on No. 3.551 The regulations for commissioning and the residual risks and instructions safety valve and gas safety block for operating hydraulic accumulators which on appropriate special measures for the gas side are in force at the place of installation must reducing the risks during installation and/ Bursting discs for gas and fluid sides be observed. The plant operator is solely or operation. See catalogue section: responsible for ensuring compliance with For safe handling and operation, the these regulations. operator must draw up a risk assessment zzSafety Equipment Relevant instructions are provided in the for the installation site, particularly in for Hydraulic Accumulators Operating Manuals for our products. combination with other components and No. 3.552 risks. 3.2. RISK OF RISE IN The resulting measures must be implemented accordingly. TEMPERATURE In the case of fundamental risks affecting Products: hydraulic accumulators, e.g. Safety and Shut-off Block with solenoid- zzExcessive pressure and operated valve (open when de-energised) in conjunction with temperature monitoring. zzIncrease in temperature (in the event of fire) See catalogue section: z we already have the relevant products zSafety and shut-off block SAF/DSV available. No. 3.551 or on request On no account must any welding, soldering Temperature fuses or mechanical work be carried out on the See catalogue section: accumulator shell. After the hydraulic line zzSafety Equipment has been connected it must be completely for Hydraulic Accumulators vented. Work on systems with hydraulic No. 3.552 accumulators (repairs, connecting pressure gauges etc) must only be carried out once the pressure and the fluid have been released. E 3.000.14/03.16

4 4. REGULATIONS 4.2.2 CERTIFICATE CODE = P European member states Certificate (KHK certificate) and EFTA states code 4.1. EUROPEAN PRESSURE For the Japanese market, HYDAC (AKZ) EQUIPMENT DIRECTIVE Technology GmbH has had approval as Austria a "Self Inspecting Manufacturer" since (PED) the year 2000. Consequently, HYDAC Belgium The European Directive 2014/68/EU is authorized to manufacture and test Bulgaria will come into effect in July 2016. It will pressure vessels for the Japanese market Cyprus replace Directive 97/23/EC and will and to import them into Japan. Czech Republic govern the design, fabrication, conformity 4.2.3 CERTIFICATE CODE = A9 Denmark assessment and placing on the market of Estonia pressure equipment and assemblies with (MANUFACTURER LICENSING CHINA) Finland a maximum permitted pressure of more Since 1998 HYDAC Technology GmbH has France than 0.5 bar. It guarantees free movement had approval from the Chinese authority of goods within the European Community. Germany "SELO" as a manufacturer of pressure Great Britain The EU member states must not prohibit, vessels and valves. HYDAC is therefore restrict or obstruct the placing on the authorized to import welded bladder, piston Greece market and the commissioning of pressure and diaphragm accumulators, and safety Hungary equipment on account of pressure-related valves, into the Chinese market. Iceland hazards, if the equipment complies Ireland with the requirements of the pressure 4.2.4 CERTIFICATE CODE = A11 U equipment directive and has the CE mark, (KGS code) Italy and is subject to a conformity assessment. Since concluding the registration Latvia Lithuania Hydraulic accumulators with a capacity of procedure in 2012 HYDAC Technology V ≤ 1 litre, a maximum permitted pressure GmbH is authorized to place pressure Luxembourg PS ≤ 1000 bar and a pressure capacity vessels and safety equipment on the Malta PS • V ≤ 50 bar • l for of fluid group Korean market according to the Korean Netherlands 2 (non-hazardous fluids) are subject Gas Safety (KGS) Code for Korea. Norway to Article 3, section 3 of the European 4.2.5. CERTIFICATE CODE = A6 Poland Pressure Equipment Directive and do not (TR-CU) Portugal receive the CE mark. Since 2014, regulation TR‑CU 032/2014 Romania Inspection of the equipment and (technical regulation of the customs union Slovakia "On the safety of pressure equipment") has installation, operational safety and repeat Slovenia testing are controlled as before by national applied for the countries of the Eurasian laws. Economic Community. Spain Sweden The equipment relating to safety is HYDAC Technology GmbH has been described in AD2000, ISO 4126 and certified in accordance with the regulation Switzerland EN 14359. to supply its product range. The repeat testing intervals are stipulated in the new German health & safety 4.3. CERTIFICATE TABLE Selection of other countries Certificate regulations. The following table lists the codes code recommended for use in the model code (AKZ) 4.2. OTHER REGULATIONS for different countries of installation. Australia F 1) Pressure accumulators which are installed The country of installation must be stated Belarus A6 overseas (outside the EU), are supplied at the time of ordering (see code in Model Canada S1 1) with the relevant test certificates required Code for the particular product: Certificate China A9 in the country of installation. Code). Hong Kong A9 HYDAC pressure vessels can be supplied For those countries not listed, please Japan P with virtually any test certificate. consult HYDAC. Alternative certificates Korea (Republic) A11 Depending on the authority, the different and variations are also possible. Please New Zealand T consult HYDAC. material requirements must be observed Russia A6 Details of some selected approvals are as South Africa S2 follows: Turkey U 4.2.1 CERTIFICATE CODE = S (ASME) Ukraine A10 Since 1985, HYDAC Technology GmbH USA S has been authorized to label pressure 1) Registration required in the individual territories or equipment that was manufactured in provinces compliance with the ASME regulations with others on request the "ASME" certification mark. 4.4. TRANSPORT REGULATIONS FOR PRESSURE VESSELS Such pressure vessels may be placed on The transport of gas-filled accumulators the market in the jurisdiction (application must be carried out with the utmost area) of "The National Board of Boiler and care and in compliance with all relevant Pressure Vessel Inspectors". transport safety regulations (e.g. in the public domain, dangerous goods regulations, etc.). E 3.000.14/03.16

5 5. PRODUCT OVERVIEW The following overview shows the standard product range of HYDAC hydraulic accumulators. For other models and sizes please ask. 5.1. BLADDER ACCUMULATORS 5.1.1 Low Pressure Benefits of HYDAC bladder accumulators: Permitted operating pressure: zzhigh discharge velocities, up to 40 bar zzno pressure differential between fluid Nominal volume: side and gas side, 2.5 ... 450 l zzcompact, low-maintenance, zzhigh charge and discharge frequencies.

5.1.2 Standard Permitted operating pressure: up to 550 bar Nominal volume: 0.5 ... 200 l

5.1.3 High pressure Permitted operating pressure: up to 1000 bar Nominal volume: 1 ... 54 l

5.2. PISTON ACCUMULATORS 5.2.1 Standard Benefits of HYDAC piston accumulators: Permitted operating pressure: zzminimal pressure differential between 210 ... 350 bar fluid side and gas side, Nominal volume: zzlarge effective volume, up to 3300 l zzvariable installation position, zzmonitoring of the piston position possible using a variety of systems, zzparticularly suitable for back-up configurations, 5.2.2 Series SK280 zzextreme flow rates, Permitted operating pressure: 280 bar zzno sudden discharge of gas when seals are worn. Nominal volume: 0.16 to 10 l

5.2.3 High pressure Permitted operating pressure: up to 1000 bar Nominal volume: up to 50 l

5.3. DIAPHRAGM ACCUMULATORS 5.3.1 Diaphragm accumulators Benefits of HYDAC diaphragm Weld and screw type accumulators: Permitted operating pressure: zzfunction-optimized and weight-optimized up to 750 bar design, Nominal volume: zzunlimited choice of installation positions, up to 4 l zzno pressure differential between fluid side and gas side, zzlow-maintenance and long service life. E 3.000.14/03.16

6 5.4. METAL BELLOWS ACCUMULATORS 5.4.1 Metal bellows accumulator Benefits of the HYDAC metal bellows Please contact us accumulator: zzdurable zzwear-free zzmedia resistant over a wide range of temperatures See also flyer zz"Heavy Diesel Engines - Metal Bellows Accumulators" No. 10.129.1 5.5. HYDRAULIC DAMPERS 5.5.1 Dampers Advantages of the HYDAC hydraulic Permitted operating pressure: damper: 10 ... 1000 bar zzreduces pressure pulsations, Nominal volume: zzimproves the suction performance of 0.075 ... 450 l displacement , zzprevents pipe breaks and damage to valves, zzprotects measuring equipment and its function in a system, zzreduces noise level in hydraulic 5.5.2 Silencer systems, Permitted operating pressure: 330 bar zzreduces maintenance and servicing costs and zzextends service life of the system.

5.6. SPECIAL ACCUMULATORS 5.6.1 Weight reduced See also flyer hydraulic accumulators zz"Weight-reduced accumulators" Over 80 % reduction in weight ompared to No. 3.305 equivalent carbon steel accumulators. The choice ranges from weight-optimized accumulators, e.g. by using aluminium, through to light-weight and ultra light- weight accumulators.

5.6.2 Spring type accumulators are equipped with a spring. The energy is produced by the spring force, instead of gas. Further information on request.

5.7. ACCUMULATOR STATIONS HYDAC supplies fully assembled piston accumulator stations which are ready for operation, complete with all the necessary valve controls, ball valves and safety equipment zzas an individual accumulator unit or zzin a back-up version with nitrogen bottles to increase the effective volume. E 3.000.14/03.16

7 5.8. ACCUMULATOR ACCESSORIES 5.8.1 Hydraulic accumulators with Using HYDAC nitrogen bottles provides back-up nitrogen bottles the following benefits: HYDAC also offers nitrogen bottles which zzcost-effective increase in the can be used to back up bladder and piston accumulator volume and as a result accumulators. Nitrogen bottles used as back-ups increase the gas volume in the zzsmaller accumulators for the same gas accumulator. volume.

5.8.2 Charging and testing unit FPU Charging hose, pressure gauge and pressure reducer for HYDAC and other brands of accumulator, up to 800 bar pre-charge pressure, higher on request.

5.8.3 Safety and shut-off block Benefits of the HYDAC Safety and Shut-off SAF/DSV Block: Nominal size: zzminimum of space and maintenance 8 ... 50 required, Permitted operating pressure: zzminimum of pipework (1 SAF replaces 400 bar, higher pressures on request up to 10 individual pipe connections, as Fluid-side protection, pressure relief valve, a rule), venting to tank and separation of the zzconsiderable reduction in installation accumulator from the fluid-side system. time, zzcan be adapted to different types and also different brands of accumulator, and zzadditional valves (pilot-operated check valves, flow control valves, etc). 5.8.4 Safety equipment zzGas safety valve GSV6 zzTemperature fuse zzBursting disc

Benefits of the HYDAC Gas Safety Block: zzGas safety block zzA gas safety block simplifies the as safety equipment for operation of the hydraulic accumulator HYDAC accumulator products. on the gas-side and also offers the possibility of installing the above safety Approval according to Pressure Equipment equipment using the various ports. Directive PED and CE mark.

5.8.5 Supports for hydraulic accumulators Accumulator sets, clamps and consoles for efficient installation of hydraulic accumulators.

5.8.6 ACCUSET SB Permitted operating pressure: 330 bar Nominal volume: 1 ... 50 l E 3.000.14/03.16

8 6. INDUSTRIES AND 6.1. INDUSTRIAL APPLICATIONS Automotive industry HYDAC Technology GmbH is zzGeneral industrial hydraulics, e.g. energy storage represented in almost all industries of the world which use hydraulic accumulators. The main sectors are industrial hydraulics, mobile technology and Mining machinery process technology. zzHydraulic accumulators, e.g. in suspended monorails Further applications in oil & gas/ zzPulsation damping offshore as well as more energy efficient systems utilizing accumulators zzComfort and safety for mobile working machines are gaining in importance. Listed below is a selection of examples with accumulators/dampers which are Iron and steel industry typical for these industries: zzAccumulator to maintain the pressure in rolling mills zzBlast furnace hydraulics

Plastics machinery zzAccumulator stations for energy storage during the injection moulding process zzPulsation damping on the hydraulic drive

Paper industry zzEnergy storage for emergency functions in friction bearing hydraulics zzEnergy storage in high/low pressure power units

Test rigs and test systems zzEnergy storage on crash test systems zzPulsation damping on servo hydraulic axes

Thermal power plants zzEmergency supply for turbine control system zzPulsation damping on pumps zzLubrication, control and seal oil supply

Forming machines zzAccumulators used to store energy to support the

Machine tools zzSupport for the hydraulics for tool drive or tool change zzEnergy storage in the compact hydraulics of machining centres

Wind turbines zzAccumulators in the pitch control system zzSupport of the pitch drive zzAccumulators on braking units E 3.000.14/03.16

9 6.2. MOBILE TECHNOLOGY 6.3. PROCESS TECHNOLOGY Automotive technology Chemical industry zzAutomatic and manual transmission zzEnergy storage and pulsation damping on dosing zzAutomatic clutch systems pumps zzEngine management systems zzSuction flow stabilisation on the suction side of pumps zzAccumulators for turbocharger emergency lubrication Loading stations / Refineries Construction Machinery zzShock absorption for valve closing zzAccumulators in braking systems zzPulsation damping on pipelines zzChassis damping zzBucket damping zzBoom damping on mobile cranes Offshore / Oil & Gas zzAccumulators to support valve closing systems Agricultural and forestry machines zzEnergy storage for deep sea rams zzFront loader damping zzBlow Out Preventers (BOP) zzAccumulators in tractor suspension zzEmergency function for safety systems systems zzAccumulators on wellhead control systems zzStone strike protection for ploughs zzBoom suspension on field sprayers Pipeline construction zzEnergy storage for emergency actuation of valve Municipal machines stations zzEnergy storage zzCompressor stations zzBoom damping zzPulsation dampers zzChassis damping

Lifting and material handling zzNoise damping zzEnergy recovery zzBraking systems

Shipping zzWater treatment plants (pump support) 7. WEBSITE zzPulsation damping on diesel engines Please visit us at the following address: www.hydac.com. zzHeave compensation (cranes) zzEmergency function for lifeboats In addition to Industries, Service and Fluid Engineering, under Products » Hydraulic Accumulators, you will find the standard product range and the comprehensive range of accessories from HYDAC TECHNOLOGY GmbH. Under Downloads you will find this product catalogue in different languages in PDF format as well as other information on HYDAC accumulator products. You can find the required product via the product search tab and download the relevant CAD model. The web version of ASPlight facilitates quick and simple input, calculation and evaluation of the required accumulator parameters. For further information on ASPlight see Section 9.4.

8. SPECIFICATION FORMS Our aim is to provide optimal customer service both before and after purchasing the accumulator.

The following specification forms are designed to help pre-select the required accumulator/damper or accessories.

You can also download these as a pdf document from the intranet and the HYDAC website (www.hydac.com/ Hydraulic accumulators) under the Downloads tab. You can then complete them at your convenience on your PC and send them to your HYDAC contact, e.g. by e-mail. The areas highlighted in green constitute the minimum

E 3.000.14/03.16 information required for a response or calculation. 10 HYDAC Technology GmbH Industriegebiet 66280 Sulzbach/Saar, Germany Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

GENERAL ACCUMULATOR SPECIFICATION FORM (PAGE 1/2) (Subject to technical modifications)

Company: Project name:

Name, First name: Application:

E-mail: Requirement: pieces/year

Telephone no.: as ¨ spare part ¨ original equipment

Note: The appropriate accumulator can be calculated using the HYDAC Accumulator Simulation Program ASP.

Type of accumulator ¨ Bladder accumulator ¨ Piston accumulator ¨ Diaphragm accumulator ¨ ______

Fluids/medium Fluid: Viscosity at 20 °C: cSt Density: kg/m³ Viscosity at operating temperature: cSt

Functioning of the pump Additional details on the accumulator ¨ Continuous operation ¨ Intermittent operation Industry: Accumulator data Country of installation: Max. operating pressure: bar Design/Certification: Min. operating pressure: bar Specification: Pre-charge pressure at 20 °C (nitrogen): bar Materials* (see catalogue section: No. 3.000, Sizing) Accumulator shell: Ambient temperature: °C Fluid connection: Operating temperature: °C Elastomer: Complete cycle time: s Additional information Installation dimensions: mm (height x Ø ) Fluid demand time schedule for ONE pump ext. and ONE consumer: Fluid connection: Type: Accumulator discharge rate: l/min for thread ¨ internal Accumulator discharge time: s ¨ external Flow rate of the pump: l/min Standard: Pump runs continuously: ¨ Gas connection: Pump starts after discharge: ¨ Coating/finish: ¨ internal ¨ external Spare parts / Accessories:see www.hydac.com Alternatively: Fluid demand diagram for SEVERAL pumps under Products /Accumulators and/or consumers (see page 2) * dependent on operating temperature and/or fluid resistance

Remarks:

Place, date: Signature: E 3.000.14/03.16

11 HYDAC Technology GmbH Industriegebiet 66280 Sulzbach/Saar, Germany Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

GENERAL ACCUMULATOR SPECIFICATION FORM (PAGE 2/2) (Subject to technical modifications)

Fluid demand diagram for several pumps and/or consumers:

Designation / example:

Qv = Consumer flow rate [l/s] EV1 AV1 EV2 AV2 EV3 AV3 EV4 AV4 EV = Switch-on time of consumer [s] Q AV = Switch-off time of consumer [s] [l/s] Consumers EP = Switch-on time of pump [s]

AP = Switch-off time of pump [s]

QV1 QV3 QV4 QV2 Time [s]

Pumps EP1 AP1 EP2 AP2

Please indicate cycle data below

Number of consumers: Number of pumps:

QV1= EV1= AV1= QP1= EP1= AP1=

QV2= EV2= AV2= QP2= EP2= AP2=

QV3= EV3= AV3= QP3= EP3= AP3=

QV4= EV4= AV4= QP4= EP4= AP4=

Q [l/s]

Time [s] E 3.000.14/03.16

12 HYDAC Technology GmbH Industriegebiet 66280 Sulzbach/Saar, Germany Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

SHOCK ABSORBER SPECIFICATION FORM (Page 1/2) (Subject to technical modifications)

Company: Project name:

Name, First name: Application:

E-mail: Requirement: pieces/year

Telephone no.: as ¨ spare part ¨ original equipment

Note: The appropriate accumulator can be calculated using the HYDAC Accumulator Simulation Program ASP.

Type of accumulator ¨ Bladder accumulator ¨ Piston accumulator ¨ Diaphragm accumulator ¨ Cause of the pressure shock Accumulator data ¨ When pump starts ¨ When pump switches off Max. operating pressure: bar ¨ When check valve flap (valve) closes Min. operating pressure: bar Pre-charge pressure at 20 °C (nitrogen): (see catalogue section: No. 3.000, Sizing) bar Fluids / media Ambient temperature: °C Fluid 1): Operating temperature: °C Density: kg/m³ Fluid connection: Type: for thread ¨ internal Pipeline data for A SINGLE pipe ¨ external Length: m Standard: Diameter (internal): mm Gas connection: Coating/finish: Wall thickness: mm ¨ internal Material of line: ¨ external Spare parts / Accessories: see www.hydac.com Max. permitted pressure in the line: bar under Products / Accumulators Total closing time of the valve: s Materials* Speed of sound in the system: m/s Accumulator shell Fluid connection: Alternatively: Elastomer: Pipeline data for ADDITIONAL sections of pipe (see page 2) Additional information on the accumulator/system Pump data Available installation space: m Zero head: m (L x W x H) Industry: Pressure of the pump at the operating point: bar Country of installation: Flow rate of the pump at the operating point: l/min Design/Certification: * dependent on operating temperature and/or fluid resistance Specification: 1) please send datasheet Remarks:

Place, date: Signature: E 3.000.14/03.16

13 HYDAC Technology GmbH Industriegebiet 66280 Sulzbach/Saar, Germany Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

SHOCK ABSORBER SPECIFICATION FORM (Page 2/2) (Subject to technical modifications) Pipeline data for additional sections of pipe Designation / Example H = Zero head of the pump [m]

Di = Internal diameter of the pipe [mm] T = Closing time of the valve [sec] (effectively approx. 30% of the total closing time) L = Length of the pipeline [m]

T H L1 L2 L3

Tank Tank

Di1 Di2 Di3

Number of different pipes: 3

L1 = 200 m Di1 = 100 mm

L2 = 50 m Di2 = 200 mm

L3 = 20 m Di3 = 500 mm

Typical values for speed of sound Water = 1200 m/s Fuel = 1100 m/s

Please complete below with the pipeline data

Number of different pipes:

L1 = m Di1 = mm L5 = m Di5 = mm

L2 = m Di2 = mm L6 = m Di6 = mm

L3 = m Di3 = mm L7 = m Di7 = mm

L4 = m Di4 = mm L8 = m Di8 = mm E 3.000.14/03.16

14 HYDAC Technology GmbH Industriegebiet 66280 Sulzbach/Saar, Germany Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

PULSATION DAMPER SPECIFICATION FORM (Subject to technical modifications)

Company: Project name:

Name, First name: Application:

E-mail: Requirement: pieces/year

Telephone no.: as ¨ spare part ¨ original equipment

Note: The appropriate pulsation damper can be calculated using the HYDAC Accumulator Simulation Program ASP.

Type of accumulator ¨ Bladder accumulator ¨ Piston accumulator ¨ Diaphragm accumulator ¨ Fluids/medium Fluid: Viscosity at 20 °C: cSt Density: kg/m³ Viscosity at operating temperature: cSt

Pump and system data Additional details on the accumulator Oper. press./pump pressure: bar Industry: Flow rate: l/min Country of installation: Design/Certification: Speed: 1/min Specification: Number of displacements: Design pressure: bar ¨ single ¨ double acting Design temperature: °C Pump factor: optional (if available) Materials* Stroke volume: 1 dm³ Accumulator shell d2 x π for piston pumps: V = x H x 10-6 Fluid connection: H 4 Elastomer: d = Ø piston: mm Additional information H = stroke length: mm Installation dimensions: mm (height x Ø ) for diaphragm pumps: see manufacturer's specifications ext. Accumulator data Fluid connection: Type: Pre-charge pressure 1): bar for thread ¨ internal Operating temperature: °C ¨ external Application: ¨ pressure side ¨ suction side Standard: Required residual pulsation: % Gas connection: Coating/finish: Result: l gas volume 2) ¨ internal

* dependent on operating temperature and/or fluid resistance ¨ external 1) see catalogue section: No. 3.000, Sizing Spare parts/Accessories: see www.hydac.com 2) under Products / Accumulators normally pre-charged with nitrogen (N2) Remarks:

Place, date: Signature: E 3.000.14/03.16

15 HYDAC Technology GmbH Industriegebiet 66280 Sulzbach/Saar, Germany Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

SILENCER SPECIFICATION FORM (Subject to technical modifications) Company: Project name: Name, First name: Application: E-mail: Requirement: pieces/year Telephone no.: as ¨ spare part ¨ original equipment

Sizing example:

E2 E1 E4 E0 0 1 Silence r 2 3 4

E5 E6 E3 5 6

Pump: A10VSO71 Design pressure: 210 bar Silencer inlet: SAE 1 1/4“ 3000 psi Pump rpm: 1500 1/min No. of pump pistons: 9 Silencer outlet: SAE 1 1/4“ 3000 psi Fluid: Aral Vitam GF Fluid density: 890 kg/m³ Design temperature: 50 °C Element no. Length [m] Ø int. [m] Ø ext. [m] Subsequent connection type Hose type E1 0.5 0.020 0.030 Straight connection – E2 0.4 – 0.200 Straight connection – E3 1.5 0.025 0.040 T-junction 4SP (DIN EN 856) E4 0.6 0.015 0.025 Pressure relief valve – E5 0.2 0.015 0.025 Right-angle – E6 0.6 0.015 0.025 Shut-off valve –

Please enter design data here:

Pump: Design pressure: bar Silencer inlet: Pump rpm: 1/min No. of pump pistons: Silencer outlet: Fluid: Fluid density: Design temperature: °C

Element no. Length [m] Ø int. [m] Ø ext. [m] Subsequent connection type Hose type E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 Remarks:

Place, date: Signature: E 3.000.14/03.16

16 HYDAC Technology GmbH Industriegebiet 66280 Sulzbach/Saar, Germany Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

METAL BELLOWS ACCUMULATOR SPECIFICATION FORM FOR HEAVY DIESEL ENGINES (Subject to technical modifications)

Company: Project name:

Name, First name: Application:

E-mail: Requirement: pieces/year

Telephone no.: as ¨ spare part ¨ original equipment

Note: The appropriate pulsation damper can be calculated using the HYDAC Accumulator Simulation Program ASP.

Engine data Manufacturer: max. "spill volume" of the high pressure injection pumps: ccm Type: max. flow of the supply line: l/min Design: ¨ Inline ¨ 2-stroke max. flow of the tank line: l/min ¨ V motor ¨ 4-stroke Fuel:

Operating conditions of the supply line:

Proportion of operation min. / max. speed pmax at Tmin pmin at Tmax Engine start / 1/min bar °C Main operation % / 1/min bar °C bar °C Auxiliary operation % / 1/min bar °C bar °C

Operating conditions of the tank line:

Proportion of operation min. / max. speed pmax at Tmin pmin at Tmax Engine start / 1/min bar °C Main operation % / 1/min bar °C bar °C Auxiliary operation % / 1/min bar °C bar °C

Additional information on the accumulator/system: Available installation space: m (L x W x H) Industry: Installation vertical: ¨ yes ¨ no Country of installation: (accumulator gas valve at top) If no, specify position: Design/Certification: Material: ¨ Carbon steel ¨ Stainless steel or (hydraulic accumulator) Finish requirement: ¨ HYDAC Standard (RAL 7035) Ship name (IMO): ¨ Ship classification: see flyer "Heavy Diesel Engines - Metal Bellows Accumulators" Spare parts/Accessories: see www.hydac.com Gas and fluid connection: No. 10.129.1 under Products / Accumulators Remarks:

Place, date: Signature: E 3.000.14/03.16

17 9. SIZING 9.1. DEFINITION OF VARIABLES FOR SIZING A HYDRAULIC ACCUMULATOR Function principle Limits for the gas pre-charge pressure Bladder accumulators

p0 ≤ 0.9 • p1 with a permitted pressure ratio of

p2 : p0 ≤ 4 : 1

For HYDAC low pressure accumulators, the following must also be taken into account:

Type SB40: p0 max = 20 bar

Type SB35H: p0 max = 10 bar

 ‚ ƒ Piston accumulators

p0,tmin ≥ 2 bar (piston type 2)

p0,tmin ≥ 10 bar (piston type 1)

p0,tmin ≤ p1 - 5 bar

In extreme cases, during slow charging (isothermal) and rapid discharge (adiabatic) of the

effective volume, and after accurate calculation, the gas pre-charge pressure p0 ≥ p1 can be selected. Accumulator supplied uncharged or with 2 bar storage pressure.

 ‚ ƒ Diaphragm accumulator

a) Permitted pressure ratio: p2 : p0 Weld type: The pressure ratio of weld-type diaphragm accumulators is between 4 : 1 and 8 : 1, depending on the design, see catalogue Section Diaphragm Accumulators, No. 3.100, section 3.1. Screw type: All sizes: 10 : 1  ‚ ƒ Other pressure ratios on request

b) p0 ≤ 0.9 • p1

Metal bellows accumulators

a) Metal bellows accumulator with convoluted bellows: The max. permitted or optimal pre-charge pressure of a metal bellows accumulator with convoluted bellows must be determined for each application by providing the particular operating conditions and in consultation with HYDAC (see "Metal Bellows Accumulator Specification Sheet for Heavy Diesel Engines"). b) Metal bellows accumulator with diaphragm bellows:

p0 ≤ 0.9 • p1 p2 : p0 ≤ 20:1 at tmin The required pressure ratio must be indicated when ordering.

 ‚ ƒ

 The accumulator is pre-charged with nitrogen. The separating element (piston, bladder, diaphragm, corrugated bellows) shuts off the fluid. ‚ The minimum operating pressure should be higher than the gas pre-charge pressure. This should prevent the separating element from striking the fluid connection every time fluid is discharged. ƒ Once the max. operating pressure is reached, the effective volume ΔV is available in the accumulator:

p0 = pre-charge pressure V0 = effective gas volume t0 = pre-charge temperature

p1 = minimum operating pressure V1 = gas volume at p1 tmin = min. operating temperature

p2 = maximum operating pressure V2 = gas volume at p2 tmax = max. operating temperature E 3.000.14/03.16

18 9.2. SELECTING THE 9.3. ACCUMULATOR SIZING ON YOUR PC – ASP 5 PRE-CHARGE The most important parameters for calculating the accumulator gas volume are pressure, volume and PRESSURE temperature. The selection of the pre-charge pressure These parameters were previously used to calculate the defines the accumulator capacity. In required accumulator size in cumbersome and complex order to obtain optimum utilization of the formulas. accumulator volume the following In 1997, HYDAC revolutionized the calculation and pre-charge pressures are recommended: simulation of hydraulic accumulators by applying program 9.2.1 Recommended values routines with real gas behaviour in its ASP ‑ Accumulator for energy storage: Simulation Program. p0,t max = 0.9 • p1 After years of experience, continuous improvement and the inclusion of new functions, ASP has developed into calculation software which makes it for shock absorption: possible for the behaviour of accumulators to be simulated with great accuracy. P = 0.6 to 0.9 • p 0,t max m ASP 5 has five elements: (p = average operating pressure for m zzsimulation, with the familiar advantages free flow) but in a completely new format and additional visualizations of the most for pulsation damping: important parameters, p = 0.6 • p zzpressure shock damping, clearly arranged 0,t max m in one program window, (p = average operating pressure) m zzpulsation damping, including corrected or pump factors, also clearly presented in a p0,t max = 0.8 • p1 program window. (for several operating pressures) zzvolume compensation and During operation the separating element zzintegration of the stand-alone, simplified (piston, bladder, diaphragm, corrugated software ASPlight. bellows) must not touch the fluid-side connection. Since the volume of the gas increases as 9.4. ACCUMULATOR CALCULATION SIMPLIFIED – ASPlight the temperature increases, the pre-charge Das ASPlight is an intelligent application pressure must be determined at the which takes into account real gas behaviour. maximum operating temperature using the This simplified software from HYDAC recommended values. Accumulator Technology enables you to 9.2.2 Limits for gas pre-charge calculate all the necessary parameters such pressure as pressure, volume and temperature in see section 9.1. different units for gases such as nitrogen or helium. The maximum input for pressure is 9.2.3 Temperature effect 2500 bar. Additional information fields help So that the recommended pre-charge to evaluate the result and to determine the pressures can be maintained, even at type of accumulator. relatively high operating temperatures, the p0 charge for charging and testing cold accumulators must be selected as follows: ASPlight is aimed at the user who is tasked with determining the essential accumulator

tcharge + 273 parameters within a short time. The software p0, t charge = p0,t max • will be a particularly useful tool in your t + 273 max role as sales consultant in the field, by providing quick, straightforward calculations for hydraulic accumulators. t0 = tcharge (pre-charge temperature in °C) To take the temperature effect into account when sizing accumulators, p0 at t0 must be ASPlight is operated via a single window and is language neutral. The design is selected as follows: comparable to a pocket calculator. Simulation curves are not shown. ASPlight is available online at www.hydac.com, and it can also be operated from a tmin + 273 p0, t min = p0,t max • smartphone via the mobile website. tmax + 273

10. NOTE HYDAC Technology GmbH Industriegebiet The information in this brochure relates to 66280 Sulzbach/Saar, Germany the operating Tel.: +49 (0) 68 97 / 509 - 01 conditions and applications described. Fax: +49 (0) 68 97 / 509 - 464 For applications and/or operating Internet: www.hydac.com conditions not described, please contact E-Mail: [email protected] the relevant technical department.

Subject to technical modifications. E 3.000.14/03.16 19 E 3.000.14/03.16

20 21 22 BULGARIA BELGIUM AUSTRALIA AUSTRIA D GERMANY CZ CZECHREPUBLIC CH SWITZERLAND CDN CANADA BR BRAZIL BLR BELARUS BG B AUS A Internet: www.hydac.bg E-mail: offi [email protected] +359 2/9706075 Fax: +3592/9706070 Tel.: 1528 Sofi a Munchen Str. 14 Business CenterIskar-Yug HYDAC EOOD +32 12/260409 Fax: +3212/260400 Tel.: 3700 Tongeren Overhaemlaan 33 HYDAC A.S./N.V. Internet: hydac.com.au E-mail: [email protected] +61 3/983608070 Fax: +613/92728900 Tel.: Altona North,VIC3025 P.O. Box224 Postal address: Altona North,VIC3025 109 DohertysRoad HYDAC PTY. LTD. E-mail: [email protected] /61811-35+43 7229 Fax: /61811-0 +437229 Tel.: 4066 Pasching Industriestr. 3 HYDAC HydraulikGes.m.b.H. 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