Bauer CAPITANO, JUNIOR, MARINER, PURUS User Manual
Operator’s Manual
High Pressure Breathing Air Compre ssors
Operator’s Manual
INTRODUCTION
This manual contains general information and instructions to operate
and maintain high pressure breathing air compressor units.
Before taking the compressor intooperation it is essentialto study the
instruction manual of that compressor.
All instructions should be observed and carried out in the order laid
down to prevent damage and premature wear to the equipment and
the units served by it.
While every effort is made to ensure the accuracy of the particulars
contained in this manual, the manufacturing company will not, under
any circumstances, be held liable for any inaccuracies or the consequences thereof.
WARNING
The breathing airproduced with thishigh pressure compressor issubject to strict quality standards.Ignoringtheoperatingand maintenance
instructions can lead to severe injury or in serious cases even death.
We reserve the right to make changes to the technology of our compressors as well as to this accompanying documentation in accordance to technical progress.
Edition January 2005
© 2005 BAUER Kompressoren GmbH, Munich
All rights reserved.
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Operator’s Manual
TABLE OF CONTENTS
1. GENERAL 1...................................................................................
1.1. PURPOSE AND SHORT DESCRIPTION 1.........................................................
1.2. THEORETICAL PRINCIPLES 2...................................................................
1.3. DESIGN AND MODE OF OPERATION 4...........................................................
2. SAFETY REGULATIONS 8......................................................................
2.1. GENERAL 8...................................................................................
2.2. NOTES AND WARNING SIGNS 9.................................................................
2.3. IDENTIFYING THE SAFETY NOTICES 9...........................................................
2.4. FUNDAMENTAL SAFETY NOTICES 9.............................................................
2.5. SAFETY REGULATIONS (EC; partly Germany, only) 12................................................
3. INSTALLATION, OPERATION 13..................................................................
3.1. INSTALLATION OF THE COMPRESSOR UNIT 13....................................................
3.2. COMPRESSOR ROOM CONDITIONS: 14...........................................................
3.3. NA TURAL VENTILATION 16.......................................................................
3.4. ARTIFICIAL VENTILATION 19.....................................................................
3.5. ELECTRICAL INSTALLATION 22...................................................................
3.6. TAKING INTO OPERATION 23.....................................................................
3.7. FILLING PROCEDURE 25........................................................................
3.8. SHUT--DOWN PROCEDURE 28...................................................................
4. MAINTENANCE 29..............................................................................
4.1. MAINTENANCE RECORD 29......................................................................
4.2. MAINTENANCE INTERVALS 29...................................................................
5. MAINTENANCE SCHEDULE 30...................................................................
5.1. MAINTENANCE INTERVALS 30...................................................................
5.2. MAINTENANCE RECORD 31......................................................................
6. STORAGE, PRESERVATION 32...................................................................
6.1. GENERAL 32...................................................................................
6.2. PREPARATION 32...............................................................................
6.3. PRESERVING THE COMPRESSOR 32.............................................................
6.4. PRESERVING THE MOTOR/ENGINE 32............................................................
6.5. PREVENTIVE MAINTENANCE DURING STORAGE 32...............................................
6.6. REACTIVATING THE COMPRESSOR UNIT 33......................................................
7. REPAIR INSTRUCTIONS 34......................................................................
7.1. GENERAL 34...................................................................................
8. TROUBLE--SHOOTING 35........................................................................
9. FILTER SYSTEM P21 37..........................................................................
9.
1. DESCRIPTION 37...............................................................................
9.2. CARTRIDGE SAFETY BORE 38...................................................................
9.3. LIFETIME 38....................................................................................
9.4. GENERAL INSTRUCTIONS FOR FILTER MAINTENANCE 39..........................................
9.5. CONDENSATE DRAINAGE 39.....................................................................
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9.6. FILTER CARTRIDGES 39.........................................................................
9.7. FILTER SERVICE LIFETIME 39....................................................................
9.8. CARTRIDGE CHANGE 40........................................................................
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TABLE OF CONTENTS
9.9. FILLING VALVE MAINTENANCE 40................................................................
9.10. REPLACEMENT INTERVALS 41...................................................................
9.11. CONDENSATE DRAINAGE 41.....................................................................
9.12. CARTRIDGE CHANGE 41........................................................................
10. FILTER SYSTEM P41 AND P61 42.................................................................
10.1. APPLICATION AND SUMMARY DESCRIPTION 42...................................................
10.2. FUNCTION 43...................................................................................
10.3. FILTER MAINTENANCE 48.......................................................................
10.4. TECHNICAL DATA 51............................................................................
11. LUBRICATING OIL LIST 52.......................................................................
11.1. GENERAL 52...................................................................................
11.2. TYPE OF OIL 53.................................................................................
11.3. O IL CHANGE 53.................................................................................
12. TRANSPORTING COMPRESSED AIR CYLINDERS 54...............................................
13. FURTHER FILLING POSSIBILITIES 55.............................................................
13.1. OVERFLOW 55..................................................................................
13.2. FILLING FROM STORAGE CYLINDERS 55.........................................................
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TABLE OF FIGURES
Fig. 1 Pressure-- and temperature increase 2.............................................................
Fig. 2 P--V Diagram 3.................................................................................
Fig. 3 Saving of work 3................................................................................
Fig. 4 Air flow diagram Purus, Utilus 10 and Junior 5.......................................................
Fig. 5 Air flow diagram Utilus, Capitano und Mariner 6......................................................
Fig. 6 Air flow diagram K14, K15, K150, K180 7..........................................................
Fig. 7 Locating air intake hose 13........................................................................
Fig. 8 Room temperature 14.............................................................................
Fig. 9 Locating the unit 15...............................................................................
Fig. 10 Cooling air flow 15................................................................................
Fig. 11 Installation of the compressor unit (natural ventilation) 16...............................................
Tab. 1 Air intake and outlet openings 17...................................................................
Fig. 12 Installation with natural ventilation, example 1 17......................................................
Fig. 13 Installation with natural ventilation, example 2 18......................................................
Fig. 14 Installation with natural ventilation, example 3 18......................................................
Fig. 15 Installation of the compressor unit (artificial ventilation) 20...............................................
Fig. 16 Installation with artificial ventilation, example 1 21......................................................
Fig. 17 Installation with artificial ventilation, example 2 21......................................................
Fig. 18 Solenoid valve plug 23............................................................................
Fig. 19 Connecting air bottle 26...........................................................................
Fig. 20 International filling connector 26....................................................................
Fig. 21 Connecting air bottle 26...........................................................................
Fig. 22 Opening of filling valve 27.........................................................................
Fig. 23 Opening of filling valve 27.........................................................................
Fig. 24 Removing air bottle 27............................................................................
Fig. 25 Removing air bottle 27............................................................................
Fig. 26 Filter system P21 37..............................................................................
Fig. 27 Safety bore 38...................................................................................
Fig. 28 Filter system P41 left, P61 right with SECURUS--monitoring unit 42......................................
Fig. 29 Oil and water separator 44.........................................................................
Fig. 30 Construction of the filter cartridges 45...............................................................
Fig. 31 Air flow diagram 47...............................................................................
Fig. 32 Cartridge change 49..............................................................................
Fig. 33 Danger label no.2 54..............................................................................
Fig. 34 Automatic switching device 56......................................................................
Fig. 35 Flow chart 56....................................................................................
Fig. 36 Filling from storage cylinders (overflow) 57
ig. 37 Filling with the compressor 57......................................................................
F
Fig. 38 Filling storage cylinders 57.........................................................................
...........................................................
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ANNEX
Important notices for the TÜV (supervising authorities) inspections of filling stations (German
Pressure Vessels Regulations)
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1. GENERAL
1.1. PURPOSE AND SHORT DESCRIPTION
High pressure compressor units are complete units for filling air tanks in the high pressure ranges PN 200 and PN 300 bar. The compressors are mainly used to compress air for breathing as required in diving and fire fighting applications, for instance.
The heart of this unit is formed by a three-- or four stage, air--cooled high pressure compressor block.
The Purus, Utilus 10 and Junior range compressor units are splash--lubricated.
From the Utilus, Capitano and Mariner rangecompressor units onwards, the last stages are lubricated by means of theforced--feed
lubrication system, the other cylinders are splash--lubricated.
All units are equipped witha breathing air -- processing system(P--filter system), that surpassesthe quality requirements of DIN3188.
1
1.2. THEORETICAL PRINCIPLES
Operator’s Manual
Fig. 1 Pressure-- and temperature increase
When the piston movesinto the cylinder,the pressure rises in thecylinder. Atthe same timehowever,the temperatureof the enclosed
gas also rises. This is a basic physical law (Gay--Lussac).
Since with increasing pressure, the occuring temperatures would soon reach inadmissibly high values, the compression has to be
divided into various stages. After every stage the gas is cooled back to approx. 10 -- 15 °C above ambient temperature. This is the
main reason for designing compressors with 3 or 4 stages.
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By dividing the compression work into various stages it results in a lower power requirment. This is visible in the p-- v diagram.
Fig. 2 shows the power requirement with a theoretical 1 stage compression to 200 bar.
Fig. 3 shows the power requirement witha3stagecompressionandthesavedwork.
200 bar
1 bar
Fig. 2 P--V Diagram
P
200 bar
P
3. Stage
Ideal theoretical
isothermal compression
actual polytropic
compression
V
saving of work
P
200 bar
2. Stage
1. Stage
1 bar
V
Fig. 3 Saving of work
By dividing the compression work it not only saves energy, but it also increases the operating safety due to a lower thermical load.
1 bar
V
3
1.3. DESIGN AND MODE OF OPERATION
1.3.1. Design
The compressor unit comprises the following major assemblies:
• compressor block
• drive motor
• filter set
• base and frame assembly with instrument/filling panel
• electric control system
• electronic monitoring system
• automatic condensate drain
1.3.2. Mode of operation; air flow diagram
The path of the air through the compressor system is shown in the following air flow diagrams.
a)
a)
a)
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a) optional extra according to order
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1.3.3. Air flow diagram 3--stage
Fig. 4 Air flow diagram Purus, Utilus 10 and Junior
1 Telescopic air intake
2 Intake filter
3 Cylinder 1st stage
4 Cylinder 2nd stage
5 Cylinder 3rd stage
6 Inter-- cooler 1st/2nd stage
7 Inter-- cooler 2nd/3rd stage
8 Intermediate separator 2nd/3rd stage
9 After-- cooler
10 Safety valve 1st stage
11 Safety valve 2nd stage
12 Final pressure safety valve
13 Central filter assembly
14 TRIPLEX longlife cartridge
15 Condensate drain valve
16 Pressure maintaining valve
17 Filling hose
18 Filling valve
19 Final pressure gauge
20 Safety valve, final pressure PN 200
21 Change-- over devicea)
a) optional extra
a)
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Fig. 5 Air flow diagram Utilus, Capitano und Mariner
1 Intake filter
2 Cylinder 1st stage
3 Cylinder 2nd stage
4 Cylinder 3rd stage
5 Inter-- cooler 1st/2nd stage
6 Inter-- cooler 2nd/3rd stage
7 After-- cooler
8 Safety valve 1st stage
9 Safety valve 2nd stage
10 Final pressure safety valve
11 Intermediate separator 2nd/3rd stage
12 Central filter assembly
13 TRIPLEX longlife cartridge
14 Condensate drain valve
15 Pressure maintainig valve
16 Filling hose
17 Filling valve
18 Final pressure gauge
19 Change-- over device
20 Safety valve, final pressure PN 200
a
) optional extra
a
)
a)
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1.3.4. Air flow diagram 4--stage
Fig. 6 Air flow diagram K14, K15, K150, K180
1 Intake filter
2 Inter-- cooler 1st/2nd stage
3 Inter-- cooler 2nd/3rd stage
4 Inter-- cooler 3rd/4th stage
5 After-- cooler
6 Intermediate separator 2nd/3rd stage
7 Intermediate separator 3rd/4th stage
8 Oil and water separator
9 Purifier
10 Pressure maitaining valve
11 Non--return valve
12 Filling valve
13 Condensate drain valve (manual)
14 Safety valve, intermediate pressure 2nd stage
15 Safety valve, intermediate pressure 3rd stage
16 Safety valve, intermediate pressure 4th stage
17 Safety valve, final pressure
18 Pressure gauge, final pressure
19 Venting valve with pressure gauge
An additional intermediate separator,1./2. stage is available for operation at high temperatures (e.g.: installation in subtropical countries) and high humidity.
The order number can be obtained through our technical customer service, Tel. 089 --78049 175
7
NOTES
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2. SAFETY REGULATIONS
2.1. GENERAL
WARNING
Never open filling or shut--off valves when under pressure and not connected as highly compressed emerging
air can cause serious accidents.
WARNING
Ensure intake air is free from noxious gas, exhaust fumes and solvent vapour. Use an intake hose and ensure
that it is mounted in such a way as to avoid taking in any noxious substances.
WARNING
Filling hoses must be in satisfactory condition and threads undamaged. Pay particular attention to damage on
the interface from hose fitting to hose. If the rubber is scored, hose must be discarded otherwise water can enter
and attack wire gauze causing it to rust and thus endangering pressure tightness.
CAUTION
Always shut down and decompress the complete system prior to carrying out any work on the compressor.
Working on compressor units requires the necessary expert knowledge!
CAUTION
Check the complete system for leakage from time to time by brushing all fittings and couplings with soapy water
or spraying with leak test spray. Repair any leakage.
CAUTION
Always disconnect the system from mains supply prior to carrying out any work on compressor systems with
electric drive motor.
CAUTION
Never repair pressure lines by soldering or welding.
CAUTION
Do not use any toxic substances like gasoline or acetone or similar to clean the compressor unit or any of its
parts.
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2.2. NOTES AND WARNING SIGNS
Notes and warning signs displayed on compressors according
to model, application or equipment.
WARNING
Hot surfaces, do not touch!
Danger of burning by touching cylinders, cylinder heads and pressure lines of individual
compressor stages.
WARNING
High voltage!
Life threatening danger of electric shock.
Maintenancework on electric units or operating equipment may only be carried out by a
qualifiedelectrician or by a person instructed
and supervised by a qualified electrician according to electrical regulations.
WARNING
Automatic compressor control, unit may
start--up without warning
Before carrying out maintenance and repair
work, s witch off at the main switch or disconnect from the mains and ensure unit will not
restart.
!
MANDAT ORY
Instructions must be readby personsoperating the machinery
The instruction manual supplied and all other
applicable instructions,regulations etc. must
be read and understood by operating personnel before using the machine.
!
WARNING
This notice is used with maintenance
work and operatingprocedures and must
be adhered to exactly in order to avoid
endangering personnel.
This notice must be complied with in
order to avoid damageto or destructionof
the machine or its equipment.
NOTICE
2.4. FUNDAMENTAL SAFETY NOTICES
Authorized use
• The machine / unit is built according to state of the art technology and established safety technical regulations. Nevertheless,its use can cause danger tolifeand limb of theoperator or third parties or damage to the machine and other
equipment.
• Operate the machine / unit only in technically perfectcondition in accordance with regulations and safety and danger
notices detailed in the instruction manual! In particular, immediately correct faults (or have them corrected) which can
impair safety!
• The machine / unit is exclusively for the compression ofmediums (air/gas) specified in section A, chapter 1.3. “Technical data”. Any other medium or use outside that specified is
not authorized. The manufacturer / supplier is not liable for
damage resulting from this. The user alone is responsible
for this risk. Authorizationfor use is also under the condition
that the instruction manual is complied with and inspection
and maintenance requirements are enforced.
Organizational measures
MANDAT ORY
Hearing protectors must be worn!
Hearing protectors must beworn when working on a machine which is running.
NOTE
Ensure correct direction of rotation!
When switching on the machine, check the
arrowto ensure correct direction of rotationof
the drive motor.
2.3. IDENTIFYING THE SAFETY NOTICES
Important instructions concerning the endangerment of personnel, technical safety and operating safety will be specially
emphasized by placing the following signs before the instructions.
• Keep the instruction manual to hand near the machine / unit
at all times in the relevant holder.
• In addition to the instruction manual, observe and comply
with universally valid legal and other obligatory regulations
regarding accident prevention and environment protection.
This can involve, for example, contact with hazardous substances or the provision / wearing of personal protective
equipment.
• In addition to theinstruction manual, provide supplementary
instructions for supervision and monitoring duties taking
into consideration exceptional factors e.g. with regard to organization of work, production, personnel employed.
• Personnel engaged to operate the machine must have read
the instruction manual before beginning work, especially
the safety notices chapter. When work is already underway
it is too late. This is particularly relevant for temporary personnel, e.g. maintenance personnel.
• At the very least, supervise temporary personnel’s work in
accordance with the instruction manual, taking intoaccount
safety and danger factors.
• Personnel may not wear long hair loose, loose clothing or
jewellery, including rings. There is a danger of injury
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Operator’s Manual
through, for example, these getting caught or being pulled
into the equipment.
• As far as necessary or according to regulations, use personal protective equipment.
• Observe all safety anddanger notices on the machine / unit.
• Keep all safety and danger notices on the machine / unit
complete and in readable condition.
• If there are any modifications to the machine / unit or operating conditions which may affect safety, stop the machine /
unit immediately and inform the department / person responsible of the fault.
• No modifications may be made to the machine / unit which
could impair safety without first obtaining permission from
the suppliers. This is also thecase withregard to installation
and adjustment of safety devices and valves as well as
welding of piping and reservoirs.
• Spare parts must always comply with the technical requirements specified by the manufacturer. This is always guaranteed with original spare parts.
• Do not carry out programme changes (software) to the programmable control system.
• Piping must be thoroughly checked (pressure and visual inspection) by the operator at appropriate time intervals, even
if no safety related faults have been noticed.
• Intervals stipulated or given in the instruction manual for recurring checks / inspections must be adhered to.
• It is absolutely essential that the workplace is appropriately
equipped for maintenance measures.
• Make sure location and operation of fire extinguishers is
known.
• Pay attention to fire warning and fire fighting procedures.
Qualifications, fundamental duties
• Work on / with the machine / unit may only be c arried out by
reliable personnel. Observe the legal minimum age permissible.
• Only employ trained personnel, clearly establish responsibility of personnel for operation, maintenance and repairwork.
• Ensure that only trained personnel work with the machine.
• Establish the responsibilities of the machine operator and
establish a procedure for him to inform a third person of unfavourable safety conditions.
• People who are being trained or introduced to the job should
only be allowed to work with the machine / unit under constant supervision of an experienced person.
• Work on the electrical equipment of the machine / unit may
only be carried out by a qualified electrician or by an instructed person under the direction and supervision of a
qualified electrician according to electrotechnical regulations.
• Work on gas equipmentmay only be carried out by qualified
personnel.
Safety notices for operation
• Do not carry out any work if safety is questionable.
• Meet all requirements demanding that the machine / unit is
only operated in safe and good working order. Only operate
the machine if all protective and safety equipment, e.g. all
detachable protective equipment, emergency shut--down
devices, soundproofing is provided and in good working
order.
• At least once every day, check the machine / unit externally
for damage and faults. Inform the department / person responsible immediately if anything is not as is should be (including operation). If necessary, shut the machine down immediately and make it safe.
• If there are any malfunctions, shut the machine / unit down
immediately and make it safe. Correct faults immediately (or
have them corrected).
• Observe switching on and off processes and monitoring indications according to the instruction manual.
• Before switching on / starting up the machine / unit, ensure
that no one can be put at risk through running the machine
/ unit.
• Carry out the setting, maintenance and inspection processes at the intervals specified in the instruction manual,
including replacement of parts / equipment. This work may
only be carried out by qualified personnel.
• Bef
ore carrying out any exceptional work or repairwork,op-
erating personnel should be informed. Call the supervisor.
• For all work concerning operation, change in production,
conversion or regulating of the machine / unit and its safety
measures such as inspection, maintenance and repairwork, observe the switching on and off processes in the instruction manual and the notices for maintenance work.
• Clear and make the maintenance area safe as far as
necessary.
• If the machine / unit is completely switched off for maintenance and repairwork, ensure that it is protected from unexpected start-- up. Turn off main control device and remove
the key and / or display a warning sign on the main switch.
• When replacing individual parts and larger assembly
groups, they must be carefully fastened to the lifting device
so that there is no risk of danger. Use only s uitable and
technically perfect lifting devices and equipment with sufficient lifting power and strength. Do not linger or work under
suspended loads.
• Only entrust an experienced person with the fixing of loads
and guiding of crane drivers. The person guiding must remain within sight or in contact with the operator.
• For assembly work above body height, use appropriate
safety approved equipment, e.g. ladders and platforms. Do
not climb on machine parts. For maintenance work at high
levels, wear a safety harness.
• Clean oil,fuel or care products fromthe machine, in particular the connections and screw joints, before carrying out
maintenance / repairwork. Do not use aggressive cleaning
fluid. Use a fibre--free cleaning cloth.
• Before cleaning the machine with water or jet of steam(high
pressure cleaner) or detergent, cover / seal all openings
which for safety and/or operating reasons no water / steam
/ detergent may penetrate. Electric motor and switch cabinets are particularly at risk.
• When cleaning the operating room, ensure that the temperature sensors of the fire alarm and sprinkler system do
not come into contact with hot cleaning fluid, in order to
avoid triggering the sprinkler system.
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Operator’s Manual
• Completely remove all covers / seals after cleaning.
• After cleaning, check all pressure lines for leaks, loose con-
nections, wear and damage. Immediately eliminate any
faults.
• Always retighten any screw connections loosened formaintenance or repairwork.
• If it is necessary to remove safety devices for maintenance
and repairwork, these must be replaced and checked immediately after completion of the maintenance or repairwork.
• Ensure safe and environmentally friendly disposal of consumables and old parts.
Particular areas of danger
• Use only original fuses with specified current rating. If there
is a failure in the electric energy supply, shut the machine /
unit down immediately.
• Work on electric units or operating equipment may only be
carriedout by a qualifiedelectrician or by a personunder the
instruction and supervision of a qualified electrician according to electric technical regulations.
• Machines and unit parts which must undergo inspection,
maintenance and repairwork, must be disconnected from
the mains supply, if specified. Parts which have been disconnected must first be checked for voltage, then earthed
and short--circuited and isolated from live neighbouring
parts.
• The electrical equipment of a machine / unit must be regularly checked. Defects, such as loose screw connections
or burnt wires, must be rectified immediately.
• If work is to be carried out on live parts, work with a second
person who can operate the emergency off switch or the
main switch in the case of an emergency. Close off the work
area with a red and white safety chain and a warning sign.
Only use voltage isolated tools.
• Only carry out welding, burning and grinding work on the
machine / unit when specifically approved. There can, for
example, be a risk of fire or explosion.
• Before carrying out welding, burning or grinding work, clean
the machine / unit and surrounding area fromdust and flammable material and ensure there is adequate ventilation
(danger of explosion!).
• When working in smallrooms, observe any national regulations.
• Only personnel with particular knowledge and experience
with pneumatics may carry out work on pneumatic equipment.
• Check all pressure lines,hoses and screw connections regularly for leaks and visible damage. Immediately repair any
damage. Escaping air or gas under pressure can cause injury and fire.
• Depressurize system and pressure lines before commencing repairwork.
• Pressurized air lines must be laid and mounted by qualified
personnel. Connections must not be mixed up. Fittings,
length and quality of the piping must correspond to requirements.
• Soundproofing equipment on the machine / unit must be in
place and functional during operation.
• The stipulated hearing protectors must be worn.
• With regard to oil, grease and other chemical substances,
observe the relevant safety regulations for the product.
• For loading,only use lifting device and equipment with sufficient lifting power and strength.
• Appoint trained guide personnel for lifting operations.
• Machines may only be lifted with a lifting device and by
trainedpersonnelaccording to instructions in theinstruction
manual (fixing points for fixing equipment etc.).
• Use only suitable transporters with sufficient carrying
power.
Secure the load properly. Use suitable fixing points.
• If necessary, provide machine / unit with transportation
brackets. Display the appropriate notice. Remove transportation brackets in the correct manner before taking into
operation.
• Parts which need to be dismantled for transport purposes
must be carefully replaced and secured before taking into
operation.
• Even when moving the machine / unit only slightly, the machine / unit must be disconnected from all external energy
sources. Before putting into use again, reconnect the machi
ne to the mains according to regulations.
• When taking back into operation, proceed according to the
instruction manual.
Notices of danger regarding pressure vessels
• Never open or loosen pressure vessel lids or pipe connection parts under pressure; always depressurise the vessel
or the unit.
• Never exceed the permissible operating pressure of the
vessels!
• Never heat the vessels or any of their parts above the
stated, maximum operating pressure.
• Always exchange damaged pressure vessels completely.
Individualparts that are subject to pressureloads cannot be
purchased as spare parts, since the vessels are tested as
a complete part and the documentation considers them as
a whole (see pressure vessel documentation, serial-numbers!).
• Always pay attention to the permissible operating mode of
the pressure vessels.
We differentiate:
-- vessels for static load
-- vessels for dynamic load
Vessels for static
These pressure vessels are permanently under virtually
constant operating pressure; the fluctuations of pressure
are very small.
Vessels for this type of load are not marked in a particular
way and may be used as long as the vessel inspections,
carried out regularly, do not uncover any safety--relevant
deficiencies.
We recommend that aluminium vessels should be exchanged after 15 years at the latest.
Vessels for dynamic
load:
load:
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Operator’s Manual
These pressure vessels may also be used under conditions
of changing operating pressure. The pressure may vary between the atmospheric and the maximum admissible operating pressure.
The pressure vessel documentation and the appropriate
notes in the operating manual particularly characterise vessels of this type as being adequate fordynamic loads. In the
technical information for these vessels you will find specifications concerning their permissible operating period.
Due to thevariationofthe operatingpressure,thesevessels
are subject to a so-- called dynamicload, which puts the vessels under great stress. The change between two different
pressures is called a load change or cycle. In the technical
information for these vessels you will find specifications
concerning the permissible number of cycles depending on
the fluctuation of the operating pressure.
Having reached half the permissible number of cycles, the
vessel has to be submitted to an internal check, in which the
critically stressed areas of the vessels are examined by
means of suitable testing methods, in order to ensure the
operating safety.
After having reached the total permissible number of load
cycles, the vessel must be exchanged and scrapped.
Record the number of load cycles in writing if you do not
have an automatic cycle--counter.
We recommend that aluminium vessels should be exchanged after 15 years at the latest.
Please pay attention to and follow these measures, for your
own safety and that of you employees and customers!
In order not to unnecessarily load the pressure vessels additionally, the non-- return valves, that are meant to avoid a
drop in pressure, and also the pressure maintaining valves,
which should reduce big pressure fluctuations as well,
should be checked regularly for internal and external tightness and functionality.
• Check the pressure vessels regularly on the inside and outside for damage from corrosion.
• Be particularly careful with second--hand pressure vessels,
when their previous operating mode is not specifically clarified.
2.5. SAFETY REGULATIONS (EC; partly Germany,
only)
A compressor is identified by German law as being a filling system if pressure cylinders are filled by the system, especially
when these cylinders are made available for third parties. The
start--up and operation of compressorsystems foruse as filling
stations is governed by the following regulations:
a-- Pressure vessel directive (Directive 97/23/EC) of
29.05.1997
b-- Operating safety regulations (BetrSichV) of 27.09.2002
c-- Machine safety law (GSG) as of 11.05.2001
d-- 14th regulation to machine safety law (14. GSGV -- pressure vessel regulation) of 03.10.2002
e-- Technical regulations for pressure gases (TRG 400,401,
402, 730).
If a high pressure compressor is used for filling pressure vessels or for the supply of pneumatic systems, the following regulations apply:
f-- Accident Prevention Regulations (UVV):
• UVV compressors (VBG 16).
Copies of the above regulations are available through the usual
outlets, e.g. in Germany from:
Carl Heymanns Verlag
Luxemburger Str. 449
50939 Köln
Beuth-- Vertrieb GmbH
Burggrafenstr. 4 -- 7
10787 Berlin
The manufacturer has complied with all applicable regulations
and the unit is prepared accordingly. If desired, we offer at our
Munich site a partial acceptance test according to § 14 BetrSichV. Please contact our Technical Service Department with
regard to this. They can also supply our leaflet “IMPORTANT
NOTES FOR CERTIFICATION”.
According to the operation safety regulations (BetrSichV), all
compressor units which will be used as filling stations must undergo an acceptance test by a professional at their location before bringing them into service.If pressure vessels (bottles) are
to be filled by the compressor fora third party then the appropriate permission must be obtained from the responsibleauthority
before the acceptance test. As a rule, this is the factory inspectorate. The procedure for obtaining permission is according to
TRG 730, guidelines for permission to set up and operate filling
stations.The testcertificates and documents delivered with the
compressor are important and may be requested during the
procedure for obtaining permission. In addition, the documents
belonging to theunit are important for recurrent inspections and
should therefore be carefully kept.
Inspections in accordance with the regulations for prevention of
accidents will be carried out by the manufacturerorby a specialist.
No guarantees whatsoever are valid for damage caused or favoured by the non-- consideration of these directions for use.
We strongly emphasize these regulations.
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