Roth BA-UAK-ASME-EN User manual

OPERATING INSTRUCTION
PISTON ACCUMULATOR
WITH ASME U-DESIGNATOR
ACCORDING ASME VIII DIV. I
Type: BA-UAK-ASME-EN
Language: English
Edition: 09-2016
Revision: 01
Translated from German original

Operating instruction piston accumulator UAK - English
General
Roth pressure equipment - identification
in accordance with the serial number on the nameplate and the according report, see
•ASME Code Sec. VIII, Division 1
Explanation
Roth piston accumulator = Roth pressure equipment
Translation
If sold to a country in the EEA, this operating instruction must be translated into the language of the
country in which the machine is to be used.
Should the translated text contain incongruities, the original operating manual (German) must be
consulted or the manufacturer contacted for clarification.
Copyright
No part of this publication may be reproduced, transmitted, sold or communicated without prior
permission. Damages will be claimed for violations.
All rights reserved.

Operating instruction piston accumulator UAK - English 1
0 Contents
0.1 Table of Contents
0 Contents____________________________________________________________________ 1
0.1 Table of Contents_____________________________________________________________ 1
0.2 Table of figures_______________________________________________________________ 1
1 Designated application_________________________________________________________ 2
1.1 Overview of standard Roth pressure equipment _____________________________________ 2
1.2 Notes on designated application _________________________________________________ 3
2 Function ____________________________________________________________________ 4
2.1 General functional description ___________________________________________________ 4
2.2 Filling and testing the pressure equipment _________________________________________ 4
2.2.1 Isochore behavior of N2________________________________________________________ 5
3 Safety______________________________________________________________________ 6
3.1 Notes / Explanations __________________________________________________________ 6
3.2 Identification / Nameplate_______________________________________________________ 6
3.3 Safety systems_______________________________________________________________ 6
3.4 Safety precautions ____________________________________________________________ 6
3.5 Responsibilities of the operator __________________________________________________ 7
4 Dangers ____________________________________________________________________ 8
4.1 General hazard notes__________________________________________________________ 8
4.2 Installation of spare and wearing parts ____________________________________________ 8
4.3 Cleaning, maintenance and repair work ___________________________________________ 8
5 Installation __________________________________________________________________ 8
5.1 Scope of delivery _____________________________________________________________ 8
5.2 Transport and packaging _______________________________________________________ 9
5.3 Storage_____________________________________________________________________ 9
5.4 Assembly / Commissioning ____________________________________________________ 10
6 Maintenance________________________________________________________________ 11
6.1 General maintenance notes____________________________________________________ 11
6.2 Periods of repeated inspection__________________________________________________ 11
7 Disturbance, causes, troubleshooting (qualified staff only) ____________________________ 12
8 Emergencies _______________________________________________________________ 12
9 Dissembling / disposal ________________________________________________________ 12
Notes __________________________________________________________________________ 13
0.2 Table of figures
Figure 1-1 Overview of standard Roth pressure equipment _____________________________ 2
Figure 2-1 Isochore behavior of N2 ________________________________________________ 5

2 Operating instruction piston accumulator UAK - English
1 Designated application
1.1 Overview of standard Roth pressure equipment
The pressure equipment essentially consist of the following components:
1. Cylinder tube
2. Piston inclusive seals
3. End cap
4. Threaded ring (not for screw-in end cap)
5. End cap seal, oil side
6. End cap seal, gas side
7. N2 non-return valve (optional)
8. Screw plug (optional)
Figure 1-1 Overview of standard Roth pressure equipment

Operating instruction piston accumulator UAK - English 3
1.2 Notes on designated application
The Roth piston accumulator (Roth pressure equipment) was manufactured exclusively for use as an
industrial and commercial component designed for acceptance and delivery of pressurised hydraulic
fluids in hydraulic systems.
Any use of the pressure equipment other than or beyond as described above or any conversion by the
operator or others shall be regarded as contrary to designated use, unless by prior written agreement
of the manufacturer.
The manufacturer shall accept no liability for damages arising from this.
The pressure equipment may only be used with non-corrosive fluids in group 2 (Art. 13, PED
2014/68/EU) on the fluid side and with nitrogen (N2) on the gas side. Wear allowance (e.g. corrosion)
is not considered. Exceptions may result from the declaration of conformity or from individual
manufacturer’s specifications of the pressure equipment.
Pursuant to ISO 4406 the degree of purity of the operating fluid shall be at least 19/17/14 (NAS 1638
Class 8) for vertical installation and at least 17/15/12 (NAS 1638 Class 6) for horizontal installation, or
better.
Depending on the mode of operation, stricter requirements might be necessary. Nitrogen (N2) Class
4.0 (99.99%) or better shall be used.
Intended use also includes compliance with the manufacturer’s operating, maintenance and
servicing instructions.
Furthermore, the operator is obliged to adhere to the legal state regulations according pressure
equipments in connection with the adherence of the mandatory tests prior to commissioning and
recurrent tests and must arrange these in compliance with the mandatory periods (see chapter 3.5).
The commissioning is prohibited until the entire system into which the pressure equipment
will be installed has been certified compliant with the national and regional regulations.
The fluids required for operation of the pressure equipment is procured and used by the
operator. Proper treatment of these fluids and the associated dangers are the sole
responsibility of the operator.
Furthermore, the selections of a fluid are into consideration low-risk operation based on
experience gained by the operator in the course of repeated use thereof in pressure
equipment.
We recommend you also concluding guarantee agreements with suppliers of the fluids.
Please request written approval from the “manufacturer” in cases of special uses or if you
have queries.
It is not permissible to interrupt / stop operation of the system in a way to allow the piston
(see Fig. 1-1, Pos. 2) to hit the end cap of oil side (see Fig. 1-1, Pos. 3) at high speed (e.g.
fast oil pressure release without end position damping)! This excludes emergency stop
systems.

4 Operating instruction piston accumulator UAK - English
2 Function
2.1 General functional description
Roth pressure equipments are cylindrical pressure vessels with a separating element between gas
and fluid volumes (see Fig. 1-1).
They are used in hydraulic systems among others for energy accumulator.If the fluid pressure rises
above the gas filling pressure, hydraulic energy is stored in fluid form. This may be utilised for work
steps when the fluid pressure falls below the pressure of the compressed gas.
2.2 Filling and testing the pressure equipment
During or after filling with N2, use foaming agents to test all screwed connections, shut-off
valves, connections and joints for gas-tight sealing.
In principle, use Roth filling and testing device and observe the relevant operating
instruction.
The pre-filling pressure (P
0
) depends on the ambient temperature (isochore behavior of N2, see
Chapter 2.2.1) and should be 5 bar below the minimum operating pressure at maximum ambient
temperature (unless otherwise specified).
Never use oxygen or other flammable gases to fill the pressure vessel.

Operating instruction piston accumulator UAK - English 5
2.2.1 Isochore behavior of N2
Determining or controlling the pre-filling pressure (P
0
) at different ambient temperatures
General
Unless otherwise specified, the given P
0
refers to room temperatures of + 20°C. Should the actual
ambient temperature be different at the time of filling or checking P
0
, the diagram may be used to find
the pressure corresponding to that temperature when filling or checking.
Example
Assume a gas system at 155 bar of pressure at a gas temperature of + 20°C. If the gas temperature
rises to + 35°C, the intersection (155 bar at + 20°C) will shift to the next pressure-temperature curve to
intersect the vertical + 35°C temperature line. The fill or corrected pressure P
0
will need to be 166 bar
in this example.
Figure 2-1 Isochore behavior of N2

6 Operating instruction piston accumulator UAK - English
3 Safety
3.1 Notes / Explanations
Operating instruction, mandatory:
marked with a “book”
Warnings:
marked with a warning triangle “danger”.
Explosion:
marked with a warning triangle “explosion”.
Notes:
marked with a “hand”.
The vessel filled with N2 already, as given on the pressure equipment nameplate.
3.2 Identification / Nameplate
The pressure equipment has a nameplate and an ASME U-Designator attached. These show
essential technical data.
Please provide the following with all your enquiries:
•Indication of the type
•Serial number
•Date of manufacture
3.3 Safety systems
The safety systems may be included in the delivery (see delivery papers) or constitute part of
the customer installation.
They will always be required and should be tested for effectiveness prior to commissioning.
3.4 Safety precautions
The operator shall instruct the operating and maintenance staff on the proper operation of the
pressure equipment and monitor compliance with the safety precautions.

Operating instruction piston accumulator UAK - English 7
The responsible specialist superiors must instruct the operating, servicing and maintenance staff
before starting in their jobs or prior to commissioning of the pressure equipment and thereafter at
appropriate intervals of at least once per year. All services, maintenance and instruction courses must
be recorded in a control book.
Qualified technician (definition based on EN 60204-1)
•A person who, based on specific training, knowledge and experience and knowledge of pertinent
standards, will be in a position to assess assigned work and recognise potential hazards.
3.5 Responsibilities of the operator
The applications and requirements of the national and regional rules and regulations are to
ascertain and take into account.
Also ensure that local regulation on
•the safety of staff (accident regulations)
•the safety of working material (protective equipment and maintenance)
•product disposal (waste disposal laws)
•material disposal (waste disposal laws)
•cleaning (cleaning agents and disposal)
•and environmental protection
will be complied with.
Local regulations must be observed during installation and commissioning carried out by the operator
itself (e.g. acceptance testing etc.).

8 Operating instruction piston accumulator UAK - English
4 Dangers
4.1 General hazard notes
Operations must remain within the maximum and minimum limits specified on the nameplate and in
the technical documentation.
The pressure equipment must be installed ensuring that operating staff will not be endangered by
escaping operating materials should parts of the safety system trigger.
Structural modifications
Structural modifications to the pressure equipment are prohibited. Mechanical reworking or welding is
prohibited.
4.2 Installation of spare and wearing parts
The manufacturer’s guarantees will lapse should parts that have not been tested or approved by the
manufacturer be installed.
Pressure-retaining components must only be replaced by or with the approval of the
manufacturer.
Renewed acceptance testing by a notified body will be required! The N2 concentration in the
environment may increase when N2 is filled or drained. Adequate ventilation must be
ensured.
4.3 Cleaning, maintenance and repair work
Cleaning, maintenance or repair work may only be carried out by qualified technicians.
These activities require that systems pressure must be relieved on the oil side, including securing
against accidental switch-on.
The gas side pressure must also be relieved before performing work on gas side components.
5 Installation
5.1 Scope of delivery
The supplied pressure equipment / components include(s) technical documentation with operating
instructions, drawings and the data report (acceptance report by the notified body in case of individual
acceptance tests).
Delivery
Incoming inspection:
•Check completeness as per the delivery note!
In case of damages:
•Check the delivery for damages (visual inspection)!
In case of complaints:
If the shipment damaged during transportation:
•Contact the most recent forwarder immediately!
•Keep the packaging (for possible inspection by the forwarder or for return shipment).

Operating instruction piston accumulator UAK - English 9
5.2 Transport and packaging
Ensure that the pressure equipment will not be damaged on the outside. Always ensure that the
pressure equipment, should it need to be returned to the manufacturer, will not be pressurized.
Use suitable transport equipment for onward transportation or installation. Do not load the threaded
bores on the face of the pressure equipment with more than the total weight given in the table. Using
lashing straps for additional securing would be sensible. Consult the drawing for the weight of the
pressure equipment or its components. Take note of the centre of gravity.
The permissible total weight of the pressure equipment for attachment of the slings to the threaded
ring (see Fig. 1-1, Pos. 4) depends on the accumulator type series:
Type series
(diameter) Fastening bores Permissible total weight of the pressure equipment (see drawing)
100 2 x M 8 500 kg
180 2 x M 12 1500 kg
250 2 x M 12 1500 kg
360 2 x M 16 2000 kg
5.3 Storage
Intermediate storage (packaged)
The pressure equipment and the spare and replacement parts are delivered to allow for storage up to
3 months.
Storage conditions
Closed and dry room according to the designated operating conditions.
Storage / packaging for further transport
The pressure equipment and any accessories must be stored to ensure that they will be protected
from external factors and to exclude damage.
The manufacturer will protect all the components of the pressure equipment from corrosion, allowing
for a time up to 3 months in storage.
Optimal short-time storage conditions:
•Dry rooms
•Protected from mechanical stress
The operator of the pressure equipment may need to implement protective measures in cases of
longer times in storage or unfavourable storage conditions. Please consult the manufacturer for
relevant advice.
The connecting apertures of the pressure equipment must be closed in transportation or storage, to
prevent the intrusion of dirt or moisture and to prevent condensation.
The operator of the system must be on receipt of the pressure equipment assume responsibility for
storage in accordance with these instructions. Lengthy periods in transport or storage whilst packaged
should be avoided.
Packaging for further transportation (change of location)
The pressure equipment and its components should be packaged to exclude mechanical damage in
the event of further transportation.

10 Operating instruction piston accumulator UAK - English
The components may need to be decontaminated before packaging for further
transportation. Consult the datasheets for the fluids coming into contact with the
components. Observe the notes on transportation and in the drawings.
5.4 Assembly / Commissioning
Setup / Installation
The assembly if the pressure equipment is to be carried out by qualified staff and must be specially
trained for this kind of work.
A vertical arrangement with the oil side at the bottom is recommended. Different arrangements are
likely to increase wear.
Use fastening hardware that is designed to handle the static and dynamic forces.
Welding or soldering on the pressure equipment or mechanical modification is prohibited.
No additional forces or moments are allowed to impact on the pressure equipment. The pressure
equipment must not be exposed to flames or electrical / magnetic fields that may heat the equipment.
Ensure that the cylinder tube (see Fig. 1-1, Pos. 1) of the pressure equipment will not be deformed or
otherwise damaged when mounting the consoles / clamp.
Extensive damage may cause the pressure equipment to explode.
Do not install and operate the pressure equipment in rooms that are unprotected
against lightning and earthquakes.
Depending on operation, surface temperatures capable of causing burns may occur at the
limits of operating conditions. The operator should provide suitable protection.
Consult Chapter 6 for service notes and test schedules.
Use the fastening hardware provided by the manufacturer to ensure that all parts will be securely
fastened.
Before assembly:
•Check the delivery for transport damage to ensure that it is technically intact.
•Instruct the qualified staff.
Prior to commissioning, the operator should:
•Check the technical documentation for completeness as per Chapter 5.1.
•Completion of the infeed and outfeed systems and the parts of the system into which the
pressure equipment will be incorporated that have a safety functionality.
•Ensuring the functionality of installed instrumentation.
The operator should have the entire system acceptance tested (see Chapter 3.5) before
commissioning the pressure equipment.
Observe Chapters 2 and 4 when filling or draining.
Uninstalling the pressure equipment
Measure and ensure that the oil and gas sides are depressurised before uninstalling.

Operating instruction piston accumulator UAK - English 11
6 Maintenance
6.1 General maintenance notes
The pressure equipment will be largely maintenance-free after filling.
To ensure perfect operation and long life of the pressure equipment, carry out the following services to
the schedule specified by the operator.
Amonthly inspection is recommended. The intervals may be adjusted depending on experience
gained.
•Check the accumulator anchoring.
•Check the connections of the lines.
•Inspect and assess the condition of the instrumentation, safety systems and seals.
•Check all screwed connections, shut-off valves, connections and joints for gas leakage using
foaming agents.
•Check the N2 pre-filling pressure (P
0
) to prevent the piston (see Fig. 1-1, Pos. 2) from colliding
with the gas-side end cap (see Fig. 1-1, Pos. 3).
6.2 Periods of repeated inspection
Initiation and execution
The operator must be responsible for compliance with and execution of period of repeated inspection
(see Operational Safety Ordinance, Section 3).

12 Operating instruction piston accumulator UAK - English
7 Disturbance, causes, troubleshooting (qualified staff only)
Disturbance Cause Troubleshooting
Pressure equipment system will not
supply hydraulic fluid •Shut-off valve closed
•Pressure relief open
•Gas-side pressure too low
•Open shut-off valve
•Close pressure relief valve
•Check the charging pressure
Hydraulic pressure too low •Shut-off valve closed
•Pump does not deliver
•Open shut-off valve
•Check the pump functionality and
repair, if necessary
N2 safety valve triggers •Gas-side pressure too high
•Operation has markedly increased
the gas temperature
•Fluid overflow
•Check charging pressure and
plant settings
•Find reason for temperature rise
•Depressurise pressure equipment
8 Emergencies
This pressure equipment is a passive system, without own drives. The stored energy will be charged
or discharged by the connected active system of the operator.
Emergency measures such as the operation of Emergency-Off systems or fast pressure relief action
should therefore preferably be defined and documented in the work instructions of the operator.
9 Dissembling / disposal
Ensure that the pressure equipment is depressurised on the gas and oil sides before disposal.
Sort the pressure equipment by materials to be disposed in accordance with applicable local
environmental regulations.
Decontaminate and dispose of any contaminated parts according to local environmental regulations.

Operating instruction piston accumulator UAK - English 13
Notes

Operating instruction piston accumulator UAK - English
Technical changes reserved